LGK-40/63IGBT

IGBT INVETER AIR PLASMA CUTTING

MACHINE

OPERATOR’S MANUAL
(PLEASE READ IT CAREFULLY BEFORE OPERATION)

CHENGDU HUAYUAN ELECTRIC EQUIPMENT CO., LTD.

 LGK-40/63IGBT OPERATOR’S MANUAL

Safety Depends on You

HUAYUAN arc welding and cutting equipments are designed and built with ample safety consideration. However,
proper installing and operating can ensure your safety.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT CASUALLY WITHOUT READING THIS MANUAL
THROUGHOUT.

Special Notes (Very Important):

1. Pay attention to avoiding the machine falling down when it is placed on the gradient ground.
2. It is forbidden to unfreeze the pipeline by the cutter.
3. The shield rank of this series of cutter is IP21S, so working in rain is not suitable.
4．The cutter has external static characteristic with rated duty cycle 60%, which means the machine can work 6
minutes and rest 4 minutes at the rated cutting current in 10 minutes. The machine has the function of thermal
protection.When the internal temperature exceeds a set temperature, thermal protection moves on and the
abnormity indicator lamp on the panel turns ON, then there is no output in cutter. The machine can become normal
and work only after the internal temperature drops down and the abnormity indicator lamp on the panel turns OFF.

Purchase Date：___________________________
Serial Number: ____________________________
Machine Model：__________________________
Purchase Place：___________________________

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 LGK-40/63IGBT OPERATOR’S MANUAL

Cautions Arc and arc rays can hurt.

All performing welding workers ought to have health qualification from the authority
organization to prevent you and others from arc radiation and burn. It should be
prevented for children to enter into dangerous area as well.
Be careful reading the following important items and the welder safety byelaw from the
authority organization. Be sure that qualified professionals perform all installation,
maintenances and repair procedures.

 1.Electric shock：The welding circuits are not insulated when welding. If you touch the
two output electrodes of the machine with your bare skin at the same time, it will
lead to electric shock, sometimes even fatal dangers. Users need to follow the items
below to avoid electric shocks:
 If possible, lay some insulating materials, which are dry and large enough, in your working field.
Otherwise, use the automatic or semiautomatic welding machine, DC welding machine as possible
as you can.
 Components in the automatic and semiautomatic welding machine such as the welding wire
reel, feed wheel, contact tip and welding head are all electric components. .
 Always be sure the machine has been connected perfectly to the work piece with the work
cables and should be as close as possible to the working area.
 The work piece should be grounded perfectly.
 Make sure that the insulating material of the electrode holder, the grounding clamp, the
welding cable and the welding head are not affected by damp, mildewed or spoilt, and be replaced
momentarily.
 Never dip the electrode in water for cooling.
 Never touch electric components of two welding machines at the same time, because this
voltage is supposed to be two times of welding voltage while the grounding mode is not clear.
 While working high above the ground or other places having the risk of falling, please be sure
to wear safety belt to avoid losing balance caused by electric shock.

 2 Arc： Use an arc welding mask to protect your eyes and skin from sparks and the
rays of the arc, pay special attention to the filter glass, which must be conformable to
the national standard.
 Use clothing made from durable flame-resistant material or sailcloth to protect your skin from
hurting by the arc rays.
 Remind other nearby personnel before working lest arc rays hurt them by accident.

 3 Fumes and Gases ： Welding may produce fumes and gases hazardous to health.
Avoid breathing these fumes and gases. While working in limited room, use enough
ventilation and/or exhaust to keep fumes and gases away from the breathing zone, or
use the respirator. Do not weld at the same time when using of degreasing, cleaning or spraying
operations. The heat and rays of the arc can react with these gases to form phosgene, a highly toxic
gas,
 Some protective gases used in welding might displace the oxygen in the air, and can lead to
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 LGK-40/63IGBT OPERATOR’S MANUAL

hurt or even death.

 Read and understand the manufacturer’s instructions for this equipment, and validate the
health certification of consumptive materials, make sure they are innocuous.

 4 Spatter：Spatter can cause fire or explosion.

 Remove fire hazards from the welding area. Remember that spatter from
welding can easily go through small cracks and touch fire hazards. Protect all kinds of lines going
though welding area, including hydraulic lines in the wild.
 Where compressed gases are to be used in the field, special precautions should be used to
prevent explosion.
 When welding stops, make certain that no live part is touching the work piece or the work
stage. Accidental contact can create a fire hazard.
 Do not weld containers or lines, which are not proved to be innocuous.
 It is very dangerous to heat, cut or weld tanks or containers at entry holes. Does not start work
until the proper steps have been taken to insure that there is no flammable or toxic gas.
 Spatter might cause burn. Wear leather gloves, heavy shirt, cuffless trousers, high shoes and a
cap over your hair to prevent from burning by spatter. Wear the ear shield when performing
sideways or face up welding. Always wear safety glasses with side shields when being in a welding
area.
 The welding cables should be as close to the welding area as possible, and the short, the better.
Avoid welding cables going through the building framework, lifting chains, AC or DC cables of other
welding machines and appliances. The welding current is strong enough to damage them while
having short circuit with them.

