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P30
Operation Manual
36 pgs1.3 Mb0

GOODWIN P30 Operation Manual

P32 Manual.p65 Issue 3 9th May 2008 Page : 1
OPERATION MANUAL
for the
GOODWIN P30
AIR PLASMA CUTTING SYSTEM
P30 Instruction Manual Revision : 5 9th May 2008
The Company reserves the right to make such changes to the design or specification of the equipment as it shall see fit. The information contained in this manual is issued for the guidance of users and does not form part of any contract. It is strongly recommended that all users and supervisors familiarise themselves with the contents...
PRIOR TO COMMENCING USE OF THE SYSTEM
...and in particular, the section on safety precautions which should be used as a guide to safe operation in accordance with the requirements of the relevant Health and Safety at Work legislation.
GOODWIN AIR PLASMA LIMITED
KERNAN DRIVE
LOUGHBOROUGH
LEICESTERSHIRE
LE11 5JF
ENGLAND
Tel No. ++(0) 01509 237369
Fax No. ++(0) 01509 234942
Email. goodwinplasma@aol.com
P32 Manual.p65 Issue 3 9th May 2008 Page : 3
Contents
1. ................................................................................................................................................. SAFETY 4
1.1 ................................................................................................................................................. General 4
1.2 .....................................................................................................................................Safety Features 5
1.3 ...................................................................................................................................... Warning Signs 5
1.4 ...................................................................................................Packaging Handling and Transport 5
2. ............................................................................INTRODUCTION TO THE PLASMA PROCESS 6
3. ................................................................................................................................... INSTALLATION 7
3.1 ....................................................................................................................................... Power Supply 7
3.2 ............................................................................................................................ Earth Requirements 7
3.3 ........................................................................................................................... Phase Determination 8
4. ........................................................................................ PLASMA AND TORCH CONNECTIONS 9
4.1 ................................................. Connecting the Torch and Plasma Earth Lead to the Power Unit 9
4.2 ...................................................................................................................... Control of Hand Torch 10
5 ........................................................................................................................................ OPERATION 11
5.1 ...............................................................................................................................Machine Controls 11
5.1.1 ..........................................................................................................................warning indicators 13
5.2 ......................................................................................................................... Power Up Procedure 14
5.3 ............................................................................................................................. Cutting Procedure 15
5.3.1. ....................................................................................................... Starting and Finishing a Cut. 15
5.3.2. ................................................................................................................Cutting With Stand Off. 15
5.3.3. ................................................................................................................................Cutting Speed. 16
5.3.4. ..........................................................................Piercing Thicker Materials with a Hand To rch 17
5.3.5. .................................................................................................... Piercing with a Machine Torch 18
5.4 ................................................................................................................................. Troubleshooting 19
5.5. .............................................................................................................................. Consumable Life. 19
5.5.1. ...................................................................................................................................Intrinsic Life. 19
5.5.2. ...................................................................................................................................... Alignment. 19
5.5.3. .........................................................................................................................Transient Damage. 19
5.5.4. .................................................................................................................... Operational Damage. 20
5.5.5. ................................................................................................................Electrode “non-starting”.20
5.6 .....................................................................................................................Changing Consumables 21
6. ........................................................................................................................... TECHNICAL DATA 23
6.1 ..........................................................................................................................................Power Unit 23
6.1.1. .............................................................................................................................. Electrical Input 23
6.1.2. ........................................................................................................................... Electrical Output 23
6.2 ............................................................................................................................ Torch and Hose Set 23
6.2.1 ......................................................................................................................................Hand Torch 23
7. ............................................................................................................... SERVICE INFORMATION 24
7.1 .................................................................................................................................. The Power Unit 24
7.1.1. ............................................................................................................................. Circuit Diagram 25
7.1.2. ............................................................................................................................. Machine Layout 26
7.1.2. ....................................................................................................................Diagnostic Indicators. 28
7.2 ........................................................................................................The Torch and Hose Set Repair 29
7.3 ....................................................................................................................................... Maintenance 30
8. .....................................................................................................................................Torch Blockage 31
8.1 ................................................................................................................................... Machine Torch 31
8.2 ......................................................................................................... Machine Torch exploded View 32
8.3 .........................................................................................................................................Hand Torch 33
8.4 ...............................................................................................................Hand Torch exploded View 34
9. ........................................................................................................................................Fault Finding 35
10. ................................................................................................................................................... Index 36
A36
1. SAFETY
1.1 General
Before any cutting operations are started, the user must ensure that the installation and proposed working methods comply with all relevant safety regulations, environmental and elec­tricity standards.
The plasma arc produced at the torch head is a jet of high energy and is potentially danger­ous. Users unfamiliar with a plasma arc should seek basic training. Goodwin Air Plasma can offer comprehensive training courses.
