ESAB HandyPlasma 380 Instruction manual

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HandyPlasma®380

Plasmarc™ Cutting System

This manual provides complete instructions for the following HandyPlasma® 380 cutting system (machine and PT-31XL torch) starting with Serial No. PPOR347001:

ESAB P/N 0558004441 - 230 V, 1-Phase, 50/60 Hz

Instruction Manual

0558004615 07 / 2004

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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 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.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.

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TABLE OF CONTENTS

SECTION TITLE PAGE

PARAGRAPH

SECTION 1 DESCRIPTION............................................................................. 11

1.1 General ........................................................................................ 11

1.2 Scope ........................................................................................... 11

1.3 System Available ......................................................................... 11

1.4 Specifications ............................................................................... 12

1.5 PT-31XL Torch Technical Data ..................................................... 14

SECTION 2 INSTALLATION ........................................................................... 15

2.1 General ........................................................................................ 15

2.2 Equipment Required .................................................................... 15

2.3 Location ....................................................................................... 15

2.4 Inspection .................................................................................... 15

2.5 Primary Electrical Input Connections .......................................... 15

2.6 Secondary (Output) Connections .................................................. 17

2.6.1 Torch Replacement ...................................................................... 17

2.6.2 Air Connection .............................................................................. 17

2.6.3 Work Lead Connection .................................................................. 17

2.7 PT-31XL Torch Consumables Installation ..................................... 20

SECTION 3 OPERATION ................................................................................ 21

3.1 Operation ...................................................................................... 22

3.2 HandyPlasma

380 Controls ......................................................... 22

3.3 Assembling PT-31XL Consumable Parts ...................................... 23

3.4 Cutting with the PT-31XL .............................................................. 23

3.5 Operating Techniques ................................................................... 25

3.6 Common Cutting Problems ........................................................... 25

SECTION 4 MAINTENANCE ............................................................................ 27

4.1 General ......................................................................................... 27

4.2 Inspection and Cleaning ................................................................ 27

4.3 Flow Switch .................................................................................. 27

4.4 PT-31XL Torch Maintenance ........................................................ 28

4.5 Power Cable And Switch Disassembly Sequence ......................... 29

SECTION 5 TROUBLESHOOTING .................................................................. 31

5.1 Troubleshooting ............................................................................ 31

5.2 Troubleshooting Guide .................................................................. 31

5.3 Sequence of Operation ................................................................. 36

SECTION 6 REPLACEMENT PARTS .............................................................. 37

6.1 General ......................................................................................... 37

6.2 Ordering ........................................................................................ 37

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TABLE OF CONTENTS

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SAFETY PRECAUTIONS

WARNING:

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.

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

These Safety Precautions are for

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

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 Processes", available from the National Fire Protection As-

sociation, 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 move-

ment 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.

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SAFETY PRECAUTIONS

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.

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PRECAUCION DE SEGURIDAD

ADVERTENCIA:

son para su protección. Ellas hacen resumen de

información proveniente de las referencias listadas en la sección "Información Adicional Sobre La Seguridad". Antes de hacer cualquier instalación o procedimiento de operación , asegúrese de leer y seguir las precauciones de seguridad listadas a continuación así como también todo manual, hoja de datos de seguridad del material, calcomanias, etc. El no observar las Precauciones de Seguridad puede resultar en daño a la persona

o muerte

PROTEJASE USTED Y A LOS DEMAS-Algunos procesos de soldadura, corte y ranurado son ruidosos y requiren protección

para los oídos. El arco, como el sol , emite rayos ultravioleta (UV) y otras radiaciones que pueden dañar la piel y los ojos. El metal caliente causa quemaduras. EL entrenamiento en el uso propio de los equipos y sus procesos es esencial para prevenir accidentes. Por lo tanto:

Estas Precauciones de Seguridad

1. Utilice gafas de seguridad con protección a los lados siempre

que esté en el área de trabajo, aún cuando esté usando careta de soldar, protector para su cara u otro tipo de protección.

2. Use una careta que tenga el filtro correcto y lente para proteger

sus ojos, cara, cuello, y oídos de las chispas y rayos del arco cuando se esté operando y observando las operaciones. Alerte a todas las personas cercanas de no mirar el arco y no exponerse a los rayos del arco eléctrico o el metal fundido.

3. Use guantes de cuero a prueba de fuego, camisa pesada de

mangas largas, pantalón de ruedo liso, zapato alto al tobillo, y careta de soldar con capucha para el pelo, para proteger el cuerpo de los rayos y chispas calientes provenientes del metal fundido. En ocaciones un delantal a prueba de fuego es necesario para protegerse del calor radiado y las chispas.

4. Chispas y partículas de metal caliente puede alojarse en las

mangas enrolladas de la camisa , el ruedo del pantalón o los bolsillos. Mangas y cuellos deberán mantenerse abotonados, bolsillos al frente de la camisa deberán ser cerrados o eliminados.

5. Proteja a otras personas de los rayos del arco y chispas

calientes con una cortina adecuada no-flamable como división.

6. Use careta protectora además de sus gafas de seguridad

cuando esté removiendo escoria o puliendo. La escoria puede estar caliente y desprenderse con velocidad. Personas cercanas deberán usar gafas de seguridad y careta protectora.

FUEGO Y EXPLOSIONES -- El calor de las

flamas y el arco pueden ocacionar fuegos.

