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Service manual
! 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 MANUFACTURERS 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 !
! 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.
TECHNICAL DATA
Rated
60% Duty Cycle
Output
100% Duty Cycle
Output Current Range
Open Circuit Voltage (max)
2
Supply cable cross section mm
Rated primary input (max)
Air Requirements
SOFTSTART
Plasma
Cooling
Max. cutting thickness
Dimensions
120A
60A/90A
60120A
310V
4x16/4x6/4x6
230V/400-415V/440V
3~50/60Hz
78A/45A/41A/phase
167kg
167kg
PT 25
Length
Height
Width
120A
60A/90A
60120A
310V
4x6
400-415V 3~50/60Hz
45A/phase
MAINTENANCE
2.1 GENERAL
If equipment doesnt 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 120 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.
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.
H. Occasionally drain water from filter below the air pressure regulator.
2.3 PT 25 TORCH CONSUMABLE PARTS.
! WARNING !
Make sure power switch is in OFF position before working on the torch.
! WARNING !
PT-25 torch contains gas flow check valve that acts in conjunction with flow switch and
circuitry inside power source. That system 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 for it contains ESABs patented safety interlock.
To assemble consumable parts refer to Fig.2-1.
A. Place nozzle, swirl baffle, electrode and valve pin into shield as shown.
B. Thread assembly on torch body and hand tighten.
Always make sure the shield is very tight before cutting.
558001457
2.4 FILTER
1. Checking of condensate level.
When condensate level reaches 10 mm, unscrew counter-clockwise knob at the bottom of filter
container and empty it.
2. Too low flow rate.
If flow rate is too low, filter refill (0457290081) is to be replaced. In order to do so, first make sure there
is no compressed air trapped in air lines. Next unscrew filter lid counter-clockwise, than unscrew filter
plate and replace refill.
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.
! 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.
! NOTE !
Before checking voltages in circuit, disconnect power supply from HF generator to prevent voltmeter
from damage and to avoid possible electric shock.
3.2 TROUBLESHOOTING GUIDE
NOTE Refer to p.3.4 and study carefully operation sequence.
NO
See p. 3.3.A
YES
NO
See p. 3.3.B
YES
NO
See p.3.3.C
NO
- Does FAULT LED (D2 front panel) lit?
YES
NO
See p. 3.3.E
See p. 3.3.F
NO
See p. 3.3.G
NO
NO
Replace PCB!
(Provided that all of above tests are OK)
NOTE: Only FAULT signal (D2) in front panel is masked by signal controlling gas valves;
the PO LED (D5 on PCB, Fig. 3-2) lights continuously whenever the air monitoring circuit is open
(independently of valve control).
a) Possible cause flow rate too low. Refer to test of p. 3.3.C and adjust air parameters.
b) Air switches CZ1, CZ2 or their wiring is faulty. Disconnect connector X1 from PCB and check with
ohmmeter sensors CZ1, CZ2 and its wiring (terminals 3 & 8 on female X1). Rectify wiring or replace
CZ1 and/or CZ2 if necessary.
NOTE: Air switch also might be stuck due to oily air, clean it in accordance with manufacturers
instruction or replace it.
F. Main contactor and/or pilot contactor doesnt operate.
NOTE: since there is applied SAFETY STOP (contactors ST1 & ST2 are switched off when main arc
does not ignite within 2 sec after depressing torch switch), test readings have to be performed within
2 sec after depressing the torch switch or, in order to extend reading time, reed relay ZS1 is to be
bypassed (e.g. by shorting terminals 1 & 2 on X1).
! WARNING !
UTMOST CARE IS TO BE PAID DURING THESE TESTS SINCE 310 VDC APPEARS AT THE
OUTPUT CIRCUIT OF UNIT AND ON THE TORCH !
! WARNING !
BEFORE BEGINNIG OF THE FOLLOWING TESTS DISCONNECT 24V SUPPLY FROM HF UNIT
(terminals T24 and T0).
