ESAB Prest-O-Lite® 550 Plasma Cutter Manual de usuario

Marca: ESAB

Modelo: Prest-O-Lite® 550 Plasma Cutter

Categoría: Sistema de soldadura

Tipo: Manual de usuario

Este manual también es adecuado para

® 550 Plasma Cutter

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

This equipment will perform in conformity with the description thereof contained in this manual and accompa-

nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-

tions 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 imme-

diately. 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 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

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 be-

fore installing or operating this equipment.

CAUTION

USER RESPONSIBILITY

TABLE OF CONTENTS

1.0 Safety Precautions ......................................................................................................................................................................5

1.1 Safety - English ...............................................................................................................................................................

1.2 Safety - Spanish .............................................................................................................................................................9

1.3 Safety - French .............................................................................................................................................................13

2.0 Description ..................................................................................................................................................................................17

2.1 General .......................................................................................................................................................................... 17

2.2 Scope .............................................................................................................................................................................. 17

2.3 Packages Available .................................................................................................................................................... 17

2.4 Speciﬁcations .............................................................................................................................................................. 18

3.0 Installation ...................................................................................................................................................................................

3.1 General ...........................................................................................................................................................................21

3.2 Equipment Required .................................................................................................................................................21

3.3 Location ..........................................................................................................................................................................21

3.4 Inspection ......................................................................................................................................................................21

3.5 Primary Electrical Input Connections ..................................................................................................................21

3.6 Secondary (Output) Connections ........................................................................................................................ 22

3.7 Connecting Prest-O-Lite

550 ................................................................................................................................ 23

4.0 Operation ....................................................................................................................................................................................

4.1 Operation ......................................................................................................................................................................

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 ..............................................................................................................................................

4.6 Common Cutting Problems ................................................................................................................................... 28

5.0 Maintenance ...............................................................................................................................................................................

5.1 General .......................................................................................................................................................................... 29

5.2 Inspection and Cleaning ......................................................................................................................................... 29

4.3 Flow Switch .................................................................................................................................................................. 29

6.0 Troubleshooting ....................................................................................................................................................................... 31

6.1 Troubleshooting ......................................................................................................................................................... 31

6.2 Troubleshooting Guide ............................................................................................................................................ 31

6.3 Sequence of Operation ............................................................................................................................................ 36

7.0 Replacement Parts ....................................................................................................................................................................37

7.1 General ...........................................................................................................................................................................

7.2 Ordering .........................................................................................................................................................................37

Section / Title Page

TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS

1.0 Safety Precautions

1.1 Safety - English

WARNING: These Safety Precautions are

for your protection. They summarize pre-

cautionary information from the references

listed in Additional Safety Information sec-

tion. 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 operat-

ing 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 protec-

tion 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.

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 protec-

tive 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 hid-

den 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 ex-

ample, 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 Protec-

tion 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.

SECTION 1 SAFETY PRECAUTIONS

1. Be sure the power source frame (chassis) is con-

nected 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 recommenda-

tions. Do not mistake the work lead for a ground

cable.

ELECTRIC AND MAGNETIC FIELDS

— May be dangerous. Electric cur-

rent ﬂowing through any conduc-

tor 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. Shield-

ing 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, stain-

less 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 opera-

tions. 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 ir-

ritation 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 discom-

fort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)

for speciﬁc ventilation recommendations.

SECTION 1 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 vio-

lently 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 instruc-

tions for mounting regulator to a compressed gas

cylinder.

2. Always secure cylinders in an upright position by

chain or strap to suitable hand trucks, undercar-

riages, 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 con-

nected. Secure and move cylinders by using suitable

hand trucks. Avoid rough handling of cylinders.

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:

1. Always have qualiﬁed personnel perform the instal

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 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 equip-

ment, ask your supplier for a copy of

"Precautions and Safe Practices for Arc

Welding, Cutting and Gouging", Form

52-529.

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"

SECTION 1 SAFETY PRECAUTIONS

5. AWS C5.5 - "Recommended Practices for Gas Tung-

sten 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 - As used

throughout this manual: Means Atten-

tion! Be Alert! Your safety is involved.

Means immediate hazards which,

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.

Means hazards which could result

in minor personal injury.

SECTION 1 SEGURIDAD

1.2 Safety - Spanish

ADVERTENCIA: Estas Precauciones de Se-

guridad son para su protección. Ellas hacen

resumen de información proveniente de las

referencias listadas en la sección "Información Adi-

cional 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 requiren

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 per-

sonas 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 chis

pas calientes con una cortina adecuada no-ﬂamable

como división.

6. Use careta protectora además de sus gafas de segu

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

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 to-

talmente 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, inspec

cione 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 corri

ente alterna (AC) en áreas húmedas,

de movimiento conﬁnado en lugares estrechos o

si hay posibilidad de caer al suelo.

SECTION 1 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 condi

ciones. 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 mien-

tras 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 MAGNETI-

COS - 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 cad-

mio 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 per-

siste.

4. Haga referencia a la publicación ANSI/ASC Standard

Z49.1 (Vea la lista a continuación) para recomen-

daciones especíﬁcas en la ventilación.

SECTION 1 SEGURIDAD

5. ADVERTENCIA-- Este producto cuando se uti-

liza para soldaduras o cortes,

produce humos o gases, los

cuales contienen químicos

conocidos por el Estado de Cali-

fornia 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 romp-

erse 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 adapta-

dores. 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, tab-

lilleros, 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 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 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 SEGU-

RIDAD -- 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"

SECTION 1 SEGURIDAD

SIGNIFICADO DE LOS SIMBOLOS

-- Según usted avanza en la lectura

de este folleto: Los Símbolos Sig

niﬁcan ¡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.

SECTION 1 SÉCURITÉ

1.3 Safety - French

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 combus

tibles de l'aire de travail et recouvrez les matériaux

avec un revêtement protecteur ininﬂammable. Les

matériaux combustibles incluent le bois, les vête-

ments, 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 incan

descent 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 tra

vail 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 in-

cendie.

6. Une fois les opérations terminées, inspectez l'aire de

travail pour assurer qu'aucune étincelle ou projec-

tion 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 mor-

telles. NE PAS utiliser un courant de

soudage c.a. dans un endroit humide, en espace

restreint ou si un danger de chute se pose.