Escoria caliente y las chispas pueden

causar fuegos y explosiones. Por lo tanto:

Remueva todo material combustible lejos del área de trabajo o cubra los materiales con una cobija a prueba de fuego. Materiales combustibles incluyen madera, ropa, líquidos y gases flamables, solventes, pinturas, papel, etc.

2. Chispas y partículas de metal pueden introducirse en las grietas y agujeros de pisos y paredes causando fuegos escondidos en otros niveles o espacios. Asegúrese de que toda grieta y agujero esté cubierto para proteger lugares adyacentes contra fuegos.

3. No corte, suelde o haga cualquier otro trabajo relacionado hasta

que la pieza de trabajo esté totalmente limpia y libre de substancias que puedan producir gases inflamables o vapores tóxicos. No trabaje dentro o fuera de contenedores o tanques cerrados. Estos pueden explotar si contienen vapores inflamables.

4. Tenga siempre a la mano equipo extintor de fuego para uso instantáneo, como por ejemplo una manguera con agua, cubeta con agua, cubeta con arena, o extintor portátil. Asegúrese que usted esta entrenado para su uso.

5. No use el equipo fuera de su rango de operación. Por ejemplo,

el calor causado por cable sobrecarga en los cables de soldar pueden ocasionar un fuego.

6. Después de termirar la operación del equipo, inspeccione el área de trabajo para cerciorarse de que las chispas o metal caliente ocasionen un fuego más tarde. Tenga personal asignado para vigilar si es necesario.

7. Para información adicional , haga referencia a la publicación NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", disponible a través de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

CHOQUE ELECTRICO -- El contacto con las partes

eléctricas energizadas y tierra puede causar daño severo o muerte. NO use soldadura de corriente alterna (AC) en áreas húmedas, de movimiento confinado en lugares estrechos o si hay posibilidad de caer al suelo.

fuente de poder esté conectado a tierra através del sistema de

electricidad primario.

2. Conecte la pieza de trabajo a un buen sistema de tierra física.

3. Conecte el cable de retorno a la pieza de trabajo. Cables y conductores expuestos o con malas conexiones pueden exponer al operador u otras personas a un choque eléctrico fatal.

4. Use el equipo solamente si está en buenas condiciones. Reemplaze cables rotos, dañados o con conductores expuestos.

5. Mantenga todo seco, incluyendo su ropa, el área de trabajo, los cables, antorchas, pinza del electrodo, y la fuente de poder.

6. Asegúrese que todas las partes de su cuerpo están insuladas de ambos, la pieza de trabajo y tierra.

7. No se pare directamente sobre metal o tierra mientras trabaja en lugares estrechos o áreas húmedas; trabaje sobre un pedazo de madera seco o una plataforma insulada y use zapatos con suela de goma.

8. Use guantes secos y sin agujeros antes de energizar el equipo.

9. Apage el equipo antes de quitarse sus guantes.

10. Use como referencia la publicación ANSI/ASC Standard Z49.1 (listado en la próxima página) para recomendaciones específicas de como conectar el equipo a tierra. No confunda el cable de soldar a la pieza de trabajo con el cable a tierra.

Asegúrese de que el chasis de la

CAMPOS ELECTRICOS Y MAGNETICOS Son peligrosos. La corriente eléctrica fluye através de cualquier conductor causando a nivel local Campos Eléctricos y Magnéticos (EMF). Las corrientes en el área de corte y soldadura, crean EMF alrrededor de los cables de soldar y las maquinas. Por lo tanto:

oldadores u Operadores que use marca-pasos para el corazón deberán consultar a su médico antes de soldar. El Campo Electromagnético (EMF) puede interferir con algunos marca-pasos.

2. Exponerse a campos electromagnéticos (EMF) puede causar otros efectos de salud aún desconocidos.

3. Los soldadores deberán usar los siguientes procedimientos para minimizar exponerse al EMF:

A. Mantenga el electrodo y el cable a la pieza de trabajo juntos,

hasta llegar a la pieza que usted quiere soldar. Asegúrelos

uno junto al otro con cinta adhesiva cuando sea posible. B. Nunca envuelva los cables de soldar alrededor de su cuerpo. C. Nunca ubique su cuerpo entre la antorcha y el cable, a la pieza

de trabajo. Mantega los cables a un sólo lado de su cuerpo.

D. Conecte el cable de trabajo a la pieza de trabajo lo más cercano

posible al área de la soldadura. E . Mantenga la fuente de poder y los cables de soldar lo más lejos

posible de su cuerpo.

1. S

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PRECAUCION DE SEGURIDAD

HUMO Y GASES -- El humo y los gases, pueden causar malestar o daño, particularmente en espacios sin ventilación. No inhale el humo o gases. El gas de protección puede causar falta de oxígeno. Por lo tanto:

1. Siempre provea ventilación adecuada en el área de trabajo por medio natural o mecánico. No solde, corte, o ranure materiales con hierro galvanizado, acero inoxidable, cobre, zinc, plomo, berílio, o cadmio a menos que provea ventilación mecánica positiva . No respire los gases producidos por estos materiales.

2. No opere cerca de lugares donde se aplique substancias químicas en aerosol. El calor de los rayos del arco pueden reaccionar con los vapores de hidrocarburo clorinado para formar un fosfógeno, o gas tóxico, y otros irritant es.

3. Si momentáneamente desarrolla inrritación de ojos, nariz o garganta mientras est á operando, es indicación de que la ventilación no es apropiada. Pare de trabajar y tome las medidas necesarias para mejorar la ventilación en el área de trabajo. No continúe operando si el malestar físico persiste.

