PLASMA ARC CUTTING SET
Service manual
0349 300 022 00-08-31 Valid from Serial No. 035 XXX-XXXX
2
! 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 MANUFACTURER’S HAZARD DATA.
ELECTRIC SHOCK - Can kill
- Install 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 zone
and 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.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING UNIT
PROTECT YOURSELF AND OTHERS !
1. TECHNICAL DATA .................................................................................................................... 3
2. MAINTENANCE ......................................................................................................................... 3
2.1 General ........................................................................................................................ 3
2.2 Inspection and cleaning ............................................................................................... 3
2.3 PT30KK consumable parts .......................................................................................... 3
3. TROUBLESHOOTING ............................................................................................................... 4
3.1 General ........................................................................................................................ 4
3.2 Test procedures .......................................................................................................... 5
3.3 Sequence of operation ................................................................................................. 6
3.4 Schematic diagram ...................................................................................................... 7
3.5 Air connections diagram .............................................................................................. 9
4. REPLACEMENT PARTS ...........................................................................................................10
! CAUTION !
Maintenance and Repair works should be performed by an experienced staff, and electrical
works only by trained electrician. Do not permit untrained persons to inspect, clean, or repair
equipment. Use recommended spare parts only.
3
1 TECHNICAL DATA
Rated 35% Duty Cycle 35A @ 94V 35A @ 94V
Output 100% Duty Cycle 20A @ 88V 20A @ 88V
Output Current Range
20÷35A 20÷35A
Open Circuit Voltage (max) 295V DC 295V DC
Rated primary input 16A/phase
400-415V 3~50Hz
28A/phase
230V 3~50Hz
Air Requirements PT 30KK 130 l/min
@ 3,5÷4,5 bar
130 l/min
@ 3,5÷4,5 bar
Max. cutting thickness 12 mm 12 mm
Dimensions Length
Height
Width
610 mm
515 mm
255 mm
610 mm
515 mm
255 mm
Weight of LPH 35 set 52kg 53kg
2 MAINTENANCE
2.1 GENERAL
If equipment doesn’t work properly, stop work immediately and investigate cause of malfunction.
Maintenance work must be performed by experienced person, and electrical work by trained
electrician. Do not permit untrained person to inspect, clean or repair the equipment. Use
recommended spare parts only.
! WARNING !
Be sure that unit is disconnected from mains by pulling out power cable plug of mains socket.
2.2 INSPECTION AND CLEANING
Frequent inspections and cleaning of LPH 35 are recommended for safe and proper operation. Some
suggestions for inspecting and cleaning are listed below:
A. Check work cable (+) for secured connection to workpiece.
B. Check if workpiece and power source are safely earth grounded.
C. Check heat shield on torch. Replace if damaged.
D. Check electrode and nozzle for wear on daily basis. Remove spatter, replace if necessary.
E. Make sure cable and hoses are not damaged and/or kink.
F. Make sure all plugs, fittings and neutral connections are tight.
G. With power cable disconnected from mains, wearing proper eye and face protection, blow inside
of machine with low-pressure dry compressed air.
CAUTION
Water or oil occasionally accumulate in compressed air lines. Be sure to blow air lines away
from unit to avoid damage of machine.
2.3 PT30KK TORCH CONSUMABLE PARTS.
! WARNING !
Make sure power switch is in OFF position before working on the torch.
! WARNING !
PT30KK is equipped with safety clamp that prevents torch from being energised with high
voltage when torch switch is accidentally closed while shield is removed. Always replace torch
with proper one manufactured by ESAB.
4
To assemble consumable parts refer to Fig.2-1.
A. Place spring, nozzle and insulating sleeve in shield as shown.
B. Screw electrode into torch head.
C. Thread assembly on torch body and hand tighten.
D. Put on assembled torch head safety clamp.
Always make sure the shield is very tight before cutting.
Fig. 2-1. Assembly of PT30KK torch head.
3 TROUBLESHOOTING
3.1 GENERAL
! WARNING !
ELECTRIC SHOCK CAN KILL! Make sure that machine is totally disconnected from mains by
unplugging its power cable plug from mains socket, before attempting any inspections or work
inside unit.
Check the problem regarding its symptoms in following troubleshooting guide. The solution may be
quite simple. If the cause can not be quickly located, shut off input power, open up the unit, and
perform visual inspection of all components and wiring. Check for secure terminal connections, loose
and/or burned wires and components, bulged or leaking capacitors, or any other sign of damage or
discoloration.
Cause of controls malfunction can be found by referring to sequence of operations and schematic
diagram (Fig. 3-1, 3-2) and by checking various components as well. A voltmeter and ohmmeter will be
necessary for some tests.
! WARNING !
Voltages found in plasma cutting equipment are high enough to cause serious injury or even
death. Be careful around equipment when covers are removed.
5
3.2 TEST PROCEDURES
A. Power light (D2) does not light.
1. Visually check machine for any damage.
2. Check if fan is running. If not, check following:
a. Check if machine is correctly plugged into mains.
b. Measure voltage level at mains terminal.
c. Check if circuit breaker Q is closed.