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-des-

sous, 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 re-

garder 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 recom-

mandé 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 égale-

ment porter des lunettes étanches par dessus leur

lunettes de sécurité.

SECTION 1 SÉCURITÉ

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 re-

spirez 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 ventila-

tion naturelle ou à l'aide de moyens mécanique.

N'eﬀectuez jamais de travaux de soudage, de coup-

age 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 ven-

tilation 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.

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 endom-

magés.

5. Veillez à garder votre environnement sec, incluant

les vêtements, l'aire de travail, les câbles, le porte-

électrode/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 directe-

ment sur le métal ou sur la terre; tenez-vous 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 MAGNÉ-

TIQUES — comportent un risque

de danger. Le courant électrique

qui passe dans n'importe quel con-

ducteur produit des champs élec-

triques 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 cer-

tains stimulateurs cardiaques.

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

tiques peut avoir des eﬀets néfastes inconnus pour

la santé.

SECTION 1 SÉCURITÉ

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 quel-

conque.

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 RELA-

TIVES 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 "Precau-

tions and Safe Practices for Arc Welding,

Cutting and Gouging", Form 52-529.

Les publications suivantes sont également recomman-

dées 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"

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 consi-

déres 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 bles-

sures 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 bran-

ché, 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 dis-

position par le Compressed Gas Association, 1235

Jeﬀerson Davis Highway, Arlington, VA 22202.

ENTRETIEN DE L'ÉQUIPEMENT -- Un équipe-

ment entretenu de façon défectueuse ou

inadéquate peut causer des blessures

graves ou mortelles. Par conséquent :

SECTION 1 SÉCURITÉ

SIGNIFICATION DES SYMBOLES

Ce symbole, utilisé partout dans ce manuel,

signiﬁe "Attention" ! Soyez vigilant ! Votre

sécurité est en jeu.

Signiﬁe un danger immédiat. La situation peut

entraîner des blessures graves ou mortelles.

Signiﬁe un danger potentiel qui peut entraîner des

blessures graves ou mortelles.

Signiﬁe un danger qui peut entraîner des blessures

corporelles mineures.

DANGER

AVERTISSEMENT

ATTENTION

2.1 GENERAL

The Prest-O-Lite

550 is a compact, completely self-con-

tained plasma cutting system. As shipped, the system is

fully assembled and ready to cut after being connected

to input power and a source of preﬁltered compressed

air (90-150 psi). The Prest-O-Lite

550 package uses the

PT-31XL torch to deliver cutting power for materials up

to 1/2 inch thick or for severing up to 5/8 inch thick. Refer

to the following paragraphs for descriptions of the Prest-

O-Lite

550 packages available as well as performance

speciﬁcations.

2.2 SCOPE

The purpose 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 source other than the Prest-O-Lite brand PT-31XL torch. Serious injury

may occur if used with any other torch.

Table 2-1. PT-31XL Spare Parts Kit Contents

Description Part Number Quantity

Spare Parts Kit P/N 0558006147 includes:

30/40 A Nozzle 0558006187 3

Electrode 0558006190 2

Swirl Baﬄe 0558006189 1

Heat Shield 0558006185 1

SECTION 2 DESCRIPTION

* Duty cycle is based on a 10-minute period; therefore, a 40% duty cycle means the machine may operate for 4 minutes with a cool

down period of 6 minutes; a 60% duty cycle 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 2-2. Prest-O-Lite

550 Speciﬁcations

2.4 SPECIFICATIONS

Refer to Tables 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 Capacity PT-31XL 50 A DCSP

Air Requirements PT-31XL 250 cfh @ 80 psi

Dimensions of Handy

Plasma

550

Length

Height

Width

14.25-in. ( 362 mm)

12.7-in. (322 mm)

6.2-in. (156 mm)

Weight (less torch) 35 lbs (16 kg)

Figure 2-2. PT-31XL Cutting Performance

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

3.5 PRIMARY ELECTRICAL INPUT

CONNECTIONS FIGURE 31

ELECTRIC SHOCK CAN KILL! 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 connec-

tions are made inside of the power source.

Be sure that the power source is properly conﬁgured

for your input power supply. Damage to the machine

may occur otherwise.

The Prest-O-Lite

550 power source operating on 230 V,

1-phase input power is equipped with a 8-ft, 3-conductor

cable with plug. An optional mating receptacle (P/N 674540)

is available. A line (wall) disconnect switch with a 40-ampere

fuse or circuit breaker should be provided at the main power

panel. The cable connecting the disconnect switch to the

receptacle should include three (two power and one ground)

No. 10 AWG insulated conductors.

The chassis must be connected to an approved electrical

ground. Failure to do so may result in electrical shock,

severe burns or death.

3.1 GENERAL

Proper installation can contribute materially to the satis-

factory and trouble-free operation of the Prest-O-Lite

550

Cutter. It is suggested that each step in this section be

studied carefully and followed as closely 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, dust,

and excessive heat to which the equipment is exposed,

should be minimized. There should be at least one foot

of clearance between the Prest-O-Lite

550 power source

and wall or any other obstruction to allow freedom of air

movement through the power source.

Installing or placing any type of ﬁltering device will restrict

the volume of intake air, thereby subjecting the power

source internal components to overheating. The warranty

is void if any type of ﬁlter device is used.

3.4 INSPECTION

A. Remove the shipping container and all packing ma-

terial and inspect for evidence of concealed damage

which may not have been apparent upon receipt of

the Prest-O-Lite

550. Notify the carrier of any defects

or damage at once.

B. Check container for any loose parts prior to disposing

of shipping materials.

C. Check air louvers and any other openings to ensure

that any obstruction is removed.

A line (wall) disconnect switch, with proper sized fuse or

circuit breaker (see Table 3.1), should be provided at the

main power panel.

SECTION 3 INSTALLATION

1. The torch connections are located at the ﬂowswitch

on upper left side of machine.

2. Thread the power cable and switch lead of the PT-

31XL through the right side (above pressure gauge)

bushing of the front panel. Connect power cable to

the torch ﬁtting (left-hand threads) and connect torch

switch leads to pins 1 and 2 of M

located in the up-

per right hand corner of machine (viewing from rear

of machine) of the control P.C. Board. Make sure the

power cable connection is wrench-tight.

3. Replace the machine cover panel.

4. Connect your air supply to the inlet connection of

the ﬁlter-regulator.

