ESAB Prest-O-Lite®125 Plasma Cutter Manual de usuario

Marca: ESAB

Modelo: Prest-O-Lite®125 Plasma Cutter

Categoría: Sistema de soldadura

Tipo: Manual de usuario

Este manual también es adecuado para

®125 Plasma Cutter

Prest-O-Lite

125 Plasma Cutter

Instruction Manual

Installation, Operation and Service

Prest-O-Lite 125 PLASMA ARC CUTTING PACKAGE - P/N 0558001432 115V 60HZ

Form No: F15-604-E 03 / 2007

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of opera-

tion 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.

Be sure this information reaches the operator.

You can get extra copies through Your supplier.

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 contami-

nated should be replaced immediately. Should such repair or replacement become necessary, the manu-

facturer 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 manu-

facturer. 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.

CAUTION

TABLE OF CONTENTS

SECTION TITLE ..........................................................................................................................PAGE

SECTION 1 DESCRIPTION ...............................................................................................................................................17

SECTION 2 INSTALLATION.............................................................................................................................................19

SECTION 3 OPERATION ..................................................................................................................................................21

SECTION 4 MAINTENANCE ...........................................................................................................................................23

SECTION 5 INSTALLATION, OPERATION AND MAINTENANCE OF PT-34 TORCH .................................27

SECTION 6 REPLACEMENT PARTS .............................................................................................................................31

6.1 General ............................................................................................................................................................31

6.2 Ordering ..........................................................................................................................................................31

TABLE OF CONTENTS

WARNING: These Safety Precautions are for

your protection. They summarize precaution-

ary 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.

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 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.

FIRES AND EXPLOSIONS -- Heat from

ﬂames and arcs can start ﬁres. Hot slag

or sparks can also cause ﬁres and explo-

sions. Therefore:

1. Remove all combustible materials well away from

the work area or cover the materials with a protec-

tive non-ﬂammable covering. Combustible mate-

rials 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 in-

stant 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 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.

SAFETY PRECAUTIONS

Safety Precautions

Safety - English

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

connected 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. Shielding 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, stainless steel, copper, zinc, lead, beryllium,

or cadmium unless positive mechanical ventila-

tion is provided. Do not breathe fumes from these

materials.

2. Do not operate near degreasing and spraying

operations. The heat or arc rays can react with chlo-

rinated hydrocarbon vapors to form phosgene, a

highly toxic gas, and other irritant gases.

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.

4. Refer to ANSI/ASC Standard Z49.1 (see listing be-

low) for speciﬁc ventilation recommendations.

SAFETY PRECAUTIONS

5. WARNING: This product, when used for weld-

ing 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 in-

structions 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

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.

5. For additional information, refer to CGA Standard

P-1, "Precautions for Safe Handling of Compressed

Gases in Cylinders", which is available from Com-

pressed 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

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.

4. Do not abuse any equipment or accessories. Keep

equipment away from heat sources such as fur-

naces, wet conditions such as water puddles, oil

or grease, corrosive atmospheres and inclement

weather.

5. Keep all safety devices and cabinet covers in posi-

tion 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 prac-

tices 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.

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 Cut-

ting"

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"

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 re-

sult in minor personal injury.

SAFETY PRECAUTIONS

Safety - Spanish

ADVERTENCIA: Estas Precauciones de

Seguridad son para su protección. Ellas

hacen resumen de información proveni-

ente de las referencias listadas en la sección "In-

formación Adicional Sobre La Seguridad". Antes

de hacer cualquier instalación o procedimiento

de operación , asegúrese de leer y seguir las pre-

cauciones 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 re-

quiren 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

chispas calientes con una cortina adecuada no-

ﬂamable como división.

6. Use careta protectora además de sus gafas de seguri-

dad 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 cau-

sando fuegos escondidos en otros niveles o espa-

cios. 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 va-

pores 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 corriente alterna (AC)

en áreas húmedas, de movimiento con-

ﬁnado en lugares estrechos o si hay posibilidad de

caer al suelo.

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

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 ener-

gizar 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 MAGNETICOS - Son

peligrosos. La corriente eléc-

trica 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 descono-

cidos.

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 soldadu-

ra.

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 venti-

lación 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 apro-

piada. 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 Stan-

dard Z49.1 (Vea la lista a continuación) para

recomendaciones especíﬁcas en la ventilación.

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

California de causar defec-

tos en el nacimiento, o en

algunos casos, Cancer. (Cali-

fornia 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,

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.

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 efectu

ar 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 Cut-

ting"

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"

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.

SEGURIDAD

Safety - French

INCENDIES ET EXPLOSIONS -- La chal-

eur 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 proté-

gées 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

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, Battery-

march 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 bles-

sures 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.

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 précau-

tions 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 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 pro-

téger 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 per-

sonnes se trouvant à proximité doivent également

porter des lunettes étanches par dessus leur lunettes

de sécurité.

SÉCURITÉ

3. Les soudeurs doivent suivre les procédures sui-

vantes 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 adhé-

sive 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 -- peu-

vent causer un malaise ou des

dommages corporels, plus par-

ticulièrement dans les espaces

restreints. Ne respirez pas les

vapeurs et les gaz. Le gaz de pro-

tection 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

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 ma-

tériaux.

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 tra-

vail 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

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.

CHAMPS ÉLECTRIQUES ET MAGNÉ-

TIQUES — comportent un risque

de danger. Le courant électrique

qui passe dans n'importe quel

conducteur produit des champs

électriques et magnétiques localisés. Le soud-

age 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 magné-

tiques peut avoir des eﬀets néfastes inconnus pour

la santé.

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

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.

INFORMATIONS SUPPLÉMENTAIRES

RELATIVES À LA SÉCURITÉ -- Pour ob-

tenir 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 recom-

mandées 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 Cut-

ting"

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

considéres par l'état de la Californie

comme étant une cause des mal-

formations 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 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 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 :

SÉCURITÉ

SIGNIFICATION DES SYMBOLES

Ce symbole, utilisé partout dans ce man-

uel, 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

SÉCURITÉ

DESCRIPTION

 plugs into standard 115 V outlet

 portable - 60 lbs (27 kg)

 cuts practically any sheet metal up to 1/8” (3mm)

thick

 low ripple for ﬁner cuts

 proven patented PT-34 torch - 15 feet (3.8m)

 spare parts kit

 1 year warranty

 30% duty cycle at rated output - fan cooled

 overtemperature light

SPECIFICATIONS

125 PLASMA CUTTER

Input Voltage .......................................115 V, 60 Hz, 1 Phase

Input Current @ rated load .............................20 A @ 115 V

Output Rating .........................................11 amps - 100 volts

Open Circuit Voltage ......................................290 V DC max.

