ESAB HandyPlasma 50 User manual

Bruksanvisning (SE) Handleiding voor het gebruik (NL)
Instruction manual (GB) Manuale duso (I )
Manual de uso (P ) Instrukcja u¿ytkowania (PL)
Bedienungsanleitung (DE) Brugervejledning (DK)
Manual de uso (ES) Käyttökäsikirja (FI)
Manuel dutilisation (FR) Bruksanvisning (NO)
ÏÄÇÃÏÓ ×ÑÇÓÅÙÓ (GR)
HandyPlasmaTM 50
0700157031-A 010303 Valid from serial number 3073070001

1 DIRECTIVE.......................................................................2
2 SAFETY.............................................................................2
3 INTRODUCTION.............................................................4
3.1 Equipment............................................................4
4 TECHNICAL DATA.........................................................5
5 INSTALLATION...............................................................5
5.1 ains and Workpiece Connection.................6
6 OPERATION.....................................................................7
6.1 Connection and Control Devices...................8
6.2 PT - 31 Torch and XT Consumables........8
6.3 Cutting with PT - 31 XL......................................9
6.4 Common Cutting Problems...........................10
7 AINTENANCE.............................................................11
7.1 Check-up and Cleaning..................................11
8 FAULT-TRACKING/TROUBLESHOOTING..............12
8.1 Troubleshooting guide....................................12
8.2 Sequence of operation...................................16
9 ORDERING SPARE PARTS.........................................17
9.1 Detail pictures....................................................17
9.2 Spare Part List....................................................18
10 ACCESSORIES............................................................18
DIAGRA .............................................................................19
1
TABLE OF CONTENTS
GB INSTRUCTION MANUAL
PLASMA ARC CUTTING PACKAGES

1 DIRECTIVE
2 SAFETY
Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety precautions
must meet the requirements that apply to this type of plasma cutting equipment. The following
recommendations should be observed in addition to the standard regulations that apply to the
workplace.
All work must be carried out by trained personnel well acquainted with the operation of the pla
sma cutting equipment. Incorrect operation of the equipment may lead to hazardous situations
which can result in injury to the operator and damage to the equipment.
1. Anyone who uses the plasma cutting equipment must be familiar with:
its operation
location of emergency stops
its function
relevant safety precautions
plasma cutting
2. The operator must ensure that:
no unauthorized person is stationed within the working area of the equipment when it is
started up
no one is unprotected when the arc is struck
3. The workplace must:
be suitable for the purpose
be free from draughts
4. Personal safety equipment
always wear recommended personal safety equipment, such as safety glasses, flame
proof clothing, safety gloves
5. General precautions
make sure the return cable is connected securely
work on high voltage equipment may only be carried by a qualified electrician
appropriate fire extinguishing equipment must be clearly marked and close at hand
Lubrication and maintenance must not be carried out on the equipment during operation.
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GB INSTRUCTION MANUAL
DECLARATION OF CONFORMITY
ESAB Welding Equipment AB, S-695 81 Laxå, Sweden, declare that pla ma cutting equipment Handy Pla ma 50
from erial Nr 307 onwards conform to tandard IEC/EN 60974-1, IEC/EN 60941-7, in accordance with the
requirement of directive (73/23/EEC) and appendix (93/68/EEC) and tandard EN 50199 in accordance with the
requirement of directive (89/336/EEC) and appendix (93/68/EEC).
Laxå 2003-02-07
HENRY SELENIUS
Vice President
ESA Welding Equipment A
695 81 Laxå Tel: [phone] Fax: [phone]
SWEDEN

