Prest-O-Lite Prest-O-Lite 125 Plasma Cutter Instruction manual

Instruction Manual

Installation, Operation and Service

Prest-O-Lite®125 Plasma Cutter

Prest-O-Lite 125 PLASMA ARC CUTTING PACKAGE - P/N 0558001432 115V 60HZ

Form No: F15-604-E 03 / 2007

Be sure this information reaches the operator.

You can get extra copies through Your supplier.

CAUTION

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of opera­tion and safe practices for arc welding and cutting equipment, we urge you to read our booklet, "Precautions
and Safe Practices for Arc Welding, Cutting, and Gouging," 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.

2

TABLE OF CONTENTS

SECTION TITLE ..........................................................................................................................PAGE

SECTION 1 DESCRIPTION ...............................................................................................................................................17

SECTION 2 INSTALLATION.............................................................................................................................................19

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

SECTION 4 MAINTENANCE ...........................................................................................................................................23

SECTION 5 INSTALLATION, OPERATION AND MAINTENANCE OF PT-34 TORCH .................................27

SECTION 6 REPLACEMENT PARTS .............................................................................................................................31

6.1 General ............................................................................................................................................................31

6.2 Ordering ..........................................................................................................................................................31

3

TABLE OF CONTENTS

4

SAFETY PRECAUTIONS

Safety Precautions

WARNING: These Safety Precautions are for

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

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

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

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

1. Always wear safety glasses with side shields in any

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

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

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

3. Wear flameproof gauntlet type gloves, heavy long-

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

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

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

5. Protect other personnel from arc rays and hot

sparks with a suitable non-flammable partition or
curtains.

6. Use goggles over safety glasses when chipping

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

Safety - English

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 non-flammable covering. Combustible mate­rials include wood, cloth, sawdust, liquid and gas
fuels, solvents, paints and coatings, paper, etc.

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

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

4. Have fire extinguishing equipment handy for in­stant use, such as a garden hose, water pail, sand
bucket, or portable fire extinguisher. Be sure you
are trained in its use.

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

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

7. For additional information, refer to NFPA Standard
51B, "Fire Prevention in Use of Cutting and Welding
Processes", available from the National Fire Protec­tion Association, Batterymarch Park, Quincy, MA

02269.

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

danger of falling.

5

SAFETY PRECAUTIONS

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 cur-

rent 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.

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.

6

SAFETY PRECAUTIONS

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 §25249.5 et seq.)

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.

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.

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.

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

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"

7

SAFETY PRECAUTIONS

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 Hand
book.

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

MEANING OF SYMBOLS
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.

- As used

-

Means hazards which could re­sult in minor personal injury.

8

SEGURIDAD

Safety - Spanish

ADVERTENCIA: Estas Precauciones de
Seguridad 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 re-

quiren 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:

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 no­flamable como división.

6. Use careta protectora además de sus gafas de seguri-

dad 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:

1. 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.

9

SEGURIDAD

1. Asegúrese de que el chasis de la 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.

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:

1. Soldadores 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 proced
imientos 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.

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 sub-

stancias 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 Stan-

dard Z49.1 (Vea la lista a continuación) para
recomendaciones específicas en la ventilación.

-

10

SEGURIDAD

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 efectu
ar 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"

11

SEGURIDAD

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.

12

SÉCURITÉ

Safety - French

AVERTISSEMENT : Ces règles de sécurité
ont pour but d'assurer votre protection. Ils
récapitulent les informations de précaution
provenant des références dans la section des

Informations de sécurité supplémentaires.
Avant de procéder à l'installation ou d'utiliser l'unité,
assurez-vous de lire et de suivre les précautions de
sécurité ci-dessous, dans les manuels, les fiches
d'information sur la sécurité du matériel et sur les
étiquettes, etc. Tout défaut d'observer ces précau­tions de sécurité peut entraîner des blessures graves

ou mortelles.

