Westweld FLG-200HD User manual

FLG-200HD/300/400HD
FINE PLASMA CUTTING MACHINE
SQK-A1/SQK-B1
MANUAL GAS CONSOLE
MANUAL
INSTRUCTION
(PLEASE READ CAREFULLY BEFORE OPERATION)

Safety Depends on You
Huayuan arc welding and plasma cutting equipments are designed and built with safety in mind.
However, your overall safety can be increased by proper installation.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE
SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be
careful.
Special Attention (Very Important):
1. AVOID FALLING DOWN WHEN THE WELDING/CUTTING MACHINE IS PLACED ON THE INCLINED
SURFACE.
2. IT CAN NOT BE USED FOR UNFREEZING PIPELINES.
3. THE INGRESS PROTECTION CLASS OF THIS SERIES MACHINE IS IP21S, AND IT IS NOT SUTABLE FOR
WORKING IN THE RAIN.
4. THIS MACHINE WITH SHARP DROP STATIC EXTERNAL CHARACTERISTIC, THE RATED DUTY CYCLE IS
100%, MEANS IT CAN CONTIGUOUSLY WORK IN NORMAL CONDITION.
5. THE EMC CLASFICATION OF THIS MACHINE IS A.
Purchase date:
Serial number:
Machine model:

Content
I. Safety instructions........................................................................................................................................1
II. Product Summary...................................................................................................................................... 3
1. System composition............................................................................................................................... 3
Model description...................................................................................................................................... 3
2. System connection diagram...................................................................................................................4
3. Features..................................................................................................................................................6
4. Usage...................................................................................................................................................... 6
5. Symbol instruction................................................................................................................................. 6
6. Working condition..................................................................................................................................7
III. Technical parameters............................................................................................................................... 8
1. Plasma power source FLG-200HD..........................................................................................................8
2. Plasma power source FLG-300HD..........................................................................................................9
3. Plasma power source FLG-400HD........................................................................................................11
3. Manual gas console SQK-A1................................................................................................................ 12
4. Manual gas console SQK-B1............................................................................................................. 13
5. HF Box QFK-D1..................................................................................................................................... 13
6. System gas supply requirements......................................................................................................... 14
7. Requirements of torch coolant............................................................................................................ 15
IV. Installation................................................................................................................................................18
1. Acceptance of delivery.........................................................................................................................18
2. Product defect solution........................................................................................................................18
3. Installation requirement...................................................................................................................... 18
4. Noise level............................................................................................................................................ 19
5. System installation Figures...................................................................................................................19
6. Grounding connection and shield installation operation....................................................................21
7. Plasma power source installation (Part A in“Figure 4-2 system installation Figure”:Plasma cutting
power source).......................................................................................................................................... 23
8. Manual gas console installation (Part B in“Figure 4-2 system installation Figure”: Manual gas
console).................................................................................................................................................... 24

9. HF box installation （“Part C in“Figure 4-2 system installation Figure”: HF Box）...........................25
10. Other cables and connecting pipes................................................................................................... 26
11. Plasma power source output signal diagram.................................................................................... 31
12. Plasma power source input signal diagram.......................................................................................32
13. Plasma torch installation....................................................................................................................33
14.Fulfil the coolant of plasma power source......................................................................................... 34
14. Gas supply system installation........................................................................................................... 35
V. Operation................................................................................................................................................... 36
1. Inspection before start.........................................................................................................................36
2. Plasma power source (machine) operation......................................................................................36
3. Manual gas console operation.............................................................................................................38
4. How to optimize cutting quality.......................................................................................................... 43
VI. Maintenance............................................................................................................................................ 47
1. Operation process................................................................................................................................ 47
2. Gas blowing process.............................................................................................................................48
3. Gas console solenoid valve operation................................................................................................. 48
4. Trouble shooting and error code......................................................................................................... 52
5. Control board indicators instruction....................................................................................................60
6. System status........................................................................................................................................61
7. Initial inspection...................................................................................................................................62
8. The maintenance of air filter............................................................................................................... 62
9. The maintenance of cooling system.................................................................................................... 63
10. Gas leakage testing............................................................................................................................ 64
11.Preventive maintenance..................................................................................................................... 66
VII. Appendix................................................................................................................................................ 68
1. Some parts of the plasma power source.............................................................................................68
2. Some parts of the gas console............................................................................................................. 69
3. Some parts of HF box........................................................................................................................... 69
4. System wiring diagram.........................................................................................................................70
5. Figure Multi-plasma power source working wiring diagram.............................................................. 71
6. Figure Complete plasma power source (machine) wiring diagram.................................................... 72