Note! This product is solely intended for plasma cutting
3
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN
WELDING AND CUTTING. ASK FOR YOUR EMPLOYERS SAFETY PRACTICES WHICH SHOULD BE BASED ON
MANUFACTURERS HAZARD DATA.
ELECTRIC SHOCK - Can ki
- Insta and earth the we ding/cutting unit in accordance with app icab e standards.
- Do not touch ive e ectrica parts or e ectrodes with bare skin, wet g oves or wet c othing.
- Insu ate yourse f from earth and the workpiece.
- Ensure your working stance is safe.
FUMES AND GASES - Can be dangerous to hea th
- Keep your head out of the fumes.
- Use venti ation, extraction at the arc, or both, to take fumes and gases away from your
breathing zone and the genera area.
ARC RAYS - Can injure eyes and burn skin.
- Protect your eyes and body. Use the correct we ding/cutting screen and fi ter ens and
wear protective c othing.
- Protect bystanders with suitab e screens and courtains.
FIRE HAZARD
- Sparks (spatter) can cause fire. Make sure therefore that there are no inf ammab e materia s
nearby.
NOISE - Excessive noice can damage hearing.
- Protect your ears. Use earmuffs or other hearing protection.
- Warn bystanders of the risk.
MALFUNCTION - Ca for expert assistance in the event of ma function.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING
PROTECT YOURSELF AND OTHERS!
WARNING!
Read and understand the instruction anual
before installing and operating
WARNING! Do not use the power sour e for thawing frozen pipes.
GB INSTRUCTION MANUAL

The HandyPlasma 50 is a compact, completely self-contained plasma cutting
system. As shipped, the system is fully assembled and eady to cut afte being
connected to input powe and a sou ce of p efilte ed comp essed ai 5-10 ba
(set to ch at 118 lt/min @ 5.2 ba ). The Handy Plasma 50 package uses the PT-
31XL to ch with 50 Amp consumables to delive cutting powe fo mate ials up to
15 mm thick o fo seve ing up to 19 mm thick. Refe to the following pa ag aphs
fo desc iptions of the Handy Plasma 50 packages available as well as
pe fo mance specifications.
Do not use any torch with this power source other than the ESAB brand
PT-31XL torch. Serious injury may occur if used with any other torch.
See below for ESABs accessories for the cutting torch.
3 INTRODUCTION
3.1 Equipment
List 3.1.1 HandyPlasma 50 Cutting Pa kages
Each HandyPlasma 50, Plasma Arc Cutting Package P/N 0700157880 includes:
N°1 Power Source HandyPlasma 50.
N°1 PT-31XL* Torch assembly with 8m service lines.
N°1 earth cable 8m length.
N°1 Torch Spare Parts Kit, see list below.
List 3.1.2 PT-31XL* Spare Parts Kit P/N 0558003464 Contents
N° 3 50A Nozzle, P/N (20861) 0558000513
N° 3 Electrode, P/N (20862) 0558000507
N° 1 Swirl affle, P/N (20463) 0558000506
N° 1 Long Heat Shield, P/N (36284) 0558000509
N° 1 O-ring, P/N (950790) 0558000514
*PT-31XL Torch Asse bly P/N 0558003467 is supplied with the nozzle, electrode, swirl baffle and heat shield
asse bled.
(Part number in braket could be found on the explo ion drawing in ide the torch pare part kit box.)
4
Fig. 3.1.2 PT - 31 spare part list and consumables
GB INSTRUCTION MANUAL

4 TECHNICAL DATA
4.1 SPECIFICATIONS
Rated Output 60% Duty Cycle* 50A @ 100V dc
100% Duty Cycle* 40A @ 96V dc
Output Current Range 20 to 50 Amperes
Open Circuit Voltage 250 V dc Nominal
Rated Primary Input I1max 400 Vac 50/60 Hz,
@ 50A 100Vdc Output 3 - Phase 13 Ampere
Power factor @ 50 A Output 0,8
Current Capacity PT-31XL 50 A dc SP
Air Requirements PT-31 XL 118 lt/min @ 5.2 bar
Length 550 mm
Dimensions of HandyPlasma 50 Height 410 mm
Width 190 mm
Weight (less torch) 19 kg
Insulation lass: F Prote tion lass: IP 22S
* Duty Cy le
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or cut at a
certain load without overloading the product.
5 INSTALLATION
T e installation must be executed by a professional.
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GB INSTRUCTION MANUAL

5.1 Mains and workpiece connection
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GB INSTRUCTION MANUAL
Fig. 5.1.1 - Mains connection
Fig. 5.1.2 - Workpiece connection
ains plug and socket
Rating P ate
(on opposite side)
Plasma torch
Earth clamp
HandyPlasma 50 Power Source

