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LPH 35

BruksanvisningBrugsanvisningBruksanvisningKyttohjeetInstruction ManualBetriebsanweisung

Manuel dinstructions

GebruiksaanwijzingInstrucciones de usoInstruzioni per lusoManual de instruesInstrukcja obsugi

0349 301 026 000831 Valid for serial no. 035-xxx-xxxx

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1. DIRECTIVE .............................................................................................................................................. 44

2. SAFETY ................................................................................................................................................... 44

3. INTRODUCTION...................................................................................................................................... 46

3.1 GENERAL .............................................................................................................................................. 463.2 SCOPE OF MANUAL............................................................................................................................. 46

3.3 TECHNICAL DATA ................................................................................................................................ 463.4 LPH 35 CUTTING SET PACKAGE........................................................................................................ 46

4. INSTALLATION....................................................................................................................................... 47

4.1 GENERAL .............................................................................................................................................. 474.2 EQUIPMENT REQUIRED...................................................................................................................... 474.3 LOCATION............................................................................................................................................. 474.4 INSPECTION ......................................................................................................................................... 474.5 AIR LINES CONNECTIOINS ................................................................................................................. 474.6 PRIMARY ELECTRICAL CONNECTIONS............................................................................................ 474.7 SECONDARY CONNECTIONS............................................................................................................. 48

5. OPERATION ............................................................................................................................................ 50

5.1 LPH 35 CONTROLS .............................................................................................................................. 50

6. MAINTENANCE....................................................................................................................................... 51

6.1 CLEANING............................................................................................................................................. 51

7. CUTTING WITH PT30KK TORCH........................................................................................................... 51

7.1 PIERCING TECHNIQUE........................................................................................................................ 52

8. FAULT TRACING .................................................................................................................................... 52

8.1 COMMON CUTTING PROBLEMS ........................................................................................................ 52

9. SPARE PARTS...................................................................................................................................... 133

10. ORDERING OF SPARE / WEAR PARTS ............................................................................................. 135

11. SCHEMATIC DIAGRAM........................................................................................................................ 136

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1. DIRECTIVE

2. SAFETY

Full responsibility for safety of personnel working on or near system rests on user of ESAB WeldingEquipment.

Wrong operation can lead to abnormal situation, injure operator and damage equipment.

ALL PERSONNEL WORKING WITH WELDING EQUIPMENT MUST BE FULLY FAMILIAR WITH

- handling of equipment- location of emergency stops- functions of equipment- applicable safety regulations- welding

Operator must make sure

- no one stays inside work area while machine starts- no one is unprotected while arc is being struck

Work area must be

- suitable for welding- free of machine parts, tools and other objects that can obstruct operator moving within area

- so arranged, that emergency stop buttons are easily accessible- free from draughts

Personal safety equipment

- always use proper safety equipment such as goggles, non flammable clothing, protective gloves- never wear loose clothing, belts, bracelets, rings etc., which may catch on equipment or cause burns

Miscellaneous

- only authorised personnel may operate electrical equipment- check whether return cables are properly fitted and earthen- requisite fire fighting equipment should be easily available in specially and clearly marked areas- lubrication and maintenance of welding equipment must not be proceeded during operation.

DECLARATION OF CONFORMITY

Esab Welding Equipment AB, S-695 81 Lax, Sweden, gives its unreserved guarantee thatPlasma Arc Cutting Set LPH 35 from serial number 910 complies with standard EN 60974-1, in

accordance with the requirements of directive (73/23/EEC) and addendum (93/68/EEC) and withstandard EN 50192, EN 50199, in accordance with the requirements of directive (89/336/EEC) andaddendum (93/68/EEC).-----------------------------------------------------------------------------------------------------------------------------------

Gteborg 99-08-30

Bo SjbergManaging DirectorESAB ABBox 8004

402 77 GteborgSweden Tel: +4631 50 90 00 Fax: +4631 50 92 61

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! WARNING !

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE

PRECAUTIONS WHEN WELDING. ASK YOUR EMPLOYER FOR SAFETY PRACTICES THAT SHOULD

BE BASED ON MANUFACTURERS HAZARD DATA.

ELECTRIC SHOCK - Can kill

- Install and earth welding equipment in accordance with obligatory standards.- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothes.- Insulate yourself from earth and workpiece.- Ensure your work position is safe.FUMES AND GASES - Can be dangerous to your health- Keep your head away from fumes.- Use ventilation and/or extraction to keep fumes and gases away from your breathing zoneand surroundings.

ARC RAYS - Can injure eyes and burn skin

- Protect your eyes and skin. Use correct welding screens, filter lens and wear protective clothes.- Protect bystanders with suitable screens or curtains.FIRE HAZARD

- Sparks (spatter) can cause fire. Make therefore sure there are no inflammable materials nearby.

NOISE - Excessive noise can damage your hearing.- Protect your ears. Use ear defenders or other hearing protection.- Warn bystanders of the risk.MALFUNCTION - Call expert assistance in event of malfunction.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING UNIT

PROTECT YOURSELF AND OTHERS!

