Prest-O-Lite 380 Instruction Manual
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Prest-O-Lite 380 Instruction Manual

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Instruction Manual
Installation, Operation and Service
Prest-O-Lite
380 Plasma Cutter
®
Prest-O-Lite®380 Plasma Cutter P/N 0558006057 - 230 V, 1-Phase, 50/60 Hz
Form No: 0558006081
03 / 2007

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  • Page 1 Instruction Manual Installation, Operation and Service Prest-O-Lite 380 Plasma Cutter ® Prest-O-Lite®380 Plasma Cutter P/N 0558006057 - 230 V, 1-Phase, 50/60 Hz Form No: 0558006081 03 / 2007...
  • Page 2 Be SURe ThIS INFORmATION ReACheS The OPeRATOR. YOU CAN GeT exTRA COPIeS ThROUGh YOUR SUPPlIeR. These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of opera- tion 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

    PT-31XL Torch Consumables Installation ............20 SeCTION 3 OPeRATION ........................ 21 Operation ........................22 Prest-O-Lite 380 Controls..................22 ® Assembling PT-31XL Consumable Parts ............23 Cutting with the PT-31XL ..................23 Operating Techniques ....................25 Common Cutting Problems ................... 25 SeCTION 4 mAINTeNANCe ......................
  • Page 4 TABle OF CONTeNTS...
  • Page 5 SAFeTY PReCAUTIONS from the National Fire Protection Association, Batterymarch WARNING: hese Safety Precautions are for your Park, Quincy, MA 02269. protection. They summarize precautionary infor- mation from the references listed in Additional eleCTRICAl ShOCK -- Contact with live electrical parts and Safety Information section.
  • Page 6 SAFeTY PReCAUTIONS troubleshooting, and maintenance work. Do not FUmeS AND GASeS -- Fumes and gases, perform any electrical work unless you are quali- can cause discomfort or harm, particu- fied to perform such work. larly in confined spaces. Do not breathe Before performing any maintenance work fumes and gases.
  • Page 7 PReCAUCION De SeGURIDAD 6. Después de termirar la operación del equipo, inspeccione el área de ADVeRTeNCIA: Estas Precauciones de Seguridad son trabajo para cerciorarse de que las chispas o metal caliente ocasionen un para su protección. Ellas hacen resumen de información fuego más tarde.
  • Page 8 PReCAUCION De SeGURIDAD hUmO Y GASeS -- el humo y los gases, pueden causar malestar mANTeNImIeNTO Del eQUIPO -- equipo defec- o daño, particularmente en espacios sin ven- tuoso o mal mantenido puede causar daño o tilación. No inhale el humo o gases. el gas de muerte.
  • Page 9 PRéCAUTIONS De SéCURITé ment le bois, les vêtements, la sciure, l’essence, le kérosène, les AVERTISSEMENT: Ces règles de sécurité ont pour objet d’ as- peintures, les solvants, le gaz naturel, l’acétylène, le propane surer votre protection. Veillez à lire et à observer les précautions et autres substances combustibles semblables.
  • Page 10 Practices for Arc Welding, Cutting and Gouging” publié prendre les mesures néces- saires à l’amélioration de par Prest-O-Lite. Nous conseillons également de consulter les publications sui-vantes, tenues à votre disposition par la ventilation. Ne poursuivez pas l’opération entreprise si l’American Welding Society, 550 N.W. LeJuene Road, Miami, le malaise persiste.

  • Page 11: Description

    (90-150 psi). The The purpose of this manual is to provide the operator with Prest-O-Lite 380 system uses the PT-31XL torch to deliver ® all the information required to install and operate the Prest-...