5. Clamp the work cable to the workpiece. Be sure the

workpiece is connected to an approved earth ground

with a properly sized ground cable.

Torch comes factory installed. These instructions are

for torch replacement.

Before making any connections to the power source

output terminals, make sure that all primary input

power to the power source is deenergized (oﬀ) at

the main disconnect switch and that the input power

cable is unplugged. For operator safety, the torch

connections are loaded.

Table 3-1. Recommended Sizes for Input Conductors and Line Fuses

Rated Input Input & GND Fuse Size

Conductor Amps

Volts Amp Phases CU/AWG*

230 27 1 No. 10 40

* Sized per National Code for 80°C rated copper conductors @ 30°C ambient. Not more than three conductors in

raceway or cable. Local codes should be followed if they specify sizes other than those listed above.

3.6 SECONDARY OUTPUT CONNECTIONS

REFER TO FIG. 31

SECTION 3 INSTALLATION

Figure 3-1. Prest-O-Lite

550 Interconnection Diagram

CUSTOMER FUSED LINE

DISCONNECT SWITCH

See Table 3-1

WORK CABLE

SAFETY

GROUND

PT-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 PRESTOLITE

550 FOR 230 Vac INPUT

SECTION 3 INSTALLATION

550 PLASMA CUTTER

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

4.1 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 No. 6 or 7 lens shade.

• Wear eye, ear, and body protection.

Position the Prest-O-Lite

550 at least 10 feet (3 me-

ters) from the cutting area. Sparks and hot slag from

the cutting operation can damage the unit.

4.2 PRESTOLITE

550 CONTROLS

(FIGURE 4-1)

A. Power Switch (located on front panel). When

placed in ON position, the white pilot light will glow

indicating control circuit is energized and the cooling

fan will run.

B. Output Current Control. Adjustable from 15 to 35

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

air to ﬂow for a few minutes. This should remove any

condensation that may have accumulated during

shutdown period. After setting the pressure, release

the button to its normal position.

D. "Over Temperature" LED Yellow light - will turn

on if the machine becomes overheated. Will turn oﬀ

automatically after the machine cools down if the

on/oﬀ switch is still on.

Figure 4-1. Prest-O-Lite

550 Controls

AIR REGULATOR

CONTROL KNOB

AIR PRESSURE

GAUGE

CURRENT

CONTROL

KNOB

REAR VIEW

POWER ON-OFF

(I-O) SWITCH &

CIRCUIT BREAKER

AIR CHECK

BUTTON

FAULT LIGHT

AMBER

AIR LIGHT

GREEN

SECTION 4 OPERATION

550 PLASMA CUTTER

Fig. 4-2 - Assembly of “XT” Consumable Parts

The PT-31XL torch head contains a gas ﬂow check

valve that acts in conjunction 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 is accidentally closed

when the shield is removed. ALWAYS REPLACE

TORCH WITH THE PROPER TORCH MANUFACTURED

BY Prest-O-Lite SINCE IT ALONE CONTAINS Prest-O-

Lite’S PATENTED SAFETY INTERLOCK.

For additional torch information, see booklet (F-14-246)

packed with the PT-31XL torch.

4.4 CUTTING WITH THE PT31XL

Wear the usual protective gloves, clothing, and hel-

met. 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 depress the torch switch unless the

torch nozzle is touching or within 0.020-in.

(less than 1/32-in.) of the workpiece.

E. "Low Air Flow" LED Green light -

will turn on during

operation when the air ﬂow is correct. Will switch oﬀ

below 15psi (1 bar).

F. On/Oﬀ Switch (White light) - will light when switched

on, even if the machine stopped for any reason. Will turn

oﬀ when switch is in OFF position or the light bulb is

defective.

G. Air Pressure Gauge (Front Panel) - Shows air pressure

in bars and psi.

4.3 ASSEMBLING PT31XL COMSUMABLE

PARTS

Make sure power switch on power source is in OFF

position and primary input power is deenergized.

To assemble “XT” consumables, remove the seat supplied with

the torch. Insert the plunger into the head. (The plunger is

reversible.) Then reassemble the seat ﬁrmly with a wrench.

Install the electrode, baﬄe, nozzle, and heat shield as shown in

Fig. 4-2. Tighten heat shield snugly but do not overtighten.

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.

Fig. 4-3 - Eﬀect of Cutting Speed

TOO FAST TOO SLOW CORRECT

NOTE: Nozzles

Marked By

Amperage

0558006190

Plunger

Seat

0558006191

Electrode

0558006192

0558006189

Baﬄe

Nozzle

Heat Shield

0558006185

30/40A

0558006187

SECTION 4 OPERATION

WHEN THE ARC BREAKS

THROUGH THE WORK, BRING THE

TORCH TO AN UPRIGHT POSI-

TION AND PROCEED TO CUT.

TO START A PIERCE, TILT THE TORCH

TO PREVENT MOLTEN MATERIAL FROM

COMING BACK AGAINST AND DAMAG-

ING THE TORCH.

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.

After placing the primary (wall) switch to the ON position and

making control and air pressure adjustments as described

above, proceed as follows:

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

0.020-in. of the workpiece) holding the torch at about

15- 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, the tip can be dragged along the

workpiece if cutting up to 1/4'’ thick material. When cut-

ting material greater than 1/4'’, maintain a 1/8'’ tip-to-work

(standoﬀ) distance.

5. When ending a cut, the torch switch should be released

and lifted oﬀ the workpiece just before the end of the cut

to minimize double-arcing which can damage the tip. This

is to prevent high frequency from reigniting after cutting

arc extinguishes.

6. In the postﬂow mode, the arc can be restarted immediately

by depressing the torch switch. The two second preﬂow

will automatically cancel.

Cutting Speed Range — Prest-O-Lite

550

(Using Air with XT Consumables @ 75 psi)

Output Cutting

Thickness Current Speed

Material (In.) (Amps) (ipm)

Carbon 1/16 30 180

Steel 1/8 30 75

(AISI 1020) 1/8 35 85

1/4 35 30

3/8 35 15

1/2 35 12

Stainless 1/16 30 200

Steel 1/8 30 85

(AISI 304) 1/8 35 85

1/4 35 30

3/8 35 14

1/2 35 10

Aluminum 1/16 30 200

(6061) 1/8 30 85

1/8 35 85

1/4 35 30

3/8 35 15

1/2 35 12

NOTE: The speeds given here are typical for best quality cuts. Your actual

speeds may vary depending on material composition, surface condi-

tion, 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.

