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LPH 35

Bruksanvisning Brugsanvisning Bruksanvisning Kyttohjeet Instruction Manual Betriebsanweisung Manuel dinstructions

Gebruiksaanwijzing Instrucciones de uso Instruzioni per luso Manual de instrues Instrukcja obsugi

0349 301 026

000831

Valid for serial no. 035-xxx-xxxx

1. 2. 3.

DIRECTIVE .............................................................................................................................................. 44 SAFETY ................................................................................................................................................... 44 INTRODUCTION ...................................................................................................................................... 46 3.1 GENERAL .............................................................................................................................................. 46 3.2 SCOPE OF MANUAL............................................................................................................................. 46 3.3 TECHNICAL DATA ................................................................................................................................ 46 3.4 LPH 35 CUTTING SET PACKAGE........................................................................................................ 46

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INSTALLATION ....................................................................................................................................... 47 4.1 GENERAL .............................................................................................................................................. 47 4.2 EQUIPMENT REQUIRED...................................................................................................................... 47 4.3 LOCATION............................................................................................................................................. 47 4.4 INSPECTION ......................................................................................................................................... 47 4.5 AIR LINES CONNECTIOINS ................................................................................................................. 47 4.6 PRIMARY ELECTRICAL CONNECTIONS............................................................................................ 47 4.7 SECONDARY CONNECTIONS............................................................................................................. 48

5. 6. 7. 8. 9.

OPERATION ............................................................................................................................................ 50 5.1 LPH 35 CONTROLS .............................................................................................................................. 50 MAINTENANCE ....................................................................................................................................... 51 6.1 CLEANING ............................................................................................................................................. 51 CUTTING WITH PT30KK TORCH........................................................................................................... 51 7.1 PIERCING TECHNIQUE........................................................................................................................ 52 FAULT TRACING .................................................................................................................................... 52 8.1 COMMON CUTTING PROBLEMS ........................................................................................................ 52 SPARE PARTS ...................................................................................................................................... 133

10. ORDERING OF SPARE / WEAR PARTS ............................................................................................. 135 11. SCHEMATIC DIAGRAM ........................................................................................................................ 136

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1.

DIRECTIVE
DECLARATION OF CONFORMITY Esab Welding Equipment AB, S-695 81 Lax, Sweden, gives its unreserved guarantee that Plasma Arc Cutting Set LPH 35 from serial number 910 complies with standard EN 60974-1, in accordance with the requirements of directive (73/23/EEC) and addendum (93/68/EEC) and with standard EN 50192, EN 50199, in accordance with the requirements of directive (89/336/EEC) and addendum (93/68/EEC). ----------------------------------------------------------------------------------------------------------------------------------Gteborg 99-08-30

Bo Sjberg Managing Director ESAB AB Box 8004 402 77 Gteborg Sweden

Tel: +4631 50 90 00

Fax: +4631 50 92 61

2.

SAFETY

Full responsibility for safety of personnel working on or near system rests on user of ESAB Welding Equipment. Wrong operation can lead to abnormal situation, injure operator and damage equipment. ALL PERSONNEL WORKING WITH WELDING EQUIPMENT MUST BE FULLY FAMILIAR WITH - handling of equipment - location of emergency stops - functions of equipment - applicable safety regulations - welding Operator must make sure - no one stays inside work area while machine starts - no one is unprotected while arc is being struck Work area must be - suitable for welding - free of machine parts, tools and other objects that can obstruct operator moving within area - so arranged, that emergency stop buttons are easily accessible - free from draughts Personal safety equipment - always use proper safety equipment such as goggles, non flammable clothing, protective gloves - never wear loose clothing, belts, bracelets, rings etc., which may catch on equipment or cause burns Miscellaneous - only authorised personnel may operate electrical equipment - check whether return cables are properly fitted and earthen - requisite fire fighting equipment should be easily available in specially and clearly marked areas - lubrication and maintenance of welding equipment must not be proceeded during operation.

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! WARNING ! ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK YOUR EMPLOYER FOR SAFETY PRACTICES THAT SHOULD BE BASED ON MANUFACTURERS HAZARD DATA. ELECTRIC SHOCK - Can kill - Install and earth welding equipment in accordance with obligatory standards. - Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothes. - Insulate yourself from earth and workpiece. - Ensure your work position is safe. FUMES AND GASES - Can be dangerous to your health - Keep your head away from fumes. - Use ventilation and/or extraction to keep fumes and gases away from your breathing zone and surroundings. ARC RAYS - Can injure eyes and burn skin - Protect your eyes and skin. Use correct welding screens, filter lens and wear protective clothes. - Protect bystanders with suitable screens or curtains. FIRE HAZARD - Sparks (spatter) can cause fire. Make therefore sure there are no inflammable materials nearby. NOISE - Excessive noise can damage your hearing. - Protect your ears. Use ear defenders or other hearing protection. - Warn bystanders of the risk. MALFUNCTION - Call expert assistance in event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING UNIT PROTECT YOURSELF AND OTHERS!

