GOODWIN P30U Operation Manual

P30U Instruction Manual Revision : 1 1st December 2006 Page 1

OPERATION MANUAL

for the

GOODWIN P30U

UNDERWATER

AIR PLASMA CUTTING SYSTEM

Page 2 P30U Instruction Manual Revision : 1 1st December 2006

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 W ork legislation.

GOODWIN AIR PLASMA LIMITED

KERNAN DRIVE

LOUGHBOROUGH

LEICESTERSHIRE

LE11 5JF

ENGLAND

Tel No. [phone]

Fax No. [phone]

Email. [e-mail]

P30U Instruction Manual Revision : 1 1st December 2006 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 theTorch 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 TORCH 17

5. 4 .............................................................................................................................. Troubleshooting 18

5.5............................................................................................................................ Consumable Life. 18

5.5.1. ..................................................................................................................... INTRINSIC LIFE. 18

5.5.2. ............................................................................................................................ ALIGNMENT. 18

5.5.3. .......................................................................................................... TRANSIENT DAMAGE. 18

5.5.4. ................................................................................................... OPERATIONAL DAMAGE. 19

5.5.5. ....................................................................................... ELECTRODE “NON-STARTING”. 19

5. 6 .................................................................................................................. Changing Consumables 20

5. 4 .............................................................................................................................. Troubleshooting 23

5.5............................................................................................................................ Consumable Life. 23

5.5.1. ..................................................................................................................... INTRINSIC LIFE. 23

5.5.2. ............................................................................................................................ ALIGNMENT. 23

5.5.3. .......................................................................................................... TRANSIENT DAMAGE. 23

5.5.4. ................................................................................................... OPERATIONAL DAMAGE. 24

5.5.5. ....................................................................................... ELECTRODE “NON-STARTING”. 24

6 . ......................................................................................................................... TECHNICAL DATA 25

6. 1 ........................................................................................................................................Power Unit 25

6.1.1. .............................................................................................................. ELECTRICAL INPUT 25

6.1.2. ........................................................................................................................ Electrical Output 25

6. 2........................................................................................................................ Torch and Hose Set 25

6.2.1 ........................................................................................................................... HAND TORCH 25

7 . ............................................................................................................ SERVICE INFORMATION 26

7. 1 ................................................................................................................................ The Power Unit 26

7.1.1. .......................................................................................................................... Circuit Diagram 27

7.1.2. ................................................................................................................ MACHINE LAYOUT 28

7.1.2. ................................................................................................ DIAGNOSTIC INDICATORS. 30

7. 2 ................................................................................................... The Torch and Hose Set Repair 31

7. 3 .................................................................................................................................... Maintenance 32

Page 4 P30U Instruction Manual Revision : 1 1st December 2006

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 or circuit
breakers 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 350V), and
when the main arc is cutting (150-200V). 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 standard torch should not be used in excessively wet conditions or if the torch or hose
set are damaged in any way.
Note that the PTU torch, its umbilical and associated extensions and connectors are designed to be used
underwater. The current specification is to a maximum of 30m, although it has been tested to a simulated
70m..
The electrical connectors are underwater mateable (to ocean depth) but in practice it is not advisable to
disconnect the coolant and air lines underwater, so this would normally be done on the surface.
c) The mains supply should be isolated from the unit AT THE SUPPLY 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. Note, however, that the plasma arc does not usually need to be observed
closely, if at all. It is more often necessary to be able to see the material surrounding the cut, so a lighter
shade than that used for welding will probably be required. Furthermore, when cutting underwater, the UV
is absorbed by the water to a considerable degree. Wear 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.
g) The wheels on the unit are meant for ease of movement around the work place and should not be
used over rough surfaces nor at excessive speeds.
h) The plasma power unit should be positioned on stable level ground and if necessary secured against
any unwanted movement.
i ) The operation of this equipment and the plasma cutting process can result in noise levels that could be
harmful. When cutting underwater the noise level from the arc is substantially reduced and does not represent
a risk to the diver. The employer should undertake a noise assessment to monitor compliance with relevant
legislation.
j) 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.
k) Care should be taken when manoeuvring the hose set with either a hand held torch or one connected
to a robotic device, 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. Hose sets that are subject to excessive mechanical tension may
result in damage to the hose set connections at the machine, the torch, or the hose set components themselves.

