HUAYUAN LGK-100.160.200IGBT User manual

LGK-100.160.200IGBT
Inverter Air Plasma Cutting Machine
OPERATOR’S MANUAL
(PLEASE READ IT CAREFULLY BEFORE OPERATION)
CHENGDU HUAYUAN ELECTRIC EQUIPMENT CO., LTD.
R
ISO9001-2000 Certification
HUAYUAN WELDER

CHENGDU HUAYUAN ELECTRIC EQUIPMENT CO.,LTD LGK-100.160.200
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Safety Depends on You
HUAYUAN arc welding and cutting equipments are designed and built with ample safety consideration. However,
proper installing and operating can ensure your safety.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT CASUALLY WITHOUT READING THIS
MANUAL THROUGHOUT.
Special Notes (Very Important):
1. Pay attention to avoiding the machine falling down when it is placed on the gradient ground.
2. It is forbidden to unfreeze the pipeline by the cutter.
3. The shield rank of this series of cutter is IP21S, so working in rain is not suitable.
4．The cutter has outer static characteristic with rated duty cycle 100%, which means the machine can work
continuously at the rated cutting current. The machine has function of thermal protection in case that its
performance deteriorates or the machine burns. When the internal temperature exceeds a set temperature,
thermal protection moves on and the abnormity indicator lamp on the panel turns ON, then the cutter is
with no output. The machine can become normal and work only after the internal temperature drops down
and the abnormity indicator lamp on the panel turns OFF.
Purchase Date：
Serial Number：
Machine Model：
Purchase Place：

CHENGDU HUAYUAN ELECTRIC EQUIPMENT CO.,LTD LGK-100.160.200
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Cauti ons
Arc and arc rays can hurt.
All performing welding workers ought to have health qualification from the authority organization to
prevent you and others from arc radiation and burn. It should be prevented for children to enter into
dangerous area as well.
Be careful reading the following important items and the welder safety byelaw from the authority
organization. Be sure that qualified professionals perform all installation, maintenances and repair
procedures.
1 Electric shock: The welding circuits are not insulated when welding. If you touch the
two output electrodes of the machine with your bare skin at the same time, it will lead to
electric shock, sometimes even fatal dangers. Users need to follow the items below to
avoid electric shocks:
If possible, lay some insulating materials, which are dry and large enough, in your working field.
Otherwise, use the automatic or semiautomatic welding machine, DC welding machine as possible
as you can.
Components in the automatic and semiautomatic welding machine such as the welding wire reel,
feed wheel, contact tip and welding head are all electric components. .
Always be sure the machine has been connected perfectly to the work piece with the work cables
and should be as close as possible to the working area.
The work piece should be grounded perfectly.
Make sure that the insulating material of the electrode holder, the grounding clamp, the welding
cable and the welding head are not affected by damp, mildewed or spoilt, and be replaced
momentarily.
Never dip the electrode in water for cooling.
Never touch electric components of two welding machines at the same time, because this voltage is
supposed to be two times of welding voltage while the grounding mode is not clear.
While working high above the ground or other places having the risk of falling, please be sure to
wear safety belt to avoid losing balance caused by electric shock.
2 Arc: Use an arc welding mask to protect your eyes and skin from sparks and the rays of
the arc, pay special attention to the filter glass, which must be conformable to the
national standard.
Use clothing made from durable flame-resistant material or sailcloth to protect your skin from
hurting by the arc rays.
Remind other nearby personnel before working lest arc rays hurt them by accident.
3 Fumes and Gases: Welding may produce fumes and gases hazardous to health. Avoid
breathing these fumes and gases. While working in limited room, use enough ventilation
and/or exhaust to keep fumes and gases away from the breathing zone, or use the
respirator. Do not weld at the same time when using of degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with these gases to form phosgene, a highly toxic gas,
Some protective gases used in welding might displace the oxygen in the air, and can lead to hurt or
even death.
Read and understand the manufacturer’s instructions for this equipment, and validate the health