 5 Cylinder：Damage of it might cause explosion.

 Make sure that the gas in the storage cylinder is qualified for welding, and the
decompression flow-meter, the adapter and the pipe are all in good condition.
 Make sure that the installation of cylinder is by the wall and bundled tightly by a chain.
 Be sure to put the cylinder in the working space with no crash or shake, and far from welding
area.
 It is forbidden to touch cylinder with the welding clamp or the work cables.
 Avoid facing the cylinder while installing the decompression flow-meter or the gasometer.
 When not working, please tighten the valve.

 6 Power ： (For electrically powered welding and cutting equipment) Turn off input
power before installation, maintenances and repair, so that avoid accident.
 HUAYUAN welding equipment is Ι class safeguard equipment; please install the equipment in
accordance with the manufacturer’s recommendations by specific persons.
 Ground the equipment perfectly in accordance with the manufacturer’s recommendations.

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 LGK-40/63IGBT OPERATOR’S MANUAL

 7 Power： (For engine driven welding and cutting equipment)

 Work in ventilated place or outdoors.

 Do not add fuel near to fire or during engine starting or welding. When not working, add fuel after
engine is cooling down; otherwise, the evaporation of hot fuel would result in dangers. Do not splash
fuel out of the fuel tank, and do not start the engine until complete evaporation of the outside fuel.

 Make sure that all the safeguard equipments, machine cover and devices are all in a good
condition. Be sure that arms, clothes and all the tools do not touch all the moving and rotating
components including V belt, gear and fan etc.
 Sometimes having to dismantle some parts of the device during maintenance, but must keep
safety awareness strongly every time.

 When engine is hot, it is forbidden to open the airtight cover of the radiator water tank to avoid
hurt by the hot vapor.

 8 Electromagnetic ： Welding current going though any area can generate

electromagnetic, as well as the welding equipment itself.
 Electromagnetic would affect cardiac pacemaker, the cardiac pacemaker users should consult
one’s doctor first.
 The effect of electromagnetic to one’s health is not confirmed, so it might have some negative
effect to one’s health.
 Welders may use following method to reduce the hazardous of electromagnetic:
 a. Bundle the cable connected to the work piece and the welding cable together.
 b. Do not enwind partially or entirely your body with the cable.
 c. Do not place yourself between the welding cable and the ground (work piece) cable, if the welding
cable is by your left side, then the ground cable should be by your left side too.
 d. The Welding cable and the ground cable are as short as possible.
 e. Do not work near to the welding power source.

 9 Lift Equipment：carton or wooden boxes package the welding machines supplied by

HUAYUAN. There is no lifting equipment in its wrapper. Users can move it to the
prospective area by a fork-lift truck, and then open the box.
 If having rings, the machine can be transited using rings. While HUAYUAN Welding Machine
Manufacture reminds users, there is possible risk to damage the welding machine. It is better to
push the welding machine moving in use of its rollers unless special situations.
 Be sure that the appurtenances are all removed off when lifting.
 When lifting, make sure that there is no person below the welding machine, and remind people
passing by at any moment.
 Do not move the hoist too fast.

10 Noise：HUAYUAN Welding Machine Manufacture reminds users: Noise beyond the limit
(over 80 db) can cause injury to vision, heart and audition depending on oneself. Please
consult local medical institution. Use the equipment with doctor’s permission would help
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 LGK-40/63IGBT OPERATOR’S MANUAL

CONTENTS

 Summary …………………………………………………………… 6

 Safety and Attention ………………………………………………… 6

 Work Environment Conditions ………………………………………… 7

 Technique Parameters……………………………………………………7

 Working Principles………………………………………………………8

 Panel and Functions ……………………………………………………10

 Protection function of the cutter…………………………………………11

 Installation and Operation……………………………………………… 11

 Maintenance …………………………………………………………… 14

 Cutting technology instruction………………………………………… 15

 Troubleshooting and Repair…………………………………………… 16

 Accessories ………………………………………………………… 18

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 LGK-40/63IGBT OPERATOR’S MANUAL

