ESAB HandyPlasma® 550 Plasmarc Cutting Package Troubleshooting instruction

HandyPlasma

®

550

PLASMARC CUTTING PACKAGE

Installation, Operation and Service Manual

This manual provides complete instructions for the following HandyPlasma ® 550 cutting packages starting with Serial

No. PPOR144027:

ESAB P/N 0558002612 - 230 V, 1-Phase, 50/60 Hz - North America

F15-706-D 12/2005

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

CAUTION

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and

Gouging,” Form 52529. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions be fore installing or operating this equipment.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompa nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.

The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a ser vice facility designated by the manufacturer.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

taBle oF contents

section / title page

1.0 Safety Precautions ......................................................................................................................................................................5

1.1 Safety - English ...............................................................................................................................................................5

1.2 Safety - Spanish .............................................................................................................................................................9

1.3 Safety - French .............................................................................................................................................................13

2.0 Description ..................................................................................................................................................................................17

2.1 General .......................................................................................................................................................................... 17

2.2 Scope .............................................................................................................................................................................. 17

2.3 Packages Available .................................................................................................................................................... 17

2.4 Specifications .............................................................................................................................................................. 18

3.0 Installation ...................................................................................................................................................................................21

3.1 General ...........................................................................................................................................................................21

3.2 Equipment Required .................................................................................................................................................21

3.3 Location ..........................................................................................................................................................................21

3.4 Inspection ......................................................................................................................................................................21

3.5 Primary Electrical Input Connections ..................................................................................................................21

3.6 Secondary (Output) Connections ........................................................................................................................ 22

3.7 Connecting HandyPlasma

®

550 ............................................................................................................................ 23

4.0 Operation .................................................................................................................................................................................... 25

4.1 Operation ...................................................................................................................................................................... 25

4.2 HandyPlasma

®

550 Controls .................................................................................................................................. 25

4.3 Assembling PT-31XL Consumable Parts ............................................................................................................ 26

4.4 Cutting with the PT-31XL ........................................................................................................................................ 26

4.5 Operating Techniques .............................................................................................................................................. 28

4.6 Common Cutting Problems ................................................................................................................................... 28

5.0 Maintenance ...............................................................................................................................................................................29

5.1 General .......................................................................................................................................................................... 29

5.2 Inspection and Cleaning ......................................................................................................................................... 29

4.3 Flow Switch .................................................................................................................................................................. 29

6.0 Troubleshooting ....................................................................................................................................................................... 31

6.1 Troubleshooting ......................................................................................................................................................... 31

6.2 Troubleshooting Guide ............................................................................................................................................ 31

6.3 Sequence of Operation ............................................................................................................................................ 36

7.0 Replacement Parts ....................................................................................................................................................................37

7.1 General ...........................................................................................................................................................................37

7.2 Ordering .........................................................................................................................................................................37

3

taBle oF contents

4

section 1 saFetY precautions

1.0 safety precautions

Warning: These Safety Precautions are for your protection. They summarize precautionary information from the references listed in Additional Safety Information section. Before performing any installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe

Safety Precautions can result in injury or death.

protect YourselF anD others -- some welding, cutting, and gouging processes are noisy and require ear protection. the arc, like the sun, emits ultraviolet (uV) and other radiation and can injure skin and eyes. hot metal can cause burns. training in the proper use of the processes and equipment is essential to prevent accidents. therefore:

1. Always wear safety glasses with side shields in any work area, even if welding helmets, face shields, and goggles are also required.

2. Use a face shield fitted with the correct filter and cover plates to protect your eyes, face, neck, and ears from sparks and rays of the arc when operating or observing operations. Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric-arc or hot metal.

3. Wear flameproof gauntlet type gloves, heavy longsleeve shirt, cuffless trousers, high-topped shoes, and a welding helmet or cap for hair protection, to protect against arc rays and hot sparks or hot metal.

A flameproof apron may also be desirable as protection against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and collars should be kept buttoned, and open pockets eliminated from the front of clothing.

5. Protect other personnel from arc rays and hot sparks with a suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be hot and can fly far.

Bystanders should also wear goggles over safety glasses.

1.1 safety - english

Fires anD explosions -- heat from

flames and arcs can start fires. hot slag or sparks can also cause fires and explosions. therefore:

1. Remove all combustible materials well away from the work area or cover the materials with a protective non-flammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hidden smoldering fire or fires on the floor below. Make certain that such openings are protected from hot sparks and metal.“

3. Do not weld, cut or perform other hot work until the workpiece has been completely cleaned so that there are no substances on the workpiece which might produce flammable or toxic vapors. Do not do hot work on closed containers. They may explode.

4. Have fire extinguishing equipment handy for instant use, such as a garden hose, water pail, sand bucket, or portable fire extinguisher. Be sure you are trained in its use.

5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and create a fire hazard.

6. After completing operations, inspect the work area to make certain there are no hot sparks or hot metal which could cause a later fire. Use fire watchers when necessary.

7. For additional information, refer to NFPA Standard

51B, "Fire Prevention in Use of Cutting and Welding

Processes", available from the National Fire Protection Association, Batterymarch Park, Quincy, MA

02269.

electrical shocK -- contact with live electrical parts and ground can cause severe injury or death. Do not use ac welding current in damp areas, if movement is confined, or if there is danger of falling.

5


1. Be sure the power source frame (chassis) is connected to the ground system of the input power.

2. Connect the workpiece to a good electrical ground.

3. Connect the work cable to the workpiece. A poor or missing connection can expose you or others to a fatal shock.

3. Welders should use the following procedures to minimize exposure to EMF:

A. Route the electrode and work cables together.

Secure them with tape when possible.

B. Never coil the torch or work cable around your body.

4. Use well-maintained equipment. Replace worn or damaged cables.

5. Keep everything dry, including clothing, work area, cables, torch/electrode holder, and power source.

6. Make sure that all parts of your body are insulated from work and from ground.

C. Do not place your body between the torch and work cables. Route cables on the same side of your body.

D. Connect the work cable to the workpiece as close as possible to the area being welded.

E. Keep welding power source and cables as far away from your body as possible.

7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand on dry boards or an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

9. Turn off the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specific grounding recommendations. Do not mistake the work lead for a ground cable.

therefore:

Fumes anD gases -- Fumes and gases, can cause discomfort or harm, particularly in confined spaces. Do not breathe fumes and gases. shielding gases can cause asphyxiation.

1. Always provide adequate ventilation in the work area by natural or mechanical means. Do not weld, cut, or gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead, beryllium, or cadmium unless positive mechanical ventilation is provided.

Do not breathe fumes from these materials.

electric anD magnetic FielDs

— may be dangerous. electric current flowing through any conductor causes localized electric and magnetic Fields (emF). Welding and cutting current creates emF around welding cables and welding machines. therefore:

1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.

2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat irritation while operating, this is an indication that ventilation is not adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not continue to operate if physical discomfort persists.

2. Exposure to EMF may have other health effects which are unknown.

6

4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specific ventilation recommendations.


5. Warning: this product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the state of california to cause birth defects and, in some cases, cancer.

