LGK-120/200/300/400HD

AIR PLASMA CUTTING MACHINE

MANUAL
INSTRUCTION

(PLEASE READ IT CAREFULLY BEFORE OPERATION)

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 100%, which means the machine can work
continuously at the rated cutting current. 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：______________
 C a u t io n s 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 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.
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 equipment, 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.
 Do not put your hand close to fans and do not move the brake handle while operating.
 Please remove the connection between the engine and the welding equipment to avoid sudden starting
during maintenance.
 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 to keeping healthy.
 Content
MANUAL INSTRUCTION ................................................................................................................................... 0

1 SUMMARY .................................................................................................................. 1
1.1 MODEL DESCRIPTION ......................................................................................................... 1
1.2 FEATURES ......................................................................................................................... 1
1.3 USAGE ............................................................................................................................. 1
1.4 SYMBOL INSTRUCTION ........................................................................................................ 1
2 SAFETY AND ATTENTION ............................................................................................. 2

3 WORKING ENVIRONMENT REQUIREMENTS ................................................................. 3

4 TECHNICAL PARAMETERS ............................................................................................ 4
4.1 MAIN TECHNICAL PARAMETERS ........................................................................................... 4
4.2 PLASMA GAS CONDITION .................................................................................................... 4
4.3 EXTERNAL CHARACTERISTIC CURVE ........................................................................................ 4
5 BASIC PRINCIPLE ......................................................................................................... 5
6 INSTALLATION AND OPERATION .................................................................................. 6
6.1 MOVING AND LIFTING ........................................................................................................ 6
6.2 OPEN THE PACKING AND CHECK ............................................................................................ 6
6.3 THE FIX AND INSTALLATION OF THE PLASMA POWER SOURCE ...................................................... 6
6.4 THE CONNECTION OF 3 PHASE INPUT POWER CABLE ................................................................. 8
6.5 THE CONNECTION OF COMPRESSED AIR AND THE OPERATION OF PRESSURE REGULATING FILTER (THE
FUNCTION OF PRESSURE REGULATING FILTER PLEASE CHECK THE BELOW FIGURE) ...................................... 9
6.6 CONNECTION OF COOLING WATER (LGK-120HD DOES NOT HAVE THIS FUNCTION) ....................... 9
6.7 THE CONNECTION OF OUTPUT TERMINAL ............................................................................. 10
6.8 THE CONNECTION OF CONTROL SIGNAL CONNECTORS (FOR CNC (AUTOMATIC) CUTTING CONNECTION)
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6.9 THE CONNECTION OF WATER COOLING MACHINE INTELLIGENT COMMUNICATION INTERFACE (THERE IS
NO THIS INTERFACE ON LGK-120HD, WHEN LGK-200/300/400HD WORK WITH WATER COOLING, THIS
INTERFACE WILL BE USED) ............................................................................................................ 12
6.10 PANEL AND IT’S FUNCTION INSTRUCTION ............................................................................. 12
6.11 PROTECTION FUNCTION INTRODUCTION ............................................................................... 18
6.12 OPERATION .................................................................................................................... 19
7 OPERATION AND SETTING ......................................................................................... 21

7.1 POWER ON SELF TEST ....................................................................................................... 21

7.2 THE AIR PRESSURE ADJUST AND DISPLAY .............................................................................. 21
7.3 LIQUID FLOW DISPLAY (NOT ON LGK-120HD) ..................................................................... 22
7.4 CUTTING CURRENT SETTING ............................................................................................... 22
 7.5 SECONDARY MENU .......................................................................................................... 22
7.6 TORCH MONITORING FUNCTION ......................................................................................... 23
8 BRIEF INTRODUCTION OF THE CUTTING TECHNOLOGY............................................... 24

8.1 MAIN CUTTING PARAMETER AND THE TECHNICAL BASIS .......................................................... 24

8.2 CUTTING BURR ELIMINATING ISSUE ..................................................................................... 26
8.3 CUTTING TABLE ............................................................................................................... 28
9 PACKING LIST ............................................................................................................ 33

9.1 PACKING LIST OF PLASMA POWER SOURCE ............................................................................ 33

9.2 SYSTEM PACKING LIST ....................................................................................................... 34
10 MAINTENANCE ...................................................................................................... 34
11 TROUBLESHOOTING............................................................................................... 34

11.1 PLEASE FIRSTLY CHECK FOLLOWING ITEMS IF ANY TROUBLES: .................................................... 35

11.2 ORDINARY TROUBLESHOOTING AS FOLLOWING SHEET:............................................................ 35
11.3 SOME POPULAR COMPONENTS SHEET AS BELOW: .................................................................. 37

12 ATTACHED DIAGRAM 1：MAIN CIRCUIT DIAGRAM................................................. 39

1 Summary
1.1 Model Description
L G K - □□□ HD

Series code
Rated cutting current
Air medium
Cutting
Plasma arc cutting machine
1.2 Features
LGK-120、200、300、400HD series plasma cutting machine have below features：
 100% (40℃) rated duty cycle, suitable for work in heavy industry;
 Adopt gas pressure sensor, the cutting torch can be properly protected when the gas
pressure is too low;
 Adopt liquid flow sensor, the cutting torch can be properly protected when the
liquid flow is too low, and the liquid flow is displayed on the display meter;
 The gas pre-flow time, gas post-flow time, current up-slope time can be separately
set according to the torch cable length;
 The plasma gas pressure can be adjusted on the panel, the pressure is displayed on
the meter, friendly operation;
 There is digital communication connector, can be connected with different
automation equipment;
 With torch monitoring function, warning to change the consumables, to longer the
torch working life;
 Intelligent fan is used to reduce the dust;
 With automatic protection of over-heating and lack-voltage.

1.3 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.

1.4 Symbol Instruction

1
 Read the manual carefully Dangerous voltage

Over-heat Input voltage

Power abnormal Output current

Air pressure Voltage output

Coolant liquid input Voltage input

Coolant liquid output Cutting

Plasma torch Check gas

Lock Ground lead

Unlock Protection ground lead

Water cooling Remote control

Air cooling Increase/ Decrease

The nozzle connection of Plasma gas and torch

plasma torch electrode

Coolant liquid and torch

Current
electrode

2 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
2
 shield 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 work-piece 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 work-piece, 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.

3 Working Environment Requirements

If not reach the flowing conditions, the cutting capacity may not reach

the technical specification values

1) Please use the machine in a clear place without any of dust, corrosive gas and
inflammables and explosives; Do not use it in open air and rain;
2) Required air relative humidity should ≤90％(at 20℃)，40℃≤50％(at 40℃)；
3) Environment temperature range should be at-10℃～40℃;
4) The coolant liquid cannot be frozen when use;
5) Any metal materials cannot be put on or insider the power source;
6) Keep the machine away from the wall of some other closure things at least 30cm,
two machines distance at least 30cm.

3
 7) Use it under altitude lower than 1000m.