CHENGDU HUAYUAN ELECTRIC EQUIPMENT CO.,LTD LGK-100.160.200
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certification of consumptive materials, make sure they are innocuous.
4 Spatter: Spatter can cause fire or explosion.
Remove fire hazards from the welding area. Remember that spatter from welding
can easily go through small cracks and touch fire hazards. Protect all kinds of lines
going though welding area, including hydraulic lines in the wild.
Where compressed gases are to be used in the field, special precautions should be used to prevent
explosion.
When welding stops, make certain that no live part is touching the work piece or the work stage.
Accidental contact can create a fire hazard.
Do not weld containers or lines, which are not proved to be innocuous.
It is very dangerous to heat, cut or weld tanks or containers at entry holes. Does not start work until
the proper steps have been taken to insure that there is no flammable or toxic gas.
Spatter might cause burn. Wear leather gloves, heavy shirt, cuffless trousers, high shoes and a cap
over your hair to prevent from burning by spatter. Wear the ear shield when performing sideways
or face up welding. Always wear safety glasses with side shields when being in a welding area.
The welding cables should be as close to the welding area as possible, and the short, the better.
Avoid welding cables going through the building framework, lifting chains, AC or DC cables of
other welding machines and appliances. The welding current is strong enough to damage them
while having short circuit with them.
5 Cylinder: Damage of it might cause explosion.
Make sure that the gas in the storage cylinder is qualified for welding, and the
decompression flow-meter, the adapter and the pipe are all in good condition.
Make sure that the installation of cylinder is by the wall and bundled tightly by a chain.
Be sure to put the cylinder in the working space with no crash or shake, and far from welding area.
It is forbidden to touch cylinder with the welding clamp or the work cables.
Avoid facing the cylinder while installing the decompression flow-meter or the gasometer.
When not working, please tighten the valve.
6 Power: (For electrically powered welding and cutting equipment) Turn off input power
before installation, maintenances and repair, so that avoid accident.
HUAYUAN welding equipment is Ι class safeguard equipment; please install the
equipment in accordance with the manufacturer’s recommendations by specific persons.
Ground the equipment perfectly in accordance with the manufacturer’s recommendations.
7 Power:(For engine driven welding and cutting equipment)
Work in ventilated place or outdoors.
Do not add fuel near to fire or during engine starting or welding. When not working,
add fuel after engine is cooling down; otherwise, the evaporation of hot fuel would
result in dangers. Do not splash fuel out of the fuel tank, and do not start the engine
until complete evaporation of the outside fuel.
Make sure that all the safeguard equipments, machine cover and devices are all in a
good condition. Be sure that arms, clothes and all the tools do not touch all the
moving and rotating components including V belt, gear and fan etc.
Sometimes having to dismantle some parts of the device during maintenance, but must keep safety
awareness strongly every time.

CHENGDU HUAYUAN ELECTRIC EQUIPMENT CO.,LTD LGK-100.160.200
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Do not put your hand close to fans and do not move the brake handle while operating.
Please remove the connection between the engine and the welding equipment to avoid sudden
starting during maintenances.
When engine is hot, it is forbidden to open the airtight cover of the radiator water tank to avoid hurt
by the hot vapor.
8 Electromagnetic: Welding current going though any area can generate electromagnetic,
as well as the welding equipment itself.
Electromagnetic would affect cardiac pacemaker, the cardiac pacemaker users should
consult one’s doctor first.
The effect of electromagnetic to one’s health is not confirmed, so it might have some negative
effect to one’s health.
Welders may use following method to reduce the hazardous of electromagnetic:
a. Bundle the cable connected to the work piece and the welding cable together.
b. Do not enwind partially or entirely your body with the cable.
c. Do not place yourself between the welding cable and the ground (work piece) cable, if the welding
cable is by your left side, then the ground cable should be by your left side too.
d. The Welding cable and the ground cable are as short as possible.
e. Do not work near to the welding power source.
9 Lift Equipment: carton or wooden boxes package the welding machines supplied by
HUAYUAN. There is no lifting equipment in its wrapper. Users can move it to the
prospective area by a fork-lift truck, and then open the box.
If having rings, the machine can be transited using rings. While HUAYUAN Welding
Machine Manufacture reminds users, there is possible risk to damage the welding
machine. It is better to push the welding machine moving in use of its rollers unless
special situations.
Be sure that the appurtenances are all removed off when lifting.
When lifting, make sure that there is no person below the welding machine, and
remind people passing by at any moment.
Do not move the hoist too fast.

10 Noise: HUAYUAN Welding Machine Manufacture reminds users: Noise beyond the
limit (over 80 db) can cause injury to vision, heart and audition depending on oneself.
Please consult local medical institution. Use the equipment with doctor’s permission
would help to keeping healthy.

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CONTENTS
一.Summary …………………………………………………………… 5
二.Safety and Attention ………………………………………………… 5
三.Work Environment Conditions ……………………………………… 7
四.Technique Parameters ……………………………………………… 8
五.Working Principles ………………………………………………… 8
六.Panel and Functions ………………………………………………… 10
七. Protection function of the cutter …………………………………….12
八.Installation and Operation ………………………………………… 13
九.Maintenance ………………………………………………………… 14
十.Cutting technology instruction ……………………………………… 23
十一.Troubleshooting and Repair ………………………………………… 20
十二、Accessories …………………………………………… 21

