ESAB HANDY PLASMA 125 Instruction Manual

HANDY PLASMA 125

PLASMA ARC CUTTING PACKAGE - P/N 37884 115V 60HZ

F15-568-D October, 2007

F15-568D

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”, Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or
operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions,
contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.

Table of Contents

Sections

Safety Precautions

Section 1, Descriptions

Section 2, Equipment Supplied

Section 3, Installation

Section 4, Operation

Section 5, Maintenance

Section 6, PT-34 Torch - Installation, Operation, and Maintenance

Section 7, Replacement Parts

Section 8, Electrical Diagrams (Schematic)

Section 8, Electrical Diagrams (Wiring)

Page

1-6

7

7

8,9

10,11

12,13

14-17

18-20

21

22,23

Back Cover Communications and Customer Services
Guide

2

SAFETY PRECAUTIONS

WARNING: These Safety Precautions are for

your protection. They summarize precaution­ary information from the references listed in

Additional Safety Information section. Before
performing any installation or operating procedures, be
sure to read and follow the safety precautions listed below
as well as all other manuals, material safety data sheets,
labels, etc. Failure to observe Safety Precautions can result
in injury or death.

PROTECT YOURSELF AND OTHERS
Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits

ultraviolet (UV) and other radiation and
can injure skin and eyes. Hot metal can cause burns.
Training in the proper use of the processes and equip­ment is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any work

area, even if welding helmets, face shields, and goggles
are also required.

2. Use a face shield fitted with the correct filter and cover

plates to protect your eyes, face, neck, and ears from
sparks and rays of the arc when operating or observing
operations. Warn bystanders not to watch the arc and
not to expose themselves to the rays of the electric-arc
or hot metal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeve

shirt, cuffless trousers, high-topped shoes, and a weld­ing helmet or cap for hair protection, to protect against
arc rays and hot sparks or hot metal. A flameproof apron
may also be desirable as protection against radiated
heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cuffs, or pockets. Sleeves and collars should be
kept buttoned, and open pockets eliminated from the
front of clothing

5. Protect other personnel from arc rays and hot sparks

with a suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag or

grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot slag
or sparks can also cause fires and ex­plosions. Therefore:

1. Remove all combustible materials well away from the

work area or cover the materials with a protective non­flammable covering. Combustible materials include wood,
cloth, sawdust, liquid and gas fuels, solvents, paints and
coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or

crevices in floors or wall openings and cause a hidden
smoldering fire or fires on the floor below. Make certain
that such openings are protected from hot sparks and
metal.“

3. Do not weld, cut or perform other hot work until the

workpiece has been completely cleaned so that there
are no substances on the workpiece which might pro­duce flammable or toxic vapors. Do not do hot work on
closed containers. They may explode.

4. Have fire extinguishing equipment handy for instant use,

such as a garden hose, water pail, sand bucket, or
portable fire extinguisher. Be sure you are trained in its
use.

5. Do not use equipment beyond its ratings. For example,
overloaded welding cable can overheat and create a fire
hazard.

6. After completing operations, inspect the work area to
make certain there are no hot sparks or hot metal which
could cause a later fire. Use fire watchers when neces­sary.

7. For additional information, refer to NFPA Standard 51B,
"Fire Prevention in Use of Cutting and Welding Pro-

--

cesses", available from the National Fire Protection Asso­ciation, Batterymarch Park, Quincy, MA 02269.

ELECTRICAL SHOCK -- Contact with live
electrical parts and ground can cause
severe injury or death. DO NOT use AC
welding current in damp areas, if move­ment is confined, or if there is danger of
falling.

1. Be sure the power source frame (chassis) is connected
to the ground system of the input power.

2. Connect the workpiece to a good electrical ground.

3. Connect the work cable to the workpiece. A poor or
missing connection can expose you or others to a fatal
shock.

4. Use well-maintained equipment. Replace worn or dam­aged cables.

5. Keep everything dry, including clothing, work area, cables,
torch/electrode holder, and power source.

6. Make sure that all parts of your body are insulated from
work

and from ground.

7. Do not stand directly on metal or the earth while working
in tight quarters or a damp area; stand on dry boards or
an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

9. Turn off the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)
for specific grounding recommendations. Do not mistake
the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS —
May be dangerous. Electric current flow­ing through any conductor causes lo­calized Electric and Magnetic Fields
(EMF). Welding and cutting current cre­ates EMF around welding cables and
welding machines. Therefore:

1. Welders having pacemakers should consult their physi­cian before welding. EMF may interfere with some pace­makers.

2. Exposure to EMF may have other health effects which are
unknown.

3. Welders should use the following procedures to minimize
exposure to EMF:
A. Route the electrode and work cables together. Secure

them with tape when possible.
B. Never coil the torch or work cable around your body.
C. Do not place your body between the torch and work

cables. Route cables on the same side of your body.

D. Connect the work cable to the workpiece as close as

possible to the area being welded.
E. Keep welding power source and cables as far away

from your body as possible.

3

10/98

FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shield­ing gases can cause asphyxiation.
Therefore:

1. Always provide adequate ventilation in the work area by
natural or mechanical means. Do not weld, cut, or gouge
on materials such as galvanized steel, stainless steel,
copper, zinc, lead, beryllium, or cadmium unless positive
mechanical ventilation is provided. Do not breathe fumes
from these materials.

2. Do not operate near degreasing and spraying opera­tions. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly toxic
gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat irritation
while operating, this is an indication that ventilation is not
adequate. Stop work and take necessary steps to im­prove ventilation in the work area. Do not continue to
operate if physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specific ventilation recommendations.