  • Page 12: Specifications

    NOTE: PT-31XL Torch Assembly P/N 0558004482 is supplied with the nozzle, electrode, swirl baffle, and heat shield assembled as part of the Prest-O-Lite 380 system. ® 1.4 SPeCIFICATIONS Refer to Tables 1-2, 1-3, and Figures 1-1 and 1-2 for Prest-O-Lite 380 technical specifications. ® Table 1-2 Prest-O-lite 380 Specifications ®...
  • Page 13 SeCTION 1 DeSCRIPTION Table 1-3 PT-31xl Torch Specifications PT-31xl Torch 75° Torch Current Capacity ............50A DCSP Shipping Wgt............1.5 lbs (0.68 kg) Length of Service Lines .........15 ft. (4.6 m) 5 1/4" (133mm) PT-31XL Torch Assembly P/N 0558004482 is supplied with the nozzle, electrode, swirl baffle, and heat shield as- Figure 1-1.

  • Page 14: 31Xl Torch Technical Data

    SeCTION 1 DeSCRIPTION...

  • Page 15: Installation

    Adequate ventilation is necessary to provide proper cooling of the Prest-O-Lite 380 and the amount of dirt, dust, and ® excessive heat to which the equipment is exposed, should Be sure that the power source is properly configured for be minimized.
  • Page 16 (Receptacle to match plug) Prefiltered AIR SUPPLY (Customer Supplied) PLUG (customer supplied) (90 to 150 psig max) NEMA 6-30 rating minimum (See Table 2.1 and WARNING in regards to chassis ground in Section 2.5.) Figure 2-1 Prest-O-lite 380 Primary Interconnection Diagram ®...

  • Page 17: Secondary (Output) Connections

    SeCTION 2 INSTAllATION 2.6 SeCONDARY (OUTPUT) CONNeCTIONS Torch comes factory installed. These instructions are for Thread the power cable and switch lead of the PT-31XL torch replacement. through the lower left side bushing of the front panel. Connect power cable to the torch fitting (left-hand threads) and connect torch trigger switch leads to pins 1 and 2 of white plug located in the lower right corner of machine.
  • Page 18 SeCTION 2 INSTAllATION 2.6 SeCONDARY (OUTPUT) CONNeCTIONS PT-31XL WORK WORK CABLE SAFETY GROUND Allow at least 10 ft (3 m)   between work and power source Figure 2-3 Prest-O-lite 380 Secondary Interconnection Diagram ®...
  • Page 19 SeCTION 2 INSTAllATION 2.6 SeCONDARY (OUTPUT) CONNeCTIONS EARTH GROUND DO NOT ATTACH WORK CABLE TO PIECE BEING CUT FREE WORK CABLE Figure 2-4 Secondary (Output) Connections GROUNDED WORK TABLE BE SURE WORK IS IN GOOD CONTACT WITH TABLE. EARTH GROUND WORK CABLE Figure 2-5 Secondary (Output) Connections...

  • Page 20: 31Xl Torch Consumables Installation

    Figure 4-3. Check o-ring for AlWAYS RePlACe TORCh WITh damage whenever the shield is removed. Replace if necessary. The PROPeR TORCh mANUFAC- TUReD BY Prest-O-lite SINCe IT AlONe CONTAINS Prest-O-lite'S PATeNTeD SAFeTY INTeRlOCK. 0558006185...

  • Page 21: Operation

    SeCTION 3 OPeRATION 3.0 OPeRATION To ensure that the Prest-O-lite 380 operates correctly please perform the following steps: 1. Turn on main power switch and make sure air is flowing to the machine. Adjust the air regulator to 65 psi before cutting operations begin.

  • Page 22: Operation

    15 second preflow sequence for air pressure adjustment. See Page Position the Prest-O-lite® 380 at least 10 feet (3 meters) from the cutting area. Sparks and hot slag from the cut- ting operation can damage the unit.

  • Page 23: Assembling Pt-31Xl Consumable Parts

    RePlACe TORCh WITh The PROPeR TORCh mANUFAC- off automatically after the machine cools down if the TUReD BY Prest-O-lite SINCe IT AlONe CONTAINS Prest- on/off switch is still on. O-lite’S PATeNTeD SAFeTY INTeRlOCK.
  • Page 24 SeCTION 3 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 3-4 Piercing Technique using the PT-31xl CAUTION: Locate t he c onsole a t l east 1 0-ft. f rom t he c ut-...