3. If above is OK, check voltage on PCB (PL60) – between points X1-6, X1-7 (24V AC±5%). If it is OK,
check LED D2 on front panel and its connections, fuse F1 (1,6A) (replace if opened) and control board.
Depending on test results, replace faulty apparatus
B. Malfunction of gas valve.
1. Check voltage on TR2 secondary terminals 11 & 12 (24 VAC). If not correct, than transformer is
faulty.
2. Check fuse F1 (1,6 A), replace if open.
3. Disconnect connectors X1, X2 and check wiring between TR2 and EZ1 check coil continuity and
resistance. Rectify miswiring or replace valve coil if necessary.
C. No airflow.
1. Check air supply. Unit requires min. 130l/min @ 3,5 bar, check supply terminal if necessary.
2. Check air line connections. Tighten if leaking. Check for any obstruction in air line as well.
3. Airflow may be blocked at torch tip. Check torch consumables. Also check for any obstructions in
torch lines.
NOTE: If above is OK, check all parts of air control and distribution circuit as per Fig. 3-7.
D. No “torch switch depressed” signal.
1. While depressing torch switch D3 LED should be lit for 2 sec (T
B
on diagram).
- If not check torch switch and leads. Unplug the torch switch leads at machine terminals, connect
ohmmeter to the leads. After switch is depressed it should read short. If not - switch or leads are
defective.
- If signal “ON” is OK – replace PCB.
E. “FAULT” LED (D1) is lit.
1. “FAULT” LED is lit (also when torch switch is released):
a) When machine is cold (i.e. it did not work within last 2÷3 hours) and LED D1 is lit, that means
temperature monitoring circuit is open. Disconnect connector X1 from PCB and check with ohmmeter
temperature switch WT1 on main transformer and its wiring. Rectify wiring or replace WT1 if
necessary.
b) When machine is hot, let it cool down. If “D1” LED is still lit, follow above p. a).
2. “FAULT” LED lights continuously, when gas valve is energised and air flows (also in postflow mode,
i.e. when torch switch is released).
c) Flow rate too low - adjust air parameters.
d) Air switch CZ1 or its wiring is faulty. Disconnect connector X1 from PCB and check with ohmmeter
sensors CZ1 and its wiring. Rectify wiring or replace CZ1.
6
3.3 SEQUENCE OF OPERATION
Fig. 3-1. Sequence of operation of power source.
T
A
– air preflow time (0,3 s)
T
B
– SAFETY STOP delay (2 sec)
T
C
– postflow time (1÷2 min)
T
D
– pilot arc duration time T
D
≤ T
B
T
E
– cutting process duration time
Description of operation sequence.
When start button (torch switch) is depressed – air immediately starts to flow, contactor ST1 turns on.
After 0,3 sec air flow stops for period of 0,2 sec, that allows to adjoin nozzle and electrode (pilot arc
current starts to flow). After 0,2 sec period nozzle is pushed away from electrode by flowing air, what
allows pilot arc to ignite and be blown out through the nozzle orifice. When torch head is close to
workpiece, main arc ignites (i.e. cutting process begins). If within 2 sec (T
B
– acc. to Fig. 3-1) main arc
(i.e. cutting) will not start, the output power will be shut off. So as to resume the work, torch switch is to
be released and depressed again. If next activation of machine will be done within air postflow period
(1÷2 min after last stop, than unit starts immediately (i.e. after 0,3 sec delay). If the postflow time (T
C
)
elapses and torch switch is depressed again, unit starts work after 0,3 sec delay time.
If main arc breaks during cutting (e.g. a hole in cut material) and torch switch is kept depressed, pilot
arc is automatically turned on and unit tries to resume cutting process. If work is not resumed within 2
sec (T
B
), the output power is shut off and starting sequence has to be repeated (release and press
again torch switch).
7
3.4 SCHEMATIC DIAGRAM
Fig. 3-2. Schematic diagram of LPH 35 power source (3x230V).
8
Fig. 3-3. Schematic diagram of LPH 35 power source (400-415V).
9
3.5 AIR CONNECTIONS DIAGRAM
Fig. 3-4. Air connections diagram of LPH 35.
10
4. SPARE PARTS
1. When ordering spare parts please specify machine model, serial number, designation and parts
order numbers as shown in spare parts list. This simplifies dispatch and ensures correct delivery.
Fig. 4-1. LPH 35 Power source – front view
Item No. Qty. Req.
3x400V/50Hz
Qty. Req.
3x230V/50Hz
Part No. Description Circuit symbol
1 1 1 0457 288 001 Plasma cutting torch PT 30KK
2 1 1 0457 288 002 Supporting sleeve
3 1 1 0457 288 003 Front cover
4 1 1 0457 290 010 Pressure gauge
5 1 1 0457 290 009 Pressure regulator
6 1 1 0457 288 004 Grip handle
7 1 1 0457 288 005 Grip
8 3 3 0457 290 003 LED – holder ( socket )
9 1 1 0457 290 004 LED ( green ) D2
10 1 1 0457 290 005 LED ( red ) D3
11 1 - 0457 288 006 Rotary cam – switch W1
11 - 1 0457 288 163 Rotary cam – switch W1
12 2 2 0457 288 007 Side panel
13 1 1 0457 290 006 LED ( yellow ) D1
14 1 1 0457 288 008 Grommet
15 1 1 0457 288 009 Current wire with clamp “ + ”
11
Fig. 4-2. LPH 35 Power source – left side view
Item No. Qty. Req.