4 Technical Parameters
4.1 Main Technical Parameters
Model
LGK-120HD LGK-200HD LGK-300HD LGK-400HD
Parameters

Rated input voltage 3～380/415V 50/60Hz

Rated input capacity 21.23VA 46.5kVA 70.42kVA 92.34kVA
Rated output current 120A 200A 300A 400A
Rated output voltage 128V 160V 200V 200V
Rated duty cycle 100% 100% 100% 100%
Open circuit voltage 308VDC 319VDC 370 VDC 370VDC
Current adjust range 30～120A 40～200A 60～300A 60～400A
Quality Cutting Thickness 0.3～25mm 1～45mm 1～50mm 1～60mm
(Carbon steel, manual cutting)
Max. Cutting Thickness 45mm 65mm 80mm 90mm
(Carbon steel, manual cutting)
Plasma gas Compressed Air
The working plasma gas 0.3～0.5MPa 0.4～0.6MPa 0.4～0.6MPa 0.4～0.6MPa
pressure
Torch cooling mode Air Cooling Air Cooling / Water Cooling
Arc striking mode HF
Insulation grade F
Protection grade IP21S
Dimension mm(L×W×H) 675×320×605 863×385×800 985×445×910 1015×445×910

NET WEIGHT 46kg 86 kg 129 kg 148 kg

4.2 Plasma gas condition

 Gas pressure range：0.5MPa～0.7MPa
 Gas supply pipe compression strength：≥1MPa
 Gas supply pipe inner dimension：≥Φ8
 Gas flow：≥180L/min
 Filter the water in the gas, then feed into the plasma

4.3 External characteristic curve

4
5 Basic Principle
The control circuit of this 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 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
figure, and principle diagram of control circuit is shown as below figure：

5
6 Installation and operation
6.1 Moving and lifting
 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；

6.2 Open the packing and check

1) Check the machine and packing according to the packing list, of there is any damage,
please try to contact the supplier

6.3 The fix and installation of the plasma power source

6
LGK-120HD Dimension and installation size

LGK-200HD Dimension and installation size

7
 LGK-300HD Dimension and installation size

LGK-400HD Dimension and installation size

6.4 The connection of 3 phase input power cable

 Power supply condition
1) Voltage fluctuation≤±10％；
2) Frequency fluctuation≤±1％；
3) Unbalance rate of three phase voltage≤5％；
4) The power supply condition please check the chart below:
Model The sectional area of The sectional area Fuse (A) Contact capacity
input copper cable of ground cable (A)
(mm2) (mm2)
8
 LGK-120HD ≥6 ≥6 60 63
LGK-200HD ≥16 ≥16 125 125

LGK-300HD ≥25 ≥25 160 150

LGK-400HD ≥50 ≥50 200 250

 The connection of power lead

Use eligible cables and sockets to connect it, and must be operated by a qualified
electrician.
 Connection of ground cable
Connect it to ground on marking of the machine body), the sectional area
must match the requirements in above form, to ground firmly. Ground connecting
method should follow state standard.

6.5 The connection of compressed air and the operation of pressure

regulating filter (The function of pressure regulating filter please check the

below figure)

Pic 7：Air filter regulator

1) The compressed gas should meet the requirement mentioned in point “4.2 Plasma
gas conditions”. Connect the gas pipe with the gas inlet of air filter on the rear panel
and hoop it tightly.
2) The air filter regulator should be checked periodically. If the water level reaches
two-thirds of filter glass, it must be drained, or the cutting incision quality will be
effected. The gas supply valve should be closed during water draining, and Gas
Checking function is selected in panel. When the indicated valve of gas pressure
meter is zero, water will drain out from drainage mouth automatically.

6.6 Connection of cooling water (LGK-120HD does not have this function)
Connect the copper tip marked with “water inlet” on the rear side with water supply
9
 pipe, and tighten it. Connect the copper tip marked with “Backwater” with water recycle
pipe, and tighten it.
Notes: when use air cooling torch, the torch selection switch on panel must be set to
air-cooled torch position, and the cooling water cannot be connected. The cooling
water is for cooling torch only, and cutter power source does not need water cooling.

6.7 The connection of output terminal

 The connection of the torch
1) Connectors instruction
 The pilot arc: to connect the arc striking wire of the torch;
 Control: Pin 1 and 2 is start control, to connect the control switch of the torch.
Pin 3 and 4 is water cooling/air cooling. When use air cooling torch, short
connect the pin 3 and 4, when use water cooling torch, don’t connect the pin 3
and 4;
 Air & Current output: the negative output connector of the machine is the
plasma gas output connector, the connector thread is M14×1.5;
 Water & Current output: the negative output connector of the machine is the
cooling water output connector, to connect the water inlet of the water cooling
torch, the connector thread is M16×1.5;
 Water Return & Current: the negative output connector of the machine is the
cooling water return connector, to connect the return water of the water
cooling torch, the connector thread is M16×1.5 (laevorotation);

Pic 8 The connectors of torch

2) The connection of air cooling torch (Please refer to the Pic 8 as above)
Firstly connect the torch air inlet cable connector with the copper tip marked with

10
 Air & Current output on the front bottom panel; then connect the torch pilot wire
to terminal marked with Pilot arc on the front panel; Finally, connect the torch
control connector to the terminal marked with Control on the front panel and
screw down the nut;
3) The Connection of water-cooling torch (Not for LGK-120HD) (Please refer to the Pic
8 as above)
Firstly connect the torch cable connector (cooling water return) with the copper tip
marked with Water Return & Current on the front panel. Connect the torch cable
connector (cooling water output) with the copper tip marked with Water & Current
output on the front panel. Connect the torch gas pipe nut with the copper tip
marked with Air & Current output. then connect the torch pilot wire to terminal
marked with Pilot arc on the front panel; Finally, connect the torch control
connector to the terminal marked with Control on the front panel and screw down
the nut;
4) The requirements of control plug connection when customers use different torches
 Use WS20J4TQ 4-pins plug;
 Requirements on air cooling torch connection:
a) Connect the 1, 2 pin of 4- pins plug to switch control wire of cutting torch;
b) Short connect 3, 4 pin of 4-pins plug by gummed wire;
c) Pilot arc wire connects cold-press joint UT-8;
 Requirements on water cooling torch:
a) Connect the 1, 2 pin of 4-pins plug to switch control wire of cutting torch;
b) The 3, 4 pin don`t connect any of wire;
c) Pilot arc wire connects cold-press joint UT-8;
5) Connection of cutting ground cable
 LGK-120HD: Connect the fast connector of cutting ground cable with the
adapter base on the front panel and screw down it clockwise. The other end of
the cutting ground cable is firmly connected to work-piece.
 LGK-200/300/400HD: Connect the cutting ground cable with the copper tip on
the front panel with nuts. The other end of the cutting ground cable is firmly
connected to work-piece.

6.8 The connection of control signal connectors (For CNC (Automatic)

cutting connection)
The socket model of the connector is : WS20K4Z, and the function for each wire pin is as

11
 following:
1) Connector pin 1 and pin 2 is signal output of success arc striking, it is one group of
contact terminal of relay, and its rated load capability is 0.3A/125VAC or 1A/30VDC.
2) Connector pin 3 and pin 4 is start control wire of the cutter, its starting method is
controlled by operating selection switch. Usually 2-Step is selected, that is, it starts
under short connection, and stops after cutting off. The two wire is used in parallel
with torch control socket pin 1, pin 2 on the front panel.