(california health & safety code

§25249.5 et seq.) cYlinDer hanDling -- cylinders, if mishandled, can rupture and violently release gas. sudden rupture of cylinder, valve, or relief device can injure or kill. therefore:

1. Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder. Do not use adaptors. Maintain hoses and fittings in good condition. Follow manufacturer's operating instructions for mounting regulator to a compressed gas cylinder.

2. Always secure cylinders in an upright position by chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure cylinders to work tables or fixtures where they may become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and flames.

Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,

"Precautions for Safe Handling of Compressed Gases in Cylinders", which is available from Compressed

Gas Association, 1235 Jefferson Davis Highway,

Arlington, VA 22202.

eQuipment maintenance -- Faulty or improperly maintained equipment can cause injury or death. therefore:

1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work.

Do not perform any electrical work unless you are qualified to perform such work.

2. Before performing any maintenance work inside a power source, disconnect the power source from the incoming electrical power.

3. Maintain cables, grounding wire, connections, power cord, and power supply in safe working order. Do not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such as furnaces, wet conditions such as water puddles, oil or grease, corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position and in good repair.

6. Use equipment only for its intended purpose. Do not modify it in any manner.

aDDitional saFetY inFormation -- For more information on safe practices for electric arc welding and cutting equipment, ask your supplier for a copy of

"precautions and safe practices for arc

Welding, cutting and gouging", Form

52-529.

The following publications, which are available from the American Welding Society, 550 N.W. LeJuene Road,

Miami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc

Welding"


Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon

Arc Gouging and Cutting"

7

section 1

5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal

Arc Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.

8. ANSI/AWS F4.1, "Recommended Safe Practices for

Welding and Cutting of Containers That Have Held

Hazardous Substances."

meaning oF sYmBols - as used throughout this manual: means attention! Be alert! Your safety is involved.

means immediate hazards which, if not avoided, will result in immediate, serious personal injury or loss of life.

means potential hazards which could result in personal injury or loss of life.

means hazards which could result in minor personal injury.

saFetY precautions

8

section 1

1.2 safety - spanish

seguriDaD

La escoria puede estar caliente y desprenderse con velocidad. Personas cercanas deberán usar gafas de seguridad y careta protectora.

aDVertencia: Estas Precauciones de Seguridad son para su protección. Ellas hacen resumen de información proveniente de las referencias listadas en la sección "Información Adicional Sobre La Seguridad". Antes de hacer cualquier instalación o procedimiento de operación , asegúrese de leer y seguir las precauciones de seguridad listadas a continuación así como también todo manual, hoja de datos de seguridad del material, calcomanias, etc.

El no observar las Precauciones de Seguridad puede resultar en daño a la persona o muerte.

por lo tanto: proteJase usteD Y a los Demas-- algunos procesos de soldadura, corte y ranurado son ruidosos y requiren protección para los oídos. el arco, como el sol , emite rayos ultravioleta

(uV) y otras radiaciones que pueden dañar la piel y los ojos. el metal caliente causa quemaduras. el entrenamiento en el uso propio de los equipos y sus procesos es esencial para prevenir accidentes.

1. Utilice gafas de seguridad con protección a los lados siempre que esté en el área de trabajo, aún cuando esté usando careta de soldar, protector para su cara u otro tipo de protección.

2. Use una careta que tenga el filtro correcto y lente para proteger sus ojos, cara, cuello, y oídos de las chispas y rayos del arco cuando se esté operando y observando las operaciones. Alerte a todas las personas cercanas de no mirar el arco y no exponerse a los rayos del arco eléctrico o el metal fundido.

3. Use guantes de cuero a prueba de fuego, camisa pesada de mangas largas, pantalón de ruedo liso, zapato alto al tobillo, y careta de soldar con capucha para el pelo, para proteger el cuerpo de los rayos y chispas calientes provenientes del metal fundido.

En ocaciones un delantal a prueba de fuego es necesario para protegerse del calor radiado y las chispas.

4. Chispas y partículas de metal caliente puede alojarse en las mangas enrolladas de la camisa , el ruedo del pantalón o los bolsillos. Mangas y cuellos deberán mantenerse abotonados, bolsillos al frente de la camisa deberán ser cerrados o eliminados.

5. Proteja a otras personas de los rayos del arco y chispas calientes con una cortina adecuada no-flamable como división.

6. Use careta protectora además de sus gafas de seguridad cuando esté removiendo escoria o puliendo.

9

Fuego Y explosiones -- el calor de

las flamas y el arco pueden ocacionar fuegos. escoria caliente y las chispas pueden causar fuegos y explosiones. por lo tanto:

1. Remueva todo material combustible lejos del área de trabajo o cubra los materiales con una cobija a prueba de fuego. Materiales combustibles incluyen madera, ropa, líquidos y gases flamables, solventes, pinturas, papel, etc.

2. Chispas y partículas de metal pueden introducirse en las grietas y agujeros de pisos y paredes causando fuegos escondidos en otros niveles o espacios.

Asegúrese de que toda grieta y agujero esté cubierto para proteger lugares adyacentes contra fuegos.

3. No corte, suelde o haga cualquier otro trabajo relacionado hasta que la pieza de trabajo esté totalmente limpia y libre de substancias que puedan producir gases inflamables o vapores tóxicos. No trabaje dentro o fuera de contenedores o tanques cerrados. Estos pueden explotar si contienen vapores inflamables.

4. Tenga siempre a la mano equipo extintor de fuego para uso instantáneo, como por ejemplo una manguera con agua, cubeta con agua, cubeta con arena, o extintor portátil. Asegúrese que usted esta entrenado para su uso.

5. No use el equipo fuera de su rango de operación. Por ejemplo, el calor causado por cable sobrecarga en los cables de soldar pueden ocasionar un fuego.

6. Después de termirar la operación del equipo, inspeccione el área de trabajo para cerciorarse de que las chispas o metal caliente ocasionen un fuego más tarde. Tenga personal asignado para vigilar si es necesario.

7. Para información adicional , haga referencia a la publicación NFPA Standard 51B, "Fire Prevention in

Use of Cutting and Welding Processes", disponible a través de la National Fire Protection Association,

Batterymarch Park, Quincy, MA 02269.

choQue electrico -- el contacto con las partes eléctricas energizadas y tierra puede causar daño severo o muerte. no use soldadura de corriente alterna (ac) en áreas húmedas, de movimiento confinado en lugares estrechos o si hay posibilidad de caer al suelo.

section 1 seguriDaD

1. Asegúrese de que el chasis de la fuente de poder esté conectado a tierra através del sistema de electricidad primario.

2. Conecte la pieza de trabajo a un buen sistema de tierra física.

3. Conecte el cable de retorno a la pieza de trabajo.

Cables y conductores expuestos o con malas conexiones pueden exponer al operador u otras personas a un choque eléctrico fatal.

4. Use el equipo solamente si está en buenas condiciones. Reemplaze cables rotos, dañados o con conductores expuestos.

5. Mantenga todo seco, incluyendo su ropa, el área de trabajo, los cables, antorchas, pinza del electrodo, y la fuente de poder.