P30U Instruction Manual Revision : 1 1st December 2006 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 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 W arning Signs

The location of the warning signs fitted to the plasma
unit are:

a) At the front of the machine ­W arning Open Circuit V oltage 300 volts.

b) At each rear lower corner of the canopy -

W arning Disconnect the Mains Supply.....

These should be maintained in a legible condition.

Page 6 P30U Instruction Manual Revision : 1 1st December 2006

2. INTRODUCTION TO THE PLASMA PROCESS

The plasma process is created by passing a stream of clean 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 the air and a recirculating water cooling system, 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.

P30U Instruction Manual Revision : 1 1st December 2006 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. The P30U has auto­matic switching of the power factor correction so that it only operates whilst cutting, so it is unlikely to
cause this problem. This may be fitted as an option to other variants.

Refer to the rating plate on the machine and Technical Data section 6.1.1. for the correct voltage
and current r equirements.

3.2 Earth Requirements

The installation should ideally 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).

Note that the Earth Loop Monitor system used in the underwater machine will ensure that a good
connection is made.

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 30amps (*) 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 re-routed 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.

*Since the workpiece will often be substantially connected to the supply earth in underwater work,
and significant currents must be allowed to flow in seawater to the torch and umbilical earth, a less
sensitive earth current relay is used. The standard machine sensitivity is 10A. This should avoid most
cases of nuisance tripping, and the need to disable the ECR.

Page 8 P30U Instruction Manual Revision : 1 1st December 2006

3.3 Phase Determination

Connect the torch to the machine (see section 4).

Fill the water system with distilled water.

Note.To avoid damaging the water pump the machine should not be run without water in the
system. Also, the machine should not be run for mor e than a few seconds without a torch connected
to the machine. It may be necessary to eliminate air from the system, and vent the de-ionizing filter,
to establish a proper flow.

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 thr ough the power
unit is from the fr ont panel to the r ear of machine. If this condition is not corr ect, change two of the
three phase connections at the power supply and check again. The fan rotation, when viewed from
the front of the machine, is anti-clockwise.

If there is any doubt regarding installation, consult your distributor or Goodwin Air
Plasma.

Fan Rotation Anti­Clockwise

W ater T ank

De-ionizing
Filter

P30U Instruction Manual Revision : 1 1st December 2006 Page 9

4 . PLASMA AND TORCH CONNECTIONS

4. 1 Connecting the Torch and Plasma Earth Lead to the Power Unit

Note. Do not run the power unit without the torch connected.

The connections to the power unit are located at the front of the unit.

The PTU torch and umbilical extensions use a specially designed electrical connector for the power,
safety earth, pilot arc, and all other electrical connections. There is a central pin that carries the
power, a pin for the pilot arc connection and 5 smaller pins for safety monitoring and the diver’s
control switch. The safety earth is made thr ough the locking sleeve. There ar e four hose connectors,
filled with quick acting connectors.

the blue hose is the cooling water to the torch;
the red hose is the cooling water return from the torch

the black hose carries the plasma air

the yellow hose is a “pneumo” connection to allow the plasma air pressure to
automatically track the working depth

The water connections are not polarised but it is advisable to follow the colour coding.
These connectors are found on the machine front panel and replicated at the socket end of the ex­tension umbilicals.
The supervisor’s remote control panel connects to a multiway socket above the torch connectors.

(Note that this is an “analogue” lamp, therefor e it may be illuminated but not at full brightness,
and the indicator (which is “digital”) on the front panel and the supervisors panel still fail to
light because of a poor connection).

When first switching on, allow enough time for the water to circulate through the system. T op up the
header tank as required. Use only distilled or de-ionised water. (See section 7.1 regarding use of
methanol in freezing conditions).

The two earth connectors (insert and twist clockwise to lock) are located on the left hand side of

the front panel. An indicator lamp indicates when an earth loop has been successfully made.