LPH 120 Bruksanvisning Brugsanvisning Bruksanvisning Käyttöohjeet Instruction Manual Betriebsanweisung Manuel d instructions Gebruiksaanwijzing Instrucciones de uso Instruzioni per l uso Manual de instruções Οδηγίες χρήσεως Instrukcja obsługi 0349 301 036 011212 Valid for serial no. 152-xxx-xxxx
1. DIRECTIVE... 44 2. SAFETY... 44 3. INTRODUCTION... 46 3.1 GENERAL... 46 3.2 SCOPE OF MANUAL... 46 3.3 TECHNICAL DATA... 46 3.4 LPH 120 CUTTING SET PACKAGE... 46 4. 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. OPERATION... 50 5.1 LPH 120 CONTROLS... 50 6. MAINTENANCE... 51 6.1 CLEANING... 51 7. CUTTING WITH PT 25 TORCH... 51 7.1 PIERCING TECHNIQUE... 52 8. FAULT TRACING... 52 8.1 COMMON CUTTING PROBLEMS... 52 9. SPARE PARTS... 133 10. ORDERING OF SPARE PARTS... 137 11. SCHEMATIC DIAGRAM... 138-43 -
1. DIRECTIVE DECLARATION OF CONFORMITY Esab Welding Equipment AB, S-695 81 Laxå, Sweden, gives its unreserved guarantee that Plasma Arc Cutting Set LPH 120 from serial number 907 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). ----------------------------------------------------------------------------------------------------------------------------------- Göteborg 99-08-30 Bo Sjöberg Managing Director ESAB AB Box 8004 402 77 Göteborg 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 - cutting 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 - 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. - 44 -
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING OR CUTTING. ASK YOUR EMPLOYER FOR SAFETY PRACTICES THAT SHOULD BE BASED ON MANUFACTURER S 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! - 45 -
3. INTRODUCTION CAUTION! All warranty undertakings of supplier cease to apply if customer attempts to rectify any faults on machine during warranty period. NOTE. Supplier reserves right to make changes within the unit without further notice. 3.1 GENERAL LPH 120 is compact, self-contained plasma cutting system. As shipped, it s fully assembled and ready to operate after being installed. The set consists of LPH 120 power source and heavy duty PT 25 torch, and is capable of severing materials up to 45 mm thick. Use only ESAB Plasmarc 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 for use with LPH 120. 3.2 SCOPE OF MANUAL Purpose of this manual is to provide the operator all information necessary to install and operate LPH 120 set. Technical reference materials are enclosed, to help with possible troubleshooting. 3.3 TECHNICAL DATA Rated 60% Duty Cycle * 120A 120A Output 100% Duty Cycle * 60A/90A 60A/90A Output Current Range 60 120A 60 120A Open Circuit Voltage 310V 310V Supply cable 4x6 mm 2 4x16/4x6/4x6 mm 2 Rated primary input (max) 400-415V 3~50/60Hz 45A/phase 230V/400-415V/440V 3~50/60Hz 78A/45A/41A/phase Air Requirements PT 25 Plasma Cooling 54 66 l/min 4,9 bar 132 170 l/min 5,2 bar 54 66 l/min 4,9 bar 132 170 l/min 5,2 bar Max. cutting thickness 45 mm 45 mm Dimensions Length Height Width 760 845 390 760 845 390 Weight of LPH 120 167kg 167kg (*) Duty cycle is based on a 10-minute period; therefore, a 60 % duty cycle means that the power source may operate for 6 minutes with a cool down period of 4 minutes. 100 % duty cycle means continuous operation of the power source. NOTE: machine has enclosure class IP23 which means, that it can be operated indoors and outdoors. NOTE: symbol S points, that unit may be operated in areas of increased electric shock hazard. 3.4 LPH 120 CUTTING SET PACKAGE No. Qty. Req. 400-415V 3~ 50/60Hz Qty. Req. 230V/400-415V/440V 3~ 50/60Hz Part No. Description 1 1-0457 291 880 Plasma arc source LPH 120 2-1 0457 291 881 Plasma arc source LPH 120 3 1 1 0457 291 018 Current wire with clamp 4 2 2 0457 290 048 Fuse 1,6A 5 1 1 0457 290 071 Quick detachable coupling 6 1 1 0457 290 072 Hose clip 7 1 1 0349 301 036 Instruction manual LPH 120 8 1 1 0558 000 724 Plasma cutting torch PT 25 9 1 1 0558 000 884 Instruction manual PT 25 10 1 1 0349 302 131 Stand off guide 11 1 1 0349 302 132 Stand off guide - 46 -
4. INSTALLATION 4.1 GENERAL Correct installation is very important for trouble-free and satisfactory operation of LPH 120. 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 300l/min @ 4,8 5,2 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 120 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 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. Operator must make sure, if unit is properly configured for mains voltage. LPH 120 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. Chassis must be properly connected to ground. Otherwise it may result in electric shock, burns or death. - 47 -