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3.

INTRODUCTION
! CAUTION! All warranty undertakings of supplier cease to apply if customer attempts to rectify any faults on machine during warranty period.

NOTE. 3.1 GENERAL

Supplier reserves right to make changes within the unit without further notice.

Purpose of this manual is to provide the operator all information necessary to install and operate LPH 35 set. Technical reference materials are enclosed, to help with possible troubleshooting. LPH 35 is compact, self-contained plasma cutting system. As shipped, its fully assembled and ready to operate after being installed. The set consists of LPH 35 power source and heavy duty PT30KK torch, and is capable of severing materials up to 12 mm thick. ! WARNING ! Use only PT30KK torches that are appropriated for use with this power source. Use of other type of torch may cause ELECTRIC SHOCK HAZARD. Do not use any other torch not designed for use with LPH 35 power unit ! 3.2 SCOPE OF MANUAL Purpose of this manual is to provide the operator all information necessary to install and operate LPH 35 set. Technical reference materials are enclosed, to help with possible troubleshooting. 3.3 TECHNICAL DATA
Rated Output Output Current Range Open Circuit Voltage Rated primary input (@ 11kVA, 35A@ 94V DC) Air Requirements Max. Cutting thickness Dimensions Weight of LPH 35 set 35% Duty Cycle * 100% Duty Cycle * 35A @ 94V 20A @ 88V 2035A 295V DC 3x400-415V 3~ 50/60Hz, 16A/phase 130 l/min @ 3,54,5 bar 12 mm 610 mm 515 mm 255 mm 52kg 35A @ 94V 20A @ 88V 2035A 295V DC 3x230V 3~ 50/60Hz, 28A/phase 130 l/min @ 3,54,5 bar 12 mm 610 mm 515 mm 255 mm 53kg

PT 30KK Length Height Width

(*) Duty cycle is based on a 10-minute period; therefore, a 35 % duty cycle means that the power source may operate for 3,5 minutes with a cool down period of 6,5 minutes. 100 % duty cycle means continuous operation of the power source. 3.4 LPH 35 CUTTING SET PACKAGE
Pos. 1 2 3 4 5 6 7 8 Qty 3x400V, 50Hz 3x230V, 50Hz 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Part No 0457 288 880 0457 288 881 0457 290 048 0457 290 071 0457 290 072 0457 288 001 0349 301 026 0349 301 007 Description Plasma arc source LPH 35 (with torch assembled, see pos. 6) Plasma arc source LPH 35 (with torch assembled, see pos. 6) Fuse element 1,6A Quick detachable coupling Hose clip PT30KK torch Instruction manual LPH 35 Instruction manual PT30KK

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4.

INSTALLATION

4.1 GENERAL Correct installation is very important for trouble-free and satisfactory operation of LPH 35. It is suggested that each step of this section is carefully studied and followed. 4.2 EQUIPMENT REQUIRED Source of clean and dry compressed air capable of forcing air flow rate of 150l/min @ 3,5 4,5 bar. Maximum air pressure at unit input should not exceed 7 bars. 4.3 LOCATION Adequate ventilation is necessary to provide proper cooling of power source. Amount of dirt, dust and excessive heat, that unit is exposed to, should be minimised. Between LPH 35 and wall (or any obstruction) should remain distance of at least 300 mm, to secure proper air movement through it. CAUTION Installation of any kind of filtering device will reduce volume of through-flowing air, subjecting therefore interior of machine to overheating. Warranty is void if any type of filter device is employed. 4.4 INSPECTION A. Remove shipping container and all packing stuff and inspect unit for any sign of damage. Notify transporters of any defects or damages at once. B. Check container for any loose parts before disposal. C. Check air louvers and any other openings to make sure any obstruction is removed. 4.5 AIR LINES CONNECTIOINS To assembly air lines put on it hose clip and press in quick detachable coupling, that are delivered in container, and tighten clip next to hose end. 4.6 PRIMARY ELECTRICAL CONNECTIONS ! WARNING ! ELECTRIC SHOCK CAN KILL! Precautionary measurements should be made to provide maximum protection against electric shock. Disconnect power cable from mains socket before any connections are made inside power source. ! WARNING ! Operator must make sure, if unit is properly configured for mains voltage. Unit configured for 3x400V MUST NOT be fed from 440V mains; it may get damaged. LPH 35 machines are equipped with 3m, 4-strands power cables for 3-phase mains connection. Switch board that unit is to be fed from must be equipped with proper line fuses or circuit breakers (see TECHNICAL DATA). Power cable may be connected directly to wall disconnect switch or be equipped with suitable plug. ! WARNING ! Chassis must be properly connected to ground. Otherwise it may result in electric shock, burns or death.

