Related Manuals for ESAB HandyPlasma 250
Summary of Contents for ESAB HandyPlasma 250
- Page 1 HandyPlasma ® Plasmarc™ Cutting System ESAB P/N 0558004440 - 115V, 1-Phase, 50/60 Hz Instruction Manual 0558005320 05 / 2007...
- 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 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
TABLE OF CONTENTS SECTION TITLE PAGE PARAGRAPH SECTION 1 DESCRIPTION ......................17 General .......................... 17 Scope ..........................17 System Available ......................17 Specifications ......................18 SECTION 2 INSTALLATION......................21 General .......................... 21 Equipment Required ....................21 Location ........................21 Inspection ........................21 Primary Electrical Input Connections .............. - Page 4 TABLE OF CONTENTS...
-
Page 5: Safety Precautions
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 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 SAFETY PRECAUTIONS 1. Always have qualified personnel perform the instal- 5. WARNING: This product, when used for welding lation, troubleshooting, and maintenance work. or cutting, produces fumes or gases Do not perform any electrical work unless you are which contain chemicals known to qualified to perform such work.
- Page 8 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 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 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 SEGURIDAD 5. ADVERTENCIA-- Este producto cuando se uti- 1. Siempre tenga personal cualificado para efec- liza para soldaduras o cortes, tuar l a instalación, diagnóstico, y mantenimiento produce humos o gases, los del equipo. No ejecute ningún trabajo eléctrico a cuales contienen químicos menos que usted esté...
- Page 12 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 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 récapitulent les informations de précaution laitier incandescent ou les étincelles provenant des références dans la section peuvent également provoquer un des Informations de sécurité...
- Page 14 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. Branchez la pièce à traiter à une bonne mise de A.
- Page 15 SÉCURITÉ ENTRETIEN DE L'ÉQUIPEMENT -- Un équipe- 5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé ment entretenu de façon défectueuse ou dans une opération de soudage ou de inadéquate peut causer des blessures coupage, dégage des vapeurs ou des graves ou mortelles. Par conséquent : gaz contenant des chimiques consi- déres par l'état de la Californie comme 1.
- Page 16 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
DO NOT USE ANY TORCH WITH THIS POWER SOURCE to input power and a source of prefiltered compressed air OTHER THAN THE ESAB BRAND PT-31XL TORCH. SERIOUS (90-150 psig / 6.2-10.3 bar). The HandyPlasma 250 system ®... -
Page 18: Specifications
PT-31XL Length 16" (406mm) Height 8" (203mm) Dimensions of HandyPlasma 250 Width 6" (152mm) Weight (with torch) 16 lbs. (7.3kg) * 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;... -
Page 19: Section 1 Description
SECTION 1 DESCRIPTION Table 1-3 PT-31XL Torch Specifications PT-31XL Torch 75° Torch Current Capacity ............50A DCSP Shipping Wgt............20 lbs (9.1 kg) Length of Service Lines .........12 ft. (3.7 m) 5.25" (133mm) PT-31XL Torch Assembly P/N 0558005300 is supplied with the nozzle, electrode, swirl baffle, and heat shield as- Figure 1-1. - Page 20 SECTION 1 DESCRIPTION...
-
Page 21: Installation
SECTION 2 INSTALLATION 2.1 GENERAL 2.5 PRIMARY ELECTRICAL INPUT CONNECTIONS Proper installation will insure satisfactory and trouble-free operation of the HandyPlasma 250 cutting package. It is ® suggested that each step in this section be studied carefully WARNING and followed. 2.2 EQUIPMENT REQUIRED ELECTRIC SHOCK CAN KILL! PRECAUTIONARY MEASURES SHOULD BE TAKEN TO PROVIDE MAXIMUM PROTECTION... - Page 22 SECTION 2 INSTALLATION 2.5 PRIMARY ELECTRICAL INPUT CONNECTIONS Recommendations for Proper Operating Performance: Proper Extension Cord When the use of an extension cord is needed, the recommended size and length is 14AWG/25ft respectively. Anything out- side the recommended specifications could cause lost in power resulting poor cut quality and capacity. Exclusive wall Outlet For optimal performance, use an exclusive wall outlet.
-
Page 23: 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 WARNING 1 and 2 of white plug located in the lower right corner... - Page 24 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 HandyPlasma 250 Secondary Interconnection Diagram ®...