1. Disconnect connector X3 from PCB (unit turned on):
- Check with voltmeter contacts of output relay on PCB:
terminals 7 & 8 for pilot contactor
terminals 6 & 7 for main contactor.
They should be shorted when torch switch is depressed; preflow delay to take into account. If results
are unsatisfactory PCB is faulty and should be replaced.
- Check with voltmeter voltage between terminals 7 & 8 and 6 & 7 on female X3 (CAUTION: 220 VAC).
If result is incorrect, than TURN OFF the unit and check contactors coils and its wiring. Rectify wiring
or replace coils if necessary.
Reconnect X3 and supply wires to HF unit.
NOTE: As to checking FAULT LED (D2), disconnect connector X1 (machine is turned on), D2 should
be lit. If not, disconnect connector X2 and put ammeter between terminals 1 & 3 of X2 on PCB.
Reading should be 1014mA. If so check LED and its wiring, otherwise replace PCB.
NOTE: If contactors operate and ARC LED (D3) does not light, disconnect connector X2 from PCB
(unit turned on), put ammeter between terminals 1 & 4 of X2 on PCB and depress torch switch.
Reading should be 1014mA. If so check LED and its wiring, otherwise replace PCB.
G. PILOT ARC fault.
(Before tests see NOTE in p. 3.3.F !)
1. Check torch. Make sure that heat shield is tight, otherwise safety circuit wont allow switch to activate
power source.
2. Check, with torch switch depressed HF generator supply voltage (24V) on terminals T24 and T0.
3. Disconnect supply From HF unit (T24 and T0), measure open circuit voltage on output of plasma
unit (290310 VDC, as per TECHNICAL DATA).
- If output voltage is not correct, check output wiring, rectifier bridge PR1 and secondary voltage of
main transformer (see WARNING in p. 3.3.F !).
- If output DC voltage is OK, turn off supply of plasma unit and check wiring of HF circuit, R3, ST2, L1.
H. HF and pilot arc are on but main arc does not transfer.
1. Make sure work clamp (+) is connected to workpiece, good electrical connection is to be provided.
2. Check torch, replace consumables if necessary, check if all parts completed.
3. Torch must be tight assembled.
I. Poor cutting performance.
1. Check air pressure regulator. It should be adjusted to 4,95,2 bar.
2. Air supplied to torch should be free from oil and water.
3. Make sure consumables attached to torch are acceptable.
4. Check open circuit voltage (as per TECHNICAL DATA).
5. Check output. Use calibrated 150 amps meter capable of measurements in presence of HF.
LED denom.
PL (G)
AL (R)
3
4
5
ON (G)
TE (R)
PO (R)
Function
Indicates main arc turned ON.
Indicates absence of main arc longer than 2 sec while torch switch is
depressed (alarm)
Indicates torch switch depressed.
Indicates overheating of power source.
Indicates too low air pressure.
G green
R red
Test points:
XP1 - +15V 2% (through 2 kohm resistor)
XP2 - GND
10
11
12
13
0,75
0558002189
14
REPLACEMENT PARTS
Qty. Req.
230V/400-415V/440V
3~50/60Hz
1
Qty. Req.
400-415V
3~50/60Hz
1
Item No.
01
Part No.
Description
Circuit
symbol
m/min
Al
Ss
3
2
1
0
0
10
15
20
25
mm
30
Al
m/min
2,5
Ss
Fig. 9
1. Assembly of stand off
guide no 0349 302 131 (50A)
1,5
1
0,5
0
0
10
15
02
25
30
Qty. Reg.
230V/400-415V/440V
3~50/60Hz
1
Qty. Reg.
400-415V
3~50/60Hz
1
Item No.
20
35
mm
40
Part No.