Weight ...................................................................60 lbs (27 kg)

PT34 TORCH

Shipping Wgt. ..........................................................2 lbs (1 kg)

Length of Service Lines .........................................15’ (3.8 m)

Dimensions:

Note the high open-circuit voltage. Use only plasma

cutting torches designed for this equipment. Do NOT

attempt to use this equipment with any process other

than plasma arc cutting.

TORCH

2 1/4”

(57mm)

5 1/4”

(133mm)

WARNING

SECTION 1 DESCRIPTION

EQUIPMENT SUPPLIED

PACKAGES AVAILABLE

Each Package includes:

PT-34, 75° Torch w/ 15-ft. lines ........................................37886

Work Cable, 12-1/2-ft .......................................................680950

Torch Guide Kit .......................604609

OPTIONAL ACCESSORIES AVAILABLE

Wheel Cart Kit Kit .....................................................0558001444

Optional Wheel Cart Kit -

Roll the 125 Plasma Cutter

around the job site with ease.

Torch Guide Kit - This complete

kit, in a rugged plastic carrying

case, includes attachments for

circle and streight line cutting on

ferrous and nonferrous metals.

Contains:

Optional Torch Spare Parts Kit - 0558006144

1- O-Ring Lube - 17672

2- Electrode - 37888

1- Swirl Baﬄe - 0558006196

2- Heat Shield - 0558006185

4- Nozzle Tip - 0558006195

SECTION 1 DESCRIPTION

INSTALLATION

Proper installation can contribute materially to satisfactory

and troublefree operation of the cutting package. It is sug-

gested that each step in this section be studied carefully

and followed as closely as possible.

A. INSPECTION AND PLACEMENT

1. Having removed the shipping container inspect for

evidence of concealed damage which may not have

been apparent upon receipt of the unit. Notify the

carrier of any defects or damage at once.

2. Check the container for any loose parts. Check air

louvers on all panels of cabinet and holes through

the base are free of any packing materials that may

obstruct air ﬂow through the power supply.

3. The components in the 125 PLASMA CUTTER console

are: maintained at proper operating temperatures by

fan cooling. Air is drawn in through the rear panel and

then out the louvers in the front panel. Locate the

power supply in an open area where air can circulate

freely through the openings. Allow at least one foot

of clearance between the power supply and wall or

any other obstruction.

The area around the power supply should be relatively

free of dust, fumes, and excessive heat.

B. PRIMARY INPUT ELECTRICAL CONNECTION

Precautionary measures should be taken to provide

maximum protection against electrical shock. Be sure

that all power is oﬀ by opening the line (wall) discon-

nect switch and by unplugging the power cord to the

unit when connections are made inside the power

supply.

1. The 125 PLASMA CUTTER is equipped with a 10-ft.,

3-conductor input power cable with a 115V plug. Plug

into standard 115 volt outlet.

Fig. 2.1 - 125 Plasma Cutter Interconnection Diagram

115V

20 amps

WORK CABLE (12-1/2’)

WORK

PT-34 TORCH w/15’ Lines

Earth Ground

WARNING

SECTION 2 INSTALLATION

2. Extension cables may result in excessive voltage drop.

Use only industrial grade 16 to 10 awg. extension

cables.

Input voltage to machine must be a minimum of 95

volts while operating.

C. SECONDARY (OUTPUT) CONNECTIONS (Refer to

Figure 2.1)

Before making any connections to the power supply

output terminals, make sure that all primary input

power to the machine is deenergized (oﬀ) and that

input power cable is unplugged.

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

piece is connected to an approved earth ground with a

properly sized ground cable. (See ﬁgure 2.1.)

The following sizes should be acceptable:

25 ft. extension - 16 awg. minimum

50 ft. extension - 14 awg. minimum

100 ft. extension - 12 awg. minumum

150 ft. extension - 10 awg. minimum

Greater than 150 ft. not recommended!

WARNING

SECTION 2 INSTALLATION

D. OPERATION

Wear the usual protective gloves, clothing and helmet.

Helmet with ﬁlter lens shade No. 6 to 8 should provide

adequate protection.

Never touch any parts forward of the torch handle (tip,

heat shield, electrode, etc.) unless the power switch is

in the OFF position.

Do not depress the torch switch unless the torch tip

is touching or within 0.020-in. (less than 1/32-in.) of

the workpiece.

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 plugging in the input power cable, and turning the

power swithc on:

Fig. 3.1 - Assembly of PT-34 Torch Front End Parts

Fig. 3.2 - Controls on 125 Plasma

Cutter Console

HEAT SHIELD

SWIRL BAFFLE

ELECTRODE

TORCH

NOZZLE (TIP)

O-RING

OVERLOAD LIGHT

(AMBER)

POWER LIGHT

POWER SWITCH

A. ADJUSTMENTS & OPERATIONS

CAUTION: Never, under any circumstances, operate the power

supply with the cover removed. In addition to the safety

hazard, improper cooling may cause damage to inter-

nal components. Keep side panels closed when unit is

energized. Also make sure you are adequately protected

before you start cutting - protective helmet and gloves

should always be worn. Refer to safetty section for ad-

ditional operating precautions.

B. TORCH ADJUSTMENTS

Make sure power switch on console is in OFF position

and unplug the input power cable.

With the torch front end facing up, assemble electrode,

swirl baﬄe, tip, and heat shield (supplied with Torch Spare

Parts Kit) in that order as shown in Figure 3.1. (Electrode is

reversible and the swirl baﬄe is symmetrical. They can be

assembled either way.) Apply silicone grease to 0-ring.(See

Figure 3.1)

Tighten heat shield snugly to hold the parts in ﬁrm contact

with each other and to the torch head. Do not overtighten

the heat shield.

The front end of the torch contains a gas ﬂow check valve

that acts in conjunction with the circuitry provided in the

power supply. This patented system provides a safety

interlock preventing the torch from being accidentally en-

ergized with high voltage when the heat shield is removed

and the torch switch is accidentally closed.

C. 125 PLASMA

CUTTER CONTROLS & ADJUSTMENTS

(See Fig. 3.2)

1. Power Switch - When placed in ON position, the cool-

ing fan will run.

2. Power Light - Will glow white to indicate that electri-

cal current has energized the system.

3. Overtemperature Light - Will glow amber under the

following conditions and contactor will be deener-

gized, when Duty Cycle has been exceeded.

a. The duty cycle of this unit is 30% at rated output

current. Duty cycle is based on a 10 minute

cycle; therefore, the unit can operate for a total

of 3 minutes and shut oﬀ for cooling a total of 7

minutes in a 10 minute period.

SECTION 3

OPERATION

WARNING

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 should begin ﬂowing

and H.F. should come on.)

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.

