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ESAB HandyPlasma 250, Instruction Manual

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39

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

®

 250 power switch is OFF?

 

 

Yes 

 

 

 

 

        No

 

           Replace 

 

 

    

            Repair/replace

 

    solenoid valve   

 

 

               control PCB

Summary of Contents for HandyPlasma 250

Page 1: ...ESAB P N 0558004440 115V 1 Phase 50 60 Hz HandyPlasma 250 Plasmarc Cutting System 0558005320 05 2007 Instruction Manual ...

Page 2: ...ll 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 contami natedshouldbereplacedimm...

Page 3: ...on 23 2 7 PT 31XL Torch Consumables Installation 26 SECTION 3 OPERATION 27 3 1 Operation 28 3 2 HandyPlasma 250 Controls 28 3 3 Assembling PT 31XL Consumable Parts 29 3 4 Cutting with the PT 31XL 29 3 5 Operating Techniques 31 3 6 Common Cutting Problems 31 SECTION 4 MAINTENANCE 33 4 1 General 33 4 2 Inspection and Cleaning 33 4 3 Flow Switch 33 4 4 PT 31XL Torch Maintenance 34 4 5 Power Cable And...

Page 4: ...4 TABLE OF CONTENTS ...

Page 5: ...hing 5 Protect other personnel from arc rays and hot sparks with a suitable non flammable partition or curtains 6 Usegogglesoversafetyglasseswhenchippingslag orgrinding Chippedslagmaybehotandcanflyfar Bystanders should also wear goggles over safety glasses FIRES AND EXPLOSIONS Heat from flames and arcs can start fires Hot slagorsparkscanalsocausefiresand explosions Therefore 1 Remove all combustib...

Page 6: ...posuretoEMFmayhaveotherhealtheffectswhich 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 Connecttheworkcabletotheworkpie...

Page 7: ...ilable from Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 EQUIPMENT MAINTENANCE Faulty or improperly maintained equipment can cause injury or death Therefore 1 Alwayshavequalifiedpersonnelperformtheinstal lation troubleshooting and maintenance work Do not perform any electrical work unless you are qualified to perform such work 2 Before performing any maintenance work ...

Page 8: ...e Practices for Welding and Cutting of Containers That Have Held Hazardous Substances Meaning of symbols As used throughout this manual Means Atten tion Be Alert Your safety is involved Meansimmediatehazardswhich if not avoided will result in im mediate serious personal injury or loss of life Means potential hazards which could result in personal injury or loss of life Meanshazardswhichcouldresult...

Page 9: ...l arco y chis pascalientesconunacortina adecuadano flamable como división 6 Usecaretaprotectoraademásdesusgafasdesegu ridad 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 lasflamasyelarco puedenocacionar fuegos Escoria caliente y las chispas ...

Page 10: ...ponerseacamposelectromagnéticos 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 a...

Page 11: ...ENTO DEL EQUIPO Equipo defectuoso o mal mantenido puede cau sar daño o muerte Por lo tanto 1 Siempre tenga personal cualificado para efec tuar 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 suministr...

Page 12: ...té 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 13: ...n Ils récapitulent les informations de précaution provenant des références dans la section desInformationsdesécuritésupplémentaires Avantde procéderàl installationoud utiliserl unité assurez vous de lire et de suivre les précautions de sécurité ci des sous dans les manuels les fiches d information sur la sécuritédumatérieletsurlesétiquettes etc Toutdéfaut d observer ces précautions de sécurité peu...

Page 14: ... Consultez ANSI ASC Standard Z49 1 à la page suivante pour des recommandations spécifiques concernant la ventilation 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 assurezunebonneconnexionafind éviter...

Page 15: ...des gaz contenant des chimiques consi déresparl étatdelaCaliforniecomme 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 observerlesprécautionsnécessaires peut produire des fissures et un échappement dangereux des gaz Unebrisuresoudaineducylindre delasoupapeou du ...

Page 16: ...ez vigilant Votre sécurité est en jeu Signifie un danger immédiat La situation peut entraîner des blessures graves ou mortelles Signifieundangerpotentielquipeutentraînerdes blessures graves ou mortelles Signifieundangerquipeutentraînerdesblessures corporelles mineures DANGER AVERTISSEMENT ATTENTION ...