4. Haga referencia a la publicación ANSI/ASC Standard Z49.1 (Vea la lista a continuación) para recomendaciones específicas en la ventilación.

5. ADVERTENCIA-- Este producto cuando se utiliza para

soldaduras o cortes, produce humos o gases, los cuales contienen químicos conocidos por el Estado de California de causar defectos en el nacimiento, o en algunos casos, Cancer. (California Health & Safety

Code §25249.5 et seq.)

MANEJO DE CILINDROS-- Los cilindros, si no son manejados correctamente, pueden romperse y liberar violentamente gases. Rotura repentina del cilindro, válvula, o válvula de escape puede causar daño o muerte. Por lo tanto:

1. Utilize el gas apropiado para el proceso y utilize un regulador diseñado para operar y reducir la presión del cilindro de gas . No utilice adaptadores. Mantenga las mangueras y las conexiones en buenas condiciones. Observe las instrucciones de operación del manufacturero para montar el regulador en el cilindro de gas comprimido.

2. Asegure siempre los cilindros en posición vertical y amárrelos con una correa o cadena adecuada para asegurar el cilindro al carro, transportes, tablilleros, paredes, postes, o armazón. Nunca asegure los cilindros a la mesa de trabajo o las piezas que son parte del circuito de soldadura . Este puede ser parte del circuito elélectrico.

3. Cuando el cilindro no está en uso, mantenga la válvula del cilindro cerrada. Ponga el capote de protección sobre la válvula si el regulador no está conectado. Asegure y mueva los cilindros utilizando un carro o transporte adecuado. Evite el manejo brusco de los

MANTENIMIENTO DEL EQUIPO -- Equipo defectuoso o mal mantenido puede causar daño o muerte. Por lo tanto:

1. Siempre tenga personal cualificado para efectuar l a instalación, diagnóstico, y mantenimiento del equipo. No ejecute ningún trabajo eléctrico a menos que usted esté cualificado para hacer el trabajo.

2. Antes de dar mantenimiento en el interior de la fuente de poder, desconecte la fuente de poder del suministro de electricidad primaria.

3. Mantenga los cables, cable a tierra, conexciones, cable primario, y cualquier otra fuente de poder en buen estado operacional. No opere ningún equipo en malas condiciones.

4. No abuse del equipo y sus accesorios. Mantenga el equipo lejos de cosas que generen calor como hornos, también lugares húmedos como charcos de agua , aceite o grasa, atmósferas corrosivas y las inclemencias del tiempo.

5. Mantenga todos los artículos de seguridad y coverturas del equipo en su posición y en buenas condiciones.

6. Use el equipo sólo para el propósito que fue diseñado. No modifique el equipo en ninguna manera.

INFORMACION ADICIONAL DE SEGURIDAD -Para más información sobre las prácticas de seguridad de los equipos de arco eléctrico para soldar y cortar, pregunte a su suplidor por una copia de "Precautions and Safe Practices for Arc Welding, Cutting and Gouging-Form 52-529.

Las siguientes publicaciones, disponibles através de la American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, son recomendadas para usted:

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."

SIGNIFICADO DE LOS SIMBOLOS -Según usted avanza en la lectura de este folleto: Los Símbolos Significan ¡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.

Significa el riesgo de un peligro potencial que puede resultar en serio daño personal o la muerte.

Significa el posible riesgo que puede resultar en menores daños a la persona.

Page 9

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 convientil 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 combustibles

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 incandescent

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 provoquer 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

Page 10

PRÉCAUTIONS DE SÉCURITÉ

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. Arrêtezvous de travailler afin de prendre les mesures nécessaires 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’éliminer 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 risque 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. Efforcez-vous 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

Cutting” AWS-A6. 3.

e. “Recommended Safe Practices for Plasma Arc

Welding” 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-S tandard

W117. 2.

Page 11

SECTION 1 DESCRIPTION

1.1 GENERAL

The HandyPlasma® 380 is a compact, completely selfcontained plasma cutting system. As shipped, the system is fully assembled and ready to cut after being connected to input power and a source of prefiltered compressed air (90-150 psi). The HandyPlasma® 380 system uses the PT-31XL torch to deliver cutting power for cutting materials up to 3/8 inch thick or for severing up to 1/2 inch thick.

The patented PT-31XL is a manual torch with a 75° head designed for use with several plasma arc cutting packages using clean, dry air as the plasma gas. The torch service line is 15 ft. (4.6m) long and is rated at 100% duty cycle for any output level of the HandyPlasma

380.

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.

1.2 SCOPE

The purpose of this manual is to provide the operator with all the information required to install and operate the HandyPlasma® 380 Plasmarc™ Cutting System. Technical reference material is also provided to assist in troubleshooting the cutting system.

1.3 SYSTEM AVAILABLE

HandyPlasma® 380 ...................................................................................................... P/N 0558004441

includes: Console with Regulator and Work Cable, PT-31XL Torch, 15 ft. (4.6m) Torch Cable and Spare Parts Kit

Optional Torch Guide Kit (0558003258) permits cutting accurate circles from 1.8 inches to 41.3 inches (45mm

to 1050mm) in diameter with a manual torch. The attachment includes a head and radius bar assembly, centerpoint / adaptor, and dual swivel castor assembly. Cuts can be made inside or outside the circle. The torch head is always held vertical during the cutting operation. The attachment is also handy for maintaining a constant standoff in other types of cutting.