E. OPERATING TECHNIQUES

1. Piercing - Thin materials may be pierced with the

torch touching the work. When piercing thicker

materials (up to 1/8-in.) immediately raise the torch

to 1/16 in. standoﬀ after initiating the cutting arc.

This will reduce the chance of spatter 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, keep torch switch depressed until

entire cutting operation is completed. This avoids the

2 second preﬂow portion of the cutting cycle.

F. COMMON CUTTING FAULTS

Listed below are common cutting problems followed by

probable cause of each. If problems are determined to

be caused by the 125 PLASMA CUTTER, see your ESAB

representative.

1. Insuﬃcient Penetration.

a. Cutting speed too fast.

b. Damaged cutting tip.

c. Improper air pressure.

2. Main Arc Extinguishes.

a. Cutting speed too slow.

3. Dross Formation. (In some materials and thick-

nesses, it may be impossible to get dross-free

cuts.)

a. Cutting speed too fast or too slow.

b. Improper air pressure.

c. Faulty tip or electrode.

4. Double Arcing. (Damaged Tip Oriﬁce.)

a. Low air pressure.

b. Damaged cutting tip.

c. Loose cutting tip.

d. Heavy spatter.

5. Uneven Arc.

a. Damaged cutting tip.

b. Electrode worn or damaged.

6. Unstable Cutting Conditions.

a. Incorrect cutting speed.

b. Loose cable or hose connections.

c. Electrode and/or cutting tip in poor condition.

7. Main Arc Does Not Strike.

a. Loose connections.

8. Poor Consumable Life.

a. Improper gas pressure.

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.

SECTION 3

OPERATION

Fig. 3.3 - Eﬀect of Cutting Speed

CORRECT

TOO FASTTOO SLOW

A. INSPECTION AND CLEANING

Frequent inspection and cleaning of the 125 PLASMA

CUTTER console is recommended. Some Suggestions for

inspecting and cleaning are as follows:

Make sure the power is shut oﬀ.

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

damaged.

2. Check the torch electrode and cutting tip for wear

every 1 or 2 hours of operation.

3. Make sure cable and hoses are not damaged or

kinked.

4. Make sure all plugs, ﬁttings, and ground connections

are tight.

5. With all input power disconnected, and wearing

proper eye and face protection, blow out the inside

of the cutting power supply using low-pressure dry

compressed air.

B. TROUBLESHOOTING

Be sure that all primary power to the machine has been

externally disconnected. Unplug before attempting

inspection or working inside of the power supply.

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, bulging or leaking capacitors, or any other

sign of damage or discoloration.

Voltages in plasma cutting equipment are high enough

to cause serious injury or possibly death. Be particu-

larly careful around equipment when the covers are

removed.

  Change electrode

  Change Tip

  Check for clean ground connection

  Check air ﬂow

  Check torch power cable for continuity

WARNING

SECTION4 MAINTENANCE

SECTION 4

MAINTENANCE

2. No Air

C. TROUBLESHOOTING GUIDE

1. Diﬃcult Starting

Yes

Power

supply

defective

High freq. unit

or compressor

defective

Depress torch switch. Compressor and high

freq. should be seen or heard.

Does high freq. come on with torch switch?

Check

continuity

of torch switch

Yes

No electrode in torch

Electrode too short

Replace electrode

Compressor Defective

Defective

torch switch

Power supply

defective

4. Amber overtemperature light turns ON while cutting.

3. Air does not shut oﬀ.

SECTION 4 MAINTENANCE

Does arc start when tip contacts work without depressing torch switch?

Yes

Check for

short in

torch switch

Cuts normally when torch switch is depressed?

Yes

Power

supply

defective

Defective

control PCB

Defective

Thermal

Switch

Is the fan running?

Yes

Run unit

on idle for

10 minutes

Normal

Duty Cycle

exceeded

Yes

Defective

fan motor

Clear

restrictions

Are there any restrictions or foreign matter?

SECTION 4 MAINTENANCE

SECTION 5

INSTALLATION, OPERATION AND MAINTENANCE OF PT-34 TORCH

WARNING

ELECTRIC SHOCK CAN KILL.

TORCH

2 1/4”

(57mm)

Fig. 5.1 - Dimensional Data PT-34 Torch

Plasma cutting uses high voltage. Skin contact with

the torch, the power source, the workpiece or any

grounded object MUST BE AVOIDED whenever the

power source is ON.

Using the torch on any power source not equipped

with a ﬂow switch safety interlock may expose op-

erator to unexpected high voltage.

INTRODUCTION

The patented PT-34is a manual torch with a 75

head de-

signed for use with several Plasma Arc Cutting Packages

using clean, dry air as the plasma gas. The service lines

are 15 feet long and the torch is rated to operate up to 50

amperes at 100% duty cycle for cutting most metals.

Follow all instructions in the appropriate booklet packed

with your 125 Plasma Cutter package. DO NOT install or

attempt to operate this torch without following these

instructions.

WARNING

A. INSTALLATION & OPERATION

Make sure power switch on the power source is in the

OFF position and PRIMARY INPUT POWER is DEENER-

GIZED.

The seat comes assembled to the front end of the torch.

Make sure seat is tightened ﬁrmly with a wrench but do

NOT overtighten.

With the torch front end facing up, assemble electrode, swirl

baﬄe, tip and heat shield in that order as shown in Figure

5.2 (Standard electrode is reversible and the swirl baﬄe is

symmetrical. They can be assembled either way.)

WARNING

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.

5 1/4”

(133mm)

The PT-34 torch head contains a gas ﬂow check valve

that acts in conjunction with the 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 ESAB SINCE IT ALONE

CONTAINS ESAB’S PATENTED SAFETY INTERLOCK.

B. MAINTENANCE

Before any maintenance is attempted on this torch,

make sure the POWER SWITCH on the power source is

in the OFF position and the PRIMARY INPUT POWER is

DEENERGIZED.

WARNING

Tighten heat shield snugly to hold the parts in ﬁrm contact

with each other and the torch head. Do not overtighten

the heat shield.

1. To disassemble the front end, hold the torch with the

shield in an upright position as shown in Figure 6.2 This

will prevent the nozzle, electrode, and swirl baﬄe from

falling free when the shield is removed. To replace any

of these parts, assemble as directed in Section III.

The gas ﬂow check valve is part of the safety interlock

and is permanently assembled in the torch head. The

head must be replaced if this valve malfunctions. The

light spring force used to close the ball check can be

felt by pushing on the electrode when assembling the

front end components.

2. Periodically check the heat shield, electrode, nozzle, and

swirl baﬄe. Replace if worn or damaged.

3. NOTE - THE ELECTRODE IS REVERSIBLE. When one end

is worn, the electrode can be reversed.