CHENGDU HUAYUAN ELECTRIC EQUIPMENT CO.,LTD LGK-100.160.200
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一． Summary
1. Model description
LGK- 100 IGBT
IGBT Inverter
Rated cutting current
Air plasma
Cutting
Plasma machine
2. Characteristics
LGK-100.160.200IGBT inverter air plasma cutting machine is a new generated
cutter of our company. It has good characteristics as following:
1．This cutting machine adopts IGBT inverter technology which has high reliability
and efficiency, light weight.
2．Pre-set current function, step-less adjustable, suitable for various thickness work piece.
Thin plate uses low current, thick plate uses high current to ensure the cutting quality
and save energy.
3．Outer and dynamic characteristics are significantly better than leakage-reactance typed
cutter. Strike arc at a high success rate with stable cutting current. Arc is stiff with
smooth incision.
4．When cutting arc, it has function of ascending current slowly, which can
effectively extend the life of wearing parts of cutting torch.
5．Quite suitable for CNC automatic cutting and has all signal output which is
needed by CNC control.
6．The cutting current is very stable and voltage in ±15% range has no influence on
cutting current.
7．100% duty cycle 。It can work long time without stopping machine in max
current.
8．Have over, under voltage and phase-lacing protection function.
3. Usage
It is suitable for cutting kinds of metal materials like low carbon steel, alloy steel
and non-ferrous metal and for the industries related to metal cutting, such as boiler
pressure container manufacturing, chemical container manufacturing, industrial
power station construction, metallurgy, chemicals, aviation and aerospace industry,
automobiles and vehicle manufacturing, construction and so on.
二． Safety and Attention
Please follow the notes for the safety of you and others.

CHENGDU HUAYUAN ELECTRIC EQUIPMENT CO.,LTD LGK-100.160.200
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It is forbidden to unfreeze the pipe line by cutting power or other usages except
for cutting.
The cutter case should ground reliably. Please make sure the grounding bolts of
power ground reliably in case of electric shock.
Cutter is the equipment with high voltage. Please wear insulated protective
shield when cutting.
When exchanging torch and wearing parts, please turn off the supply power first.
Protective shield should be worn.
In case of any damage for eyes from ultraviolet radiation and strong light and for
skin from splashes, please wear some protective shield according to related rules
and regulations of labor protection.
It is forbidden to inhale harmful gases.
Cutting may produce fumes and gases hazardous to health. Please wear
responding shields and install aerator following related rules and regulations of
labor protection.
Cutting cannot proceed in closed container.
The work piece just for cutting is at high temperature. Please prevent from scald.
Protective gas cylinder and air compressor should be fixed displayed and
prevented from collision.
Cutter and cutting place should be far away from flammable materials.
Prevent foreign bodies from entering inside the machine. And protect the cable
from sharp materials.
Protect the machine from fall or collision.
In case of fall or collision, it can be used only after professional check and
confirm it normal.
In the face or inside of the cutting work piece, there should be no flammable and
explosive materials or chemical materials harmful to human.。
Installation and repair person must have electrician operation certificate which is
authorized by our country.
Cutting operation person should read this manual carefully and know the
operation method well.
三． Work Environment Requirements
Welding performance may not fit technique standards without the following
conditions.
1. It should be placed with small dust, no corrosive gases and no flammable and
explosive materials. Avoid vertical sunshine and rain;
2. Air relative humidity is no more than 90% at 20℃and no more than 50% at 40℃
3. When using air cooling torch, the ambient temperature should be from -10℃to
40℃.
4. It should avoid metal foreign bodies entering into the cutting power.
5. Cutting power should be 30cm away from the wall or other sealed-in objects. The
distance between two sets should be above 30cm.
6. The operation height should be less than 1000m.

CHENGDU HUAYUAN ELECTRIC EQUIPMENT CO.,LTD LGK-100.160.200
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四、Technique Parameters
1. Main technique parameters
LGK-100IGBT
LGK-160IGBT
LGK-200IGBT
Shell shield rank
IP21S
Rated input voltage
3～50Hz 380V
Rated input capability
14.5KVA
26.3KVA
34.9KVA
Rated output current
100A
160A
200A
Rated output voltage
120V
144V
160V
Rated duty cycle
100%
100%
100%
Open circuit voltage
285VDC
315VDC
315VDC
Current adjusting range
30～100A
40～160A
40～200A
Insulation level
F
F
F
Quality cutting capability（steel）
0.3～22mm
1～35mm
1～45mm
Max cutting capability（steel）
40mm
55mm
65mm
Applying plasma air
Compressed air
Compressed air
Compressed air
Work plasma gas pressure range
0.4~0.5MPa
0.4~0.6MPa
0.45~0.6MPa
Torch cooling method
Air-cooling
Air-cooling
Air-cooling
Air striking method
Secondary arc striking with high voltage non-contact
Dimension(L×W×H)
695×320×580mm
800×380×610mm
800×380×810mm
Weight
51Kg
73Kg
90Kg
2．Plasma gas conditions
Work pressure range：0.4MPa～0.6MPa
Gas supply pipe voltage-withstand ：≥1MPa
Gas supply pipe internal dimension：≥Φ8
Gas supply flux：≥180L/min
Filter water from gas and then put it into cutter
五．Work principles
The main circuit of cutting machine adopts advanced electron parts—IGBT as the
main inverter switch component. Three-phase AC power source is rectified at fundamental
frequency by the full-bridge and changed to 20KHz high-frequency current. After transformed
low voltage by the high-frequency transformer, rectified by fast recovery diodes and filter
reactor, the high-frequency current outputs cutting current. The control circuit controls output
current by adjusting pulse width of driving signal and obtains real time cutting current by its
sensor at output terminal in series as the negative feedback control signal which input into
special PWM adjusting integrated circuit after comparing with current adjusting signal, then
output controlled driving plus to control IGBT. Thereby maintain the strict invariableness of
output current and obtain dropping constant-current characteristic. Striking arc adopts
high-frequency striking model. The main circuit refers to appendix figure1，principle frame of
control circuit is shown as figure 2.