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3. INTRODUCTION

! CAUTION!All warranty undertakings of supplier cease to apply if customer attempts to rectify

any faults on machine during warranty period.

NOTE. Supplier reserves right to make changes within the unit without further notice.

3.1 GENERAL

Purpose of this manual is to provide the operator all information necessary to install and operate LPH 35 set.Technical reference materials are enclosed, to help with possible troubleshooting.

LPH 35 is compact, self-contained plasma cutting system. As shipped, its fully assembled and ready tooperate after being installed. The set consists of LPH 35 power source and heavy duty PT30KK torch, and iscapable of severing materials up to 12 mm thick.

! WARNING !Use only PT30KK torches that are appropriated for use with this power source. Use of other type oftorch may cause ELECTRIC SHOCK HAZARD. Do not use any other torch not designed for use with

LPH 35 power unit !

3.2 SCOPE OF MANUAL

Purpose of this manual is to provide the operator all information necessary to install and operate LPH 35 set.Technical reference materials are enclosed, to help with possible troubleshooting.

3.3 TECHNICAL DATA

Rated 35% Duty Cycle * 35A @ 94V 35A @ 94V

Output 100% Duty Cycle * 20A @ 88V 20A @ 88V

Output Current Range 2035A 2035A

Open Circuit Voltage 295V DC 295V DC

Rated primary input (@ 11kVA, 35A@ 94V DC) 3x400-415V3~ 50/60Hz, 16A/phase

3x230V3~ 50/60Hz, 28A/phase

Air Requirements PT 30KK 130 l/min @ 3,54,5 bar 130 l/min @ 3,54,5 bar

Max. Cutting thickness 12 mm 12 mm

Dimensions LengthHeightWidth

610 mm515 mm255 mm

610 mm515 mm255 mm

Weight of LPH 35 set 52kg 53kg

(*) Duty cycle is based on a 10-minute period; therefore, a 35 % duty cycle means that the power sourcemay operate for 3,5 minutes with a cool down period of 6,5 minutes.100 % duty cycle means continuous operation of the power source.

3.4 LPH 35 CUTTING SET PACKAGE

QtyPos.

3x400V, 50Hz 3x230V, 50Hz

Part No Description

1 1 - 0457 288 880 Plasma arc source LPH 35 (with torch assembled, see pos. 6)

2 - 1 0457 288 881 Plasma arc source LPH 35 (with torch assembled, see pos. 6)

3 1 1 0457 290 048 Fuse element 1,6A

4 1 1 0457 290 071 Quick detachable coupling

5 1 1 0457 290 072 Hose clip

6 1 1 0457 288 001 PT30KK torch

7 1 1 0349 301 026 Instruction manual LPH 35

8 1 1 0349 301 007 Instruction manual PT30KK

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4. INSTALLATION

4.1 GENERAL

Correct installation is very important for trouble-free and satisfactory operation of LPH 35. It is suggested thateach step of this section is carefully studied and followed.

4.2 EQUIPMENT REQUIRED

Source of clean and dry compressed air capable of forcing air flow rate of 150l/min @ 3,5 4,5 bar.Maximum air pressure at unit input should not exceed 7 bars.

4.3 LOCATION

Adequate ventilation is necessary to provide proper cooling of power source. Amount of dirt, dust andexcessive heat, that unit is exposed to, should be minimised. Between LPH 35 and wall (or any obstruction)should remain distance of at least 300 mm, to secure proper air movement through it.

CAUTIONInstallation of any kind of filtering device will reduce volume of through-flowing air, subjecting

therefore interior of machine to overheating. Warranty is void if any type of filter device is employed.

4.4 INSPECTION

A. Remove shipping container and all packing stuff and inspect unit for any sign of damage.Notify transporters of any defects or damages at once.

B. Check container for any loose parts before disposal.C. Check air louvers and any other openings to make sure any obstruction is removed.

4.5 AIR LINES CONNECTIOINS

To assembly air lines put on it hose clip and press in quick detachable coupling, that are delivered incontainer, and tighten clip next to hose end.

4.6 PRIMARY ELECTRICAL CONNECTIONS

! WARNING !ELECTRIC SHOCK CAN KILL! Precautionary measurements should be made to provide maximumprotection against electric shock. Disconnect power cable from mains socket before anyconnections are made inside power source.

! WARNING !Operator must make sure, if unit is properly configured for mains voltage. Unit configured for 3x400VMUST NOT be fed from 440V mains; it may get damaged.

LPH 35 machines are equipped with 3m, 4-strands power cables for 3-phase mains connection. Switch

board that unit is to be fed from must be equipped with proper line fuses or circuit breakers (see TECHNICALDATA). Power cable may be connected directly to wall disconnect switch or be equipped with suitable plug.

! WARNING !Chassis must be properly connected to ground. Otherwise it may result in electric shock, burns ordeath.

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4.7 SECONDARY CONNECTIONS

! WARNING !Before making any connections make sure unit is disconnected from mains.