5. WARNING: This product, when used for welding or

cutting, produces fumes or gases which
contain chemicals known to the State of
California to cause birth defects and, in
some cases, cancer. (California Health &

Safety Code

CYLINDER HANDLING -- Cylinders, if
mishandled, can rupture and violently
release gas. Sudden rupture of cylin­der, valve, or relief device can injure or
kill. Therefore:

1. Use the proper gas for the process and use the proper
pressure reducing regulator designed to operate from
the compressed gas cylinder. Do not use adaptors.
Maintain hoses and fittings in good condition. Follow
manufacturer's operating instructions for mounting regu­lator to a compressed gas cylinder.

2. Always secure cylinders in an upright position by chain
or strap to suitable hand trucks, undercarriages, benches,
walls, post, or racks. Never secure cylinders to work
tables or fixtures where they may become part of an
electrical circuit.

3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not con­nected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases in
Cylinders", which is available from Compressed Gas
Association, 1235 Jefferson Davis Highway, Arlington,
VA 22202.

§25249.5 et seq.)

EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:

1. Always have qualified personnel perform the installa­tion, troubleshooting, and maintenance work. Do not
perform any electrical work unless you are qualified to
perform such work.

2. Before performing any maintenance work inside a power
source, disconnect the power source from the incoming
electrical power.

3. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do not
operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position
and in good repair.

6. Use equipment only for its intended purpose. Do not
modify it in any manner.

ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for elec­tric arc welding and cutting equipment, ask
your supplier for a copy of "Precautions and
Safe Practices for Arc Welding, Cutting and
Gouging", Form 52-529.

The following publications, which are available from the
American Welding Society, 550 N.W. LeJuene Road, Mi­ami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"

5. AWS C5.5 - "Recommended Practices for Gas Tungsten
Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal Arc
Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Hand­book.

8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."

MEANING OF SYMBOLS - As used through­out this manual: Means Attention! Be Alert!
Your safety is involved.

Means immediate hazards which, if
not avoided, will result in immediate,
serious personal injury or loss of life.

Means potential hazards which could
result in personal injury or loss of life.

Means hazards which could result in
minor personal injury.

4

SP98-10

PRÉCAUTIONS DE SÉCURITÉ

AVERTISSEMENT: Ces règles de sécurité ont pour
objet d’ assurer votre protection. Veillez à lire et à
observer les précautions énoncées ci-dessous avant de
monter l’ équipement ou de commercer à l’utiliser. Tout
défaut d’observation de ces précautions risque
d’entraîner des blessures graves ou mortelles.

1. PROTECTION INDIVIDUELLE-- Les brûlures de la
peau et des yeux dues au rayonnement de l’arc
électrique ou du métal incandescent, lors du
soudage au plasma ou à l’électrode ou lors du
gougeage à l’arc, peuvent s’avérer plus graves que
celles résultant d’une exposition prolongée au soleil.
Aussi convient-il d’observer les précautions
suivantes:

a. Portez un écran facial adéquat muni des plaques

protectrices et des verres filtrants appropriés afin de
vous protéger les yeux, le visage, le cou et les
oreilles des étincelles et du rayonnement de l’arc
électrique lorsque vous effectuez des soudures ou
des coupes ou lorsque vous en observez l’exécution.

AVERTISSEZ les personnes se trouvant à proximité

de façon à ce qu’elles ne regardent pas l’arc et à ce
qu’elles ne s’exposent pas à son rayonnement, ni à
celui du métal incandescent.

b. Portez des gants ignifugés à crispins, une tunique

épaisse à manches longues, des pantalons sans
rebord, des chaussures à embout d’acier et un
casque de soudage ou une calotte de protection, afin
d’éviter d’exposer la peau au rayonnement de l’arc
électrique ou du métal incandescent. ll est
également souhaitable d’utiliser un tablier
ininflammable de façon à se protéger des étincelles
et du rayonnement thermique.

c. Les étincelles ou les projections de métal incandes-

cent risquent de se loger dans des manches
retroussées, des bords relevés de pantalons ou
dans des poches. Aussi convient-il de garder
boutonnés le col et les manches et de porter des
vêtements sans poches à l’avant.

d. Protégez des étincelles et du rayonnement de l’arc

électrique les autres personnes travaillant à
proximité à l’aide d’un écran ininflammable adéquat.

e. Ne jamais omettre de porter des lunettes de sécurité

lorsque vous vous trouvez dans un secteur où l’on
effectue des opérations de soudage ou de coupage
à l’arc. Utilisez des lunettes de sécurité à écrans ou
verres latéraux pour piquer ou meûler le laitier. Les
piquetures incandescentes de laitier peuvent être
projetées à des distances considérables. Les
personnes se trouvant à proximité doivent
également porter des lunettes de protection.

f. Le gougeage à l’arc et le soudage à l’arc au plasma

produisent un niveau de bruit extrêmement élevé (de
100 à 114 dB) et exigent par conséquent l’emploi de
dispositifs appropriés de protection auditive.