Figure 4-4. Piercing Technique using the PT-31XL

SECTION 4 OPERATION

4.5 OPERATING TECHNIQUES

1. Piercing - Materials (up to 1/4-in. thick) may be pierced

with the torch touching the work. When piercing thicker

materials (up to 3/16-in. aluminum or 1/4-in. stainless

or carbon steel) immediately raise the torch to 1/16-in.

standoﬀ after initiating the cutting arc. This will reduce

the chance of spatter from entering the torch and pre-

vent the possibility of welding the tip to the plate. The

torch should be angled at about 30° when starting to

pierce, and then straightened after accomplishing the

pierce.

2. Grate Cutting - For rapid restarts, such as grate or

heavy mesh cutting, do not release the torch switch.

This avoids the 2 second preﬂow portion of the cutting

cycle.

4.6 COMMON CUTTING PROBLEMS

Listed below are common cutting problems followed by the

probable cause of each. If problems are determined 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 thick-

nesses, it may be impossible to get dross-free

cuts.)

1. Cutting speed too fast or too slow.

2. Improper air pressure.

3. Faulty nozzle or electrode.

D. Double Arcing. (Damaged Nozzle Oriﬁce.)

1. Low air pressure.

2. Damaged cutting nozzle.

3. Loose cutting nozzle.

4. Heavy spatter.

E. Uneven Arc.

1. Damaged cutting nozzle or worn electrode.

F. Unstable Cutting Conditions.

1. Incorrect cutting speed.

2. Loose cable or hose connections.

3. Electrode and/or cutting nozzle in poor condi-

tion.

G. Main Arc Does Not Strike.

1. Loose connections.

H. Poor Consumable Life.

1. Improper gas pressure.

2. Contaminated air supply.

SECTION 4 OPERATION

5.1 GENERAL

If this equipment does not operate properly, stop work

immediately and investigate the cause of the malfunc-

tion. 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.

Be sure that the wall disconnect switch or wall circuit

breaker is open before attempting any inspection or

work inside of the Prest-O-Lite

550.

5.2 INSPECTION AND CLEANING

Frequent inspection and cleaning of the Prest-O-Lite

550 is

recommended for safety and proper operation. Some sug-

gestions for inspecting and cleaning are as follows:

A. Check work cable to workpiece connection.

B. Check safety earth ground at workpiece and at power

source chassis.

C. Check heat shield on torch. It should be replaced if

damaged.

D. Check the torch electrode and cutting nozzle for wear on

a daily basis. Remove spatter or replace if necessary.

E. Make sure cable and hoses are not damaged or

kinked.

F. Make sure all ﬁttings and ground connections are

tight.

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 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 Prest-O-Lite

550 using low-pressure dry

compressed air.

5.3 FLOW SWITCH FIGURE 51

When excessive contamination is found in the air, the

ﬂow switch (FS) should be removed, disassembled and

cleaned as follows:

A. Ensure the system is shut down and there is no

trapped air under pressure in the piping.

B. Remove the piston plug.

C. Remove the spring (FS-4 only). Use care when han-

dling spring to prevent distortion.

D. Remove the piston.

E. Clean all parts with cleaning agent.

NOTE

Ensure cleaning agent does not contain solvents

which can degrade polysulfone. Warm water and

detergent is recommended for cleaning. Allow all

parts to dry thoroughly before reassembly.

Reassemble the ﬂow switch in reverse order.

Figure 5-1. Disassembly / Assembly of Flow Switch

SECTION 5 MAINTENANCE

The cause of control malfunctions can be found by

referring to the sequence of operations and electri-

cal schematic diagram (Figure 5-1) and checking

the various components. A volt-ohmmeter will be

necessary for some of these checks.

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.

NOTE

Before checking voltages in the circuit, disconnect the

power from the high frequency generator to avoid dam-

aging your voltmeter.

6.1 TROUBLESHOOTING

ELECTRIC SHOCK CAN KILL! Be sure that all primary

power to the machine has been externally discon-

nected. 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 termi-

nal connections, loose or burned wiring or components,

bulged or leaking capacitors, or any other sign of damage

or discoloration.

Depress torch switch. After 2 seconds, is high frequency present?

Repair/replace

high frequency

unit

Repair/replace

power source

Yes

6.2 TROUBLESHOOTING GUIDE

A. Diﬃcult Starting.

• Change electrode

• Change nozzle

• Check for good, clean connection of work lead to workpiece

• Check air pressure 55 -65 psi (4 - 5 bar)

• Check torch power cable for continuity

Is the "Air" LED light on

Repair/replace

control PCB

Yes No

SECTION 6 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

Does air ﬂow even when Prest-O-Lite

550 power switch is 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

D. On/Oﬀ switch light not energized.

Is switch 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

Unsolved

E. Temperature LED light ON.

Is the unit overheated?

(LED turns oﬀ

when 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

NOTES:

1. When the torch switch is depressed during postﬂow period, the postﬂow and preﬂow times are canceled,

and the HF is energized immediately. The postﬂow time starts 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

SECTION 7 REPLACEMENT PARTS

7.1 General

Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on

the unit nameplate.

To ensure proper operation, it is recommended that only genuine Prest-O-Lite parts and products be used with

this equipment. The use of non-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 customer information only.

Hardware items should be available through local sources.

Note

7.0 Replacement Parts

SECTION 7 REPLACEMENT PARTS

Spare Parts List

Prest-O-Lite

550

Item No. Part No. Description Cct. Ref.

1 0558004493Y Cover (Not Shown)

2 0558002033 Knob

3 0558002754 Inverter/Main PCB

4 0558002755 Control PCB

5 0558002756 HF PCB

6 0558002757 HF Generator

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 REPLACEMENT PARTS

NOTES

Original release 06 / 2006

03 / 2007 - Revised Title Page layout / text.

