ESAB HandyPlasma 550 Installation, Operation And Service Manual
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ESAB HandyPlasma 550 Installation, Operation And Service Manual

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®
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

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Summary of Contents for ESAB HandyPlasma 550

  • Page 1: Safety - Spanish

    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...
  • Page 2 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,”...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Section / Title Page Safety Precautions ..................................5 Safety - English ................................5 Safety - Spanish ................................9 Safety - French ................................13 Description ....................................17 General ..................................17 Scope ....................................17 Packages Available ..............................17 Specifications ................................18 Installation ....................................21 General ...................................21 Equipment Required ..............................21 Location ..................................21 Inspection ..................................21...
  • Page 4 TABLE OF CONTENTS...

  • Page 5: Safety Precautions

    SECTION 1 SAFETY PRECAUTIONS Safety Precautions Safety - English WARNING: These Safety Precautions are FIRES AND EXPLOSIONS -- Heat from for your protection. They summarize pre- flames and arcs can start fires. Hot cautionary information from the references slag or sparks can also cause fires and listed in Additional Safety Information sec- explosions.
  • Page 6 SECTION 1 SAFETY PRECAUTIONS 1. Be sure the power source frame (chassis) is con- 3. Welders should use the following procedures to nected to the ground system of the input power. minimize exposure to EMF: 2. Connect the workpiece to a good electrical A.
  • Page 7 SECTION 1 SAFETY PRECAUTIONS 5. WARNING: This product, when used for welding 1. Always have qualified personnel perform the instal- or cutting, produces fumes or gases lation, troubleshooting, and maintenance work. which contain chemicals known to Do not perform any electrical work unless you are the State of California to cause birth qualified to perform such work.
  • Page 8 SECTION 1 SAFETY PRECAUTIONS 5. AWS C5.5 - "Recommended Practices for Gas Tung- sten Arc Welding“ 6. AWS C5.6 - "Recommended Practices for Gas Metal Arc Welding"“ 7. AWS SP - "Safe Practices" - Reprint, Welding Hand- book. 8. ANSI/AWS F4.1, "Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances."...

  • Page 9: Description

    ® 550 packages available as well as perfor- mance specifications. 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 ®...

  • Page 10: Specifications

    SECTION 2 DESCRIPTION 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 40% Duty Cycle* 35 A @ 120 V dc Output 60% Duty Cycle* 30 A @ 120 V dc 100% Duty Cycle* 22 A @ 120 V dc...
  • Page 11 SECTION 2 DESCRIPTION Table 2-3. PT-31XL Torch Specifications PT-31XL Torch 75° Torch Current Capacity ............50A DCSP Shipping Wgt............... 2 lbs (1 kg) 5 1/4" Length of Service Lines ........25-ft. (7.6 m) (133mm) Figure 2-1. PT-31XL Dimensions Figure 2-2. PT-31XL Cutting Performance...
  • Page 12 SECTION 2 DESCRIPTION...

  • Page 13: Installation

    SECTION 3 INSTALLATION 3.5 PRIMARY ELECTRICAL INPUT 3.1 GENERAL CONNECTIONS FIGURE 31 Proper installation can contribute materially to the satisfac- ® tory and trouble-free operation of the HandyPlasma cutting package. It is suggested that each step in this section ELECTRIC SHOCK CAN KILL! Precautionary measures be studied carefully and followed as closely as possible.

  • Page 14: Secondary (Output) Connections

    SECTION 3 INSTALLATION The torch connections are located at the flowswitch 3.6 SECONDARY OUTPUT CONNECTIONS on upper left side of machine. REFER TO FIG. 31 Thread the power cable and switch lead of the PT- 31XL through the right side (above pressure gauge) Torch comes factory installed.

  • Page 15: Connecting Handyplasma ® 550

    SECTION 3 INSTALLATION ® CONNECTING HANDYPLASMA 550 FOR 230 Vac INPUT PT-31XL WORK CABLE WORK SAFETY GROUND 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)
  • Page 16 SECTION 3 INSTALLATION EARTH GROUND DO NOT ATTACH WORK CABLE TO PIECE BEING CUT FREE WORK CABLE GROUNDED WORK TABLE BE SURE WORK IS IN GOOD CONTACT WITH TABLE. EARTH GROUND WORK CABLE...