Page 17: ...ovided to assist in troubleshooting the cutting system 1 3 SYSTEM AVAILABLE HandyPlasma 250 P N 0558004440 includes Console with Regulator and Work Cable PT 31XL Torch 12 ft 3 7m Torch Cable and Spare Parts Kit SECTION 1 DESCRIPTION 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...

Page 18: ...e 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 Table 1 2 HandyPlasma 250 Specifications 1 4 Specifications Refer to Tables 1 2 1 3 and Figures 1 1 and 1 2 for HandyPlasma 250 technical specifications Table 1 1 PT 31XL Spare Parts Kit Contents Torch Current Capacity Minimum Air Supply Requirements Rated ...

Page 19: ...f Service Lines 12 ft 3 7 m Figure 1 1 PT 31XL Dimensions PT 31XL Torch Assembly P N 0558005300 is supplied with the nozzle electrode swirl baffle and heat shield as sembled 0 20 40 60 80 100 120 140 0 0625 0 125 0 25 0 3125 Steel Thickness In mm Cut Data In Min mm min 0 06 1 6 0 12 3 2 0 25 6 4 0 31 7 9 Steel Thickness In mm Cut Data In Min mm min 140 3556 120 3048 100 2540 80 2032 60 1524 40 101...

Page 20: ...20 SECTION 1 DESCRIPTION ...

Page 21: ...ig 118 l m 5 2 bar is required for the cutting opera tion The air supply should not exceed 150 psig 10 3 bar the maximum inlet pressure rating of the air filter regulator supplied with the package 2 3 Location Adequateventilationisnecessarytoprovidepropercooling of the HandyPlasma 250 and the amount of dirt dust and excessive heat to which the equipment is exposed should beminimized Thereshouldbea...

Page 22: ...pliances increases the risk of improper voltage and current to the unit This may reduce cut quality and cut capacity ION ion correcte contribue matériellement à un nnement du module de découpage Nous ons que chaque étape de cette section soit ent étudiée et respectée ON ET PLACEMENT voir déballé le contenu de l emballage z le pour détecter tout dommage éventuel arent à la réception de l appareil P...

Page 23: ...e 2 1 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 1 Removethemachinecover...

Page 24: ...CTION 2 INSTALLATION WORK CABLE SAFETY GROUND PT 31XL WORK between work and power source Allow at least 10 ft 3 m Figure 2 3 HandyPlasma 250 Secondary Interconnection Diagram 2 6 SECONDARY OUTPUT CONNECTIONS ...

Page 25: ...D DO NOT ATTACH WORK CABLE TO PIECE BEING CUT FREE GROUNDED WORK TABLE EARTH GROUND WORK CABLE BE SURE WORK IS IN GOOD CONTACT WITH TABLE Figure 2 4 Secondary Output Connections Figure 2 5 Secondary Output Connections 2 6 SECONDARY OUTPUT CONNECTIONS ...

Page 26: ...ghtened firmly with a wrench but do NOT overtighten 2 7 PT 31XL Torch CONSUMABLES Installation Figure 2 6 Assembly of Standard Consumable Parts NOTE Nozzles Marked By Amperage 18205 Electrode 18785 Baffle Nozzle 15 20A Heat Shield 20282 19667 1 Todisassemblethefrontend holdthetorchwiththeshieldinanuprightposition This will prevent the nozzle electrode and swirl baffle from falling free when the sh...

Page 27: ...e air is flowing to the machine Adjust the air regulator to 75 psig 5 2 bar 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 ...

Page 28: ...3 2 HandyPlasma 250 CONTROLS FIGURE 3 1 A PowerSwitch locatedonfrontpanel Whenplaced inONposition theswitchbecomesilluminatedandthe cooling fan will run B AirPressureAdjustmentControl Whenmainpower switch is turned on and air is flowing to the machine the air regulator can be adjusted to the desired pres sure 65 75psig 4 5 5 2bar beforecuttingoperations begin NOTE This pressure adjustment must be ...

Page 29: ...matically after the machine cools down if the on off switch is still on LowAirFlow LED Greenlight willturnonduring operation when the air flow is set correctly the LED will switch off below 15 psig 1 0 bar On OffSwitch Orangelight willlightwhenpower supply is switched on and power is applied AirPressureGauge SidePanel Showsairpressure in bars and psi 3 3 ASSEMBLING PT 31XL COMSUMABLE PARTS MAKE SU...

Page 30: ... 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 alongtheworkpiece Itmaybenecessarytocutwitha tip to work standoff distanceofupto0 06 1 6mm due to various material ...