CHENGDU HUAYUAN ELECTRIC EQUIPMENT CO.,LTD LGK-100.160.200
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A C
D C
D C
A C
3-phase input（ AC）
I G B T I n v e r t e r
D C o u t p u t
I G B T d r i v e
c i r c u i t
Fundamental
frequency
rectifier&filter
R e c t i f i e r u n i t
C u r r e n t s a m p l i n g
Indu ctan ce
filt er
H i g h f r e q u e n c y
t r a n s f o r m e r
N e g a t i v e f e e d b a c k
c o n t r o l c i r c u i t
Overheat,under voltage
protection circuit
C u r r e n t g i v i n g
c o n t r o l c i r c u i t P I a d j u s t m e n t
c o n t r o l c i r c u i t
P W M c i r c u i t
Figure 2 Principle diagram
Common component list as diagram1
Diagram 1 Common component list
六． Panel and its functions（see Figure 3）
No.
Symbol
Components name
Model
Remark
1
V2、V3
IGBT module
SKM100GB128D
LGK-100IGBT
2
TA1
Hall current sensor
TKC-100BS
LGK-160IGBT
3
QF1
Air switch
DZ47-63/3P D63
LGK-200IGBT
4
R6～8
Resistance
RXGL-1.8Ω/100W
LGK-100IGBT
5
YV1
Magnetic gas
valve
Q22XD-5-36V AC
LGK-160、200IGBT
6
KM1
Contactor
CDC1-16-24VAC
LGK-100、160IGBT
7
EV1
Cooling Fan
200FZY2-D/AC220
（with capacitor）winding
LGK-200IGBT
8
RP1
Potentiometer RV24YN-20S-B502
9
KT1
Temperature relay JUC-6F-75℃closed
10
SA1、SA2
Vessel shaped
switch R13-66A
11
Air filter regulator AFR-2000-A
12
C16
Capacitor 0.0056U/20KVDC
13
BP1
Pressure
controller
YKC 0.3/0.25
Open external screw 1/8
14
AP1
Program control
broad LGKAP1
LGK-100IGBT
15
AP2
Main control
broad LGK7AP2
LGK-160、200IGBT

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a) Digital ammeter: Displaying cutting current
b) Cutting current adjusting knob: Adjusting cutting current
c) Power indicator lamp: Indicating if the cutter is conducted.
d) Air pressure indicator lamp：It is ON when the pressure of compressed air exceeds
0.2Mpa. It is OFF when the pressure is less than 0.15Mpa.
e) Cutting indicator lamp: Indicating if cutting proceeds.
f) Overload indicator lamp: It is ON when the cutter is over loaded(generally because
cooling fan is damaged.)
g) Supply abnormality indicator lamp: It is ON when power source misses phase or it is
less than 310VAC.
h) Gas control selection switch: When it turns on TEST, gas valve opens to test gas flux.
When it turns on Cutting and cutting starts, the gas valve opens automatically.
i) Operation mode selection switch: When it turns on Non Self-lock, the torch switch
should be pressed at the process of cutting. When it turns on Self-lock, press the
torch switch and loosen it, the cutting can proceed.
j) Cutting ground wire outlet: To connect cutting ground wire
k) Torch control outlet: To connect torch control signal line
l) Torch arc striking terminal: To connect torch arc striking wire
m) Output connector of gas and power: The current output connector is also air outlet
which is used for connecting air cooling cable outlet of torch.
n).. Spare wire hole for the are voltage output: the arc voltage output wire is not
connected when the machine finished, when needed, please open the head cover of
the cutter, using a two cored wire to join with the terminal of the LGK7-AP5, which
has two output signal, one is the 1:1 output and the other is 1:20 output, please
connect the wire according to the requirements, and pay attention to the negative and
positive electrode.
o) . Control signal connector: To control automatic cutting equipment
p). Power source switch：Control the ON/OFF of 3-phase power supply of cutter.；
q). Air voltage regulation filter ：For adjusting usage pressure of compressed air and
filtrating water from air.
r). Hydraulic pressure indicate lights: connect the cooling water supply, when current
>0.45L/min, the light will be on.]
s). The water/air torch choose function: the air torch is only suitable for the air torch
setting position, the same as the water torch.
t). Water/electricity output joint: the current output joint is also the water output joint,, it
is for join with the water cooling cable.
u). The water recycle joint of the torch: It is use for join with the water recycle pipe.
v). Water recycle joint: it is use for join with the water tank recycle pipe.
w). Water input joint: it is use for join with the water tank output pipe.

