ESAB HandyPlasma 50 Instruction manual / Spare parts list (Replacement parts)

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HandyPlasma

Bruksanvisning (SE) Handleiding voor het gebruik (NL) Instruction manual (GB) Manuale duso (IT) Manual de uso (PT) Instrukcja u¿ytkowania (PL) Bedienungsanleitung (DE) Brugervejledning (DK) Manual de uso (ES) Käyttökäsikirja (FI) Manuel dutilisation (FR) Bruksanvisning (NO)

ПДЗГПУ ЧСЗУЕЩУ (GR)

0700157031-A 010303 Valid from serial number 3073070001

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INSTRUCTION MANUAL

PLASMA ARC CUTTING PACKAGES

TABLE OF CONTENTS

1 DIRECTIVE.......................................................................2

2 SAFETY.............................................................................2

3 INTRODUCTION.............................................................4

3.1 Equipment............................................................4

4 TECHNICAL DATA.........................................................5

5 INSTALLATION...............................................................5

5.1 Mains and Workpiece Connection.................6

6 OPERATION.....................................................................7

6.1 Connection and Control Devices...................8

6.2 PT - 31 Torch and XT Consumables........8

6.3 Cutting with PT - 31 XL......................................9

6.4 Common Cutting Problems...........................10

7 MAINTENANCE.............................................................11

7.1 Check-up and Cleaning..................................11

8 FAULT-TRACKING/TROUBLESHOOTING..............12

8.1 Troubleshooting guide....................................12

8.2 Sequence of operation...................................16

9 ORDERING SPARE PARTS.........................................17

9.1 Detail pictures....................................................17

9.2 Spare Part List....................................................18

10 ACCESSORIES............................................................18

DIAGRAM.............................................................................19

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INSTRUCTION MANUAL

1 DIRECTIVE

DECLARATION OF CONFORMITY

ESAB Welding Equipment AB, S-695 81 Laxå, Sweden, declares that plasma cutting equipment Handy Plasma 50

from serial Nr 307 onwards conforms to standard IEC/EN 60974-1, IEC/EN 60941-7, in accordance with the requirement of directive (73/23/EEC) and appendix (93/68/EEC) and standard EN 50199 in accordance with the requirements of directive (89/336/EEC) and appendix (93/68/EEC).

Laxå 2003-02-07

HENRY SELENIUS Vice President ESAB Welding Equipment AB 695 81 Laxå Tel: +46-584-81000 Fax: +46-584-411924 SWEDEN

2 SAFETY

Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of plasma cutting equipment. The following recommendations should be observed in addition to the standard regulations that apply to the workplace.

All work must be carried out by trained personnel well-acquainted with the operation of the plasma cutting equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the operator and damage to the equipment.

1. Anyone who uses the plasma cutting equipment must be familiar with:

- its operation

- location of emergency stops

- its function

- relevant safety precautions

- plasma cutting

2. The operator must ensure that:

- no unauthorized person is stationed within the working area of the equipment when it is started up

- no one is unprotected when the arc is struck

3. The workplace must:

- be suitable for the purpose

- be free from draughts

4. Personal safety equipment

- always wear recommended personal safety equipment, such as safety glasses, flameproof clothing, safety gloves

5. General precautions

- make sure the return cable is connected securely

- work on high voltage equipment may only be carried by a qualified electrician

- appropriate fire extinguishing equipment must be clearly marked and close at hand

- Lubrication and maintenance must not be carried out on the equipment during operation.

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ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING AND CUTTING. ASK FOR YOUR EMPLOYERS SAFETY PRACTICES WHICH SHOULD BE BASED ON MANUFACTURERS HAZARD DATA.

ELECTRIC SHOCK - Can kill

- Install and earth the welding/cutting unit in accordance with applicable standards.

- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

- Insulate yourself from earth and the workpiece.

- Ensure your working stance is safe.