6. Asegúrese que todas las partes de su cuerpo están insuladas de ambos, la pieza de trabajo y tierra.

7. No se pare directamente sobre metal o tierra mientras trabaja en lugares estrechos o áreas húmedas; trabaje sobre un pedazo de madera seco o una plataforma insulada y use zapatos con suela de goma.

8. Use guantes secos y sin agujeros antes de energizar el equipo.

9. Apage el equipo antes de quitarse sus guantes.

10. Use como referencia la publicación ANSI/ASC

Standard Z49.1 (listado en la próxima página) para recomendaciones específicas de como conectar el equipo a tierra. No confunda el cable de soldar a la pieza de trabajo con el cable a tierra.

campos electricos Y magneticos - son peligrosos. la corriente eléctrica fluye através de cualquier conductor causando a nivel local campos eléctricos y magnéticos

(emF). las corrientes en el área de corte y soldadura, crean emF alrrededor de los cables de soldar y las maquinas. por lo tanto:

1. Soldadores u Operadores que use marca-pasos para el corazón deberán consultar a su médico antes de soldar. El Campo Electromagnético (EMF) puede interferir con algunos marca-pasos.

2. Exponerse a campos electromagnéticos (EMF) puede causar otros efectos de salud aún desconocidos.

3. Los soldadores deberán usar los siguientes procedimientos para minimizar exponerse al EMF:

A. Mantenga el electrodo y el cable a la pieza de trabajo juntos, hasta llegar a la pieza que usted quiere soldar. Asegúrelos uno junto al otro con cinta adhesiva cuando sea posible.

B. Nunca envuelva los cables de soldar alrededor de su cuerpo.

C. Nunca ubique su cuerpo entre la antorcha y el cable, a la pieza de trabajo. Mantega los cables a un sólo lado de su cuerpo.

D. Conecte el cable de trabajo a la pieza de trabajo lo más cercano posible al área de la soldadura.

E. Mantenga la fuente de poder y los cables de soldar lo más lejos posible de su cuerpo.

causar falta de oxígeno.

por lo tanto: humo Y gases -- el humo y los gases, pueden causar malestar o daño, particularmente en espacios sin ventilación. no inhale el humo o gases. el gas de protección puede

1. Siempre provea ventilación adecuada en el área de trabajo por medio natural o mecánico. No solde, corte, o ranure materiales con hierro galvanizado, acero inoxidable, cobre, zinc, plomo, berílio, o cadmio a menos que provea ventilación mecánica positiva . No respire los gases producidos por estos materiales.

2. No opere cerca de lugares donde se aplique substancias químicas en aerosol. El calor de los rayos del arco pueden reaccionar con los vapores de hidrocarburo clorinado para formar un fosfógeno, o gas tóxico, y otros irritant es.

3. Si momentáneamente desarrolla inrritación de ojos, nariz o garganta mientras est á operando, es indicación de que la ventilación no es apropiada.

Pare de trabajar y tome las medidas necesarias para mejorar la ventilación en el área de trabajo.

No continúe operando si el malestar físico persiste.

4. Haga referencia a la publicación ANSI/ASC Standard

Z49.1 (Vea la lista a continuación) para recomendaciones específicas en la ventilación.

10

section 1 seguriDaD

5. aDVertencia-- este producto cuando se utiliza para soldaduras o cortes, produce humos o gases, los cuales contienen químicos conocidos por el estado de california de causar defectos en el nacimiento, o en algunos casos, cancer. (california health & safety code §25249.5 et seq.) maneJo De cilinDros-- los cilindros, si no son manejados correctamente, pueden romperse y liberar violentamente gases. rotura repentina del cilindro, válvula, o válvula de escape puede causar daño o muerte. por lo tanto:

1. Utilize el gas apropiado para el proceso y utilize un regulador diseñado para operar y reducir la presión del cilindro de gas . No utilice adaptadores. Mantenga las mangueras y las conexiones en buenas condiciones. Observe las instrucciones de operación del manufacturero para montar el regulador en el cilindro de gas comprimido.

2. Asegure siempre los cilindros en posición vertical y amárrelos con una correa o cadena adecuada para asegurar el cilindro al carro, transportes, tablilleros, paredes, postes, o armazón. Nunca asegure los cilindros a la mesa de trabajo o las piezas que son parte del circuito de soldadura . Este puede ser parte del circuito elélectrico.

3. Cuando el cilindro no está en uso, mantenga la válvula del cilindro cerrada. Ponga el capote de protección sobre la válvula si el regulador no está conectado. Asegure y mueva los cilindros utilizando un carro o transporte adecuado. Evite el manejo brusco de los

mantenimiento Del eQuipo -- equipo defectuoso o mal mantenido puede causar daño o muerte. por lo tanto:

1. Siempre tenga personal cualificado para efectuar l a instalación, diagnóstico, y mantenimiento del equipo. No ejecute ningún trabajo eléctrico a menos que usted esté cualificado para hacer el trabajo.

2. Antes de dar mantenimiento en el interior de la fuente de poder, desconecte la fuente de poder del suministro de electricidad primaria.

3. Mantenga los cables, cable a tierra, conexciones, cable primario, y cualquier otra fuente de poder en buen estado operacional. No opere ningún equipo en malas condiciones.

4. No abuse del equipo y sus accesorios. Mantenga el equipo lejos de cosas que generen calor como hornos, también lugares húmedos como charcos de agua , aceite o grasa, atmósferas corrosivas y las inclemencias del tiempo.

5. Mantenga todos los artículos de seguridad y coverturas del equipo en su posición y en buenas condiciones.

6. Use el equipo sólo para el propósito que fue diseñado. No modifique el equipo en ninguna manera.

inFormacion aDicional De seguriDaD -- para más información sobre las prácticas de seguridad de los equipos de arco eléctrico para soldar y cortar, pregunte a su suplidor por una copia de "precautions and safe practices for arc Welding, cutting and gouging-Form 52-529.

Las siguientes publicaciones, disponibles através de la American Welding Society, 550 N.W. LeJuene Road,

Miami, FL 33126, son recomendadas para usted:



Welding"


Cutting"



11

section 1 signiFicaDo De los simBolos

-- según usted avanza en la lectura de este folleto: los símbolos significan ¡atención! ¡esté alerta! se trata de su seguridad.

significa riesgo inmediato que, de no ser evadido, puede resultar inmediatamente en serio daño personal o la muerte.

significa el riesgo de un peligro potencial que puede resultar en serio daño personal o la muerte.

significa el posible riesgo que puede resultar en menores daños a la persona.

seguriDaD

12

section 1

1.3 safety - French

aVertissement : Ces règles de sécurité ont pour but d'assurer votre protection. Ils récapitulent les informations de précaution provenant des références dans la section des Informations de sécurité supplémentaires. Avant de procéder à l'installation ou d'utiliser l'unité, assurez-vous de lire et de suivre les précautions de sécurité ci-dessous, dans les manuels, les fiches d'information sur la sécurité du matériel et sur les étiquettes, etc. Tout défaut d'observer ces précautions de sécurité peut entraîner des blessures graves ou mortelles.

protÉgeZ-Vous -- les processus de soudage, de coupage et de gougeage produisent un niveau de bruit élevé et exige l'emploi d'une protection auditive. l'arc, tout comme le soleil, émet des rayons ultraviolets en plus d'autre rayons qui peuvent causer des blessures à la peau et les yeux. le métal incandescent peut causer des brûlures. une formation reliée à l'usage des processus et de l'équipement est essentielle pour prévenir les accidents. par conséquent:

1. Portez des lunettes protectrices munies d'écrans latéraux lorsque vous êtes dans l'aire de travail, même si vous devez porter un casque de soudeur, un écran facial ou des lunettes étanches.

