Hansen HP63 User manual

0
OPERATION
MANUAL
IGBT INVERTER AIR PLASMA
CUTTING MACHINE
HP63/HP100/HP160
ATTENTION
For safety guarantee, only the person with operating certificate or
expert skills can collocate, check, maintain, fix and repair the welder.
For safety guarantee, please completely read and understand the details
in this manual before using.
Keep the manual in convenient place for easy reading.

1
CATALOGUE
1、CHARACTERISTICS&APPLICATIONS……………………………...2
2、SAFETY ATTENTION………………………………………….……3
3、TECHNICAL PARAMETER…………………………………...……4
4、INSTALLING &CONNECTION………………………………..…...5
5、PREPARE FOR CUTTING…………………………………………10
6、DAILY MAINTAIN&CHECK……………………………………...12
7、FAULT REPAIR……………………………………………….……13
8、CIRCUIT DIAGRAM………………………………………….……16

2
1、 CHARACTERISTICS&APPLICATIONS
HP100 air plasma cutting machine, can invert the working frequency DC of
50Hz into the high frequency of 20KHz, with IGBT and soft switch technology and
application of PWM technique, then reduce voltage, rectifies current and output a
high DC power source and suitable for cutting. The character is as follows:
The machine is projected by adopting entire-bridge inverter technique and with
IGBT elements.
1. Inverter frequency is above 20KHZ by adopting PWM technique.
2. Can preset and continuous adjust the current, suitable for different thickness work
piece, make sure cutting quality and save energy.
3. Arc ignition of cutting machine is adopted with small flow of air and HF transfer
arc method for 100% arc ignition.
4. With over-heat、over-current and arc starting protection.
Suitable for application:
Such as carbon steel, alloy steel, nonferrous metals etc.
For operation in machinery industry, petroleum industry, ship building industry,
vehicle industry, electricity industry and decoration.

3
2、SAFETY ATTENTION
2.1 Avoid body event to assure safely operate obey the following point:
a. The power item of input side、the location choosing、high-pressure gas
use、store and supply, welding products store and trash handling etc.
Please follow related laws or enterprise standard.
b. Clothing wear and safety tools equip. To avoid eye inflammation and skin
burn, please obey related safety and healthy regulation, please wear related
protecting tools.
c. To avoid noxious gas and stifled(the welding soot and CO2are harmful to
body)，must obey related regulation regarding the soot handling. Installing
partial exhausting equipment or use effective breathing protecting
equipment.
d. Can not operate without the welding machine cover.
2.2 Avoid machine burning and fire
a. Avoid fire because of overheated, please keep 50cm distance between welding
power and the wall or combustibles
b. Avoid fire because of spark. Forbid spark to touch the combustibles or enter
the inspiration、any open part of welding machine.
c. Avoid damaged by falling or break. During assemble welding machine in
frame, to assure security and avoid slipping please fasten the welding machine
first.
d. Forbid to have gas pipe or any seal can and pipe inside the welding machine.
2.3 Electric connecting item
a. Before connecting operate must turn off power and assure safety.
b. Forbid touch electric part or touch with wet glove.
c. Choose correct line type
d. Avoid heavy touch on line and touch welding part.
e. Connect the line joint well, use insulating tape around bare wire.
f. Handle ground connection between machine cover and work-piece holder by
professional worker.
g. Turnoff all power after finish welding.

4
3、TECHNICAL PARAMETER
Table 1、Cutting Par a m et e r
Model
Data
HP63
HP100
HP160
Rated Input Voltage (V)
3-Phase 50Hz
380/415
Rated Input Current (A)
12
27
39
Open Voltage（V）
245
300
325
Range for cutting current
(A)
30-63
30-100
30-160
Related Duty Cycle
100
Best cutting thickness
（carbon steel mm）
12
22
35
Max. cutting thickness
（carbon steel mm）
20
40
55
Shell Protection Degree
IP21S
Insulated Class
F
Dimension (D×W×H mm)
640*335*670
690*335*670
700*350*660
Weight（KG）
50
55
60