SECTION 5

INSTALLATION, OPERATION AND MAINTENANCE OF PT-34 TORCH

Do not continue to use one end allowing it to erode to

a length shorter than 3/8-in. as shown in Figure 5.3. The

electrode opens the gas ﬂow check valve. If one end is

continually used, it will be too short to open the valve

when reversed.

4. Apply a small amount of lubricant P/N 17672 to the heat

shield as shown in Figure 5.3 or to the O-ring. Check

O-ring for damage whenever the shield is removed.

Replace if necessary. (O-ring P/N 950790 is also supplied

in spare parts kit.)

Fig5. 2 - Front End Assembly

3/8”

MIN.

LUBRICANT CAN BE

APPLIED TO O-RING OR

HEAT SHIELD

Fig. 5.3 - O-ring and Electrode Maintenance

ELECTRODE

EACH END CAN BE USED UNTIL

IT WEARS TO 3/8” LONG.

HEAT SHIELD

SWIRL BAFFLE

ELECTRODE

TORCH

NOZZLE (TIP)

PT-34

5. The power cable and switch leads in the service line

should be inspected periodically. If there are any cuts

through the protective sheath or if gas leaks are noted,

replace the damaged component.

By following steps 1, 2, and 3 in Figure 5.5 the service line

can be removed from the torch. To disassemble the service

line, lay the line out straight, remove the tape from around

the switch lead splices, and free the switch by cutting the

leads close to the splices. (Replacement switches have

extra long leads to make up for any loss due to cutting.)

Remove the rubber boot from the inlet end of the cable

and remove the tape that secures the sheath at each end.

Pull the sheath oﬀ the cable (over small ﬁtting at torch

end). Note that the switch leads wrapped around the

power cable are secured with tape several places along

the cable. The leads, switch cord plug, and strain relief can

now be removed. DO NOT remove the white tape that

forms a band around the power cable at each end. The

sheath is taped to the cable in front of the band which acts

as a shoulder to prevent the sheath from sliding back on

the cable. (Replacement cables have this tape in place.) If

the switch leads are to be replaced, replace with 16 AWG

STRANDED COPPER, 600- VOLT, 90

C INSULATED WIRE.

Reassemble in reverse order.

6. To reposition the switch on the torch, slide the ﬂex sup-

port back, remove the tape securing the spliced leads

to the power cable, reposition switch, retape the leads,

and pull the ﬂex support back in place.

NOTE: A thin ﬁlm of silicone lubricant P/N 17672 applied

inside of the ﬂex support will ease the assembly of

this part.

SECTION 5

INSTALLATION, OPERATION AND MAINTENANCE OF PT-34 TORCH

Included with

POWER CABLE SHEATH ASSY. (50-FT.) - 19027

Fig 5.4 - PT-34 Torch Assembly, P/N 37886 (15 ft. lines)

CONSUMABLES

Torch is completely assembled from

the factory. Additional parts are in-

cluded with spare parts kit No. 37918

- or may be purchased seperately.

ELECTRODE

37888 (multiples of 2)

SWIRL BAFFLE

18785

NOZZLE (Tip)

37887 (multiples of 5)

HEAT SHIELD

20282

SEAT - 19679

(Included with Head)

HEAD - 20072

(Includes, Ring and Seat)

POWER CABLE

HANDLE - 18208

SWITCH BAND - 18207

SWITCH - 18224

(2) SPLICES (Supplied with Switch)

FLEX SUPPORT - 18225

SHEATH

5/8 X 18 L.H.

STRAIN RELIEF - 18226

1/4 Fast On

19675 (15 ft.)

19672 (15 ft.)

SECTION 5

INSTALLATION, OPERATION AND MAINTENANCE OF PT-34 TORCH

Fig. 5.5 - Power Cable and Switch Disassembly Sequence

WARNING

BE SURE to tighten ﬁttings securely using 2 wrenches

during reassembly. (Factory recommended torque is

30 in-lbs). Failure to do so could result in serious injury

to the operator.

Pull ﬂex support back. Remove

tape holding splices.

Slide switch and band from

handle. Snip leads at splice to

replace switch.

Unscrew handle and

power cable from head

6.1 GENERAL

Replacement Parts are illustrated on the following ﬁgures.

When ordering replacement parts, order by part number

and part name, as illustrated on the ﬁgure.

Always provide the series or serial number of the unit on

which the parts will be used. The serial number is stamped

on the unit nameplate.

6.2 ORDERING

Replacement parts may be ordered from your Prest-O-Lite

distributor or from:

Prest-O-Lite Welding & Cutting Products

Attn: Customer Service Dept.

PO Box 100545, Ebenezer Road

Florence, SC, 29501-0545

Be sure to indicate any special shipping instructions when

ordering replacement parts.

Refer to the Communications Guide on back cover of this

manual for a list of customer service phone numbers.

SECTION 6

REPLACEMENT PARTS

SECTION 6

REPLACEMENT PARTS

Figure 7.1 - 125 Plasma Cutter (Internal Right Side View)

BUSHING, SNAP - 634818

POWER SWITCH - 634518

SWITCH SEAL - 951474

POWER LIGHT, WHITE - 951526

OVER TEMP LIGHT, AMBER - 951815

SCREW PHTF 8-32 X .38

LOCK WASHER #8

FLAT WASHER #8

TERMINAL BUSHING - 13730583

SCREW PHTF 6-32 X .38

SCREW PHTF 10-32 X .50

WASHER, LOCK, EXT TOOTH #10

BUSBAR,TAB - 0558001163

CAPACITOR, (800mf 450 VDC) - 37858

HOSE ASSEMBLY - 0558001162

PRESSURE SWITCH - 0558001159

PLUG HOUSING (15 POS) - 951504

PC BOARD, LOGIC - 38168

COOLING FAN - 2046032

DIODE (BRIDGE RECTIFIER) - 37855

GROMMET (.212 ID) - 950518

GROMMET (0.63) - 92W57

SCREW PHTF 10-24 X .50

DECAL, GROUND - 2091558

FOOT, RUBBER - 182W12

SCREW PHTF 8-32 X .38

SCREW PHTF 10-24 X .38

CAPACITOR, (120UF 240 VAC) - 37856

GROMMET (0.63) - 92W57

SCREW PHTF 6-32 X .38

WASHER, FLAT #6

RELAY, (DPDT 25A 120VAC) - 952577

(PL1)

(PL2)

(S1)

(K1)

(C1)

(BR1)

(PCB1)

(PCB1-P1)

(C2)

SCREW PHTF 8-32 X .63

LOCK WASHER #8

FLAT WASHER #8

TRANSFORMER

0558005244

SECTION 6

REPLACEMENT PARTS

Figure 7.2 - 125 Plasma Cutter (Internal Left Side View)

