HUAYUAN LGK-200IGBT User manual

LGK-200IGBT（B）
PLASMA CUTTING MACHINE
MANUAL
INSTRUCTION
(PLEASE READ IT CAREFULLY BEFORE OPERATION)

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 external static characteristic with rated duty cycle 100%, which means the machine can work
continuously at the rated cutting current. The machine has the function of thermal protection. When the internal
temperature exceeds a set temperature, thermal protection moves on and the abnormity indicator lamp on the panel turns
ON, then there is no output in cutter. The machine can become normal and work only after the internal temperature drops
down and the abnormity indicator lamp on the panel turns OFF.
5. The EMC grade of this machine is A
Purchase Date：_______________
Serial Number：_______________
Machine Model：______________
Purchase Place：______________

Cautions
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
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 equipment, 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.
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 maintenance.
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.

CATALOGUE
Summary.....................................................................................................................................6
Model description................................................................................................................6
Features................................................................................................................................6
Usage...................................................................................................................................6
Symbol instructions.............................................................................................................6
Safety and attention ....................................................................................................................7
Working Environment Requirements .........................................................................................8
Environmental condition .....................................................................................................8
Power supply condition.......................................................................................................8
Technical parameters..................................................................................................................8
Main technical parameters...................................................................................................8
Plasma gas condition...........................................................................................................9
External characteristic curve ...............................................................................................9
System instruction ......................................................................................................................9
Working principles ..............................................................................................................9
Machine working theory....................................................................................................10
Installation and operation .........................................................................................................10
Moving and lifting.............................................................................................................10
Open the packing and check..............................................................................................10
The fix and installation of the plasma power source.........................................................10
The connection of three phase input cable ........................................................................11
Panel and its functions.......................................................................................................13
Protection function introduction........................................................................................14
Operation...........................................................................................................................15
Gouging operation.............................................................................................................16
Cutting operation...............................................................................................................16
Gouging technology instruction ...............................................................................................17
Cutting technology instruction .................................................................................................19
The related main technical parameters..............................................................................19
Eliminate the cutting burr..................................................................................................20
Repair and maintenance............................................................................................................21
Trouble shooting.......................................................................................................................21
Trouble shooting................................................................................................................21
Some main components sheet............................................................................................23
Packing list ...............................................................................................................................23
Attached diagram：main circuit diagram ................................................................................24

Summary
Model description
L G K -□□□ IGBT
IGBT Inverter
Rated cutting current
Air
Cutting
Plasma
Features
It has good characteristics as following:
1) It can be used for cutting and gouging both
2) This cutting machine adopts IGBT inverter technology which has high reliability and efficiency. It is light
weight.
3) Pre-set current function. Step-less adjustable cutting current, suitable for cutting various thickness work-piece.
To ensure cutting quality and save energy, low current is applied to cut thin plate, and high current is
applied to cut thick plate.
4) External and dynamic characteristics cutter are significantly better than leakage-reactance typed cutter. High success
rate in striking arc. Stable cutting current. Good arc stiffness. Clean and smooth incision. Excellent technology
performance.
5) It has the function of ascending current slowly, which can effectively extend the work life of wearing parts
and cutting torch.
6) Quite suitable for CNC automatic cutting and has all signal output which is required by CNC control.
7) The cutting current is very stable and it will not be influenced by grid voltage fluctuation.
8) 100% duty cycle. It can work continuously under max current.
9) Have over/ under voltage and phase missing protection function.
Usage
It is suitable for cutting kinds of metal materials like low carbon steel, alloy steel and non -ferrous metal
and is widely applied in the manufacturing of boiler pressure container, chemical container, industrial power
station construction, metallurgy, aerospace industry, automobiles, building an so on.
Symbol instructions
There are below symbols on this machine.