Description
Circuit
symbol
2,5
Al
Ss
m/min
2
1,5
1
0,5
0
0
10
15
20
25
30
35
40
mm
45
50
Qty. Req.
400-415V
3~ 50/60Hz
1
1
3
1
1
1
1
1
1
1
1
1
1
1
2
Qty. Req.
230V/400-415V/440V
3~ 50/60Hz
1
1
3
1
1
1
1
1
1
1
1
1
1
1
2
Part No.
0457 291 001
0457 291 002
0349 302 057
0457 290 003
0457 290 004
0457 290 005
0457 290 006
0457 290 007
0457 290 008
0457 290 009
0457 290 010
0457 290 011
0457 290 012
0457 291 018
0558 000 724
0457 290 015
16
Description
Front cover
Rotary cam switch
Rotary cam switch
LED holder ( socket )
LED ( green )
LED ( red )
LED ( yellow )
Push button switch
Push button cap ( detachable )
Pressure regulator
Pressure gauge
Current connector socket
Rubber grommet ( with support sleeve )
Current wire with clamp
Plasma cutting torch PT 25
Side panel
Circuit symbol
W1
W1
D1
D3
D2
W2
Qty. Req.
400-415V
3~ 50/60Hz
1
1
3
1
1
1
1
1
2
1
2
1
1
1
1
4
Qty. Req.
230V/400-415V/440V
3~ 50/60Hz
1
1
3
1
1
1
1
1
2
1
2
1
1
1
1
4
10
1
1
1
1
1
1
1
1
1
2
1
1
10
1
1
1
1
1
1
1
1
1
2
1
1
Part No.
0457 291 003
0349 302 058
0457 291 004
0457 290 018
0457 290 019
0457 290 020
0457 290 021
0457 290 083
0349 302 055
0457 290 025
0457 290 026
0457 290 027
0457 290 028
0457 291 005
0457 291 006
0457 290 030
0457 291 007
0457 290 032
0457 290 033
0457 290 034
0558 000 756
0457 291 008
0457 291 009
0457 291 010
0457 291 011
0457 291 012
0457 290 037
0457 290 041
0457 290 042
0457 290 031
0457 291 020
0457 291 021
17
Description
Transformer
Transformer
Resistor set
Resistor (1,65 )
Contactor 220V
Ignition block 24V
Choke
Circuit breaker
Circuit breaker
Choke
Swivel wheel ( with brake ) assy
Base frame
Fixed wheel assy
Pipe coupler ( straight )
Coupler
Pressure switch
Electromagnetic valve
Stub pipe
Reinforced PVC hose 51,5
Hose clip
Receptacle 5 Pole
Stub pipe
Insulating sleeve
Special nut
Stub pipe
Insulating sleeve
Special nut
Console
Temperature switch
Electromagnetic valve
Stub pipe
Coupler
Circuit symbol
TR1
TR1
R3
ST2
HF
L1
Q
Q
L2
CZ1
EZ1
G1
WT1
EZ2, EZ3
Qty. Req.
400-415V
3~ 50/60Hz
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
-
Qty. Req.
230V/400-415V/440V
3~ 50/60Hz
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
Part No.
