HUAYUAN LGK-63MA User manual

LGK-63/100MA
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 60%, which means the machine can
work 6 minutes and rest 4 minutes at the rated cutting current in 10 minutes. 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 onthe panel turns OFF.
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 specialattention 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 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.

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 reducethe hazardous of electromagnetic:
a. Bundle the cableconnected 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 groundcable 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.

CONTENT
1 Summary ........................................................................................................................................................... 1
1.1 Model description........................................................................................................................................1
1.2 Characteristics .............................................................................................................................................1
1.3 Usage..........................................................................................................................................................1
2 Safety and Attention........................................................................................................................................... 1
3 Work Environment Requirements ........................................................................................................................ 2
4 Technical Parameters.......................................................................................................................................... 2
4.1 Main technical parameters ...........................................................................................................................2
4.2 Plasma gas conditions ..................................................................................................................................3
4.3 External Characteristic..................................................................................................................................3
5 Work principles ..................................................................................................................................................3
6 Panel and its functions........................................................................................................................................ 5
7 Installation and Operation .................................................................................................................................. 6
7.1 Transport and Lift.........................................................................................................................................6
7.2 Installation and Connection ..........................................................................................................................6
7.3 Power supply requirements..........................................................................................................................6
7.4 Installation of power wire.............................................................................................................................7
7.5 Connection of compressed gas and the usage of air filter regulator .................................................................7
7.6 Connection of cutting torch ..........................................................................................................................7
7.7 Connection of cutting ground wire ................................................................................................................7
7.8 Operation Caution........................................................................................................................................8
8 Maintenance...................................................................................................................................................... 9
9 Cutting technology instruction............................................................................................................................. 9
9.1 The related main technical parameters..........................................................................................................9
9.2 Eliminate the cutting burr........................................................................................................................... 10
10 Troubleshooting & repair ................................................................................................................................ 11
11 Accessories..................................................................................................................................................... 11

1
1Summary
1.1 Model description
L G K - □□□ IGBT
IGBT Inverter
Rated Cutting Current
Air Plasma
Cutting
Plasma Cutting
1.2 Characteristics
LGK-IGBT inverter air plasma cutting machine is the latest development cutter in our company. It has good characteristics
as following:
1) This cutting machine adopts IGBT inverter technology which has high reliability and efficiency. It is light weight.
2) Stepless adjustable cutting current, suitable for cutting various thickness workpiece. To ensure cutting quality and
save energy, low current is applied to cut thin plate, and high current is applied to cut thick plate.
3) External and dynamic characteristics cutter are significantly better than leakage-reactance typed cutter. High success rate in
striking arc. Stablecutting current.Good arc stiffness. Clean and smooth incision. Excellent technology performance.
4) The cutting current is very stable and it will not be influenced bygrid voltage fluctuation.
5) There is over-voltage protection function.
6) Fast cutting speed, high production efficiency, and the speed is 2-5 times higher than flame cutting speed.
7) Compressed air as cutting gas is low cost.
1.3 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 and other metal-cutting fields.
2Safety 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.

2
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 workpiece 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 fromfall or collision.
In case of fall or collision, it can be used only after professional checking.
In the surface or inside of the cutting workpiece, 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.
3Work Environment Requirements
Welding performance may not meet technique standards without the following conditions.
It should be placed with small dust, no corrosive gases and no flammable and explosive materials. Avoid vertical sunshine and
rain;
Air relative humidity is no more than 90% at 20℃and no more than 50% at 40℃
When using air cooling torch, the ambient temperature should be from -10℃to 40℃.
It should avoid metal foreign bodies entering into the cutting power.
Cutting power should be 30cm away from the wall or other sealed-in objects. The distance between two sets should be above
30cm.
The operation height should be less than 1000m.
4Technical Parameters
4.1 Main technical parameters
Model
Parameters
LGK-63MA
LGK-100MA
Input Voltage
3～380/415V 50/60 Hz
Rated Input Capacity
9.3KVA
15.8KVA
Open Circuit Voltage
260VDC
280VDC
Rated Output current
63A
100A
Current Adjusting Range
30～63A
30～100A
Rated Output Voltage
105.2V
120V
QualityCuttingThickness(steel)
0.1～12mm
0.1～22mm
MaxCuttingThickness(steel)
20mm
40mm
Weight
24.5Kg
28Kg
Shell Shield Rank
IP21S

3
4.2 Plasma gas conditions
Work pressure range：0.3MPa～0.5MPa
Gas supply pipe compression strength：≥1MPa
Gas supply pipe inner dimension：≥Φ8
Gas supply flux：≥40L/min
Filter water from gas and then put it into cutter
4.3 External Characteristic
External Characteristic
5Work principles
The control circuit of cutting machine adopts advanced electronic part IGBT as the main inverter switch component.
Three-phase AC power is converted to 20KHz high-frequency DCcurrent 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 figure1，and principle diagram of control circuit is shown as figure 2.
I
270V
240V
40A
U
63A/105.2V
40A/96V
63A
296V
100A
100A/120V

4
Figure 2 Principle diagram
Common component list as diagram 1
No.
Symbol
Components
name
Model
Remark
1
V1
Three phase
rectifier
MDS35-14
LGK-40、63IGBT
MDS75-12
LGK-100IGBT
2
V2～V5
IGBT single
module
IKW25N120T2
LGK-40IGBT
IKW40N120T2
LGK-63IGBT
V2、V3
GD75HFV120C2S
LGK-100IGBT
3
V6、V7
Diode module
DWM2F60N060
LGK-40、63IGBT
V4～V7
LGK-100IGBT
4
TA1
Hall current
sensor
TKC-100BS
LGK-40、63IGBT
TA1、TA2
LGK-100IGBT
5
QF1
Breaker
DZ47-63/3P D25
LGK-40、63IGBT
DZ47-63/63A
LGK-100IGBT
6
YV1
Magnetic gas
valve
DF2-B-3/36V AC
LGK-40、63IGBT
Q-5AC36V
LGK-100IGBT
7
EV1
Cooling fan
2123XSL
LGK-40、63IGBT
200FZY2-D/220V
LGK-100IGBT
8
RP1
Potentiomete
r
WH118-2W-4.7K