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切割电 流
Cutting current
A
华远焊机
NHUAYUAN WELDER
R
电源指 示
Power
气 压 切割 过热 供电异 常
Air pressure Inc ise Overload
指示灯
INVERTER AIR PLAS MA CUTTING MACHINE
逆变式空气等离子切割机
LGK-100IGBT
Input fault
自锁 试气
4-Step Check air
非自锁
2- St ep
切割
In ci se
I n di ca to r
切割地线
Work cable
引弧
Strike arc line
控制
Control signal Output air & current
气电输出
9
7
8
65
1
2
34
10
11 12 13
控制讯 号
C on t r ol S ig n al
弧压输 出
Ar c Vo l ta g e
此开关仅作保护用
请另配电源开关！
Th is swit ch is o nly use d for Protec tion ！
输入 3/ N ～3 8 0 V
In p u t 3/N ～3 80 V
3～ 5 0 H z
绝 缘等 级 :F
防 护 等级 : I P2 1S
冷却方式：风冷
U2
X
I2
型 号 :LGK-100IGBT
f
1f2
3～
10 0 %
100A
1 20 V
U1= 380V
GB15579.1-2004
出 厂编号 :
R
30A/92V-100A/120V
I1max =22 A I1eff =22 A
U0=2 85V
重量 ： 51 kg
地址 ：成 都市 武侯科 技园 武兴 四路 5 号
四川华远焊接系统有限公司
14 15 16 17
Figure 3 Function of pane
七． Protection function of the cutter
Air pressure protection
1. When the indicate number of the air pressure meter, which is on the back of the cutter,
lower than 0.2 MPa, it will protect the circuit and the welder cannot open.
2. When the indicate number lower than 0.15 MPa during the process, the cutting arc
will stop.
Note: When adjust the air pressure, the panel function must set to ‘air trying’.
Water pressure protection（LGK-100 without this function）
1. When the water supply lower than 0.45L/min, it will protect the circuit and the cutter
will not start.
2. When the water supply lower than 0.4L/min during the process, it will protect the
circuit, the cutting arc will stop automatically.
Over-heat protection
When the ambient temperature is too high or the cooling fan is broken,, the cutter
will be over heated under the rated current, it will protect the circuit, and the cutting arc
will stop automatically.
Abnormal power supply protection
1. When supply lack of phrase,, it will protect the circuit, and the arc striking will not
success.
2. When the 3 phrase lower than 330VAC, it will protect the circuit and the arc striking
will not success.

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Note: the water and air pressure protection is only for protecting the torch.
八．Installation and Operation
a) Transport and Lift
i. Power source should be shut off before moving the cutter.
ii. The wheels of cutter should face down during transportation. It is forbidden to
be displayed transversely or upended.
iii. When lifting, tie the scope with enough strength to the diagonally ring and lift
vertically.
iv. During the long-distance transportation, prevent the cutter from traversing and
locking the wheels. Shock absorption foam should be placed around with no
rain.
b) Installation and Connection
A . Power source should be shut off before installation and connection.
B . Installation environment should fit the third requirement
C . If cutting power source is slanted, prevent it from falling down.
D .Shield rank for cutting power is IP21S. The installation and operation cannot
proceed in the rain.
E .Power supply requirements
i. Voltage fluctuation≤±20％；
ii. Frequency fluctuation≤±1％；
iii. Asymmetry rate of three-phase supply system≤5％；
iv. Power supply wire profile, ground wire profile, air switch and fuse should
refer to the diagram below.
Items
LGK-100
LGK-160
LGK-200
Power supply wire profile
（mm2）
≥6
≥10
≥16
Ground wire profile（mm2）
≥6
≥6
≥10
Air switch capacity（A）
100A
100A
160A
Fuse capacity（A）
45
60
90
F .Installation of power wire
Shut off the power switch first. Connect the power input wire of cutter back panel to
switchbox fitting the parameters in the diagram above.
G .Connection of ground wire
Connect the green-yellow wire of power source line which profile must match with
above form to ground with conducting wires firmly.
H .Connection of compressed gas.