BUSHING, STRAIN RELIEF - 23606172

TERMINAL BLOCK (2 POS 20A) - 950487

SCREW PHTF 6-32 X .50

WASHER, FLAT #6

SCREW PHTF 6-32 X .25

SCREW PHTF 10-24 X .50

WASHER, FLAT #10

DIODE (BRIDGE RECTIFIER) - 37855

BULKHEAD ADAPTOR - 58V75

NUT, HEX 8-32

LOCKWASHER EXT TOOTH #8

COUPLING COIL

(HIGH FREQ.) - 32969

ELBOW 1/4 NPT

BUSHING (SNAP) - 950823

SPARK GAP ASSEMBLY - 0558001180

BUSHING (SNAP) - 639533

TRANSFORMER ASSEMBLY - 0558001212

RESISTOR - 17280025

RESISTOR - 17240225

AIR COMPRESSOR - 37857

(TB1)

(BR2)

(T3)

(T1)

(R2)

(R1)

(M2)

POWER CORD (10 FT.)

-0558001381

SWITCH TERMAN (131°F) - 950710

(TS1)

CAPACITOR - 0558005245

SECTION 6

REPLACEMENT PARTS

LABEL, WARNING - 2091514

HANDLE - 951575

SCREW PHTF 10-24 X .38

LOGO, PREST-O-LITE

0558954037

COVER - 37952M

SCREW PHTF 10-24 X .38

LABEL, DANGER HIGH VOLTAGE - 954008

TORCH CABLE STRAIN RELIEF -

0558001157

LOCKNUT (1 in. CONDUIT) - 950435

TORCH - 37886

Figure 7.3 - 125 Plasma Cutter (External View)

TORCH CABLE STRAIN RELIEF -

0558001157

LOCKNUT (1 in. CONDUIT) - 950435

Figure 8.1 - 125 Plasma Cutter Schematic Diagram for: 115V 60HZ Domestic and 230V Export Models

NOTES:

1. Connections for 115v Operation.

2. Connections for 230V Operation.

D-0558001341-C

Figure 8.2a - 125 Plasma Cutter Wiring Diagram for: 115V 60HZ Domestic and 230V Export Models

D-0558001342-E

Figure 8.2b - 125 Plasma Cutter Wiring Diagram for: 115V 60HZ Domestic and 230V Export Models

D-0558001342-E

Notes

Revision History

03 / 2007 - Revised Title Page, layout / text, safety section & section format of manual.

