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Prest-O-Lite 550 Instruction Manual

Installation, operation and service
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Instruction Manual
Installation, Operation and Service
Prest-O-Lite® 550 Plasma Cutter
Prest-O-Lite® 550 Plasma Cutter P/N 0558006058 - 230 V, 1-Phase, 50/60 Hz - North America
Form No: 0558006082
03 / 2007

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Summary of Contents for Prest-O-Lite 550

  • Page 1 Instruction Manual Installation, Operation and Service Prest-O-Lite® 550 Plasma Cutter Prest-O-Lite® 550 Plasma Cutter P/N 0558006058 - 230 V, 1-Phase, 50/60 Hz - North America Form No: 0558006082 03 / 2007...

  • Page 2: User Responsibility

    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

    Connecting Prest-O-Lite 550 ..........................23 ® Operation ....................................25 Operation ..................................25 Prest-O-Lite 550 Controls ............................25 ® Assembling PT-31XL Consumable Parts ......................26 Cutting with the PT-31XL ............................26 Operating Techniques .............................. 28 Common Cutting Problems ........................... 28 Maintenance ....................................29 General ..................................
  • 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 4. Locate cylinders away from heat, sparks, and flames. The following publications, which are available from Never strike an arc on a cylinder. the American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are recommended to you: 5. For additional information, refer to CGA Standard P-1, "Precautions for Safe Handling of Compressed Gases...
  • 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: Safety - Spanish

    sectioN 1 seguriDaD safety - spanish La escoria puede estar caliente y desprenderse con velocidad. Personas cercanas deberán usar gafas aDVerteNcia: Estas Precauciones de Se- de seguridad y careta protectora. guridad son para su protección. Ellas hacen resumen de información proveniente de las Fuego Y explosioNes -- el calor de referencias listadas en la sección "Información Adi- las flamas y el arco pueden ocacionar...
  • Page 10 sectioN 1 seguriDaD 1. Asegúrese de que el chasis de la fuente de poder 3. Los soldadores deberán usar los siguientes proced- esté conectado a tierra através del sistema de imientos para minimizar exponerse al EMF: electricidad primario. 2. Conecte la pieza de trabajo a un buen sistema de A.
  • Page 11 Las siguientes publicaciones, disponibles através de 3. Cuando el cilindro no está en uso, mantenga la la American Welding Society, 550 N.W. LeJuene Road, válvula del cilindro cerrada. Ponga el capote de Miami, FL 33126, son recomendadas para usted: protección sobre la válvula si el regulador no...
  • Page 12 sectioN 1 seguriDaD sigNiFicaDo De los simBolos -- según usted avanza en la lectura de este folleto: los símbolos sig- nifican ¡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.

  • Page 13: Safety - French

    sectioN 1 sÉcuritÉ safety - French iNceNDies et explosioNs -- la chaleur provenant des flammes ou de aVertissemeNt : Ces règles de sécurité l'arc peut provoquer un incendie. le ont pour but d'assurer votre protection. Ils laitier incandescent ou les étincelles récapitulent les informations de précaution provenant des références dans la section peuvent également provoquer un...
  • Page 14 sectioN 1 sÉcuritÉ 1. Assurez-vous que le châssis de la source 3. Les soudeurs doivent suivre les procédures suivantes d'alimentation est branché au système de mise à pour minimiser l'exposition aux champs électriques la terre de l'alimentation d'entrée. et magnétiques : 2.
  • Page 15 à votre disposition par l'American Welding flammes. Ne jamais amorcer l'arc sur un cylindre. Society, 550 N.W. LeJuene Road, Miami, FL 33126 : 5. Pour de l'information supplémentaire, consultez 1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"...
  • Page 16 sectioN 1 sÉcuritÉ 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.

  • Page 17: Description

    ® 550 packages available as well as performance specifications. Do not use any torch with this power source other than the prest-o-lite brand pT-31Xl torch. serious injury may occur if used with any other torch. 2.3 pacKaGe aVaIlaBle Prest-O-Lite® 550 Plasma Cutter ............................P/N 0558006058...

  • Page 18: Specifications

    2 DescriptioN 2.4 specIfIcaTIons Refer to Tables 2-2, 2-3, and Figures 2-1 and 2-2 for Prest-O-Lite 550 technical specifications. ® Table 2-2. prest-o-lite 550 specifications ® Rated 40% Duty Cycle* 35 A @ 120 V dc Output 60% Duty Cycle*...
  • Page 19 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 20 sectioN 2 DescriptioN...

  • Page 21: Installation

    Adequate ventilation is necessary to provide proper cool- ing of the Prest-O-Lite ® 550 and the amount of dirt, dust, The Prest-O-Lite 550 power source operating on 230 V, ® and excessive heat to which the equipment is exposed, 1-phase input power is equipped with a 8-ft, 3-conductor should be minimized.

  • Page 22: 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 23: Connecting Prest-O-Lite ® 550

    3 iNstallatioN connecTInG presT-o-lITe 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...
  • Page 24 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 25: Operation

    550 at least 10 feet (3 me- ® ters) from the cutting area. sparks and hot slag from the cutting operation can damage the unit.

  • Page 26: Assembling Pt-31Xl Consumable Parts

    TorcH WITH THe proper TorcH manufacTureD air pressure Gauge (front panel) - Shows air pressure By prest-o-lite sInce IT alone conTaIns prest-o- lite’s paTenTeD safeTy InTerlocK. in bars and psi. For additional torch information, see booklet (F-14-246) packed with the PT-31XL torch.
  • Page 27 TO PREVENT MOLTEN MATERIAL FROM COMING BACK AGAINST AND DAMAG- ING THE TORCH. figure 4-4. piercing Technique using the pT-31Xl cutting speed range — prest-o-lite ® CAUTION: Locate the console at least 10-ft. from the cutting (using air with XT consumables @ 75 psi) work area.

  • Page 28: Section 4 Operation

    Listed below are common cutting problems followed by the unstable cutting conditions. probable cause of each. If problems are determined to be caused by the Prest-O-Lite 550, refer to the maintenance ® Incorrect cutting speed. section of this manual. If the problem is not corrected Loose cable or hose connections.

  • Page 29: Maintenance

    550. ® Remove the piston. 5.2 InspecTIon anD cleanInG Clean all parts with cleaning agent. Frequent inspection and cleaning of the Prest-O-Lite 550 is ® recommended for safety and proper operation. Some sug- noTe gestions for inspecting and cleaning are as follows: ensure cleaning agent does not contain solvents which can degrade polysulfone.
  • Page 30 sectioN 5 maiNteNaNce...

  • Page 31: 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 32 Repair /replace power source air does not shut off Does arc start when nozzle contacts work without depressing torch switch? Check for short in torch switch Does air flow even when Prest-O-Lite 550 power switch is OFF? ® Replace Repair/replace control...
  • Page 33 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 34 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 35 sectioN 6 trouBleshootiNg...

  • Page 36: 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 37: Replacement Parts

    To ensure proper operation, it is recommended that only genuine Prest-O-Lite parts and products be used with this equipment. The use of non-Prest-O-Lite parts may void your warranty. Replacement parts may be ordered from your Prest-O-Lite Distributor.
  • Page 38 sectioN 7 replacemeNt parts...

  • Page 39: Spare Parts List

    7 replacemeNt parts spare parts list prest-o-lite ® 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...
  • Page 40 Notes...
  • Page 41 Notes...
  • Page 42 Notes...

  • Page 43: Revision History

    reVisioN historY Original release 06 / 2006 03 / 2007 - Revised Title Page layout / text.
  • Page 44 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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