Hansen HP63 Operation Manual

CUTTING MACHINE HP63/HP100/HP160 ATTENTION For safety guarantee, only the person with operating certificate or expert skills can collocate, check, maintain, fix and repair the welder. For safety guarantee, please completely read and understand the details in this manual before using. Keep the manual in convenient place for easy reading.

6、DAILY MAINTAIN&CHECK……………………………………...12 7、FAULT REPAIR……………………………………………….……13 8、CIRCUIT DIAGRAM………………………………………….……16

50Hz into the high frequency of 20KHz, with IGBT and soft switch technology and application of PWM technique, then reduce voltage, rectifies current and output a high DC power source and suitable for cutting. The character is as follows: The machine is projected by adopting entire-bridge inverter technique and with IGBT elements. 1. Inverter frequency is above 20KHZ by adopting PWM technique. 2. Can preset and continuous adjust the current, suitable for different thickness work piece, make sure cutting quality and save energy. 3. Arc ignition of cutting machine is adopted with small flow of air and HF transfer arc method for 100% arc ignition. 4. With over-heat、over-current and arc starting protection. Suitable for application: Such as carbon steel, alloy steel, nonferrous metals etc. For operation in machinery industry, petroleum industry, ship building industry, vehicle industry, electricity industry and decoration.

a. The power item of input side、the location choosing、high-pressure gas use、store and supply, welding products store and trash handling etc. Please follow related laws or enterprise standard. b. Clothing wear and safety tools equip. To avoid eye inflammation and skin burn, please obey related safety and healthy regulation, please wear related protecting tools. c. To avoid noxious gas and stifled(the welding soot and CO2 are harmful to body)，must obey related regulation regarding the soot handling. Installing partial exhausting equipment or use effective breathing protecting equipment. d. Can not operate without the welding machine cover. 2.2 Avoid machine burning and fire a. Avoid fire because of overheated, please keep 50cm distance between welding power and the wall or combustibles b. Avoid fire because of spark. Forbid spark to touch the combustibles or enter the inspiration、any open part of welding machine. c. Avoid damaged by falling or break. During assemble welding machine in frame, to assure security and avoid slipping please fasten the welding machine first. d. Forbid to have gas pipe or any seal can and pipe inside the welding machine. 2.3 Electric connecting item a. Before connecting operate must turn off power and assure safety. b. Forbid touch electric part or touch with wet glove. c. Choose correct line type d. Avoid heavy touch on line and touch welding part. e. Connect the line joint well, use insulating tape around bare wire. f. Handle ground connection between machine cover and work-piece holder by professional worker. g. Turnoff all power after finish welding.

Model Data HP63 HP100 HP160 Rated Input Voltage (V) 3-Phase 50Hz 380/415 Rated Input Current (A) 12 27 39 Open Voltage（V） 245 300 325 Range for cutting current (A) 30-63 30-100 30-160 Related Duty Cycle 100 Best cutting thickness （carbon steel mm） 12 22 35 Max. cutting thickness （carbon steel mm） 20 40 55 Shell Protection Degree IP21S Insulated Class F Dimension (D×W×H mm) 640*335*670 690*335*670 700*350*660 Weight（KG） 50 55 60

Welding machine must put on flat、cleaning and dry ground. Forbid to put the welding machine on following situation: a. Under hard sunshine and raining place； b. With dusty and combustible gas place c. With harmful or caustic gas place； d. With high temperature and steam place e. Vibration and collision place f. The distance between other circumambience smaller than 50 cm g. The temperature higher than +40℃or lower than -10℃ 4.2 Ground connecting Connect the machine’s ground connecting port to power’s ground connecting port and avoid damaged by electric shock. 4.3 Ventilation To assure welding quality must reduce the wind influence. If operate in seal space should supply aeration equipment and avoid lack of oxygen. 4.4 Power and line Table 3 -power and line Model HP63 HP100 HP160 Power 3-Phase，AC 380V/415V 50Hz Capacity Power ≥12KVA ≥18KVA ≥34KVA Engine 2 times than 12KVA 2 times than 18KVA 2 times than 34KVA Input Protect Equipment Fuse 20A 30A 55A Leak electricity safeguard machine 20A 30A 55A Input cable(mm2) ≥4mm2 ≥6 mm2 ≥10 mm2 Output cable(mm2) ≥10mm2 ≥16 mm2 ≥25 mm2 Groud cable(mm2) ≥14 mm2 ≥14 mm2 ≥14 mm2

b. Turn off the cutting machine before connecting cable. c. All joint must connect well, use insulating tape around bare wire. d. After connecting, put power cable cover on machine, then fasten with screw (forbid to operate with cover open) e. To assure security forbid to input force on the cable. FIG 1. HP63/HP100