Form No: F15-604-E 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®125 Plasma Cutter Prest-O-Lite 125 PLASMA ARC CUTTING PACKAGE - P/N 0558001432 115V 60HZ Form No: F15-604-E 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...........................................................................................................................PAGE SECTION 1 DESCRIPTION................................................................................................................................................17 SECTION 2 INSTALLATION.............................................................................................................................................19 SECTION 3 OPERATION...................................................................................................................................................21 SECTION 4 MAINTENANCE............................................................................................................................................23 SECTION 5 INSTALLATION, OPERATION AND MAINTENANCE OF PT-34 TORCH..................................27 SECTION 6 6.1 6.2 REPLACEMENT PARTS..............................................................................................................................31 General.............................................................................................................................................................31 Ordering...........................................................................................................................................................31 TABLE OF CONTENTS safety precautions Safety - English Safety Precautions 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. 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: A. Route the electrode and work cables together. Secure them with tape when possible. 2. Connect the workpiece to a good electrical ground. B. Never coil the torch or work cable around your body. 3. Connect the work cable to the workpiece. A poor or missing connection can expose you or others to a fatal shock. 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. D. Connect the work cable to the workpiece as close as possible to the area being welded. 5. Keep everything dry, including clothing, work area, cables, torch/electrode holder, and power source. 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. Therefore: 8. Put on dry, hole-free gloves before turning on the power. 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. 9. Turn off the power before removing your gloves. 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. safety precautions 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. 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.) 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 52529. 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" EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death. Therefore: 3. AWS C5.2 - "Recommended Practices for Plasma Arc Cutting" 4. AWS C5.3 - "Recommended Practices for Air Carbon Arc Gouging and Cutting" 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. Meansimmediatehazardswhich, 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. sEGURIDAD 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 noflamable 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. 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 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 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 sÉCURITÉ 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 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; tenezvous 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 : CHAMPSÉLECTRIQUESETMAGNÉTIQUES — 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 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. sÉCURITÉ ENTRETIEN DE L'ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou inadéquate peut causer des blessures graves ou mortelles. Par conséquent : 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.) 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 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 1 DESCRIPTION PT-34 Torch Description          Shipping Wgt............................................................2 lbs (1 kg) Length of Service Lines..........................................15’ (3.8 m) Dimensions: plugs into standard 115 V outlet portable - 60 lbs (27 kg) cuts practically any sheet metal up to 1/8” (3mm) thick low ripple for finer cuts proven patented PT-34 torch - 15 feet (3.8m) spare parts kit 1 year warranty 30% duty cycle at rated output - fan cooled overtemperature light 75o TORCH 2 1/4” (57mm) SPECIFICATIONS 5 1/4” (133mm) 125 PLASMA CUTTER Input Voltage........................................115 V, 60 Hz, 1 Phase Input Current @ rated load..............................20 A @ 115 V Output Rating..........................................11 amps - 100 volts Open Circuit Voltage.......................................290 V DC max. ! WARNING Note the high open-circuit voltage. Use only plasma cutting torches designed for this equipment. Do NOT attempt to use this equipment with any process other than plasma arc cutting. Weight....................................................................60 lbs (27 kg) OPTIONAL ACCESSORIES AVAILABLE EQUIPMENT SUPPLIED Optional Torch Spare Parts Kit - 0558006144 PACKAGES AVAILABLE 1- O-Ring Lube - 17672 2- Electrode - 37888 1- Swirl Baffle - 0558006196 2- Heat Shield - 0558006185 4- Nozzle Tip - 0558006195 Contains: Each Package includes: PT‑34, 75° Torch w/ 15‑ft. lines......................................... 37886 Work Cable, 12‑1/2‑ft........................................................680950 Torch Guide Kit - This complete kit, in a rugged plastic carrying case, includes attachments for circle and streight line cutting on ferrous and nonferrous metals. Torch Guide Kit........................604609 Optional Wheel Cart Kit Roll the 125 Plasma Cutter around the job site with ease. Wheel Cart Kit Kit......................................................0558001444 17 SECTION 1 DESCRIPTION 18 SECTION 2 INSTALLATION 115V 20 amps WORK CABLE (12-1/2’) PT-34 TORCH w/15’ Lines Earth Ground WORK Fig. 2.1 - 125 Plasma Cutter Interconnection Diagram INSTALLATION ! Proper installation can contribute materially to satisfactory and troublefree operation of the cutting package. It is suggested that each step in this section be studied carefully and followed as closely as possible. The area around the power supply should be relatively free of dust, fumes, and excessive heat. B. PRIMARY INPUT ELECTRICAL CONNECTION A. INSPECTION AND PLACEMENT 1. 2. 3. WARNING Having removed the shipping container inspect for evidence of concealed damage which may not have been apparent upon receipt of the unit. Notify the carrier of any defects or damage at once. 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 the power supply. Check the container for any loose parts. Check air louvers on all panels of cabinet and holes through the base are free of any packing materials that may obstruct air flow through the power supply. 1. The components in the 125 PLASMA CUTTER console are: maintained at proper operating temperatures by fan cooling. Air is drawn in through the rear panel and then out the louvers in the front panel. Locate the power supply in an open area where air can circulate freely through the openings. Allow at least one foot of clearance between the power supply and wall or any other obstruction. 19 The 125 PLASMA CUTTER is equipped with a 10‑ft., 3‑conductor input power cable with a 115V plug. Plug into standard 115 volt outlet. SECTION 2 2. INSTALLATION Extension cables may result in excessive voltage drop. Use only industrial grade 16 to 10 awg. extension cables. The following sizes should be acceptable: 25 ft. extension - 16 awg. minimum 50 ft. extension - 14 awg. minimum 100 ft. extension - 12 awg. minumum 150 ft. extension - 10 awg. minimum Greater than 150 ft. not recommended! Input voltage to machine must be a minimum of 95 volts while operating. C. SECONDARY (OUTPUT) CONNECTIONS (Refer to Figure 2.1) ! WARNING Before making any connections to the power supply output terminals, make sure that all primary input power to the machine is deenergized (off) and that input power cable is unplugged. Clamp the work cable to the workpiece. Be sure the workpiece is connected to an approved earth ground with a properly sized ground cable. (See figure 2.1.) 