2. Portez un écran facial muni de verres filtrants et de plaques protectrices appropriées afin de protéger vos yeux, votre visage, votre cou et vos oreilles des

étincelles et des rayons de l'arc lors d'une opération ou lorsque vous observez une opération. Avertissez les personnes se trouvant à proximité de ne pas regarder l'arc et de ne pas s'exposer aux rayons de l'arc

électrique ou le métal incandescent.

3. Portez des gants ignifugiés à crispin, une chemise

épaisse à manches longues, des pantalons sans rebord et des chaussures montantes afin de vous protéger des rayons de l'arc, des étincelles et du métal incandescent, en plus d'un casque de soudeur ou casquette pour protéger vos cheveux. Il est également recommandé de porter un tablier ininflammable afin de vous protéger des étincelles et de la chaleur par rayonnement.

4. Les étincelles et les projections de métal incandescent risquent de se loger dans les manches retroussées, les rebords de pantalons ou les poches. Il est recommandé de garder boutonnés le col et les manches et de porter des vêtements sans poches en avant.

5. Protégez toute personne se trouvant à proximité des

étincelles et des rayons de l'arc à l'aide d'un rideau ou d'une cloison ininflammable.

6. Portez des lunettes étanches par dessus vos lunettes de sécurité lors des opérations d'écaillage ou de meulage du laitier. Les écailles de laitier incandescent peuvent être projetées à des distances considérables.

Les personnes se trouvant à proximité doivent également porter des lunettes étanches par dessus leur lunettes de sécurité.

13

sÉcuritÉ

incenDies et explosions -- la

chaleur provenant des flammes ou de l'arc peut provoquer un incendie. le laitier incandescent ou les étincelles peuvent également provoquer un incendie ou une explosion. par conséquent :

1. Éloignez suffisamment tous les matériaux combustibles de l'aire de travail et recouvrez les matériaux avec un revêtement protecteur ininflammable. Les matériaux combustibles incluent le bois, les vêtements, la sciure, le gaz et les liquides combustibles, les solvants, les peintures et les revêtements, le papier, etc.

2. Les étincelles et les projections de métal incandescent peuvent tomber dans les fissures dans les planchers ou dans les ouvertures des murs et déclencher un incendie couvant à l'étage inférieur

Assurez-vous que ces ouvertures sont bien protégées des étincelles et du métal incandescent.

3. N'exécutez pas de soudure, de coupe ou autre travail à chaud avant d'avoir complètement nettoyé la surface de la pièce à traiter de façon à ce qu'il n'ait aucune substance présente qui pourrait produire des vapeurs inflammables ou toxiques. N'exécutez pas de travail à chaud sur des contenants fermés car ces derniers pourraient exploser.

4. Assurez-vous qu'un équipement d'extinction d'incendie est disponible et prêt à servir, tel qu'un tuyau d'arrosage, un seau d'eau, un seau de sable ou un extincteur portatif. Assurez-vous d'être bien instruit par rapport à l'usage de cet équipement.

5. Assurez-vous de ne pas excéder la capacité de l'équipement. Par exemple, un câble de soudage surchargé peut surchauffer et provoquer un incendie.

6. Une fois les opérations terminées, inspectez l'aire de travail pour assurer qu'aucune étincelle ou projection de métal incandescent ne risque de provoquer un incendie ultérieurement. Employez des guetteurs d'incendie au besoin.

7. Pour obtenir des informations supplémentaires, consultez le NFPA Standard 51B, "Fire Prevention in

Use of Cutting and Welding Processes", disponible au

National Fire Protection Association, Batterymarch

Park, Quincy, MA 02269.

choc ÉlectriQue -- le contact avec des pièces électriques ou les pièces de mise à la terre sous tension peut causer des blessures graves ou mortelles. ne pas utiliser un courant de soudage c.a. dans un endroit humide, en espace restreint ou si un danger de chute se pose.

section 1 sÉcuritÉ

1. Assurez-vous que le châssis de la source d'alimentation est branché au système de mise à la terre de l'alimentation d'entrée.

2. Branchez la pièce à traiter à une bonne mise de terre électrique.

3. Branchez le câble de masse à la pièce à traiter et assurez une bonne connexion afin d'éviter le risque de choc électrique mortel.

4. Utilisez toujours un équipement correctement entretenu. Remplacez les câbles usés ou endommagés.

5. Veillez à garder votre environnement sec, incluant les vêtements, l'aire de travail, les câbles, le porte-

électrode/torche et la source d'alimentation.

6. Assurez-vous que tout votre corps est bien isolé de la pièce à traiter et des pièces de la mise à la terre.

7. Si vous devez effectuer votre travail dans un espace restreint ou humide, ne tenez vous pas directement sur le métal ou sur la terre; tenez-vous sur des planches sèches ou une plate-forme isolée et portez des chaussures à semelles de caoutchouc.

8. Avant de mettre l'équipement sous tension, isolez vos mains avec des gants secs et sans trous.

9. Mettez l'équipement hors tension avant d'enlever vos gants.

10. Consultez ANSI/ASC Standard Z49.1 (listé à la page suivante) pour des recommandations spécifiques concernant les procédures de mise à la terre. Ne pas confondre le câble de masse avec le câble de mise à la terre.

3. Les soudeurs doivent suivre les procédures suivantes pour minimiser l'exposition aux champs électriques et magnétiques :

A. Acheminez l'électrode et les câbles de masse ensemble. Fixez-les à l'aide d'une bande adhésive lorsque possible.

B. Ne jamais enrouler la torche ou le câble de masse autour de votre corps.

C. Ne jamais vous placer entre la torche et les câbles de masse. Acheminez tous les câbles sur le même côté de votre corps.

D. Branchez le câble de masse à la pièce à traiter le plus près possible de la section à souder.

E. Veillez à garder la source d'alimentation pour le soudage et les câbles à une distance appropriée de votre corps.

les Vapeurs et les gaZ -- peuvent causer un malaise ou des dommages corporels, plus particulièrement dans les espaces restreints. ne respirez pas les vapeurs et les gaz. le gaz de protection risque de causer l'asphyxie. par conséquent : champs ÉlectriQues et magnÉtiQues — comportent un risque de danger. le courant électrique qui passe dans n'importe quel conducteur produit des champs électriques et magnétiques localisés. le soudage et le courant de coupage créent des champs électriques et magnétiques autour des câbles de soudage et l'équipement. par conséquent :

1. Un soudeur ayant un stimulateur cardiaque doit consulter son médecin avant d'entreprendre une opération de soudage. Les champs électriques et magnétiques peuvent causer des ennuis pour certains stimulateurs cardiaques.

