L-TEC PLASMAWELD 202 User manual

PLASMAWELD 202, 402 Instruction manual PLW 202 1 010 210 00, PLW 402 1 010 177 00 – Version 2/2008
L-TEC Schweißtechnik GmbH
Walzwerkstraße 8a | D-57537 Wissen
Phone: (+49) 27 42 / 75-0 | Fax: (+49) 27 42 / 7 52 71
E-Mail: [email protected] | Internet: www.ltec-wissen.de

2
Safety advice...................................................................................................................................................................................................................... 3
Technical data PLW 202.............................................................................................................................................................................................4
Technical data PLW 402.............................................................................................................................................................................................5
Technical description.................................................................................................................................................................................................... 6
Installation.....................................................................................................................................................................................................................7-12
Starting up / Welding..................................................................................................................................................................................................13
Data sheet plasma welding....................................................................................................................................................................................14
Accessoires.......................................................................................................................................................................................................................15
Maintenance.....................................................................................................................................................................................................................15
Trouble shooting ............................................................................................................................................................................................................16
Spare parts................................................................................................................................................................................................................17-23
Wiring diagram............................................................................................................................................................................................................... 24
Annex EMC............................................................................................................................................................................................................... 25-26
Index

3
WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE
PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYER‘S SAFETY PRACTICES WHICH
SHOULD BE BASED ON MANUFACTURER‘S HAZARD DATA .
ELECTRIC SHOCK ... CAN KILL!
Install and earth the welding or cutting equipment in accordance with applicable standards.
Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
Insulate yourself from earth and workpiece.
Ensure that your working place is safe.
FUMES AND GASES ... CAN BE DANGEROUS TO HEALTH!
Keep your head out of the fumes.
Use ventilation, extraction of fumes at the arc or both to keep fumes and gases out of your breathing
zone and the general area.
ARC RAYS ... CAN INJURE EYES AND BURN SKIN!
Protect your eyes and body. Use the correct welding screen and filter lens and wear protective,
insulating and non-flammable clothing.
Protect bystanders with suitable screens or curtains.
FIRE HAZARD!
Sparks and spatters can cause fire. Make sure, that there is no inflammable material
in the surrounding of welding and cutting works.
MALFUNCTION!
Call for expert assistance in the event of malfunction.
Read and understand the instruction manual before installation and operation
Protect yourself and others!
Safety advice

4
Mains:
Mains voltage (V) 3-phase 230 400 500
Permanent power (kVA) 9,7 9,7 9,7
Permanent current (A) 24,4 14,0 11,2
Max. current (A) 31,4 18,0 14,5
Power factor cos phi 0,85 0,85 0,85
Frequency (Hz) 50/60
Fuses, slow blow (A) 35 20 16
Welding:
Current range DC 5 - 220 A
Duty cycle Plasma, 60% ED 220 A
TIG 100% ED 170 A
STICK
Open circuit voltage DC 98V DC
Construction:
Dimensions (mm) L/W/H 1020/570/960
Weight (kg) 150
Protection class IP 23 M
Cooling F
Insulation class F
Standards EN 60974-1
VDE 0544-1
EN 50199
S-Mark Yes
CE-Mark Yes
Technical data PLW 202

5
Mains:
Mains voltage (V) 3-phase 230 400 500
Permanent power (kVA) 19,4 19,4 19,4
Permanent current (A) 49 28 22
Max. current (A) 61 35 28
Power factor cos phi 0,85 0,85 0,85
Frequency (Hz) 50/60
Fuses, slow blow (A) 63 35 35
Welding:
Current range DC 6 - 400 A
Duty cycle Plasma, 60% ED 400 A
TIG 100% ED 310 A
STICK
Open circuit voltage DC 98V DC
Construction:
Dimensions (mm) L/W/H 1020/570/960
Weight (kg) 273
Protection class IP 23 M
Cooling F
Insulation class F
Standards EN 60974-1
VDE 0544-1
EN 50199
S-Mark Yes
CE-Mark Yes
Technical data PLW 402