Page 12

SECTION 1 DESCRIPTION

Table 1-1 PT-31XL Spare Parts Kit Contents

Description Part Number Quantity Spare Parts Kit P/N 0558003301 includes:

30/40 A Nozzle 20860 3 Electrode 20862 2 Swirl Baffle 20463 1 Heat Shield 20282 1 Lubricant, 1/4 oz. 17672 1

NOTE: PT-31XL Torch Assembly P/N 0558004482 is supplied with the nozzle, electrode, swirl

baffle, and heat shield assembled as part of the HandyPlasma® 380 system.

1.4 SPECIFICATIONS

Refer to Tables 1-2, 1-3, and Figures 1-1 and 1-2 for HandyPlasma® 380 technical specifications.

Table 1-2 HandyPlasma® 380 Specifications

35% Duty Cycle* 30 A @ 92 V dc

Rated Output

60% Duty Cycle* 27 A @ 91 V dc

100% Duty Cycle* 21 A @ 88 V dc

Output Current Range 15 to 30 Amperes

Open Circuit Voltage 270 V dc Nominal

Rated Primary Input @ 30 A @ 92 VDC Output

208/230 VAC,

50/60 Hz, 1-Phase

19/18 A

Power Factor @ 30 Amperes Output 81% (1-Phase)

Current Capa city PT-31XL 50 A DCSP

Torch Current Capacity

Air Requirements PT-31XL 250 cfh @ 80 psi

Minimum Air Supply Requirements

Dimensions of Handy Plasma 380

Length Height

Width

17.75-in. ( 450.8 mm)

11.12-in. (282.6 mm)

5.75-in. (146.1 mm)

Weight (with torch) 22 lbs (10 kg)

* 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; a 60% duty cycle means the machine may operate for 6 minutes with a cool down period of 4 minutes; a 100% duty cycle means the machine may operate continuously.

Page 13

SECTION 1 DESCRIPTION

Table 1-3 PT-31XL Torch Specifications

PT-31XL Torch

Current Capacity ....................................... 50A DCSP

Shipping Wgt. ................................... 1.5 lbs (0.68 kg)

Length of Service Lines .......................... 15 ft. (4.6 m)

PT-31XL Torch Assembly P/N 0558004482 is supplied with the nozzle, electrode, swirl baffle, and heat shield assembled.

2 1/4"

(57mm)

75° Torch

5 1/4"

(133mm)

Figure 1-1. PT-31XL Dimensions

Figure 1-2. PT-31XL Cutting Performance

Page 14

SECTION 1 DESCRIPTION

Page 15

SECTION 2 INSTALLATION

2.1 GENERAL

Proper installation will insure satisfactory and trouble-free operation of the HandyPlasma® 380 cutting package. It is suggested that each step in this section be studied carefully and followed.

2.2 EQUIPMENT REQUIRED

A source of clean, prefiltered dry air that supplies 250 cfh at 80 psig is required for the cutting operation. The air supply should not exceed 150 psig (the maximum inlet pressure rating of the air filter-regulator supplied with the package).

2.3 LOCATION

Adequate ventilation is necessary to provide proper cooling of the HandyPlasma® 380 and the amount of dirt, dust, and excessive heat to which the equipment is exposed, should be minimized. There should be at least one foot of clearance between the HandyPlasma® 380 power source and wall or any other obstruction to allow freedom of air movement through the power source.

Installing or placing any type of filtering device will restrict the volume of intake air, thereby subjecting the power source internal components to overheating. The warranty is void if any type of filter device is used.

C. Check air louvers and any other openings to ensure

that any obstruction is removed.

2.5 PRIMARY ELECTRICAL INPUT CONNECTIONS

ELECTRIC SHOCK CAN KILL! 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 of the power source.

Be sure that the power source is properly configured for your input power supply. DO NOT connect a power source configured for 208/230 V to a 460 V input power supply. Damage to the machine may occur.

The HandyPlasma VAC, 1-phase input power and is equipped with a 8-ft, 3conductor cable. The customer is responsible for supplying a plug with a NEMA 6-30 rating minimum ir desired.

380 power source operates on 230

2.4 INSPECTION

A. Remove the shipping container and all packing

material and inspect for evidence of concealed damage which may not have been apparent upon receipt of the HandyPlasma® 380. Notify the carrier of any defects or damage at once.

B. Check container for any loose parts prior to dispos-

ing of shipping materials.

Table 2.1. Recommended Sizes for Input Conductors and Line Fuses

Rated Input Input & GND Fuse Size

Volts Amp Phases CU/AWG*

208 19 1 No. 10 30 230 18 1 No. 10 30

* Sized per National Code for 80°C rated copper conductors @ 30°C ambient. Not more than three

conductors in raceway or cable. Local codes should be followed if they specify sizes other than those listed above.

The chassis must be connected to an approved electrical ground. Failure to do so may result in electrical shock, severe burns or death.

A line (wall) disconnect switch, with proper sized fuse or circuit breaker (see Table 2.1), should be provided at the main power panel.

Conductor Amps

Page 16

SECTION 2 INSTALLATION

2.5 PRIMARY ELECTRICAL INPUT CONNECTIONS

CUSTOMER FUSED LINE DISCONNECT SWITCH

See Table 2.1

Prefiltered AIR SUPPLY (Customer Supplied) (90 to 150 psig max)

Figure 2-1 HandyPlasma® 380 Primary Interconnection Diagram

RECEPTACLE - NEMA 6-30 rating minimum (Receptacle to match plug)

PLUG (customer supplied) NEMA 6-30 rating minimum

(See Table 2.1 and WARNING

in regards to chassis ground in Section 2.5.)