REVISION HISTORY

Form No: 0558006082 03 / 2007

A. CUSTOMER SERVICE QUESTIONS:

Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST

Order Entry Product Availability Pricing Order Information Returns

B. ENGINEERING SERVICE:

Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST

Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting

C. TECHNICAL SERVICE:

Telephone: (800) 372-2123/ 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 3:30 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

Telephone: (800) 372-2123

Fax: (843) 664-4462

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

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

Prest-O-Lite Welding & Cutting Products,

PO Box 100545, Florence, SC

COMMUNICATION GUIDE - CUSTOMER SERVICES

A member of the

ESAB Group

Transcripción de documentos

Instruction Manual Installation, Operation and Service Prest-O-Lite® 550 Plasma Cutter Prest-O-Lite® 550 Plasma Cutter P/N 0558006058 - 230 V, 1-Phase, 50/60 Hz - North America Form No: 0558006082 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. table of contents Section / Title 1.0 Page Safety Precautions.......................................................................................................................................................................5 1.1 Safety - English................................................................................................................................................................5 1.2 Safety - Spanish..............................................................................................................................................................9 1.3 Safety - French..............................................................................................................................................................13 2.0 Description...................................................................................................................................................................................17 2.1 General........................................................................................................................................................................... 17 2.2 Scope............................................................................................................................................................................... 17 2.3 Packages Available..................................................................................................................................................... 17 2.4 Specifications............................................................................................................................................................... 18 3.0 Installation....................................................................................................................................................................................21 3.1 General............................................................................................................................................................................21 3.2 Equipment Required..................................................................................................................................................21 3.3 Location...........................................................................................................................................................................21 3.4 Inspection.......................................................................................................................................................................21 3.5 Primary Electrical Input Connections...................................................................................................................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 Troubleshooting.......................................................................................................................................................... 31 6.2 Troubleshooting Guide............................................................................................................................................. 31 6.3 Sequence of Operation............................................................................................................................................. 36 7.0 Replacement Parts.....................................................................................................................................................................37 7.1 General............................................................................................................................................................................37 7.2 Ordering..........................................................................................................................................................................37 table of contents section 1 safety precautions 1.0 Safety Precautions 1.1 Safety - English 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. 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. 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 longsleeve 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. 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. section 1 safety precautions 1. Be sure the power source frame (chassis) is connected to the ground system of the input power. 3. Welders should use the following procedures to minimize exposure to EMF: 2. Connect the workpiece to a good electrical ground. A. Route the electrode and work cables together. Secure them with tape when possible. 3. Connect the work cable to the workpiece. A poor or missing connection can expose you or others to a fatal shock. 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. 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. 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. 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. 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. 8. Put on dry, hole-free gloves before turning on the power. Therefore: 9. Turn off the power before removing your gloves. 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. 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. 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. ELECTRIC AND MAGNETIC FIELDS — May be dangerous. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding and cutting current creates EMF around welding cables and welding machines. Therefore: 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. 1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers. 4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specific ventilation recommendations. 2. Exposure to EMF may have other health effects which are unknown. section 1 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.) 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. CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release gas. Sudden rupture of cylinder, valve, or relief device can injure or kill. Therefore: 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. 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. 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. 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. 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. 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. 4. Locate cylinders away from heat, sparks, and flames. Never strike an arc on a cylinder. The following publications, which are available from the American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are recommended to you: 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. 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" EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death. Therefore: 4. AWS C5.3 - "Recommended Practices for Air Carbon Arc Gouging and Cutting" section 1 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 Handbook. 