GOODWIN P30U User manual

P30U Instruction Manual Revision : 1 1st December 2006 Page 1
OPERATION MANUAL
for the
GOODWIN P30U
UNDERWATER
AIR PLASMA CUTTING SYSTEM

Page 2 P30U Instruction Manual Revision : 1 1st December 2006
TheCompanyreservestherighttomakesuchchangestothedesignorspecificationofthe
equipmentasitshallseefit. The informationcontainedinthis manualisissuedfor theguidanceofusers
anddoesnotformpartof any contract. It is strongly recommended that allusersandsupervisors
familiarisethemselveswiththecontents...
PRIOR TO COMMENCING USE OF THE SYSTEM
...andinparticular,the section on safety precautions which should be used asaguidetosafe
operationin accordance with therequirementsoftherelevantHealth and Safety atWorklegislation.
GOODWIN AIR PLASMA LIMITED
KERNAN DRIVE
LOUGHBOROUGH
LEICESTERSHIRE
LE11 5JF
ENGLAND
Tel No. [phone]
Fax No. [phone]
Email. [email protected]

P30U Instruction Manual Revision : 1 1st December 2006 Page 3
Contents
1................................................................................................................................................. SAFETY 4
1.1................................................................................................................................................General 4
1.2.................................................................................................................................. Safety Features 5
1.3.................................................................................................................................... Warning Signs 5
1.4................................................................................................ Packaging Handling and Transport 5
2........................................................................ INTRODUCTION TO THE PLASMA PROCESS 6
3.................................................................................................................................INSTALLATION 7
3.1......................................................................................................................................Power Supply 7
3.2..........................................................................................................................Earth Requirements 7
3.3........................................................................................................................ Phase Determination 8
4......................................................................................PLASMA AND TORCH CONNECTIONS 9
4.1.............................................Connecting the Torch and Plasma Earth Lead to the Power Unit 9
4.2........................................................................................................................ Control of theTorch 10
5 ...................................................................................................................................... OPERATION 11
5.1............................................................................................................................Machine Controls 11
5.1.1 .........................................................................................................WARNING INDICATORS 13
5.2.......................................................................................................................Power Up Procedure 14
5.3...........................................................................................................................Cutting Procedure 15
5.3.1. ....................................................................................STARTING AND FINISHING A CUT. 15
5.3.2. .............................................................................................. CUTTING WITH STAND OFF. 15
5.3.3. .....................................................................................................................CUTTING SPEED. 16
5.3.4. ...................................... PIERCING THICKER MATERIALS WITH A HAND TORCH 17
5.4.............................................................................................................................. Troubleshooting 18
5.5............................................................................................................................ Consumable Life. 18
5.5.1. ..................................................................................................................... INTRINSIC LIFE. 18
5.5.2. ............................................................................................................................ALIGNMENT. 18
5.5.3. ..........................................................................................................TRANSIENT DAMAGE. 18
5.5.4. ................................................................................................... OPERATIONAL DAMAGE. 19
5.5.5. .......................................................................................ELECTRODE “NON-STARTING”. 19
5.6..................................................................................................................Changing Consumables 20
5.4.............................................................................................................................. Troubleshooting 23
5.5............................................................................................................................ Consumable Life. 23
5.5.1. ..................................................................................................................... INTRINSIC LIFE. 23
5.5.2. ............................................................................................................................ALIGNMENT. 23
5.5.3. ..........................................................................................................TRANSIENT DAMAGE. 23
5.5.4. ................................................................................................... OPERATIONAL DAMAGE. 24
5.5.5. .......................................................................................ELECTRODE “NON-STARTING”. 24
6..........................................................................................................................TECHNICAL DATA 25
6.1........................................................................................................................................Power Unit 25
6.1.1. ..............................................................................................................ELECTRICAL INPUT 25
6.1.2. ........................................................................................................................ Electrical Output 25
6.2........................................................................................................................ Torch and Hose Set 25
6.2.1 ........................................................................................................................... HAND TORCH 25
7. ............................................................................................................ SERVICE INFORMATION 26
7.1................................................................................................................................The Power Unit 26
7.1.1. .......................................................................................................................... Circuit Diagram 27
7.1.2. ................................................................................................................MACHINE LAYOUT 28
7.1.2. ................................................................................................DIAGNOSTIC INDICATORS. 30
7.2................................................................................................... The Torch and Hose Set Repair 31
7.3.................................................................................................................................... Maintenance 32