6
The plasma arc welding machines PLASMAWELD 202 and 402 have been developed for welding with
transferred arc, i. e. the main arc transfers from the tungsten to the work piece. These units can also be
used for TIG, TIG pilot arc and manual metal arc (MMA) welding.
The power supplies can be used in confined spaces and are labelled with the S-mark according to EN 60
974-1.
Infinitely variable adjustment of the welding current makes the units suitable for micro-plasma and high
current plasma as well as for plasma key hole welding.
The pilot arc , started by HF, remains ignited and permits safe and touch-free starting of the main arc.
By means of rh 19“ rack control system, the units can be used for all manual and automatic plasma wel-
ding applications.
The required welding current and gas flow can be preset before starting the welding operation.
The power supplies are equipped with a constant current control so variations of the mains voltage or
different arc length do not effect the current of the main arc.
The following materials can be welded: high-, low- and unalloyed steel; nickel, copper, titanium , zirconium
and their alloys.
The compact construction with built in water cooler for the torch enables easy transportation of the machi-
nes.
Warning!
This product is intended for industrial use (Class A). In a domestic environment this product may cau-
se radio interference. It is the users responsibility to take adequate precautions.
The welding equipment creates a noise level of < 70 dB(A) at idle.
An emission level related to the work-place cannot be stated, because this value is depending on the
method and the surroundings. It is conditioned by a variety of parameters e.g. the welding or cutting
process, the kind of current, the power, the kind of material, resonance’s of the workpiece, the surroun-
dings and more.
Technical description

7
On the last page of these instruction manual a picture of the unit marked with symbols is located. Please
unfold and refer to this page in conjunction with the following instructions.
1. Mains connection
The units are factory connected to 400 V 50/60 Hz. They also can be used on 230 V 50/60 Hz and 500 V
50/60 Hz mains. The wiring instruction for reconnection is located inside of the machines near the input
terminal (460V 50/60Hz option).
Important! In case the machines are used with 230 V mains voltage, the mains
cable delivered must be replaced by one with a bigger cross section.
230 V 400/460/500 V
PLW 202 4 x 4 mm² 4 x 2,5 mm²
PLW 402 4 x 10 mm² 4 x 4 mm²
The mains plug must comply to country regulations and must be connected by an electrician. Check the
mains voltage before the machine is switched on.
2. Coolant
Pull the plastic plug of the cooling unit and check the water level. Liquid level should be about 3 cm (1“)
below the filling hole. If not, top up the tank using LoDuct cooling fluid.
Caution! Electrolytic corrosion may shorten the live time of the torch, when normal mains
water is used. Lo Duct contains glycol. Do not give access to children. Injurious to
health when drunk.
3. Gas connection
At the rear of the machine a cylinder mounting position is provided. The cylinders must always be secured
with the chains. Fit the regulators and the gas hoses for Ar/H2 and Ar to the cylinders. Connect the other
ends of the hoses to the corresponding connections clearly marked on the back side of the machines.
Open the valve of the bottle slowly and adjust the gas pressure to 6 bar.
Optional two different flow meter slide-in modules are available. It depends on the welding application
which type of flow meter slide-in module is required.
Welding gas: Pilot gas: Slide-in module Standard at
0 - 20 l/min 0 - 1,1 l/min 1 261 051 PLW 202
0 - 20 l/min 0 - 7 l/min 1 261 050 PLW 402
Installation

8
4. Torch connection
The manual welding torches PT 75 and PT-150 as well as the machine torches PT-8 and PT 300 can be
connected with the central connector B easily and without tools. Make sure, that the water in- and outlet
hoses are connected to the corresponding colour coded quick connections.
At socket Athe control plug is connected, when manual torches are fitted, whereas a foot switch has to be
fitted to this socket, when machine torches are used.
The pilot circuit is connected to the torch via socket C.
5. Pilot arc current adjustment
The PLW 402 pilot arc current is factory set for PT-300 and PT-8 to 10 A. If PT-75 or PT-150 resp. PTM-150
are used, pilot current must be reduced to 5A. This is performed by eliminating jumper at resistor R105.
The PLW 202 pilot arc current is factory set to 5A and can be increased to 10A by connecting jumper at
resistor R105.
Disconnect machine from mains before opening the machine!
6. Connection of work return lead and electrode holder lead
a) The work return lead is connected to socket Hmarked with symbol work clamp.
b) When MMA-welding the electrode holder has to be connected either to plus (+) or minus (-) at socket
H depending on the kind of electrode to be welded.
7. Connection of remote controls
At the 5-pole socket Gthe following remote controls may be connected:
a) Foot remote control FC 4
b) Manual remote control
c) Pulse unit
Article numbers see accessories
Installation