- Page 25 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 26: Pt-31Xl Torch Consumables Installation
VOLTAGE IF THE TORCH SWITCH the shield is removed. Replace if necessary. IS ACCIDENTALLY CLOSED WHEN THE SHIELD IS REMOVED. AL- WAYS REPLACE TORCH WITH THE PROPER TORCH MANUFAC- TURED BY ESAB SINCE IT ALONE CONTAINS ESAB'S PATENTED SAFETY INTERLOCK. 19667 20282 18785... -
Page 27: Operation
SECTION 3 OPERATION 3.0 OPERATION To ensure that the HandyPlasma 250 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 75 psig (5.2 bar) before cutting operations begin. -
Page 28: Operation
SECTION 3 OPERATION CAUTION 3.1 OPERATION WARNING Position the HandyPlasma® 250 at least 10 feet (3 meters) from the cutting area. Sparks and hot slag from the cut- ting operation can damage the unit. ELECTRIC SHOCK CAN KILL. • DO NOT OPERATE THE UNIT WITH THE COVER RE- HandyPlasma 250 CONTROLS ®... -
Page 29: Assembling Pt-31Xl Consumable Parts
ACCIDENTALLY CLOSED WHEN THE SHIELD IS REMOVED. ALWAYS REPLACE TORCH WITH THE PROPER TORCH On/Off Switch (Orange light) - will light when power MANUFACTURED BY ESAB SINCE IT ALONE CONTAINS supply is switched on and power is applied. ESAB’S PATENTED SAFETY INTERLOCK. - Page 30 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 the console at least 10 ft.
-
Page 31: Operating Techniques
250, refer to the maintenance ® Output Cutting section of this manual. If the problem is not corrected after Thickness Current Speed referring to the maintenance section, contact your ESAB Material (in. / mm) (Amps) (ipm / mm/m) representative. Carbon .06 (1.6) - Page 32 SECTION 3 OPERATION...
-
Page 33: Maintenance
Remove the piston plug. 4.2 INSPECTION AND CLEANING Remove the spring (FS-4 only). Use care when handling Frequent inspection and cleaning of the HandyPlasma 250 is spring to prevent distortion. recommended for safety and proper operation. Some sug- gestions for inspecting and cleaning are as follows: Remove the piston. -
Page 34: Pt-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. This will prevent the nozzle, electrode, and swirl baffle from falling free when the shield is removed. WARNING The gas flow check valve is part of the safety interlock and is permanently as- sembled in the torch head. -
Page 35: Power Cable And Switch Disassembly Sequence
SECTION 4 MAINTENANCE 4.5 POWER CABLE AND SWITCH DISASSEMBLY SEQUENCE... - Page 36 SECTION 4 MAINTENANCE...
-
Page 37: Troubleshooting Guide
SECTION 5 TROUBLESHOOTING 5.1 TROUBLESHOOTING The cause of control malfunctions can be found by referring to the sequence of operations and electrical schematic diagram WARNING 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 38 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? Yes • No electrode in torch • No valve pin in torch • Replace electrode Check continuity of torch switch • Replace valve pin Replace torch switch Repair /replace power source...
-
Page 39: Troubleshooting
SECTION 5 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 HandyPlasma 250 power switch is OFF? ®... - Page 40 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 41 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: 20% @ 18A Repair power source Repair fan No current output Is input voltage within -10% of units input rating? See "D"...
-
Page 42: 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 43: General
6.1 GENERAL 6.2 ORDERING Replacement Parts are illustrated on the following figures. Replacement parts may be ordered from your ESAB distribu- When ordering replacement parts, order by part number tor or from: and part name, as illustrated on the figure. - Page 44 SECTION 6 REPLACEMENT PARTS HANDY PLASMA 250 – SPARE PARTS HANDY PLASMA 250 SPARE PARTS Inverter block – lateral views Rear Front Front Rear...
-
Page 45: Replacement Parts
SECTION 6 REPLACEMENT PARTS HANDY PLASMA 250 SPARE PARTS LIST Item No. ESAB Part No. Description 0558004440 Handy Plasma 250 0558006063 Lid with Handle 0558006064 Power Logics PCB 0558006065 Control PCB 0558006066 Control / HF PCB 0558006067 HF Generator 0700156006 Air Nipple, 0.125"... - Page 46 SECTION 6 REPLACEMENT PARTS...
-
Page 47: Revision History
Revision History Original release 03 / 2005 02 / 2006 - Updated replacement parts per Tecla supplied information. 06 / 2006 - Removed board schematics and added machine schematic sent by Tecla. 09 / 2006 - At Figures 2-6, 3-2 & 4-3 changed "XT" to Standard, removed p/n 19679 & changed P/N 28785 to 18785. 05 / 2007 - Added "Recommendations for Proper Operating Performance"... - Page 48 ESAB Welding & Cutting Products, Florence, SC Welding Equipment COMMUNICATION GUIDE - CUSTOMER SERVICES A. 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 B. ENGINEERING SERVICE:...
Need help?
Do you have a question about the HandyPlasma 250 and is the answer not in the manual?
Questions and answers