FUMES AND GASES - Can be dangerous to health

- Keep your head out of the fumes.

- Use ventilation, extraction at the arc, or both, to take fumes and gases away from your

ARC RAYS - Can injure eyes and burn skin.

- Protect your eyes and body. Use the correct welding/cutting screen and filter lens and

- Protect bystanders with suitable screens and courtains.

INSTRUCTION MANUAL

breathing zone and the general area.

wear protective clothing.

FIRE HAZARD

- Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE - Excessive noice can damage hearing.

- Protect your ears. Use earmuffs or other hearing protection.

- Warn bystanders of the risk.

MALFUNCTION - Call for expert assistance in the event of malfunction.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING

PROTECT YOURSELF AND OTHERS!

WARNING!

Read and understand the instruction manual before installing and operating

WARNING! Do not use the power source for thawing frozen pipes.

Note! This product is solely intended for plasma cutting

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INSTRUCTION MANUAL

3 INTRODUCTION

The HandyPlasma 50 is a compact, completely self-contained 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 5-10 bar (set torch at 118 lt/min @ 5.2 bar). The Handy Plasma 50 package uses the PT31XL torch with 50 Amp consumables to deliver cutting power for materials up to 15 mm thick or for severing up to 19 mm thick. Refer to the following paragraphs for descriptions of the Handy Plasma 50 packages available as well as performance specifications.

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.

See below for ESABs accessories for the cutting torch.

3.1 Equipment

List 3.1.1 HandyPlasma 50 Cutting Packages

Each HandyPlasma 50, Plasma Arc Cutting Package P/N 0700157880 includes: N°1 Power Source HandyPlasma 50. N°1 PT-31XL* Torch assembly with 8m service lines. N°1 earth cable 8m length. N°1 Torch Spare Parts Kit, see list below.

List 3.1.2 PT-31XL* Spare Parts Kit P/N 0558003464 Contents

N° 3 50A Nozzle, P/N (20861) 0558000513 N° 3 Electrode, P/N (20862) 0558000507 N° 1 Swirl Baffle, P/N (20463) 0558000506 N° 1 Long Heat Shield, P/N (36284) 0558000509

N° 1 O-ring, P/N (950790) 0558000514

*PT-31XL Torch Assembly P/N 0558003467 is supplied with the nozzle, electrode, swirl baffle and heat shield assembled.

(Part numbers in brakets could be found on the explosion drawings inside the torch spare part kit box.)

Fig. 3.1.2 PT - 31 spare part list and consumables

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INSTRUCTION MANUAL

4 TECHNICAL DATA

4.1 SPECIFICATIONS

Rated Output 60% Duty Cycle* 50A @ 100V dc

100% Duty Cycle* 40A @ 96V dc

Output Current Range 20 to 50 Amperes

Open Circuit Voltage 250 V dc Nominal

Rated Primary Input I1max 400 Vac 50/60 Hz, @ 50A 100Vdc Output 3 - Phase 13 Ampere

Power factor @ 50 A Output 0,8

Current Capacity PT-31XL 50 A dc SP

Air Requirements PT-31 XL 118 lt/min @ 5.2 bar

Length 550 mm

Dimensions of HandyPlasma 50 Height 410 mm

Width 190 mm

Weight (less torch) 19 kg

Insulation class: F Protection class: IP 22S

* Duty Cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or cut at a certain load without overloading the product.

5 INSTALLATION

The installation must be executed by a professional.

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INSTRUCTION MANUAL

5.1 Mains and workpiece connection

Fig. 5.1.1 - Mains connection

Mains plug and socket

HandyPlasma 50 Power Source

Fig. 5.1.2 - Workpiece connection

Plasma torch

Earth clamp

Rating Plate (on opposite side)

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INSTRUCTION MANUAL

6 OPERATION

General safety regulations for the handling of the equipment can be found on page 2 and 3. Read through before you start using the equipment!

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 proper lens shade.  Wear eye, ear, and body protection.