Page 4 P30U Instruction Manual Revision : 1 1st December 2006
1. SAFETY
1.1 General
Before any cutting operations are started, the user must ensure that the installation and proposed
working methods comply with all relevant safety regulations, environmental and electricity standards.
The plasma arc produced at the torch head is a jet of high energy and is potentially dangerous. Users
unfamiliar with a plasma arc should seek basic training. Goodwin Air Plasma can offer comprehensive
training courses.
Inaddition, the following points areparticularly important:
a) The mains connection must be properly grounded and the supply lines fitted with fuses or circuit
breakers of the specified rating. The mains cable must be properly secured and protected from possible
damage.
b) High voltage exists at the torch when power is applied and the pilot arc is struck (up to 350V), and
when the main arc is cutting (150-200V). Under no circumstances should anyone touch the nozzle with
power applied to the torch. All adjustments and replacement of parts should be done with the power unit
supply isolated. The standard torch should not be used in excessively wet conditions or if the torch or hose
set are damaged in any way.
Note that the PTU torch, its umbilical and associated extensions and connectors are designed to be used
underwater. The current specification is to a maximum of 30m, although it has been tested to a simulated
70m..
The electrical connectors are underwater mateable (to ocean depth) but in practice it is not advisable to
disconnect the coolant and air lines underwater, so this would normally be done on the surface.
c) The mains supply should be isolated from the unit AT THE SUPPLY before removing any panels
from the unit. Only authorised service personnel should remove panels.
d) Keep the work area clear of all inflammable materials. Ensure that any material ejected from the cut
is not a hazard to the operator or to others.
e) Protection is necessary against ultraviolet radiation emitted from the arc. A helmet or shield with
shade glass is recommended. Note, however, that the plasma arc does not usually need to be observed
closely, if at all. It is more often necessary to be able to see the material surrounding the cut, so a lighter
shade than that used for welding will probably be required. Furthermore, when cutting underwater, the UV
is absorbed by the water to a considerable degree. Wear gloves and adequate protective clothing where
appropriate.Adequate screening should be arranged to protect others in the vicinity or passing by in a similar
manner to that required for arc welding operations.
f) Adequate ventilation or fume extraction to remove the cutting fume and dust is required at all times
around any plasma cutting operation.
g) The wheels on the unit are meant for ease of movement around the work place and should not be
used over rough surfaces nor at excessive speeds.
h) The plasma power unit should be positioned on stable level ground and if necessary secured against
any unwanted movement.
i) The operation of this equipment and the plasma cutting process can result in noise levels that could be
harmful. When cutting underwater the noise level from the arc is substantially reduced and does not represent
a risk to the diver. The employer should undertake a noise assessment to monitor compliance with relevant
legislation.
j) Material to be cut should be supported in such a way that any material cut from the work piece will
not be a hazard and fall onto the user, the equipment, or others in the vicinity.
k) Care should be taken when manoeuvring the hose set with either a hand held torch or one connected
to a robotic device, that it does not snag on objects or other equipment which may result in damage to the
hose set, or topple the objects or equipment. Hose sets that are subject to excessive mechanical tension may
result in damage to the hose set connections at the machine, the torch, or the hose set components themselves.