◆ Summary
1. Model description
L G K - □□□ IGBT
IGBT Inverter

Rated cutting current

Air plasma

Cutting

Plasma cutting
2. Characteristics
LGK-40/63IGBT inverter air plasma cutting machine is the latest development cutter in our
company. It has good characteristics as following:
1) This cutting machine adopts IGBT inverter technology which has high reliability and
efficiency. It is light weight.
2) Stepless adjustable cutting current, suitable for cutting various thickness workpiece. To
ensure cutting quality and save energy, low current is applied to cut thin plate, and high
current is applied to cut thick plate.
3) External and dynamic characteristics cutter are significantly better than leakage-reactance
typed cutter. High success rate in striking arc. Stable cutting current. Good arc stiffness. Clean
and smooth incision. Excellent technology performance.
4) The cutting current is very stable and it will not be influenced by grid voltage fluctuation.
5) There is over-voltage protection function.
6) Fast cutting speed, high production efficiency, and the speed is 2-5 times higher than
flame cutting speed.
7) Compressed air as cutting gas is low cost.
3. Usage
It is suitable for cutting kinds of metal materials like low carbon steel, alloy steel and
non-ferrous metal and is widely applied in the manufacturing of boiler pressure
container, chemical container, industrial power station construction, metallurgy,
aerospace industry, automobiles, building an so on.

◆ Safety and Attention

 Please follow the notes for the safety of you and others.
 It is forbidden to unfreeze the pipe line by cutting power or other usages except for
cutting.
 The cutter casing should ground reliably. Please make sure the grounding bolts of
power ground reliably in case of electric shock.
 Cutter is the equipment with high voltage. Please wear insulated protective shield
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 LGK-40/63IGBT OPERATOR’S MANUAL

when cutting.
 When exchanging torch and wearing parts, please turn off the supply power first.
 Protective shield should be worn.
In order to avoid any hurt to eyes from ultraviolet radiation and strong light and to
skin from spatter, please wear protective shield according to related rules and
regulations of labor protection.
 It is forbidden to inhale harmful gases.
The fumes and gases produced during cutting is hazardous to health. Please wear
protective shields and install aerator according to related rules and regulations of
labor protection.
 Cutting cannot proceed in closed container.
 The workpiece just after being cut is at high temperature. Please prevent from
scald.
 Protective gas cylinder and air compressor must be placed in a fixed position and
prevented from collision.
 Cutter and cutting place should be far away from flammable materials.
 Prevent foreign bodies from entering inside the machine. And protect the cable
from sharp materials.
 Protect the machine from fall or collision.
 In case of fall or collision, it can be used only after professional checking.
 In the surface or inside of the cutting workpiece, there should be no flammable and
explosive materials or chemical materials harmful to human.
 Installation and repair person must have state-authorized electrician operation
certificate.
 Cutting operation person should read this manual carefully and know the operation
method well.
◆ Work Environment Requirements
Welding performance may not meet technique standards without the following conditions.

 It should be placed with small dust, no corrosive gases and no flammable and explosive
materials. Avoid vertical sunshine and rain;
 Air relative humidity is no more than 90% at 20℃ and no more than 50% at 40℃
 When using air cooling torch, the ambient temperature should be from -10℃ to 40℃.
 It should avoid metal foreign bodies entering into the cutting power.
 Cutting power should be 30cm away from the wall or other sealed-in objects. The
distance between two sets should be above 30cm.
 The operation height should be less than 1000m.

◆ Technique Parameters
1. Main technique parameters:

LGK-40IGBT LGK-63IGBT

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 LGK-40/63IGBT OPERATOR’S MANUAL

Rated input voltage 3～50Hz 380V

Rated input capability 6.0KVA 9.9KVA
Open circuit voltage 222VDC 260VDC
Rated output current 40A 63A
Current adjusting range 20～40A 30～63A
Rated output voltage 96V 105.2V
Rated duty cycle 60% 60%
Insulation level F F
Quality cutting thickness（steel） 0.1～7mm 0.1～12mm
Max cutting thickness（steel） 12mm 20mm
Applied plasma air Compressed air Compressed air
Cooling model Air-cooling Air-cooling
Dimension(L×W×H) 585×280×485mm
Weight 25Kg 800×380×610mm 26Kg
Shell shield rank IP21S

2．Plasma gas conditions

 Work pressure range：0.3MPa～0.5MPa
 Gas supply pipe compression strength：≥1MPa
 Gas supply pipe inner dimension：≥Φ8
 Gas supply flux：≥40L/min
 Filter water from gas and then put it into cutter
U

