ESAB HandyPlasma 250 User manual

ESAB P/N 0558004440 - 115V, 1-Phase, 50/60 Hz

HandyPlasma

®

250

Plasmarc™ Cutting System

0558005320 05 / 2007

Instruction Manual

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

PARAGRAPH

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

1.1 General .......................................................................................................................... 17

1.2 Scope ............................................................................................................................. 17

1.3 System Available ........................................................................................................ 17

1.4 Specications .............................................................................................................. 18

SECTION 2 INSTALLATION........................................................................................................... 21

2.1 General .......................................................................................................................... 21

2.2 Equipment Required ................................................................................................ 21

2.3 Location ........................................................................................................................ 21

2.4 Inspection ..................................................................................................................... 21

2.5 Primary Electrical Input Connections ................................................................. 21

2.6 Secondary (Output) Connections ........................................................................ 23

2.6.1 Torch Replacement ................................................................................................... 23

2.6.2 Air Connection ............................................................................................................ 23

2.6.3 Work Lead Connection ............................................................................................ 23

2.7 PT-31XL Torch Consumables Installation .......................................................... 26

SECTION 3 OPERATION ................................................................................................................ 27

3.1 Operation ..................................................................................................................... 28

3.2 HandyPlasma

®

250 Controls ................................................................................... 28

3.3 Assembling PT-31XL Consumable Parts ............................................................ 29

3.4 Cutting with the PT-31XL ........................................................................................ 29

3.5 Operating Techniques .............................................................................................. 31

3.6 Common Cutting Problems ................................................................................... 31

SECTION 4 MAINTENANCE ......................................................................................................... 33

4.1 General .......................................................................................................................... 33

4.2 Inspection and Cleaning ......................................................................................... 33

4.3 Flow Switch .................................................................................................................. 33

4.4 PT-31XL Torch Maintenance .................................................................................. 34

4.5 Power Cable And Switch Disassembly Sequence .......................................... 35

SECTION 5 TROUBLESHOOTING .............................................................................................. 39

5.1 Troubleshooting ........................................................................................................ 39

5.2 Troubleshooting Guide ........................................................................................... 39

5.3 Sequence of Operation ........................................................................................... 44

SECTION 6 REPLACEMENT PARTS ........................................................................................... 45

6.1 General .......................................................................................................................... 45

6.2 Ordering ........................................................................................................................ 45

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5

SAFETY PRECAUTIONS

1.0 Safety Precautions

1.1 Safety - English

WARNING: These Safety Precautions are

for your protection. They summarize pre-

cautionary information from the references

listed in Additional Safety Information sec-

tion. Before performing any installation or operating

procedures, be sure to read and follow the safety

precautions listed below as well as all other manuals,

material safety data sheets, labels, etc. Failure to observe

Safety Precautions can result in injury or death.

PROTECT YOURSELF AND OTHERS --

Some welding, cutting, and gouging

processes are noisy and require ear

protection. The arc, like the sun, emits

ultraviolet (UV) and other radiation

and can injure skin and eyes. Hot metal can cause

burns. Training in the proper use of the processes

and equipment is essential to prevent accidents.

Therefore:

1. Always wear safety glasses with side shields in any

work area, even if welding helmets, face shields, and

goggles are also required.

2. Use a face shield tted with the correct lter 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 ameproof gauntlet type gloves, heavy long-

sleeve shirt, cuess 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 ameproof apron may also be desirable as protec-

tion against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cus, 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-ammable partition or

curtains.

6. Use goggles over safety glasses when chipping slag

or grinding. Chipped slag may be hot and can y far.

Bystanders should also wear goggles over safety

glasses.

FIRES AND EXPLOSIONS -- Heat from

ames and arcs can start res. Hot

slag or sparks can also cause res and

explosions. Therefore:

1. Remove all combustible materials well away from

the work area or cover the materials with a protec-

tive non-ammable 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 oors or wall openings and cause a hid-

den smoldering re or res on the oor 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 ammable or toxic vapors. Do not do hot

work on closed containers. They may explode.

4. Have re extinguishing equipment handy for instant

use, such as a garden hose, water pail, sand bucket,

or portable re extinguisher. Be sure you are trained

in its use.