1. Connect air supply line to inlet of regulator.2. Clamp work cable to workpiece. Make sure the workpiece is connected to ground with properly sized

cable.

Fig. 4-1. LPH 35 connection diagram.

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Fig. 4-2. Ground and current cable connections.

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5. OPERATION

! WARNING !ELECTRIC SHOCK CAN KILL!

- Do not operate unit with cover removed.- Do not feed unit while its being held or carried.

- Do not touch any part of torch head (nozzle, heat shield, electrode) when unit is turned on.

! WARNING !ARC RAYS CAN BURN EYES OR SKIN!

NOISE CAN DAMAGE HEARING!- Wear helmet with No. 6 or 7 lens.

- Wear eye, ear and body protection.

CAUTIONPosition machine at least 3 m from cutting zone. Sparks and hot slag can damage it.

5.1 LPH 35 CONTROLS

A. Power switch / Output current setting - turns the unit on when selected 20A or 35A position, Powerindicator lights green, cooling fan starts running.

B. Air pressure regulator adjust air pressure within 3,5 4,5 bar.C. Fault light -will glow yellow under following conditions (operation will be stopped):

- FLOW FAULT (continuous light) - indicates too low air flow rate.- OVER TEMPERATURE (continuous light) indicates that the maximum allowable temperature of the

power unit (the transformer) has been exceeded.Allow unit to cool down before returning to operate.

When fault clears, all signals will automatically reset.D. ARC-ON LIGHT. When lit red indicates that main contactor is closed, which means torch is

energised and source is ready to cut. In case of no indication while torch switch is depressedimmediately turn the machine off and call service.

NOTE: ARC ON light may turn off if within 2 sec since torch switch is depressed cutting process will not beproceed. It is automatic feature that guarantees safe operation of machine (obligatory for units with Ssymbol).

Fig. 5-1. LPH 35 Controls

Table for Fig. 5-1

Pos. Description

1 Power switch knob2 LED Power on3 LED (Arc on )4 LED FAULT5 Pressure gauge

6 Air pressure regulator knob7 Torch PT 30KK-connection8 Work cable-connection

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6. MAINTENANCE

NOTE: All warranty undertakings given by supplier cease to apply if customer attempts to rectify anyfaults on machine during warranty period.

6.1 CLEANING

A. Power source should be regularly blown with dry compressed air at reduced pressure, more frequently indirty environment.

7. CUTTING WITH PT30KK TORCH

Use the following procedures to cut with the PT30KK torch.

A. Hold the torch nozzle approximately 3 to 5 mm above the work and tilted at about 15-30.This reduces the chance of spatter entering the nozzle.If the standoff tool is being used, set the standoff between 5 and 6 mm.

B. Depress the torch switch. Air should flow from the torch nozzle.

C. After ca 0,1sec - the pilot arc should start and the main arc should immediately follow - allowing the cut tobegin.D. After starting the cut, the torch should be maintained at a 5-15 forward angle. This angle is especially

useful in helping to create a drop cut. When not using the standoff guide, the nozzle should be heldapproximately 6 mm from the work.

E. For rapid re-start, such as grate or heavy mesh cutting, do not release the torch switch.

NOTE: When replacing the nozzle, always inspect the electrode for wear. If the depth of the crateris 1,52,0mm (see Fig.7-1 ) - replace the electrode. If the electrode is used beyond thisrecommended wear limit, damage to the torch and power source may occur. Nozzle life is alsogreatly reduced when using the electrode beyond the recommended limit.

Fig. 7-1. Electrode Wear Limit Fig. 7-2. Effect of cutting speed

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7.1 PIERCING TECHNIQUE

Fig.7-3. Piercing technique using PT30KK torch.

8. FAULT TRACING

8.1 COMMON CUTTING PROBLEMS

Below are listed common cutting problems, followed by possible cause of each. If its still impossibleto correct the problem, contact your ESAB distributor.

A. Insufficient penetration.1. Too low current.2. Cutting speed too fast.

3. Damaged cutting nozzle.4. Improper air pressure.5. Low air flow rate.

E. Uneven arc.1. Damaged nozzle or worn electrode.

B. Main arc extinguishes.1. Cutting speed too slow.2. Worn electrode

F. Unstable cutting conditions.1. Incorrect cutting speed.2. Lose cable or hose connections.3. Electrode and/or nozzle in poor condition.

C. Dross formation.(For some material thickness it may be impossible toget dross free cuts.)

1. Current too low.

2. Cutting speed too fast or too slow.3. Improper air pressure.4. Defective nozzle or electrode.5. Low air flow rate.

G. Main arc does not transfer.1. Worn electrode.2. Loose connections.3. Worn cable.

D. Double arcing.1. Low air pressure.2. Damaged cutting nozzle.3. Loose cutting nozzle.4. Heavy spatter accumulation on nozzle.

H. Short consumables life.1. Improper gas pressure.2. Loose connections.3. Low air flow rate.