8. ANSI/AWS F4.1, "Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances." Meaning of symbols - As used 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. Means hazards which could result in minor personal injury. section 1 sEGURIDAD 1.2 Safety - Spanish La escoria puede estar caliente y desprenderse con velocidad. Personas cercanas deberán usar gafas de seguridad y careta protectora. 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. 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. PROTEJASE USTED Y A LOS DEMAS-Algunos procesos de soldadura, corte y ranurado son ruidosos y requiren 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 no-flamable como división. 6. Use careta protectora además de sus gafas de seguridad cuando esté removiendo escoria o puliendo. 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. section 1 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. 3. Los soldadores deberán usar los siguientes procedimientos 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 substancias 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 Standard Z49.1 (Vea la lista a continuación) para recomendaciones específicas en la ventilación. 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. 10 section 1 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.) 1. Siempre tenga personal cualificado para efectuar 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. 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. 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. 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. Las siguientes publicaciones, disponibles através de la American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, son recomendadas para usted: 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 1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting" 2. AWS C5.1 - "Recommended Practices for Plasma Arc Welding" MANTENIMIENTO DEL EQUIPO -- Equipo defectuoso o mal mantenido puede causar daño o muerte. Por lo tanto: 3. AWS C5.2 - "Recommended Practices for Plasma Arc Cutting" 4. AWS C5.3 - "Recommended Practices for Air Carbon Arc Gouging and Cutting" 11 section 1 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 section 1 sÉCURITÉ 1.3 Safety - French 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 : 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. 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. 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 latéraux 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. 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 section 1 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; tenez-vous 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. 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. 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 magnétiques peut avoir des effets néfastes inconnus pour la santé. 14 section 1 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.) 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. 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. 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 section 1 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 2 description 2.1 General 2.2 scope The Prest-O-Lite® 550 is a compact, completely self-contained plasma cutting system. As shipped, the system is fully assembled and ready to cut after being connected to input power and a source of prefiltered compressed air (90-150 psi). The Prest-O-Lite® 550 package uses the PT-31XL torch to deliver cutting power for materials up to 1/2 inch thick or for severing up to 5/8 inch thick. Refer to the following paragraphs for descriptions of the PrestO-Lite® 550 packages available as well as performance specifications. The purpose 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. Do not use any torch with this power source other than the Prest-O-Lite brand PT-31XL torch. Serious injury may occur if used with any other torch. 2.3 PACKAGE AVAILABLE Prest-O-Lite® 550 Plasma Cutter........................................................................................................................................ P/N 0558006058 includes: Console with Regulator and Work Cable Torch Spare Parts Kit Table 2-1. PT-31XL Spare Parts Kit Contents Description Part Number Spare Parts Kit P/N 0558006147 includes: 30/40 A Nozzle Electrode Swirl Baffle Heat Shield 0558006187 0558006190 0558006189 0558006185 17 Quantity 3 2 1 1 section 2 description 2.4 Specifications Refer to Tables 2-2, 2-3, and Figures 2-1 and 2-2 for Prest-O-Lite® 550 technical specifications. Table 2-2. Prest-O-Lite® 550 Specifications Rated Output Output Current Range Open Circuit Voltage Rated Primary Input @ 35 A @ 120 VDC Output Power Factor @ 35 Amperes Output Current Capacity Air Requirements Dimensions of Handy Plasma® 550 40% Duty Cycle* 60% Duty Cycle* 100% Duty Cycle* 230 VAC, 50/60 Hz, 1-Phase 35 A @ 120 V dc 30 A @ 120 V dc 22 A @ 120 V dc 15 to 35 Amperes 230 V dc Nominal 27 A 81% (1-Phase) PT-31XL PT-31XL Length Height Width Weight (less torch) 50 A DCSP 250 cfh @ 80 psi 14.25-in. ( 362 mm) 12.7-in. (322 mm) 6.2-in. (156 mm) 35 lbs (16 kg) * Duty cycle is based on a 10-minute period; therefore, a 40% duty cycle means the machine may operate for 4 minutes with a cool down period of 6 minutes; a 60% duty cycle 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. 18 section 2 description 2 1/4" (57mm) 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) 75° Torch 5 1/4" (133mm) Figure 2-1. PT-31XL Dimensions Figure 2-2. PT-31XL Cutting Performance 19 section 2 description 20 section 3 installation 3.5 Primary Electrical InpuT Connections (Figure 3-1) 3.1 General Proper installation can contribute materially to the satisfactory and trouble-free operation of the Prest-O-Lite® 550 Cutter. It is suggested that each step in this section be studied carefully and followed as closely as possible. ELECTRIC SHOCK CAN KILL! 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 of the power source. 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). Be sure that the power source is properly configured for your input power supply. Damage to the machine may occur otherwise. 3.3 Location Adequate ventilation is necessary to provide proper cooling of the Prest-O-Lite® 550 and the amount of dirt, dust, and excessive heat to which the equipment is exposed, should be minimized. There should be at least one foot of clearance between the Prest-O-Lite® 550 power source and wall or any other obstruction to allow freedom of air movement through the power source. The Prest-O-Lite® 550 power source operating on 230 V, 1-phase input power is equipped with a 8-ft, 3-conductor cable with plug. An optional mating receptacle (P/N 674540) is available. A line (wall) disconnect switch with a 40-ampere fuse or circuit breaker should be provided at the main power panel. The cable connecting the disconnect switch to the receptacle should include three (two power and one ground) No. 10 AWG insulated conductors. Installing or placing any type of filtering device will restrict the volume of intake air, thereby subjecting the power source internal components to overheating. The warranty is void if any type of filter device is used. The chassis must be connected to an approved electrical ground. Failure to do so may result in electrical shock, severe burns or death. 3.4 Inspection A. Remove the shipping container and all packing material and inspect for evidence of concealed damage which may not have been apparent upon receipt of the Prest-O-Lite® 550. Notify the carrier of any defects or damage at once. B. Check container for any loose parts prior to disposing of shipping materials. C. Check air louvers and any other openings to ensure that any obstruction is removed. A line (wall) disconnect switch, with proper sized fuse or circuit breaker (see Table 3.1), should be provided at the main power panel. 21 section 3 installation 1. 3.6 SECONDARY (OUTPUT) CONNECTIONS (Refer to Fig. 3-1) 2. Torch comes factory installed. These instructions are for torch replacement. 