2. PRÉVENTION DES INCENDES-- Les projections de
laitier incandescent ou d’étincelles peuvent
provoquer de graves incendies au contact de
matériaux combustibles solides, liquides ou gazeux.
Aussi faut-il observer les précautions suivantes:

a. Éloigner suffisamment tous les matériaux combus-

tibles du secteur où l’on exécute des soudures ou

des coupes à l’arc, à moins de les recouvrir
complètement d’une bâche non-inflammable. Ce
type de matériaux comprend notamment le bois, les
vêtements, la sciure, l’essence, le kérosène, les
peintures, les solvants, le gaz naturel, l’acétylène, le
propane et autres substances combustibles
semblables.

b. Les étincelles ou les projections de métal incandes-

cent peuvent tomber dans des fissures du plancher
ou dans des ouvertures des murs et y déclencher
une ignition lente cachée. Veiller à protéger ces
ouvertures des étincelles et des projections de
métal.

c. N’exécutez pas de soudures, de coupes,

d’opérations de gougeage ou autres travaux à chaud
à la surface de barils, bidons, réservoirs ou autres
contenants usagés, avant de les avoir nettoyés de
toute trace de substance susceptible de produire des
vapeurs inflammables ou toxiques.

d. En vue d’assurer la prévention des incendies, il

convient de disposer d’un matériel d’extinction prêt à
servir immédiatement, tel qu’un tuyau d’arrosage, un
seau à eau, un seau de sable ou un extincteur
portatif.

e. Une fois le travail à l’arc terminé, inspectez le

secteur de façon à vous assurer qu’aucune étincelle
ou projection de métal incandescent ne risque de
provoquer ultérieurement un feu.

3. CHOC ÉLECTRIQUE-- Le gougeage à l’arc et à l’arc
au plasma exige l’emploi de tensions à vide
relativement importantes; or, celles-ci risquent de
causer des dommages corporels graves et même
mortels en cas d’utilisation inadéquate. La gravité du
choc électrique reçu dépend du chemin suivi par le
courant à travers le corps humain et de son intensité.

a. Ne laissez jamais de surfaces métalliques sous

tension venir au contact direct de la peau ou de
vêtements humides. Veillez à porter des gants bien
secs.

b. Si vous devez effectuer un travail sur une surface

métallique ou dans un secteur humide, veillez à
assu-rer votre isolation corporelle en portant des
gants secs et des chaussures à semelles de ca­outchouc et en vous tenant sur une planche ou une
plate-forme sèche.

c. Mettez toujours à la terre le poste de soudage/

coupage en le reliant par un câble à une bonne prise
de terre.

d. N’utilisez jamais de câbles usés ou endommagés. Ne

surchargez jamais le câble. Utilisez toujours un
équipement correctement entretenu.

e. Mettez l’équipement hors tension lorsqu’il n’est pas

en service. une mise à la masse accidentelle peut en
effet prov oquer une surchauffe de l’équipement et un
danger d’incendie. Ne pas enrouler ou passer le
câble autour d’une partie quelconque du corps.

f. Vérifiez si le câble de masse est bien relié à la pièce

en un point aussi proche que possible de la zone de
travail. Le branchement des câbles de masse à
l’ossature du bâtiment ou en un point éloigné de la
zone de travail augmente en effet le risque de
passage d’un courant de sortie par des chaînes de

5

9/97

levage, des câbles de grue ou divers chemins
électriques.

g. Empêchez l’apparition de toute humidité, notamment

sur vos vêtements, à la surface de l’emplacement de
travail, des câbles, du porte-électrode et du poste de
soudage/coupage. Réparez immédiatement toute
fuite d’eau.

4. VENTILATION-- La respiration prolongée des
fumées résultant des opérations de soudage/
coupage, à l’intérieur, d’un local clos, peut provoquer
des malaises et des dommages corporels. Aussi
convient-il d’observer les précautions suivantes:

a. Assurez en permanence une aération adéquate de

l’emplacement de travail en maintenant une ventila­tion naturelle ou à l’aide de moyens mécaniques.
N’effectuez jamais de travaux de soudage ou de
coupage sur des matériaux de zinc, de plomb, de
beryllium ou de cadmium en l’absence de moyens
mécaniques de ventilation capables d’empêcher
l’inhalation des fumées dégagées par ces matériaux.

b. N’effectuez jamais de travaux de soudage ou de

coupage à proximité de vapeurs d’hydrocarbure
chloré résultant d’opérations voisines de
dégraissage ou de pulvérisation. La chaleur
dégagée ou le rayonnement de l’arc peut déclencher
la formation de phosgène -- gaz particulièrement
toxique -- et d’autres gaz irritants, à partir des
vapeurs de solvant.

c. Une irritation momentanée des yeux, du nez ou de la

gorge constatée au cours de l’utilisation de
l’équipement dénote un défaut de ventilation.
Arrêtez-vous de travailler afin de prendre les
mesures néces- saires à l’amélioration de la
ventilation. Ne poursuivez pas l’opération entreprise
si le malaise persiste.

d. Certaines commandes comportent des canalisations

où circule de l’hydrogène. L’armoire de commande
est munie d’un ventilateur destiné à empêcher la
formation de poches d’hydrogène, lesquelles
présentent un danger d’explosion; ce ventilateur ne
fonctionne que si l’interrupteur correspondant du
panneau avant se trouve placé en position ON
(Marche). Veillez à manœuvrer cette commande en
vérifiant si le couvercle est bien en place, de façon à
assurer l’efficacité de la ventilation ainsi réalisée. Ne
jamais débrancher le ventilateur.

e. Les fumées produites par l’opération de soudage ou

de coupage peuvent s’avérer toxiques. Aussi est-il
nécessaire de disposer en permanence d’un
dispositif adéquat de ventilation de type aspirant,
afin d’élimi-ner du voisinage de l’opérateur tout
dégagement de fumée visible.

f. Consultez les recommandations particulières en

matière de ventilation indiquées à l’alinéa 6 de la
norme Z49.1 de l’AWS.