Page 17

SECTION 2 INSTALLATION

2.6 SECONDARY (OUTPUT) CONNECTIONS

Torch comes factory installed. These instructions are for torch replacement.

Before making any connections to the power source output terminals, make sure that all primary input power to the power source is deenergized (off) at the main disconnect switch and that the input power cable is unplugged. For operator safety, the torch connections are loaded.

2.6.1 Torch Replacement

1. Remove the machine cover panel. The torch connection is located on the lower side of machine. See Figure 2-2 below.

2. Thread the power cable and switch lead of the PT-31XL 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. Make sure the power cable connection is wrench-tight.

3. Replace the machine cover panel.

2.6.2 Air Connection

1. Connect your air supply to the inlet connection of the filter-regulator. See Figure 2-1.

2.6.3 Work Lead Connection

1. 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 Figures 2-3, 2-4 and 2-5.

rear

front

Torch Connection

Figure 2-2. Torch Connection

Page 18

SECTION 2 INSTALLATION

2.6 SECONDARY (OUTPUT) CONNECTIONS

PT-31XL

SAFETY GROUND

WORK

WORK CABLE

½½

Figure 2-3 HandyPlasma® 380 Secondary Interconnection Diagram

Allow at least 10 ft (3 m)

between work and power source

¾¾

Page 19

SECTION 2 INSTALLATION

2.6 SECONDARY (OUTPUT) CONNECTIONS

EARTH GROUND

DO NOT ATTACH WORK

WORK CABLE

CABLE TO PIECE BEING CUT FREE

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

SECTION 2 INSTALLATION

2.7 PT-31XL TORCH CONSUMABLES INSTALLATION

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.

WARNING

The PT-31XL torch head contains a gas flow check valve that acts in conjunction with the flow 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. ALWAYS REPLACE TORCH WITH THE PROPER TORCH MANUFACTURED BY ESAB SINCE IT ALONE CONTAINS ESAB'S PATENTED SAFETY INTERLOCK.

Follow all safety instructions included in this manual. DO NOT install or attempt to operate this torch without following these safety instructions.

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

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.

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.

3. Do not continue to use if the electrode end erodes to a length shorter than 16mm [5/8 in.] as shown in Fugure 2-6 below.

4. Apply a small amount of lubricant P/N 0558000443 (17672), supplied in spare parts kit, to the heat shield or to the o-ring as shown in Figure 4-3. Check oring for damage whenever the shield is removed. Replace if necessary.

NOTE: Nozzles Marked By Amperage

20324

Plunger

Figure 2-6 Assembly of “XT” Consumable Parts

19679

Seat

20862

Electrode

20463

Baffle

20860

Nozzle 30/40A

20282

Heat Shield

Page 21

SECTION 3 OPERATION

3.0 OPERATION

To ensure that the HandyPlasma 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.

NOTE:

This pressure adjustment must be made within 15 seconds after the machine is turned on. If this is not done within the allotted time the main power must be turned off and back on again to activate the 15 second preflow sequence for air pressure adjustment.

2. Set output current from 15 to 30 amperes to suit cutting conditions prior to operation of the machine. See Page 25.

Page 22

SECTION 3 OPERATION

3.1 OPERATION

ELECTRIC SHOCK can kill.

• Do NOT operate the unit with the cover removed.

• Do NOT apply power to the unit while holding or carrying the unit.

• Do NOT touch any torch parts forward of the torch handle (nozzle, heat shield, electrode, etc.) with power switch on.

ARC RAYS can burn eyes and skin;

NOISE can damage hearing.

• Wear welding helmet with No. 6 or 7 lens shade.

• Wear eye, ear, and body protection.

Position the HandyPlasma® 380 at least 10 feet (3 meters) from the cutting area. Sparks and hot slag from the cutting operation can damage the unit.

3.2 HandyPlasma® 380 CONTROLS (FIGURE 3-1)

A. Power Switch (located on rear panel). When

placed in ON position, the green pilot light will glow indicating control circuit is energized and the cooling fan will run.

B. Output Current Control. Adjustable from 15 to 30

amperes to suit cutting conditions. Set output current to suit cutting conditions prior to operation of machine. See Page 22.

C. Air Pressure Adjustment Control. When main

power switch is turned on and air is flowing to the machine, the air regulator can be adjusted to the desired pressure (65-70 psig) before cutting operations begin.

NOTE: This pressure adjustment must be made

within 15 seconds after the machine is turned on. If this is not done within the allotted time the main power must be turned off and back on again to activate the 15 second preflow sequence for air pressure adjustment. See Page 21.

POWER ON-OFF

CURRENT

CONTROL

TEMPERATURE AIR

AIR PRESSURE

GAUGE

AIR REGULATOR CONTROL KNOB

CURRENT CONTROL

KNOB

Figure 3-1 HandyPlasma® 380 Controls

Page 23

SECTION 3 OPERATION

E. "Over Temperature" LED (Yellow light) - will turn

on if the machine becomes overheated and will turn off automatically after the machine cools down if the on/off switch is still on.

"Low Air Flow" LED (Green light) - will turn on

during operation when the air flow is set correctly the LED will switch off below 15psi (1 bar).

On/Off Switch LED (Green light) - will light when

power supply is switched on and power is applied. LED will turn off when switch is in OFF position.

Air Pressure Gauge (Side Panel) - Shows air

pressure in bars and psi.

3.3 ASSEMBLING PT-31XL COMSUMABLE PARTS

Make sure power switch on power source is in OFF position and primary input power is deenergized.