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4.7 SECONDARY CONNECTIONS ! WARNING ! Before making any connections make sure unit is disconnected from mains. 1. Connect air supply line to inlet of regulator. 2. Clamp work cable to workpiece. Make sure the workpiece is connected to ground with properly sized cable.

Fig. 4-1. LPH 35 connection diagram.

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Fig. 4-2. Ground and current cable connections.

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5.

OPERATION

! WARNING ! ELECTRIC SHOCK CAN KILL! - Do not operate unit with cover removed. - Do not feed unit while its being held or carried. - Do not touch any part of torch head (nozzle, heat shield, electrode) when unit is turned on. ! WARNING ! ARC RAYS CAN BURN EYES OR SKIN! NOISE CAN DAMAGE HEARING! - Wear helmet with No. 6 or 7 lens. - Wear eye, ear and body protection. CAUTION Position machine at least 3 m from cutting zone. Sparks and hot slag can damage it. 5.1 LPH 35 CONTROLS A. Power switch / Output current setting - turns the unit on when selected 20A or 35A position, Power indicator lights green, cooling fan starts running. B. Air pressure regulator adjust air pressure within 3,5 4,5 bar. C. Fault light -will glow yellow under following conditions (operation will be stopped): - FLOW FAULT (continuous light) - indicates too low air flow rate. - OVER TEMPERATURE (continuous light) indicates that the maximum allowable temperature of the power unit (the transformer) has been exceeded. Allow unit to cool down before returning to operate. When fault clears, all signals will automatically reset. D. ARC-ON LIGHT. When lit red indicates that main contactor is closed, which means torch is energised and source is ready to cut. In case of no indication while torch switch is depressed immediately turn the machine off and call service. NOTE: ARC ON light may turn off if within 2 sec since torch switch is depressed cutting process will not be proceed. It is automatic feature that guarantees safe operation of machine (obligatory for units with S symbol). Table for Fig. 5-1 Pos. 1 2 3 4 5 6 7 8 Description Power switch knob LED Power on LED (Arc on ) LED FAULT Pressure gauge Air pressure regulator knob Torch PT 30KK-connection Work cable-connection

Fig. 5-1. LPH 35 Controls

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6.

MAINTENANCE

NOTE: All warranty undertakings given by supplier cease to apply if customer attempts to rectify any faults on machine during warranty period. 6.1 CLEANING A. Power source should be regularly blown with dry compressed air at reduced pressure, more frequently in dirty environment.

7.

CUTTING WITH PT30KK TORCH

Use the following procedures to cut with the PT30KK torch. A. Hold the torch nozzle approximately 3 to 5 mm above the work and tilted at about 15-30. This reduces the chance of spatter entering the nozzle. If the standoff tool is being used, set the standoff between 5 and 6 mm. B. Depress the torch switch. Air should flow from the torch nozzle. C. After ca 0,1sec - the pilot arc should start and the main arc should immediately follow - allowing the cut to begin. D. After starting the cut, the torch should be maintained at a 5-15 forward angle. This angle is especially useful in helping to create a drop cut. When not using the standoff guide, the nozzle should be held approximately 6 mm from the work. E. For rapid re-start, such as grate or heavy mesh cutting, do not release the torch switch. NOTE: When replacing the nozzle, always inspect the electrode for wear. If the depth of the crater is 1,52,0mm (see Fig.7-1 ) - replace the electrode. If the electrode is used beyond this recommended wear limit, damage to the torch and power source may occur. Nozzle life is also greatly reduced when using the electrode beyond the recommended limit.

Fig. 7-1. Electrode Wear Limit

Fig. 7-2. Effect of cutting speed

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7.1 PIERCING TECHNIQUE

Fig.7-3. Piercing technique using PT30KK torch.

8.

FAULT TRACING

8.1 COMMON CUTTING PROBLEMS Below are listed common cutting problems, followed by possible cause of each. If its still impossible to correct the problem, contact your ESAB distributor. A. Insufficient penetration. 1. Too low current. 2. Cutting speed too fast. 3. Damaged cutting nozzle. 4. Improper air pressure. 5. Low air flow rate. B. Main arc extinguishes. 1. Cutting speed too slow. 2. Worn electrode E. Uneven arc. 1. Damaged nozzle or worn electrode.

F. Unstable cutting conditions. 1. Incorrect cutting speed. 2. Lose cable or hose connections. 3. Electrode and/or nozzle in poor condition.

G. Main arc does not transfer. C. Dross formation. 1. Worn electrode. (For some material thickness it may be impossible to 2. Loose connections. get dross free cuts.) 3. Worn cable. 1. Current too low. 2. Cutting speed too fast or too slow. 3. Improper air pressure. 4. Defective nozzle or electrode. 5. Low air flow rate. D. Double arcing. 1. Low air pressure. 2. Damaged cutting nozzle. 3. Loose cutting nozzle. 4. Heavy spatter accumulation on nozzle. H. Short consumables life. 1. Improper gas pressure. 2. Loose connections. 3. Low air flow rate.

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