PROTÉGEZ-VOUS -- Les processus de
soudage, de coupage et de gougeage

produisent un niveau de bruit élevé et
exige l'emploi d'une protection auditive. L'arc, tout
comme le soleil, émet des rayons ultraviolets en plus
d'autre rayons qui peuvent causer des blessures à la
peau et les yeux. Le métal incandescent peut causer
des brûlures. Une formation reliée à l'usage des
processus et de l'équipement est essentielle pour
prévenir les accidents. Par conséquent:

1. Portez des lunettes protectrices munies d'écrans la-

téraux lorsque vous êtes dans l'aire de travail, même
si vous devez porter un casque de soudeur, un écran
facial ou des lunettes étanches.

2. Portez un écran facial muni de verres filtrants et de

plaques protectrices appropriées afin de protéger
vos yeux, votre visage, votre cou et vos oreilles des
étincelles et des rayons de l'arc lors d'une opération
ou lorsque vous observez une opération. Avertissez les
personnes se trouvant à proximité de ne pas regarder
l'arc et de ne pas s'exposer aux rayons de l'arc électrique
ou le métal incandescent.

3. Portez des gants ignifugiés à crispin, une chemise

épaisse à manches longues, des pantalons sans rebord
et des chaussures montantes afin de vous protéger des
rayons de l'arc, des étincelles et du métal incandescent,
en plus d'un casque de soudeur ou casquette pour pro­téger vos cheveux. Il est également recommandé de
porter un tablier ininflammable afin de vous protéger
des étincelles et de la chaleur par rayonnement.

4. Les étincelles et les projections de métal incandescent

risquent de se loger dans les manches retroussées, les
rebords de pantalons ou les poches. Il est recommandé
de garder boutonnés le col et les manches et de porter
des vêtements sans poches en avant.

5. Protégez toute personne se trouvant à proximité des

étincelles et des rayons de l'arc à l'aide d'un rideau ou
d'une cloison ininflammable.

6. Portez des lunettes étanches par dessus vos lunettes de

sécurité lors des opérations d'écaillage ou de meulage
du laitier. Les écailles de laitier incandescent peuvent
être projetées à des distances considérables. Les per­sonnes se trouvant à proximité doivent également
porter des lunettes étanches par dessus leur lunettes
de sécurité.

INCENDIES ET EXPLOSIONS -- La chal­eur provenant des flammes ou de l'arc

peut provoquer un incendie. Le laitier
incandescent ou les étincelles peuvent

également provoquer un incendie ou

une explosion. Par conséquent :

1. Éloignez suffisamment tous les matériaux combus­tibles de l'aire de travail et recouvrez les matériaux
avec un revêtement protecteur ininflammable. Les
matériaux combustibles incluent le bois, les vête­ments, la sciure, le gaz et les liquides combustibles,
les solvants, les peintures et les revêtements, le
papier, etc.

2. Les étincelles et les projections de métal incan­descent peuvent tomber dans les fissures dans
les planchers ou dans les ouvertures des murs et
déclencher un incendie couvant à l'étage inférieur
Assurez-vous que ces ouvertures sont bien proté­gées des étincelles et du métal incandescent.

3. N'exécutez pas de soudure, de coupe ou autre tra­vail à chaud avant d'avoir complètement nettoyé la
surface de la pièce à traiter de façon à ce qu'il n'ait
aucune substance présente qui pourrait produire
des vapeurs inflammables ou toxiques. N'exécutez
pas de travail à chaud sur des contenants fermés
car ces derniers pourraient exploser.

4. Assurez-vous qu'un équipement d'extinction
d'incendie est disponible et prêt à servir, tel qu'un
tuyau d'arrosage, un seau d'eau, un seau de sable
ou un extincteur portatif. Assurez-vous d'être bien
instruit par rapport à l'usage de cet équipement.

5. Assurez-vous de ne pas excéder la capacité de
l'équipement. Par exemple, un câble de soudage
surchargé peut surchauffer et provoquer un in­cendie.

6. Une fois les opérations terminées, inspectez l'aire
de travail pour assurer qu'aucune étincelle ou
projection de métal incandescent ne risque de
provoquer un incendie ultérieurement. Employez
des guetteurs d'incendie au besoin.

7. Pour obtenir des informations supplémentaires,
consultez le NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible
au National Fire Protection Association, Battery­march Park, Quincy, MA 02269.