270V

240V

63A/105.2V

40A/96V

I
40A 63A

Figure 1 External characteristic

◆ Work principles
The control circuit of cutting machine adopts advanced electronic part IGBT as the main inverter
switch component. Three-phase AC power is converted to 20KHz high-frequency DC current after
being rectified by three phase rectifier. Then under the function of IGBT inverter the DC current is
inverted to AC high frequency current, which is inverted to DC current after experiencing voltage
reduction in high frequency transformer, current rectifying in fast recovery diode. This DC current is
filtered through reactor, and the output cutting current is obtained. Control circuit can control output
current by controlling driven pulse width. The real time cutting current, which is obtained through
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 LGK-40/63IGBT OPERATOR’S MANUAL

current sensor connected to output terminal in series, is used as negative feedback control signal.
After comparing with current adjusting signal, the negative control signal is sent to PWM adjusting
integrated circuit, then a controlled driving pulse is output to control IGBT. Thereby a constant output
current can be maintained, and a steep dropping & constant current external characteristic is
obtained. Striking arc adopts high-frequency striking model. The main circuit refers to appendix
figure1，and principle diagram of control circuit is shown as figure 2.

Fu n d am e n ta l
DC AC High fre quen cy AC
fr e q ue n c y I GBT In verte r Rect ifie r un it
re c t if i e r& f i lt e r tran sfor mer

DC
3-phase input（ AC） IGBT dri ve
circ uit

Indu ctan ce
DC output
filt er
O ve r h e at , u nd e r v o l ta g e
p ro t e c ti o n c i r cu i t
PWM circ uit

Cu rr en t gi vi ng PI a dj us tm en t Ne ga ti ve f ee db ac k
co nt ro l ci rc ui t Cu rr en t sa mp li ng
co nt ro l ci rc ui t co nt ro l ci rc ui t

Figure 2 Principle diagram

 Common component list as diagram1

No. Symbol Components name Model Remark

1 V1 Three phase rectifier MDS40C-12
IKW25N120T2 LGK-40IGBT
2 V2～V5 IGBT module
IKW40N120T2 LGK-63IGBT
3 V6、V7 Diode module DWM2F60N060
4 TA1 Hall current sensor TKC-100BS
5 QF1 Breaker DZ47-63/3P D25
6 R5 Resistor RXG7-10Ω/50W
7 YV1 Magnetic gas valve DF2-B-3/36V AC
8 EV1 Cooling fan 2123XSL
9 RP1 Potentiometer WH118-2W-4.7K
JUC-6F-75℃ normally
10 KT1 Temperature relay
close
11 BP1 Pressure controller YKC 0.2/0.15
12 AP1 Main control board LGK4063IGBT-AP1
13 AP3 HF board LGK7-63AP3
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 LGK-40/63IGBT OPERATOR’S MANUAL

14 AP5 Filter board LGK63IGBT-AP5

15 Air filter regulator GFR-200-08
Diagram Common component list

◆ Panel and its functions（see Figure 3）

1 2 3 4 10 11

5 此 开关仅作保 护用
请 另配电源开 关！
Th is s wit ch i s on ly u se d fo r Pr ot ec tio n ！
输 入 3～ 380V
I np ut 3～38 0V

电源 指示 气压 供 电异 常 过热
Powe r Air pressur e I nput fault Ov erload
切割
50
L GK -63 IG BT
I nc is e
40
63
30

试气
切 割电流
Chec k air

6
Cutting current

成 都 华远 电 器 设 备 有 限 公司 R

地 址 ： 成 都 市 武侯 区 武 侯 科 技 园 武 兴四 路 5号
名称： 空气等 离子切 割机 型号 : L G K - 6 3 I G B T
出厂 编 号: 重 量 ： 26kg
3 ～f 1
f 2
GB15 579. 1-200 4
30 A /9 2 V -6 3 A/ 1 0 6V
X 60 % 100 %
I2 63 A 4 9A
U0 =2 70V
U2 1 06V 99 .6V