5. ENTRETIEN DE L’ÉQUIPEMENT-- Un équipement
entretenu de façon défectueuse ou inadéquate ris-

que non seulement de réaliser un travail de
mauvaise qualité mais, chose plus grave encore,
d’entraîner des dommages corporels graves, voire
mortels en déclenchant des incendies ou des chocs
électriques. Observez par conséquent les
précautions suivantes:

a. Eff orcez-v ous de toujours confier à un personnel qua-

lifié l’installation, le dépannage et l’entretien du poste
de soudage et de coupage. N’effectuez aucune
réparation électrique sur l’équipement à moins d’être
qua-lifié à cet effet.

b. Ne procédez jamais à une tâche d’entretien

quelconque à l’intérieur du poste de soudage/
coupage, avant d’avoir débranché l’alimentation
électrique.

c. Maintenez en bon état de fonctionnement les câbles,

le câble de masse, les branchements, le cordon
d’alimentation et le poste de soudage/coupage.
N’utilisez jamais le poste ou l’équipement s’il
présente une défectuosité quelconque.

d. Prenez soin du poste de soudage et de coupage et

des équipements accessoires. Gardez-les à l’écart
des sources de charleur, notamment des fours, de
l’humidité, des flaques d’eau maintenez-les à l’abri
des traces d’huile ou de graisse, des atmosphères
corrosives et des intempéries.

e. Laissez en place tous les dispositifs de sécurité et

tous les panneaux de l’armoire de commande en
veillant à les garder en bon état.

f. Utilisez le poste de soudage/coupage conformément

à son usage prévu et n’effectuez aucune modifica­tion.

6. INFORMATIONS COMPLÉMENTAIRES RELATIVES
À LA SÉCURITÉ--

Pour obtenir des informations complémentaires sur

les règles de sécurité à observer pour le montage et
l’utilisation d’équipements de soudage et de
coupage électriques et sur les méthodes de travail
recommandées, demandez un exemplaire du livret
N° 52529 “Precautions and Safe Practices for Arc
Welding, Cutting and Gouging” publié par ESAB.
Nous conseillons également de consulter les publica­tions sui-vantes, tenues à votre disposition par
l’American Welding Society, 550 N.W. LeJuene
Road, Miami, FL 32126:

a. “Safety in Welding and Cutting” AWS Z49.1
b. “Recommended Safe Practices for Gas-Shielded Arc

Welding “AWS A6. 1.

c. “Safe Practices for Welding and Cutting Containers

That Have Held Combustibles” AWS-A6.0.

d. “Recommended Safe Practices for Plasma Arc Cut-

ting” AWS-A6. 3.

e. “Recommended Safe Practices for Plasma Arc Weld-

ing” AWS-C5. 1.

f. “Recommended Safe Practices for Air Carbon Arc

Gouging and Cutting” AWS-C5. 3.

g. “Code For Safety in Welding and Cutting”

CSA-Standard W117. 2.

6

9/97

SECTION 1

DESCRIPTION

Description

 plugs into standard 115 V outlet
 portable - 60 lbs (27 kg)
 cuts practically any sheet metal up to 1/8” (3mm) thick
 low ripple for finer cuts
 proven patented PT-34 torch - 15 feet (3.8m)
 spare parts kit
 1 year warranty
 30% duty cycle at rated output - fan cooled
 overtemperature light

SPECIFICA TIONS

HANDY PLASMA 125

Input Volt age........................1 15 V , 60 Hz, 1 Phase

Input Current @ rated load ...............20 A @ 115 V

Output Rating ..........................11 amps - 100 volts

Open Circuit Volt age...................... 290 V DC max.

Dimensions:

Weight .............................................. 60 lbs (27 kg)

PT-34 Torch

Shipping Wgt. ....................................... 2 lbs (1 kg)

Length of Service Lines .........................15’ (3.8 m)

Dimensions:

75o TORCH

2 1/4"

(57mm)

5 1/4"

(133mm)

Note the high open-circuit voltage. Use only plasma
cutting torches designed for this equipment. Do
NOT attempt to use this equipment with any pro­cess other than plasma arc cutting.

SECTION 2

EQUIPMENT SUPPLIED

P ACKAGES AV AILABLE

Each Package includes:

PT-34, 75° T orch w/ 15-f t. lines......................... 378 86

Work Cable, 12-1/2-ft ..................................... 680950

EQUIPMENT

OPTIONAL ACCESSORIES A V AILABLE

Optional Torch Spare Parts Kit P/N 37918 contains:

2- O-ring, P/N 950790

2- Heat Shield, P/N 20282
4- Nozzle T ip, P/N 37887

T orch Guide Kit - This complete
kit, in a rugged plastic carrying
case, includes attachments for
circle and streight line cutting on
ferrous and nonferrous metals.

Torch Guide Kit.............................................. 604609

Wheel Cart Kit Kit .................................. 0558001444

7

1- O-Ring Lube, P/N 17672
2- Electrode, P/N 37888
1- Swirl Baffle, P/N 18785

Optional Wheel Cart Kit -

Roll the Handy Plasma
around the job site with ease.

SECTION 3

INSTALLA TION

115V
20 amps

WORK CABLE (12-1/2’)

PT-34 TORCH w/15’ Lines

WORK

Fig. 3.1 - Handy Plasma 125 Interconnection Diagram

INSTALLATION

Proper installation can contribute materially to satis­factory and troublefree operation of the cutting pack­age. It is suggested that each step in this section be
studied carefully and followed as closely as possible.