6 OPERATION
ELECTRIC SHOCK can kill.
 Do NOT operate the unit with the cover removed.
 Do NOT apply power to the unit while holding or
carrying the unit.
 Do NOT touch any torch parts forward of the torch
handle (nozzle, heat shield, electrode, etc.) with
power switch on.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
 Wear welding helmet with proper lens shade.
 Wear eye, ear, and body protection.
Position the Handy Plasma (at least) 3 meters from
the cutting area. Sparks and hot slag from the cutting
operation can damage the unit.
General safety regulations for the handling of the equipment can be found on page
2 and 3. Read through before you start using the equipment!
Do not use any torch with this power source other than the ESAB brand
PT-31 XL torch. Serious injury may occur if used with any other torch.
7
GB INSTRUCTION MANUAL

6.1 Connection and control devices - front panel
6.2 PT - 31 Torc and XT Consumables
When assembling or replacing XT consumables, make sure power switch
on power source is in OFF position and primary input power is deenergized.
The PT-31 to ch of Handy Plasma is o iginally assembled and tested.
The PT-31 XL torch head contains a gas flow check valve that acts in
conjuction with the flow switch and circuitry within the power source. This
system prevents the torch from being energized with high voltage if the torch
switch accidentally closed when the shield is removed. ALWAYS REPLACE
TORCH WITH THE PROPER TORCH ANUFACTURED BY ESAB SINCE IT
ALONE CONTAINS ESABS PATENTED SAFETY INTERLOCK.
8
6.1.2 Handy Plasma 50 CONTROLS
1. Power Switch. When placed in On
position, the g een light will glow
indicating cont ol ci cuit is ene gized and
the cooling fan will un.
2 . Output Current Control. Adjustable
f om 25 to 50 ampe es to suit cutting
conditions.
3. Air Check Switch. When p essed,
(ON position), ai filte - egulato can be
adjusted to desi ed p essu e befo e
cutting ope ations. By keeping it p essed,
allow ai flow fo a few minutes. This
should emove any condensation that may
have accumulated du ing shutdown
pe iod.
4. While flowing, the g een LED will light
up.
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Manometer To r c h
ON/OFF
Switch
Air Check
Switch
Earth
Connector
12
34
Overheating LED
GB INSTRUCTION MANUAL

6.3 Cutting wit PT - 31 XL
Wear the usual protective gloves, clothing and helmet. Helmet with filter lens
shade No. 6 or 7 should provide adequate protection for your eyes.
Never touch any parts forward of the torch handle (tip, heat shield, electrode,
etc.) unless the power switch is in the OFF position.
Caution: Do not dep ess the to ch switch unless the to ch nozzle is touching o within
1 mm (1/32-in.)of the wo kpiece.
9
Tab. 6.3.1 Effect of cutting speed
TOO FAST TOO SLOW CORRECT
Tab. 6.3.2 Piercing Technique using PT - 31 XL
TO START A PIERCE, TILT THE
TORCH TO PREVENT MOLTEN
MATERIAL FROM COMING BAC
AGAINST AND DAMAGING THE
TORCH
WHEN THE ARC BREA S
THROUGH THE WOR ,
BRING THE TORCH TO AN
UPRIGHT POSITION AND
PROCEED TO CUT.
GB INSTRUCTION MANUAL