CHOC ÉLECTRIQUE -- Le contact avec des
pièces électriques ou les pièces de mise à
la terre sous tension peut causer des bles­sures graves ou mortelles. NE PAS utiliser

un courant de soudage c.a. dans un endroit
humide, en espace restreint ou si un danger de chute
se pose.

13

SÉCURITÉ

1. Assurez-vous que le châssis de la source
d'alimentation est branché au système de mise
à la terre de l'alimentation d'entrée.

2. Branchez la pièce à traiter à une bonne mise de
terre électrique.

3. Branchez le câble de masse à la pièce à traiter
et assurez une bonne connexion afin d'éviter le
risque de choc électrique mortel.

4. Utilisez toujours un équipement correctement
entretenu. Remplacez les câbles usés ou endom­magés.

5. Veillez à garder votre environnement sec, incluant
les vêtements, l'aire de travail, les câbles, le porte­électrode/torche et la source d'alimentation.

6. Assurez-vous que tout votre corps est bien isolé
de la pièce à traiter et des pièces de la mise à la
terre.

7. Si vous devez effectuer votre travail dans un
espace restreint ou humide, ne tenez vous pas
directement sur le métal ou sur la terre; tenez­vous sur des planches sèches ou une plate-forme
isolée et portez des chaussures à semelles de
caoutchouc.

8. Avant de mettre l'équipement sous tension, isolez
vos mains avec des gants secs et sans trous.

9. Mettez l'équipement hors tension avant d'enlever
vos gants.

10. Consultez ANSI/ASC Standard Z49.1 (listé à
la page suivante) pour des recommandations
spécifiques concernant les procédures de mise
à la terre. Ne pas confondre le câble de masse
avec le câble de mise à la terre.

CHAMPS ÉLECTRIQUES ET MAGNÉ­TIQUES — comportent un risque
de danger. Le courant électrique
qui passe dans n'importe quel

conducteur produit des champs
électriques et magnétiques localisés. Le soud­age et le courant de coupage créent des champs
électriques et magnétiques autour des câbles de
soudage et l'équipement. Par conséquent :

1. Un soudeur ayant un stimulateur cardiaque doit

consulter son médecin avant d'entreprendre une
opération de soudage. Les champs électriques
et magnétiques peuvent causer des ennuis pour
certains stimulateurs cardiaques.

2. L'exposition à des champs électriques et magné-

tiques peut avoir des effets néfastes inconnus pour
la santé.

3. Les soudeurs doivent suivre les procédures sui­vantes pour minimiser l'exposition aux champs
électriques et magnétiques :

A. Acheminez l'électrode et les câbles de masse

ensemble. Fixez-les à l'aide d'une bande adhé­sive lorsque possible.

B. Ne jamais enrouler la torche ou le câble de masse

autour de votre corps.

C. Ne jamais vous placer entre la torche et les

câbles de masse. Acheminez tous les câbles sur
le même côté de votre corps.

D. Branchez le câble de masse à la pièce à traiter

le plus près possible de la section à souder.

E. Veillez à garder la source d'alimentation pour le

soudage et les câbles à une distance appropriée
de votre corps.

LES VAPEURS ET LES GAZ -- peu­vent causer un malaise ou des

dommages corporels, plus par­ticulièrement dans les espaces
restreints. Ne respirez pas les
vapeurs et les gaz. Le gaz de pro­tection risque de causer l'asphyxie.

Par conséquent :

1. Assurez en permanence une ventilation adéquate
dans l'aire de travail en maintenant une ventila­tion naturelle ou à l'aide de moyens mécanique.
N'effectuez jamais de travaux de soudage, de
coupage ou de gougeage sur des matériaux tels
que l'acier galvanisé, l'acier inoxydable, le cuivre,
le zinc, le plomb, le berylliym ou le cadmium en
l'absence de moyens mécaniques de ventilation
efficaces. Ne respirez pas les vapeurs de ces ma­tériaux.

2. N'effectuez jamais de travaux à proximité d'une
opération de dégraissage ou de pulvérisation.
Lorsque la chaleur

ou le rayonnement de l'arc entre en contact avec

les vapeurs d'hydrocarbure chloré, ceci peut
déclencher la formation de phosgène ou d'autres
gaz irritants, tous extrêmement toxiques.