P30U Instruction Manual Revision : 1 1st December 2006 Page 5
1.2 Safety Features
Theplasma unitincludesthefollowing featuresforthesafety oftheoperator:
* Thebodyof the plasma torch isearthed.
* Thecontinuityof the torch earth and the voltage on the body ismonitored.
* Cuttingcurrentflowinginthesupply earthismonitored.
* Thevoltage onthetorchnozzleis monitored.
* Inthe event of a faulty conditionoftheabove,themachinewillswitch off power to the
torch.
Theemergencystopprocedure is to hit the redemergencystopbutton located on the lower front
controlpanel.
Atool(10mmspanner)isrequired to remove the canopy for access totheinternalcomponents.Under
nocircumstances shouldthecanopybe removedwhilstthemains supplyisstillconnected. Onlysuitably
trainedand authorised personnel should remove thecanopy.
1.4 Packaging Handling and Transport
Shouldtheplasmaunitneedtobeshipped,werecommendre-useof the original packing crate.Also:-
a)That the hose setbe disconnected to preventany damage to thehose set / plasmaconnections.
b)Thatthe control panel is adequately protected against potential damage.
c)Any lifting shouldbedoneusingtheeyebolt located in thetopofthecanopytogether with certified
liftingequipment (not supplied). Precautionsshouldbetakentoprevent rotation about theeyebolt.
d)The plasma unit shouldbeshippedandstoredin the upright positiontoavoidanyheavyinternal
componentsbreakingfreefromtheirmountings.
e)Storageshouldbeundercover, preferably in a clean dry environment.
1.3 Warning Signs
Thelocation ofthewarningsigns fittedtotheplasma
unitare:
a) Atthe front of the machine -
WarningOpenCircuitVoltage300volts.
b) Ateach rear lower cornerof the canopy -
WarningDisconnectthe MainsSupply.....
Theseshouldbemaintained inalegiblecondition.

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2. INTRODUCTION TO THE PLASMA PROCESS
Theplasmaprocess is created by passingastream of clean air,provided by an oil freecompressor,
throughaNOZZLEin the torch.Theairstreamis ionised by a PILOTARC,initiated by aHIGH
FREQUENCYunit (HF Unit) which passes fromtheELECTRODEtothenozzlewhenthe torch is
activated.When the PILOTARC is broughtcloseto the workpiece,MAINARCisTRANSFERRED
tothework piece as a jet of high energy which rapidly meltsanymetalwithwhichitmakescontact,
providingfastcutting,low residualheatinput,andlowmaterialdistortion.
Theelectrodeandnozzlearecooledbytheairandarecirculating water cooling system, and as the air is
passedthroughthenozzleitis caused to swirl around the arc byaSWIRLBUSHtoaid stability of the
arc.
TheHFunitoperates automatically to establish an arcwhenpoweris applied to the torch anditceases
tooperatewhenthepilotor main arc is established.

P30U Instruction Manual Revision : 1 1st December 2006 Page 7
3. INSTALLATION
Maybecarried out by a competentelectrician.No specialist tools are required.
3.1 Power Supply
Thepowerunitisprovidedwithalengthofflexiblecablewhichmustbeconnectedtoa3-phase
andearthelectrical supply.The supply should befittedwithfusesorcircuitbreakersofappropriate
ratingand a means of isolating thepowerunitfromthesupplyshouldbe provided.Aplug should be
fittedifappropriate.Themachine isphase/rotationsensitive.
Thepowerunit has power factorcorrectioncapacitors fitted as standard.It must be noted that
whentheunitderivesitspowerfromagenerator, the power factorcorrectionmaydisturbthegenera-
tors’automaticvoltagecontrol. If recommended by GoodwinAirPlasma,thepowerfactorcorrection
circuitcanbe disconnected however this will increase the input current demand. TheP30Uhasauto-
maticswitching of thepowerfactorcorrectionso that itonlyoperateswhilstcutting, so itisunlikelyto
causethisproblem.Thismaybefittedasanoptiontoothervariants.
Refer to the rating plate on the machine and Technical Data section 6.1.1. for the correct voltage
and current requirements.
3.2 Earth Requirements
Theinstallation should ideally be arranged suchthattheonlypathtoearth(or ground) from the work
pieceisbywayofthe plasma earth lead connected to the frontofthemachine.
Wherethematerialtobecut forms part of the structure which isearthedorgroundedtothe mains
electricalsupply system,thenthecuttingcurrent couldflowthroughthat route ratherthantheplasma
earthleadtothe machine.Always ensure thatthereisa good connection between the workpieceand
themachine via the plasma earth leadasapoorconnectionwillcauseexcessive current in the mains
supplyearth whichwillcreatea currenttripfaultcondition (seesection7.4fault finding).
NotethattheEarthLoopMonitorsystemusedintheunderwatermachinewillensurethatagood
connectionismade.
Ininstallations where it isnotpossibletoavoidearth current trips, eventhoughagoodcutting
currentearthpathhasbeenensured,itwillbenecessarytocheck that the alternative mains earth paths
aresubstantial enough tocarryhighercurrentsthan the currenttripsettingof30amps (*) withoutcausing
damage,aswherethecuttingearthisnotconnectedtotheworkpieceatall,thiswouldbethefullcutting
current.Iftheearthpathsare not substantial they must be uprated orre-routedtoavoidthepossibility of
damage.Oncethenecessarychecksand precautions have been taken, the earth currenttripcircuitmay
bedisabledbymeansoftheswitchontheEarthCurrentRelay (ECR) located inside the power unit.
*Sincethe workpiece will often be substantiallyconnectedtothesupplyearthinunderwater work,
andsignificant currents must beallowedtoflowinseawater to the torchandumbilicalearth,aless
sensitiveearth current relayisused.Thestandard machine sensitivityis10A. Thisshouldavoid most
casesofnuisancetripping,andthe need to disable the ECR.