5. Do not use equipment beyond its ratings. For ex-

ample, overloaded welding cable can overheat and

create a re 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 re. Use re 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 conned, or if there is

danger of falling.

6

SAFETY PRECAUTIONS

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

nected to the ground system of the input power.

2. Connect the workpiece to a good electrical

ground.

3. Connect the work cable to the workpiece. A poor

or missing connection can expose you or others

to a fatal shock.

4. Use well-maintained equipment. Replace worn or

damaged cables.

5. Keep everything dry, including clothing, work

area, cables, torch/electrode holder, and power

source.

6. Make sure that all parts of your body are insulated

from work and from ground.

7. Do not stand directly on metal or the earth while

working in tight quarters or a damp area; stand

on dry boards or an insulating platform and wear

rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the

power.

9. Turn o the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on

next page) for specic grounding recommenda-

tions. Do not mistake the work lead for a ground

cable.

ELECTRIC AND MAGNETIC FIELDS

— May be dangerous. Electric cur-

rent owing 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 eects 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 conned spaces. Do

not breathe fumes and gases. Shield-

ing gases can cause asphyxiation.

Therefore:

1. Always provide adequate ventilation in the work area

by natural or mechanical means. Do not weld, cut, or

gouge on materials such as galvanized steel, stain-

less steel, copper, zinc, lead, beryllium, or cadmium

unless positive mechanical ventilation is provided.

Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying opera-

tions. The heat or arc rays can react with chlorinated

hydrocarbon vapors to form phosgene, a highly

toxic gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat ir-

ritation while operating, this is an indication that

ventilation is not adequate. Stop work and take

necessary steps to improve ventilation in the work

area. Do not continue to operate if physical discom-

fort persists.

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

for specic ventilation recommendations.

7

SAFETY PRECAUTIONS

5. WARNING: This product, when used for welding

or cutting, produces fumes or gases

which contain chemicals known to

the State of California to cause birth

defects and, in some cases, cancer.

(California Health & Safety Code

§25249.5 et seq.)

CYLINDER HANDLING -- Cylinders,

if mishandled, can rupture and vio-

lently release gas. Sudden rupture

of cylinder, valve, or relief device can

injure or kill. Therefore:

1. Use the proper gas for the process and use the

proper pressure reducing regulator designed to

operate from the compressed gas cylinder. Do not

use adaptors. Maintain hoses and ttings in good

condition. Follow manufacturer's operating instruc-

tions for mounting regulator to a compressed gas

cylinder.

2. Always secure cylinders in an upright position by

chain or strap to suitable hand trucks, undercar-

riages, benches, walls, post, or racks. Never secure

cylinders to work tables or xtures where they may

become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have

valve protection cap in place if regulator is not con-

nected. Secure and move cylinders by using suitable

hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and ames.

Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,

"Precautions for Safe Handling of Compressed Gases

in Cylinders", which is available from Compressed

Gas Association, 1235 Jeerson Davis Highway,

Arlington, VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or

improperly maintained equipment can

cause injury or death. Therefore:

1. Always have qualied personnel perform the instal-

lation, troubleshooting, and maintenance work.

Do not perform any electrical work unless you are

qualied to perform such work.

2. Before performing any maintenance work inside a

power source, disconnect the power source from

the incoming electrical power.

3. Maintain cables, grounding wire, connections, power

cord, and power supply in safe working order. Do

not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep

equipment away from heat sources such as furnaces,

wet conditions such as water puddles, oil or grease,

corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position

and in good repair.

6. Use equipment only for its intended purpose. Do

not modify it in any manner.

ADDITIONAL SAFETY INFORMATION -- For

more information on safe practices for

electric arc welding and cutting equip-

ment, ask your supplier for a copy of

"Precautions and Safe Practices for Arc

Welding, Cutting and Gouging", Form

52-529.

The following publications, which are available from

the American Welding Society, 550 N.W. LeJuene Road,

Miami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc

Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc

Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon

Arc Gouging and Cutting"

8

SAFETY PRECAUTIONS

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

sten Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal

Arc Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Hand-

book.

8. ANSI/AWS F4.1, "Recommended Safe Practices for

Welding and Cutting of Containers That Have Held

Hazardous Substances."

