ESAB HandyPlasma 550 Installation, Operation And Service Manual Download Page 1

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This manual provides complete instructions for the following HandyPlasma

550 cutting packages starting with Serial

No. PPOR144027:

ESAB P/N 0558002612 - 230 V, 1-Phase, 50/60 Hz - North America

HandyPlasma

550

PLASMARC CUTTING PACKAGE

F15-706-D

12/2005

Installation, Operation and Service Manual

Summary of Contents for HandyPlasma 550

Page 1: ... for the following HandyPlasma 550 cutting packages starting with Serial No PPOR144027 ESAB P N 0558002612 230 V 1 Phase 50 60 Hz North America HandyPlasma 550 PLASMARC CUTTING PACKAGE F15 706 D 12 2005 Installation Operation and Service Manual ...

Page 2: ...le responsibility for any malfunction which results from improper use faulty maintenance damage improper repair or alteration by anyone other than the manufacturer or a ser vice facility designated by the manufacturer BE SURE THIS INFORMATION REACHES THE OPERATOR YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER These INSTRUCTIONS are for experienced operators If you are not fully familiar with the p...

Page 3: ...ns 21 3 6 Secondary Output Connections 22 3 7 Connecting HandyPlasma 550 23 4 0 Operation 25 4 1 Operation 25 4 2 HandyPlasma 550 Controls 25 4 3 Assembling PT 31XL Consumable Parts 26 4 4 Cutting with the PT 31XL 26 4 5 Operating Techniques 28 4 6 Common Cutting Problems 28 5 0 Maintenance 29 5 1 General 29 5 2 Inspection and Cleaning 29 4 3 Flow Switch 29 6 0 Troubleshooting 31 6 1 Troubleshooti...

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

Page 5: ... clothing 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 comb...

Page 6: ...2 ExposuretoEMFmayhaveotherhealtheffectswhich 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 Connecttheworkcabletothewor...

Page 7: ...s 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 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 ...

Page 8: ...d Safe 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 Meanshazardswhichcouldr...

Page 9: ...ference material is also provided to assist in troubleshooting the cutting package 2 3 PACKAGE AVAILABLE HandyPlasma 550 North America see Note 1 below P N 0558002612 includes Console with Regulator and Work Cable Torch Spare Parts Kit 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 Table 2 1 PT 31XL Spare Pa...

Page 10: ...2 2 2 3 and Figures 2 1 and 2 2 for HandyPlasma 550 technical specifications SECTION 2 DESCRIPTION Rated Output 40 Duty Cycle 35 A 120 V dc 60 Duty Cycle 30 A 120 V dc 100 Duty Cycle 22 A 120 V dc Output Current Range 15 to 35 Amperes Open Circuit Voltage 230 V dc Nominal Rated Primary Input 35 A 120 VDC Output 230 VAC 50 60 Hz 1 Phase 27 A Power Factor 35 Amperes Output 81 1 Phase Current Capacit...

Page 11: ...erformance 2 1 4 57mm 5 1 4 133mm 75 Torch Table 2 3 PT 31XL Torch Speciﬁcations PT 31XL Torch Current Capacity 50A DCSP Shipping Wgt 2 lbs 1 kg Length of Service Lines 25 ft 7 6 m Figure 2 1 PT 31XL Dimensions SECTION 2 DESCRIPTION ...

Page 12: ...20 SECTION 2 DESCRIPTION ...

Page 13: ...ly as possible 3 2 EQUIPMENT REQUIRED A source of clean prefiltered dry air that supplies 250 cfh at 80 psig is required for the cutting operation The air supply should not exceed 150 psig the maximum inlet pressure rating of the air filter regulator supplied with the package 3 3 LOCATION Adequate ventilation is necessary to provide proper cool ing of the HandyPlasma 550 and the amount of dirt dus...

Page 14: ...he workpieceisconnectedtoanapprovedearthground with a properly sized ground cable Torchcomesfactoryinstalled Theseinstructionsare for torch replacement Beforemakinganyconnectionstothepowersource output terminals make sure that all primary input power to the power source is deenergized oﬀ at themaindisconnectswitchandthattheinputpower cable is unplugged For operator safety the torch connections are...

Page 15: ... 31XL WORK PLUG between work and power source Allow at least 10 ft 3 m RECEPTACLE P N 674540 Optional for 230 V 1 phase power sources Prefiltered AIR SUPPLY Customer Supplied 90 to 150 psig max See Table 3 1 and WARNING in regards to chassis ground in Section 3 5 3 7 CONNECTING HANDYPLASMA 550 FOR 230 Vac INPUT SECTION 3 INSTALLATION ...

Page 16: ...24 GROUNDED WORK TABLE EARTH GROUND WORK CABLE BE SURE WORK IS IN GOOD CONTACT WITH TABLE WORK CABLE EARTH GROUND DO NOT ATTACH WORK CABLE TO PIECE BEING CUT FREE SECTION 3 INSTALLATION ...

Page 17: ...tlightwillglow indicatingcontrolcircuitisenergizedandthecooling fan will run B OutputCurrentControl Adjustablefrom15to35 amperes to suit cutting conditions C Air Check Push Button Switch When energized air filter regulator can be adjusted to desired pres sure 55 65 psig before cutting operations Allow airtoflowforafewminutes Thisshouldremoveany condensation that may have accumulated during shutdow...