3. 4. Before making any connections to the power source output terminals, make sure that all primary input power to the power source is deenergized (off) at the main disconnect switch and that the input power cable is unplugged. For operator safety, the torch connections are loaded. 5. The torch connections are located at the flowswitch on upper left side of machine. Thread the power cable and switch lead of the PT31XL through the right side (above pressure gauge) bushing of the front panel. Connect power cable to the torch fitting (left-hand threads) and connect torch switch leads to pins 1 and 2 of M2 located in the upper right hand corner of machine (viewing from rear of machine) of the control P.C. Board. Make sure the power cable connection is wrench-tight. Replace the machine cover panel. Connect your air supply to the inlet connection of the filter-regulator. Clamp the work cable to the workpiece. Be sure the workpiece is connected to an approved earth ground with a properly sized ground cable. Table 3-1. Recommended Sizes for Input Conductors and Line Fuses Rated Input Input & GND Fuse Size Conductor Amps Volts Amp Phases CU/AWG* 230 * 27 1 No. 10 40 Sized per National Code for 80°C rated copper conductors @ 30°C ambient. Not more than three conductors in raceway or cable. Local codes should be followed if they specify sizes other than those listed above. 22 section 3 installation 3.7 Connecting Prest-O-Lite® 550 for 230 vac input 550 PLASMA CUTTER PT-31XL WORK CABLE WORK SAFETY GROUND Allow at least 10 ft (3 m) between work and power source Prefiltered AIR SUPPLY (Customer Supplied) (90 to 150 psig max) CUSTOMER FUSED LINE DISCONNECT SWITCH * See Table 3-1 RECEPTACLE (P/N 674540) (Optional for 230 V, 1-phase power sources) PLUG Table 3-1 and WARNING * (See in regards to chassis ground in Section 3.5.) Figure 3-1. Prest-O-Lite® 550 Interconnection Diagram 23 section 3 installation EARTH GROUND DO NOT ATTACH WORK CABLE TO PIECE BEING CUT FREE WORK CABLE GROUNDED WORK TABLE BE SURE WORK IS IN GOOD CONTACT WITH TABLE. EARTH GROUND WORK CABLE 24 section 4 operation 4.1 Operation 4.2 Prest-O-Lite® 550 CONTROLS (FIGURE 4-1) A. Power Switch (located on front panel). When placed in ON position, the white pilot light will glow indicating control circuit is energized and the cooling fan will run. 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. B. Output Current Control. Adjustable from 15 to 35 amperes to suit cutting conditions. C. Air Check Push Button Switch. When energized, air filter-regulator can be adjusted to desired pressure (55-65 psig) before cutting operations. Allow air to flow for a few minutes. This should remove any condensation that may have accumulated during shutdown period. After setting the pressure, release the button to its normal position. ARC RAYS can burn eyes and skin; NOISE can damage hearing. • Wear welding helmet with No. 6 or 7 lens shade. • Wear eye, ear, and body protection. D. "Over Temperature" LED Yellow light - will turn on if the machine becomes overheated. Will turn off automatically after the machine cools down if the on/off switch is still on. Position the Prest-O-Lite® 550 at least 10 feet (3 meters) from the cutting area. Sparks and hot slag from the cutting operation can damage the unit. AIR REGULATOR CONTROL KNOB FAULT LIGHT AMBER POWER ON-OFF (I-O) SWITCH & CIRCUIT BREAKER REAR VIEW 550 PLASMA CUTTER AIR LIGHT GREEN AIR CHECK BUTTON AIR PRESSURE GAUGE CURRENT CONTROL KNOB Figure 4-1. Prest-O-Lite® 550 Controls 25 section 4 E. operation "Low Air Flow" LED Green light - will turn on during operation when the air flow is correct. Will switch off below 15psi (1 bar). The PT-31XL torch head contains a gas flow check valve that acts in conjunction 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 is accidentally closed when the shield is removed. ALWAYS REPLACE TORCH WITH THE PROPER TORCH MANUFACTURED BY Prest-O-Lite SINCE IT ALONE CONTAINS Prest-OLite’S PATENTED SAFETY INTERLOCK. F. On/Off Switch (White light) - will light when switched on, even if the machine stopped for any reason. Will turn off when switch is in OFF position or the light bulb is defective. G. Air Pressure Gauge (Front Panel) - Shows air pressure in bars and psi. For additional torch information, see booklet (F-14-246) packed with the PT-31XL torch. 4.3 ASSEMBLING PT-31XL COMSUMABLE PARTS 4.4 Cutting with the PT-31XL Wear the usual protective gloves, clothing, and helmet. Helmet with filter lens shade No. 6 or 7 should provide adequate protection for your eyes. Make sure power switch on power source is in OFF position and primary input power is deenergized. To assemble“XT”consumables, remove the seat supplied with the torch. Insert the plunger into the head. (The plunger is reversible.) Then reassemble the seat firmly with a wrench. Install the electrode, baffle, nozzle, and heat shield as shown in Fig. 4-2. Tighten heat shield snugly but do not overtighten. 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 depress the torch switch unless the torch nozzle is touching or within 0.020-in. (less than 1/32-in.) of the workpiece. 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. TOO FAST TOO SLOW CORRECT Fig. 4-3 - Effect of Cutting Speed Baffle 0558006189 Plunger 0558006192 Seat 0558006191 Electrode 0558006190 NOTE: Nozzles Marked By Amperage Nozzle 0558006187 30/40A Fig. 4-2 - Assembly of “XT” Consumable Parts 26 Heat Shield 0558006185 section 4 operation 2 1 WHEN THE ARC BREAKS THROUGH THE WORK, BRING THE TORCH TO AN UPRIGHT POSITION AND PROCEED TO CUT. TO START A PIERCE, TILT THE TORCH TO PREVENT MOLTEN MATERIAL FROM COMING BACK AGAINST AND DAMAGING THE TORCH. Figure 4-4. Piercing Technique using the PT-31XL CAUTION: Cutting Speed Range — Prest-O-Lite® 550 (Using Air with XT Consumables @ 75 psi) Locate the console at least 10-ft. from the cutting work area. Chips and hot slag from the cutting operation can damage the console. After placing the primary (wall) switch to the ON position and making control and air pressure adjustments as described above, proceed as follows: 1. Touch the tip of the torch to the workpiece (or within 0.020-in. of the workpiece) holding the torch at about 15- 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, the tip can be dragged along the workpiece if cutting up to 1/4'’ thick material. When cutting material greater than 1/4'’, maintain a 1/8'’ tip-to-work (standoff ) distance. 5. When ending a cut, the torch switch should be released and lifted off the workpiece just before the end of the cut to minimize double-arcing which can damage the tip. This is to prevent high frequency from reigniting after cutting arc extinguishes. 6. In the postflow mode, the arc can be restarted immediately by depressing the torch switch. The two second preflow will automatically cancel. Thickness Material (In.) Output Current (Amps) Cutting Speed (ipm) Carbon Steel (AISI 1020) 1/16 1/8 1/8 1/4 3/8 1/2 30 30 35 35 35 35 180 75 85 30 15 12 Stainless Steel (AISI 304) 1/16 1/8 1/8 1/4 3/8 1/2 30 30 35 35 35 35 200 85 85 30 14 10 Aluminum (6061) 1/16 1/8 1/8 1/4 3/8 1/2 30 30 35 35 35 35 200 85 85 30 15 12 NOTE: 27 The speeds given here are typical for best quality cuts. Your actual 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. section 4 operation 4.5 OPERATING TECHNIQUES C. 1. Piercing - Materials (up to 1/4-in. thick) may be pierced with the torch touching the work. When piercing thicker materials (up to 3/16-in. aluminum or 1/4-in. stainless or carbon steel) immediately raise the torch to 1/16-in. standoff after initiating the cutting arc. This will reduce the chance of spatter from entering the torch and prevent the possibility of welding the tip to the plate. The torch should be angled at about 30° when starting to pierce, and then straightened after accomplishing the pierce. 2. Grate Cutting - For rapid restarts, such as grate or heavy mesh cutting, do not release the torch switch. This avoids the 2 second preflow portion of the cutting cycle. Dross Formation. (In some materials and thicknesses, it may be impossible to get dross-free cuts.) 1. 