Do not use any torch with this power source other than the ESAB brand PT-31 XL torch. Serious injury may occur if used with any other torch.

Position the Handy Plasma (at least) 3 meters from the cutting area. Sparks and hot slag from the cutting

operation can damage the unit.

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INSTRUCTION MANUAL

6.1 Connection and control devices - front panel

6.1.2 Handy Plasma 50 CONTROLS

1. Power Switch. When placed in On

position, the green light will glow indicating control circuit is energized and the cooling fan will run. 2 . Output Current Control. Adjustable from 25 to 50 amperes to suit cutting conditions.

3. Air Check Switch. When pressed, (ON position), air filter-regulator can be adjusted to desired pressure before cutting operations. By keeping it pressed, allow air flow for a few minutes. This should remove any condensation that may have accumulated during shutdown period.

4. While flowing, the green LED will light up.

Manometer

ON/OFF Switch

Air Check Switch

To r c h

Overheating LED

Earth Connector

6.2 PT - 31 Torch and XT Consumables

When assembling or replacing XT consumables, make sure power switch on power source is in OFF position and primary input power is deenergized.

The PT-31 torch of Handy Plasma is originally assembled and tested.

The PT-31 XL torch head contains a gas flow check valve that acts in conjuction 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 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.

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INSTRUCTION MANUAL

6.3 Cutting with PT - 31 XL

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 or within

1 mm (1/32-in.)of the workpiece.

TOO FAST TOO SLOW CORRECT

Tab. 6.3.1 Effect of cutting speed

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

Tab. 6.3.2 Piercing Technique using PT - 31 XL

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INSTRUCTION MANUAL

6.4 COMMON CUTTING PROBLEMS

Listed below are common cutting problems followed by the probable cause of each. If problems are determined to be caused by Handy Plasma, 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 Estinguishes.

Cutting speed too slow.

C. Dross Formation. (In some materials and thicknesses, 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 Arching. (Damaged nozzle orifice)

1. Low air pressure.

2. Damaged cutting nozzle

3. Loose cutting nozzle.

4. Heavy spatter.

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. (Loose connections)

H. Poor Consumable Life.

1. Improper gas pressure.

2. Contaminated air supply.

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INSTRUCTION MANUAL

7 MAINTENANCE

Regular maintenance is important for safe, reliable operation.

Note:

All warranty undertakings given by the supplier cease to apply if the customer attempts to rectify any faults on the machine during the warranty period.

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 Handy Plasma.

7.1 CHECK - UP AND CLEANING

Water or oil occasionally accumulates in compressed air lines. Be sure to direct the first blast of air away from the equipment to avoid damage to Handy Plasma.

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

A. Check work cable to work piece connection. B. Check safety earth ground at work piece 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.

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INSTRUCTION MANUAL

8 FAULT-TRACING / TROUBLESHOOTING

Try these recommended checks and inspections before sending for an authorized service technician.

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. Those indications do not invalidate all other safety regulations and restrictions expressed in other sections of this manual.

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.

8.1 TROUBLESHOOTING GUIDE

Any remedy that requires an intervention inside the machine must be executed by an authorized service center.

A. Difficult Starting.

 Change electrode  Change nozzle  Check for good, clean connection of work lead to workpiece  Check air pressure (5 - 5,5 bar)  Check torch power cable for continuity

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

NoYes

Is the Air LED light on? Repair/replace HF PCB

Yes No

Repair/replace Repair/replace Control power source control PCB Flow Switch

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B. No Air

Is air hose connected?

Yes No Connect

Is air adjusted to 4 - 5 bar ?

Yes No Adjust

Yes No  No electrode in torch

Check continuity of torch switch  Replace valve pin

INSTRUCTION MANUAL

Check torch integrity

 No valve pin in torch  Replace electrode

OK No Replace torch switch

Repair/replace power source

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

Does air flow even when Handy Plasma power switch is OFF?

