HandyPlasma

TM

70

Bruksanvisning (SE)

Instruction manual (GB)

Manual de uso (PT)

Bedienungsanleitung (DE)

Manual de uso (ES)

Manuel d’utilisation (FR)

ÏÄÇÃÏÓ ×ÑÇÓÅÙÓ (GR)

Handleiding voor het gebruik (NL)

Manuale d’uso (IT)

Instrukcja u¿ytkowania (PL)

Brugervejledning (DK)

Käyttökäsikirja (FI)

Bruksanvisning (NO)

0700158031-A 010303 Valid from serial number 3073070001

19

GB INSTRUCTION MANUAL

PLASMA ARC CUTTING PACKAGES

TABLE OF CONTENTS

1 DIRECTIVE.......................................................................2

2 SAFETY.............................................................................2

3 INTRODUCTION.............................................................4

3.1 Equipment............................................................4

4 TECHNICAL DATA.........................................................5

5 INSTALLATION...............................................................5

5.1 Mains and Workpiece Connection.................6

6 OPERATION.....................................................................7

6.1 Connection and Control Devices...................8

6.2 PT - 27 Torch......................................................8

6.3 Cutting with PT - 27 Torch................................9

6.4 Common Cutting Problems...........................10

7 MAINTENANCE.............................................................11

7.1 Check-up and Cleaning..................................11

8 FAULT-TRACKING/TROUBLESHOOTING..............12

8.1 Troubleshooting guide....................................12

8.2 Sequence of operation...................................16

9 ORDERING SPARE PARTS.........................................17

9.1 Detail pictures....................................................17

9.2 Spare Part List....................................................18

10 ACCESSORIES............................................................18

DIAGRAM.............................................................................19

1

GB INSTRUCTION MANUAL

1 DIRECTIVE

DECLARATION OF CONFORMITY

ESAB Welding Equipment AB, S-695 81 Lax å, Sweden, declares that plasma cutting equipment Handy Plasma 70 from serial Nr 307 onwards conforms to standard IEC/EN 60974-1, IEC/EN 60941-7, in accordance with the requirement of directive (73/23/EEC) and appendix (93/68/EEC) and standard EN 50199 in accordance with the requirements of directive (89/336/EEC) and appendix (93/68/EEC).

Laxå 2003-02-07

HENRY SELENIUS

Vice President

ESAB Welding Equipment AB

695 81 Laxå

SWEDEN

2 SAFETY

Tel: +46-584-81000 Fax: +46-584-411924

Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of plasma cutting equipment. The following recommendations should be observed in addition to the standard regulations that apply to the workplace.

All work must be carried out by trained personnel well-acquainted with the operation of the plasma cutting equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the operator and damage to the equipment.

1.

Anyone who uses the plasma cutting equipment must be familiar with:

- its operation

- location of emergency stops

- its function

- relevant safety precautions

- plasma cutting

2.

The operator must ensure that:

- no unauthorized person is stationed within the working area of the equipment when it is started up

- no one is unprotected when the arc is struck

3.

The workplace must:

- be suitable for the purpose

- be free from draughts

4.

Personal safety equipment

- always wear recommended personal safety equipment, such as safety glasses, flameproof clothing, safety gloves

5. General precautions

- make sure the return cable is connected securely

- work on high voltage equipment may only be carried by a qualified electrician

- appropriate fire extinguishing equipment must be clearly marked and close at hand

- Lubrication and maintenance must not be carried out on the equipment during operation.

2

GB INSTRUCTION MANUAL

Note! This product is solely intended for plasma cutting

3

GB INSTRUCTION MANUAL

3 INTRODUCTION

The HandyPlasma 70 is a compact, completely self-contained plasma cutting system. As shipped, the system is fully assembled and ready to cut after being connected to input power and a source of prefiltered compressed air 5-10 bar

(set torch at 150 lt/min @ 5.2 bar). The Handy Plasma 70 package uses the PT-

27 torch to deliver cutting power for materials up to 19 mm thick or for severing up to 22 mm thick. Refer to the following paragraphs for descriptions of the Handy

Plasma 70 packages available as well as performance specifications.