2. 3. D. Cutting speed too fast or too slow. Improper air pressure. Faulty nozzle or electrode. Double Arcing. (Damaged Nozzle Orifice.) 1. 2. 3. 4. Low air pressure. Damaged cutting nozzle. Loose cutting nozzle. Heavy spatter. E. Uneven Arc. 4.6 Common Cutting Problems 1. Damaged cutting nozzle or worn electrode. Listed below are common cutting problems followed by the probable cause of each. If problems are determined 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. F. Unstable Cutting Conditions. 1. 2. 3. Insufficient Penetration. 1. 2. 3. Incorrect cutting speed. Loose cable or hose connections. Electrode and/or cutting nozzle in poor condition. G. Main Arc Does Not Strike. Cutting speed too fast. Damaged cutting nozzle. Improper air pressure. 1. Loose connections. H. Poor Consumable Life. B. Main Arc Extinguishes. 1. 2. 1. Cutting speed too slow. 28 Improper gas pressure. Contaminated air supply. section 5 maintenance 5.1 General G. 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. Be sure that the wall disconnect switch or wall circuit breaker is open before attempting any inspection or work inside of the Prest-O-Lite® 550. 5.2 Inspection and Cleaning Frequent inspection and cleaning of the Prest-O-Lite® 550 is recommended for safety and proper operation. Some suggestions for inspecting and cleaning are as follows: A. Check work cable to workpiece connection. B. Check safety earth ground at workpiece and at power source chassis. C. Check heat shield on torch. It should be replaced if damaged. D. Check the torch electrode and cutting nozzle for wear on a daily basis. Remove spatter or replace if necessary. E. F. Make sure cable and hoses are not damaged or kinked. With all input power disconnected, and wearing proper eye and face protection, blow out the inside of the Prest-O-Lite® 550 using low-pressure dry compressed air. 5.3 Flow Switch (Figure 5-1) When excessive contamination is found in the air, the flow switch (FS) should be removed, disassembled and cleaned as follows: A. Ensure the system is shut down and there is no trapped air under pressure in the piping. B. Remove the piston plug. C. Remove the spring (FS-4 only). Use care when handling spring to prevent distortion. D. Remove the piston. E. Clean all parts with cleaning agent. NOTE Ensure cleaning agent does not contain solvents which can degrade polysulfone. Warm water and detergent is recommended for cleaning. Allow all parts to dry thoroughly before reassembly. Reassemble the flow switch in reverse order. PISTON PLUG SPRING Make sure all fittings and ground connections are tight. PISTON 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 the Prest-O-Lite® 550. FLOW SWITCH Figure 5-1. Disassembly / Assembly of Flow Switch 29 section 5 maintenance 30 section 6 TROUBLESHOOTING 6.1 Troubleshooting The cause of control malfunctions can be found by referring to the sequence of operations and electrical schematic diagram (Figure 5-1) and checking the various components. A volt-ohmmeter will be necessary for some of these checks. 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. 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. 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. NOTE Before checking voltages in the circuit, disconnect the power from the high frequency generator to avoid damaging your voltmeter. 6.2 Troubleshooting Guide A. Difficult Starting. • Change electrode • Change nozzle • Check for good, clean connection of work lead to workpiece • Check air pressure 55 -65 psi (4 - 5 bar) • Check torch power cable for continuity Depress torch switch. After 2 seconds, is high frequency present? Yes No Is the "Air" LED light on Yes Repair/replace power source Repair/replace high frequency unit No Repair/replace control PCB 31 section 6 TROUBLESHOOTING 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 Check continuity of torch switch • • • • Replace torch switch OK No No electrode in torch No valve pin in torch Replace electrode Replace valve pin 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 Prest-O-Lite® 550 power switch is OFF? Yes Replace solenoid valve No Repair/replace control PCB 32 section 6 TROUBLESHOOTING D. On/Off switch light not energized. Is switch ON? Yes No Turn on switch No Insert plug Is plug in receptacle? Yes Is cooling fan turning? Yes No Replace On/Off switch Check voltage at receptacle and input power line Yes No Replace On/Off switch 33 Check main fuses section 6 TROUBLESHOOTING E. Temperature LED light ON. Is the unit overheated? (LED turns off when unit cools down.) Yes No Duty cycle exceeded: 40% @ 35 A or 100% @ 22 A output Is cooling air flowing? Repair power source F. No current output Is input voltage within -10% of units input rating? Yes Yes No See (D.) sequence above Unsolved Repair/replace Inverter 34 No Repair fan section 6 TROUBLESHOOTING 35 section 6 TROUBLESHOOTING 6.3 sequence of operation TORCH SWITCH GAS SOLENOID VALVE PUSH RELEASE OPEN 2 SEC. PREFLOW CLOSE 10 SEC Postflow FLOW SWITCH FAULT OVERLOAD LIGHT HF CIRCUIT INVERTER CUTTING ARC (CURRENT) CLOSE OPEN ENERGIZE NOTES: 1. When the torch switch is depressed during postflow period, the postflow and preflow times are canceled, and the HF is energized immediately. The postflow time starts from the moment the torch switch is released. 2. When the amber fault pilot light comes on, cutting operation should be stopped. 36 section 7 replacement parts 7.0 Replacement Parts 7.1 General Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on the unit nameplate. 7.2 Ordering To ensure proper operation, it is recommended that only genuine Prest-O-Lite parts and products be used with this equipment. The use of non-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. Note Bill of material items that have blank part numbers are provided for customer information only. Hardware items should be available through local sources. 37 3 11 7 15 17 2 12 5 4 14 6 9 13 10 8 replacement parts 16 section 7 section 7 replacement parts Spare Parts List Prest-O-Lite® 550 Item No. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 0558004493Y 0558002033 0558002754 0558002755 0558002756 0558002757 0558002738 0558004479 951202 0558004399 0558002746 0558002747 0558002764 0558004498 680560 21710 21711 0558004494Y 0558004478 Description Cct. Ref. Cover (Not Shown) Knob Inverter/Main PCB Control PCB HF PCB HF Generator Fan Fan Grid Flow Switch Main Power Cable w/Plug 10Ft. EMI Filter ON/OFF Switch Solenoid Valve Assembly Plasma Torch Earth Cable w/Clamp Air Regulator/Filter Pressure Gauge Side Panel (Not Shown) Handle (Not Shown) VR1 & 2 S1 notes 40 notes 41 notes revision history Original release 06 / 2006 03 / 2007 - Revised Title Page layout / text. Prest-O-Lite Welding & Cutting Products, PO Box 100545, Florence, SC COMMUNICATION GUIDE - CUSTOMER SERVICES A. CUSTOMER SERVICE QUESTIONS: Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST Order Entry Product Availability Pricing Order Information Returns B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting C. TECHNICAL SERVICE: Telephone: (800) 372-2123/ Fax: (843) 664-4452 Part Numbers Technical Applications Specifications Hours: 8:00 AM to 5:00 PM EST Equipment Recommendations LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST D. E. F. G. H. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4487 / Fax: (843) 664-5557 Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST WELDING EQUIPMENT TRAINING Telephone: (843)664-4428 / Fax: (843) 679-5864 Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST WELDING PROCESS ASSISTANCE: Telephone: (800) 372-2123 Hours: 7:30 AM to 4:00 PM EST TECHNICAL ASST. CONSUMABLES: Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST IF YOU DO NOT KNOW WHOM TO CALL Telephone: (800) 372-2123 Fax: (843) 664-4462 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: 0558006082 03 / 2007 A member of the ESAB Group