2. L'exposition à des champs électriques et magnétiques peut avoir des effets néfastes inconnus pour la santé.

14

1. Assurez en permanence une ventilation adéquate dans l'aire de travail en maintenant une ventilation naturelle ou à l'aide de moyens mécanique.

N'effectuez jamais de travaux de soudage, de coupage ou de gougeage sur des matériaux tels que l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc, le plomb, le berylliym ou le cadmium en l'absence de moyens mécaniques de ventilation efficaces. Ne respirez pas les vapeurs de ces matériaux.

2. N'effectuez jamais de travaux à proximité d'une opération de dégraissage ou de pulvérisation.

Lorsque la chaleur

ou le rayonnement de l'arc entre en contact avec les vapeurs d'hydrocarbure chloré, ceci peut déclencher la formation de phosgène ou d'autres gaz irritants, tous extrêmement toxiques.

3. Une irritation momentanée des yeux, du nez ou de la gorge au cours d'une opération indique que la ventilation n'est pas adéquate. Cessez votre travail afin de prendre les mesures nécessaires pour améliorer la ventilation dans l'aire de travail. Ne poursuivez pas l'opération si le malaise persiste.

4. Consultez ANSI/ASC Standard Z49.1 (à la page suivante) pour des recommandations spécifiques concernant la ventilation.

section 1 sÉcuritÉ

5. aVertissement : ce produit, lorsqu'il est utilisé dans une opération de soudage ou de coupage, dégage des vapeurs ou des gaz contenant des chimiques considéres par l'état de la californie comme

étant une cause des malformations congénitales et dans certains cas, du cancer. (california health & safety code §25249.5 et seq.) manipulation Des cYlinDres -- la manipulation d'un cylindre, sans observer les précautions nécessaires, peut produire des fissures et un

échappement dangereux des gaz. une brisure soudaine du cylindre, de la soupape ou du dispositif de surpression peut causer des blessures graves ou mortelles. par conséquent :

1. Utilisez toujours le gaz prévu pour une opération et le détendeur approprié conçu pour utilisation sur les cylindres de gaz comprimé. N'utilisez jamais d'adaptateur. Maintenez en bon état les tuyaux et les raccords. Observez les instructions d'opération du fabricant pour assembler le détendeur sur un cylindre de gaz comprimé.

2. Fixez les cylindres dans une position verticale, à l'aide d'une chaîne ou une sangle, sur un chariot manuel, un châssis de roulement, un banc, un mur, une colonne ou un support convenable. Ne fixez jamais un cylindre à un poste de travail ou toute autre dispositif faisant partie d'un circuit électrique.

3. Lorsque les cylindres ne servent pas, gardez les soupapes fermées. Si le détendeur n'est pas branché, assurez-vous que le bouchon de protection de la soupape est bien en place. Fixez et déplacez les cylindres à l'aide d'un chariot manuel approprié.

Toujours manipuler les cylindres avec soin.

4. Placez les cylindres à une distance appropriée de toute source de chaleur, des étincelles et des flammes. Ne jamais amorcer l'arc sur un cylindre.

5. Pour de l'information supplémentaire, consultez

CGA Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", mis à votre disposition par le Compressed Gas Association, 1235

Jefferson Davis Highway, Arlington, VA 22202.

entretien De l'ÉQuipement -- un équipement entretenu de façon défectueuse ou inadéquate peut causer des blessures graves ou mortelles. par conséquent :

1. Efforcez-vous de toujours confier les tâches d'installation, de dépannage et d'entretien à un personnel qualifié. N'effectuez aucune réparation

électrique à moins d'être qualifié à cet effet.

2. Avant de procéder à une tâche d'entretien à l'intérieur de la source d'alimentation, débranchez l'alimentation électrique.

3. Maintenez les câbles, les fils de mise à la terre, les branchements, le cordon d'alimentation et la source d'alimentation en bon état. N'utilisez jamais un

équipement s'il présente une défectuosité quelconque.

4. N'utilisez pas l'équipement de façon abusive. Gardez l'équipement à l'écart de toute source de chaleur, notamment des fours, de l'humidité, des flaques d'eau, de l'huile ou de la graisse, des atmosphères corrosives et des intempéries.

5. Laissez en place tous les dispositifs de sécurité et tous les panneaux de la console et maintenez-les en bon état.

6. Utilisez l'équipement conformément à son usage prévu et n'effectuez aucune modification.

inFormations supplÉmentaires relatiVes À la sÉcuritÉ -- pour obtenir de l'information supplémentaire sur les règles de sécurité à observer pour l'équipement de soudage à l'arc électrique et le coupage, demandez un exemplaire du livret "precautions and safe practices for arc Welding, cutting and gouging", Form 52-529.

Les publications suivantes sont également recommandées et mises à votre disposition par l'American Welding

Society, 550 N.W. LeJuene Road, Miami, FL 33126 :



Welding"


Cutting"



15

section 1 signiFication Des sYmBoles ce symbole, utilisé partout dans ce manuel, signifie "attention" ! soyez vigilant ! Votre sécurité est en jeu.

Danger

signifie un danger immédiat. la situation peut entraîner des blessures graves ou mortelles.

aVertissement

signifie un danger potentiel qui peut entraîner des blessures graves ou mortelles.

attention

signifie un danger qui peut entraîner des blessures corporelles mineures. sÉcuritÉ

16

section 2 Description

2.1 General

The HandyPlasma ® 550 is a compact, completely selfcontained 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 (90-150 psi). The HandyPlasma ® 550 package uses the PT-31XL torch to deliver cutting power for materials up to 1/2 inch thick or for severing up to 5/8 inch thick.

Refer to the following paragraphs for descriptions of the

HandyPlasma ® 550 packages available as well as performance specifications.

2.2 ScOpe

The purpose of this manual is to provide the operator with all the information required to install and operate the HandyPlasma ® 550 plasmarc cutting package.

Technical reference material is also provided to assist in troubleshooting the cutting package.

Do not use any torch with this power source other than the eSaB brand pT-31Xl torch. Serious injury may occur if used with any other torch.

2.3 pacKaGe aVaIlaBle

HandyPlasma ® 550 - North America (see Note 1 below) ......................................................................................... P/N 0558002612 includes:

Console with Regulator and Work Cable

Torch

Spare Parts Kit

Description

Table 2-1. pT-31Xl Spare parts Kit contents part number

Spare parts Kit p/n 0558003301 includes:

30/40 A Nozzle

Electrode

Swirl Baffle

Heat Shield

20860

20862

20463

20282

Quantity

1

1

3

2

nOTe:

1.) PT-31XL Torch Assembly P/N 0558004498, on North American machine 0558002612, is supplied with the nozzle, electrode, swirl baffle, and heat shield assembled.

2.) PT-31XL Torch Assembly P/N 21985, on Asian machine 0558003178, is supplied with the nozzle, electrode, swirl baffle, and heat shield assembled.

17


1.4 SpecIfIcaTIOnS

Refer to Tables 2-2, 2-3, and Figures 2-1 and 2-2 for HandyPlasma ® 550 technical specifications.