A. INSPECTION AND PLACEMENT

1. Having removed the shipping container inspect for
evidence of concealed damage which may not
have been apparent upon receipt of the unit. No­tify the carrier of any defects or damage at once.

2. Check the container for any loose parts. Check air
louvers on all panels of cabinet and holes through
the base are free of any packing materials that may
obstruct air flow through the power supply.

3. The components in the HANDY PLASMA 125 con­sole are: maintained at proper operating tempera­tures by fan cooling. Air is drawn in through the
rear panel and then out the louvers in the front
panel. Locate the power supply in an open area

Earth Ground

where air can circulate freely through the open­ings. Allow at least one foot of clearance between
the power supply and wall or any other obstruc­tion. The area around the power supply should

be relatively free of dust, fumes, and excessive
heat.

B. PRIMARY INPUT ELECTRICAL CONNECTION

Precautionary measures should be taken to pro­vide maximum protection against electrical shock.
Be sure that all power is off by opening the line
(wall) disconnect switch and by unplugging the
power cord to the unit when connections are made
inside the power supply .

1. The HANDY PLASMA 125 is equipped with a 10-ft.,
3-conductor input power cable with a 115V plug.
Plug into standard 1 15 volt outlet.

8

SECTION 3

2. Extension cables may result in excessive voltage
drop. Use only industrial grade 16 to 10 awg. ex­tension cables.

The following sizes should be acceptable:
25 ft. extension - 16 awg. minimum
50 ft. extension - 14 awg. minimum
100 ft. extension - 12 awg. minumum
150 ft. extension - 10 awg. minimum

Greater than 150 ft. not recommended!

Input voltage to machine must be a minimum of
95 volts while operating.

C. SECONDARY (OUTPUT) CONNECTIONS (Re-

fer to Figure 3.1)

INSTALLA TION

HEAT SHIELD

NOZZLE (TIP)

SWIRL BAFFLE

ELECTRODE

O-RING

TORCH

Fig. 3.2 - Assembly of PT -34 Torch Front End Part s

Before making any connections to the power sup­ply output terminals, make sure that all primary in­put power to the machine is deenergized (off) and
that input power cable is unplugged.

Clamp the work cable to the workpiece. Be sure the
workpiece is connected to an approved earth ground
with a properly sized ground cable.

(See figure 3.1.)

D. ADJUSTMENTS & OPERATIONS

CAUTION: Never, under any circumst ances, operate

the power supply with the cover removed.
In addition to the safety hazard, improper
cooling may cause damage to internal
components. Keep side panels closed
when unit is energized. Also make sure
you are adequately protected before you
start cutting - protective helmet and gloves
should always be worn. Refer to page 2
for additional operating precautions.

A. TORCH ADJUSTMENTS

The front end of the torch contains a gas flow check
valve that acts in conjunction with the circuitry provided
in the power supply . This patented system provides a
safety interlock preventing the torch from being acci­dentally energized with high voltage when the heat
shield is removed and the torch switch is accidentally
closed.

B. HANDY PLASMA

125 CONTROLS & ADJUST-

MENTS (See Fig. 3.3)

1. Power Switch - When placed in ON position, the

cooling fan will run.

2. Power Light - Will glow white to indicate that elec­trical current has energized the system.

3. Overtemperature Light - Will glow amber under
the following conditions and contactor will be deen­ergized, when Duty Cycle has been exceeded.

OVERLOAD LIGHT
(AMBER)

Make sure power switch on console is in OFF po­sition and unplug the input power cable.

With the torch front end facing up, assemble electrode,
swirl baffle, tip, and heat shield (supplied with Torch
Spare Parts Kit) in that order as shown in Figure 3.2.
(Electrode is reversible and the swirl baffle is symmetri­cal. They can be assembled either way .) Apply silicone
grease to 0-ring.(See Figure 3.2)

Tighten heat shield snugly to hold the parts in firm con­tact with each other and to the torch head. Do not over­tighten the heat shield.

POWER LIGHT

POWER SWITCH

Fig. 3.3 - Controls on Handy Plasma 125 Console

9

SECTION 4

a. The duty cycle of this unit is 30% at rated out-

put current. Duty cycle is based on a 10 minute
cycle; therefore, the unit can operate for a to­tal of 3 minutes and shut off for cooling a total
of 7 minutes in a 10 minute period.

OPERA TION

Wear the usual protective gloves, clothing and hel­met. Helmet with filter lens shade No. 6 to 8 should
provide adequate protection.

OPERATION

TOO FASTTOO SLOW

CORRECT

Never touch any parts forward of the torch handle
(tip, heat shield, electrode, etc.) unless the power
switch is in the OFF position.

Do not depress the torch switch unless the torch
tip is touching or within 0.020-in. (less than 1/32-in.)
of the workpiece.

CAUTION:Locate the console at least 10-ft. from the

cutting work area. Chips and hot slag, from
the cutting operation, can damage the con­sole.

After plugging in the input power cable, and turning the
power swithc on:

1. T ouch the tip of the torch to the workpiece (or within

0.020 in. of the workpiece) holding the torch at
about 15- 30o angle to avoid damaging the tip.

2. Depress the torch switch. (Air should begin flow­ing and H.F. should come on.)

3. Two seconds after depressing torch switch, the
plasma arc will start cutting.

Fig. 4.1 - Effect of Cutting Speed

2. Grate Cutting - For rapid restarts, such as grate

or heavy mesh cutting, keep torch switch de­pressed until entire cutting operation is completed.
This avoids the 2 second preflow portion of the
cutting cycle.