4.7 SECONDARY CONNECTIONS Before making any connections make sure unit is disconnected from mains (by unplugging power cable, opening switchboard switch or opening disconnect switch). 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 120 connection diagram. - 48 -
Fig. 4-2. Ground and current cable connections. - 49 -
5. OPERATION ELECTRIC SHOCK CAN KILL! - Do not operate unit with cover removed. - Do not feed unit while it s being held or carried. - Do not touch any part of torch head (nozzle, heat shield and electrode) when unit is turned on. 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 120 CONTROLS A. POWER SWITCH. Turns the unit on when set to 60A/90A/120A, power indicator lights green, fan starts running. B. OUPUT CURRENT CONTROL. Stepwise by means of POWER SWITCH. C. AIR TEST BUTTON (on front panel of the unit) in test position enables setting pressure before cutting is started. The following activities shall be done to set the required pressure: set air pressure knob 6 to maximum pressure (knob turned maximally to the right ) when air test button 3 pressed, set the pressure of 5,2 bar by means of pre-regulator on air filter 19, observing the readings of pressure gouge 7 when air test button 3 pressed, set the pressure of 4,9 bar by means air pressure knob 6 block the air pressure knob and air filter pre-regulator before turning D. FAULT LIGHT. Will glow yellow under following conditions: FLOW FAULT. Indicates too low air flow rate. (continuous light, only when el-valve opened) OVER TEMPERATURE. Indicates that duty cycle has been exceeded. (flashing light) Allow unit to cool down before returning to work. After fault abates, all signals will automatically reset. E. ARC-ON LIGHT. When lit red indicates that main contactor is closed, which means torch is energised (CAUTION! 310V) 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). No. 1 2 3 4 5 6 7 8 9 10 19 Description power switch knob power on LED air test button arc on LED fault LED air pressure knob pressure gauge line outlet (rubber) current cable socket wheel air filter-preregulator Fig. 5-1. LPH 120 Controls. - 50 -
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. B. Occasionally drain water or oil from steam trap. 7. CUTTING WITH PT 25 TORCH Use the following procedures to cut with the PT 25 torch. A. Hold the torch nozzle approximately 3 to 5 mm above the work and tilted at about 15-30º. This reduces the chance of spatter entering the nozzle B. Depress the torch switch. Air should flow from the torch nozzle. C. 1,5 seconds after depressing the torch switch (at first start or after 1 min pause), the pilot arc should start. The main arc should immediately follow, allowing the cut to begin. D. After starting the cut, the torch should be maintained at a 5-15º 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 2.5 4 mm from the work. E. When ending a cut, the torch switch should be released and lifted off the workpiece just before the end of the cut. This is to prevent the high frequency from re-igniting after cutting arc extinguishes and causing damage to the nozzle (double arcing). F. For rapid re-starts, such as grate or heavy mesh cutting, do not release the torch switch. In the postflow mode (i.e. 1 min period, when el-valve remains opened), the arc can restart immediately by depressing the torch switch. So as to avoid the 1,5-second preflow portion of the cutting cycle, work should be undertaken within 1 min. Fig. 7-1. Effect of cutting speed. - 51 -
7.1 PIERCING TECHNIQUE Fig.7-2. Piercing technique using PT 25 torch. 8. FAULT TRACING 8.1 COMMON CUTTING PROBLEMS Below are listed common cutting problems, followed by possible cause of each. If problems are caused by power source, refer to maintenance section of this manual. If it s 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 C. Dross formation. (For some material thickness it may be impossible to get dross free cuts.) 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. 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. 1. Worn electrode. 2. Loose connections. 3. Worn cable. H. Short consumables life. 1. Improper gas pressure. 2. Loose connections. 3. Low air flow rate. - 52 -