5
4、INSTALLING &CONNECTION
4.1 Operate situation
Welding machine must put on flat、cleaning and dry ground. Forbid to put the
welding machine on following situation:
a. Under hard sunshine and raining place；
b. With dusty and combustible gas place
c. With harmful or caustic gas place；
d. With high temperature and steam place
e. Vibration and collision place
f. The distance between other circumambience smaller than 50 cm
g. The temperature higher than +40℃or lower than -10℃
4.2 Ground connecting
Connect the machine’s ground connecting port to power’s ground connecting
port and avoid damaged by electric shock.
4.3 Ventilation
To assure welding quality must reduce the wind influence. If operate in seal
space should supply aeration equipment and avoid lack of oxygen.
4.4 Power and line
Table 3 -power and line
Model
HP63
HP100
HP160
Power
3-Phase，AC 380V/415V 50Hz
Capacity
Power
≥ 12KVA
≥ 18KVA
≥ 34KVA
Engine
2 times than 12KVA
2 times than 18KVA
2 times than 34KVA
Input
Protect
Equipment
Fuse
20A
30A
55A
Leak electricity
safeguard
machine
20A
30A
55A
Input cable(mm2)
≥ 4mm2
≥ 6 mm2
≥ 10 mm2
Output cable(mm2)
≥ 10mm2
≥ 16 mm2
≥ 25 mm2
Groud cable(mm2)
≥14 mm2
≥14 mm2
≥14 mm2

6
4.5 Connect
a. The connecting must according to the Table 3 requirement
b. Turn off the cutting machine before connecting cable.
c. All joint must connect well, use insulating tape around bare wire.
d. After connecting, put power cable cover on machine, then fasten with screw
(forbid to operate with cover open)
e. To assure security forbid to input force on the cable.
FIG 1. HP63/HP100

7
FIG 2. HP160

8
4.6 Front and Back panel
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
电源开
电源关
FIG 3. front and back panel for HP63/HP100
FIG 4. front and back panel for HP160
Table 4

9
NO
Name
Function
1
Fuse
When short circuit the fuse welt to protect control transformer
2
Current
Adjust cutting current
3
Digital meter
Indicate preset current when machine stand by, indicate welding
current when cutting
4
Torch（-）
Power cathode,to connect the tie-in of water cooling torch
5
Torch switch
Joint torch control connector
6
Starting arc
Connect torch starting arc line
7
Work piece
（+）
Power anode, joint work piece
8
Air switch
Automatic to turn off power when machine overload or get
wrong, normally, this switch need to be turn on
9
Power
Power indicator, when cutting machine turn on, the indicator
will be light
10
Cutting
Cutting indicator,will be light when cutting torch turn on
11
Air pressure
Air pressure indicator, when low than 0.2Mpa,cutting machine
will stop work
12
Over-heat
Over-heat indicator, when cutting machine is over-heat, they can
not work
13
Lock/Unlock
Transfer switch, when in “lock”, press torch switch to ignite
arc,can loosen switch, cutting machine still go on cutting, if
press the torch switch again, cutting will stop
14
Air test/Cutting
When turn on air test, gas valve in cutting machine will be
opened to check gas flow rate, when turn on cutting, gas valve
will be automaticly open and supply gas when machine is
cutting.
15
Power box
Connect input cable
16
Control sign
Automaticly connect with cutting machine:①②：torch switch；
⑥⑦： successful to ignite arc
17
Output arc
Automaticly connect with cutting machine ①：+，②：-
18
Fixed clamp
Fixed input cable
21
Ground bolt
Make sure peoples’ safety
19
Air pressure
regulator
Adjust pressure of compressed air and to filter water in the air
20
Inlet of
compressed air
Connect gas tube and air pressure regulatorto supply gas for
cutting machine
21
ground
screwbolt
In order to make sure safety,please ground connection with this
screwbolt
22
Hydroelectric
interface
Power output(-), be used for connecting with hydroelectric
interface of water-cooling cutting torch
23
Gas electric
interface
Power output(-), be used for connecting with gas electric
interface of air-cooling cutting torch or inlet connection of
water-cooling cutting torch
24
Water pressure
Indicator of water pressure flow will be light when water
pressure is lower, and cutting machine will stop work.
25
Water return
Usd for connecting with water return pipe’s lead arc of water-
cooling cutting torch
26
Water-cooling/
air-cooling
According with cooling type of your cutting torch to chose
corresponding switch, when is “water-cooling”, if no water flow,