6.9 The connection of water cooling machine intelligent communication interface

(There is no this interface on LGK-120HD, when LGK-200/300/400HD work with water
cooling, this interface will be used)
The socket model of the connector is : WS20J7TQ, and the function for each wire pin is
as following:
1) Connector pin 3 and pin 4 is start control wire of the cutter, it is one group of
contact terminal of relay, it’s on closing status when the torch switch is on, and it’s
on breaking status when the torch switch is off. Its rated load capability is
0.3A/125VAC or 1A/30VDC
2) Connector pin 5 and pin 6 is protection signal that water cooling machine output to
plasma cutter, when short connect the pin 5 and 6, there will be no current and
voltage output from the plasma cutter.
Special note: To confirm the good cooling performance, and lengthen the
consumable life, you’d better choose the water cooling machine from HUAYUAN.

6.10 Panel and it’s function instruction

Note: The title number is corresponding to the number on the Pic 9, for example,
the “1）” is corresponding to “1”on Pic 9.
1) The gas pressure adjusting valve: to adjust the gas pressure, pull it out and contra
rotate to reduce the gas pressure, rotate it clockwise to increase the gas pressure;
2) Torch lock function indicator: Press “OPERATE” key, when this indicator is on, mean
it’s on “torch lock” status;
3) Torch unlock function indicator: Press “OPERATE” key, when this indicator is on,
mean it’s on “torch unlock” status;
4) ”OPERATE” key: To choose the “torch unlock” and “torch lock” function. When it
turns on “torch lock”, the torch switch should be pressed in the process of cutting,
and the cutting stops after loosening the switch. When it turns on “torch unlock”,
press the torch switch and loosen it, the cutting starts to work, and the stops after
pressing the switch again;
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5) Current display indicator light: Press “DISPLAY” key, when this indicator is on it,
means the digital displaying meter (Number 8) is displaying the current value. When
there is starting signal (No.12 indicator light is on), the output current value is
displaying, when it’s not starting, the pre-setting current value is displaying;
6) Plasma gas pressure displaying indicator light: Press “DISPLAY” key, when this
indicator is on it, means the digital displaying meter (Number 8) is displaying the
plasma gas pressure value;
7) Water coolant flow displaying indicator light: Press “DISPLAY” key, when this
indicator is on it, means the digital displaying meter （Number 8） is displaying the
water coolant flow value;
8) Digital displaying meter: Displaying pre-set cutting current, real current, plasma gas
pressure, parameters on secondary menu and error code;
9) The “DISPLAY” key: to swift the different displaying function of “A”/ “Mpa”/“L/min”
(There is no “L/min” displaying function on LGK-120HD);
10) AIR PRESSURE indicator light：to indicate the status of plasma gas pressure.
 If this indicator light is ON: means the plasma gas pressure ≥0.38MPa, it’s
normal.
 The indicator light 0.3s on and 0.3s off (Quick flashing): means the plasma gas
pressure is in warning value range(0.3MPa≤air pressure＜0.38MPa ), now the
cutter can work, but the cutting quality may get bad, and the consumables may
burned faster;
 The indicator light is off: means the plasma gas pressure ＜0.3MPa, now the
cutter stop working;
 The indicator light 1s on and 1s off (Slow flashing): means the plasma gas
pressure was too low but back to normal now. And this slow flashing status will
keep 3 minutes. It’s normal.
11) COOLANT FLOW displaying indicator light (There is no this indicator on LGK-120HD):
to indicate the torch coolant flow status.
 If this indicator light is ON: means the coolant flow ≥2.7L/min, it’s normal.
 The indicator light 0.3s on and 0.3s off (Quick flashing): means the coolant flow
is in warning value range(2.0L/min≤ coolant flow＜2.7L/min), now the cutter
can work, but the consumables may burned much faster;
 The indicator light is off: means the coolant flow ＜2L/min, now the cutter stop
working;
 The indicator light 1s on and 1s off (Slow flashing): means the coolant flow was
too low (＜2L/min )but back to normal now. And this slow flashing status will
13
 keep 3 minutes. It’s normal.
12) START indicator light: When the light ON means the cutting machine got the starting
signal, start to cut;
13) OVER LOAD indicator light: when the inner cutter temperature is too high (Usually
when the cooling fan is broken), this indicator light flashing (Light on 0.3s and off
0.3s), and the cutter stop working. After the temperature is back to normal, the
indicator light will slow flash and start to work again;
14) INPUT FAULT indicator light: when the power supply is lower than 280VAC, this
indicator start flashing (0.3s on and 0.3s off) and stop working. After the power
input back to normal, the indicator light will slow flash and start to work again;
15) AIR CHECKING indicator light: when this indicator is on, mean it’s on air checking
status;
16) AIR CHECKING key: press this key and the indicator light will on(No.15), now the
cutter is in gas checking status, all the gas valve of the cutter will be opened;
17) Cutting current adjusting knob: Adjusting cutting current; at the same time, it’s also
a choose key as secondary menu;

Pic 9：LGK-120HD Panel function view

14
18) AIR COOLING indicator light (There is no this indicator on LGK-120HD)：Press
“TORCH” key, when this light is on, means the air cooling torch can be used, the
maximum current will be limited under 120A;
19) WATRT COOLING indicator light (There is no this indicator on LGK-120HD)：Press
“TORCH” key, when this light is on, means the water cooling torch can be used;
20) TORCH style selection key (Not on LGK-120HD)：to choose a suitable torch;
21) Cutting ground cable connection thread hole: To pass through the cutting ground
cable;
22) Cutting torch connection thread hole: To pass through the cutting torch cable;
23) Power switch: To control the ON/OFF of 3-phase power supply of cutter;
24) Control signal connector: To control automatic cutting equipment (there is starting
signal and arc striking success signal)
 Pin 1 and 2 is pilot arc signal output, it’s a group of relay contact inside, after
striking the arc, the contact closed, can control the load with rated loading
capacity of 5A/250VAC or 5A/30VDC;
 Pin 3 and 4 is starting signal, the starting mode please check No.4;
25) Intelligent communication connector of water cooling machine (Not on LGK-120HD):
only if work with a water cooling machine, connect with this connector;
 Pin 3 and 4 is the starting signal output of the water cooling machine, it’s a
group of relay contact inside, when there is starting signal. the contact closed,
can control the load with rated loading capacity of 0.3A/125VAC or 1A/30VDC;
 Pin 5 and 6 is the protecting signal input of the water cooling machine, the
cutter stop working as soon as get this signal from the water cooling machine;

15
 Pic 10：LGK-200HD Panel function view

26) Arc voltage output: the cutter output arc voltage, Pin 1 is “＋” and pin 2 is
“－” . The default arc voltage output is 1:1. There is also 1：20, 1:50 and 1:100 arc
voltage output inside the machine, If it is needed, please open the cutter top cover,
and use two-core rubber wire to connect the wire terminal on printed board PL13,
Please connect the wire according to the requirements, and pay attention to the
negative and positive electrode. This signal is not insulated, please make sure there
is no any of potential relationship between the connected equipment and the
cutter;
27) Fuse holder of arc voltage signal;
28) The power input connecting box: to connect the 3 phase power input;
29) Ground protection terminal;
30) The plasma gas inlet: to connect the compressed air;