3. Une irritation momentanée des yeux, du nez ou
de la gorge au cours d'une opération indique que
la ventilation n'est pas adéquate. Cessez votre tra­vail afin de prendre les mesures nécessaires pour
améliorer la ventilation dans l'aire de travail. Ne
poursuivez pas l'opération si le malaise persiste.

4. Consultez ANSI/ASC Standard Z49.1 (à la page
suivante) pour des recommandations spécifiques
concernant la ventilation.

14

SÉCURITÉ

5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé
dans une opération de soudage ou
de coupage, dégage des vapeurs ou
des gaz contenant des chimiques
considéres par l'état de la Californie
comme étant une cause des mal­formations congénitales et dans
certains cas, du cancer. (California
Health & Safety Code §25249.5 et
seq.)

MANIPULATION DES CYLINDRES --

La manipulation d'un cylindre, sans
observer les précautions nécessaires,
peut produire des fissures et un

échappement dangereux des gaz. Une
brisure soudaine du cylindre, de la soupape ou du
dispositif de surpression peut causer des blessures
graves ou mortelles. Par conséquent :

1. Utilisez toujours le gaz prévu pour une opération

et le détendeur approprié conçu pour utilisation
sur les cylindres de gaz comprimé. N'utilisez jamais
d'adaptateur. Maintenez en bon état les tuyaux et
les raccords. Observez les instructions d'opération
du fabricant pour assembler le détendeur sur un
cylindre de gaz comprimé.

2. Fixez les cylindres dans une position verticale, à

l'aide d'une chaîne ou une sangle, sur un chariot
manuel, un châssis de roulement, un banc, un
mur, une colonne ou un support convenable. Ne
fixez jamais un cylindre à un poste de travail ou
toute autre dispositif faisant partie d'un circuit
électrique.

3. Lorsque les cylindres ne servent pas, gardez les

soupapes fermées. Si le détendeur n'est pas bran­ché, assurez-vous que le bouchon de protection de
la soupape est bien en place. Fixez et déplacez les
cylindres à l'aide d'un chariot manuel approprié.
Toujours manipuler les cylindres avec soin.

4. Placez les cylindres à une distance appropriée

de toute source de chaleur, des étincelles et des
flammes. Ne jamais amorcer l'arc sur un cylindre.

5. Pour de l'information supplémentaire, consultez

CGA Standard P-1, "Precautions for Safe Handling
of Compressed Gases in Cylinders", mis à votre dis­position par le Compressed Gas Association, 1235
Jefferson Davis Highway, Arlington, VA 22202.

ENTRETIEN DE L'ÉQUIPEMENT -- Un équipe­ment entretenu de façon défectueuse ou
inadéquate peut causer des blessures
graves ou mortelles. Par conséquent :

1. Efforcez-vous de toujours confier les tâches
d'installation, de dépannage et d'entretien à un
personnel qualifié. N'effectuez aucune réparation
électrique à moins d'être qualifié à cet effet.

2. Avant de procéder à une tâche d'entretien à
l'intérieur de la source d'alimentation, débranchez
l'alimentation électrique.

3. Maintenez les câbles, les fils de mise à la terre,
les branchements, le cordon d'alimentation et la
source d'alimentation en bon état. N'utilisez jamais
un équipement s'il présente une défectuosité
quelconque.

4. N'utilisez pas l'équipement de façon abusive.
Gardez l'équipement à l'écart de toute source
de chaleur, notamment des fours, de l'humidité,
des flaques d'eau, de l'huile ou de la graisse, des
atmosphères corrosives et des intempéries.

5. Laissez en place tous les dispositifs de sécurité et
tous les panneaux de la console et maintenez-les
en bon état.

6. Utilisez l'équipement conformément à son usage
prévu et n'effectuez aucune modification.

INFORMATIONS SUPPLÉMENTAIRES
RELATIVES À LA SÉCURITÉ -- Pour ob­tenir de l'information supplémentaire
sur les règles de sécurité à observer
pour l'équipement de soudage à l'arc
électrique et le coupage, demandez un
exemplaire du livret "Precautions and
Safe Practices for Arc Welding, Cutting
and Gouging", Form 52-529.