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I. Safety instructions
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.
Carefully read the following important items and the welder safety bye-law from the authority organization. Be sure that
qualified professionals perform all installation, maintenance 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 spoil, 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
greasing, 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 O2gen 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

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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, cuff-less 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, maintenance 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:

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a. Bundle the cable connected to the work piece and the welding cable together.
b. Do not en-wind 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.
II. Product Summary
1. System composition
1) Plasma power source
Model description
F L G - □□□ HD
Inverter fine plasma cutting power source include FLG-200HD, FLG-300HD, and FLG-400HD,
they are generally called cutting power source. It is a constant current power source. The
external cable interface of the cutting power source is exactly the same. The power source
can communicate with CNC (Computer digital controller) through RS-422 serial
communication protocol or discrete communication protocol. The working power supply of
the whole cutting system is controlled by the switch on the cutting power source panel.
When the switch on the panel is turned on, the green power indicator is on, and the cutting
system is on power for working.
Rated cutting current
Cutting
Plasma arc cutting machine
Product series code
Product classification code

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2) Manual gas console
There are two models of manual gas console ：SQK-A1 and SQK-B1.The external cable
interfaces of the two manual Gas consoles are exactly the same，It matches cutting power
supply of FLG-200HD、FLG-300HD、FLG-400HD.
SQK-A1 has 4 gas input interfaces,when changing cutting technology and switch gas,the
manual gas console automatically distributes the required gas type and gas flow.
SQK-B1 has 2 gas input interfaces,when changing cutting technology and switch gas,need to
connect the required gas to gas input interfaces manually. And gas console automatically
distributes the required gas flow.
3)HF box
QFK-D1 High frequency box mainly used to generate high frequency pulse, to generate pilot
arc. When the pilot arc approaches the work-piece, the main arc is generated, then pilot arc
close. Another function is to receive commands from the manual gas console, switch
preflow gas and cutflow gas. The high frequency box can be used with both manual gas
console SQK-A1,SQK-B1.
4) Plasma torch
Fine plasma cutting torch HYC-400H transmit control current to work-piece by arc, to
realize metal cutting.
2. System connection diagram

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Figure 2-1 System connection diagram

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3. Features
1) The CRCTech is used on this machine, the ripple of the output current is small, which
makes reliable cutting quality and glossy cut;
2) A specially adjusted torch cooling system with high- power & high lift pump and
high-power heat radiation structure, which highly lengthen the consumables working
life;
3) With separate gas input connectors for different gas cutting process, get the best
cutting condition for different metal materials;
4) Excellent high frequency arc ignition controlling technology, separate design of high
frequency box and plasma power source, which highly reduces the high frequency
disturb and get 100% arc starting success rate ;
5) Various of communication control connector, can easily work with different type of
CNC control systems.
4. Usage
1) It’s suitable for CNC cutting of carbon steel, stainless steel and aluminum, etc.
2) It’s widely used in manufacturing of boiler,chemical pressure vessels, shipyard,
construction engineering and so on.
5. Symbol instruction
Input voltage
Output current
Coolant level
Coolant flow
Cutting
Over heat
Dangerous Voltage
Warning!
Please read instruction
Button "press in" to turn off
the power
Button "pop up“ to connect
power
Fuse
Pilot arc
Working cable
Plasma gas
Coolant input
Shield gas

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Coolant output
Ground connection
Negative pole
Figure 2-2 Symbol instruction
6. Working condition
Note: Under any of following situations, the cutting machine may cannot
meet the technology require or cannot working normally.
Under any circumstance, the ambient temperature should higher than the
coolant freezing point, as the freezing coolant will cause cooling system
damage, make the copper tube\pump and torch crack.
The coolant in the water tank must be clean up if the machine not use or
stock for a long time
1) Please use the machine in a clear place without any of dust, corrosive gas and
flammables and explosives. Do not use it in open air and in rain.
2) Environment temperature range is -10℃～40℃; and -20℃～+55℃when delivery
and storage.
3) Required air relative humidity should ≤90％(at 20℃); ≤50％(at 40℃)；
4) The dust, acid, corrosive gas or substances around shall not exceed the normal
content,except those produced in the cutting process.
5) Use it under altitude lower than 1000m.
6) The gradient of cutting power shall not exceed 10°.
7) Avoid using it under direct sunlight ,in rain or snow.
8) Do not cover the ventilation hole during the working, use and stored in a well
ventilated environment.
9) Prevent metallic foreign matters from entering the cutting power supply.
10) Keep the machine away from the wall of some other closure things at least 50cm,
two machines distance at least 50cm.