MEANING OF SYMBOLS - As used

throughout this manual: Means Atten-

tion! Be Alert! Your safety is involved.

Means immediate hazards which,

if not avoided, will result in im-

mediate, serious personal injury

or loss of life.

Means potential hazards which

could result in personal injury or

loss of life.

Means hazards which could result

in minor personal injury.

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17

1.1 GENERAL

The HandyPlasma

®

250 is a compact, completely self-con-

tained plasma cutting system. As shipped, the system is

fully assembled and ready to cut after being connected

to input power and a source of preltered compressed air

(90-150 psig / 6.2-10.3 bar). The HandyPlasma

®

250 system

uses the PT-31XL torch to deliver cutting power for cutting

materials up to 0.25" (6.4mm) thick or for severing up to

0.31 (7.9mm) thick.

DO NOT USE ANY TORCH WITH THIS POWER SOURCE

OTHER THAN THE ESAB BRAND PT-31XL TORCH. SERIOUS

INJURY MAY OCCUR IF USED WITH ANY OTHER TORCH.

1.2 SCOPE

The purpose of this manual is to provide the operator

with all the information required to install and operate the

HandyPlasma

®

250 Plasmarc™ Cutting System. Technical ref-

erence material is also provided to assist in troubleshooting

the cutting system.

1.3 SYSTEM AVAILABLE

HandyPlasma

®

250 ................................................................................................................................................P/N 0558004440

includes: Console with Regulator and Work Cable, PT-31XL Torch, 12 ft. (3.7m) Torch Cable and Spare Parts Kit

SECTION 1 DESCRIPTION

The patented PT-31XL is a manual torch with a 75

°

head

designed for use with several plasma arc cutting packages

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

is 12 ft. (3.7m) long and is rated at 100% duty cycle for any

output level of the HandyPlasma

®

250.

Optional Torch Guide Kit (0558003258) permits cutting accurate circles from 1.8" to 41.3" (45mm to 1050mm) in diam-

eter with a manual torch. The attachment includes a head and radius bar assembly, center-point / adaptor, and dual swivel

castor assembly. Cuts can be made inside or outside the circle. The torch head is always held vertical during the cutting

operation. The attachment is also handy for maintaining a constant stando in other types of cutting.

WARNING

18

Description Part Number Quantity

Spare Parts Kit P/N 0558005281 includes:

15/20 A Nozzle 19667 3

Electrode 18205 2

Swirl Bae 18785 1

Heat Shield 20282 1

Lubricant, 1/4 oz. 17672 1

O-ring, 0.47" (12mm) ID x 0.078" (2mm) 950790 5

NOTE: PT-31XL Torch Assembly P/N 0558005300 is supplied with the nozzle, electrode, swirl

bae, and heat shield assembled as part of the HandyPlasma

®

250 system.

SECTION 1 DESCRIPTION

* Duty cycle is based on a 10-minute period; therefore, a 40% duty cycle means the machine may operate for 4 minutes with a cool down period of 6

minutes; a 60% duty cycle means the machine may operate for 6 minutes with a cool down period of 4 minutes; a 100% duty cycle means the machine

may operate continuously.

Table 1-2 HandyPlasma

®

250 Specications

1.4 SPECIFICATIONS

Refer to Tables 1-2, 1-3, and Figures 1-1 and 1-2 for HandyPlasma

®

250 technical specications.

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

Torch Current Capacity

Minimum Air Supply Requirements

Rated Output

Output Current

Open Circuit Voltage

Weight (with torch)

Dimensions of HandyPlasma 250

Power Factor @ 18 Amperes Output

Rated Primary Input

@ 18A @ 87.2 VDC Output

20% Duty Cycle*

115 VAC,

50/60 Hz, 1-Phase

PT-31XL

Length

Height

Width

250 cfh @ 75 psi (118 l/m @ 5.2 bar)

50A DCSP

81% (1-Phase)

20A

260 VDC Nominal

18 Amperes

18A @ 87.2 VDC

16" (406mm)

8" (203mm)

6" (152mm)

16 lbs. (7.3kg)

19

SECTION 1 DESCRIPTION

Figure 1-2. PT-31XL Cutting Performance

2.25"

(57mm)

5.25"

(133mm)

75° Torch

Table 1-3 PT-31XL Torch Specications

PT-31XL Torch

Current Capacity ...........................................................50A DCSP

Shipping Wgt. ........................................................20 lbs (9.1 kg)

Length of Service Lines .........................................12 ft. (3.7 m)

Figure 1-1. PT-31XL Dimensions

PT-31XL Torch Assembly P/N 0558005300 is supplied with

the nozzle, electrode, swirl bae, and heat shield as-

sembled.