9
8. Connection for automatic welding
With socket bthe machine can be connected to an automatic control (see wiring diagram)
Wiring diagram of 5-pole socket on adjusting board
* When switching on the pilot arc about the contacts 1and 3of the socket bthe switch fremains
into mid position.
Starting up
A. Plasma Welding
1. Open cylinder valves and handwheels for gas flow rate at regulators.
2. Switch main switch Fon. Fan and water pump will start, lamp dwill light.
3. Keep torch away from work
4. Set switch ito symbol
5. set switch kto symbol
6. Push test button for plasma gas and adjust flow rate acc. to data sheet plasma welding
7. set switch fto symbol (Pilot arc will ignite after a gas pre-flow time of about 5 sec. and
lamp ewill light up.
8. Keep button Edepressed and adjust welding current. Amperage is preset at potentiometer a
and can be read from ammeter D.
9. Actuate torch switch or foot switch and adjust flow rate of shielding gas at the other regulator.
10. Adjust gas post-flow time on potentiometer l
Installation
Start
Pilot extern on* View of the front
Current relais

10
Adjustment of tungsten with torch PT-8
Set switch Fto mid position and operate torch switch or foot switch. HF will start. Check whether HF
sparks over to nozzle on all sides. If not, readjust tungsten electrode of torch. This adjustment is very im-
portant and should be repeated regularly.
The electrodes of all other torches are centred by the insulation tube inside the torches automatically.
B. TIG-Schweißen
1. Substitute the plasma-torch by an appropriate TIG-torch.
2. Open cylinder valve and adjust gas flow rate to the value desired.
3. Switch main switch Fon. (Fan and water pump will start. Lamp dwill light.
4. Set switch ito (4-stroke) or (2-stroke)
5. Set switch kto
6. Set switch fto
7. Turn potentiometer ccounterclockwise to 0
8. Keep button Edepressed and adjust welding current. Amperage is preset at potentiometer a and can
be read from ammeter D.
C. TIG-Pilot-Welding
Connection of the plasma torch and adjustment of power supply is done as described under paragraph A.
Only the plasma torch has to be modified as follows:
Redrill the aperture of the torch tip to a diameter of 5,5 - 6,0 mm and slide out the electrode until it protru-
des about 1,5 mm beyond the tip face. Potentiometer cmust be turned to 0 during this welding procedure.
D. Switching off Plasma- and TIG-Pilot-Welding
To switch off the pilot arc, set switch fto mid position.
Wait about 15 sec. until the post flow time for the pilot gas has passed, before switching off the machine
with the main switch. During this time the electrode can cool down protected against oxidation by the pilot
gas.
Even in case of an emergency stop command by a automatic control the post flow process will be initia-
ted.
Installation

11
E. Manual Metal Arc Welding
1. Remove TIG- or plasma-torch control cable plug (Water pump is now out of operation).
2. Connect electrode holder
3. Set switch kto symbol
4. Set switch fto mid position
5. Keep button Edepressed and adjust welding current. Amperage is preset at potentiometer aand can
be read from ammeter D.
Installation

12
Welding
A. Plasma-welding
1. Current down slope time can be adjusted at poti cto give a delay time of 0,5 to 5,0 s. after the third
operation in the 4-stroke mode has been activated (see tain diagram).
2. Position of poti hdefines duration of current up-slope (see trin diagram), whereas time of down-
slope tf is set at poti m.
3. Activate torch- or foot switch (lamp gwill light) 1. and 2. stroke.
4. To finish the welding operation, down-slope is initiated by actuating torch- or foot- switch. 3. stroke
(closing of keyhole)
The Plasma-key-hole system is used for porosity-free closing of key-hole circular wel-
ding after 360° during overlap. This shall reached by lower the Plasma-beam to a soft
arc, during welding of overlap. By this event, down-slop of pilot gas is first, down-slop
of welding current is after time delay according to the material thickness.
5. After the time set at poti chas passed, down-slope starts. When down-slope is over, switch can be
released.
Installation
Torch
switch