Les publications suivantes sont également recom­mandées et mises à votre disposition par l'American
Welding Society, 550 N.W. LeJuene Road, Miami, FL
33126 :

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"

15

SÉCURITÉ

SIGNIFICATION DES SYMBOLES
Ce symbole, utilisé partout dans ce man­uel, signifie "Attention" ! Soyez vigilant !
Votre sécurité est en jeu.

DANGER

Signifie un danger immédiat. La situation peut
entraîner des blessures graves ou mortelles.

AVERTISSEMENT

Signifie un danger potentiel qui peut entraîner
des blessures graves ou mortelles.

ATTENTION

Signifie un danger qui peut entraîner des blessures
corporelles mineures.

16

SECTION 1 DESCRIPTION

PT34 TORCH

DESCRIPTION

 plugs into standard 115 V outlet
 portable - 60 lbs (27 kg)
 cuts practically any sheet metal up to 1/8” (3mm)

thick

 low ripple for finer cuts
 proven patented PT-34 torch - 15 feet (3.8m)
 spare parts kit
 1 year warranty
 30% duty cycle at rated output - fan cooled
 overtemperature light

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

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

Dimensions:

75o TORCH

2 1/4”

(57mm)

SPECIFICATIONS

125 PLASMA CUTTER

Input Voltage .......................................115 V, 60 Hz, 1 Phase

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

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

Open Circuit Voltage ......................................290 V DC max.

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

EQUIPMENT SUPPLIED

PACKAGES AVAILABLE

Each Package includes:

PT-34, 75° Torch w/ 15-ft. lines ........................................37886

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

5 1/4”

(133mm)

WARNING

!

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

OPTIONAL ACCESSORIES AVAILABLE

Optional Torch Spare Parts Kit - 0558006144

Contains:

1- O-Ring Lube - 17672
2- Electrode - 37888
1- Swirl Baffle - 0558006196
2- Heat Shield - 0558006185
4- Nozzle Tip - 0558006195

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

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

Optional Wheel Cart Kit -

Roll the 125 Plasma Cutter
around the job site with ease.

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

17

SECTION 1 DESCRIPTION

18

SECTION 2 INSTALLATION

115V
20 amps

WORK CABLE (12-1/2’)

PT-34 TORCH w/15’ Lines

WORK

Fig. 2.1 - 125 Plasma Cutter Interconnection Diagram

INSTALLATION

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

A. INSPECTION AND PLACEMENT

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

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

3. The components in the 125 PLASMA CUTTER console
are: maintained at proper operating temperatures by
fan cooling. Air is drawn in through the rear panel and
then out the louvers in the front panel. Locate the
power supply in an open area where air can circulate
freely through the openings. Allow at least one foot
of clearance between the power supply and wall or
any other obstruction.

Earth Ground

WARNING

!

The area around the power supply should be relatively

free of dust, fumes, and excessive heat.

B. PRIMARY INPUT ELECTRICAL CONNECTION

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

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

19

SECTION 2 INSTALLATION

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

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

Greater than 150 ft. not recommended!

Input voltage to machine must be a minimum of 95

volts while operating.

C. SECONDARY (OUTPUT) CONNECTIONS (Refer to

Figure 2.1)

WARNING

!

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

Clamp the work cable to the workpiece. Be sure the work­piece is connected to an approved earth ground with a
properly sized ground cable. (See figure 2.1.)

20

SECTION 3

OPERATION

A. ADJUSTMENTS & OPERATIONS

CAUTION: Never, under any circumstances, operate the power

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

B. TORCH ADJUSTMENTS

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

With the torch front end facing up, assemble electrode,
swirl baffle, tip, and heat shield (supplied with Torch Spare
Parts Kit) in that order as shown in Figure 3.1. (Electrode is
reversible and the swirl baffle is symmetrical. They can be
assembled either way.) Apply silicone grease to 0-ring.(See
Figure 3.1)

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

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

HEAT SHIELD

NOZZLE (TIP)

SWIRL BAFFLE

ELECTRODE

TORCH

O-RING

Fig. 3.1 - Assembly of PT-34 Torch Front End Parts

D. OPERATION

WARNING

!