0

20

40

60

80

100

120

140

0.0625 0.125 0.25 0.3125

Steel Thickness In. (mm)

Cut Data In./Min. (mm/min)

0.06 (1.6) 0.12 (3.2) 0.25 (6.4)

0.31 (7.9)

Steel Thickness In. (mm)

Cut Data In./Min. (mm/min)

140

(3556)

120

(3048)

100

(2540)

80

(2032)

60

(1524)

40

(1016)

20

(508)

0

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21

Table 2.1. Recommended Sizes for Input Conductors and Line Fuses

Rated Input Input & GND Fuse Size

Conductor Amps

Volts Amp Phases CU/AWG*

115 18 1 No. 10 30

SECTION 2 INSTALLATION

2.5 PRIMARY ELECTRICAL INPUT

CONNECTIONS

ELECTRIC SHOCK CAN KILL! PRECAUTIONARY MEASURES

SHOULD BE TAKEN TO PROVIDE MAXIMUM PROTECTION

AGAINST ELECTRICAL SHOCK. BE SURE THAT ALL POWER

IS OFF BY OPENING THE LINE (WALL) DISCONNECT SWITCH

AND BY UNPLUGGING THE POWER CORD TO THE UNIT

WHEN CONNECTIONS ARE MADE INSIDE OF THE POWER

SOURCE.

Be sure that the power source is properly congured for

your input power supply. DO NOT connect a power source

congured for 115V to a 208/230V input power supply.

Damage to the machine may occur.

The HandyPlasma

®

250 power source operates on 115 VAC,

1-phase input power and is equipped with a 8 ft. (2.4m), 3-

conductor cable. The customer is responsible for supplying

a plug with a NEMA 6-30 rating minimum ir desired.

THE CHASSIS MUST BE CONNECTED TO AN APPROVED

ELECTRICAL GROUND. FAILURE TO DO SO MAY RESULT

IN ELECTRICAL SHOCK, SEVERE BURNS OR DEATH.

2.1 GENERAL

Proper installation will insure satisfactory and trouble-free

operation of the HandyPlasma

®

250 cutting package. It is

suggested that each step in this section be studied carefully

and followed.

2.2 EQUIPMENT REQUIRED

A source of clean, pre-ltered dry air that supplies 250 cfh at

75 psig (118 l/m @ 5.2 bar) is required for the cutting opera-

tion. The air supply should not exceed 150 psig (10.3 bar)

(the maximum inlet pressure rating of the air lter-regulator

supplied with the package).

2.3 LOCATION

Adequate ventilation is necessary to provide proper cooling

of the HandyPlasma

®

250 and the amount of dirt, dust, and

excessive heat to which the equipment is exposed, should

be minimized. There should be at least one foot of clearance

between the HandyPlasma

®

250 power source and wall or

any other obstruction to allow freedom of air movement

through the power source.

Installing or placing any type of ltering device will restrict

the volume of intake air, thereby subjecting the power source

internal components to overheating. The warranty is void if

any type of lter device is used.

2.4 INSPECTION

A. Remove the shipping container and all packing mate-

rial and inspect for evidence of concealed damage

which may not have been apparent upon receipt of the

HandyPlasma

®

250. Notify the carrier of any defects or

damage at once.

B. Check container for any loose parts prior to disposing

of shipping materials.

C. Check air louvers and any other openings to ensure

that any obstruction is removed.

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

circuit breaker (see Table 2.1), should be provided at the

main power panel.

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

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

WARNING

CAUTION

22

SECTION 2 INSTALLATION

Figure 2-1 HandyPlasma

®

250 Primary Interconnection Diagram

CUSTOMER FUSED LINE

DISCONNECT SWITCH

See Table 2.1

PLUG (customer supplied)

NEMA 5-20 rating minimum

RECEPTACLE - NEMA 5-20 rating minimum

(Receptacle to match plug)

Preltered AIR SUPPLY (Customer Supplied)

(90 to 150 psig / 6.2 to 10.3 bar max)

*

(See Table 2.1 and WARNING

in regards to chassis ground

in Section 2.5.)