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Hoop
Gas pressure
regulating valve
Inlet pipe
Draining water tip
The compressed gas should fit the second rule of the fourth item. Connect the
gas pipe with the gas inlet of inhaler on the back panel and hoop tightly.
c) Connection of cutting torch
1. Choose the nozzle of torch.
Different nozzle aperture diameter is suited by different current range,
please choose it refer to the form as below.
Nozzle
aperture
dia.（mm）
1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6
Suitable
current
（A）
20～
30
30～
40
40～
65
70～
90
80～
100
110～
130
140～
170
180～
210
220～
250
2. Connection of gas cooling torch: first connect the torch cable connector
M14 nut with the copper nozzle signed with Gas& Power Output on the
front panel, screw down the nut; then connect the torch striking wire to
terminal post signed with Arc Striking on the front panel and screw down
the nut. Finally, connect the torch control pin to the outlet signed with
Control on the front panel and screw down the nut.
Special notes: it should not exceed the rated current of torch when use gas
cooling torch, or it will be damaged by heat.
3. The requirements on connection of control pin when customers change
different torch from another factory.
Adopt WS20J4TQ 4-core pin form WEIPU Electrical Appliance Co., Ltd
Requirements on gas cooling torch:
1). Connect the 1,2 pin of 4-core pin to switch control wire of cutting torch.
2). Short connect 3,4 pin of 4-core pin by gummed wire.
3). Striking arc wire connects cold-press joint UT-8.
d) Connection of cutting ground wire
Connect the fast connector of cutting ground wire with the outlet signed with Cutting
Ground Wire on the front panel and screw down it clockwise. The other end of the cutting

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ground wire is firmly connected to work piece.
Operation method
e) Security Notes
f) Close the power switch after installation and connection. Then the power indicator
lamp should be ON.
g) Start gas supply equipment and turn on the switch. Then the power indicator lamp
on the panel should be ON. If the gas pressure is less than 0.25Mpa, the lamp will
be OFF. It needs to check gas source.
h) Gas control switch turns onto Gas Test. Adjust the pressure Adj. knob of inhaler on
the back panel to make the pressure and flux fit cutting condition, usually
0.45MPa.
i) Select panel operation method and control switch point. At Non self-lock point, the
Notes:
Operation strictly accordant with the following steps
Notice
Electric shock may
hurt or even kill
man.
Cutting may cause fire or explosion
Splashes may ignite flammable materials nearby.
Those materials should be 10m away from the
working place.
Shut off the power during connection
Do not touch the conducted parts
Fume & dust is harmful.
Do not breathe in the fume and dust
caused by cutting
Clean up the oil spot on work piece.
Keep fresh air in working place
Fume extraction equipment should
be prepared.
Arc may hurt your eyes and skin.
Strong arc may hurt your eyes.
Ultraviolet radiation generated by arc may hurt
skin and eyes. Please wear shielded guard when
cutting.
Overheated part may hurt
your skin.
Do not touch the overheated part on
the work piece.
Do not touch hot cable or torch just
by hands.
Fast moving thing may injure you.
Do not put your hands or other things into the
fan shield.
Cover the opened case shell well during cutting
operation.
In case of injury for your skin and eyes, please wear
required guards according to Labor Security and Hygiene
rules. Electrode and nozzle should be replaced only after
the cutter is power off.
Operation should proceed according to related Labor and
Security regulations.

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torch switch should be pressed all the time during cutting. At Self-lock point, press
the torch switch and then loosen it. Cutting can start. User can make selection with
regard to his operation habit.
j) Adjust cutting current button to needed current according to the value in digital
display. (This machine has pre-set function)
k) Checking the panel indicator lamps. The state of indicator lamps related to
operation is shown as following diagram.
Indicator
Lamp
Power
Cutting
Gas
pressure
Water
pressure
Overheated
Supply
abnormity
State
ON
OFF
ON
ON
OFF
OFF
l) Keep the torch nozzle 2 to 5mm away from work piece. The axis line of nozzle
should be perpendicular to work piece face. Press torch switch. Compressed gas
bursts out from nozzle. After primary gas supply for 1 to 2 seconds, high
frequency is made. Arc is striking. Move torch and cutting begins.
m) When operation method of front panel is at Non self-lock point, press the torch
switch and strike arc, and then cutting begins. Loosen the switch with no voltage
output, and then cutting ends, and compressed gas stops supply after lasting for 9
seconds. When it is at Self-lock point, press the switch and loosen it, and strike arc
automatically. Press the switch again or press it till the arc is off, then there is no
voltage output. Cutting ends, and compressed gas stops supply after lasting 9
seconds.
九.Maintenance
a) The cutter can not be operated and placed in strong sunshine.
b) The cutter cannot be operated and placed in moist environment.
c) The vent hole should not be covered when the cutter is operated.
d) The cutter should be operated and placed in drafty environment.
e) The case should be opened once a year at least. Clean up the dust and
metal scraps inside the machine by compressed gas.
f) Check regularly if the cable insulation cover is damaged. If there is
any damage, repair it or change it.
g) Check regularly if the electric connection is loose and then tighten it.
h) Let out regularly the water and impurities from filtering reducing
valve.
Notes: When maintaining the cutter, professional electrician should be asked to dismantle
the power wire from switchbox and open the machine case.
十. Cutting technology instruction
1. The related main technical parameter
Cutting material and thickness
The cutting material and thickness are the basement of the parameter, if the
material is thick, it should adopt large current and diameter of the nozzle, different
material with the same thickness, the parameter should also be different.