Install the electrode, baffle, nozzle, and heat shield as shown in Fig. 3-2. Tighten heat shield snugly but do not overtighten.

3.4 CUTTING WITH THE PT-31XL

Wear the usual protective gloves, clothing, and helmet. Helmet with filter lens shade No. 6 or 7 should provide adequate protection for your eyes.

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

CAUTION: Do not depress the torch switch unless the

torch nozzle is touching the workpiece or within 0.02" (0.51mm) of workpiece.

19679

Seat

NOTE: Nozzles Marked By Amperage

20324

Plunger

Figure 3-2 Assembly of “XT” Consumable Parts

20862

Electrode

TOO FAST TOO SLOW CORRECT

Figure 3-3 Effect of Cutting Speed

20282

20463

Baffle

20860

Nozzle 30/40A

Heat Shield

Page 24

SECTION 3 OPERATION

WHEN THE ARC BREAKS

THROUGH THE WORK, BRING THE TORCH TO AN UPRIGHT POSITION AND PROCEED TO CUT.

TO START A PIERCE, TILT THE

TORCH TO PREVENT MOLTEN MATERIAL FROM COMING BACK AGAINST AND DAMAGING THE TORCH.

Figure 3-4 Piercing Technique using the PT-31XL

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 placing the primary (wall) switch to the ON position and making control and air pressure adjustments as described above, proceed as follows:

1. Touch the tip of the torch to the workpiece holding the torch at about 15- 30° angle to avoid damaging the tip.

2. Depress the torch switch. (Air and high frequency should energize.)

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

4. After starting the cut, bring the torch to an upright position and proceed to cut by dragging the torch along the workpiece. It may be necessary to cut with a tip-to-work (standoff) distance of up to 1/16" due to various material surface conditions.

5. When ending a cut, the torch switch should be released to minimize double-arcing which can damage the tip. This is to prevent high frequency from reigniting after cutting arc extinguishes.

6. In the postflow mode, the arc can be restarted immediately by depressing the torch switch. The two second preflow will automatically cancel.

Page 25

SECTION 3 OPERATION

Cutting Speed Range — HandyPlasma® 380

(Using Air with XT Consumables @ 70 psi)

3.6 COMMON CUTTING PROBLEMS

Thickness Current Speed

Output Cutting

Material (In.) (Amps) (ipm)

Carbon 1/16 30 170 Steel 1/8 30 75 (AISI 1020) 3/16 30 48

1/4 30 25 3/8 30 12

Stainless 1/16 30 170 Steel 1/8 30 72 (AISI 304) 3/16 30 45

1/4 30 23 3/8 30 10

Aluminum 1/16 30 170 (6061) 1/8 30 75

3/16 30 50 1/4 30 26 3/8 30 12

NOTE:

The speeds given here are typical for best quality cuts. Your actual speeds may vary depending on material composition, surface condition, operator technique, etc. If cutting speed is too fast, you may lose the cut. With slower speeds excessive dross may accumulate. If speed is too slow, the arc may extinguish. Air cutting typically produces a rough face on stainless steel and aluminum.

Listed below are common cutting problems followed by the probable cause of each. If problems are determined to be caused by the HandyPlasma® 380, refer to the maintenance section of this manual. If the problem is not corrected after referring to the maintenance section, contact your ESAB representative.

A. Insufficient Penetration.

1. Cutting speed too fast.

2. Damaged cutting nozzle.

3. Improper air pressure.

B. Main Arc Extinguishes.

Cutting speed too slow.

C. Dross Formation. (In some materials and thick-

nesses, it may be impossible to get dross-free cuts.)

1. Cutting speed too fast or too slow.

2. Improper air pressure.

3. Faulty nozzle or electrode.

D. Double Arcing. (Damaged Nozzle Orifice.)

1. Low air pressure.

2. Damaged cutting nozzle.

3. Loose cutting nozzle.

4. Heavy spatter.

3.5 OPERATING TECHNIQUES

1. Piercing - Materials may be pierced with the torch

touching the work. When piercing thicker materials of 1/4" or more, immediately raise the torch to 1/16" standoff after initiating the cutting arc. This will reduce the chance of spatter from entering the torch and prevent the possibility of welding the tip to the plate. The torch should be angled at about 30° when starting to pierce. After completing the pierce, bring the torch to an upright position and proceed to cut by dragging the torch along the workpiece. Reference Figure 3-4.

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

heavy mesh cutting, do not release the torch switch. This avoids the 2 second preflow portion of the cutting cycle.

E. Uneven Arc.

Damaged cutting nozzle or worn electrode.

F. Unstable Cutting Conditions.

1. Incorrect cutting speed.

2. Loose cable or hose connections.

3. Electrode and/or cutting nozzle in poor condition.

G. Main Arc Does Not Strike.

1. Loose connections

2. Missing torch parts

3. Air pressure too high or too low

4. Work lead not properly connected

H. Poor Consumable Life.

1. Improper air pressure.

2. Contaminated air supply.

Page 26

SECTION 3 OPE RATION

Page 27

SECTION 4 MAINTENANCE

4.1 GENERAL

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.

Be sure that the wall disconnect switch or wall circuit breaker is open before attempting any inspection or work inside of the HandyPlasma 380.

4.2 INSPECTION AND CLEANING

Frequent inspection and cleaning of the HandyPlasma 380 is recommended for safety and proper operation. Some suggestions for inspecting and cleaning are as follows:

Air Pressure

Regulator Bowl

Button

Figure 4-1 Draining Bowl

4.3 FLOW SWITCH (FIGURE 4-2)

When excessive contamination is found in the air, the flow switch (FS) should be removed, disassembled and cleaned as follows:

A. Ensure the system is shut down and there is no

trapped air under pressure in the piping.