16
 Pic 11：LGK-300/400HD Panel function view

31) Water inlet connector (Not on LGK-120HD): to connect the outlet pipe of the water
cooling machine, the pipe inner diameter is Φ10;
32) Water back connector (Not on LGK-120HD): to connect the backwater pipe of the
water cooling machine, the pipe diameter is Φ10;
33) The water coolant filter (Not on LGK-120HD): to filter the water coolant back to the
cooling machine from the torch;
34) The torch connection instruction;
35) SHEET METAL cutting function indicator light (Only on LGK-120HD): Press
“WORKPIECE” key, when the indicator is on, if the plasma arc stop during cutting
process, the cutter will not work anymore until get a new starting signal, this
function is for normal cutting;
36) MESH METAL cutting function indicator light (Only on LGK-120HD): Press
“WORKPIECE” key, when the indicator is on, if the plasma arc stop during cutting
process, the cutter will strike the arc again within 0.3s, this function is for cutting the
work-piece which have gaps;

17
 37) “WORKPIECE” key (Only for lgk-120HD), to choose the suitable work-piece;
38) Cutting ground cable socket: to connect the ground cutting cable;
39) The control socket of cutting torch: to connect the control signal wire of the cutting
torch.
Pin 1 and 2 is starting control, when the external switch is on, the cutter start to
work. Pin 3 and 4 not using;
40) Torch arc striking terminal: to connect the arc striking wire of the torch;
41) Air & Current output: the negative output connector of the machine is the plasma
gas output connector; the connector thread is M14×1.5.

6.11 Protection function introduction

1) Air pressure protection
 When the cutting air pressure is lower than 0.3MPa, the protection circuit starts
working and the cutter cannot start, and error code E80 will be displayed;
 When the air pressure is lower than 0.3MPa during cutting, the protection
circuit starts working and the cutter cannot start, the cutting arc will extinguish
automatically;
Note: When adjust the air pressure, the panel function must be set to ‘GAS
TEST’！
2) Water pressure protection(LGK-120HD does not have this function)
 When the water supply flow is lower than 2L/min, the COOLANT FLOW indicator
light will not on, if press the torch switch 0.9S, the water flow still lower than
20.L/min, protection circuit starts working and cutter cannot start;
 When the water supply is lower than 2L/min during the process, protection
circuit starts working and cutting arc extinguishes automatically;
3) Over-heat 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;
4) Power supply input fault protection
When 3 phrase power supply is lower than 280VAC, protection circuit starts
working and there is no arc striking;
Note: the water and air pressure protection function is for protecting the torch
only!
5) Notes of anti-interference (Specially pay attention when work on CNC automatic
cutting equipment)

18
  Cover the whole torch cable (from torch holder to output terminal ) of the
cutter with shielding layer, the shielding layer should be metal hose or shielding
net pipe made of aluminum or copper, metal materials which is magnetic
conducted cannot be used, the shielding layer don't need to connect with
ground;
 All the control lines which connected with plasma power source should be
shielding wire, the shielding layer should be connected ground well;
 The control system of CNC cutting machine should be away from the cutting
table, torch cables and cutting torch head, especially the cutting torch heard.
When striking arc, the high frequency spark arc on the cutting torch head may
produce strong space spreading high frequency disturb signal, which may crash
the control system;
 There should be shields on the controller of CNC system, and the shielding
layers should be ground connected well;
 All the lines connected with CNC controller and cutting table should be shielding
wire (Such as the control wire of step motor ,limit switch etc.), and the shielding
layers should be ground connected well;
 The pile of the ground cable should be connected with ground well.

6.12 Operation
1) Safety note

Operation strictly accordant with the following steps

Notes:

Electric shock may hurt Cutting may cause fire or explosion

or even kill man. (Splashes may ignite flammable materials
Notice
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 (Strong arc may hurt your eyes.
dust caused by cutting (Ultraviolet radiation generated by arc may

(Clean up the oil spot on work hurt skin and eyes. Please wear shielded guard
piece. when cutting.

(Keep fresh air in working place

(Fume extraction equipment

19
 should be prepared.

Overheated part may hurt your Fast moving thing may injure you.
skin. (Do not put your hands or other things into

(Do not touch the overheated part the fan shield.

on the work piece. (Cover the opened case shell well during

(Do not touch hot cable or torch cutting operation.

just 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.

Turn on the power switch after installation and connection. Then the power indicator
lamp is ON;
2) 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 0.3Mpa, the lamp will be
OFF, a error code E80 will be displayed on the meter, then the gas source should be
checked;
3) Start water supply equipment. The indicator lamp of water pressure on panel is ON
when opens water supply valve. (LGK-120HD does not have this function)
4) Place the gas control switch to “GAS TEST”, adjust the Adjusting knob of air filter
regulator to make the output pressure and flux fit cutting condition. After adjusting,
press the “GAS TEST” again to place it on “Cutting “process (The “GAS TEST”
indicator lamp is off).
5) Press “OPERATION” key and put it on “TORCH UNLOCK”, then the torch switch
should be pressed continuously during cutting. After loosening, the cutting stops.
When put it to “TORCH LOCK”, press the torch switch and then loosen it, and cutting
can start. User can make selection according to his operation habit;
6) Checking the panel indicator lamps. The indicator lamps status, under which cutting
can be operated is shown as following sheet.
Lamp Air pressure Coolant flow Over load Input fault
Status On On Off Off

20
 Sheet 4：Indicator lamp status
Notes: there is no water pressure indicator on LGK-120HD, and the water pressure
indicator will be OFF when gas-cooled torch is equipped on
LGK-200/300/400HD cutter.
7) Keep the torch nozzle 2mm~ 5mm away from work-piece. The axis line of nozzle
should be perpendicular to work-piece, and starts cutting from the edge of
work-piece. When the plate thickness is ≤ 12mm, the piercing can be done
wherever on the work-piece, and start the cutting. The cutting torch should be
inclined to one side a little during piercing on work-piece, so that the molten metal
can be blown away easily. Piercing is not recommended, because it damages nozzle
easily, it is better to drill a hole in arc striking point first, then strikes arc on the edge
of the hole. Press down torch switch, compressed gas sprays out from nozzle, and
cutting indicating lamp is ON. After gas pre-flows for 1 second (The default gas
pre-flow time of LGK-200/300/400HD is 1 second, LGK-120HD is 0.5 second) , high
frequency is generated, arc is stroke, and cutting begins by moving torch;
8) When the control switch of operation method on front panel is at “Torch Unlock”,
press the torch switch and the cutting starts after arc striking. After loosening the
switch, there is no voltage output, and cutting stops, and compressed gas stops
supplying after 10 seconds. When it is at “Torch Lock”, press down the switch and
loosen it, and cutting starts after arc striking automatically. Press the switch again or
press it till the arc is off, then there is no voltage output, cutting stops, and
compressed gas stops supplying after10 seconds.