Table 2-2. Handyplasma

®

550 Specifications

Rated

Output

Output Current Range

Open Circuit Voltage

Rated Primary Input

@

35 A @ 120 VDC Output

Power Factor @

35 Amperes Output

Current Capacity

Air Requirements

Dimensions of Handy

Plasma

®

550

Weight (less torch)

40% Duty Cycle*

60% Duty Cycle*

35 A @ 120 V dc

30 A @ 120 V dc

100% Duty Cycle* 22 A @ 120 V dc

15 to 35 Amperes

230 VAC, 50/60 Hz,

1-Phase

PT-31XL

PT-31XL

Length

Height

Width

230 V dc Nominal

27 A

81% (1-Phase)

50 A DCSP

250 cfh @ 80 psi

14.25-in. ( 362 mm)

12.7-in. (322 mm)

6.2-in. (156 mm)

35 lbs (16 kg)

* Duty cycle is based on a 10-minute period; therefore, a 40% duty cycle means the machine may operate for 4 minutes with a cool down period of 6 minutes; a 60% duty cycle means the machine may operate for 6 minutes with a cool down period of 4 minutes; a

100% duty cycle means the machine may operate continuously.

18

section 2

Table 2-3. pT-31Xl Torch Specifications pT-31Xl Torch

Current Capacity ...........................................................50A DCSP

Shipping Wgt. ..............................................................2 lbs (1 kg)

Length of Service Lines ........................................ 25-ft. (7.6 m)

Description

75° Torch

5 1/4"

(133mm)

figure 2-1. pT-31Xl Dimensions figure 2-2. pT-31Xl cutting performance

19


20

section 3

3.1 General

Proper installation can contribute materially to the satisfactory and trouble-free operation of the HandyPlasma ® 550 cutting package. It is suggested that each step in this section be studied carefully and followed as closely as possible.

3.2 eQuIpMenT reQuIreD

A source of clean, prefiltered dry air that supplies 250 cfh at 80 psig is required for the cutting operation. The air supply should not exceed 150 psig (the maximum inlet pressure rating of the air filter-regulator supplied with the package).

3.3 lOcaTIOn

Adequate ventilation is necessary to provide proper cooling of the HandyPlasma ® 550 and the amount of dirt, dust, and excessive heat to which the equipment is exposed, should be minimized. There should be at least one foot of clearance between the HandyPlasma ® 550 power source and wall or any other obstruction to allow freedom of air movement through the power source.

Installing or placing any type of filtering device will restrict the volume of intake air, thereby subjecting the power source internal components to overheating. The warranty is void if any type of filter device is used.

3.4 InSpecTIOn

A. Remove the shipping container and all packing material and inspect for evidence of concealed damage which may not have been apparent upon receipt of the

HandyPlasma

®

550. Notify the carrier of any defects or damage at once.

B. Check container for any loose parts prior to disposing of shipping materials.

C. Check air louvers and any other openings to ensure that any obstruction is removed.

installation

3.5 prIMary elecTrIcal InpuT cOnnecTIOnS (fIGure 3-1)

elecTrIc SHOcK can KIll! precautionary measures should be taken to provide maximum protection against electrical shock. Be sure that all power is off by opening the line (wall) disconnect switch and by unplugging the power cord to the unit when connections are made inside of the power source.

Be sure that the power source is properly configured for your input power supply. Damage to the machine may occur otherwise.

The HandyPlasma

®

550 power source operating on 230 V,

1-phase input power is equipped with a 8-ft, 3-conductor cable with plug. An optional mating receptacle (P/N 674540) is available. A line (wall) disconnect switch with a 40-ampere fuse or circuit breaker should be provided at the main power panel. The cable connecting the disconnect switch to the receptacle should include three (two power and one ground)

No. 10 AWG insulated conductors.

The chassis must be connected to an approved electrical ground. failure to do so may result in electrical shock, severe burns or death.

A line (wall) disconnect switch, with proper sized fuse or circuit breaker (see Table 3.1), should be provided at the main power panel.

21

section 3 installation

3.6 SecOnDary (OuTpuT) cOnnecTIOnS

(refer TO fIG. 3-1)

Torch comes factory installed. These instructions are for torch replacement.

Before making any connections to the power source output terminals, make sure that all primary input power to the power source is deenergized (off) at the main disconnect switch and that the input power cable is unplugged. for operator safety, the torch connections are loaded.

1. The torch connections are located at the flowswitch on upper left side of machine.

2. Thread the power cable and switch lead of the PT-

31XL through the right side (above pressure gauge) bushing of the front panel. Connect power cable to the torch fitting (left-hand threads) and connect torch switch leads to pins 1 and 2 of M

2

located in the upper right hand corner of machine (viewing from rear of machine) of the control P.C. Board. Make sure the power cable connection is wrench-tight.

3. Replace the machine cover panel.

4. Connect your air supply to the inlet connection of the filter-regulator.

5. Clamp the work cable to the workpiece. Be sure the workpiece is connected to an approved earth ground with a properly sized ground cable.

Table 3-1. recommended Sizes for Input conductors and line fuses rated Input

Volts amp phases

Input & GnD conductor cu/aWG*

fuse Size amps

230 27 1 No. 10 40

*

Sized per National Code for 80°C rated copper conductors @ 30°C ambient. Not more than three conductors in raceway or cable. Local codes should be followed if they specify sizes other than those listed above.

22

section 3

3.7 cOnnecTInG HanDyplaSMa

®

550 fOr 230 Vac InpuT

installation

PT-31XL

SAFETY

GROUND

WORK

WORK CABLE

Allow at least 10 ft (3 m) between work and power source

Prefiltered AIR SUPPLY (Customer Supplied)

(90 to 150 psig max)

CUSTOMER FUSED LINE

DISCONNECT SWITCH

*

See Table 3-1

RECEPTACLE (P/N 674540)

(Optional for 230 V, 1-phase power sources)

PLUG

figure 3-1. Handyplasma

®

550 Interconnection Diagram

23

*

(See Table 3-1 and WARNING in regards to chassis ground in Section 3.5.)

section 3

EARTH GROUND

installation

WORK CABLE

GROUNDED

WORK TABLE

DO NOT ATTACH WORK CABLE

TO PIECE BEING CUT FREE

EARTH GROUND

BE SURE WORK IS IN GOOD

CONTACT WITH TABLE.

24

WORK CABLE

section 4

4.1 OperaTIOn

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 no. 6 or 7 lens shade.

• Wear eye, ear, and body protection.

operation

4.2 HanDyplaSMa

®

550 cOnTrOlS

(fIGure 4-1)

a. power Switch (located on front panel). When placed in ON position, the white pilot light will glow indicating control circuit is energized and the cooling fan will run.

B. Output current control. Adjustable from 15 to 35 amperes to suit cutting conditions.

c.

air check push Button Switch. When energized, air filter-regulator can be adjusted to desired pressure (55-65 psig) before cutting operations. Allow air to flow for a few minutes. This should remove any condensation that may have accumulated during shutdown period. After setting the pressure, release the button to its normal position.