21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 电源开 电源关 FIG 3. front and back panel for HP63/HP100 FIG 4. front and back panel for HP160 Table 4

2 Current Adjust cutting current 3 Digital meter Indicate preset current when machine stand by, indicate welding current when cutting 4 Torch（-） Power cathode,to connect the tie-in of water cooling torch 5 Torch switch Joint torch control connector 6 Starting arc Connect torch starting arc line 7 Work piece （+） Power anode, joint work piece 8 Air switch Automatic to turn off power when machine overload or get wrong, normally, this switch need to be turn on 9 Power Power indicator, when cutting machine turn on, the indicator will be light 10 Cutting Cutting indicator,will be light when cutting torch turn on 11 Air pressure Air pressure indicator, when low than 0.2Mpa,cutting machine will stop work 12 Over-heat Over-heat indicator, when cutting machine is over-heat, they can not work 13 Lock/Unlock Transfer switch, when in “lock”, press torch switch to ignite arc,can loosen switch, cutting machine still go on cutting, if press the torch switch again, cutting will stop 14 Air test/Cutting When turn on air test, gas valve in cutting machine will be opened to check gas flow rate, when turn on cutting, gas valve will be automaticly open and supply gas when machine is cutting. 15 Power box Connect input cable 16 Control sign Automaticly connect with cutting machine:①②：torch switch； ⑥⑦：successful to ignite arc 17 Output arc Automaticly connect with cutting machine ①：+，②：- 18 Fixed clamp Fixed input cable 21 Ground bolt Make sure peoples’ safety 19 Air pressure regulator Adjust pressure of compressed air and to filter water in the air 20 Inlet of compressed air Connect gas tube and air pressure regulatorto supply gas for cutting machine 21 ground screwbolt In order to make sure safety,please ground connection with this screwbolt 22 Hydroelectric interface Power output(-), be used for connecting with hydroelectric interface of water-cooling cutting torch 23 Gas electric interface Power output(-), be used for connecting with gas electric interface of air-cooling cutting torch or inlet connection of water-cooling cutting torch 24 Water pressure Indicator of water pressure flow will be light when water pressure is lower, and cutting machine will stop work. 25 Water return Usd for connecting with water return pipe’s lead arc of water- cooling cutting torch 26 Water-cooling/ air-cooling According with cooling type of your cutting torch to chose corresponding switch, when is “water-cooling”, if no water flow,

torch need to make sure under “water-cooling”condition, otherwise the cutting torch will be damaged. 27 Water inlet To link through water pipe and water outlet. 28 Water return To link through water pipe and water return 5、PREPARE FOR WELDING 5.1 Connect cutting machine According with 4.5 and F1 requirement to connect with cutting machine. 5.2 Cutting operation a. Turn on the power source, cooling fan will be work as usual. b. Turn on gas switch and put the switch to “air test”, then rotate air pressure regulator to chose suitable gas flow rate. If air pressure low than 0.2Mpa,cutting machine will stop wor, if everything is ok, air pressure light will turn off, please put “air test/ cutting” switch to “cutting” at this time. Note:air pressure ≥0.45～0.6MPa，flow rate ≥300L/min. c. This cutting machine standard collocate adopt non-contact cutting torch. When cutting, nozzel will not meet work piece due to if they get to each other, it’s easy to damage electrode and nozzel. at this time, in order to control cutting torch height, we usually match series of cutting tool、photoelectric follow- up、robot and CNC cutting machien tool. Operation point as follows: a) Trolley the cutting torch to meet workpiece, and keep distance 2-5mm, make sure nozzel axes apeak to surface of work piece （F3）. b) Turn on cutting switch, ignite plasma arc, cutting work piece fully, keep an even speed to move along with cutting direction. Cutting speed is: base on cutting pierce, be fit for rapid to cut, if too slow will affect cutting quality even arc break off. Pleasse control towing angle in 10°（F3）, cutting quality is perfect. If too fast won’t pierce, even spatter. c) Generally speaking cutting from edge of work piece, when need to cut from middle of work piece, if material thickness is ≤5mm (stainless steel or carton steel, if other material, need to cut back on cutting thickness), can directly cutting pierce. Method: put cutting torch on starting point of cutting sew, make nozzel and work piece an included angle about 75°, then, turn on torch switch, ignite arc to pierce work piece, adjust torch axes to apeak work piece. But if material thickness ≥5mm and need to cut in middle, please drill a hole which diameter is ≥3mm, ignite arc to cut in hole. If finish cutting, unlock torch switch, break off plasma arc.compressed air will be delayed spurt to cooling cutting torch. After some minutes pls move torch to finish cutting.