Yes No

Replace Repair/replace solenoid valve control PCB

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D. ON/OFF Switch light not energized.

Is mains 400 Volt switch ON?

INSTRUCTION MANUAL

Yes No Turn on switch

Is plug in receptacle?

Yes No Insert plug in receptacle

Is cooling fan turning?

Yes No

Replace

ON/OFF Switch

Check voltage at receptacle and input power line

Yes No Check main fuses

Replace ON/OFF Switch

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E. Temperature LED light ON.

INSTRUCTION MANUAL

Is the unit overheated? ("Fault" lights turns off when Unit cools down.)

Yes No

Duty cycle exceeded: 60% @ 50 A, Yes No or 100% @ 40 A output

Is cooling air flowing?

F. No current output

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

Repair power source Repair fan

Yes No

See (D.) sequence above

Unsolved

Repair power source

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INSTRUCTION MANUAL

8.2 SEQUENCE OF OPERATION

A. LOCK-IN "OFF" position

TORCH SWITCH

GAS SOLENOID VALVE

PUSH RELEASE

OPEN CLOSE

2 SEC.

FLOW SWITCH CLOSE

OVERHEATING LIGHT

HF CIRCUIT

INVERTER

CUTTING ARC (CURRENT)

PREFLOW

ENERGIZE

10 SEC

Postflow

OPEN

NOTES:

1. When the torch switch is pushed during postflow period, the postflow and preflow times are canceled, and the HF is energized immediately.

2. When the air flow LED comes off, cutting operation should be stopped. The postflow time starts from the moment the torch switch is released.

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INSTRUCTION MANUAL

9 - ORDERING SPARE PARTS

9.1 - Detail pictures - Handy Plasma 50

Rear

Front

17 - Power module - bottom side

4 - HF PCB

21 - INPUT PCB

13 - Inverter PCB

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9.2 - Spare Part List

Handy Plasma 50 is designed and tested in accordance with the international and European standards IEC/EN 60974-1 and EN 50199. It is the obligation of the service unit which has carried out the service or repair work to make sure that the product still conforms to the said standard.

Spare parts are ordered through your nearest ESAB representative, see back cover. When ordering spare parts, please state machine type, and number as well as designation and spare part number as shown in the spare part list. This will semplify dispatch and ensure you get the right part. Nevertheless, any replacement

of parts inside the machine must be executed by an authorized service center.

Item No. Part No. Description

1 0700157001 LID WITH HANDLE

2 0700157002 BOTTOM CASE (CHASSIS) 3 0700157003 CONTROL PCB 4 0700157004 HIGH FREQUENCY PCB 5 0700157005 HF GENERATOR 6 0700156006 AIR NIPPLE 1/8 Di a. 8mm, L=20mm 7 0700157007 POWER CABLE

8 0558003467 PT - 31 XL TORCH Ass.ly 9 0700157008 AIR GAUGE FILTER

10 0700156009 FAN 11 0700157010 EMC FILTER 12 0558000410 FLOW SWITCH P/N 951202

13 0700157011 INVERTER PCB

14 0700157012 ON/OFF SWITCH knob ass.ly 15 0700157013 EARTH CABLE W/CLAMP, L=8m 16 0700157014 FAN GRID 17 0700157015 POWER MODULE 18 0700157016 CHOKE (INDUCTANCE)

19 0700157017 TRANSFORMER

20 0700157018 HEAT SINK WITH DIODES 21 0700157019 INPUT PCB MODULE 22 0700157020 AUXILLARY TRANSFORMER

23 0700157021 24 0700157022 MANOMETER (FRONT PANEL) 25 0700157023 AIR CHECK SWITCH (FRONT PANEL)

26 0700157024 SOLENOID VALVE ASS.LY

INSTRUCTION MANUAL

10 ACCESSORIES

For plasma torch PT - 31, please see section 3.1 Equipment, page 4.

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