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Nozzle select
The three main dimension of nozzle are the diameter of nozzleφ, the
hole length ιand the compact angle α,can affect the cutting. It should be
a dimension of the hole length and the diameter, the value is usually
lower than 2, it usually take
   

, the compact angle usually takeα
＝30°～60°, and now it usually takeα＝30°
Cutting current and arc voltage
The cutting current should be according to the diameter of the nozzle, the
relationship between the two should be as: I（current A）＝（70～100）×φ（mm）.
As the increasing of the metal thickness, the arc current affection for the cutting
speed will become less. But the more increasing of the current, the more burnt
damage will happen for the electrode and the nozzle. So when cutting the metal
work-piece with large thickness, it usually increase the speed through the arc voltage
increasing. The actual arc voltage is decided not only by the air but also by the air
current and nozzle shape. The more air current is, the more voltage will increase.
Air current Q
The arc voltage will increase as the air current increase, that is if the power
increase, the speed will be quicker, so as the cutting capacity and quality. Because if
the arc compact increase, the energy will be more concentrate, the arc temperature
will increase rapidly, and the spray speed will increase, as well as the arc current
capacity. But large current may cause the unstable of the plasma arc. The air current
will be stable for one torch under the usual circumstance. It can be adjust a little
when the cutting thickness is large.
The distance between the nozzle and the work-piece (d)
If the d is too high, the power of plasma for metal melting will be
decrease, so as the cutting ability, the prick on the button will increase,
and the unstably of the arc will increase. However, if the d is too small,
the short current between the nozzle and the work-piece will increase,
usually ensure there is no short current, we take d as small as possible.
The cutting thickness for air plasma is 2～5mm, the work-piece can also
contact with the nozzle, that is the nozzle glide on the surface of the
work-piece. This cutting method is called contact cutting, the cutting
thickness is the half as the ordinary cutting.
no-load voltage
It needs power source with high no-load voltage when cutting material with
large thickness, the no-load voltage is related with air, for example, using argon gas,
the voltage may lower, while using air.
cutting speed
The cutting speed is related with many parameter, the main parameter is the
cutting thickness, current, air current and nozzle diameter. There maybe a little spare
space to ensure the cutting quality and speed.
2. diminish the cutting prink
the characteristic of the cutting prink
The ordinary cutting surface is smooth and beautiful, but if the parameter not

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suitable, some prink maybe left on the cutting surface.
Slag is coagulated on the lower side of the cutting slide when cutting the metal
or oxide. This is because the melted metal is heavier than its oxide and blow.
When cutting the alloy steel, the melted metal is uneasy to blow away because
of its bad fluidity, in addition, the alloy steel have bad thermal conductivity, the
cutting surface bottom is easy over-heated, the left melted metal melting with the
cutting bottom shaped the strong prink.
On the contract, the cutting bottom is not easy to shape melted metal when
cutting copper, aluminium and its alloy. The prink is easy to mop.
the factors affecting the forming of prink
The fluidity of the melted metal is not good, when the power is too small or the
plasma arc compact not good, the temperature of melted metal during the cutting
process is low, lucidity is not good, at this time, even the air current blows strong,
it is not easy to blow away the metal, so the prink formed.
When cutting the thick material , the large cutting seam formed the drag. During the
cutting process, different parts of the metal felt different heat, the heat on the upside
is larger than the downside, so the distance on the upside is longer than the
downside, this is called the cutting drag, which is related with the shape of plasma
and cutting speed. When the flame is short while the cutting speed is quick, the
distance difference increase, so the vertical and horizontal blow power of the arc
formed, the vertical one help to blow away the melted metal, while the horizontal
one make the melted metal flow away, the over-heated metal will melt parts of the
material bottom, then formed prink when they are cooling.
The over-heated of the bottom. When the cutting speed is too slow, the downside of
the cutting surface is over-heated, even melted, the connect of the liquid metal and
the bottom increase, so the melted metal is uneasy to be blow away.
The air current blow force is not enough. When cutting with plasma, the arc blow
force including the air current blow and the arc electromagnetic force, of this, the air
current blow act the main function, if the air current blow force is not strong enough,
it cannot ensure all the prink will be flow away, then the prink formed.
the measurement to diminish the prink,
Ensure the center between electrode and nozzle precise joint so that the compact
of the plasma arc will not be damaged and the flame not concentrate to weaken the
cutting capacity.
Enough power source to ensure the fluidity of the melted metal, as well as increase
the stability of the cutting speed and process. This made it possible to adopt large
air current to enlarge the air blow force, then diminish the prink.
Adjust suitable air current and cutting speed. If the air current is too low, the blow
force is not enough, while if too high, the plasma arc will be shorten, the cutting
surface will be “V” shape, the drag enlarge. The two condition will form prink.
When cutting speed is slow, the cutting surface is large and rough, the bottom is
easy to be over-heated, while the cutting speed is fast, the drag is enlarge, this is
not good for the prink diminish.
So under certain circumstance, the air current and cutting speed has a match range.
diminish the cutting surface slanting and rounding problem