Do not use any torch with this power source other than the ESAB brand

PT-27 torch. Serious injury may occur if used with any other torch.

See below for ESAB’s accessories for the cutting torch.

3.1 Equipment

List 3.1.1 HandyPlasma 70 Cutting Packages

Each HandyPlasma 70, Plasma Arc Cutting Package P/N 0700158880 includes:

N°1 Power Source HandyPlasma 70.

N°1 PT-27* Torch assembly with 8m service lines.

N°1 earth cable 8m length.

N°1 Torch Spare Parts Kit, see list below.

List 3.1.2

PT-27* Spare Parts Kit P/N 0558003466 Contents

N° 3 Nozzle, P/N (33369) 70 Amp

N° 3 Electrode, P/N (33366XL)

N° 1 Swirl Baffle, P/N (33367)

0558000363

0558000364

0558000365

N° 1 Long Heat Shield, P/N (35547) 0558000486

N° 1 Stand-off, P/N (34396) 0558000367

*PT-27 Torch Assembly P/N 0558000487 is supplied with the nozzle, electrode, swirl baffle and heat shield assembled.

(Part numbers in blankets could be found on the explosion drawings inside the torch spare part kit box.)

Fig. 3.1.2 PT - 27 spare part list and consumables

4

GB INSTRUCTION MANUAL

4 TECHNICAL DATA

4.1 SPECIFICATIONS

Rated Output

40% Duty Cycle*

60% Duty Cycle*

100% Duty Cycle*

70A @ 128V dc

54A @ 121V dc

45A @ 118V dc

Output Current Range

Open Circuit Voltage

Rated Primary Input I

Current Capacity

Air Requirements

Weight (less torch)

Insulation class: F

1 max

@ 70A 128Vdc Output

Power factor @ 70 A Output

Dimensions of HandyPlasma 70

26 to 70 Amperes

250 V dc Nominal

400 Vac 50/60 Hz,

3 - Phase

PT-27

PT-27

Length

Height

Width

21 Ampere

0,8

70 A dc SP

150 lt/min @ 5.2 bar

550 mm

410 mm

190 mm

19 kg

Protection class: IP 22S

* Duty Cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or cut at a certain load without overloading the product.

5 INSTALLATION

The installation must be executed by a professional.

5

GB INSTRUCTION MANUAL

5.1 Mains and workpiece connection

Fig. 5.1.1 - Mains connection

Mains plug and socket

HandyPlasma 70 Power Source

Fig. 5.1.2 - Workpiece connection

Plasma torch

Rating Plate

(on opposite side)

Earth clamp

6

GB INSTRUCTION MANUAL

6 OPERATION

General safety regulations for the handling of the equipment can be found on page

2 and 3. Read through before you start using the equipment!

ELECTRIC SHOCK can kill.

• Do NOT operate the unit with the cover removed.

• Do NOT apply power to the unit while holding or carrying the unit.

• Do NOT touch any torch parts forward of the torch handle (nozzle, heat shield, electrode, etc.) with power switch on.

ARC RAYS can burn eyes and skin;

NOISE can damage hearing.

• Wear welding helmet with proper lens shade.

• Wear eye, ear, and body protection.

Do not use any torch with this power source other than the ESAB brand

PT-31 XL torch. Serious injury may occur if used with any other torch.

Position the Handy Plasma (at least) 3 meters from the cutting area. Sparks and hot slag from the cutting operation can damage the unit.

7

GB INSTRUCTION MANUAL

6.1 Connection and control devices - front panel

6.1.2 Handy Plasma 70 CONTROLS

1. Power Switch. When placed in On position, the green light will glow indicating control circuit is energized and the cooling fan will run.

2 . Output Current Control. Adjustable from 25 to 70 amperes to suit cutting conditions.