In addition, the following points are particularly important:
a) The mains connection must be properly grounded and the supply lines fitted with fuses of
the specified rating. The mains cable must be properly secured and protected from possible damage.
b) High voltage exists at the torch when power is applied and the pilot arc is struck (up to
95V), and when the main arc is cutting (95V). Under no circumstances should anyone touch the nozzle with power applied to the torch. All adjustments and replacement of parts should be done with the power unit supply isolated. The torch should not be used in excessively wet conditions or if the torch or hose set are damaged in any way .
c) The mains supply should be isolated from the unit A T THE SUPPL Y before removing any
panels from the unit. Only authorised service personnel should remove panels.
d) Keep the work area clear of all inflammable materials. Ensure that any material ejected
from the cut is not a hazard to the operator or to others.
e) Protection is necessary against ultraviolet radiation emitted from the arc. A helmet or
shield with shade glass is recommended. W ear gloves and adequate protective clothing where appropriate. Adequate screening should be arranged to protect others in the vicinity or passing by in a similar manner to that required for arc welding operations.
f ) Adequate ventilation or fume extraction to remove the cutting fume and dust is required at
all times around any plasma cutting operation. When cutting flat sheet, a shallow water bed cutting table will greatly reduce the fumes and dust which mainly occur below the cut.
g ) The plasma power unit should be positioned on stable level ground and if necessary
secured against any unwanted movement.
h ) The operation of this equipment and the plasma cutting process can result in noise levels
that could be harmful. The employer should undertake a noise assessment to monitor compliance with relevant legislation.
i ) Material to be cut should be supported in such a way that any material cut from the work
piece will not be a hazard and fall onto the user, the equipment, or others in the vicinity.
j) Care should be taken when manoevering the hose set with the hand held torch so that it
does not snag on objects or other equipment which may result in damage to the hose set, or topple the objects or equipment. Excessive mechanical tension may result in damage to the hose set connections or to the hose set components themselves.
P32 Manual.p65 Issue 3 9th May 2008 Page : 5
1.2 Safety Features
The plasma unit includes the following features for the safety of the operator:
* The body of the plasma torch is earthed. * The continuity of the torch earth and the voltage on the body is monitored. * Cutting current flowing in the supply earth is monitored. * The voltage on the torch nozzle is monitored. * In the event of a faulty condition of the above, the machine will switch off power to the
torch.
* The access door for the torch connections is interlocked.
The emergency stop procedure is to hit the red emergency stop button located on the lower front control panel.
A tool (10mm spanner) is required to remove the canopy for access to the internal components. Under no circumstances should the canopy be removed whilst the mains supply is still con­nected. Only suitably trained and authorised personnel should remove the canopy .
1.4 Packaging Handling and Transport
Should the plasma unit need to be shipped, we recommend re-use of the original packing crate. Also:-
a) That the hose set be disconnected to prevent any damage to the hose set / plasma connections. b) That the control panel is adequately protected against potential damage. c) Any lifting should be done using the eyebolt located in the top of the canopy together with certified lifting equipment (not supplied). Precautions should be taken to prevent rotation about the eyebolt. d) The plasma unit should be shipped and stored in the upright position to avoid any heavy internal components breaking free from their mountings. e) Storage should be undercover, preferably in a clean dry environment.
1.3 Warning Signs
The location of the warning signs fitted to the plasma unit are:
a) At the front of the machine ­Warning Open Circuit Voltage 300 volts.
b) At each rear lower corner of the canopy -
Warning Disconnect the Mains Supply.....
These should be maintained in a legible condition.
2. INTRODUCTION TO THE PLASMA PROCESS
The plasma process is created by passing a stream of clean ionised air, provided by an oil free compressor, through a NOZZLE in the torch. The air stream is ionised by a PILOT ARC, initiated by a HIGH FREQUENCY unit (HF Unit) which passes from the ELECTRODE to the nozzle when the torch is activated. When the PILOT ARC is brought close to the work piece, MAIN ARC is TRANSFERRED to the work piece as a jet of high energy which rapidly melts any metal with which it makes contact, providing fast cutting, low residual heat input, and low material distortion.
The electrode and nozzle are cooled by air (and water in water cooled torches), and as the air is passed through the nozzle it is caused to swirl around the arc by a SWIRL BUSH to aid stability of the arc.
The HF unit operates automatically to establish an arc when power is applied to the torch and it ceases to operate when the pilot or main arc is established.
P32 Manual.p65 Issue 3 9th May 2008 Page : 7
3. INSTALLATION
May be carried out by a competent electrician. No specialist tools are required.
3.1 Power Supply
The power unit is provided with a length of flexible cable which must be connected to a 3 phase and earth electrical supply . The supply should be fitted with fuses or circuit breakers of appropriate rating and a means of isolating the power unit from the supply should be provided. A plug should be fitted if appropriate. The machine is phase/rotation sensitive.
The power unit has power factor correction capacitors fitted as standard. It must be noted that when the unit derives its power from a generator, the power factor correction may disturb the generators' automatic voltage control. If recommended by Goodwin Air Plasma, the power factor correction circuit can be disconnected however this will increase the input current demand.
