Prest-O-Lite 550 Instruction Manual Download

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Prest-O-Lite® 550 Plasma Cutter P/N 0558006058 - 230 V, 1-Phase, 50/60 Hz - North America

Prest-O-Lite® 550 Plasma Cutter

Instruction Manual

Installation, Operation and Service

Form No: 0558006082

03 / 2007

Summary of Contents for 550

Page 1: ...Prest O Lite 550 Plasma Cutter P N 0558006058 230 V 1 Phase 50 60 Hz North America Prest O Lite 550 Plasma Cutter Instruction Manual Installation Operation and Service Form No 0558006082 03 2007 ...

Page 2: ...e 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 pr...

Page 3: ... 21 3 6 Secondary Output Connections 22 3 7 Connecting Prest O Lite 550 23 4 0 Operation 25 4 1 Operation 25 4 2 Prest O Lite 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: ... 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 combu...

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: ... 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 w...

Page 8: ... 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 Meanshazardswhichcouldre...

Page 9: ...os del 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 chi...

Page 10: ... 2 Exponerseacamposelectromagnéticos 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 sol...

Page 11: ...ENIMIENTO 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 sumi...

Page 12: ...ón Esté Alerta Se trata de su seguridad Significa riesgo inmediato que de no ser evadido puede resultar inmediatamente en serio daño personal o la muerte Significa el riesgo de un peligro potencial que puede resultar en serio daño personal o la muerte Significa el posible riesgo que puede resultar en menores daños a la persona ...

Page 13: ...ection 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 sécurit...

Page 14: ...ste 4 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 é...

Page 15: ...s ou 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 delasoupapeo...

Page 16: ...n Soyez 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: ...pose of this manual is to provide the operator with all the information required to install and operate the Prest O Lite 550 Plasma Cutter Technical reference material is also provided to assist in troubleshooting the Cutter 2 3 PACKAGE AVAILABLE Prest O Lite 550 Plasma Cutter P N 0558006058 includes Console with Regulator and Work Cable Torch Spare Parts Kit Do not use any torch with this power s...

Page 18: ...2 2 2 3 and Figures 2 1 and 2 2 for Prest O Lite 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 Capaci...

Page 19: ...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 20: ...20 section 2 description ...

Page 21: ...osely 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 Prest O Lite 550 and the amount of dirt...

Page 22: ...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 ar...

Page 23: ...K 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 Prest O Lite 550 for 230 vac input section 3 installation 550 PLASMA CUTTER ...

Page 24: ...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 25: ...ow 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 shutdownperiod Afte...

Page 26: ...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 prima...

Page 27: ...ch 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 Prest O Lite 550 Using Air with XT...

Page 28: ...mined to be caused by the Prest O Lite 550 refer to the maintenance section of this manual If the problem is not corrected after referring to the maintenance section contact your Prest O Lite 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 thi...

Page 29: ...ure 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 Prest O Lite 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 Pre...

Page 30: ...30 section 5 maintenance ...

Page 31: ... 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 bulg...

Page 32: ... 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 33: ...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 34: ...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 35: ...35 section 6 TROUBLESHOOTING ...

Page 36: ...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 37: ...n Prest O Lite parts may void your warranty Replacement parts may be ordered from your Prest O Lite 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 c...

Page 38: ...12 5 4 2 17 14 3 11 7 8 16 10 9 13 6 15 section 7 replacement parts ...

Page 39: ...erator 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 re...

Page 40: ...40 notes ...

Page 41: ...41 notes ...

Page 42: ...notes ...

Page 43: ...Original release 06 2006 03 2007 Revised Title Page layout text revision history ...

Page 44: ...s 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 800 372 2123 Hours 7 30 AM to 4 00 PM EST H TECHNICAL ASST CONSUMABLES Telephone 800 933 7070 Hours 7 30 AM to 5 00 PM EST IF YOU DO NOT KNOW WHOM TO CALL Teleph...

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