20 OPERATION SECTION 3 A. ADJUSTMENTS & OPERATIONS HEAT SHIELD CAUTION: Never, under any circumstances, operate the power supply with the cover removed. In addition to the safety hazard, improper cooling may cause damage to internal components. Keep side panels closed when unit is energized. Also make sure you are adequately protected before you start cutting ‑ protective helmet and gloves should always be worn. Refer to safetty section for additional operating precautions. NOZZLE (TIP) SWIRL BAFFLE ELECTRODE O-RING TORCH B. TORCH ADJUSTMENTS Fig. 3.1 - Assembly of PT-34 Torch Front End Parts Make sure power switch on console is in OFF position and unplug the input power cable. D. OPERATION With the torch front end facing up, assemble electrode, swirl baffle, tip, and heat shield (supplied with Torch Spare Parts Kit) in that order as shown in Figure 3.1. (Electrode is reversible and the swirl baffle is symmetrical. They can be assembled either way.) Apply silicone grease to 0‑ring.(See Figure 3.1) WARNING Wear the usual protective gloves, clothing and helmet. Helmet with filter lens shade No. 6 to 8 should provide adequate protection. Never touch any parts forward of the torch handle (tip, heat shield, electrode, etc.) unless the power switch is in the OFF position. Tighten heat shield snugly to hold the parts in firm contact with each other and to the torch head. Do not overtighten the heat shield. Do not depress the torch switch unless the torch tip is touching or within 0.020‑in. (less than 1/32‑in.) of the workpiece. The front end of the torch contains a gas flow check valve that acts in conjunction with the circuitry provided in the power supply. This patented system provides a safety interlock preventing the torch from being accidentally energized with high voltage when the heat shield is removed and the torch switch is accidentally closed. 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 plugging in the input power cable, and turning the power swithc on: C. 125 PLASMA CUTTER CONTROLS & ADJUSTMENTS (See Fig. 3.2) 1. Power Switch ‑ When placed in ON position, the cooling fan will run. 2. Power Light - Will glow white to indicate that electrical current has energized the system. 3. Overtemperature Light ‑ Will glow amber under the following conditions and contactor will be deenergized, when Duty Cycle has been exceeded. a. ! OVERLOAD LIGHT (AMBER) The duty cycle of this unit is 30% at rated output current. Duty cycle is based on a 10 minute cycle; therefore, the unit can operate for a total of 3 minutes and shut off for cooling a total of 7 minutes in a 10 minute period. POWER LIGHT POWER SWITCH Fig. 3.2 - Controls on 125 Plasma Cutter Console 21 OPERATION SECTION 3 1. Touch the tip of the torch to the workpiece (or within 0.020 in. of the workpiece) holding the torch at about 15‑ 30o angle to avoid damaging the tip. 2. Depress the torch switch. (Air should begin flowing and H.F. should come on.) 3. Two seconds after depressing torch switch, the plasma arc will start cutting. 4. TOO SLOW After starting the cut, the tip can be dragged along the workpiece. TOO FAST CORRECT Fig. 3.3 - Effect of Cutting Speed E. OPERATING TECHNIQUES 1. Piercing ‑ Thin materials may be pierced with the torch touching the work. When piercing thicker materials (up to 1/8‑in.) immediately raise the torch to 1/16 in. standoff after initiating the cutting arc. This will reduce the chance of spatter entering the torch and prevent the possibility of welding the tip to the plate. The torch should be angled at about 30o when starting to pierce, and then straightened after accomplishing the pierce. 4. Double Arcing. (Damaged Tip Orifice.) a. b. c. d. 5. Uneven Arc. a. b. 2. Grate Cutting ‑ For rapid restarts, such as grate or heavy mesh cutting, keep torch switch depressed until entire cutting operation is completed. This avoids the 2 second preflow portion of the cutting cycle. a. b. c. Listed below are common cutting problems followed by probable cause of each. If problems are determined to be caused by the 125 PLASMA CUTTER, see your ESAB representative. a. Loose connections. 8. Poor Consumable Life. Cutting speed too fast. Damaged cutting tip. Improper air pressure. a. Improper gas pressure. 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. 2. Main Arc Extinguishes. Cutting speed too slow. 3. Dross Formation. (In some materials and thicknesses, it may be impossible to get dross‑free cuts.) a. b. c. Incorrect cutting speed. Loose cable or hose connections. Electrode and/or cutting tip in poor condition. 7. Main Arc Does Not Strike. 1. Insufficient Penetration. a. Damaged cutting tip. Electrode worn or damaged. 6. Unstable Cutting Conditions. F. COMMON CUTTING FAULTS a. b. c. Low air pressure. Damaged cutting tip. Loose cutting tip. Heavy spatter. Cutting speed too fast or too slow. Improper air pressure. Faulty tip or electrode. 22 SECTION4 MAINTENANCE B. TROUBLESHOOTING A. INSPECTION AND CLEANING ! Frequent inspection and cleaning of the 125 PLASMA CUTTER console is recommended. Some Suggestions for inspecting and cleaning are as follows: ! Be sure that all primary power to the machine has been externally disconnected. Unplug before attempting inspection or working inside of the power supply. WARNING 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, bulging or leaking capacitors, or any other sign of damage or discoloration. Make sure the power is shut off. 1. Check heat shield on torch. It should be replaced if damaged. 2. Check the torch electrode and cutting tip for wear every 1 or 2 hours of operation. 3. Make sure cable and hoses are not damaged or kinked. 4. Make sure all plugs, fittings, and ground connections are tight. 5. With all input power disconnected, and wearing proper eye and face protection, blow out the inside of the cutting power supply using low‑pressure dry compressed air. WARNING ! WARNING 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.  Change electrode  Change Tip  Check for clean ground connection  Check air flow  Check torch power cable for continuity 23 MAINTENANCE SECTION 4 C. TROUBLESHOOTING GUIDE 1. Difficult Starting Depress torch switch. Compressor and high freq. should be seen or heard. Yes No Power supply defective High freq. unit or compressor defective 2. No Air Does high freq. come on with torch switch? Yes No No electrode in torch Electrode too short Replace electrode Compressor Defective Check continuity of torch switch No OK Power supply defective 24 Defective torch switch SECTION 4 MAINTENANCE 3. Air does not shut off. Does arc start when tip contacts work without depressing torch switch? Yes No Check for short in torch switch Cuts normally when torch switch is depressed? Yes No Defective control PCB Power supply defective 4. Amber overtemperature light turns ON while cutting. Is the fan running? No Are there any restrictions or foreign matter? Yes Run unit on idle for 10 minutes No Defective Thermal Switch OK Normal Duty Cycle exceeded 25 Yes No Clear restrictions Defective fan motor SECTION 4 MAINTENANCE 26 SECTION 5 INSTALLATION, OPERATION AND MAINTENANCE OF PT-34 TORCH ! INTRODUCTION The patented PT-34is a manual torch with a 75o head designed for use with several Plasma Arc Cutting Packages using clean, dry air as the plasma gas. The service lines are 15 feet long and the torch is rated to operate up to 50 amperes at 100% duty cycle for cutting most metals. ! WARNING 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. WARNING Follow all instructions in the appropriate booklet packed with your 125 Plasma Cutter package. DO NOT install or attempt to operate this torch without following these instructions. ELECTRIC SHOCK CAN KILL. Plasma cutting uses high voltage. Skin contact with the torch, the power source, the workpiece or any grounded object MUST BE AVOIDED whenever the power source is ON. Using the torch on any power source not equipped with a flow switch safety interlock may expose operator to unexpected high voltage. ! WARNING The PT-34 torch head contains a gas flow check valve that acts in conjunction with the 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 ESAB SINCE IT ALONE CONTAINS ESAB’S PATENTED SAFETY INTERLOCK. 75o TORCH 2 1/4” (57mm) B. MAINTENANCE 5 1/4” (133mm) ! Fig. 5.1 - Dimensional Data PT-34 Torch Before any maintenance is attempted on this torch, make sure the POWER SWITCH on the power source is in the OFF position and the PRIMARY INPUT POWER is DEENERGIZED. A. INSTALLATION & OPERATION ! WARNING WARNING Make sure power switch on the power source is in the OFF position and PRIMARY INPUT POWER is DEENERGIZED. 