Refer to the rating plate on the machine and Technical Data section 6.1.1. for the correct voltage and current requirements.
3.2 Earth Requirements
The installation should be arranged such that the only path to earth (or ground) from the work piece is by way of the plasma earth lead connected to the front of the machine.
Where the material to be cut forms part of the structure which is earthed or grounded to the mains electrical supply system, then the cutting current could flow through that route rather than the plasma earth lead to the machine. Always ensure that there is a good connection between the work piece and the machine via the plasma earth lead as a poor connection will cause excessive current in the mains supply earth which will create a current trip fault condition (see section 7.4 fault finding).
In installations where it is not possible to avoid earth current trips, even though a good cutting current earth path has been ensured, it will be necessary to check that the alternative mains earth paths are substantial enough to carry higher currents than the current trip setting of 10 amps without causing damage, as where the cutting earth is not connected to the work piece at all, this would be the full cutting current. If the earth paths are not substantial they must be uprated or re­routed to avoid the possibility of damage. Once the necessary checks and precautions have been taken, the earth current trip circuit may be disabled by means of the switch on the Earth Current Relay (ECR) located inside the power unit.
PLASMA
TORCH
PLASMA
MACHINE
WORK
PIECE
MAINS
SUPPLY
PLASMA EARTH LEAD
POSSIBLE ALTERNATIVE PATH
+
-
PLASMA
POWER SUPPLY
FOR CUTTING CURRENT
EARTH
CURRENT
RELAY
3.3 Phase Determination
Connect the torch to the machine (see section 4).
Fill the water system with distilled water.
Note. T o avoid damaging the water pump the machine should not be run without water in the system, also, the machine should not be run for more than a few seconds without a torch connected to the machine.
Switch on the machine by rotating the main isolator and pressing the on/off button ensuring the emergency stop switch is unlatched.
Correct phase connection is determined by checking that the cooling air flowing through the power unit is from the front panel to the rear of machine. Also, the water return flow , with a torch connected, can be seen as a jet of water inside the water tank through the filler opening once the filler cap is removed. If the fan rotation not correct, change two of the three phase connections at the power supply and check again.
If there is any doubt regarding installation, consult your distributor or Goodwin Air Plasma.
Fan Rotation Anti­Clockwise
W ater Jet inside W ater T ank
Compressed Air Cooling Radiator
Optional W ater Filter
P32 Manual.p65 Issue 3 9th May 2008 Page : 9
4. PLASMA AND TORCH CONNECTIONS
4.1 Connecting the Torch and Plasma Earth Lead to the Power Unit
EURO PLUG TORCH CONNECTOR
W A TER RETURN
W A TER SUPPL Y
DIAGRAM TO SHOW HOSE SET CONNECTIONS
Note. Do not run the power unit without the torch connected. POINTED TOOL
The plasma earth lead is connected via the push in and twist clockwise socket.
The water fittings cannot be fitted incorrectly although the return line (long) will fit in the supply outlet (short) for back flushing the torch. T o remove the water hoses, push the water connector collars to release (both together to avoid loss of water). When first switching on, allow enough time for the water to circulate through the system. A solid flow of water should be seen inside the filler orifice when the filler cap is removed, top up the header tank as required. Use only distilled or de-ionised water. (See section 7.1 regarding use of methanol in freezing conditions).
T orch connection to the power unit is made by a "push in" connector plug to a socket on the front of the power unit designed to prevent accidental removal of the hose set. A pointed tool is supplied in the tool kit for the purpose of allowing the hose set to be connected and disconnected.
T o connect the hose set, insert the connector plug into the socket and press the pointed tool into the small hole (see illustration), whilst rotating the knurled securing collar.
Note that a sealing ring is located in the base of the torch connector socket to form an air seal with the centre power pin. Care should be taken to ensure that this seal is not displaced and that the end of the pin is not damaged when the torch plug is removed.
4.2 Control of Hand Torch
The hand torch is provided with a press on / release off control switch on the handle for operation of the plasma arc.
Note. Cooling air will flow through the torch at all times when the machine is switched on.
If a hand torch is to be used in conjunction with a mechanical manipulator or tractor unit etc., when the operation of the handle mounted press on / release off control switch will not be possible, plug the remote control (optional extra) switch unit into the remote control socket as for the machine torch.
P32 Manual.p65 Issue 3 9th May 2008 Page : 11
WARNING INDICATORS
ON / OFF BUTTONS
MAIN ISOLATOR
EMERGENCY STOP
OUTPUT ON LAMP
AIR PRESSURE
GAUGE
AIR REGULA TOR
RESET BUTTON VOLTMETER
5 OPERATION
5.1 Machine Controls
The front panel of the machine provides a range of displays and control gear to ensure correct operation
ON / OFF BUTTONS Switches auxiliary circuits on and off. ie Compressor, water pump, cooling fan and control circuits
MAIN ISOLA TOR Isolates machine from mains supply. It may be padlocked in the off position.
EMERGENCY STOP Switches machine off. The switch latches mechanically and must be rotated to release.
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