U1 =3 80V I1m a x =15 A I1 ef f =1 1.6 A

3 ～5 0H z

冷却 方式： 风冷 防 护 等 级 ： I P2 1S 绝缘等 级：F

切 割地 线 控制 气电输出
Work cable Control signal Output air & current

7 8 9 12
Figure 3 Function of panel
1. Power indicator lamp: Indicating if the cutter is energized.
2. Air pressure indicator lamp：It is ON when the pressure of compressed air exceeds 0.2Mpa.
It is OFF when the pressure is less than 0.15Mpa.
3. Power supply abnormality indicator lamp: It is ON when power supply is more than 440VAC
or less than 300VAC；
4. Overload indicator lamp: It is ON when the cutter is over loaded (generally it is on when
cooling fan is damaged.)
5. Gas control selection switch: When it switches to Check air, gas valve opens to test gas flux.
When it switches to Cutting, the gas valve opens during cutting automatically.
6. Cutting current adjusting knob: Adjusting cutting current；
7. Cutting ground wire outlet: To connect cutting ground wire；
8. Torch control outlet: To connect torch control signal wire;
9. Air & Power output terminal: the current output terminal is also the compressed air output
terminal. It is gas pipe connector to connect water-cooled torch when the water-cooled
torch is used, and it is connector to connect torch air-cooled cable when air-cooled torch is
used.
10. Power source switch: Control the ON/OFF of 3-phase power supply of cutter.；
11. Power source line：For connecting 3-phase power supply. The green-yellow line is used for
protecting ground line, and it must be connected to the ground firmly；

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 LGK-40/63IGBT OPERATOR’S MANUAL

12. Air pressure regulation filter：For adjusting work pressure of compressed air and filtrating
water from air.
◆ Protection function of the cutter

 Air pressure protection

1. When the indicated value of the pressure meter, which is fixed on the back of the cutter, is
lower than 0.2 MPa, the protection circuit starts working and the cutter cannot start.
2. When the indicated value is lower than 0.15 MPa during cutting, the cutting arc will
extinguish.
 Note: When adjust the air pressure, the panel function must be set to Check air.
 Over load protection
When the ambient temperature is too high or the cooling fan is broken, the cutter will be
over heated under the rated current, and heat protection circuit starts working, the cutting arc will
extinguish automatically.
 Power supply abnormal protection
1. When the 3 phase power supply is higher than 440VAC, protection circuit starts working and
there will be no arc striking.
2. When the 3 phrase power supply is lower than 300VAC, protection circuit starts working and
there will be no arc striking.

◆ Installation and Operation

1. Transport and Lift

 Power source should be shut off before moving the cutter.
 The cutter bottom should be kept downwards during transportation. It is forbidden to
have cutter placed transversely or upended.
 When lifting, it must be lifted vertically.
 During the long-distance transportation, it must prevent the cutter from raining and
moving back and forth inside box. Shock absorption foam should be placed around
cutter.
2. Installation and Connection
 A . Power source should be shut off before installation and connection.
 B. Installation environment details refers to the point “Work Environment Requirements”.
 C. If cutting power source is placed in a slanted surface, it must be prevented from falling
down.
 D. Shield rank for cutting power is IP21S. The installation and operation cannot be
proceeded in the rain.
3. Power supply requirements
 Voltage fluctuation≤±10％；
 Frequency fluctuation≤±1％；
 Asymmetry rate of three-phase supply system≤5％；
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 LGK-40/63IGBT OPERATOR’S MANUAL

 Power supply wire cross profile, ground wire cross profile, breaker and fuse should refer
to the diagram below.
Items LGK-40IGBT LGK-63IGBT
Power supply wire cross profile（mm2） 2.5-4 4-6
Ground wire cross profile（mm2） 2.5-4 4-6
Breaker capacity（A） 20 30
Fuse capacity（A） 20 30
4. Installation of power wire
Shut off the power switch first. Connect the power input wire of cutter back panel to
distribution box which meets the parameters in the diagram above. The green-yellow wire is
protection ground wire, which must be connected to earth reliably. Earth connecting method
should follow state standard.
5. Connection of compressed gas and the usage of air filter regulator

Gas pressure
regulating valve

Inlet pipe
Hoop

Draining water tip

The compressed gas should meet the requirement mentioned in point “Plasma gas
conditions”. Connect the gas pipe with the gas inlet of air filter on the back panel and hoop it
tightly.
The usage of air filter regulator is as follows. When it is to adjust pressure, lift up air
pressure regulating valve, and rotate it. Left rotation aims to reduce outlet gas pressure, right
rotation aims to increase outlet gas pressure. After the gas pressure is adjusted properly, press
down regulating valve.
The air filter regulator should be checked periodically. If the water level reaches two-thirds
of filter glass, it must be drained, or this will affect incision quality. The gas supply valve should
be closed during water draining, and Check air function is selected on panel. When the indicated
valve of gas pressure meter is zero, water will drain out from drainage mouth automatically.
6. Connection of cutting torch
Firstly connect the torch cable connector M16 nut with the copper nozzle marked with Air &
Power Output on the front panel, and screw down the nut, then put on insulation sleeve; Connect
the torch control plug to the outlet marked with Control on the front panel and screw down the
nut.
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 LGK-40/63IGBT OPERATOR’S MANUAL