Read the manual carefully
Dangerous voltage
Over-heat
Input voltage
Power abnormal
Output current
Air pressure
Voltage output
Coolant liquid input
Voltage input
Coolant liquid output
Cutting
Plasma torch
Check gas
Lock
Ground lead
Unlock
Protection ground lead
Water cooling
Remote control
Air cooling
Increase/ Decrease
The nozzle connection of
plasma torch
Plasma gas and torch
electrode
Current
Coolant liquid and torch
electrode
Safety and attention
Please follow the notes for the safety of you and others.
It is forbidden to unfreeze the pipe line by cutting power or other usages except for cutting.
The cutter casing 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 order to avoid any hurt to eyes from ultraviolet radiation and strong light and to skin from spatter, please
wear protective shield according to related rules and regulations of labor protection.

It is forbidden to inhale harmful gases.
The fumes and gases produced during cutting is hazardous to health. Please wear protective shields and
install aerator according to related rules and regulations of labor protection.
Cutting cannot proceed in closed container.
The work-piece just after being cut is at high temperature. Please prevent from scald.
Protective gas cylinder and air compressor must be placed in a fixed position 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 checking.
In the surface 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 state-authorized electrician operation certificate.
Cutting operation person should read this manual carefully and know the operation method well.
Working Environment Requirements
Environmental condition
Please use the machine in a clear place without any of dust, corrosive gas and inflammables and explosives; Do
not use it in open air and rain;
Required air relative humidity should ≤90％(at 20℃)，40℃≤50％(at 40℃)；
Environment temperature range should be at-10℃～40℃;
The coolant liquid cannot be frozen when use;
Any metal materials cannot be put on or insider the power source;
Keep the machine away from the wall of some other closure things at least 30cm, two machines distance at least
30cm.
Use it under altitude lower than 1000m.
Power supply condition
Power supply：3～380V/50Hz；
Voltage fluctuation range ＜±10%；
Frequency fluctuation range＜±1%；
Unbalance rate of three phase voltage ＜±5%；
When use engine generator: the output power of the generator have to be 2 times higher than the rated power
of the plasma power source, with compensating coil;
Technical parameters
Main technical parameters
Item
Parameter
Rated input voltage
3～380/415V 50/60Hz
Rated input capacity
46.7kVA
Rated output current
200A
Rated output voltage
160V
Rated duty cycle
100%
Non-load voltage
315VDC

0
100
200
300
400
500
0 50 100 150 200 250
Current adjust range
40～200A
Quality cutting thickness（steel）
1～45mm
Max. cutting thickness（steel）
65mm
Plasma gas
Compressed air
Air pressure（gouging）
0.35～0.45Mpa
Air pressure（cutting）
0.45～0.6MPa
Torch cooling mode
Air/water cooling
Arc strike mode
Non-contact
Insulation grade
F
Protection grade
IP21S
Dimension mm(L×W×H)
800×380× 810
Weight
82kg
Plasma gas condition
Gas pressure range：0.5MPa～0.7MPa
Gas supply pipe compression strength：≥1MPa
Gas supply pipe inner dimension：≥Φ8
Gas flow：≥180L/min
Filter the water in the gas, then feed into the plasma
External characteristic curve
System instruction
Working principles
The control circuit of this cutting machine adopts advanced electronic part IGBT as the main inverter switch component.
Three-phase AC power is converted to 20KHz high-frequency DC current after being rectified by three phase rectifier. Then
under the function of IGBT inverter the DC current is inverted to AC high frequency current, which is inverted to DC current
after experiencing voltage reduction in high frequency transformer, current rectifying in fast recovery diode. This DC current
is filtered through reactor, and the output cutting current is obtained. Control circuit can control output current by
controlling driven pulse width. The real time cutting current, which is obtained through current sensor connected to output
terminal in series, is used as negative feedback control signal. After comparing with current adjusting signal, the negative
control signal is sent to PWM adjusting integrated circuit, then a controlled driving pulse is output to control IGBT. Thereby a
constant output current can be maintained, and a steep dropping & constant current external characteristic is obtained.
Striking arc adopts high-frequency striking model. The main circuit refers to appendix figure, and principle diagram of
control circuit is shown as below figure.
（V）
（A）