B. Remove the piston plug.

C. Remove the spring (FS-4 only). Use care when

handling spring to prevent distortion.

D. Remove the piston.

A. Check work cable to workpiece connection.

B. Check safety earth ground at workpiece and at power

source chassis.

C. Check heat shield on torch. It should be replaced if

damaged.

D. Check the torch electrode and cutting nozzle for wear

on a daily basis. Remove spatter or replace if necessary.

E. Make sure cable and hoses are not damaged or

kinked.

F. Make sure all fittings and ground connections are

tight.

G. With all input power disconnected, and wearing

proper eye and face protection, blow out the inside of the HandyPlasma

380 using low-pressure dry com-

pressed air.

H. Water or oil occasionally accumulates in the bowl of

the air pressure regulator. To drain bowl, turn machine off with air supplied to the machine, then push upward on the button located on the bottom of the bowl. See Figure 4-1.

E. Clean all parts with cleaning agent.

NOTE Ensure cleaning agent does not contain solvents which can degrade polysulfone. Warm water and detergent is recommended for cleaning. Allow all parts to dry thoroughly before reassembly.

Reassemble the flow switch in reverse order.

PISTON PLUG

SPRING

PISTON

FLOW SWITCH

Figure 4-2 Disassembly / Assembly of Flow Switch

Page 28

SECTION 4 MAINTENANCE

4.4 PT-31XL TORCH 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 POWER is DEENERGIZED.

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.

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

3. Do not continue to use if the electrode end erodes to a length shorter than 16mm [5/8 in.] as shown in Fugure 4-3 below.

4. Apply a small amount of lubricant P/N 0558000443 (17672), supplied in spare parts kit, to the heat shield as shown in Figure 4-3 below or to the o-ring. Check o-ring for damage whenever the shield is removed. Replace if necessary.

5. The power cable and switch 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 Subsection 4.5 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 cable. 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 order.

C (194° F) INSULATED WIRE. Reassemble in reverse

Lubricant can be applied to

O-ring or Heat Shield

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 0558000443 (17672), supplied with the

spare parts kit, applied inside of the flex support will ease the assembly

"XT" Electrode Replace electrode when end wears to 16mm (0.63") long.

16mm (0.63")

Minimum

Figure 4-3 O-ring and Electrode Maintenance

Page 29

SECTION 4 MAINTENANCE

4.5 POWER CABLE AND SWITCH DISASSEMBLY SEQUENCE

Slide switch and band from

handle. Snip leads at splice

to replace switch.

Unscrew handle and

power cable from head

WARNING

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.

Pull flex support back.

Remove tape holding

splices.

Page 30

SECTION 4 MAINTENANCE

WORK LEAD

CONNECTION

TORCH

CONNECTION

Page 31

SECTION 5 TROUBLESHOOTING

5.1 TROUBLESHOOTING

ELECTRIC SHOCK CAN KILL! Be sure that all primary power to the machine has been externally disconnected. Open the line (wall) disconnect switch or circuit breaker before attempting inspection or work inside of the power source.

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

The cause of control malfunctions can be found by referring to the sequence of operations and electrical schematic diagram and checking the various components. A volt-ohmmeter will be necessary for some of these checks.

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.

NOTE

Before checking voltages in the circuit, disconnect the power from the high frequency generator to avoid damaging your voltmeter.

5.2 TROUBLESHOOTING GUIDE

A. Difficult Starting.

• Change electrode

• Change nozzle

• Check for good, clean connection of work lead to workpiece

• Check air pressure 65-70 psig (4.5 - 4.8 bar)

• Check torch power cable for continuity

Depress torch switch. After 2 seconds, is high frequency present?

Yes

Is the "Air" LED light on

Yes No

Repair/replace power source

Repair/replace control PCB

Repair/replace high frequency unit

Page 32

SECTION 5 TROUBLESHOOTING

B. No Air

Is air hose connected?

Yes No Connect

Is air adjusted to 65 - 70 psig (4.5 - 4.8 bar)?

Yes No Adjust

Does air come on when main power turned on?

Yes No • No electrode in torch

• No valve pin in torch

• Replace electrode

Check continuity of torch switch • Replace valve pin

OK No Replace torch switch

Repair /replace power source

Page 33

SECTION 5 TROUBLESHOOTING

C. Air does not shut off

Does arc start when nozzle contacts work without depressing torch switch?

Yes No

Check for short in torch switch or torch switch leads

Does air flow even when HandyPlasma

380 power switch is OFF?

Yes No

Replace Repair/replace control

solenoid valve PCB

Page 34

SECTION 5 TROUBLESHOOTING

D. Power switch light not energized.

Is switch ON?

Yes No Turn on switch

Is input power plug in receptacle?

Yes No Insert plug

Is cooling fan turning?

Yes

Check voltage at receptacle and input power line

Yes

No Check main fuses

Replace main power switch

Page 35

SECTION 5 TROUBLESHOOTING

E. Temperature LED light ON.

Is the unit overheated?

(LED turns off

when unit cools down.)

Yes No

Is cooling air flowing?

Duty cycle exceeded:

35% @ 30 A Yes No

or 100% @ 21 A output

F. No current output

Is input voltage within -10% of units input rating?