Page 18: ...tion when the air flow is correct Will switch off below 15psi 1 bar F On OﬀSwitch Whitelight willlightwhenswitched on evenifthemachinestoppedforanyreason Willturn off when switch is in OFF position or the light bulb is defective G AirPressureGauge FrontPanel Showsairpressure in bars and psi 4 3 ASSEMBLING PT 31XL COMSUMABLE PARTS Make sure power switch on power source is in OFF position and primar...

Page 19: ...rch switch should be released and lifted off the workpiece just before the end of the cut tominimizedouble arcingwhichcandamagethetip This is to prevent high frequency from reigniting after cutting arc extinguishes 6 Inthepostflowmode thearccanberestartedimmediately by depressing the torch switch The two second preflow will automatically cancel Cutting Speed Range HandyPlasma 550 Using Air with XT...

Page 20: ...are determined to be causedbytheHandyPlasma 550 refertothemaintenance section of this manual If the problem is not corrected after referring to the maintenance section contact your ESAB representative A Insuﬃcient Penetration 1 Cutting speed too fast 2 Damaged cutting nozzle 3 Improper air pressure B Main Arc Extinguishes 1 Cutting speed too slow C Dross Formation In some materials and thick nesse...

Page 21: ...sure cable and hoses are not damaged or kinked F Make sure all fittings and ground connections are tight Wateroroiloccasionallyaccumulatesincompressedair lines Besuretodirecttheﬁrstblastofairawayfromthe equipment to avoid damage to the HandyPlasma 550 PISTON PLUG PISTON SPRING FLOW SWITCH G With all input power disconnected and wearing proper eye and face protection blow out the inside of the Hand...

Page 22: ...30 SECTION 5 MAINTENANCE ...

Page 23: ...t breaker before attempting inspection or work inside of the power source Check the problem against the symptoms in the following troubleshootingguide Theremedymaybequitesimple 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 bul...

Page 24: ...OFF Yes No Replace Repair replace control solenoid valve PCB B No Air Is air hose connected Yes No Connect Is air adjusted to 55 65psi 4 5 bar Yes No Adjust Does air come on with air check switch 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 6 TROUBLESHOOTING ...

Page 25: ...witch ON Yes No Turn on switch Is plug in receptacle Yes No Insert plug 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 SECTION 6 TROUBLESHOOTING ...

Page 26: ...en unit cools down Yes No Is cooling air flowing Duty cycle exceeded 40 35 A Yes No or 100 22 A output Repair power source Repair fan F No current output Is input voltage within 10 of units input rating Yes No See D sequence above Repair replace Inverter SECTION 6 TROUBLESHOOTING ...

Page 27: ...35 SECTION 6 TROUBLESHOOTING ...

Page 28: ...ts from the moment the torch switch is released 2 When the amber fault pilot light comes on cutting operation should be stopped PUSH RELEASE TORCH SWITCH OPEN CLOSE GAS SOLENOID VALVE PREFLOW FLOW SWITCH CLOSE FAULT OVERLOAD LIGHT HF CIRCUIT INVERTER CUTTING ARC CURRENT ENERGIZE 10 SEC Postflow OPEN 2 SEC 6 3 SEQUENCE OF OPERATION SECTION 6 TROUBLESHOOTING ...

Page 29: ...f non ESAB parts may void your warranty Replacement parts may be ordered from your ESAB Distributor Be sure to indicate any special shipping instructions when ordering replacement parts Refer to the Communications Guide located on the back page of this manual for a list of customer service phone numbers 7 2 Ordering Bill of material items that have blank part numbers are provided for customer info...

Page 30: ...12 5 4 2 17 14 3 11 7 8 16 10 9 13 6 15 SECTION 7 REPLACEMENT PARTS ...

Page 31: ...rator 7 0558002738 Fan VR1 2 8 0558004479 Fan Grid 9 951202 Flow Switch 10 0558004399 Main Power Cable w Plug 10Ft 11 0558002746 EMI Filter 12 0558002747 ON OFF Switch S1 13 0558002764 Solenoid Valve Assembly 14 0558004498 Plasma Torch 15 680560 Earth Cable w Clamp 16 21710 Air Regulator Filter 17 21711 Pressure Gauge 18 0558004494Y Side Panel Not Shown 19 0558004478 Handle Not Shown SECTION 7 REP...

Page 32: ...40 NOTES ...

Page 33: ...41 NOTES ...

Page 34: ...42 NOTES ...

Page 35: ...mary Input row Section 2 Deleted DO NOT connect a power source conﬁgured for 208 230 V to a 460 V input power supply from caution paragraph Section 2 Table 2 1 deleted 208 V 29 A row Section 2 Deleted 200 208 reference in heading and added 230 Section 3 Enlarged figure 3 2 4 Added schematic per Larry Bryant request 5 Revision D 05 2005 added Air Line Filter Regulator p n 0558005394 note in Replace...

Page 36: ...ax 843 664 5557 Hours 7 30 AM to 3 30 PM EST Repair Estimates Repair Status F WELDING EQUIPMENT TRAINING Telephone 843 664 4428 Fax 843 679 5864 Hours 7 30 AM to 4 00 PM EST Training School Information and Registrations G WELDING PROCESS ASSISTANCE Telephone 800 ESAB 123 Hours 7 30 AM to 4 00 PM EST H TECHNICAL ASST CONSUMABLES Telephone 800 933 7070 Hours 7 30 AM to 5 00 PM EST IF YOU DO NOT KNOW...

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