10
machine will stop work automatically. If chose “water cooling”
torch need to make sure under “water-cooling”condition,
otherwise the cutting torch will be damaged.
27
Water inlet
To link through water pipe and water outlet.
28
Water return
To link through water pipe and water return
5、PREPARE FOR WELDING
5.1 Connect cutting machine
According with 4.5 and F1 requirement to connect with cutting machine.
5.2 Cutting operation
a. Turn on the power source, cooling fan will be work as usual.
b. Turn on gas switch and put the switch to “air test”, then rotate air pressure regulator to
chose suitable gas flow rate. If air pressure low than 0.2Mpa,cutting machine will stop
wor, if everything is ok, air pressure light will turn off, please put “air test/ cutting”
switch to “cutting” at this time.
Note:air pressure ≥0.45～0.6MPa，flow rate ≥300L/min.
c. This cutting machine standard collocate adopt non-contact cutting torch. When cutting, nozzel will not
meet work piece due to if they get to each other, it’s easy to damage electrode and nozzel. at this time,
in order to control cutting torch height, we usually match series of cutting tool、photoelectric follow-
up、robot and CNC cutting machien tool.
Operation point as follows:
a) Trolley the cutting torch to meet workpiece, and keep distance 2-5mm, make sure nozzel axes
apeak to surface of work piece （F3）.
b) Turn on cutting switch, ignite plasma arc, cutting work piece fully, keep an even speed to move
along with cutting direction. Cutting speed is: base on cutting pierce, be fit for rapid to cut, if too
slow will affect cutting quality even arc break off. Pleasse control towing angle in 10°（F3）,
cutting quality is perfect. If too fast won’t pierce, even spatter.
c) Generally speaking cutting from edge of work piece, when need to cut from middle of work piece,
if material thickness is ≤5mm (stainless steel or carton steel, if other material, need to cut back
on cutting thickness), can directly cutting pierce. Method: put cutting torch on starting point of
cutting sew, make nozzel and work piece an included angle about 75°, then, turn on torch switch,
ignite arc to pierce work piece, adjust torch axes to apeak work piece. But if material thickness
≥5mm and need to cut in middle, please drill a hole which diameter is ≥3mm, ignite arc to cut in
hole. If finish cutting, unlock torch switch, break off plasma arc.compressed air will be delayed
spurt to cooling cutting torch. After some minutes pls move torch to finish cutting.

11
FIG 5.
5.3 Cutting torch for installing、maintenance and replacement
（1）Install cutting torch please reference picture F4. please note must make sure electrode is
tightened.
（2）Please replace nozzle on time when centre hole of nozzle is damaged( F5).
（3）Please replace electrode on time when electrode hafnium is damaged(F6).
FIG 6.

12
FIG 7.
FIG 8.
（4）When gas tube、shield cap、cable is damaged need to replace on time.
（5）When you need dismantle the cutting torch, please demount bolt M3,then insulated
pipe, at last is connect and transfer arc.when installing, please take care every joint
and insulated pipe to make sure safety in igniting arc.
（6）Cutting torch and cable team can not touch high temperature work piece.

13
6、DAILY MAINTAIN&CHECK
Safety warm：Before maintaining must switch off the power to avoid to be injured
such as electric shock and burned, and please wait for 10 minutes then start to repair.
Table 5 reference for daily maintain
ITEM
EVERY ONE OR TWO MONTH TO CHECK
AND MAINTAIN
1．Switch function for power
source
2．Cooling fan if is working
normally
3．If have unusual vibrate、noise
and smell.
4．If the cable connector is over-
heat.
5．Welding cable if is over-heat.
6．Cable if is damaged.
7．All cable connector if is loosen.
1．Remove smudginess：
Make use compressed air to remove
smudginess, especially for inductance 、
transformer、transistor and PCB.
2．Repaire for circuit diagram：
Check input ports, output ports and exterior
cable.
3．Check earth cable if is all right.