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

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

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

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

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

C. 125 PLASMA CUTTER CONTROLS & ADJUSTMENTS

(See Fig. 3.2)

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

ing fan will run.

2. Power Light - Will glow white to indicate that electri-

cal current has energized the system.

3. Overtemperature Light - Will glow amber under the

following conditions and contactor will be deener­gized, when Duty Cycle has been exceeded.

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

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

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

OVERLOAD LIGHT
(AMBER)

POWER LIGHT

POWER SWITCH

Fig. 3.2 - Controls on 125 Plasma Cutter Console

21

SECTION 3

1. Touch the tip of the torch to the workpiece (or within

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

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

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

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

E. OPERATING TECHNIQUES

OPERATION

TOO FASTTOO SLOW

Fig. 3.3 - Effect of Cutting Speed

CORRECT

1. Piercing - Thin materials may be pierced with the

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

2. Grate Cutting - For rapid restarts, such as grate or
heavy mesh cutting, keep torch switch depressed until
entire cutting operation is completed. This avoids the
2 second preflow portion of the cutting cycle.

F. COMMON CUTTING FAULTS

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

1. Insufficient Penetration.

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

2. Main Arc Extinguishes.

a. Cutting speed too slow.

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

4. Double Arcing. (Damaged Tip Orifice.)

a. Low air pressure.
b. Damaged cutting tip.
c. Loose cutting tip.
d. Heavy spatter.

5. Uneven Arc.

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

6. Unstable Cutting Conditions.

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

7. Main Arc Does Not Strike.

a. Loose connections.

8. Poor Consumable Life.

a. Improper gas pressure.

If this equipment does not operate properly, stop
work immediately and investigate the cause of the
malfunction. Maintenance work must be performed
by an experienced person, and electrical work by a
trained electrician. Do not permit untrained persons
to inspect, clean, or repair this equipment. Use only
recommended replacement parts.

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

22

SECTION4 MAINTENANCE

A. INSPECTION AND CLEANING

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

WARNING

!

Make sure the power is shut off.

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

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

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

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

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

B. TROUBLESHOOTING

WARNING

!

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

Check the problem against the symptoms in the following
troubleshooting guide. The remedy may be quite simple.
If the cause cannot be quickly located, shut off the input
power, open up the unit, and perform a simple visual
inspection of all the components and wiring. Check for
secure terminal connections, loose or burned wiring or
components, bulging or leaking capacitors, or any other
sign of damage or discoloration.

WARNING

!

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.

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

23

SECTION 4

C. TROUBLESHOOTING GUIDE

1. Difficult Starting

Depress torch switch. Compressor and high

freq. should be seen or heard.

MAINTENANCE

2. No Air

Yes

Power

supply

defective

No

High freq. unit
or compressor

defective

Does high freq. come on with torch switch?

No

Yes

No electrode in torch
Electrode too short
Replace electrode
Compressor Defective

Check

continuity

of torch switch

OK

Power supply

defective

No

Defective

torch switch

24

SECTION 4 MAINTENANCE

3. Air does not shut off.

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

Yes

Check for

short in

torch switch

Cuts normally when torch switch is depressed?

Yes

Defective

control PCB

4. Amber overtemperature light turns ON while cutting.

Is the fan running?

No

No

No

Power

supply

defective

Yes

Run unit

on idle for

10 minutes

OK

Normal

Duty Cycle

exceeded

No

Defective

Thermal

Switch

Are there any restrictions or foreign matter?

Yes

Clear

restrictions

25

Defective

fan motor

No

SECTION 4 MAINTENANCE

26

SECTION 5

INSTALLATION, OPERATION AND MAINTENANCE OF PT-34 TORCH

INTRODUCTION

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

WARNING

!

ELECTRIC SHOCK CAN KILL.

Plasma cutting uses high voltage. Skin contact with

the torch, the power source, the workpiece or any
grounded object MUST BE AVOIDED whenever the
power source is ON.

Using the torch on any power source not equipped

with a flow switch safety interlock may expose op­erator to unexpected high voltage.

75o TORCH

2 1/4”

(57mm)

WARNING

!

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

Follow all instructions in the appropriate booklet packed
with your 125 Plasma Cutter package. DO NOT install or
attempt to operate this torch without following these
instructions.