2.5 PRIMARY ELECTRICAL INPUT CONNECTIONS

Recommendations for Proper Operating Performance:

Proper Extension Cord

When the use of an extension cord is needed, the recommended size and length is 14AWG/25ft respectively. Anything out-

side the recommended specications could cause lost in power resulting poor cut quality and capacity.

Exclusive wall Outlet

For optimal performance, use an exclusive wall outlet. Combining power supply with additional appliances increases the risk

of improper voltage and current to the unit. This may reduce cut quality and cut capacity.

8

INSTALLATION

Une installation correcte contribue matériellement à un

bon fonctionnement du module de découpage. Nous

recommandons que chaque étape de cette section soit

soigneusement étudiée et respectée.

A. INSPECTION ET PLACEMENT

1. Après avoir déballé le contenu de l’emballage,

inspectez-le pour détecter tout dommage éventuel

non apparent à la réception de l’appareil. Prévenez

immédiatement le transporteur de tout défaut ou

dommage.

2. Examinez le conteneur pour déceler toutes les pièces

lâches. Vériﬁez que les bouches d’aération sur les

panneaux de l’armoire et les ouvertures de la base ne

sont pas obstruées par des matières d’emballage qui

pourraient entraver la bonne circulation de l’air dans

le boc d’alimentation électrique.

3. Les éléments de la console du CUTTER PLASMA

125 sont : maintenus aux températures de

fonctionnement appropriés par un refroidissement par

ventilateur. L’air est aspiré par le panneau arrière, puis

ressort par les bouches d’aération du panneau avant.

Placez le bloc d’alimentation dans un espace ouvert

où l’air peut circuler librement par les ouvertures.

Laissez au moins un dégagement de 30 cm entre

l’alimentation électrique et le mur ou une autre

obstruction. L’espace environnant de l’alimentation

électrique doit être relativement protégé des

poussières, des émanations et de la chaleur

excessive.

B. BRANCHEMENT ÉLECTRIQUE D’ENTRÉE

PRINCIPALE

Prenez toutes les mesures nécessaires pour fournir

une protection maximum contre le risque de chocs

électriques. Assurez-vous que toute l’alimentation

électrique est coupée au niveau du coupe-circuit

principal (mur) et débranchez le cordon secteur de

l’appareil quand des branchements sont eﬀectuées à

l’intérieur du bloc d’alimentation électrique.

1. Le CUTTER PLASMA 125 est muni d’un câble

d’alimentation d’entrée de 3 mètres (10 pieds), à

3 conducteurs, muni d’une ﬁche de 115 V. Branchez

dans une prise normale de 115 V.

SECTION 3

INSTALLATION

Fig. 3.1 - 125 Schéma d’interconnexion du Cutter Plasma 125

115 V

20 A

CÂBLE DE TRAVAIL

(3,8 m/12-1/2 pieds)

TRAVAIL

TORCHE PT-34 avec des

lignes de 4,6 m (15 pieds)

Masse

!

AVERTISSEMENT

23

SECTION 2 INSTALLATION

Torch comes factory installed. These instructions are for

torch replacement.

BEFORE MAKING ANY CONNECTIONS TO THE POWER

SOURCE OUTPUT TERMINALS, MAKE SURE THAT ALL

PRIMARY INPUT POWER TO THE POWER SOURCE IS

DEENERGIZED (OFF) AT THE MAIN DISCONNECT SWITCH

AND THAT THE INPUT POWER CABLE IS UNPLUGGED.

FOR OPERATOR SAFETY, THE TORCH CONNECTIONS ARE

LOADED.

Front

Rear

Torch Connection

Figure 2-2. Torch Connection

2.6 SECONDARY OUTPUT CONNECTIONS

1. Connect your air supply to the inlet connection of the

lter-regulator. See Figure 2-1.

2. Thread the power cable and switch lead of the PT-31XL

through the lower left side bushing of the front panel.