（1）Install cutting torch please reference picture F4. please note must make sure electrode is tightened. （2）Please replace nozzle on time when centre hole of nozzle is damaged( F5). （3）Please replace electrode on time when electrode hafnium is damaged(F6). FIG 6.

（5）When you need dismantle the cutting torch, please demount bolt M3,then insulated pipe, at last is connect and transfer arc.when installing, please take care every joint and insulated pipe to make sure safety in igniting arc. （6）Cutting torch and cable team can not touch high temperature work piece.

such as electric shock and burned, and please wait for 10 minutes then start to repair. Table 5 reference for daily maintain ITEM EVERY ONE OR TWO MONTH TO CHECK AND MAINTAIN 1．Switch function for power source 2．Cooling fan if is working normally 3．If have unusual vibrate、noise and smell. 4．If the cable connector is over- heat. 5．Welding cable if is over-heat. 6．Cable if is damaged. 7．All cable connector if is loosen. 1．Remove smudginess： Make use compressed air to remove smudginess, especially for inductance 、 transformer、transistor and PCB. 2．Repaire for circuit diagram： Check input ports, output ports and exterior cable. 3．Check earth cable if is all right.

cannot be eliminated, please contact with manufactory. Attention： 1．Before the maintenance or repair, make sure the power is off to avoid electric shock. 2．The machine has tested before leaving factory, any modification is not allowed. 3．During the inspection of wire connecting, please don’t change any connecting. Table 6 Inspection item Failure Causing Cannot ignition Power switch damaged or switch wire broken The cable which connect with work piece damaged, or the clamp cable damaged Input power lack phase Over loading, over heating or over current protection Input power cable loosing Output power cable loosing Compressed air pressure is too low Arc is unstable, or arc break frequently Output power cable loosing Input power cable with bad connection Decrease of output current Input power is less than 330V～440V Input power canle is too thin Power capacity is low

indicator light not work 1. Indicator light damaged Change 2. 2A Fuse damaged Change 3. No output power Repair 4.Lack phase of input power Repair 5. Power switch damaged Change 6. Control PCB damaged Repair 7.Control transformer damaged Change 2 Switch on, power indicator light on, but the fan not work 1.Fan stopp Clear the fan 2. Fan capacitor damaged Change 3. Fan wire damaged repair 4. Fan damaged Change or repair 3 Switch on, power indicator light on, fan works, turn on the “air test”, but no air flow 1. No input compressed air Check the air source and hose 2. Air pressure filter adjusting error, pressure meter shows zero, “air pressure lack” indicator light on Readjust the air pressure filter, method ：turn “air pressure filter” clockwise to increase the pressure, turn anti-clockwise to decrease pressure 3. “Air test” switch damaged Change 4. Main electromagnetism valve damaged Change or repair 5. Air hose damaged Repair 4 Turn on “Test air”, nozzle fill with air, turn on “Cutting”, and turn on the cutting torch, there is no air 1.Torch switch damaged, or switch wire damaged Change or repair 2. Air valve QF1 damaged Change 3. Control PCB damaged Repair 5 Turn on the cutting torch, nozzle with air but torch not work 1. Input power lack phase Repair 2. Input air flow is not enough Increase input air 3. Nozzle, electrode or other parts damaged Change 4. Torch damaged Change 6 Kerf deflexion 1. Nozzle or electrode damaged Change 2. Nozzle and electrode does notinstall correctly Reinstall 3. Cutting speed is too fast Reduce cutting speed 4. Nozzle and cutting matericl out of the vertical Adjusting

achieved 1. Input voltage lacking Check input voltage 2. Input power capacity lacking Increase input power capacity 3. The pressure of input air is not correct Adjust the input air pressure 4. Input air flow is small, such as pressure meter drops to 0.3MPa during the operation，and pressure recover after stop working Increase the input air pressure to 300L/min；If the air hose is small, please change the hose to bigger than Φ8mm 5. Cutting speed is too fast Reduce cutting speed 6. Nozzle burned Change a new nozzle 7. Electrode burned Change a new electrode 8. Nozzle size is not fitted Change to the right nozzle 9. Air hose or cutting cable damaged Repair or replace a new one 10 Kerf with poor quality 1. Cutting speed is too slow Increase cutting speed 2. Nozzle or electrode damaged Change a new one 3. Set value is not fit to cutting material and thickness Adjust set value 4. Wrong size nozzle Change right nozzle 11 Torch burned 1. Nozzle or electrode loosing Fasten the nozzle or electrode 2. Torch wire connector loosing, or cable/hose damaged Repair 3. Torch connector with poor insulation condition. Make sure the torch connector with good insulation. 4. Shield cap of cutting torch has been damaged Change a new one 5.Compress air is over wet Clear the water in “air pressure valve”, if the air was over wet, please install water filter Lv1~2 6. Electrode burned Change a new one

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