14
7、 TROUBLE SHOOTING
Inspector can check the machine follow Table 6, and repair follow Table 7. If the failure
cannot be eliminated, please contact with manufactory.
Attention：
1．Before the maintenance or repair, make sure the power is off to avoid electric shock.
2．The machine has tested before leaving factory, any modification is not allowed.
3．During the inspection of wire connecting, please don’t change any connecting.
Table 6 Inspection item
Failure
Causing
Cannot ignition
Power switch damaged or switch wire broken
The cable which connect with work piece damaged, or
the clamp cable damaged
Input power lack phase
Over loading, over heating or over current protection
Input power cable loosing
Output power cable loosing
Compressed air pressure is too low
Arc is unstable, or arc
break frequently
Output power cable loosing
Input power cable with bad connection
Decrease of output current
Input power is less than 330V～440V
Input power canle is too thin
Power capacity is low

15
Table 7 Inspection Table
NO.
Failure
Causing
Solution
1
Switch on, but power
indicator light not
work
1. Indicator light damaged
Change
2. 2A Fuse damaged
Change
3. No output power
Repair
4.Lack phase of input power
Repair
5. Power switch damaged
Change
6. Control PCB damaged
Repair
7.Control transformer
damaged
Change
2
Switch on, power
indicator light on, but
the fan not work
1.Fan stopp
Clear the fan
2. Fan capacitor damaged
Change
3. Fan wire damaged
repair
4. Fan damaged
Change or repair
3
Switch on, power
indicator light on, fan
works, turn on the
“air test”, but no air
flow
1. No input compressed air
Check the air source and
hose
2. Air pressure filter
adjusting error, pressure
meter shows zero, “air
pressure lack” indicator
light on
Readjust the air pressure
filter, method ：turn “air
pressure filter” clockwise to
increase the pressure, turn
anti-clockwise to decrease
pressure
3. “Air test” switch damaged
Change
4. Main electromagnetism
valve damaged
Change or repair
5. Air hose damaged
Repair
4
Turn on “Test air”,
nozzle fill with air,
turn on “Cutting”,
and turn on the
cutting torch, there is
no air
1.Torch switch damaged, or
switch wire damaged
Change or repair
2. Air valve QF1 damaged
Change
3. Control PCB damaged
Repair
5
Turn on the cutting
torch, nozzle with air
but torch not work
1. Input power lack phase
Repair
2. Input air flow is not
enough
Increase input air
3. Nozzle, electrode or other
parts damaged
Change
4. Torch damaged
Change
6
Kerf deflexion
1. Nozzle or electrode
damaged
Change
2. Nozzle and electrode does
notinstall correctly
Reinstall
3. Cutting speed is too fast
Reduce cutting speed
4. Nozzle and cutting
matericl out of the vertical
Adjusting

16
NO.
Failure
Causing
Solution
9
Set cutting
thickness cannot be
achieved
1. Input voltage lacking
Check input voltage
2. Input power capacity lacking
Increase input power
capacity
3. The pressure of input air is not
correct
Adjust the input air
pressure
4. Input air flow is small, such as
pressure meter drops to
0.3MPa during the
operation，and pressure
recover after stop working
Increase the input air
pressure to 300L/min；If
the air hose is small, please
change the hose to bigger
than Φ8mm
5. Cutting speed is too fast
Reduce cutting speed
6. Nozzle burned
Change a new nozzle
7. Electrode burned
Change a new electrode
8. Nozzle size is not fitted
Change to the right nozzle
9. Air hose or cutting cable
damaged
Repair or replace a new
one
10
Kerf with poor
quality
1. Cutting speed is too slow
Increase cutting speed
2. Nozzle or electrode damaged
Change a new one
3. Set value is not fit to cutting
material and thickness
Adjust set value
4. Wrong size nozzle
Change right nozzle
11
Torch burned
1. Nozzle or electrode loosing
Fasten the nozzle or
electrode
2. Torch wire connector loosing,
or cable/hose damaged
Repair
3. Torch connector with poor
insulation condition.
Make sure the torch
connector with good
insulation.
4. Shield cap of cutting torch has
been damaged
Change a new one
5.Compress air is over wet
Clear the water in “air
pressure valve”, if the air
was over wet, please install
water filter Lv1~2
6. Electrode burned
Change a new one