13
B. TIG-Welding
1. Position of poti hdefines the duration of up-slope, while time of down-slope is set at poti m.
2. Depending on the position of switch i, the machine can be operated in 2- or 4-stroke mode:
2-stroke mode Symbol
1. Press torch- or foot-switch = Welding
2. Release torch- or foot-switch = End of welding and gas post-flow
4-stroke mode Symbol
1. Press torch- or foot-switch = Gas pre-flow and HF
2. Release torch- or foot-switch = Welding with current up-slope
3. Press torch or foot-switch = Current down-slope
4.Release torch- or foot-switch = End of welding and gas post-flow
C. TIG-pilot arc welding
Welding process runs as with Plasma welding
D. MMA Welding
1. Hot-Start
When switch-potentiometer his in position 0, current drops down immediately from maximum value of
power supply to preset value.
2. Soft-Start
When switch-potentiometer his turned clockwise, soft-start function is switched on. Up-slope time
from basic current to preset welding current is infinitely variable.
Starting up / Welding

14Data for plasma welding
Data for plasma welding (recommended values)
Material Material- Edge- Welding Pilot gas Welding gas Travel-
thickness prepa- current Gasrate Flow Gasrate Flow speed
(mm) ration (A) (l/min) (l/min) (cm/min)
For torch PT-150 / PTM-150
Stainless 0,5 II 16 Ar 0,3 1%H2+Ar 7 25
Steel 1,5 II 45 Ar 0,3 5%H2+Ar 12 25
2,0 II 90 Ar 0,5 5%H2+Ar 12 30
3,0 L 80 Ar 0,7 5%H2+Ar 10 15
Carbon- 1,5 II 80 Ar 0,7 Ar 10 20
Steel 3,0 L 100 Ar 0,7 Ar 10 20
Titanium 0,6 II 13 Ar 0,3 Ar 8 17
1,2 II 60 Ar 2,0 Ar 12 50
For torches PT-8 / PT-300
Stainless 0,5 II 16 Ar 0,3 1%H2+Ar 7 25
Steel 1,5 II 45 Ar 0,5 5%H2+Ar 12 25
2,4 II 170 Ar 2,4 5%H2+Ar 12 50
4,5 II 260 Ar 6,0 5%H2+Ar 12 35
9,5 Y
Rootpass 245 Ar 4,0 5%H2+Ar 12 25
Coverpass 220 Ar 6,0 5%H2+Ar 12 20
3,0 L 80 Ar 0,7 5%H2+Ar 10 15
Carbon- 1,5 II 80 Ar 0,7 Ar 10 20
Steel 3,2 II 185 Ar 5,0 5%H2+Ar 12 30
3,0 L 100 Ar 0,7 Ar 10 20

15
A. For Plasma Welding
1. Pulse unit p/n: 1 090 123
2. Manual remote control 8 m cable p/n: 1 090 124
16 m cable p/n: 1 090 125
25 m cable p/n: 1 090 126
3. Foot remote control FC 4 p/n: 1 090 130
ATTENTION: If foot remote control is used, switch-imust be in pos.
and poti cset to 0.
B. for TIG welding only
Combined pulse-/dual current-control p/n: 1 270 253
Maintenance
REMARK
This plasma welding unit is designed, manufactured and tested for highest quality standards in order to
ensure long trouble-free service life. Regular maintenance is, however, of utmost importance for reliable
and safe operation of the unit. Your attention is therefore drawn to all maintenance instructions included in
this operating manual.
As a general rule each welding unit should be thoroughly inspected, tested and serviced at least once a
year. In the case of high loading of the units, maintenance should be performed more frequently.
Wear is a slow process in the case of electro-mechanical and moving components in particular. If wear is
detected in good time, repair costs are kept low and advantages are significant as regards performance,
reliability and safety. Unnoticed wear can become dangerous both for the equipment and the user.
Have this unit inspected and maintained by authorised dealers at regular intervals.
Note: Use original L-TEC parts throughout; otherwise the warranty will rendered null and void.
Accessoires