6.4 COMMON CUTTING PROBLEMS
Listed below a e common cutting p oblems followed by the p obable cause of each.
If p oblems a e dete mined to be caused by Handy Plasma, efe to the maintenance
section of this manual. If the p oblem is not co ected afte efe ing to the maintenance
section, contact you ESAB ep esentative.
A. Insufficient Penetration.
1. Cutting speed too fast.
2. Damaged cutting nozzle.
3. Imp ope ai p essu e.
B. ain Arc Estinguishes.
Cutting speed too slow.
C. Dross Formation. (In some mate ials and thicknesses, it may be impossible to get
d oss-f ee cuts)
1. Cutting speed too fast o too slow.
2. Imp ope ai p essu e.
3. Faulty nozzle o elect ode.
D. Double Arching. (Damaged nozzle o ifice)
1. Low ai p essu e.
2. Damaged cutting nozzle
3. Loose cutting nozzle.
4. Heavy spatte .
E. Uneven Arc.
Damaged cutting nozzle o wo n elect ode
F. Unstable Cutting Conditions.
1. Inco ect cutting speed.
2. Loose cable o hose connections.
3. Elect ode and/o cutting nozzle in poo condition.
G. ain Arc Does Not Strike. (Loose connections)
H. Poor Consumable Life.
1. Imp ope gas p essu e.
2. Contaminated ai supply.
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GB INSTRUCTION MANUAL
10

7 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
Note:
All warranty undertakings given by the supplier cease to apply if the customer attempts
to rectify any faults on the machine during the warranty period.
If this equipment does not operate properly, stop work immediately and investiga-
te the cause of the malfunction. aintenance work must be performed by an
experienced person, and electrical work by a trained electrician. Do not permit
untrained persons to inspect, clean, or repair this equipment. Use only
recommended replacement parts.
Be sure that the wall disconnect switch or wall circuit breaker is open before
attempting any inspection or work inside of the Handy Plasma.
7.1 CHECK - UP AND CLEANING
Water or oil occasionally accumulates in compressed air lines. Be sure to direct
the first blast of air away from the equipment to avoid damage to Handy Plasma.
F equent inspection and cleaning of the Handy Plasma is ecommended fo safety and
p ope ope ation. Some suggestions fo inspecting and cleaning a e as follows:
A. Check wo k cable to wo k piece connection.
B. Check safety ea th g ound at wo k piece and at powe sou ce chassis.
C. Check heat shield on to ch. It should be eplaced if damaged.
D. Check the to ch elect ode and cutting nozzle fo wea on a daily basis. Remove
spatte o eplace if necessa y.
E. Make su e cable and hoses a e not damaged o kinked.
F. Make su e all fittings and g ound connections a e tight.
11
GB INSTRUCTION MANUAL

8 FAULT-TRACING / TROUBLESHOOTING
Try these recommended checks and inspections before sending for an authorized
service technician.
ELECTRIC SHOCK CAN KILL! Be sure that all primary power to the machine has
been externally disconnected.Open the line (wall) disconnect switch or circuit
breaker before attempting inspection or work inside of the power source.
Check the problem against the symptoms in the following troubleshooting guide. The remedy may be quite
simple. If the cause cannot be quickly located, shut off the input power, open up the unit, and perform a
simple visual inspection of all the components and wiring. Check for secure terminal connections, loose or
burned wiring or components, bulged or leaking capacitors, or any other sign of damage or discoloration.
Those indications do not invalidate all other safety regulations and restrictions expressed in other sections
of this manual.
Voltages in plasma utting equipment are high enough to ause serious injury or possibly death.
Be parti ularly areful around equipment when the overs are removed.
NOTE
efore checking voltages in the circuit, disconnect the power from the high frequency generator to avoid
damaging your voltmeter.
8.1 TROUBLESHOOTING GUIDE
Any remedy that requires an intervention inside the machine must be e ecuted by
an authorized service center.
A. Diffi ult Starting.
 Change electrode
 Change nozzle
 Check for good, clean connection of work lead to workpiece
 Check air pressure (5 - 5,5 bar)
 Check torch power cable for continuity
Depress torch switch. After 2 seconds, is high frequency present?
NoYes
Is the Air LED light on? Repair/replace HF PC
Yes No
Repair/replace Repair/replace Control
power source control PC Flow Switch
12
GB INSTRUCTION MANUAL

B. No Air
Is air hose connected?
Yes No Connect
Is air adjusted to 4 - 5 bar ?
Yes No Adjust
Check torch integrity
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
C. Air does not shut off
Does arc start when nozzle contacts work without depressing torch switch?
Yes No
Check for short in torch switch
Does air flow even when Handy Plasma power switch is OFF?
Yes No
Replace Repair/replace
solenoid valve control PC
13
GB INSTRUCTION MANUAL