3. Air Check Switch. When pressed,

(ON position), air filter-regulator can be adjusted to desired pressure before cutting operations. By keeping it pressed, allow air flow for a few minutes. This should remove any condensation that may have accumulated during shutdown period.

4. While flowing, the green LED will light up.

1

123456789012345678901

123456789012345678901

123456789012345678901

123456789012345678901

123456789012345678901

123456789012345678901

123456789012345678901

123456789012345678901

123456789012345678901

123456789012345678901 Manometer

123456789012345678901

123456789012345678901

123456789012345678901

123456789012345678901

123456789012345678901

123456789012345678901

123456789012345678901

123456789012345678901

123456789012

123456789012

123456789012

123456789012

123456789012 ON/OFF

123456789012

Switch

123456789012

123456789012

123456789012

123456789012

12345

12345

12345

12345

12345

Air Check

Switch

2

1234567890123456

1234567890123456

1234567890123456

1234567890123456

1234567890123456

1234567890123456

1234567890123456 Torch

1234567890123456

1234567890123456

1234567890123456

1234567890123456

1234567890123456

1234567890123456

1234567890123456

3

Overheating LED

4

Earth

Connector

6.2 PT - 27 Torch

When assembling or replacing consumables, make sure power switch on power source is in OFF position and primary input power is deenergized.

The PT-27 torch of Handy Plasma 70 is originally assembled and tested.

The PT-27 torch head contains a gas flow check valve that acts in conjuction with the flow switch and circuitry within the power source. This system prevents the torch from being energized with high voltage if the torch switch accidentally closed when the shield is removed. ALWAYS REPLACE TORCH

WITH THE PROPER TORCH MANUFACTURED BY ESAB SINCE IT ALONE

CONTAINS ESAB’S PATENTED SAFETY INTERLOCK.

8

GB INSTRUCTION MANUAL

6.3 Cutting with PT - 27

Wear the usual protective gloves, clothing and helmet. Helmet with filter lens shade No. 6 or 7 should provide adequate protection for your eyes.

Never touch any parts forward of the torch handle (tip, heat shield, electrode, etc.) unless the power switch is in the OFF position.

TOO FAST TOO SLOW CORRECT

Tab. 6.3.1 Effect of cutting speed

WHEN THE ARC BREAKS

THROUGH THE WORK,

BRING THE TORCH TO AN

UPRIGHT POSITION AND

PROCEED TO CUT.

TO START A PIERCE, TILT THE

TORCH TO PREVENT MOLTEN

MATERIAL FROM COMING BACK

AGAINST AND DAMAGING THE

TORCH

Tab. 6.3.2

Piercing Technique using PT - 27

9

GB INSTRUCTION MANUAL

6.4 COMMON CUTTING PROBLEMS

WARNING!

1) The PILOT ARC must be ignited just before the cutting operation. If it’s ignited and not becoming CUTTING ARC, it will vanish after 3 seconds.

2) If torch trigger will be repeatedly pressed for PILOT ARC ignition without cutting operation, machine will go overloaded and stop for few seconds.

Listed below are common cutting problems followed by the probable cause of each.

If problems are determined to be caused by Handy Plasma, refer to the maintenance section of this manual. If the problem is not corrected after referring to the maintenance section, contact your ESAB representative.

A.

Insufficient Penetration.

1.

Cutting speed too fast.

2.

Damaged cutting nozzle.

3.

Improper air pressure.

B.

Main Arc Estinguishes.

Cutting speed too slow.

C.

Dross Formation. (In some materials and thicknesses, it may be impossible to get dross-free cuts)

1.

Cutting speed too fast or too slow.

2.

Improper air pressure.

3.

Faulty nozzle or electrode.

D.

Double Arching. (Damaged nozzle orifice)

1.

Low air pressure.

2.

Damaged cutting nozzle

3.

Loose cutting nozzle.

4.

Heavy spatter.

E.

Uneven Arc.

Damaged cutting nozzle or worn electrode

F.

Unstable Cutting Conditions.

1.