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3.3 Phase Determination
Connectthetorch to the machine (seesection4).
Fill the water system with distilled water.
Note.To avoid damaging the water pump the machine should not be run without water in the
system. Also, the machine should not be run for more than a few seconds without a torch connected
to the machine. It may be necessary to eliminate air from the system, and vent the de-ionizing filter,
to establish a proper flow.
Switch on the machine by rotating the main isolator and pressing the on/off button ensuring the
emergency stop switch is unlatched.
Correct phase connection is determined by checking that the cooling air flowing through the power
unit is from the front panel to the rear of machine. If this condition is not correct, change two of the
three phase connections at the power supply and check again. The fan rotation, when viewed from
the front of the machine, is anti-clockwise.
If there is any doubt regarding installation, consult your distributor or GoodwinAir
Plasma.
FanRotationAnti-
Clockwise
Water Tank
De-ionizing
Filter

P30U Instruction Manual Revision : 1 1st December 2006 Page 9
4. PLASMA AND TORCH CONNECTIONS
4.1 Connecting the Torch and Plasma Earth Lead to the Power Unit
Note. Donotrunthepowerunitwithoutthetorchconnected.
Theconnectionstothepowerunit are located at the front of theunit.
The PTU torch and umbilical extensions use a specially designed electrical connector for the power,
safety earth, pilot arc, and all other electrical connections. There is a central pin that carries the
power, a pin for the pilot arc connection and 5 smaller pins for safety monitoring and the diver’s
control switch. The safety earth is made through the locking sleeve. There are four hose connectors,
filled with quick acting connectors.
the blue hose is the cooling water to the torch;
the red hose is the cooling water return from the torch
the black hose carries the plasma air
the yellow hose is a “pneumo” connection to allow the plasma air pressure to
automatically track the working depth
Thewaterconnectionsarenotpolarisedbutitisadvisabletofollowthecolourcoding.
Theseconnectors are found on the machine front paneland replicated at the socket end of the ex-
tensionumbilicals.
Thesupervisor’sremote control panel connects to a multiway socketabovethetorchconnectors.
(Note that this is an “analogue” lamp, therefore it may be illuminated but not at full brightness,
and the indicator (which is “digital”) on the front panel and the supervisors panel still fail to
light because of a poor connection).
Whenfirst switching on, allow enough timeforthewatertocirculatethroughthe system. Top upthe
headertankas required. Use only distilledorde-ionised water. (See section 7.1regardinguse of
methanolinfreezingconditions).
Thetwoearth connectors (insert andtwistclockwise to lock) arelocated on the left handside of
thefrontpanel. An indicator lamp indicates when an earth loop has been successfullymade.

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4.2 Control of theTorch
Notethatthetorchhasa switch for use by the diver,but that this is used in conjunctionwiththe
supervisorspaneland a communications procedure to energise the torch. The torch will de-energiseif
thediver’sswitchisreleased at any time.
Note that it is good practice to leave the power unit running at all times when the torch
is underwater to prevent the torch and air hose filling with water.
Cooling air will flow through the torch at all times when the machine is switched on.