17
8、CIRCUIT DIAGRAM
Q F1
CN 13
97 97
105
87
86
50
52
51
52
52
50
51 3 2
1
4
3
2
1
97
731
2
CN 12
1 2 397
56
72
80
97
98
96
2
1
3
2
1
2
3
4 3 2 1
97 65 20
CN 9
CN 14CN 15
CN 3
CN 10
W
1
V
2
U
71
70
~
~ ~
BR1
RY 4
Q 3
C1- 9
C8
C2, 3
RY 1
RY 3
RY 2
S 1
C1
TV S1
8 4 8 5
Q 4 C10- 1 8
TV S2
8 6 8 7
Q 1
TV S1
8 0 8 1
Q 2
TV S2
8 2 8 3
L3
+
-
8 7 8 6
~ ~
FU SE
C8
TS
S4
68
67
66
1
2
3
CN 8 97
59 20 61 60
1 2 4 3 5
CN 6
CN 1
M1
~10 V
6
7
8
9
1
3
CT 1
380V 220V
0V
T1
FS
FH 7.8 20 .4 1 3
R1,2,3,4,5
L1
L2
B A
R3 R4 R4
R3
97 96
1 3
2
3
4
5
97
2 1
CN 9
CN 10
CN 11
CN 8
85
84
8 5 8 4
1
3
CN 6
83
82
8 3 8 2
1
3
CN 4
81
80
8 1 8 0
1
3
CN 2
~19 V ~19 V
1
98 2
2
2
2
2
D 1
D 2
D 3 D 4
A B
H GQ
200T
R1 R2
R1 R2
~16 V ~16 V ~16 V ~16 V ~16 V ~16 V ~16 V ~16 V
94 95
1 3
CN 7
87 2 92 93
1 3
CN 5
85 2 90 91
1 3
CN 3
83 2 88 89
1 3
CN 1
81 2
TR1
C6 C7
CT 3
6T
993
105
1
101
102
97
106
100
104
103
97
97
64
63
97
1
2
4
3
5
CN 5
662
RP 1
4K 7
55
54 1 2
C9 C10
J1 J1- 1
TR 2
18T/5 T
57
97
1
2
CN 2
S3
+15V
-15V
OUT
GND
LE M
检气 焊接
自锁
非自锁
CN 11
2 3 1
T2
~24V
0V
380V
D1 D2
+'
2
R 1 -9
2
R 1 1 -2 0
2
R 1 -9
2
R 1 1 -2 0
C1 C2 C1 C2
100
R3
100
R4
100
R5
KM 1 -1
C7
C7 C6
2
R1
2
R2 R3 C 3 C 4
C1 C2
C5
2
R4
X1
X2 X3X4
X5
FH7.820.416
FH7.820.415
FH7.820.415
C
D
21
0V 110V
CN 4
QF2 KM 1
25V
S2
2 1
FH7.820.412
C D
3 69
97 59 20 61 60
1 2 4 3 5
CN 1
586
切 割
气 压 水 压过 热
电 源
58 6
FH7.820.418
S5
7
CN 7
200 201
FH7.820.296
50
R1
50
R2
FH7.820.294
FH7.820.323
FH7.820.327
FH7.820.327
H C- II- AP 2
H P -A P1
H P -A P2
H P -A P5
H P -A P4
HP-AP3
H P -A P3
H C- II- AP 8
H C- II- AP 8
HC-II-AP5
H C- II- AP 3
R 1 -2R1 - 1
FH4.702.051
FH4.702.048
-
+ 1 2 3
1 2 3 4 5 6 7
115
116
115 116
115 116
71 69
TS O K