L-TEC PLASMAWELD 202 Manual de usuario
PLASMAWELD 202, 402 Instruction manual PLW 202 1 010 210 00, PLW 402 1 010 177 00 – Version 2/2008
L-TEC Schweißtechnik GmbH
Walzwerkstraße 8a | D-57537 Wissen
Phone: (+49) 27 42 / 75-0 | Fax: (+49) 27 42 / 7 52 71
2
Safety advice...................................................................................................................................................................................................................... 3
Technical data PLW 202.............................................................................................................................................................................................4
Technical data PLW 402.............................................................................................................................................................................................5
Technical description.................................................................................................................................................................................................... 6
Installation.....................................................................................................................................................................................................................7-12
Starting up / Welding..................................................................................................................................................................................................13
Data sheet plasma welding....................................................................................................................................................................................14
Accessoires.......................................................................................................................................................................................................................15
Maintenance.....................................................................................................................................................................................................................15
Trouble shooting ............................................................................................................................................................................................................16
Spare parts................................................................................................................................................................................................................17-23
Wiring diagram............................................................................................................................................................................................................... 24
Annex EMC............................................................................................................................................................................................................... 25-26
Index
3
WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE
PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYER‘S SAFETY PRACTICES WHICH
SHOULD BE BASED ON MANUFACTURER‘S HAZARD DATA .
ELECTRIC SHOCK ... CAN KILL!
Install and earth the welding or cutting equipment in accordance with applicable standards.
Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
Insulate yourself from earth and workpiece.
Ensure that your working place is safe.
FUMES AND GASES ... CAN BE DANGEROUS TO HEALTH!
Keep your head out of the fumes.
Use ventilation, extraction of fumes at the arc or both to keep fumes and gases out of your breathing
zone and the general area.
ARC RAYS ... CAN INJURE EYES AND BURN SKIN!
Protect your eyes and body. Use the correct welding screen and filter lens and wear protective,
insulating and non-flammable clothing.
Protect bystanders with suitable screens or curtains.
FIRE HAZARD!
Sparks and spatters can cause fire. Make sure, that there is no inflammable material
in the surrounding of welding and cutting works.
MALFUNCTION!
Call for expert assistance in the event of malfunction.
Read and understand the instruction manual before installation and operation
Protect yourself and others!
Safety advice
4
Mains:
Mains voltage (V) 3-phase 230 400 500
Permanent power (kVA) 9,7 9,7 9,7
Permanent current (A) 24,4 14,0 11,2
Max. current (A) 31,4 18,0 14,5
Power factor cos phi 0,85 0,85 0,85
Frequency (Hz) 50/60
Fuses, slow blow (A) 35 20 16
Welding:
Current range DC 5 - 220 A
Duty cycle Plasma, 60% ED 220 A
TIG 100% ED 170 A
STICK
Open circuit voltage DC 98V DC
Construction:
Dimensions (mm) L/W/H 1020/570/960
Weight (kg) 150
Protection class IP 23 M
Cooling F
Insulation class F
Standards EN 60974-1
VDE 0544-1
EN 50199
S-Mark Yes
CE-Mark Yes
Technical data PLW 202
5
Mains:
Mains voltage (V) 3-phase 230 400 500
Permanent power (kVA) 19,4 19,4 19,4
Permanent current (A) 49 28 22
Max. current (A) 61 35 28
Power factor cos phi 0,85 0,85 0,85
Frequency (Hz) 50/60
Fuses, slow blow (A) 63 35 35
Welding:
Current range DC 6 - 400 A
Duty cycle Plasma, 60% ED 400 A
TIG 100% ED 310 A
STICK
Open circuit voltage DC 98V DC
Construction:
Dimensions (mm) L/W/H 1020/570/960
Weight (kg) 273
Protection class IP 23 M
Cooling F
Insulation class F
Standards EN 60974-1
VDE 0544-1
EN 50199
S-Mark Yes
CE-Mark Yes
Technical data PLW 402
6
The plasma arc welding machines PLASMAWELD 202 and 402 have been developed for welding with
transferred arc, i. e. the main arc transfers from the tungsten to the work piece. These units can also be
used for TIG, TIG pilot arc and manual metal arc (MMA) welding.
The power supplies can be used in confined spaces and are labelled with the S-mark according to EN 60
974-1.
Infinitely variable adjustment of the welding current makes the units suitable for micro-plasma and high
current plasma as well as for plasma key hole welding.
The pilot arc , started by HF, remains ignited and permits safe and touch-free starting of the main arc.
By means of rh 19“ rack control system, the units can be used for all manual and automatic plasma wel-
ding applications.
The required welding current and gas flow can be preset before starting the welding operation.
The power supplies are equipped with a constant current control so variations of the mains voltage or
different arc length do not effect the current of the main arc.
The following materials can be welded: high-, low- and unalloyed steel; nickel, copper, titanium , zirconium
and their alloys.
The compact construction with built in water cooler for the torch enables easy transportation of the machi-
nes.
Warning!
This product is intended for industrial use (Class A). In a domestic environment this product may cau-
se radio interference. It is the users responsibility to take adequate precautions.
The welding equipment creates a noise level of < 70 dB(A) at idle.
An emission level related to the work-place cannot be stated, because this value is depending on the
method and the surroundings. It is conditioned by a variety of parameters e.g. the welding or cutting
process, the kind of current, the power, the kind of material, resonance’s of the workpiece, the surroun-
dings and more.
Technical description
7
On the last page of these instruction manual a picture of the unit marked with symbols is located. Please
unfold and refer to this page in conjunction with the following instructions.