E. COMMON CUTTING FAULTS

Listed below are common cutting problems followed
by probable cause of each. If problems are determined
to be caused by the HANDY PLASMA 125, see your
ESAB representative.

1. Insufficient Penetration.

a. Cutting speed too fast.
b. Damaged cutting tip.
c. Improper air pressure.

2. Main Arc Extinguishes.

4. After starting the cut, the tip can be dragged along
the workpiece.

D. OPERA TING TECHNIQUES

1. Piercing - Thin materials may be pierced with the

torch touching the work. When piercing thicker ma­terials (up to 1/8-in.) immediately raise the torch to
1/16 in. standoff after initiating the cutting arc. This
will reduce the chance of spatter entering the torch
and prevent the possibility of welding the tip to the
plate. The torch should be angled at about 30
starting to pierce, and then straightened after ac­complishing the pierce.

o

when

a. Cutting speed too slow.

3. Dross Formation. (In some materials and thick­nesses, it may be impossible to get dross-free
cuts.)

a. Cutting speed too fast or too slow.
b. Improper air pressure.
c. Faulty tip or electrode.

4. Double Arcing. (Damaged Tip Orifice.)

a. Low air pressure.
b. Damaged cutting tip.

10

SECTION 4

OPERATION

c. Loose cutting tip.
d. Heavy spatter.

5. Uneven Arc.

a. Damaged cutting tip.
b. Electrode worn or damaged.

6. Unstable Cutting Conditions.

a. Incorrect cutting speed.
b. Loose cable or hose connections.
c. Electrode and/or cutting tip in poor condition.

7. Main Arc Does Not Strike.

a. Loose connections.

8. Poor Consumable Life.

a. Improper gas pressure.

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.

SECTION 5 MAINTENANCE

A. INSPECTION AND CLEANING

B. TROUBLESHOOTING

Frequent inspection and cleaning of the HANDY
PLASMA 125 console is recommended. Some Sug­gestions for inspecting and cleaning are as follows:

Make sure the power is shut off.

1. Check heat shield on torch. It should be replaced
if damaged.

2. Check the torch electrode and cutting tip for wear
every 1 or 2 hours of operation.

3. Make sure cable and hoses are not damaged or
kinked.

4. Make sure all plugs, fittings, and ground connec­tions are tight.

5. With all input power disconnected, and wearing
proper eye and face protection, blow out the in­side of the cutting power supply using low-pressure
dry compressed air.

Be sure that all primary power to the machine has
been externally disconnected. Unplug before at­tempting inspection or working inside of the power
supply.

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, bulging or leaking capacitors,
or any other sign of damage or discoloration.

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.

11

SECTION 5

C. TROUBLESHOOTING GUIDE

1. Difficult Starting

 Change electrode
 Change Tip
 Check for clean ground connection
 Check air flow
 Check torch power cable for continuity

Depress torch switch. Compressor and

high freq. should be seen or heard.

MAINTENANCE

2. No Air

Yes

Power

supply

defective

No

High freq. unit

or compressor

defective

Does high freq. come on with torch switch?

No

Check

continuity

of torch switch

No

Defective

torch switch

Yes

No electrode in torch
Electrode too short
Replace electrode
Compressor Defective

Power supply

defective

OK

12

SECTION 5 MAINTENANCE

3. Air does not shut off.

Does arc start when tip contact s work without depressing torch switch?

Yes

Check for

short in

torch switch

Cuts normally when torch switch is depressed?

Yes

Defective

control PCB

4. Amber overtemperature light turns ON while cutting.

Is the fan running?

No

Are there any restrictions or foreign matter?

No

No

Power

supply

defective

Yes

Run unit

on idle for

10 minutes

OK

Normal

Duty Cycle

exceeded

No

Defective

Thermal

Switch

Yes

Clear

restrictions

13

No

Defective
fan motor

SECTION 6

INST ALLATION, OPERATION AND MAINTENANCE OF PT-34 TORCH

INTRODUCTION

The patented PT-34is a manual torch with a 75
designed for use with se veral Plasma Arc Cutting Pac k­ages using clean, dry air as the plasma gas. The ser­vice lines are 15 feet long and the torch is rated to
operate up to 50 amperes at 100% duty cycle for cut­ting most metals.

WARNING

!

Plasma cutting uses high voltage. Skin contact
with the torch, the power source, the workpiece
or any grounded object MUST BE AVOIDED
whenever the power source is ON.
Using the torch on any power source not
equipped with a flow switch safety interlock may
expose operator to unexpected high voltage.

2 1/4"

(57mm)

ELECTRIC SHOCK CAN KILL.

75o TORCH

o

head

WARNING

!

BE SURE to install the swirl baffle in the torch.
Failure to do so would allow the nozzle (tip) to
contact the electrode. This contact would permit
high voltage to be applied to the nozzle. Your
contact with the nozzle or workpiece could then
result in serious injury or death by electric shock.

Follow all instructions in the appropriate booklet packed
with your Handy Plasma package. DO NOT install or
attempt to operate this torch without following these
instructions.

WARNING

!

The PT-34 torch head contains a gas flow check
valve that acts in conjunction with the switch and
circuitry within the power source. This system pre­vents the torch from being energized with high volt­age if the torch switch is accidentally closed when
the shield is removed. ALW AYS REPLACE TORCH
WITH THE PROPER TORCH MANUF A CTURED BY
ESAB SINCE IT ALONE CONTAINS ESAB'S PAT­ENTED SAFETY INTERLOCK.