16
All L-TEC units are subjected to a thorough quality control check and final inspection. Nevertheless,
if there is a malfunction, please make a first check for general faults as follow:
Main input voltage
Fuses
Gas supply
Electrical connections
Fault indications
Digital readout
Are fans and water pump running
Unusual noise
Mistake in operation
Torch problems
HF
Open circuit voltage (Set switch kto symbol and measure between
output)
Check logic functions of power source
If you can’t solve the problem, please get in contact with our service department.
Trouble shooting

17
Item Designation PLW 202 PLW 402 Designation
Part No. Part No. on circuit diagram
1 Control panel PLW 202/402 kpl. 1 170 168 00 1 170 168 00 A101
2 Pilot receptable 1 441 834 00 1 441 834 00 X107
3 Receptable for welding cable 7021 440 698 00 1 440 698 00
4 Central connection 1 260 795 00 1 260 795 00 ZA
5 Receptable 5-pol. 1 440 162 00 1 440 162 00 X101
6 Main switch 1 441 317 00 1 442 523 00 Q101
7 Water connection 1 260 983 00 1 260 983 00
1 260 984 00 1 260 984 00
Spare parts list for power source PLW 202/ 402
1
5
6
7
2
3
4

18
Item Designation PLW 202/402 Designation on
Part No. circuit diagram
8 Display board 1 270 363 00 A107
9 Gas test push bottom 1 442 005 00
10 Adjusting board PLW 1 270 295 00 A102
11 Rotating knob 1 440 214 00
12 Regulator board 1 270 254 00 A103
13 Logic board 1 270 447 00 A104
14 Flowmeter Pilot gas 0-7 l/min 1 431 846 00
14.1 Flowmeter Pilot gas 0-1,1 l/min 1 432 016 00
15 Flowmeter welding gas 0-20 l/min 1 432 015 00
15.1 Flowmeter welding gas 0-20 l/min 1 432 015 00
16 Signallamp green 1 440 901 00
16.1 Lamp 60V 1 440 902 00
17 Signal lamp white 1 441 523 00
18 Switch 1 441 381 00
19 Rotating knob 1 430 941 00
Spare parts list for power source PLW 202/ 402
16 17 18 17 19 18
8 9 10 11 12 13 14 15

19
Item Designation PLW 202/402 Designation on
Part No. circuit diagram
20 HF-Generator SIG 3.1 1 170 100 00 G101
22 Contactor 42V 1 442 708 00 K101-K103,K105, K106
23 Capacitor fan 3µF/400V 1 441 785 00 C103
24 Water pump incl. capacitor 1 431 679 00 M105, C105
25 Fan Ø 150mm 1 441 550 00 M106, M107
26 Relays board 1 270 517 00 A110
26.1 Water flow switch 1 431 657 00 F106
28 Relays Pilot 1 270 830 00 K104
Spare parts list for power source PLW 202/ 402
22 26 26.1
25
25
21 28 20 22 23 24

20
Item Designation PLW 202 PLW 402 Designation on
Part No. Part No. circuit diagram
29 Filter board 1 270 614 00 1 270 614 00 A106
30 Thyristorbridge 1 443 024 00 1 441 530 00 A108
31 Steering roller 1 430 640 00 1 430 640 00
32 Main inductor 1 130 061 00 1 130 059 00 L101
33 HF-inductor 1 130 037 00 1 130 080 00 L102
34 Pedestal mounted roller 1 430 639 00 1 430 639 00
35 Fan Ø 300 mm 1 442 707 00 1 442 707 00 M103
36 Main transformer 1 120 266 00 1 120 256 00 T101
Spare parts list for power source PLW 202/ 402
29
30
35
31 32 33 36 34