WARNING

!

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

5 1/4”

(133mm)

Fig. 5.1 - Dimensional Data PT-34 Torch

A. INSTALLATION & OPERATION

WARNING

!

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

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

With the torch front end facing up, assemble electrode, swirl
baffle, tip and heat shield in that order as shown in Figure

5.2 (Standard electrode is reversible and the swirl baffle is

symmetrical. They can be assembled either way.)

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

B. MAINTENANCE

WARNING

!

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

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

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

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

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

27

SECTION 5

INSTALLATION, OPERATION AND MAINTENANCE OF PT-34 TORCH

Do not continue to use one end allowing it to erode to
a length shorter than 3/8-in. as shown in Figure 5.3. The
electrode opens the gas flow check valve. If one end is
continually used, it will be too short to open the valve
when reversed.

4. Apply a small amount of lubricant P/N 17672 to the heat
shield as shown in Figure 5.3 or to the O-ring. Check
O-ring for damage whenever the shield is removed.
Replace if necessary. (O-ring P/N 950790 is also supplied
in spare parts kit.)

HEAT SHIELD

NOZZLE (TIP)

SWIRL BAFFLE

ELECTRODE

TORCH

5. The power cable and 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 Figure 5.5 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, 90m C INSULATED WIRE.
Reassemble in reverse order.

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.

Fig5. 2 - Front End Assembly

LUBRICANT CAN BE
APPLIED TO O-RING OR
HEAT SHIELD

PT-34

ELECTRODE

EACH END CAN BE USED UNTIL

3/8”

MIN.

IT WEARS TO 3/8” LONG.

Fig. 5.3 - O-ring and Electrode Maintenance

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

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

28

SECTION 5

INSTALLATION, OPERATION AND MAINTENANCE OF PT-34 TORCH

(2) SPLICES (Supplied with Switch)

SWITCH - 18224

FLEX SUPPORT - 18225

SHEATH

19675 (15 ft.)

SWITCH BAND - 18207

5/8 X 18 L.H.

STRAIN RELIEF - 18226

HANDLE - 18208

POWER CABLE

19672 (15 ft.)

1/4 Fast On

SEAT - 19679

(Included with Head)

Included with

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

HEAD - 20072

0

75

(Includes, Ring and Seat)

CONSUMABLES

Torch is completely assembled from

the factory. Additional parts are in-

cluded with spare parts kit No. 37918

- or may be purchased seperately.

29

ELECTRODE

37888 (multiples of 2)

SWIRL BAFFLE

18785

NOZZLE (Tip)

37887 (multiples of 5)

HEAT SHIELD

20282

Fig 5.4 - PT-34 Torch Assembly, P/N 37886 (15 ft. lines)

SECTION 5

INSTALLATION, OPERATION AND MAINTENANCE OF PT-34 TORCH

2

WARNING

Slide switch and band from

handle. Snip leads at splice to

replace switch.

!

Unscrew handle and

power cable from head

3

BE SURE to tighten fittings securely using 2 wrenches

during reassembly. (Factory recommended torque is

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

to the operator.

1

Fig. 5.5 - Power Cable and Switch Disassembly Sequence

Pull flex support back. Remove

tape holding splices.

30

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 Prest-O-Lite
distributor or from:

Prest-O-Lite 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.

31

SECTION 6

REPLACEMENT PARTS

(S1)

SCREW PHTF 8-32 X .38

LOCK WASHER #8

TERMINAL BUSHING - 13730583

SCREW PHTF 6-32 X .38

SCREW PHTF 10-32 X .50

WASHER, LOCK, EXT TOOTH #10

SCREW PHTF 8-32 X .63

LOCK WASHER #8

FLAT WASHER #8

FLAT WASHER #8

0558005244

TRANSFORMER

(PL1)

POWER LIGHT, WHITE - 951526

OVER TEMP LIGHT, AMBER - 951815

(PL2)