Page 31: ...ctual 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 Cutting Speed Range HandyPlasma 250 Using Air with Standard Consumables 75 psig 5 2...

Page 32: ...32 SECTION 3 OPERATION ...

Page 33: ... F Make sure all fittings and ground connections are tight G Withallinputpowerdisconnected andwearingproper eye and face protection blow out the inside of the HandyPlasma 250usinglow pressuredrycompressed air H Wateroroiloccasionallyaccumulatesinthebowlofthe 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 o...

Page 34: ...e 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 l...

Page 35: ...TORQUE IS 30 IN LBS 3 4 m n FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY TO THE OPERATOR Pull flex support back Remove tape holding splices 1 2 3 Slide switch and band from handle Snip leads at splice to replace switch Unscrew handle and power cable from head 4 5 POWER CABLE AND SWITCH DISASSEMBLY SEQUENCE WARNING ...

Page 36: ...36 SECTION 4 MAINTENANCE ...

Page 37: ...ATTEMPTINGINSPECTIONOR WORK INSIDE OF THE POWER SOURCE Check the problem against the symptoms in the following troubleshooting guide The remedy may be quite simple If thecausecannotbequicklylocated shutofftheinputpower open up the unit and perform a simple visual inspection of all the components and wiring Check for secure termi nal connections loose or burned wiring or components bulged or leakin...

Page 38: ... 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 SECTION 5 TROUBLESHOOTING ...

Page 39: ...f 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 250 power switch is OFF Yes No Replace Repair replace solenoid valve control PCB ...

Page 40: ...itch 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 No Check voltage at receptacle and input power line No Check main fuses Replace main power switch Yes Yes ...

Page 41: ...Is the unit overheated LED turns off when unit cools down Yes No Is cooling air flowing Duty cycle exceeded 20 18A Yes No Repair power source Repair fan F No current output Is input voltage within 10 of units input rating Yes No See D sequence Repair replace Inverter ...

Page 42: ...ER CUTTING ARC CURRENT ENERGIZE 10 14 SEC ONDS Postflow OPEN SECTION 5 TROUBLESHOOTING NOTES 1 Whenthetorchswitchisdepressedduringpostflowperiod thepostflowandpreflowtimesarecanceled and the HF is energized immediately The postflow time starts from the moment the torch switch is released 5 3 SEQUENCE OF OPERATION 2 SECONDS ...

Page 43: ... which the parts will be used The serial number is stamped on the unit nameplate 6 2 Ordering ReplacementpartsmaybeorderedfromyourESABdistribu tor 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 ...

Page 44: ...4 SECTION 6 REPLACEMENT PARTS HANDY PLASMA 250 SPARE PARTS Inverter block lateral views 22 21 20 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 23 22 21 Rear Front Front Rear Handy Plasma 250 Spare Parts ...

Page 45: ...er Cable 9 0558002767 Air Gauge Filter Assembly 10 0558006068 Fan 11 0558006069 Fan Grid 12 0558006070 EMC Filter 13 951202 Flow Switch Assembly 14 0558005300 PT 31 Torch Assembly 15 0558006071 Inverter Block 16 0558006072 Rectifier 17 0558006073 On Off Switch 18 0558006074 Solenoid Valve 19 0558006075 Earth Cable with Clamp 20 0558002768 Monometer 21 0558006076 Transformer Ferrites 22 0558006077 ...

Page 46: ...rches PT 31XL Torch Assembly 12 3 7m lines P N 0558005300 Assembled w 15 20A high performance consumables used on HandyPlasma 250 FEMALE TORCH CONNECTION P N 0558004947 USED ON HANDY PLASMA 250 When ordering The PT 31XL Torch Assembly for use on the Handy Plasma 250 P N 0558004947 must ALSO be orDEred ELECTRODE 18205 SWIRL BAFFLE 18785 NOZZLE Tip 19667 HEAT SHIELD 20282 STANDARD CONSUMABLES Not in...

Page 47: ...06 Removed board schematics and added machine schematic sent by Tecla 09 2006 At Figures 2 6 3 2 4 3 changed XT to Standard removed p n 19679 changed P N 28785 to 18785 05 2007 Added Recommendations for Proper Operating Performance in Subsection 2 5 and showed proper 115V plug and receptacle Figure 2 1 in Section 2 ...

Page 48: ...rized 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 ...

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