  • Page 17: Operation

    SECTION 4 OPERATION 4.1 OPERATION ® 4.2 HANDYPLASMA 550 CONTROLS (FIGURE 4-1) Power Switch (located on front panel). When placed in ON position, the white pilot light will glow ELECTRIC SHOCK can kill. indicating control circuit is energized and the cooling •...

  • Page 18: Cutting With The Pt-31Xl

    ALWAYS REPLACE TORCH WITH THE PROPER TORCH MANUFACTURED BY ESAB Air Pressure Gauge (Front Panel) - Shows air pressure SINCE IT ALONE CONTAINS ESAB’S PATENTED SAFETY in bars and psi.
  • Page 19 SECTION 4 OPERATION WHEN THE ARC BREAKS THROUGH THE WORK, BRING THE TORCH TO AN UPRIGHT POSI- TION AND PROCEED TO CUT. TO START A PIERCE, TILT THE TORCH TO PREVENT MOLTEN MATERIAL FROM COMING BACK AGAINST AND DAMAG- ING THE TORCH. Figure 4-4.

  • Page 20: Operating Techniques

    If the problem is not corrected Loose cable or hose connections. after referring to the maintenance section, contact your Electrode and/or cutting nozzle in poor condi- ESAB representative. tion. Insufficient Penetration. Main Arc Does Not Strike.

  • Page 21: Maintenance

    SECTION 5 MAINTENANCE 5.1 GENERAL 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. If this equipment does not operate properly, stop work 5.3 FLOW SWITCH FIGURE 51...
  • Page 22 SECTION 5 MAINTENANCE...

  • Page 23: Troubleshooting

    SECTION 6 TROUBLESHOOTING 6.1 TROUBLESHOOTING The cause of control malfunctions can be found by referring to the sequence of operations and electri- cal 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 discon- nected.
  • Page 24 SECTION 6 TROUBLESHOOTING No Air Is air hose connected? Connect Is air adjusted to 55 - 65psi (4 - 5 bar)? Adjust Does air come on with air check switch? • No electrode in torch • No valve pin in torch •...
  • Page 25 SECTION 6 TROUBLESHOOTING On/Off switch light not energized. Is switch ON? Turn on switch Is plug in receptacle? Insert plug Is cooling fan turning? Replace On/Off switch Check voltage at receptacle and input power line Check main fuses Replace On/Off switch...
  • Page 26 SECTION 6 TROUBLESHOOTING Temperature LED light ON. Is the unit overheated? (LED turns off when unit cools down.) Is cooling air flowing? Duty cycle exceeded: 40% @ 35 A or 100% @ 22 A output Repair power source Repair fan No current output Is input voltage within -10% of units input rating? See (D.) sequence above...
  • Page 27 SECTION 6 TROUBLESHOOTING...

  • Page 28: Sequence Of Operation

    SECTION 6 TROUBLESHOOTING SEQUENCE OF OPERATION PUSH RELEASE TORCH SWITCH OPEN CLOSE GAS SOLENOID VALVE 2 SEC. PREFLOW 10 SEC Postflow OPEN FLOW SWITCH CLOSE FAULT OVERLOAD LIGHT ENERGIZE HF CIRCUIT INVERTER CUTTING ARC (CURRENT) NOTES: When the torch switch is depressed during postflow period, the postflow and preflow times are canceled, and the HF is energized immediately.

  • Page 29: Replacement Parts

    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.
  • Page 30 SECTION 7 REPLACEMENT PARTS...

  • Page 31: Spare Parts List

    SECTION 7 REPLACEMENT PARTS Spare Parts List ® HandyPlasma Item No. Part No. Description Cct. Ref. 0558004493Y Cover (Not Shown) 0558002033 Knob 0558002754 Inverter/Main PCB 0558002755 Control PCB 0558002756 HF PCB 0558002757 HF Generator 0558002738 VR1 & 2 0558004479 Fan Grid 951202 Flow Switch 0558004399...
  • Page 32 NOTES...
  • Page 33 NOTES...
  • Page 34 NOTES...

  • Page 35: Revision History

    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.
  • Page 36 ESAB Welding & Cutting Products, Florence, SC Welding Equipment COMMUNICATION GUIDE - CUSTOMER SERVICES CUSTOMER SERVICE QUESTIONS: Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST Order Entry Product Availability Pricing Order Information Returns ENGINEERING SERVICE:...

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