Huayuan LGK Series IGBT Plasma Cutter Instruction Manual

1. Introduction

This manual provides essential information for the safe and efficient operation, setup, and maintenance of your Huayuan LGK Series IGBT Plasma Cutter. Please read this manual thoroughly before operating the machine to ensure proper usage and to prevent damage or injury.

The Huayuan LGK series plasma cutters are advanced power sources designed for various metal cutting applications, including handheld, semi-automatic, and CNC cutting. They feature IGBT inverter technology for stable cutting current and high reliability.

2. Key Features

• Soft Switching Inverter Technology: Ensures very stable cutting current.
• High Load Duration: Designed for heavy industrial use.
• Current Ramping Technology: Reduces torch accessory consumption, extending consumable life.
• Wide Grid Voltage Adaptability: Compatible with various power supply conditions.
• Unique Dustproof Design: Enhances reliability and extends machine lifespan in challenging environments.
• Compact Structure: Small size and light weight, suitable for mounting on CNC machine tools.
• Cost-Effective Operation: Utilizes cheap compressed air as the cutting gas source.
• Precise Current Control: Features precise preset cutting current with stepless adjustment.
• Plasma Gas Pressure Detection: Includes detection and indication functions for plasma gas pressure.
• Gas Test Function: Facilitates easy adjustment of air pressure.
• Automatic Protection: Equipped with overheat, overvoltage, undervoltage, and phase loss automatic protection mechanisms.

3. Components Overview

Familiarize yourself with the main components and controls of your plasma cutter:

Figure 3.1: Rear Panel Controls and Connections (LGK-120IGBT model shown)

Key Labeled Parts:

• Handle: For carrying the unit.
• Air Pressure: Gauge or indicator for air pressure.
• Start: Button or indicator for starting the cutting process.
• Torch Unlock/Lock: Mechanism for securing or releasing the cutting torch.
• Heat Radiation Hole: Vents for heat dissipation.
• GND Outlet: Ground connection terminal.
• Input Fault: Indicator for power input issues.
• Overload: Indicator for overload conditions.
• Cutting Air Checking: Control or indicator related to cutting air flow.
• Control Signal: Connection for external control signals (e.g., from a CNC machine).
• Air/Current Output: Connections for the cutting torch, delivering air and current.
• Pilot Arc: Indicator or control for the pilot arc function.

Figure 3.2: LGK-160IGBT Plasma Cutter with cutting torch and various consumables.

4. Setup Instructions

1. Unpacking: Carefully remove the plasma cutter and all accessories from the packaging. Inspect for any shipping damage.
2. Placement: Place the machine on a stable, level surface in a well-ventilated area, away from flammable materials. Ensure adequate clearance around the heat radiation holes for proper cooling.
3. Power Connection: Connect the plasma cutter to a suitable power supply (3~380V/50HZ as per specifications). Ensure the power source matches the machine's requirements.
4. Grounding: Connect the machine to a proper electrical ground using the GND Outlet. This is crucial for safety.
5. Air Compressor Connection: Connect a compressed air source to the machine's air inlet. Ensure the air pressure is within the recommended range for your model (refer to specifications). Use the gas test function to adjust air pressure as needed.
6. Torch Connection: Securely connect the cutting torch to the Air/Current Output and ensure the torch unlock/lock mechanism is engaged.
7. Workpiece Clamp: Attach the workpiece clamp (ground clamp) securely to the material to be cut, ensuring good electrical contact.
8. Consumables: Install the appropriate cutting consumables (nozzle, electrode, shield cup) into the torch head according to the material and thickness you intend to cut.

5. Operating Instructions

The LGK series plasma cutters support various cutting modes:

Figure 5.1: Three primary cutting modes: Handheld, CNC, and Semi-auto Plasma Cutting.

5.1. General Operation Steps

1. Power On: Turn on the main power switch of the plasma cutter.
2. Set Cutting Current: Adjust the cutting current to the desired level based on the material type and thickness. The machine features precise preset and steplessly adjustable current.
3. Check Air Pressure: Verify that the plasma gas pressure is correct using the machine's detection function. Adjust if necessary.
4. Initiate Arc: For handheld cutting, position the torch over the workpiece and press the trigger to initiate the pilot arc. For CNC or semi-auto modes, follow the specific control system's instructions.
5. Cutting: Maintain a consistent torch height and travel speed for optimal cut quality.
6. Power Off: After cutting, release the trigger, allow the post-flow air to cool the torch, then turn off the machine.

5.2. Cutting Material and Thickness Examples

Figure 5.2: Examples of cutting capabilities for different materials and thicknesses.

The machine is capable of cutting various metals including carbon steel, stainless steel, aluminum, and titanium. Refer to the specifications table for recommended cutting thicknesses for each model.

6. Maintenance

Regular maintenance ensures the longevity and optimal performance of your plasma cutter.

• Daily Checks: Inspect the cutting torch for wear on consumables (nozzle, electrode, shield cup). Replace worn parts immediately. Check air lines for leaks.
• Weekly Checks: Clean the machine's exterior, especially the heat radiation holes, to ensure proper airflow and cooling. Check all electrical connections for tightness.
• Air System Maintenance: Regularly drain any moisture from the air compressor and the machine's air filter/regulator. Clean or replace air filters as needed.
• Torch Maintenance: Keep the torch body clean. Avoid dropping or damaging the torch.
• General Cleaning: The unique dustproof design helps, but periodic cleaning of internal components by qualified personnel is recommended.

7. Troubleshooting

The LGK series plasma cutters are equipped with automatic protection features to help diagnose and prevent damage:

• Overheat Protection: If the machine overheats, it will automatically shut down. Allow it to cool down before resuming operation. Ensure proper ventilation.
• Overvoltage/Undervoltage Protection: The machine will indicate an input fault if the voltage is outside the acceptable range. Check your power supply.
• Phase Loss Protection: In three-phase models, the machine will protect itself if a phase is lost. Verify all phases are connected correctly.
• No Arc/Poor Cut Quality:
• Check consumables for wear and replace if necessary.
• Verify correct air pressure and flow.
• Ensure the workpiece clamp has good contact.
• Adjust cutting current and travel speed.
• Error Codes: Refer to the machine's display for any error codes and consult the full service manual or contact support for specific interpretations.

8. Specifications

Below are the general specifications for the Huayuan LGK series plasma cutters. Specific values may vary by model.

Figure 8.1: Overview of LGK Series Models and their key specifications.

Additional Specifications:

• Is Smart Device: Yes
• Origin: Mainland China
• Certification: CE
• Max. Output Power: Up to 300W (depending on model)
• Packaging: Export Plywood
• Machine Language: English, Portuguese, Italian, Russian, French, German, Spanish, Polish, Korean, Turkish, Greek, Chinese, Czech, Japanese, Slovak, Thai, Vietnamese, Romanian (Customized)

9. User Tips

• Voltage Compatibility: Always verify the input voltage requirements of your specific plasma cutter model (e.g., 380V) against your available power supply to ensure compatibility and prevent damage.
• Consumable Life: Utilize the current ramping technology by setting appropriate cutting parameters to extend the life of your torch consumables.
• Ventilation: Always operate the plasma cutter in a well-ventilated area to dissipate fumes and heat effectively.

10. Warranty and Support

Your Huayuan LGK Series Plasma Cutter comes with a 2-year warranty.

For after-sales service and support, you can expect online or local service. The process typically involves:

Figure 10.1: After-Sales Service Process Flow.

If you encounter any issues, please contact the seller or an authorized service center. They will guide you through checking if the issue is covered under warranty, and arrange for online service, remote desktop support, or assign a local technician/engineer if necessary.