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III. Technical parameters
1. Plasma power source FLG-200HD
1) Basic parameters
Table 3-1 FLG-200HD technical parameters
Item
Unit
Parameter
Input power
V/Hz
3～380±15% 50/60
Rated input current
A
71
Rated input capacity
kVA
48.6
Rated open circuit voltage
V
360
Power factor
-
0.92
Efficiency
-
93%
Rated duty cycle
-
100%（40℃）
Rated output current/voltage
A/V
200/200
Rated output current range
A
15～200
Arc striking mode
-
Non-contact
Quality cutting thickness (Carbon steel)
mm
25 (*1)
Piercing cutting thickness (Carbon
steel)
mm
25 (*2)
Max cutting thickness
mm
50 (*3)
Insulation grade
-
F
Cooling mode
-
Air cooling
Protection grade
-
IP21S
Note: above(*1/*2/*3) cutting thickness is working with the parts listed in this instruction manual,
even though can cut thicker material, but recommend cutting higher 80% materials thickness
within 25mm,and start cutting from edge. Piercing cutting should not exceed 25mm.

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2)Dimension and weight
Figure 3-1 FLG-200HD Dimension and weight
3) Static external characteristic
Figure 3-2 FLG-200HD Static external characteristic
2. Plasma power source FLG-300HD
1) Basic parameters
Table 3-2 FLG-300HD technical parameters
Item
Unit
Parameter
Input power
V/Hz
3～380±15% 50/60
Rated input current
A
110
Rated input capacity
kVA
72.4
Rated open circuit voltage
V
370
Power factor
-
0.92
Efficiency
-
93%

10
Rated duty cycle
-
100%（40℃）
Rated output current/voltage
A/V
300/210
Rated output current range
A
15～300
Arc striking mode
-
Non-contact
Quality cutting thickness (Carbon
steel)
mm
38 (*1)
Piercing cutting thickness (Carbon
steel)
mm
38 (*2)
Max cutting thickness
mm
64 (*3)
Insulation grade
-
F
Cooling mode
-
Air cooling
Protection grade
-
IP21S
Note: above(*1/*2/*3) cutting thickness is working with the parts listed in this instruction manual, even
though can cut thicker material, but recommend cutting higher 80% materials thickness within 38mm,and
start cutting from edge. Piercing cutting should not exceed 38mm.
1) Dimension and weight
Figure 3-3 FLG-300HD dimension and weight

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2) Static external characteristic
Figure 3-4 FLG-300HD Static external characteristic
3. Plasma power source FLG-400HD
1) Basic parameters
Table 3-3 FLG-400HD technical parameters
Item
Unit
Parameter
Input power
V/Hz
3～380±15% 50/60
Rated input current
A
140
Rated input capacity
kVA
93
Rated open circuit voltage
V
370
Power factor
-
0.91
Efficiency
-
94%
Rated duty cycle
-
100%（40℃）
Rated output current/voltage
A/V
400/200
Rated output current range
A
15～400
Arc striking mode
-
Non-contact
Quality cutting thickness (Carbon
steel)
mm
50 (*1)
Piercing cutting thickness (Carbon
steel)
mm
50 (*2)
Max cutting thickness
mm
80 (*3)
Insulation grade
-
F
Cooling mode
-
Air cooling
Protection grade
-
IP21S
Note: above(*1/*2/*3) cutting thickness is working with the parts listed in this instruction manual, even
though can cut thicker material, but recommend cutting higher 80% materials thickness within 50mm,and
start cutting from edge. Piercing cutting should not exceed 50mm.