5 1/4"

(133mm)

Fig. 6.1 - Dimensional Data PT-34 Torch

A. INSTALLATION & OPERATION

WARNING

!

Make sure power switch on the power source is in
the OFF position and PRIMARY INPUT POWER is
DEENERGIZED.

The seat comes assembled to the front end of the torch.
Make sure seat is tightened firmly with a wrench but
do NOT overtighten.

With the torch front end facing up, assemble electrode,
swirl baffle, tip and heat shield in that order as shown
in Figure 6.2 (Standard electrode is reversible and the
swirl baffle is symmetrical. The y can be assembled ei­ther way.)

B. MAINTENANCE

WARNING

!

Before any maintenance is attempted on this torch,
make sure the POWER SWITCH on the power source is
in the OFF position and the PRIMARY INPUT PO WER is
DEENERGIZED.

1. To disassemble the front end, hold the torch with the
shield in an upright position as shown in Figure 6.2
This will prevent the nozzle, electrode, and swirl
baffle from falling free when the shield is remov ed.
T o replace any of these parts, assemble as directed
in Section III.

The gas flow check valve is part of the safety inter­lock and is permanently assembled in the torch head.
The head must be replaced if this valve malfunc­tions. The light spring force used to close the ball
check can be felt by pushing on the electrode when
assembling the front end components.

2. Periodically check the heat shield, electrode, nozzle,
and swirl baffle. Replace if worn or damaged.

Tighten heat shield snugly to hold the parts in firm con­tact with each other and the torch head. Do not over­tighten the heat shield.

3. NOTE - THE ELECTRODE IS REVERSIBLE. When
one end is worn, the electrode can be reversed.

14

SECTION 6

INST ALLATION, OPERATION AND MAINTENANCE OF PT-34 TORCH

Do not continue to use one end allowing it to erode to a
length shorter than 3/8-in. as shown in Figure 6.3. The
electrode opens the gas flow check valve. If one end is
continually used, it will be too short to open the valve
when reversed.

4. Apply a small amount of lubricant P/N 17672 to the
heat shield as shown in Figure 6.3 or to the O-ring.
Check O-ring for damage whenever the shield is re­moved. Replace if necessary. (O-ring P/N 950790
is also supplied in spare parts kit.)

HEAT SHIELD

NOZZLE (TIP)

SWIRL BAFFLE

ELECTRODE

TORCH

5. The power cable and s witch leads in the service line
should be inspected periodically. If there are any
cuts through the protective sheath or if gas leaks
are noted, replace the damaged component.

By following steps 1, 2, and 3 in Figure 6.5 the service
line can be removed from the torch. To disassemble
the service line, lay the line out straight, remove the
tape from around the switch lead splices, and free the
switch by cutting the leads close to the splices. (Re­placement switches have extra long leads to make up
for any loss due to cutting.) Remove the rubber boot
from the inlet end of the cable and remove the tape
that secures the sheath at each end. Pull the sheath
off the cable (over small fitting at torch end). Note that
the switch leads wrapped around the power cable are
secured with tape several places along the cab le. The
leads, switch cord plug, and strain relief can now be
removed. DO NOT remove the white tape that forms a
band around the power cable at each end. The sheath
is taped to the cable in front of the band which acts as
a shoulder to prevent the sheath from sliding back on
the cable. (Replacement cables have this tape in
place.) If the switch leads are to be replaced, replace
with 16 AWG STRANDED COPPER, 600- VOLT, 90
C INSULATED WIRE. Reassemble in reverse order.

m

Fig6. 2 - Front End Assembly

LUBRICANT CAN BE
APPLIED TO O-RING OR
HEAT SHIELD

ELECTRODE

EACH END CAN BE USED

3/8"

MIN.

UNTIL IT WEARS TO 3/8"
LONG.

6. To reposition the switch on the torch, slide the flex
support back, remove the tape securing the spliced
leads to the power cable, reposition switch, retape
the leads, and pull the flex support back in place.

NOTE: A thin film of silicone lubricant P/N 17672 ap-

plied inside of the flex support will ease the
assembly of this part.

PT-34

Fig. 6.3 - O-ring and Electrode Maintenance

15

SECTION 6

INST ALLATION, OPERA TION AND MAINTENANCE OF PT-34 TORCH

FLEX SUPPORT - 18225

SHEATH

19675 (15 ft.)

(2) SPLICES (Supplied with Switch)

SWITCH - 18224

SWITCH BAND - 18207

5/8 X 18 L.H.

STRAIN RELIEF - 18226

HANDLE - 18208

POWER CABLE

19672 (15 ft.)

1/4 Fast On

SEAT - 19679

(Included with Head)

Included with

POWER CABLE SHEATH ASSY. (50-FT.) - 19027

HEAD - 20072

0

75

(Includes, Ring and Seat)

ELECTRODE

CONSUMABLES

Torch is completely assembled

from the factory. Additional parts

are included with spare parts kit No.

37918 - or may be purchased

seperately.

16

(multiples of 2)

SWIRL

BAFFLE

37888

18785

(multiples of 5)

NOZZLE (Tip)

37887

HEAT SHIELD

20282

Fig 6.4 - PT-34 Torch Assembly, P/N 37886 (15 ft. lines)

SECTION 6

INST ALLATION, OPERATION AND MAINTENANCE OF PT-34 TORCH

2

WARNING

Slide switch and band from

handle. Snip leads at splice

to replace switch.

!

Unscrew handle and

power cable from head

3

BE SURE to tighten fittings securely using 2 wrenches

during reassembly. (Factory recommended torque

is 30 in-lbs). Failure to do so could result in serious

injury to the operator.