7 Operation and setting

7.1 Power on self test
After power on, the cutting machine self testing steps as below, need 7 seconds:
① Test the LED status, firstly all the LED will be on, then all off, and the normally
display;
② Make one self test of gas and display the air pressure value;
③ The last memory status is recalled and displayed on the panel, then turn to standby
mode;
Note: a intelligent cooling fan is used on the cutting machine, the cooling fan works
when cutting, the cooling fan stops after stopping cutting 8 munities.

7.2 The air pressure adjust and display

21
 Press “DISPLAY” key and display the air pressure on the meter, now the “MPa” lamp
is on, press “GAS TEST” key and open the big&small gas valve, pull out the knob and

Pull out the AP DISP

knob and AP
rotate it

rotate it to adjust the pressure.

7.3 Liquid flow display (Not on LGK-120HD)

Firstly press “TORCH” key and switch to WATER COOLING status, then press
“DISPLAY” key and switch to liquid flow display on the meter, then the “L/min” lamp will

Press it

Press it

be on.

7.4 Cutting current setting

Press “DISPLAY” key and display the current on the meter, then rotate to adjust the
current. The below picture is based on LGK-200HD.

Current Display Knob

Current Press it

① In standby mode, the meter displays the pre-setting current.

② In cutting mode, the meter displays the actual cutting current, when adjust the
current, the meter will display the pre-setting current again, after adjusting, meter
displays the actual current again.

7.5 Secondary menu

7.5.1 Operation
① In standby mode, press “OPERATE” key 5 seconds, turn to secondary menu;
② Rotate the knob, choose content, press confirm key and entre parameter adjusting;
③ Rotate the knob, adjust the parameter value, press confirm key to save the
parameter;

22
 ④ Press “OPERATE” key 5 seconds again to quit the secondary menu. If there is no any
of operation in 30 seconds, it will quit the secondary menu automatically.
(The confirm key of LGK-120HD is “WORKPIECE” key, the confirm key of
LGK-200/300/400HD is “TORCH” key)

Display the menu code Menu choose or parameter

or parameter adjust

Press 5 Confir
seconds m key

7.5.2 Secondary menu content

Code Content Adj. range Unit Default Remarks
Gas pre-flow time LGK-120HD is 0.5s，
P01 0.2～5 s 0.5 or 1
set LGK-200/3000/400HD is 1 s
Gas post-flow time
P02 5～100 s 10
set
Current up-slope
P03 0.1～1 s 0.2
time set
P04 Cutting time set 1～999 Min. 999 If reach the set value, there will
be warning or controlling,
P05 Piercing time set 1～999 Time 999 cutting stops
Cutting rest time
P06 - Min -
disp.
Piercing rest time
P07 - Time -
disp.
On (1): Cannot cut after
Monitor control
P08 0 or 1 - 0 warning
switch
Off (0)：Can cut after warning
1 means reset immediately,
Monitor parameter Reset (1)
P09 - 0 the cutting time and arc
reset Keep (0)
striking time rest
Monitor warning On (1) To open/close the torch
P10 - 0
function off (0) monitoring function
Note: long press “DISPLAY” key 7 seconds, can restore factory setting, the the P01~P10 back to
default values.
Sheet 5: The content of secondary menu

7.6 Torch monitoring function

1) To confirm the cutting quality and protect the torch from overusing of nozzle and

23
 electrode, can choose to use this monitoring warning function, to monitor the
piercing times, and actual cutting time; it displays the warning codes when reach the
set values; When the nozzle and electrode is monitored to reach the working life,
there are two options set in the secondary menu: stop working or just display the
warning information.
 If you want to use the monitoring function, please set it refer to “2) how to use;
 If you want to use the monitoring function, enter secondary menu and choose
“P10 monitoring warning function”, set the value to “0” and press confirm key.
(The factory default is on “0”)
2) How to use:
After change a new electrode and nozzle, please use the monitoring warning
function.
 Step 1: enter secondary menu and choose “P09 monitoring parameter reset”,
set the value to “1” and press confirm key, then the cutting time and arc striking
time back to 0;
 Step 2: enter secondary menu and choose “P04 cutting time set” and “P05
piercing time set”, set a suitable value according to the working life of nozzle
and electrode;
 Step 3: enter secondary menu and choose “P08 monitoring control switch”, set
the value to “1” and press confirm key, then the cutting will be stopped after
warning, if set the value to “0”, then only the warning information will be
displayed, the machine can keep working;
 Step 4: enter secondary menu and choose “P10 monitoring warning function”,
set the value to “1” and press confirm key and finish the setting, quit the
secondary menu.
Note: for detailed operation information of function key and secondary menu,
please refer to “7.5 secondary menu.
3) If the torch monitoring function has warning the nozzle/electrode working life
correctly, the cutting time and arc striking time will be set back to 0 automatically
after changing the new nozzle/electrode.
4) If the nozzle/electrode working condition is still good when the warning, then the
set cutting time and piercing times should be set to longer;

8 Brief introduction of the cutting technology

8.1 Main cutting parameter and the technical basis
24
1) The cutting material kind and thickness
The cutting material kind and thickness is the basis to choose a cutting parameter,
for example, if the material is thick, then we choose a bigger cutting current and
bigger diameter nozzles. Even the thickness is same, but different material, we have
to choose a different cutting technology.
2) Cutting current and arc voltage
The selection of cutting current should be according to the diameter of the nozzle,
the relationship between the two should be as: I(current A)＝(70～100)×φ(mm).
As the increase of the metal thickness, the influence of arc current to the cutting
speed will become less. But as the increase of current, the burning damage will be
worse for the electrode and the nozzle. So when cutting a thick metal work-piece,
usually increase the arc voltage to increase the cutting speed. The actual arc voltage
is decided not only by the gas type (or fixed gas type), but also the gas flow and
nozzle shape (specially the nozzle diameter). Working voltage increases with the
increase of gas flow.
3) Gas 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
4) The distance between the nozzle and the work-piece (d)
If the d is too big, the blow power of plasma arc for molten metal decreases, so does
the cutting ability, and the burr on the bottom increases, meanwhile the instability
of the arc increases. However, if the d is too small, it increases the possibility of
short circuit between the nozzle and the work-piece. Usually d should be as small as
possible on condition that no short circuit is caused between nozzle and work-piece.
The d under normal cutting of air plasma is usually 2～5mm. The work-piece can
also contact with the nozzle during air plasma cutting, that is, the nozzle glide on the
surface of the work-piece. This cutting method is called contact cutting, and the
cutting thickness is the half as the ordinary cutting
5) Open circuit voltage
The power source with high open circuit voltage is required for cutting thick
work-piece. The open circuit voltage is related with air type, for example, by using
25
 argon the open circuit voltage may be lower, while it is higher by using air, nitrogen,
hydrogen.
6) Cutting speed
The cutting speed is related with many parameters. The main parameters
determining cutting speed include work-piece 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.