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The cutting surface will be a little slant and the upper side will be a little round
when cutting with air plasma. Though the slanting range is acceptable during the
welding process, in order to improve the cutting quality, many people paid attention
on it. Usually slowing down the cutting speed properly can avoid the slanting, but this
may enlarge the cutting surface and decrease the production capacity. So this
measurement is not wildly used. Recently, people can avoid the slanting by the nozzle
improvement, this is called super cutting method. That is adopting muti-nozzle during
the cutting process, the air current from the small hole is parallel with those from the
main hole, this can avoid the falling of the plasma flame to get the parallel cutting
surface, square upper side and no slag seam on the lower side.
十一. Troubleshooting & repair
If there is trouble caused by high voltage in the machine, professional electrician or
serviceman of our company should be asked to repair.
Please check following first when there is trouble.
1、The three-phase power should be 380±40VAC，check if it missed phase or voltage
fluctuation exceeds its supply range.
2、Check if the supply abnormity indicator lamp is ON. If it is ON, check if the
three-phase power switch of switchbox is damaged, and if the fuse and the machine
power wire are well firmed. Otherwise it will cause phase missing or bad contact,
which makes the machine work abnormally.
3、Check if the torch switch and its wire are damaged or short-circuit, and if the nozzle
and electrode are damaged.
4、If control pin has connection error when customers use different torch, refer to
Connection of Torch in manual to check it.
5、Check the cutting ground wire is in good condition.
6、Check if compressed gas inhaler at the back of the machine can drain regularly.
7、 Check if the panel gas pressure indicator lamp is ON. If it is not ON, check if
compressed gas pipe is firmly connected with normal pressure. When the pressure is
less than 0.3Mpa, the lamp is not ON.
8、 Check if the panel overheat indicator lamp is ON. If yes, check if the temperature
relay on the radiator is damaged or not.
9、Open the coping to check if the lead type fuse beside the control transformer has
been fused.
Ordinary trouble and repair as following diagram
Trouble Reasons Solutions
1.When the power is
switched on, the
lamp and the digital
meter are not ON.
1.Three-phase power misses phase
2.Supply power is damaged
3.Power control fuse is broken
1.Check three-phase power source
2.Change power switch
3.Change power control fuse
2．Supply abnormity
indicator lamp is ON
without arc striking
1．Three-phase power misses phase
2. Three-phase power overload or
in low voltage
Check three-phase power source to
ensure the supply voltage accords with
the supply requirements.

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3. No arc striking or
arc breaking during
cutting. Overheat
indicator lamp is
ON.
1．The ambient temperature is too
high.
2．When cutting, cooling fan
rotates slowly or do not rotate, so it
cools badly
3．Temperature relay is damaged
1．Let the cutter not work for a while
2．Check fan power source or change
cooling fan
3．Change temperature relay
4．It cannot start.
Gas pressure lamp is
not ON.
1．No gas pressure
2．The pressure of gas supply is too
low
1．Connect the gas source
2. Adjust the pressure of gas supply.
5. With no arc
striking, cutting
indicator lamp, gas
pressure lamp are
ON, and supply
abnormity indicator
lamp and overheat
lamp are not ON.
1．Cutting ground wire is not well
connected.
2．Gas pressure is too high.
3．Torch electrode and nozzle are
badly broken.
4．Torch electrode and arc striking
wire short-circuit, which cause the
damage of torch.
1．Connect the cutting ground wire well
2．Low the pressure of gas supply
3．Change the electrode and nozzle
4．Change the torch
6．Cutting with low
capacity
1．Gas pressure is too high or too
low.
2．Work piece is too thick
3．Torch electrode and nozzle are
broken
4．Plasma arc is not perpendicular
to the work piece
5．Cutting speed is too fast or too
slow
1．Adjust gas pressure
2．The thickness of work piece should
be with the quality cutting range.
3．Change electrode and nozzle
4．Adjust torch angle
5．Adjust cutting speed
7．Electrode and
nozzle is used for a
short time
1．Gas pressure is two low
2．Nozzle is too near from the work
piece. The distance is less than
2mm.
1．Adjust gas pressure
2．The distance should be from 2mm to
5mm
If the troubles cannot be resolved, please inform our local agent of the specific problems
or contact us directly.
十二、Accessories
1. Cutting power source 1set
2. Air cooling torch(cable 5m) 1
3. Ground cable 3m 25mm2(withDJK-50 red connector and ground clamp) 1
4. Electrode 5
5. Nozzle 5
6. Shield 2
7. Product certificate 1
8. Operator’s manual 1