3x400V/50Hz
Qty. Req.
3x230V/50Hz
Part No. Description Circuit symbol
40 1 1 0457 288 010 Transformer TR1
41
41
1
-
-
1
0457 288 011
0457 288 169
Rear shield
Rear shield
42 1 1 0457 289 027 Fan M1
43 1 1 0457 288 012 Fan support
44 1 - 0457 288 013 Supply cable
44 - 1 0457 288 164 Supply cable
45 1 1 0457 288 014 Coupler
46 1 1 0457 288 015 Coupler nut
47 1 1 0457 288 016 Roof
48 1 1 0457 290 029 Coupler
49 1 1 0457 288 017 Special nut
50 1 1 0457 290 030 Pressure switch CZ1
51 1 1 0457 290 031 Electromagnetic valve EZ1
52 1 1 0349 302 077
Rectifier block ass′ y
PR1
53 1 1 0457 288 018 Support ( left )
54 1 1 0457 288 019 Electronic PCB PL60
55 1 1 0457 288 020 Insulating sleeve
56 1 1 0457 288 021 Stub pipe
57 1 1 0457 288 022 Special nut
58 1 1 0457 289 025 Terminal block ( 2-way )
59 1 1 0457 288 023
Current sensor ass′y
ZS1
63 1 1 0457 290 047 Fuse holder
64 1 1 0457 290 048 Fuse 1,6A F1
65 1 1 0457 290 071 Quick detachable coupling
66 1 1 0457 290 072 Hose clip
67 1 1 0457 290 082 Reed – relay contact ZZ
68 1 1 0457 290 083 Circuit breaker Q
12
Fig. 4-3. LPH 35 Power source – right side view
Item
No.
Qty. Req.
3x400V/50Hz
Qty. Req.
3x230V/50Hz
Part No. Description
Circuit symbol
100 1 - 0457 288 024 Contactor ST1
100 - 1 0457 288 166 Contactor ST1
101 4 4 0457 288 025 Insulating sleeve
102 2 2 0457 288 026
Swivel wheel ass′y
103 1 1 0457 288 027 Base frame
104 1 - 0457 289 018 Transformer TR2
104 - 1 0457 288 165 Transformer TR2
105 1 1 0457 288 028 Resistor set R1, R2
106 2 2 0457 289 009
Resistor 3,75Ω
107 1 - 0457 288 029 Cable gland
107 - 1 0457 289 032 Cable gland
108 1 - 0457 288 030 Locknut
108 - 1 0457 289 033 Locknut
109 1 1 0457 288 031 Support ( right )
110 1 1 0457 290 042 Temperature switch WT1
111
112
1
2
1
2
0457 288 032
0457 288 033
Support
Fixed wheel ass′y
113 3 - 0457 288 034 Auxiliary contact
113 - 3 0457 288 167 Auxiliary contact
5. ORDERING OF SPARE / WEAR PARTS
1. When ordering spare parts please specify machine model, serial number, designation and parts
order numbers as shown in spare parts list. This simplifies dispatch and ensures correct delivery.
ESAB AB
SE--695 81 LAXÅ
SWEDEN
Phone +46 584 81 000
Fax +46 584 123 08
www.esab.com
020314
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna--Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
BELGIUM
S.A. ESAB N.V.
Brussels
Tel: +32 2 745 11 00
Fax: +32 2 726 80 05
THE CZECH REPUBLIC
ESAB V AMBERK s.r.o.
Prague
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Copenhagen-- Valby
Tel:+4536300111
Fax:+4536304003
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
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Cergy Pontoise
Tel:+33130755500
Fax:+33130755524
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Tel: +49 212 298 0
Fax: +49 212 298 204
GREAT BRITAIN
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Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
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Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
HUNGARY
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Tel:+3612044182
Fax:+3612044186
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Tel:+3902979681
Fax:+390297289181
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Tel: +31 30 248 59 22
Fax: +31 30 248 52 60
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AS ESAB
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Tel:+4733121000
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Tel:+421744882426
Fax:+421744888741
SPAIN
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Alcobendas (Madrid)
Tel: +34 91 623 11 00
Fax: +34 91 661 51 83
SWEDEN
ESAB Sverige AB
Gothenburg
Tel:+4631509500
Fax:+4631509222
ESAB International AB
Gothenburg
Tel:+4631509000
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Dietikon
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North and South America
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CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
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ESAB S.A.
Contagem-- MG
Tel: +55 31 333 43 33
Fax: +55 31 361 31 51
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
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ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
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ESAB Welding & Cutting Products
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Tel: +1 843 669 44 11
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Tel: +61 2 9647 1232
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Tel: +60 3 703 36 15
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Representative offices
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Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
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