8.2 Cutting burr eliminating issue

1) The characteristics of the cutting 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 (stainless 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, when cut copper or aluminum, the incision bottom is difficult to be
melted together with molten metal, and the burr formed under incision is come off
easily.
2) 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 speed. When the
flame is short while the cutting speed is too fast, drag L increases, so the

26
 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.
3) 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 flow and cutting speed. If the air flow 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 flow
and cutting speed.
4) Diminish the cutting surface slanting and rounding issue
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
27
 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.

8.3 Cutting table

To get excellent cutting quality, reduce the burr as soon as possible, we recommend
user refer to the “cutting table” and choose a suitable cutting parameter. However, according
to different working conditions and cutting materials, user should adjust it as actual
condition.
Cut from edge unless you have to make a piercing.
Choose suitable consumables according to different cutting technology. When change
the consumables, power have to be off, and use the equipped torch use wrench.
The values in the cutting table below is based on “System components” in this
operation manual, it’s a useful reference for some cutting condition.
NOTE: If different torch is used, then the consumables different, the values should be different with the
below table.

Cutting table 1:
Low carbon steel
Air
300A cutting current

Shielding cap Shielding cap Out shielding cap Inner shielding cap Nozzle Swirl ring Electrode
sleeve
HY02711 HY02701 HY02601 HY02501 HY02428 HY02301 HY02211

Distance between
Arc Cutting Initial piercing Piercing
Plasma gas Thickness torch and
voltage speed height time
work-piece
Pressure Mpa mm mm V mm/min mm s

28
 0.47 8 1.5 125 4000 6 0.5
12 2.5 135 3000 7
1
16 3.5 139 2400 8
0.49 20 3.5 145 1900 9 1.5
25 5.5 155 1500 2
11
30 7.5 168 1200
2.5
0.52 32 8.5 172 900 12
35 175 650
0.57 9.5
38 180 600 Cut from edge
0.60 50 10 198 300
 The gas pressure in this table is the gas pressure that displayed on the plasma power source panel
when cutting.
 The values in the table is based on the plasma working with Huayuan water cooler.

29
Cutting table 2:
Low carbon steel
Air
260A cutting current
Shielding cap Shielding cap Out shielding cap Inner shielding cap Nozzle Swirl ring Electrode
sleeve
HY02711 HY02701 HY02601 HY02501 HY02425 HY02301 HY02211

Distance
Initial
between torch Arc Piercing
Plasma gas Thickness Cutting speed piercing
and voltage time
height
work-piece
Pressure Mpa mm mm V mm/min mm s

8 1.3 128 4000 5 0.4

0.47
12 1.7 135 3000 6
0.5
16 2 137 2100 8
0.49 20 4 150 1600 9 0.8
25 5 158 1300 11 1.2
0.50 30 8 170 1000 12 1.2
0.57 35 8 177 700
0.58 38 8.5 184 600 Cut from edge
0.60 50 9 200 300
 The gas pressure in this table is the gas pressure that displayed on the plasma power source panel
when cutting.
 The values in the table is based on the plasma working with Huayuan water cooler.

30
Cutting table 3:
Low carbon steel
Air
200A cutting current

Shielding cap Shielding cap Out shielding cap Inner shielding cap Nozzle Swirl ring Electrode
sleeve
HY02711 HY02701 HY02601 HY02501 HY02423 HY02301 HY02211

Distance
Initial
between torch Arc Piercing
Plasma gas Thickness Cutting speed piercing
and voltage time
height
work-piece
Pressure Mpa mm mm V mm/min mm s

8 2 137 3000 5 0.5

0.47
12 2 139 2500 5 0.8
16 4 150 1800 8 1
0.49 20 4 152 1200 8 1.2
25 5.5 162 950 11 1.5
30 5.5 166 650
0.50 32 6 168 500 Cut from edge
50 7 185 200
 The gas pressure in this table is the gas pressure that displayed on the plasma power source panel
when cutting.
 The values in the table is based on the plasma working with Huayuan water cooler.

31
Cutting table 4:
Low carbon steel
Air
160A cutting current
Shielding cap Shielding cap Out shielding cap Inner shielding cap Nozzle Swirl ring Electrode
sleeve
HY02711 HY02701 HY02601 HY02501 HY02419 HY02301 HY02211

Distance
Initial
between torch Arc Piercing
Plasma gas Thickness Cutting speed piercing
and voltage time
height
work-piece

Pressure Mpa mm mm V mm/min mm s

6 2 145 3300 4 0.4

0.47
8 2.5 147 2800 5 0.5
12 3 155 2300 6 0.6
16 3.5 160 1500 7 0.7
0.50 20 4 165 1000 8 0.9
25 4.5 172 700
Cut from edge
30 4.5 178 450
 The gas pressure in this table is the gas pressure that displayed on the plasma power source panel
when cutting.
 The values in the table is based on the plasma working with Huayuan water cooler.

32
Cutting table 5:
Low carbon steel
Air
100A cutting current

Shielding cap Shielding cap Out shielding cap Inner shielding cap Nozzle Swirl ring Electrode
sleeve
HY02711 HY02701 HY02601 HY02501 HY02417 HY02301 HY02211

Distance
Initial
between torch Arc Piercing
Plasma gas Thickness Cutting speed piercing
and voltage time
height
work-piece

Pressure Mpa mm mm V mm/min mm s

4 2 140 4400 4 0.4

6 2 145 3100 4 0.4
8 3 150 2200 6 0.6
0.45 10 3 155 1800 6 0.8
12 3 160 1300 6 1
16 4 168 800
Cut from edge
20 4 178 450
 The gas pressure in this table is the gas pressure that displayed on the plasma power source panel
when cutting.
 The values in the table is based on the plasma working with Huayuan water cooler.

9 Packing List
9.1 Packing list of plasma power source

33
 1. Plasma power source * 1 set
2. M16 thread adaptor * 1 set (Not on LGK-120HD)
3. Ground cable * 1 piece
4. Hose clamp *6 pieces (2 pieces on LGK-120HD)
5. Fuse
6. Copper terminal *3 pieces
7. Control connector (Only for CNC use)
8. Hex wrench * 1 piece
9. Documents: Operation manual * 1 copy, Certificate 1 copy, Guarantee card * 1 copy

9.2 System packing list

1. Plasma power source
2. Water cooling unit (Buy separately) (Not on LGK-120HD)
3. Plasma torch (Buy separately)

10 Maintenance
1） Do not use or store the plasma cutting machine under strong sunlight;
2） Do not use or store the plasma cutting machine in wet environment;
3） Do not cover the plasma cutting machine when working;
4） Use and store it in a well ventilated working environment;
5） Open and clear inside the machine with dry compressed air, at least once a year, to
clear the dust and metal filing;
6） Check the insulation of all cables regularly, repair or change it if any damages;
Check the insulation of all connections inside the machine, tighten it if any loosen;
7） Discharge the water and impurities in the filter regularly;
8） Clear or change the liquid filter regularly, the recommended period is every 6
months or 300 arc hours. If find there is some impurities on the filter cylinder or
filter net, open the discharge valve on the bottom to clear automatically, if can not
clear well, rotate and remove the cylinder, take out the filter net and clear again, if
the filter net is broken, have to change a new one. (Not on LGK-120HD)
Note: only guaranteed electrician can maintain this machine, and the power have to
be cut when do the maintenances.

