Handy Plasma 70

Handy Plasma 70
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
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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
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INSTRUCTION MANUAL
1 DIRECTIVE
DECLARATION OF CONFORMITY
ESAB Welding Equipment AB, S-695 81 Laxå, 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
Tel: +46-584-81000
Fax: +46-584-411924
2 SAFETY
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.
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INSTRUCTION MANUAL
Note! This product is solely intended for plasma cutting
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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 PT27 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
List 3.1.1
Equipment
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
0558000363
N° 3 Electrode, P/N (33366XL)
0558000364
N° 1 Swirl Baffle, P/N (33367)
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
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INSTRUCTION MANUAL
4 TECHNICAL DATA
4.1 SPECIFICATIONS
Rated Output
40% Duty Cycle*
70A @ 128V dc
60% Duty Cycle*
54A @ 121V dc
100% Duty Cycle*
45A @ 118V dc
Output Current Range
26 to 70 Amperes
Open Circuit Voltage
250 V dc Nominal
Rated Primary Input I1max
@ 70A 128Vdc Output
400 Vac 50/60 Hz,
3 - Phase
Power factor @ 70 A Output
21 Ampere
0,8
Current Capacity
PT-27
Air Requirements
PT-27
150 lt/min @ 5.2 bar
Dimensions of HandyPlasma 70
Length
Height
Width
550 mm
410 mm
190 mm
Weight (less torch)
70 A dc SP
19 kg
Insulation class: F
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.
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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
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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.
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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
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Manometer
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Torch
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ON/OFF
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Switch
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Air Check
Switch
2
Overheating LED
3
6.2
Earth
Connector
4
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.
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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
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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.
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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.
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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
power source
Repair/replace
control PCB
Repair/replace HF PCB
Control
Flow Switch
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B.
INSTRUCTION MANUAL
No Air
Is air hose connected?
Yes
No
Connect
Is air adjusted to 4 - 5 bar ?
Yes
No
Adjust
Check torch integrity
Yes
No
•
•
•
•
Check continuity of torch switch
OK
No
No electrode in torch
No valve pin in torch
Replace electrode
Replace valve pin
Replace torch switch
Repair/replace power source
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
Replace
solenoid valve
No
Repair/replace
control PCB
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D.
INSTRUCTION MANUAL
ON/OFF Switch light not energized.
Is main 400 Volt switch ON?
Yes
No
Turn on switch
No
Insert plug in receptacle
Is plug in receptacle?
Yes
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
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E.
INSTRUCTION MANUAL
Temperature LED light ON.
Is the unit overheated?
("Fault" lights turns off
when Unit cools down.)
Yes
No
Is cooling air flowing?
Duty cycle exceeded:
45% @ 70 A
or 100% @ 50 A output
Yes
Repair power source
F.
No current output
Is input voltage within ±10% of units input rating?
Yes
No
See (D.) sequence above
Unsolved
Repair power source
15
No
Repair fan
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INSTRUCTION MANUAL
8.2 SEQUENCE OF OPERATION
A.
LOCK-IN "OFF" position
PUSH
RELEASE
TORCH SWITCH
OPEN
CLOSE
GAS SOLENOID VALVE
2 SEC.
PREFLOW
10 SEC
Postflow
FLOW SWITCH
CLOSE
OPEN
OVERHEATING LIGHT
ENERGIZE
HF CIRCUIT
INVERTER
PILOT ARC (CURRENT)
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.
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INSTRUCTION MANUAL
9 - ORDERING SPARE PARTS
9.1 - Detail pictures - Handy Plasma 70
9 26
12
8
6
3
16
14
10
15
Rear
7
22
Front
11
19
2
20
5
18
17 - Power module - bottom side
21 - INPUT PCB
4 - HF PCB
13 - Inverter PCB
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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.
PART NO.
DESCRIPTION
1
0700157001
2
0700158001
LID WITH HANDLE
BOTTOM CASE (CHASSIS)
3
0700158002
CONTROL PCB
4
0700157004
HIGH FREQUENCY PCB
5
0700157005
HF GENERATOR
6
0700156006
AIR NIPPLE 1/8” Dia. 8mm, L=20mm
7
0700157007
POWER CABLE
8
0558000487
PT - 27 TORCH Ass.ly
9
0700157008
AIR GAUGE FILTER
10
0700156009
FAN
11
0700157010
EMC FILTER
12
0558000410
FLOW SWITCH P/N 951202
13
0700157011
INVERTER PCB
14
0700157012
ON/OFF SWITCH KNOB ASS.LY
15
0700157013
EARTH CABLE W/CLAMP, L=8m
16
0700157014
FAN GRID
17
0700158003
POWER MODULE
18
0700157016
CHOKE (INDUCTANCE)
19
0700158004
TRANSFORMER
20
0700157018
HEAT SINK WITH DIODES
21
0700157019
INPUT PCB MODULE
22
0700157020
AUXILLARY TRANSFORMER
23
0700157021
24
0700157022
MANOMETER (FRONT PANEL)
25
0700157023
AIR CHECK SWITCH (FRONT PANEL)
26
0700157024
SOLENOID VALVE ASS.LY
27
0700158031
Multilanguage user manual
10 ACCESSORIES
For plasma torch PT - 27, please see section 3.1 Equipment, page 4.
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