1. To disassemble the front end, hold the torch with the shield in an upright position as shown in Figure 6.2 This will prevent the nozzle, electrode, and swirl baffle from falling free when the shield is removed. To replace any of these parts, assemble as directed in Section III. The seat comes assembled to the front end of the torch. Make sure seat is tightened firmly with a wrench but do NOT overtighten. The gas flow check valve is part of the safety interlock and is permanently assembled in the torch head. The head must be replaced if this valve malfunctions. The light spring force used to close the ball check can be felt by pushing on the electrode when assembling the front end components. With the torch front end facing up, assemble electrode, swirl baffle, tip and heat shield in that order as shown in Figure 5.2 (Standard electrode is reversible and the swirl baffle is symmetrical. They can be assembled either way.) Tighten heat shield snugly to hold the parts in firm contact with each other and the torch head. Do not overtighten the heat shield. 2. Periodically check the heat shield, electrode, nozzle, and swirl baffle. Replace if worn or damaged. 3. NOTE - THE ELECTRODE IS REVERSIBLE. When one end is worn, the electrode can be reversed. 27 SECTION 5 INSTALLATION, OPERATION AND MAINTENANCE OF PT-34 TORCH 5. The power cable and switch leads in the service line should be inspected periodically. If there are any cuts through the protective sheath or if gas leaks are noted, replace the damaged component. Do not continue to use one end allowing it to erode to a length shorter than 3/8-in. as shown in Figure 5.3. The electrode opens the gas flow check valve. If one end is continually used, it will be too short to open the valve when reversed. By following steps 1, 2, and 3 in Figure 5.5 the service line can be removed from the torch. To disassemble the service line, lay the line out straight, remove the tape from around the switch lead splices, and free the switch by cutting the leads close to the splices. (Replacement switches have extra long leads to make up for any loss due to cutting.) Remove the rubber boot from the inlet end of the cable and remove the tape that secures the sheath at each end. Pull the sheath off the cable (over small fitting at torch end). Note that the switch leads wrapped around the power cable are secured with tape several places along the cable. The leads, switch cord plug, and strain relief can now be removed. DO NOT remove the white tape that forms a band around the power cable at each end. The sheath is taped to the cable in front of the band which acts as a shoulder to prevent the sheath from sliding back on the cable. (Replacement cables have this tape in place.) If the switch leads are to be replaced, replace with 16 AWG STRANDED COPPER, 600- VOLT, 90m C INSULATED WIRE. Reassemble in reverse order. 4. Apply a small amount of lubricant P/N 17672 to the heat shield as shown in Figure 5.3 or to the O-ring. Check O-ring for damage whenever the shield is removed. Replace if necessary. (O-ring P/N 950790 is also supplied in spare parts kit.) HEAT SHIELD NOZZLE (TIP) SWIRL BAFFLE ELECTRODE TORCH 6. To reposition the switch on the torch, slide the flex support back, remove the tape securing the spliced leads to the power cable, reposition switch, retape the leads, and pull the flex support back in place. NOTE: Fig5. 2 - Front End Assembly PT-34 LUBRICANT CAN BE APPLIED TO O-RING OR HEAT SHIELD 3/8” ELECTRODE EACH END CAN BE USED UNTIL IT WEARS TO 3/8” LONG. MIN. Fig. 5.3 - O-ring and Electrode Maintenance 28 A thin film of silicone lubricant P/N 17672 applied inside of the flex support will ease the assembly of this part. 29 HEAT SHIELD 20282 NOZZLE (Tip) 37887 (multiples of 5) SWIRL BAFFLE 18785 ELECTRODE 37888 (multiples of 2) CONSUMABLES Torch is completely assembled from the factory. Additional parts are included with spare parts kit No. 37918 - or may be purchased seperately. POWER CABLE 19672 (15 ft.) FLEX SUPPORT - 18225 5/8 X 18 L.H. SHEATH 19675 (15 ft.) Included with POWER CABLE SHEATH ASSY. (50-FT.) - 19027 1/4 Fast On STRAIN RELIEF - 18226 HANDLE - 18208 Fig 5.4 - PT-34 Torch Assembly, P/N 37886 (15 ft. lines) (Included with Head) SEAT - 19679 (Includes, Ring and Seat) 750 HEAD - 20072 SWITCH BAND - 18207 SWITCH - 18224 (2) SPLICES (Supplied with Switch) SECTION 5 INSTALLATION, OPERATION AND MAINTENANCE OF PT-34 TORCH 30 Slide switch and band from handle. Snip leads at splice to replace switch. ! WARNING BE SURE to tighten fittings securely using 2 wrenches during reassembly. (Factory recommended torque is 30 in-lbs). Failure to do so could result in serious injury to the operator. 3 Unscrew handle and power cable from head Fig. 5.5 - Power Cable and Switch Disassembly Sequence 1 Pull flex support back. Remove tape holding splices. 2 SECTION 5 INSTALLATION, OPERATION AND MAINTENANCE OF PT-34 TORCH SECTION 6 REPLACEMENT PARTS 6.1 General 6.2 Ordering Replacement Parts are illustrated on the following figures. When ordering replacement parts, order by part number and part name, as illustrated on the figure. Replacement parts may be ordered from your Prest-O-Lite distributor or from: Prest-O-Lite Welding & Cutting Products Attn: Customer Service Dept. PO Box 100545, Ebenezer Road Florence, SC, 29501-0545 Always provide the series or serial number of the unit on which the parts will be used. The serial number is stamped on the unit nameplate. Be sure to indicate any special shipping instructions when ordering replacement parts. Refer to the Communications Guide on back cover of this manual for a list of customer service phone numbers. 31 32 SCREW PHTF 6-32 X .38 WASHER, FLAT #6 SCREW PHTF 10-24 X .38 DECAL, GROUND - 2091558 FOOT, RUBBER - 182W12 SCREW PHTF 8-32 X .38 SCREW PHTF 8-32 X .38 BUSHING, SNAP - 634818 POWER SWITCH - 634518 (S1) SWITCH SEAL - 951474 POWER LIGHT, WHITE - 951526 (PL2) OVER TEMP LIGHT, AMBER - 951815 (PL1) TRANSFORMER 0558005244 SCREW PHTF 8-32 X .63 LOCK WASHER #8 FLAT WASHER #8 SCREW PHTF 8-32 X .38 LOCK WASHER #8 FLAT WASHER #8 SCREW PHTF 10-32 X .50 WASHER, LOCK, EXT TOOTH #10 SCREW PHTF 6-32 X .38 TERMINAL BUSHING - 13730583 Figure 7.1 - 125 Plasma Cutter (Internal Right Side View) (K1) RELAY, (DPDT 25A 120VAC) - 952577 GROMMET (0.63) - 92W57 (C1) CAPACITOR, (120UF 240 VAC) - 37856 SCREW PHTF 10-24 X .50 GROMMET (0.63) - 92W57 (BR1) DIODE (BRIDGE RECTIFIER) - 37855 GROMMET (.212 ID) - 950518 COOLING FAN - 2046032 PC BOARD, LOGIC - 38168 (PCB1) PLUG HOUSING (15 POS) - 951504 (PCB1-P1) PRESSURE SWITCH - 0558001159 HOSE ASSEMBLY - 0558001162 (C2) CAPACITOR, (800mf 450 VDC) - 37858 BUSBAR,TAB - 0558001163 SECTION 6 REPLACEMENT PARTS 33 RESISTOR - 17240225 (R1) AIR COMPRESSOR - 37857 (M2) POWER CORD (10 FT.) -0558001381 BUSHING, STRAIN RELIEF - 23606172 (TB1) TERMINAL BLOCK (2 POS 20A) - 950487 SCREW PHTF 6-32 X .25 Figure 7.2 - 125 Plasma Cutter (Internal Left Side View) (R2) RESISTOR - 17280025 SPARK GAP ASSEMBLY - 0558001180 BUSHING (SNAP) - 639533 (T1) TRANSFORMER ASSEMBLY - 0558001212 BUSHING (SNAP) - 950823 CAPACITOR - 0558005245 ELBOW 1/4 NPT COUPLING COIL (T3) (HIGH FREQ.) - 32969 NUT, HEX 8-32 LOCKWASHER EXT TOOTH #8 BULKHEAD ADAPTOR - 58V75 (TS1) SWITCH TERMAN (131°F) - 950710 SCREW PHTF 10-24 X .50 WASHER, FLAT #10 SCREW PHTF 6-32 X .50 WASHER, FLAT #6 (BR2) DIODE (BRIDGE RECTIFIER) - 37855 SECTION 6 REPLACEMENT PARTS SECTION 6 REPLACEMENT PARTS LABEL, WARNING - 2091514 HANDLE - 951575 SCREW PHTF 10-24 X .38 LOGO, PREST-O-LITE 0558954037 TORCH CABLE STRAIN RELIEF 0558001157 LOCKNUT (1 in. CONDUIT) - 950435 COVER - 37952M SCREW PHTF 10-24 X .38 LABEL, DANGER HIGH VOLTAGE - 954008 TORCH - 37886 Figure 7.3 - 125 Plasma Cutter (External View) 34 Figure 8.1 - 125 Plasma Cutter Schematic Diagram for: 115V 60HZ Domestic and 230V Export Models 1. Connections for 115v Operation. 2. Connections for 230V Operation. NOTES: D-0558001341-C 35 36 D-0558001342-E Figure 8.2a - 125 Plasma Cutter Wiring Diagram for: 115V 60HZ Domestic and 230V Export Models D-0558001342-E 37 Figure 8.2b - 125 Plasma Cutter Wiring Diagram for: 115V 60HZ Domestic and 230V Export Models Notes 38 Revision History 03 / 2007 - Revised Title Page, layout / text, safety section & section format of manual. 39 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: F15-604-E 03 / 2007 A member of the ESAB Group