D. ON/OFF Swit h light not energized.
Is mains 400 Volt switch ON?
Yes No Turn on switch
Is plug in receptacle?
Yes No Insert plug in receptacle
Is cooling fan turning?
Yes No
Replace
ON/OFF Switch
Check voltage at receptacle and input power line
Yes No Check main fuses
Replace ON/OFF
Switch
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GB INSTRUCTION MANUAL

E. Temperature LED light ON.
Is the unit overheated?
("Fault" lights turns off
when Unit cools down.)
Yes No
Is cooling air flowing?
Duty cycle exceeded:
60% @ 50 A, Yes No
or 100% @ 40 A output
Repair power source Repair fan
F. No urrent output
Is input voltage within ±10% of units input rating?
Yes No
See (D.) sequence above
Unsolved
Repair power source
15
GB INSTRUCTION MANUAL

ENERGIZE
10 SEC
Postflow
OPEN
2 SEC.
NOTES:
1. When the torch switch is pushed during postflow period, the postflow and preflow times are canceled, and
the HF is energized immediately.
2. When the air flow LED comes off, cutting operation should be stopped. The postflow time starts from the
moment the torch switch is released.
TORCH SWITCH
OPEN CLOSE
GAS SOLENOID VALVE
PREFLOW
FLOW SWITCH CLOSE
OVERHEATING LIGHT
HF CIRCUIT
INVERTER
CUTTING ARC (CURRENT)
8.2 SEQUENCE OF OPERATION
A. LOCK-IN "OFF" position
PUSH RELEASE
16
GB INSTRUCTION MANUAL

9 - ORDERING SPARE PARTS
9.1 - Detail pictures - Handy Plasma 50
17
Rea F ont
17 - Power module - bottom side 21 - INPUT PCB
4 - HF PCB 13 - Inverter PCB
2
11
7
10
16
6
9
8
3
14
15
20
18
19
22
5
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GB INSTRUCTION MANUAL
26

10 ACCESSORIES
For plasma torch PT - 31, please see section 3.1 Equipment, page 4.
18
9.2 - Spare Part List
Handy Plasma 50 is designed and tested in accordance with the international
and European standards IEC/EN 60974-1 and EN 50199.
It is the obligation of the service unit which has carried out the service or repair
work to make sure that the product still conforms to the said standard.
Spa e pa ts a e o de ed th ough you nea est ESAB ep esentative, see back cove . When
o de ing spa e pa ts, please state machine type, and numbe as well as designation and
spa e pa t numbe as shown in the spa e pa t list.
This will semplify dispatch and ensu e you get the ight pa t. Neve theless, any replacement
of parts inside the machine must be e ecuted by an authorized service center.
Item No. Part No. Des ription
GB INSTRUCTION MANUAL
1 0700157001 LID WITH HANDLE
2 0700157002 BOTTOM CASE (CHASSIS)
3 0700157003 CONTROL PCB
4 0700157004 HIGH FREQUENCY PCB
5 0700157005 HF GENERATOR
6 0700156006 AIR NIPPLE 1/8 Dia. 8mm, L=20mm
7 0700157007 POWER CABLE
8 0558003467 PT - 31 XL TORCH Ass.ly
9 0700157008 AIR GAUGE FILTER
10 0700156009 FAN
11 0700157010 EMC FILTER
12 0558000410 FLOW SWITCH P/N 951202
13 0700157011 INVERTER PCB
14 0700157012 ON/OFF SWITCH knob ass.ly
15 0700157013 EARTH CABLE W/CLAMP, L=8m
16 0700157014 FAN GRID
17 0700157015 POWER MODULE
18 0700157016 CHO E (INDUCTANCE)
19 0700157017 TRANSFORMER
20 0700157018 HEAT SIN WITH DIODES
21 0700157019 INPUT PCB MODULE
22 0700157020 AUXILLARY TRANSFORMER
23 0700157021
24 0700157022 MANOMETER (FRONT PANEL)
25 0700157023 AIR CHEC SWITCH (FRONT PANEL)
26 0700157024 SOLENOID VALVE ASS.LY