7. Connection of cutting ground wire

Connect the fast connector of cutting ground wire with the outlet marked with Cutting
Ground Wire on the front panel and screw down it clockwise. The other end of the cutting
ground wire is connected to workpiece firmly.
 Operation method
1. Security notes

Operation strictly accordant with the following steps

Notes:

Electric shock may Cutting may cause fire or explosion

hurt or even kill  Splashes may ignite flammable materials
Notice man. nearby. Those materials should be 10m away
 Shut off the power during from the working place.
connection
Do not touch the conducted parts
Fume & dust is harmful. Arc may hurt your eyes and skin.
Do not breathe in the fume and dust Strong arc may hurt your eyes.
caused by cutting Ultraviolet radiation generated by arc may hurt
Clean up the oil spot on work piece. skin and eyes. Please wear shielded guard
Keep fresh air in working place when cutting.
 Fume extraction equipment should
be prepared.
Overheated part may hurt Fast moving thing may injure you.
your skin.  Do not put your hands or other things into the
Do not touch the overheated part on fan shield.
the work piece. Cover the opened case shell well during cutting
 Do not touch hot cable or torch just operation.
by hands.

In case of injury for your skin and eyes, please wear

required guards according to Labor Security and Hygiene
rules. Electrode and nozzle should be replaced only after
the cutter is power off.

Operation should proceed according to related Labor and

Security regulations.

2. Turn on the power switch after installation and connection. Then the power indicator lamp
is ON.
3. Start gas supply equipment and turn on the gas supply switch, the power indicator lamp on
the panel is ON. If the gas pressure is less than 0.25Mpa, the lamp will be OFF, then the gas
source should be checked.
4. Gas control switch switches to Check air. Adjust the pressure Adjusting knob of gas filter on
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 LGK-40/63IGBT OPERATOR’S MANUAL

the back panel to make the pressure and flux fit cutting condition. After adjusting, set the
switch to Cutting position.
5. Set the cutting current to required value.
6. Let the nozzle axes plumb the workpiece and cling to it firmly, press down the torch switch
and start to cut by striking arc from the edge of workpiece. To punch hole by plasma arc in
the middle of workpiece is not proposed, because the nozzle would be damaged easily. It is
better to punch a hole in the arc-striking position first, then strike arc from the edge of the
hole.
7. If want to stop cutting, please loosen the torch switch, cutting arc extinguishes, and gas
supply will stop in 5-8S automatically.
 Operation Caution
1. Before operation, operator must put on insulating shoes and wear insulating gloves &
protection glasses. The earth line must be connected reliably.

2. If to use contact arc striking method, firstly press down torch switch, then have nozzle
contact workpiece edge quickly, this will be beneficial for arc striking cutting. If it is difficult
to strike arc, the gas pressure can be adjusted to lower limit.

3. The water in reducing valve and air compressor should be drained out frequently. The
cutting speed should not be too fast, so that it can avoid molten slag and arc reflection
caused by incomplete cutting, but the cutting speed should not be too slow too, it will have
workpiece red-hot and affect cutting quality. When the cutting stops, firstly loosen torch
switch, then lift up torch. To follow above can have nozzle work life improved a lot.
4. The status of gas pressure, voltage, electrode and nozzle should be observed closely during
cutting. Do not have electrode and conductive tip short circuit caused by copper spraying
after using up hafnium wire in electrode, and damage cutting torch. The hafnium wire in
each electrode is about 3mm in length. After nozzle aperture is enlarged, cutting quality
and thickness will decrease seriously, so the nozzle must be replaced immediately.
5. If the cutting seam is deviated seriously, the nozzle must be checked if it flanges and
deviates. Or the nozzle and electrode must be replaced. Notice: the roughness of cutting
surface is related to cutting plate surface. If the plate surface is rough and not clear, cutting
moving is uneven, then the incision is big and surface quality decreases seriously.
6. The work life of electrode and nozzle is related to plate thickness and operation technology.
Normally every electrode can keep using for 1 hour continuously.
 Maintenance
1. The cutter cannot be operated and placed in strong sunshine.
2. The cutter cannot be operated and placed in moist environment.
3. The vent hole should not be covered when the cutter is operated.
4. The cutter should be operated and placed in drafty environment.
5. The cutter casing should be opened once a year at least. Clean up the dust and metal scraps
inside the machine by use of compressed gas.
6. Check regularly if the cable insulation cover is damaged. If there is any damage, repair it or
change it.
7. Check regularly if the electric connection is loose and then tighten it.
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 LGK-40/63IGBT OPERATOR’S MANUAL