  • Page 25: Operating Techniques

    If problems are determined to be Material (In.) (Amps) (ipm) caused by the Prest-O-Lite 380, refer to the maintenance ® section of this manual. If the problem is not corrected after Carbon 1/16 Steel referring to the maintenance section, contact your Prest-O-...
  • Page 26 SeCTION 3 OPeRATION...

  • Page 27: Maintenance

    4.2 INSPeCTION AND CleANING Remove the piston plug. Frequent inspection and cleaning of the Prest-O-Lite 380 is Remove the spring (FS-4 only). Use care when handling recommended for safety and proper operation. Some sug- spring to prevent distortion.

  • Page 28: 31Xl Torch Maintenance

    SeCTION 4 mAINTeNANCe 4.4 PT-31xl TORCh mAINTeNANCe 1. To disassemble the front end, hold the torch with the shield in an upright position. WARNING This will prevent the nozzle, electrode, and swirl baffle from falling free when the shield is removed. Before any maintenance is attempted The gas flow check valve is part of the safety interlock and is permanently as- on this torch, make sure the POWeR...

  • Page 29: Power Cable And Switch Disassembly Sequence

    SeCTION 4 mAINTeNANCe 4.5 POWeR CABle AND SWITCh DISASSemBlY SeQUeNCe...
  • Page 30 SeCTION 4 mAINTeNANCe...

  • Page 31: Troubleshooting

    SeCTION 5 TROUBleShOOTING The cause of control malfunctions can be found by 5.1 TROUBleShOOTING referring to the sequence of operations and electrical schematic diagram and checking the various compo- nents. 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.
  • Page 32 SeCTION 5 TROUBleShOOTING No Air Is air hose connected? Connect Is air adjusted to 65 - 70 psig (4.5 - 4.8 bar)? Adjust Does air come on when main power turned on? • No electrode in torch • No valve pin in torch •...
  • Page 33 TROUBleShOOTING Air does not shut off Does arc start when nozzle contacts work without depressing torch switch? Check for short in torch switch or torch switch leads Does air flow even when Prest-O-Lite ® 380 power switch is OFF? Replace...
  • Page 34 SeCTION 5 TROUBleShOOTING Power switch light not energized. Is switch ON? Turn on switch Is input power plug in receptacle? Insert plug Is cooling fan turning? Check voltage at receptacle and input power line Check main fuses Replace main power switch...
  • Page 35 SeCTION 5 TROUBleShOOTING Temperature leD light ON. Is the unit overheated? (LED turns off when unit cools down.) Is cooling air flowing? Duty cycle exceeded: 35% @ 30 A or 100% @ 21 A output Repair power source Repair fan No current output Is input voltage within -10% of units input rating? See "D"...

  • Page 36: Sequence Of Operation

    SeCTION 5 TROUBleShOOTING SeQUeNCe OF OPeRATION PUSH RELEASE TORCH SWITCH OPEN CLOSE GAS SOLENOID VALVE 10-14 SEC- SECONDS ONDS PREFLOW 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 37: Replacement Parts

    RePlACemeNT PARTS 6.1 GeNeRAl 6.2 ORDeRING Replacement Parts are illustrated on the following figures. Replacement parts may be ordered from your Prest-O-Lite When ordering replacement parts, order by part number distributor or from: and part name, as illustrated on the figure.
  • Page 38 SeCTION 6 RePlACemeNT PARTS rear front front rear rear front front rear rear front front rear...
  • Page 39 58V75 Female Torch Connector Plug: 0558004947 Plug Is Attached To Torch And Connects to Mating Male Connector Located Inside Machine Cover. * See Page 11 for illustration of complete Prest-O-Lite ® 380 package ** Includes Torch & Spare Parts Kit...
  • Page 40 SeCTION 6 RePlACemeNT PARTS...
  • Page 41 Notes...
  • Page 42 Notes...
  • Page 43 Revision history Original release 06 / 2006 03 / 2007 - Revised Title Page layout / text.
  • Page 44 Prest-O-lite Welding & Cutting Products, PO Box 100545, Florence, SC 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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