Incorrect cutting speed.

2.

Loose cable or hose connections.

3.

Electrode and/or cutting nozzle in poor condition.

G.

Main Arc Does Not Strike. (Loose connections)

H.

Poor Consumable Life.

1.

Improper gas pressure.

2.

Contaminated air supply.

10

GB INSTRUCTION MANUAL

7 MAINTENANCE

Regular maintenance is important for safe, reliable operation.

Note:

All warranty undertakings given by the supplier cease to apply if the customer attempts to rectify any faults on the machine during the warranty period.

If this equipment does not operate properly, stop work immediately and investigate the cause of the malfunction. Maintenance work must be performed by an experienced person, and electrical work by a trained electrician. Do not permit untrained persons to inspect, clean, or repair this equipment. Use only recommended replacement parts.

Be sure that the wall disconnect switch or wall circuit breaker is open before attempting any inspection or work inside of the Handy Plasma.

7.1 CHECK - UP AND CLEANING

Water or oil occasionally accumulates in compressed air lines. Be sure to direct the first blast of air away from the equipment to avoid damage to Handy Plasma.

Frequent inspection and cleaning of the Handy Plasma is recommended for safety and proper operation. Some suggestions for inspecting and cleaning are as follows:

A. Check work cable to work piece connection.

B. Check safety earth ground at work piece and at power source chassis.

C. Check heat shield on torch. It should be replaced if damaged.

D. Check the torch electrode and cutting nozzle for wear on a daily basis. Remove spatter or replace if necessary.

E. Make sure cable and hoses are not damaged or kinked.

F. Make sure all fittings and ground connections are tight.

11

GB INSTRUCTION MANUAL

8 FAULT-TRACING / TROUBLESHOOTING

Try these recommended checks and inspections before sending for an authorized service technician.

ELECTRIC SHOCK CAN KILL! Be sure that all primary power to the machine has been externally disconnected.Open the line (wall) disconnect switch or circuit breaker before attempting inspection or work inside of the power source.

Check the problem against the symptoms in the following troubleshooting guide. The remedy may be quite simple. If the cause cannot be quickly located, shut off the input power, open up the unit, and perform a simple visual inspection of all the components and wiring. Check for secure terminal connections, loose or burned wiring or components, bulged or leaking capacitors, or any other sign of damage or discoloration.

Those indications do not invalidate all other safety regulations and restrictions expressed in other sections of this manual.

Voltages in plasma cutting equipment are high enough to cause serious injury or possibly death.

Be particularly careful around equipment when the covers are removed.

NOTE

Before checking voltages in the circuit, disconnect the power from the high frequency generator to avoid damaging your voltmeter.

8.1 TROUBLESHOOTING GUIDE

Any remedy that requires an intervention inside the machine must be executed by an authorized service center.

A. Difficult Starting.

• Change electrode

• Change nozzle

• Check for good, clean connection of work lead to workpiece

• Check air pressure (5 - 5,5 bar)

• Check torch power cable for continuity

Depress torch switch. After 2 seconds, is pilot arc present?

Yes No

Is the “Air” LED light on?

Yes No

Repair/replace HF PCB

Repair/replace power source

Repair/replace Control

control PCB Flow Switch

12

GB INSTRUCTION MANUAL

B. No Air

Is air hose connected?

Yes No

Is air adjusted to 4 - 5 bar ?

Yes No

Yes

Check torch integrity

No

Check continuity of torch switch

OK No

Repair/replace power source

Connect

Adjust

• No electrode in torch

• No valve pin in torch

• Replace electrode

• Replace valve pin

Replace torch switch

C. Air does not shut off

Does arc start when nozzle contacts work without depressing torch switch?

Yes No

Check for short in torch switch

Does air flow even when Handy Plasma power switch is OFF?

Yes No

Replace solenoid valve

Repair/replace

control PCB

13

GB INSTRUCTION MANUAL

D. ON/OFF Switch light not energized.

Is main 400 Volt switch ON?