8. Drain out regularly the water and impurities from filtering reducing valve.
Notes: When maintaining the cutter, professional electrician is required to dismantle
the power wire from distribution box and open the machine casing.
 Cutting technology instruction
1. The related main technical parameters
 Cutting material and thickness
The selection of cutting technical parameters is based on the cutting material and
thickness. If the material is thick, it should adopt large current and nozzle with big aperture.
For different material under the same thickness, the parameter should also be different.
 Air flow Q
The arc voltage increases as the increase of air flow, that is, the arc power, the cutting
speed, as well as the cutting capacity and quality is improved accordingly. Because the arc
compression level increases, the energy is more concentrated, the arc beam temperature,
the arc spraying speed, as well as the arc current impulsion increases. But overlarge current
may cause the instability of the plasma arc. Usually no change is made to air flow for one
torch. But it can be adjusted a little when the cutting torch or cutting thickness is different.
 Cutting speed
The cutting speed is related with many parameters. The main parameters determining
cutting speed include workpiece thickness, cutting current, air flux and nozzle aperture. A
proper drag is allowed during cutting. The cutting speed should be increased as much as
possible, but the incision quality must be guaranteed.
2. Eliminate the cutting burr
 The characteristics of the incision burr
The ordinary cutting surface is smooth and clean, but if the parameter selection is not
suitable, and electrode centering is not good, then burr may be formed on the cutting
surface.
Slag is formed by molten metal and its oxide which is adhesive to the bottom edge of
incision and solidified. The reason for forming this slag is that the molten metal adhesive
strength is bigger than the gravity and blow strength of metal oxide.
When cutting the alloy steel, the molten metal is difficult to be blown away because of
its bad fluidity, in addition, the alloy steel have bad thermal conductivity, the incision
bottom is over-heated easily, the left molten metal and incision bottom melts into one,
thereby the irremovable and tough burr is formed.
On the contrary, the incision bottom is difficult to be melted together with molten
metal, and the burr formed under incision is come off easily.
 The factors affecting the forming of burr
 The fluidity of the molten metal is not good, when the power is too small or the plasma
arc compression effect is not good, the temperature of molten metal during the cutting
process is low, fluidity is weak, even if the air current blow force is strong, it is still difficult
to blow away the metal completely, so the burr is formed.
 When cutting the thick plate, the burr is caused by the drag of overlarge cutting seam.
During the cutting process, the heat received by different parts of metal is different, the
heat on the upper incision is larger than that of the lower incision, so the upper part
melting speed is faster than that of lower part, thereby a distance between them is formed,
it is called drag L of cutting seam. The drag size is related to plasma arc shape and cutting
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 LGK-40/63IGBT OPERATOR’S MANUAL

speed. When the flame is short while the cutting speed is too fast, drag L increases, so
the vertical and horizontal blow force of the arc is formed, the vertical one helps to blow
away the molten metal, while the horizontal one makes the molten metal flow backward
along with incision bottom, this over-heated metal will melt parts of the bottom metal
again, then the burr is formed when they cool down and melt together.
 The burr is caused by overheat bottom. When the cutting speed is too slow, but the
incision bottom is so over-heated that it melts, the liquid metal flows to bottom metal and
combines into one which makes the difficulty to blow away molten metal by air current,
and then the burr is formed.
 The air current blow force is not enough. When cutting with plasma, the arc blow force
consists of the air current blow force and the arc electromagnetic force, the air current
blow force acts the main function. If the air current blow force is not strong enough, it
cannot ensure all the burr is flown away, then the burr is formed.
 The measurement to eliminate burr
 Ensure the centering between electrode and nozzle precisely, so that the compression of
the plasma arc is not damaged, the concentration of flame and cutting capacity can be
guaranteed.
 Enough power to ensure the fluidity of molten metal, as well as increase the stability of
the cutting speed and operation. This makes it possible to adopt large air flux to enlarge
the air blow force, and beneficial for eliminating burr.
 Adjust suitable air flux and cutting speed. If the air flux is too small, the blow force is not
enough, while if too big, the plasma arc will be shorten, the incision will be “V” shape, the
drag enlarge. The burr can be formed under both conditions. When cutting speed is too
slow, the incision is large and rough, the bottom is easy to be over-heated, while the
cutting speed is fast, the drag is enlarged, this is not beneficial for eliminating burr.
 So under certain circumstance, there exists a proper selection range for air flux and cutting
speed.
 Diminish the cutting surface slanting and rounding problem
The incision surface is a little slant and the upper side is a little round during cutting with
air plasma. Though the slanting range is acceptable during the cutting process, in order to
improve the cutting quality, people begins to pay attention to this problem. Usually slowing
down the cutting speed properly can avoid the slanting, but this may enlarge the effect zone
and incision width, as well as decrease the production capacity, so this measurement is not
wildly used. Recently, people can avoid the slanting by improving the nozzle structure, this is
called super cutting method. By adopting multi-hole nozzle during the cutting process, the
air current from the small hole is parallel with that from the main hole, this can avoid the
dispersing of the plasma flame on metal top, and then a parallel incision, square upper side
and no metal slag seam on the lower side is obtained.
 Troubleshooting & repair
1. If there is trouble caused by high voltage in the machine, a professional electrician or
serviceman of our company is required to repair it.
2. Please check following first when there is trouble.
1) The three-phase power should be 380±40VAC，check if it misses phase or voltage fluctuation
exceeds its required range of power supply；
2) Check if the supply abnormity indicator lamp is ON. If it is ON, check if the three-phase
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 LGK-40/63IGBT OPERATOR’S MANUAL