11 Troubleshooting
There is high voltage inside the machine, only guaranteed electrician can repair this

34
machine!

11.1 Please firstly check following items if any troubles:

1) The three-phase power should be 380/415±40VAC，check if it default 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 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) If the control plug is connected mistakenly after user exchanging a different torch
from another manufacturer, please proceed the checking as per “torch connection”
mentioned in instruction manual;
5) Check if the cutting ground cable is well connected；
6) Check if the water in compressed air filter fixed at the back of machine is drained
regularly；
7) 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, when 0.3MPa≤gas
pressure<0.38MPa, the lamp blink and warn, when the gas pressure is higher than
0.38Mpa, the lamp keep on;
8) When the water cooling torch is applied, check if the water pressure indicator lamp
on panel is ON. If it is not ON, check if the cooling water current is normal. When
the water flow is lower than 2.0L/Min, the lamp is not ON, when 2.0L/min ≤ water
flow<2.7L/min, the lamp blink and warn, when the water flow is higher than
2.7L/min, the lamp keep on;
9) Check if the overheat indicator lamp on panel is ON. If yes, check if the temperature
relay on the radiator is damaged or not;
10) Open the machine top to check if the lead-typed fuse next to the control
transformer has been fused;

11.2 Ordinary troubleshooting as following sheet:

Code Trouble Possible reasons Solutions

When the power is 1.Three-phase power misses phase 1.Check three-phase power source
switched on, the 2.Supply power switch is damaged 2.Change power switch
/
lamp and the digital 3.Power control fuse 3A is broken 3.Change power control fuse
meter are not ON.

35
 Cannot start the
cutting, the gas 1．No gas pressure; 1．Connect the gas supply;
E80
pressure indicator 2．Gas pressure too low; 2．Adjust the gas pressure;
lamp is off
Cannot start the 1. Connect the cooling water supply;
cutting, the water 1. No water flow; 2. Check if the water flow is normal, the
E81
flow indicator lamp 2. Water flow is too low; water cooling flow should higher than
is off 2.0L/min;
No arc striking, and
1．Three-phase power default phase; Check three-phase power source to ensure
the power supply
E82 2. Three-phase power is overload the supply voltage accords with the supply
abnormal indicator
under voltage; requirements.
lamp is ON
The plasma receive a protection order
Cannot start the Check if the water cooling unit is
E84 from the intelligent water cooling
machine over-heating;
unit;
The torch monitoring function is on, ”Cut off the power and change the
E85 / and the nozzle, electrode consumables, please refer to “7.6 torch
consumption life is over; monitoring function”
1．The ambient temperature is too 1．Let the cutter rest for a while, and will
3. No arc striking or
high. come to work normally later.
arc breaking during
2．When cutting, cooling fan rotates 2．Check fan power source or change cooling
/ cutting. Overheat
slowly or do not rotate, so the cooling fan
indicator lamp is
effect is weak. 3．Change temperature relay
ON.
3．Temperature relay is damaged
1 ． Cutting ground wire is not well 1．Connect the cutting ground wire well
No arc striking,
connected. 2．Lower the gas supply pressure
cutting indicator
2．Gas pressure is too high. 3．Change the electrode and nozzle
lamp, gas pressure
3 ． Torch electrode and nozzle are 4．Change the torch
lamp are ON, and
/ badly broken. 5. Change HF board
power supply
4 ． Torch electrode and arc striking
abnormity indicator
wire is short circuit, which cause the
lamp and overheat
damage of torch.
lamp are not ON.
5. HF board is damaged.
1．Gas pressure is too high or too low. 1．Adjust gas pressure
2. The Air filter regulator cup is filled. 2. Water draining regularly
3．Work-piece is too thick 3．The thickness of work-piece should be
4 ． Torch electrode and nozzle are within the quality cutting range.
/ Bad cutting quality
broken 4．Change electrode and nozzle
5．Plasma arc is not perpendicular to 5．Adjust torch angle
the work-piece 6．Adjust cutting speed
6．Cutting speed is too fast or too slow
1, Gas pressure is two low 1．Adjust gas pressure
2, Nozzle is too close to work-piece. 2．The distance should be within 2mm to
The distance is less than 2mm. 5mm
Electrode and 3. Nozzle aperture is small, and not 3. Select a proper nozzle matched with
/ nozzle work life is matched with applied current. applied current.
very short. 4. Electrode and nozzle is under 4. Change a good quality electrode and
quality problem. nozzle.
5. The torch bought by user himself is 5. Buy a good quality torch.
under quality problem.
1.three phases rectifier is damaged. 1.change a three phases rectifier under
2.IGBT module is damaged. same model.
/ 9.supply power trips 3.other components in main control 2.change IGBT module under same model.
circuit is damaged. 3.check and change the damaged
components.

36
 1. Fast recovery diode of secondary 1. Change fast recovery diode under same
No arc striking, and rectifying is damaged. model.
guiding arc spraying 2. High frequency board PL13 is 2. Check and change the damaged
out, but there is damaged. frequency board PL13.
high frequency. 3. High frequency leakage in cutter 3. Check leakage point, and strengthen
output circuit. insulation function.
1. Three phases rectifier is damaged. 1. Change a three phases rectifier under
2. IGBT module is damaged. same model.
/ Supply power trips 3. Other components in main control 2. Change IGBT module under same model.
circuit is damaged. 3.Check and change the damaged
components.
Sheet 6: Error code and troubleshooting
If got any problems not included in this sheet and cannot solved, please try to contact
the local agent or the manufacture.

11.3 Some popular components sheet as below:

No. Components name Components Model Components code Remarks
2MBI100VA-120 LGK-120HD
V2、V3
1. IGBT module CM200DC-24NFM LGK-200HD
CM150DC-24NFM V3~V6 LGK-300、400HD

TA1、TA2 LGK-120、200HD
TKC200BR
2. Hall sensor TA3、TA4 LGK-300、400HD
TKC500BR TA5 LGK-300、400HD
DZ47-63/3P D63 LGK-120HD
3. Air breaker QF1
CDB2-125/3P/D80 LGK-200HD
4. AC contactor CJ20-100/380V KM1 LGK-300、400HD
Controlling
5. TL07 TM1
transformer

Electro pneumatic DF2-3B-AC36V(3mm) G1/8 YV1

6.
valve Q-5AC36V(5mm) G1/8 YV2
EV1 LGK-120HD
200FZY2-D/AC220
7. Cooling fan EV1、EV2 LGK-200HD
200FZY6-SF/220V EV1、EV2 LGK-300、400HD
8. Encoder RE1202BB1-H01-0003 XZ1
JUC-6F-75℃ KT1 LGK-120HD
9. Temperature relay KT1、KT2 LGK-200HD
KSD305A 75℃
KT1、KT2、KT3 LGK-300、400HD
Gas pressure
10. IP11C BP1
sensor
11. Liquid flow sensor SEN-HZ21WI BP2

37
12. Control board PL12 AP1
13. Driving board PT05（10Ω） AP2
High frequency
14. HFAP1 AP3
board
15. Arc striking board PL13 AP4
PL15 LGK-120HD
16. Panel AP5 LGK-200、300、
PL14
400HD
GF20008W LGK-120HD
17. Gas filter LGK-200、300、
GF30010
400HD
Sheet 7：Popular components list