Yes No

Is plug in receptacle?

Yes

Is cooling fan turning?

Yes No

Replace

ON/OFF Switch

No

Turn on switch

Insert plug in receptacle

Check voltage at receptacle and input power line

Yes No Check main fuses

Replace ON/OFF

Switch

14

GB INSTRUCTION MANUAL

E.

Temperature LED light ON.

Is the unit overheated?

("Fault" lights turns off when Unit cools down.)

Yes

Duty cycle exceeded:

45% @ 70 A or 100% @ 50 A output

No

Is cooling air flowing?

Yes No

Repair power source Repair fan

F.

No current output

Is input voltage within ±10% of units input rating?

Yes No

See (D.) sequence above

Unsolved

Repair power source

15

GB INSTRUCTION MANUAL

8.2 SEQUENCE OF OPERATION

A.

LOCK-IN "OFF" position

PUSH

TORCH SWITCH

OPEN

GAS SOLENOID VALVE

2 SEC.

RELEASE

PREFLOW

FLOW SWITCH CLOSE

CLOSE

10 SEC

Postflow

OPEN

OVERHEATING LIGHT

HF CIRCUIT

INVERTER

PILOT ARC (CURRENT)

ENERGIZE

NOTES:

1.

When the torch switch is pushed during postflow period, the postflow and preflow times are canceled, and the HF is energized immediately.

2.

When the air flow LED comes off, cutting operation should be stopped. The postflow time starts from the moment the torch switch is released.

16

GB INSTRUCTION MANUAL

9 - ORDERING SPARE PARTS

9.1 - Detail pictures - Handy Plasma 70

9

26

12

6

16

10

Rear

7

22

11

19

20

2

5

17 - Power module - bottom side

18

21 - INPUT PCB

8

3

14

15

Front

4 - HF PCB

17

13 - Inverter PCB

GB INSTRUCTION MANUAL

9.2 - Spare Part List

Handy Plasma 70 is designed and tested in accordance with the international and European standards IEC/EN 60974-1 and EN 50199.

It is the obligation of the service unit which has carried out the service or repair work to make sure that the product still conforms to the said standard.

Spare parts are ordered through your nearest ESAB representative, see back cover. When ordering spare parts, please state machine type, and number as well as designation and spare part number as shown in the spare part list.

This will semplify dispatch and ensure you get the right part. Nevertheless, any replacement of parts inside the machine must be executed by an authorized service center.

ITEM NO.

17

18

19

20

21

22

23

24

25

26

27

9

10

11

12

13

14

15

16

1

2

3

4

5

6

7

8

PART NO.

DESCRIPTION

0700157001 LID WITH HANDLE

0700158001 BOTTOM CASE (CHASSIS)

0700158002 CONTROL PCB

0700157004 HIGH FREQUENCY PCB

0700157005 HF GENERATOR

0700156006 AIR NIPPLE 1/8” Dia. 8mm, L=20mm

0700157007 POWER CABLE

0558000487 PT - 27 TORCH Ass.ly

0700157008 AIR GAUGE FILTER

0700156009 FAN

0700157010 EMC FILTER

0558000410 FLOW SWITCH P/N 951202

0700157011 INVERTER PCB

0700157012 ON/OFF SWITCH KNOB ASS.LY

0700157013 EARTH CABLE W/CLAMP, L=8m

0700157014 FAN GRID

0700158003 POWER MODULE

0700157016 CHOKE (INDUCTANCE)

0700158004 TRANSFORMER

0700157018 HEAT SINK WITH DIODES

0700157019 INPUT PCB MODULE

0700157020 AUXILLARY TRANSFORMER

0700157021

0700157022 MANOMETER (FRONT PANEL)

0700157023 AIR CHECK SWITCH (FRONT PANEL)

0700157024 SOLENOID VALVE ASS.LY

0700158031 Multilanguage user manual

10 ACCESSORIES

For plasma torch PT - 27, please see section 3.1 Equipment, page 4.

18

19