power switch of distribution box is damaged, and if the fuse and the machine power wire are
well equipped. Otherwise it will cause phase missing or bad contact, which makes the
machine work abnormally；
3) Check if the torch switch and its wire are damaged or short-circuit, and if the nozzle and
electrode are damaged；
4) Check if the cutting ground wire is well connected；
5) Check if the water in compressed air filter fixed at the back of machine is drained regularly；
6) Check if the gas pressure indicator lamp on the panel is ON. If it is not ON, check if
compressed gas pipe is well connected , and if the gas pressure is normal. When the gas
pressure is less than 0.3Mpa, the lamp is not ON.
7) Open the machine top cover to check if the lead-typed fuse next to the control transformer
has been fused；
 Ordinary trouble and repair as following diagram
Trouble Reasons Solutions
1. When the power 1.Three-phase power misses phase 1.Check three-phase power source
is switched on, the 2.Supply power is damaged 2.Change power switch
lamp and the digital 3.Power control fuse 1.5A is broken 3.Change power control fuse
meter are not ON.
2．Supply abnormity 1．Three-phase power misses phase Check three-phase power source to
indicator lamp is ON 2. Three-phase power over voltage ensure the supply voltage accordance
without arc striking or under voltage with the supply requirements.
1．The ambient temperature is too 1 ． Let the cutter rest for a while, and
3. No arc striking or
high. will come to work normally later.
arc breaking during
2 ． When cutting, cooling fan 2 ． Check fan power source or change
cutting. Overheat
rotates slowly or do not rotate, so cooling fan
indicator lamp is
the cooling effect is bad. 3．Change temperature relay
ON.
3．Temperature relay is damaged
4 ． It cannot start. 1．No gas pressure 1．Connect the gas source
Gas pressure lamp is 2．The pressure of gas supply is too 2. Adjust gas supply pressure.
not ON. low
5. Without arc 1．Cutting ground wire is not well 1．Connect the cutting ground wire well
striking, cutting connected. 2．Lower the pressure of gas supply
indicator lamp, gas 2．Gas pressure is too high. 3．Change the electrode and nozzle
pressure lamp are 3 ． Torch electrode and nozzle are 4．Change the torch
ON, and supply badly broken.
abnormity indicator 4．Torch is damaged.
lamp and overheat
lamp are not ON.
1．Gas pressure is too high or too 1．Adjust gas pressure
low. 2．The thickness of workpiece should be
2．Workpiece is too thick within the quality cutting range.
3 ． Torch electrode and nozzle are 3．Change electrode and nozzle
6 ． Weak cutting
broken 4．Adjust torch angle
quality
4．Plasma arc is not perpendicular 5．Adjust cutting speed
to the workpiece
5．Cutting speed is too fast or too
slow
If the troubles cannot be resolved, please inform our local agent of the specific problems or
contact us directly.
 Accessories
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 LGK-40/63IGBT OPERATOR’S MANUAL

1. Cutting power source 1set

2. Cutting torch 1pc
3. Ground cable 3m(with DJK-16 red connector and ground clamp) 1pc
4. Product certificate 1pc
5. Instruction manual 1pc

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The final explanation right is reserved to Huayuan Company!

If there is any change in the manual, please forgive not to inform separately!

Chengdu Huayuan Electric Equipment Co. Ltd.

Address: Add: No.1299,Konggang 2nd Road, Shuangliu County, Chengdu, China

Postcode: 610207

Tel: 0086-28-85011951-855

Fax: 0086-28-85033444

E-mail: hy_sales@126.com hwayuansales@163.com

www.hwayuan.com