D. "Over Temperature" leD yellow light - will turn on if the machine becomes overheated. Will turn off automatically after the machine cools down if the on/off switch is still on.

position the Handyplasma ® 550 at least 10 feet (3 meters) from the cutting area. Sparks and hot slag from the cutting operation can damage the unit.

AIR REGULATOR

CONTROL KNOB

REAR VIEW

FAULT LIGHT

AMBER

POWER ON-OFF

(I-O) SWITCH &

CIRCUIT BREAKER

AIR LIGHT

GREEN

AIR CHECK

BUTTON

AIR PRESSURE

GAUGE

CURRENT

CONTROL

KNOB

figure 4-1. Handyplasma

®

550 controls

25

section 4 e.

"low air flow" leD Green light - will turn on during operation when the air flow is correct. Will switch off below 15psi (1 bar).

f.

On/Off Switch (White light) - will light when switched on, even if the machine stopped for any reason. Will turn off when switch is in OFF position or the light bulb is defective.

G. air pressure Gauge (front panel) - Shows air pressure in bars and psi.

4.3 aSSeMBlInG pT-31Xl cOMSuMaBle parTS

operation

The pT-31Xl torch head contains a gas flow check valve that acts in conjunction 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 is 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.

For additional torch information, see booklet (F-14-246) packed with the PT-31XL torch.

4.4 cuTTInG WITH THe pT-31Xl

Make sure power switch on power source is in Off position and primary input power is deenergized.

To assemble “XT” consumables, remove the seat supplied with the torch. Insert the plunger into the head. (The plunger is reversible.) Then reassemble the seat firmly with a wrench.

Install the electrode, baffle, nozzle, and heat shield as shown in

Fig. 4-2. Tighten heat shield snugly but do not overtighten.

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.

CAUTION: Do not depress the torch switch unless the torch nozzle is touching or within 0.020-in.

(less than 1/32-in.) of the workpiece.

Be Sure to install the swirl baffle in the torch. failure to do so would allow the nozzle (tip) to contact the electrode. This contact would permit high voltage to be applied to the nozzle. your contact with the nozzle or workpiece could then result in serious injury or death by electric shock.

TOO FAST TOO SLOW CORRECT

fig. 4-3 - effect of cutting Speed

NOTE: Nozzles

Marked By

Amperage

Plunger

20324

Seat

19679

Electrode

20862

Baffle

20463

Nozzle

20860

30/40A

fig. 4-2 - assembly of “XT” consumable parts

26

Heat Shield

20282

section 4 operation

2

WHEN THE ARC BREAKS

THROUGH THE WORK, BRING THE

TORCH TO AN UPRIGHT POSI-

TION AND PROCEED TO CUT.

1

TO START A PIERCE, TILT THE TORCH

TO PREVENT MOLTEN MATERIAL FROM

COMING BACK AGAINST AND DAMAG-

ING THE TORCH.

figure 4-4. piercing Technique using the pT-31Xl

CAUTION: Locate the console at least 10-ft. from the cutting work area. Chips and hot slag from the cutting operation can damage the console.

After placing the primary (wall) switch to the ON position and making control and air pressure adjustments as described above, proceed as follows:

1. Touch the tip of the torch to the workpiece (or within

0.020-in. of the workpiece) holding the torch at about

15- 30° angle to avoid damaging the tip.

2. Depress the torch switch. (Air and high frequency should energize.)

3. Two seconds after depressing torch switch, the plasma arc will start cutting.

4. After starting the cut, the tip can be dragged along the workpiece if cutting up to 1/4'’ thick material. When cutting material greater than 1/4'’, maintain a 1/8'’ tip-to-work

(standoff) distance.

5. When ending a cut, the torch switch should be released and lifted off the workpiece just before the end of the cut to minimize double-arcing which can damage the tip. This is to prevent high frequency from reigniting after cutting arc extinguishes.

6. In the postflow mode, the arc can be restarted immediately by depressing the torch switch. The two second preflow will automatically cancel.

27

Material

cutting Speed range — Handyplasma ® 550

(using air with XT consumables @ 75 psi)

Thickness

(In.)

Output

Current

(Amps)

Cutting

Speed

(ipm)

Carbon

Steel

(AISI 1020)

Stainless

Steel

(AISI 304)

1/16

1/8

1/8

1/4

3/8

1/2

1/16

1/8

1/8

1/4

3/8

1/2

30

30

35

35

35

35

30

30

35

35

35

35

30

14

10

200

85

85

30

15

12

180

75

85

Aluminum

(6061)

1/16

1/8

1/8

1/4

3/8

1/2

30

30

35

35

35

35

200

85

85

30

15

12

NOTE: The speeds given here are typical for best quality cuts. Your actual speeds may vary depending on material composition, surface condition, operator technique, etc. If cutting speed is too fast, you may lose the cut. With slower speeds excessive dross may accumulate.

If speed is too slow, the arc may extinguish. Air cutting typically produces a rough face on stainless steel and aluminum.

section 4

4.5 OperaTInG TecHnIQueS

1. piercing - Materials (up to 1/4-in. thick) may be pierced with the torch touching the work. When piercing thicker materials (up to 3/16-in. aluminum or 1/4-in. stainless or carbon steel) immediately raise the torch to 1/16-in. standoff after initiating the cutting arc. This will reduce the chance of spatter from entering the torch and prevent the possibility of welding the tip to the plate. The torch should be angled at about 30° when starting to pierce, and then straightened after accomplishing the pierce.

2. Grate cutting - For rapid restarts, such as grate or heavy mesh cutting, do not release the torch switch.

This avoids the 2 second preflow portion of the cutting cycle.

4.6 cOMMOn cuTTInG prOBleMS

Listed below are common cutting problems followed by the probable cause of each. If problems are determined to be caused by the HandyPlasma ® 550, 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 extinguishes.

1. Cutting speed too slow.

operation 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 arcing. (Damaged Nozzle Orifice.)

1. Low air pressure.

2. Damaged cutting nozzle.

3. Loose cutting nozzle.

4. Heavy spatter.

e. uneven arc.

1. 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.

1. Loose connections.

H. poor consumable life.

1. Improper gas pressure.

2. Contaminated air supply.

28

section 5

5.1 General

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 Handyplasma

®

550.

5.2 InSpecTIOn anD cleanInG

Frequent inspection and cleaning of the HandyPlasma

®

550 is recommended for safety and proper operation. Some suggestions for inspecting and cleaning are as follows:

A. Check work cable to workpiece connection.

B. Check safety earth ground at workpiece 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.

maintenance

G. With all input power disconnected, and wearing proper eye and face protection, blow out the inside of the HandyPlasma ® 550 using low-pressure dry compressed air.

5.3 flOW SWITcH (fIGure 5-1)

When excessive contamination is found in the air, the flow switch (FS) should be removed, disassembled and cleaned as follows:

A. Ensure the system is shut down and there is no trapped air under pressure in the piping.

B. Remove the piston plug.

C. Remove the spring (FS-4 only). Use care when handling spring to prevent distortion.

D. Remove the piston.

E. Clean all parts with cleaning agent.

nOTe ensure cleaning agent does not contain solvents which can degrade polysulfone. Warm water and detergent is recommended for cleaning. allow all parts to dry thoroughly before reassembly.