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2) Dimension and weight
Figure 3-5 FLG-400HD dimension and weight
3) Static external characteristic
Figure 3-6 FLG-400HD Static external characteristic
3. Manual gas console SQK-A1
1) Manual gas console SQK-A1 has 4 gas input interfaces, they are Air, N2(or Ar), O2,
H35(or F5);
2) Max. input gas pressure is 132 PSI/0.9 MPa;

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3) Dimension and weight as Figure 3-7.
Figure 3-7 SQK-A1 dimension and weight
4. Manual gas console SQK-B1
1) Manual gas console SQK-B1has 2 gas input interfaces,they are Air and O2/ N2/ Ar;
2) Max. input gas pressure is 132 PSI/0.9 MPa;
3) Dimension and weight as Figure 3-8.
Figure 3-8 SQK-B1 Dimension and weight
5. HF Box QFK-D1

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Figure 3-9 Dimension and weight
6. System gas supply requirements
Table 3-4 System gas supply requirements
Requirements of gas quality, pressure and flow
Gas
Quality
Pressure±10%
Flow
O2（Oxygen）
Purity≥99.5%
Clean, dry and oil free
0.8MPa / 8bar / 115PSI
70 L/min
N2（Nitrogen）
Purity≥99.99%
Clean, dry and oil free
0.8MPa / 8bar / 115PSI
195 L/min
AIR（Air）
Clean, dry and oil free
0.8MPa / 8bar / 115 PSI
190 L/min
H35(Argon-hydrogen)
Purity≥99.995%
（H35=65% Ar,35% H2）
0.8MPa / 8bar / 115 PSI
70 L/min
F5(Nitrogen-hydrogen)
Purity≥99.98%
（F5=95% N2,5% H2）
0.8MPa / 8bar / 115 PSI
70 L/min
Ar（Argon）
Purity≥99.99%
Clean, dry and oil free
0.8MPa / 8bar / 115 PSI
70 L/min
Note:
The Air in above table should accordance with the ISO standard 8573.1 grade, as following.
① Solid particle grade: Grade 1,0.1~0.5μm particle not exceed 100pc,0.5 ～5.0μm particle not
exceed 1pc per 1CBM air;
② Temperature: Grade 4, humidity pressure must be less or equal to 3℃;
③ Oil: Grade 2, the density of the oil in air can not exceed 0.1mg/m3.
Table 3-5 SQK-A1 gas type
Gas type
Low carbon steel
STAINLESS STEEL
ALUMINUM

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Plasma gas
Shield gas
Plasma gas
Shield gas
Plasma gas
Shield gas
30~50A
O2
O2
N2
N2
Air
Air
F5
N2
80A
O2
Air
F5
N2
-
-
130A
O2
Air
N2
N2
Air
Air
H35
N2
H35
N2
200A
O2
Air
N2
N2
N2
N2
H35
N2
H35
N2
260A
O2
Air
N2
Air
N2
Air
H35
N2
H35
N2
300A
O2
Air
N2
Air
N2
Air
H35
N2
H35
N2
400A
O2
Air
N2
Air
N2
Air
H35
N2
H35
N2
Table 3-6 SQK-B1 gas type
GAS TYPE
Low carbon steel
STAINLESS STEEL
ALUMINUM
Plasma gas
Shield gas
Plasma gas
Shield gas
Plasma gas
Shield gas
30~50A
O2
O2
N2
N2
Air
Air
80A
O2
Air
-
-
-
-
130A
O2
Air
N2
N2
Air
Air
200A
O2
Air
N2
N2
N2
N2
260A
O2
Air
N2
Air
N2
Air
300A
O2
Air
N2
Air
N2
Air
400A
O2
Air
N2
Air
N2
Air
7. Requirements of torch coolant
When delivery the plasma cutting power source, make sure there is no coolant in the coolant
tank.

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Before fulfil coolant, check which coolant is suitable for the current working environment.
Following warnings and precautions.
Warning!
Coolant is irritating to skin and eyes, drink may cause mortal dangerous.
Ethylene propylene glycol and phenylpropanetriazole are irritating to skin and eyes,
drink may cause mortal dangerous. Use lots of water to wash if coolant contact skin or
eye. If ingested, seek medical attention immediately.
Always use ethylene propylene glycol in the coolant compound, do not use
the vehicle antifreeze to instead, the antifreeze corrosion inhibitor will
damage coolant system .
Use pure water in the coolant compound to prevent corrosion of the
cutting torch cooling system.
1) The Huayuan standard coolant liquid is suitable to work in temperature between -12℃
and +40℃(10℉~104℉);
The Huayuan standard coolant liquid of this cutting system is composed by 69.9% water, 30%
ethylene propylene glycol and 0.1% benzotriazole.
If temperature is beyond of the range, please refer to the suggestion of homemade
compound coolant in this manual;
2) Self-make mixed coolant for low temperature (Under -12℃).
When the temperature is lower than the following table notes, must
increase ethylene propylene glycol , or it may cause torch head crack, tube
crack or torch system damages.
Please refere to the below table for suitable percentage composition of propylene glycol