1

Pull flex support back.

Remove tape holding

splices.

17

Fig. 6.5 - Power Cable and Switch Disassembly Sequence

SECTION 7

REPLACEMENT P ARTS

(S1)

SCREW PHTF 8-32 X .63

LOCK WASHER #8

SCREW PHTF 8-32 X .38

LOCK WASHER #8

FLAT WASHER #8

TERMINAL BUSHING - 13730583

SCREW PHTF 6-32 X .38

SCREW PHTF 10-32 X .50

WASHER, LOCK, EXT TOOTH #10

FLAT WASHER #8

(PL1)

0558005244

TRANSFORMER

OVER TEMP LIGHT, AMBER -

951815

BUSHING, SNAP - 634818

POWER SWITCH - 634518

POWER LIGHT, WHITE - 951526

SWITCH SEAL - 951474

(PL2)

FOOT, RUBBER - 182W12

SCREW PHTF 8-32 X .38

SCREW PHTF 8-32 X .38

DECAL, GROUND - 2091558

SCREW PHTF 10-24 X .38

SCREW PHTF 6-32 X .38

WASHER, FLAT #6

BUSBAR,TAB - 0558001163

(PCB1-P1)

CAPACITOR, (800mf 450 VDC) - 37858

HOSE ASSEMBLY - 0558001162

(C2)

PRESSURE SWITCH - 0558001159

PLUG HOUSING (15 POS) - 951504

PC BOARD, LOGIC - 38168

(PCB1)

18

GROMMET (.212 ID) - 950518

COOLING FAN - 2046032

GROMMET (0.63) - 92W57

Figure 7.1 - Handy Plasma 125 (Internal Right Side View)

RELAY, (DPDT 25A 120VAC) - 952577

SCREW PHTF 10-24 X .50

GROMMET (0.63) - 92W57

CAPACITOR, (120UF 240 VAC) - 37856

(C1)

DIODE (BRIDGE RECTIFIER) - 37855

(BR1)

(K1)

SECTION 7

TERMINAL BLOCK (2 POS 20A) - 950487
(TB1)

SCREW PHTF 6-32 X .50

WASHER, FLAT #6

SCREW PHTF 10-24 X .50

WASHER, FLAT #10

BUSHING, STRAIN RELIEF -

23606172

SCREW PHTF 6-32 X .25

POWER CORD (10 FT.)

-0558001381

REPLACEMENT P ARTS

(M2)

(R1)

AIR COMPRESSOR - 37857

RESISTOR - 17240225

SWITCH TERMAN (131°F) - 950710

DIODE (BRIDGE RECTIFIER) - 37855

(TS1)

(BR2)

BULKHEAD ADAPTOR - 58V75

(T3)

COUPLING COIL

NUT, HEX 8-32

LOCKWASHER EXT TOOTH #8

ELBOW 1/4 NPT

(HIGH FREQ.) - 32969

19

TRANSFORMER ASSEMBLY - 0558001212

BUSHING (SNAP) - 639533

(T1)

BUSHING (SNAP) - 950823

CAPACITOR - 0558005245

SPARK GAP ASSEMBLY - 0558001180

RESISTOR - 17280025

(R2)

Figure 7.2 - Handy Plasma 125 (Internal Left Side View)

SECTION 7

REPLACEMENT P ARTS

LABEL, WARNING - 2091514

SCREW PHTF 10-24 X .38

LOGO,ESAB - 13734588

COVER - 37952Y

SCREW PHTF 10-24 X .38

LABEL, DANGER HIGH VOLTAGE - 954008

HANDLE - 951575

TORCH CABLE STRAIN RELIEF ­0558001157
LOCKNUT (1 in. CONDUIT) - 950435

TORCH - 37886

Figure 7.3 - Handy Plasma 125 (External View)

20

D-0558001341-C

21

NOTES:

1. Connections for 115v Operation.

Figure 8.1 - Handy Plasma 125 Schematic Diagram for: 1 15V 60HZ Domestic and 230V Export Models

2. Connections for 230V Operation.

D-0558001342-E

Figure 8.2a - Handy Plasma 125 Wiring Diagram for: 1 15V 60HZ Domestic and 230V Export Models

22

D-0558001342-E

Figure 8.2b - Handy Plasma 125 Wiring Diagram for: 115V 60HZ Domestic and 230V Export Models

23

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS: Telephone: [phone] / Fax: [phone]

Order Entry Product Availability Pricing Delivery
Order Changes Saleable Goods Returns Shipping Information

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Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations

C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: [phone]

Part Numbers Technical Applications Hours: 8:00 AM to 5:00 PM EST
Performance Features Technical Specifications Equipment Recommendations

D. LITERATURE REQUESTS: Telephone: [phone] / Fax: [phone]

E. WELDING EQUIPMENT REPAIRS: Telephone: [phone] / Fax: [phone]

Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST

F. WELDING EQUIPMENT TRAINING:

Telephone: [phone] / Fax: [phone]
Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST

G. WELDING PROCESS ASSISTANCE:

Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES:

Telephone : [phone] Hours: 7:30 AM to 5:00 PM EST

Hours: 8:00 AM to 7:00 PM EST

Hours: 7:30 AM to 4:00 PM EST

Telephone: (800) ESAB-123/ Fax: [phone]/ Web:http://www.esab.com

F15-568-D 10 / 2007

IF YOU DO NOT KNOW WHOM TO CALL

Hours: 7:30 AM to 5:00 PM EST

24