1. Mains connection
The units are factory connected to 400 V 50/60 Hz. They also can be used on 230 V 50/60 Hz and 500 V
50/60 Hz mains. The wiring instruction for reconnection is located inside of the machines near the input
terminal (460V 50/60Hz option).
Important! In case the machines are used with 230 V mains voltage, the mains
cable delivered must be replaced by one with a bigger cross section.
230 V 400/460/500 V
PLW 202 4 x 4 mm² 4 x 2,5 mm²
PLW 402 4 x 10 mm² 4 x 4 mm²
The mains plug must comply to country regulations and must be connected by an electrician. Check the
mains voltage before the machine is switched on.
2. Coolant
Pull the plastic plug of the cooling unit and check the water level. Liquid level should be about 3 cm (1“)
below the filling hole. If not, top up the tank using LoDuct cooling fluid.
Caution! Electrolytic corrosion may shorten the live time of the torch, when normal mains
water is used. Lo Duct contains glycol. Do not give access to children. Injurious to
health when drunk.
3. Gas connection
At the rear of the machine a cylinder mounting position is provided. The cylinders must always be secured
with the chains. Fit the regulators and the gas hoses for Ar/H2 and Ar to the cylinders. Connect the other
ends of the hoses to the corresponding connections clearly marked on the back side of the machines.
Open the valve of the bottle slowly and adjust the gas pressure to 6 bar.
Optional two different flow meter slide-in modules are available. It depends on the welding application
which type of flow meter slide-in module is required.
Welding gas: Pilot gas: Slide-in module Standard at
0 - 20 l/min 0 - 1,1 l/min 1 261 051 PLW 202
0 - 20 l/min 0 - 7 l/min 1 261 050 PLW 402
Installation
8
4. Torch connection
The manual welding torches PT 75 and PT-150 as well as the machine torches PT-8 and PT 300 can be
connected with the central connector B easily and without tools. Make sure, that the water in- and outlet
hoses are connected to the corresponding colour coded quick connections.
At socket Athe control plug is connected, when manual torches are fitted, whereas a foot switch has to be
fitted to this socket, when machine torches are used.
The pilot circuit is connected to the torch via socket C.
5. Pilot arc current adjustment
The PLW 402 pilot arc current is factory set for PT-300 and PT-8 to 10 A. If PT-75 or PT-150 resp. PTM-150
are used, pilot current must be reduced to 5A. This is performed by eliminating jumper at resistor R105.
The PLW 202 pilot arc current is factory set to 5A and can be increased to 10A by connecting jumper at
resistor R105.
Disconnect machine from mains before opening the machine!
6. Connection of work return lead and electrode holder lead
a) The work return lead is connected to socket Hmarked with symbol work clamp.
b) When MMA-welding the electrode holder has to be connected either to plus (+) or minus (-) at socket
H depending on the kind of electrode to be welded.
7. Connection of remote controls
At the 5-pole socket Gthe following remote controls may be connected:
a) Foot remote control FC 4
b) Manual remote control
c) Pulse unit
Article numbers see accessories
Installation
9
8. Connection for automatic welding
With socket bthe machine can be connected to an automatic control (see wiring diagram)
Wiring diagram of 5-pole socket on adjusting board
* When switching on the pilot arc about the contacts 1and 3of the socket bthe switch fremains
into mid position.
Starting up
A. Plasma Welding
1. Open cylinder valves and handwheels for gas flow rate at regulators.
2. Switch main switch Fon. Fan and water pump will start, lamp dwill light.
3. Keep torch away from work
4. Set switch ito symbol
5. set switch kto symbol
6. Push test button for plasma gas and adjust flow rate acc. to data sheet plasma welding
7. set switch fto symbol (Pilot arc will ignite after a gas pre-flow time of about 5 sec. and
lamp ewill light up.
8. Keep button Edepressed and adjust welding current. Amperage is preset at potentiometer a
and can be read from ammeter D.
9. Actuate torch switch or foot switch and adjust flow rate of shielding gas at the other regulator.
10. Adjust gas post-flow time on potentiometer l
Installation
Start
Pilot extern on* View of the front
Current relais
10
Adjustment of tungsten with torch PT-8
Set switch Fto mid position and operate torch switch or foot switch. HF will start. Check whether HF
sparks over to nozzle on all sides. If not, readjust tungsten electrode of torch. This adjustment is very im-
portant and should be repeated regularly.
The electrodes of all other torches are centred by the insulation tube inside the torches automatically.
B. TIG-Schweißen
1. Substitute the plasma-torch by an appropriate TIG-torch.
2. Open cylinder valve and adjust gas flow rate to the value desired.
3. Switch main switch Fon. (Fan and water pump will start. Lamp dwill light.
4. Set switch ito (4-stroke) or (2-stroke)
5. Set switch kto
6. Set switch fto
7. Turn potentiometer ccounterclockwise to 0
8. Keep button Edepressed and adjust welding current. Amperage is preset at potentiometer a and can
be read from ammeter D.
C. TIG-Pilot-Welding
Connection of the plasma torch and adjustment of power supply is done as described under paragraph A.
Only the plasma torch has to be modified as follows:
Redrill the aperture of the torch tip to a diameter of 5,5 - 6,0 mm and slide out the electrode until it protru-
des about 1,5 mm beyond the tip face. Potentiometer cmust be turned to 0 during this welding procedure.
D. Switching off Plasma- and TIG-Pilot-Welding
To switch off the pilot arc, set switch fto mid position.
Wait about 15 sec. until the post flow time for the pilot gas has passed, before switching off the machine
with the main switch. During this time the electrode can cool down protected against oxidation by the pilot
gas.
Even in case of an emergency stop command by a automatic control the post flow process will be initia-
ted.
Installation
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