Yes No

Repair power source Repair fan

See "D" sequence

Unsolved

Repair/replace Inverter

Page 36

SECTION 5 TROUBLESHOOTING

5.3 SEQUENCE OF OPERATION

TORCH SWITCH

PUSH RELEASE

OPEN CLOSE

GAS SOLENOID VALVE

SECONDS

FLOW SWITCH CLOSE

FAULT OVERLOAD LIGHT

ENERGIZE

HF CIRCUIT

PREFLOW

10-14

SECONDS

Postflow

OPEN

INVERTER

CUTTING ARC (CURRENT)

NOTES:

1. When the torch switch is depressed during postflow period, the postflow and preflow times are canceled, and the HF is energized immediately. The postflow time starts from the moment the torch switch is released.

Page 37

SECTION 6 REPLACEMENT PARTS

6.1 GENERAL

Replacement Parts are illustrated on the following figures. When ordering replacement parts, order by part number and part name, as illustrated on the figure.

Always provide the series or serial number of the unit on which the parts will be used. The serial number is stamped on the unit nameplate.

6.2 ORDERING

Replacement parts may be ordered from your ESAB distributor or from:

ESAB Welding & Cutting Products Attn: Customer Service Dept. PO Box 100545, Ebenezer Road Florence, SC, 29501-0545

Be sure to indicate any special shipping instructions when ordering replacement parts.

Refer to the Communications Guide on back cover of this manual for a list of customer service phone numbers.

Page 38

SECTION 6 REPLACEMENT PARTS

18 12

8 7 9 17

frontrear

5 4

frontrear

front

13 11

6 10

rear

rear front front rear

Page 39

SECTION 6 REPLACEMENT PARTS

Nr. Description

*1 HandyPlasma® 380 Package** 0558004441 *2 Lid with handle 0558004643 3 Knob dia. 25 mm complete 0558002735 4 Control PCB 0700156003 5 Control/HF PCB 0700156004 6 HF Generator 0700156005 7 Air Nipple 1/8" 0700156006

8 Power Cable 0558003342 9 Air Gauge/ Filter Assy. 0558002767 10 Fan 0558002738

11 Fan Grid 0558002739 12 EMC Filter 0558002746 13 Flow Switch Assy. 951202 *14 PT - 31 Torch Assy. 0558004482

15 Inverter PCB 0700156011 16 Bottom Plate 0700156014 17 On/Off Switch 0700156012 18 Solenoid Valve Assy. 0558007784 *19 Work Cable w/clamp 0700156013 20 Pressure Guage 0558002768

21 Choke 0700156015 22 Transformer (ferrites) 0700156016 23 Heat Sink w/Diodes 0700156017

24 Adaptor, Bulk Head 58V75

ESAB Part #

25 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 HandyPlasma® 380 package

** Includes Torch & Spare Parts Kit

Page 40

SECTION 6 REPLACEMENT PARTS

BOOT -49N83

FLEX SUPPORT - 18225

(2) SPLICES (Supplied with Switch)

SHEATH

19675 (15')

5/8 X 18 L.H.

HANDLE - 18208

POWER CABLE

19672 (15')

(USED ON HANDY PLASMA 380)

BLY FOR USE ON THE HANDY PLASMA 380,

P/N 0558004947 MUST ALSO BE ORDERED.

FEMALE TORCH CONNECTION -P/N 0558004947

* WHEN ORDERING THE PT-31XL TORCH ASSEM-

For Replacement Torches:

SWITCH - 18224

SWITCH BAND - 18207

HEAD - 20072

(Includes, Ring and Seat)

"XT"

CONSUMABLES

Not included with torch.

PLUNGER -

20324

Included with

"XT" consumables KIT:

SEAT - 19679

(Included with Head)

SWIRL BAFFLE -

20862

20463

ELECTRODE -

NOZZLE (Tip)

HEA T SHIELD -

20282

HEA T SHIELD,

LONG - 36284

PT-31XL Torch Assembly, 15' lines, P/N 0558004482 (Assembled w/ 30/40A high performance consumables) (used on HandyPlasma® 380) *

Page 41

Notes

Page 42

Notes

Page 43

Revision History

Original release 01 / 2004

05 / 2004 - Text updates made on Pages 20, 21 and 22

07 / 2004 - General revisions made to remove remaining information not applicable to the newest model HandyPlasma

380. Included additional safety, installation, operation, technical information and replacement parts for the PT-31XL torch.

See Pages 11, 13, 15, 16, 17, 18, 19, 20, 21, 28, 29, 34, 38, 39 and 40.

Page 44

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:

Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST

Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting

C. TECHNICAL SERVICE:

Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Hours: 8:00 AM to 5:00 PM EST

Part Numbers Technical Applications Specifications Equipment Recommendations

D. LITERATURE REQUESTS:

Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS:

Telephone: (843) 664-4487 / Fax: (843) 664-5557 Hours: 7:30 AM to 3:30 PM EST

Repair Estimates Repair Status

F. WELDING EQUIPMENT TRAINING

Telephone: (843)664-4428 / Fax: (843) 679-5864 Hours: 7:30 AM to 4:00 PM EST

Training School Information and Registrations

G. WELDING PROCESS ASSISTANCE:

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

H. TECHNICAL ASST. CONSUMABLES:

Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123

Fax: (843) 664-4452

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

visit us on the web at http://www.esabna.com

The ESAB web site offers

Comprehensive Product Information

Material Safety Data Sheets

Warranty Registration

Instruction Literature Download Library

Distributor Locator

Global Company Information

Press Releases

Customer Feedback & Support

0558004615 07 / 2004