Reassemble the flow switch in reverse order.

SPRING

PISTON PLUG

PISTON

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 the Handyplasma

®

550.

FLOW SWITCH

figure 5-1. Disassembly / assembly of flow Switch

29

section 5 maintenance

30

section 6

6.1 TrOuBleSHOOTInG

trouBleshooting

The cause of control malfunctions can be found by referring to the sequence of operations and electrical schematic diagram (figure 5-1) and checking the various components. a volt-ohmmeter will be necessary for some of these checks.

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.

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.

6.2 TrOuBleSHOOTInG GuIDe

a. Difficult Starting.

• Change electrode

• Change nozzle

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

• Check air pressure 55 -65 psi (4 - 5 bar)

• Check torch power cable for continuity

Depress torch switch. After 2 seconds, is high frequency present?

Yes

Is the "Air" LED light on

Yes No

Repair/replace power source

Repair/replace control PCB

No

Repair/replace high frequency unit

31

section 6

B. no air

Is air hose connected?

Yes No Connect

Is air adjusted to 55 - 65psi (4 - 5 bar)?

Yes No

Does air come on with air check switch?

Yes No

Check continuity of torch switch

OK No

Adjust

• No electrode in torch

• No valve pin in torch

• Replace electrode

• Replace valve pin

Replace torch switch

Repair /replace power source

trouBleshooting 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 HandyPlasma ® 550 power switch is OFF?

Yes No

Replace solenoid valve

Repair/replace control

32

PCB

section 6 trouBleshooting

D. On/Off switch light not energized.

Is switch ON?

Yes No Turn on switch

Is plug in receptacle?

Yes No Insert plug

Is cooling fan turning?

Yes No

Replace

On/Off switch

Check voltage at receptacle and input power line

Yes No Check main fuses

Replace On/Off switch

33

section 6 trouBleshooting e. Temperature leD light On.

Is the unit overheated?

(LED turns off when unit cools down.)

f.

Yes

Duty cycle exceeded:

40% @ 35 A or 100% @ 22 A output

no current output

No

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

Is cooling air flowing?

Yes No

Repair power source Repair fan

Yes No

See (D.) sequence above

Unsolved

Repair/replace Inverter

34

section 6 trouBleshooting

35

section 6

6.3 SeQuence Of OperaTIOn

trouBleshooting

TORCH SWITCH

PUSH

GAS SOLENOID VALVE

2 SEC.

OPEN

PREFLOW

RELEASE

FLOW SWITCH CLOSE

CLOSE

10 SEC

Postflow

OPEN

FAULT OVERLOAD LIGHT

HF CIRCUIT

INVERTER

CUTTING ARC (CURRENT)

ENERGIZE

nOTeS:

1. When the torch switch is depressed during postflow period, the postflow and preflow times are canceled, and the HF is energized immediately. The postflow time starts from the moment the torch switch is released.

2. When the amber fault pilot light comes on, cutting operation should be stopped.

36

section 7 replacement parts

7.0 replacement parts

7.1 general

Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on the unit nameplate.

7.2 ordering

To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this equipment. The use of non-ESAB parts may void your warranty.

Replacement parts may be ordered from your ESAB Distributor.

Be sure to indicate any special shipping instructions when ordering replacement parts.

Refer to the Communications Guide located on the back page of this manual for a list of customer service phone numbers.

note

Bill of material items that have blank part numbers are provided for customer information only.

Hardware items should be available through local sources.

37

section 7 replacement parts

section 7

Item no.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

part no.

0558004493Y

0558002033

0558002754

0558002755

0558002756

0558002757

0558002738

0558004479

951202

0558004399

0558002746

0558002747

0558002764

0558004498

680560

21710

21711

0558004494Y

0558004478

Spare parts list

Handyplasma

®

550

Description

Cover (Not Shown)

Knob

Inverter/Main PCB

Control PCB

HF PCB

HF Generator

Fan

Fan Grid

Flow Switch

Main Power Cable w/Plug 10Ft.

EMI Filter

ON/OFF Switch

Solenoid Valve Assembly

Plasma Torch

Earth Cable w/Clamp

Air Regulator/Filter

Pressure Gauge

Side Panel (Not Shown)

Handle (Not Shown)

replacement parts cct. ref.

VR1 & 2

S1

notes

40

notes

41

notes

42

reVision historY

1. "A" revision of this manual denotes changes and additions to the replacement parts section and incorporates various editorial changes.

2. "B" revision changes Spare Parts Kit from 21980 to 0558003301.

3. Revision "C" -

Front - Deleted "208" reference in description.

Section 1 - Table 1-2, changed NOTE p/n from: 21985 to: 0558004498.

Section 1 - Table 1-3, deleted 208 V & 29 A reference at Rated Primary Input row.

Section 2 - Deleted "

DO nOT connect a power source configured for 208/230 V to a 460 V input

power supply." from caution paragraph.

Section 2 - Table 2-1, deleted 208 V / 29 A row.

Section 2 - Deleted "200/208" reference in heading and added "230".

Section 3 - Enlarged figure 3-2.

4. Added schematic per Larry Bryant request.

5. Revision "D" - 05/2005 - added Air Line Filter Regulator p/n 0558005394 note in Replacement Parts section per CN

#053013. Updated format.

6. Revision "D" - 12/2005 - Removed Air Line Filter Regulator p/n 0558005394 note in Replacement Parts section per D.

Smith.

43

C.

B.

D.

A.

E.

F.

G.

H.

esaB Welding & cutting products, Florence, sc Welding equipment communication guiDe - customer serVices

CUSTOMER SERVICE QUESTIONS:

Telephone: (800)362-7080 / Fax: (800) 634-7548

Order Entry Product Availability

Hours: 8:00 AM to 7:00 PM EST

Pricing Order Information Returns

ENGINEERING SERVICE:

Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST

Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting

TECHNICAL SERVICE:

Telephone: (800) ESAB-123/ Fax: (843) 664-4452

Part Numbers Technical Applications Specifications

LITERATURE REQUESTS:

Telephone: (843) 664-5562 / Fax: (843) 664-5548


Equipment Recommendations


WELDING EQUIPMENT REPAIRS:

Telephone: (843) 664-4487 / Fax: (843) 664-5557

Repair Estimates Repair Status


WELDING EQUIPMENT TRAINING

Telephone: (843)664-4428 / Fax: (843) 679-5864

Training School Information and Registrations

WELDING PROCESS ASSISTANCE:

Telephone: (800) ESAB-123

TECHNICAL ASST. CONSUMABLES:

Telephone : (800) 933-7070




iF You Do not KnoW Whom to call

Telephone: (800) ESAB-123

Fax: (843) 664-4462

Hours: 7:30 AM to 5:00 PM EST or visit us on the web at http://www.esabna.com

The ESAB web site offers

Comprehensive Product Information

Material Safety Data Sheets

Warranty Registration

Instruction Literature Download Library

Distributor Locator

Global Company Information

Press Releases

Customer Feedback & Support

F15-706-D 12/2005

No results