38
 12 Attached diagram 1：Main circuit diagram
V2 V3 C7
L5 THF1 XS6
C9 C10 C11 21 RV2 R6 R7
C3 10 V4 25
C15
C1 C2
XS4 G3 G1
L1 V1
TM1 17 C8

1 4

5 2
QF1

3
1 E3 E1
5 C5 XS8
13 14 18 27 27
2 6
R1 V5
7
3 G4 G2
C4 R5
L6 XS7
FU2
4 1.5A E2 24
E4 22
8 19
11
TA2 TA1
L3

＋ 15V

-15V

Out

0V

＋ 15V

-15V

Out

0V
15 C12 16 L4

4
TA3 20
24 24 27 25
KT1

TM1 G4 E4 E3 G3 G2 E2 E1 G1 AP2
415V 110V
380V
KTa 63 64 65 66 1:1 20:1 50:1 100:1 －
215V 36V Gd Ed Ec Gc KTb TAa TAb Gb Eb Ea Ga

0V 0V PT05
+15V -15V GND GD WD FU1
1A

XS3 1 2
1:1 －
0 30 31 32 81 82 +15V -15V GND GD WD +15V -15V GND GD WD 36b 34b 33b 35b 36a 34a 33a 35a 36c 34c 33c 35c
79 给定 温温 63 XS3
80 64 1
39

EV1
65 2

77 66

78 95
96
C16
37 93

38 AP1 94 XS2 1 2 3 4
91 93 94 91 92
92 99 98
39
XS2
C18 1

SB1 86
2
4
3
HFAP1
87

C19 88
40 89
69 70 71 72 73 74 75 76 43 44 45 83 84 85 49 50 51 52 53 54 55 56 57 58 68 90 90 68

XS1 1 2 3 4
40 39

XS1
1
2 3 YV1 YV2
4

XZ1
P

AP3

EC11
3
B
2
BP1 C
1
A

LGK-120HD
 V2 V3 C7
L5 THF1 XS6
C3 10 C9 C10 C11 C12 C4 C5 C6 21 RV1 R10 R11 25
V4
C26
C1 C2
XS4 G3 G1
L1 TM1 17
V1 C8

1 4

5 2
QF1 12

3
1 E3 E1
5 XS8
L2 13 14 18 27 27
2 6
R1 V5
7
3 G4 G2
C4 R5
L6 R12 XS7
FU2
4 1.5A E2 24
E4 22
8 19
11
TA2 TA1
L3

＋ 15V

-15V

Out

0V

＋ 15V

-15V

Out

0V
15 C12 16 L4

4
TA3 C14 20
23 24 27 25
KT1

TM1 G4 E4 E3 G3 G2 E2 E1 G1 AP2
415V 110V
380V
KTa 63 64 65 66 1:1 20:1 50:1 100:1 －
215V 36V Gd Ed Ec Gc KTb TAa TAb Gb Eb Ea Ga

0V 0V PT05
+15V -15V GND GD WD FU1
1A

EV2

XS3 1 2
1:1 －
0 30 31 32 81 82 +15V -15V GND GD WD +15V -15V GND GD WD 36b 34b 33b 35b 36a 34a 33a 35a 36c 34c 33c 35c
79 63 XS3
40

C17 80 64 1
EV1
65 2

77 66

78 95
C16 96

37 93

38
AP1 94 XS2 1 2 3 4
91 93 94 91 92
92 99 98
39
XS2
C18 1

SB1 86
2
4
3
HFAP1
87

C19 88 XS8 1 2 3 4 5 6 7
40 89
89 88 86 87
69 70 71 72 73 74 75 76 43 44 45 83 84 85 49 50 51 52 53 54 55 56 57 58 68 90 XS8 90 68

XS1 1 2 3 4 2 1
40 39 37 38
5 4 3

7 6
XS1
1
2 3 YV1 YV2
4

XZ1
P

AP3

EC11
3
B
2
BP1 BP2 C
1
A

LGK-200HD
 V5 V6 C20
L9
C16 C17 C18 V9 22a
10b

C12 R4 Gc Ga TM2 18a

V2 12b
Ec Ea

C11
14a 15a 19a
C25
R3
V10
13b
L1 Gd Gb
L3
Ed Eb
20a
11b
C9 TA3
XS6 TA1 L5 C23 L7

＋ 15V

-15V

Out

0V
16a 17a

4
KM1 C24 21a

3
1 KT2
5 Gd Ed Ec Gc Gb Eb Ea Ga
2 6
7
3
Gd Ed Ec Gc TAa TAb KTa KTb Gb Eb Ea Ga

4 PT05
+15V -15V GND GD WD QY
FU1
1.5A

L8 XS6
C13 C14 C15 V7 22a
10a V3 V4 C19 25 离离离 / 出出
/回出 铜 回
THF1
RV1 C25
C10 R2 G3 G1 TM1 18a
V1

1 4

5 2
12a

3
E3 E1 XS8
14a 15a 19a 27 23
C26 C9 引引线
R1 28
V8
13a
L2 G4 G2 R7
L10 R12 XS7
L2
8 E2 24
E4 切切切线
20a
11a
TA4 TA5 FU2
L4

＋ 15V

-15V

Out

0V

＋ 15V

-15V

Out

0V
TA2 16a C21 17a L6 R6 1A

4
21a
KT1 C22
TM1
6 G4 E4 E3 G3 G2 E2 E1 G1
415V 110V 23
23 26
380V
215V 36V Gd Ed Ec Gc TAa TAb KTa KTb Gb Eb Ea Ga
AP2
PT05
0V 0V
63 64 65 66 1:1 20:1 50:1 100:1 －
+15V -15V GND GD WD
41

FU1
EV2 1A

79 80 0 30 31 32 81 82 +15V -15V GND GD WD +15V -15V GND GD WD 36a 34a 33a 35a 36b 34b 33b 35b 36c 34c 33c 35c

XS3 1 2
63 1:1 －
64
C17 XS3
EV1 65 1
66 2
77
78 XS4
C16
95 XS4 1 2
1
96 95 96
2
37

38
AP1 99 98
93 XS2
94
39 XS2 1 2 3 4
1
C18 91 93 94 91 92
2 3

92 4
SB1
HFAP1
XS8
C19
40 86
87 XS8 1 2 1
2 3 4 5 6 7
5 4 3
88 89 88 86 87
89 7 6
XS1 1 2 3 4
40 39 37 38
69 70 71 72 73 74 75 76 43 44 45 83 84 85 49 50 51 52 53 54 55 56 57 58 68 90
90 68
XS1
1
2 3
4

YV1 YV2

XZ1
P

AP3
EC11

3
B
2
BP1 BP2 C
1
A

LGK-300HD
The final explanation rights reserved to Westweld Company!

If there is any changes in the user’s manual, forgive not to inform separately!

Westweld Ltd

4-23-4, No.51, Xuefu Avenue, Nanan, Chongqing, China

E-mail: [email protected] [email protected]

www.westweld.com