BUSHING, SNAP - 634818

POWER SWITCH - 634518

SWITCH SEAL - 951474

FOOT, RUBBER - 182W12

SCREW PHTF 8-32 X .38

SCREW PHTF 8-32 X .38

DECAL, GROUND - 2091558

SCREW PHTF 10-24 X .38

SCREW PHTF 6-32 X .38

WASHER, FLAT #6

BUSBAR,TAB - 0558001163

CAPACITOR, (800mf 450 VDC) - 37858

HOSE ASSEMBLY - 0558001162

(C2)

(PCB1-P1)

PRESSURE SWITCH - 0558001159

PLUG HOUSING (15 POS) - 951504

PC BOARD, LOGIC - 38168

(PCB1)

32

GROMMET (.212 ID) - 950518

COOLING FAN - 2046032

SCREW PHTF 10-24 X .50

GROMMET (0.63) - 92W57

DIODE (BRIDGE RECTIFIER) - 37855

(BR1)

GROMMET (0.63) - 92W57

RELAY, (DPDT 25A 120VAC) - 952577

(K1)

CAPACITOR, (120UF 240 VAC) - 37856

(C1)

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

SECTION 6

SCREW PHTF 6-32 X .50

SCREW PHTF 10-24 X .50

WASHER, FLAT #10

SCREW PHTF 6-32 X .25

TERMINAL BLOCK (2 POS 20A) - 950487

(TB1)

WASHER, FLAT #6

-0558001381

POWER CORD (10 FT.)

BUSHING, STRAIN RELIEF - 23606172

REPLACEMENT PARTS

(M2)

(R1)

AIR COMPRESSOR - 37857

RESISTOR - 17240225

SWITCH TERMAN (131°F) - 950710

DIODE (BRIDGE RECTIFIER) - 37855

(TS1)

(BR2)

BULKHEAD ADAPTOR - 58V75

NUT, HEX 8-32

LOCKWASHER EXT TOOTH #8

(T3)

COUPLING COIL

(HIGH FREQ.) - 32969

33

ELBOW 1/4 NPT

BUSHING (SNAP) - 950823

CAPACITOR - 0558005245

RESISTOR - 17280025

(R2)

TRANSFORMER ASSEMBLY - 0558001212

BUSHING (SNAP) - 639533

(T1)

SPARK GAP ASSEMBLY - 0558001180

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

SECTION 6

REPLACEMENT PARTS

LABEL, WARNING - 2091514

SCREW PHTF 10-24 X .38

LOGO, PREST-O-LITE

COVER - 37952M

SCREW PHTF 10-24 X .38

LABEL, DANGER HIGH VOLTAGE - 954008

HANDLE - 951575

0558954037

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

TORCH - 37886

Figure 7.3 - 125 Plasma Cutter (External View)

34

Figure 8.1 - 125 Plasma Cutter Schematic Diagram for: 115V 60HZ Domestic and 230V Export Models

NOTES:

1. Connections for 115v Operation.

2. Connections for 230V Operation.

D-0558001341-C

35

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

D-0558001342-E

36

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

D-0558001342-E

37

Notes

38

Revision History

03 / 2007 - Revised Title Page, layout / text, safety section & section format of manual.

39

Prest-O-Lite Welding & Cutting Products,

PO Box 100545, Florence, SC

COMMUNICATION GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS:
Telephone: [phone] / Fax: [phone] Hours: 8:00 AM to 7:00 PM EST
Order Entry Product Availability Pricing Order Information Returns

B. ENGINEERING SERVICE:
Telephone: [phone] / Fax : [phone] Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting

C. TECHNICAL SERVICE:
Telephone: [phone]/ Fax: [phone] Hours: 8:00 AM to 5:00 PM EST
Part Numbers Technical Applications Specifications Equipment Recommendations

D. LITERATURE REQUESTS:
Telephone: [phone] / Fax: [phone] Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS:
Telephone: [phone] / Fax: [phone] Hours: 7:30 AM to 3:30 PM EST
Repair Estimates Repair Status

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

G. WELDING PROCESS ASSISTANCE:
Telephone: [phone] Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES:
Telephone : [phone] Hours: 7:30 AM to 5:00 PM EST

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: [phone]

Fax: [phone]

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

or

visit us on the web at http://www.all-statewelding.com

The Prest-O-Lite 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

Form No: F15-604-E 03 / 2007

A member of

the ESAB Group