0457 290 043
0349 302 059
0457 291 013
0457 290 045
0457 290 046
0457 290 047
0457 290 048
0457 291 014
0349 302 061
0457 290 050
0457 290 051
0457 290 052
0457 290 053
0457 290 054
0457 290 055
0457 290 056
0457 290 057
0457 290 058
0457 290 059
0457 290 060
0457 290 061
0457 290 062
0457 290 063
0457 290 064
0457 290 065
0558 001 457
0457 291 016
0457 290 066
0457 290 067
0457 290 068
0457 290 069
0457 290 082
0349 302 062
Description
Transformer
Transformer
Current sensor assy
Electronic PCB
Rectifier bridge
Fuse holder
Fuse 1,6A
Contactor
Contactor
Capacitor
Clamping ring
Grip handle
Roof
Rectifier block assy
Capacitor 5F 450/500V
Resistor 330k 0,25W
Resistor 22 2W
Lug
Supporting shelf for rectifier bridge
Capacitor 30F 450/500V
Bracket ( capacitors assy )
Fan guard
Fan 220V 50Hz 0,145kW 1320obr./min
Capacitor 5F 400V
Terminal block ( 3-way )
Pressure sensor ( switch )
Pipe coupler
Varistor
Connector
Connector
Connector
Reed relay contact
Auxiliary contact
18
Circuit symbol
TR2
TR2
ZS1
PL50
PR2
F1, F2
ST1
ST1
C6
PR1
C4
R2
R1
C1,C2,C3
M1
C5
LZ1
CZ2
V1
X2
X3
X1
ZZ
ST1
Qty. Req.
400-415V
3~ 50/60Hz
1
1
1
1
1
1
1
1
1
1
1
1
Qty. Req.
230V/400-415V/440V
3~ 50/60Hz
1
1
1
1
1
1
1
1
1
1
1
1
Part No.
0457 291 017
0457 290 071
0457 290 072
0457 290 073
0457 289 029
0457 290 075
0457 290 076
0457 290 077
0457 291 019
0457 290 079
0349 302 060
0457 290 080
0457 290 081
Description
Circuit symbol
Rear shield
Quick detachable coupling
Hose clip
Pipe stub
Filter - regulator
Pipe coupler ( elbow )
Pipe coupler ( straight )
Pneumatic hose PVC 8x1,25
Supply cable
Metal cable gland
Metal cable gland
Locknut
Filter cartridge 5m
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
19
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 VAMBERK s.r.o.
Prague
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Copenhagen--Valby
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 204
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
ITALY
ESAB Saldatura S.p.A.
Mesero (Mi)
Tel: +39 02 97 96 81
Fax: +39 02 97 28 91 81
THE NETHERLANDS
ESAB Nederland B.V.
Utrecht
Tel: +31 30 248 59 22
Fax: +31 30 248 52 60
NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
POLAND
ESAB Sp.z.o.o
Warszaw
Tel: +48 22 813 99 63
Fax: +48 22 813 98 81
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 1 837 1527
Fax: +351 1 859 1277
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
SPAIN
ESAB Ibrica S.A.
Alcobendas (Madrid)
Tel: +34 91 623 11 00
Fax: +34 91 661 51 83
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
ESAB International AB
Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
SWITZERLAND
ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
Asia/Pacific
AUSTRALIA
ESAB Australia Pty Ltd
Ermington
Tel: +61 2 9647 1232
Fax: +61 2 9748 1685
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 6539 7124
Fax: +86 21 6543 6622
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
INDONESIA
P.T. Esabindo Pratama
Jakarta
Tel: +62 21 460 01 88
Fax: +62 21 461 29 29
MALAYSIA
ESAB (Malaysia) Snd Bhd
Selangor
Tel: +60 3 703 36 15
Fax: +60 3 703 35 52
SINGAPORE
ESAB Singapore Pte Ltd
Singapore
Tel: +65 861 43 22
Fax: +65 861 31 95
Representative offices
BULGARIA
ESAB Representative Office
Sofia
Tel/Fax: +359 2 974 42 88
EGYPT
ESAB Egypt
Dokki--Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
ROMANIA
ESAB Representative Office
Bucharest
Tel/Fax: +40 1 322 36 74
RUSSIA-- CIS
ESAB Representative Office
Moscow
Tel: +7 095 937 98 20
Fax: +7 095 937 95 80
ESAB Representative Office
St Petersburg
Tel: +7 812 325 43 62
Fax: +7 812 325 66 85
Distributors
BRAZIL
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
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 44 58
ESAB AB
SE-- 695 81 LAX
SWEDEN
Phone +46 584 81 000
Fax +46 584 123 08
www.esab.com
020314