Connect power cable to the torch tting (left-hand

threads) and connect torch trigger switch leads to pins

1 and 2 of white plug located in the lower right corner

of machine. Make sure the power cable connection is

wrench-tight.

3. Replace the machine cover panel.

1. Remove the machine cover panel. The torch connection

is located on the lower side of machine. See Figure 2-2

below.

2.6.1 Torch Replacement

2.6.2 Air Connection

1. 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 Figures 2-3, 2-4

and 2-5.

2.6.3 Work Lead Connection

WARNING

24

SECTION 2 INSTALLATION

WORK CABLE

SAFETY

GROUND

PT-31XL

WORK

between work and power source

Allow at least 10 ft (3 m)

Figure 2-3 HandyPlasma

®

250 Secondary Interconnection Diagram

2.6 SECONDARY OUTPUT CONNECTIONS

25

SECTION 2 INSTALLATION

WORK CABLE

EARTH GROUND

DO NOT ATTACH WORK CABLE

TO PIECE BEING CUT FREE

GROUNDED

WORK TABLE

EARTH GROUND

WORK CABLE

BE SURE WORK IS IN GOOD

CONTACT WITH TABLE.

Figure 2-4 Secondary (Output) Connections

Figure 2-5 Secondary (Output) Connections

2.6 SECONDARY OUTPUT CONNECTIONS

26

SECTION 2 INSTALLATION

Follow all safety instructions included in this manual. DO NOT install or attempt to

operate this torch without following these safety instructions.

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 NOZ-

ZLE OR WORKPIECE COULD THEN

RESULT IN SERIOUS INJURY OR

DEATH BY ELECTRIC SHOCK.

THE PT-31XL TORCH HEAD CON-

TAINS A GAS FLOW CHECK

VALVE THAT ACTS IN CONJUNC-

TION WITH THE FLOW SWITCH

AND CIRCUITRY WITHIN THE

POWER SOURCE. THIS SYSTEM

PREVENTS THE TORCH FROM

BEING ENERGIZED WITH HIGH

VOLTAGE IF THE TORCH SWITCH

IS ACCIDENTALLY CLOSED WHEN

THE SHIELD IS REMOVED. AL-

WAYS REPLACE TORCH WITH

THE PROPER TORCH MANUFAC-

TURED BY ESAB SINCE IT ALONE

CONTAINS ESAB'S PATENTED

SAFETY INTERLOCK.

The seat comes assembled to the front end of the torch. Make sure seat is tightened

rmly with a wrench but do NOT overtighten.

2.7 PT31XL TORCH CONSUMABLES INSTALLATION

Figure 2-6 Assembly of Standard Consumable Parts

NOTE: Nozzles

Marked By

Amperage

18205

Electrode

18785

Bae

Nozzle

15/20A

Heat Shield

20282

19667

1. To disassemble the front end, hold the torch with the shield in an upright position.

This will prevent the nozzle, electrode, and swirl bae from falling free when the

shield is removed.

The gas ow check valve is part of the safety interlock and is permanently as-

sembled 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 bae. Replace if

worn or damaged.

3. Do not continue to use if the electrode end erodes to a length shorter than 16mm

[5/8 in.] as shown in Fugure 2-6 below.

4. Apply a small amount of lubricant P/N 17672, supplied in spare parts kit, to the heat

shield or to the o-ring as shown in Figure 4-3. Check o-ring for damage whenever

the shield is removed. Replace if necessary.

WARNING

27

SECTION 3 OPERATION

3.0 OPERATION

To ensure that the HandyPlasma 250 operates correctly please perform

the following steps:

1. Turn on main power switch and make sure air is owing to the machine. Adjust

the air regulator to 75 psig (5.2 bar) before cutting operations begin.

NOTE:

This pressure adjustment must be made within 15 seconds after the machine is

turned on. If this is not done within the allotted time the main power must be

turned o and back on again to activate the 15 second preow sequence for air

pressure adjustment.

28

SECTION 3 OPERATION

3.1 OPERATION

ELECTRIC SHOCK CAN KILL.

• DO NOT OPERATE THE UNIT WITH THE COVER RE-

MOVED.

• DONOTAPPLYPOWERTOTHEUNITWHILEHOLDING

OR CARRYING THE UNIT.

• DONOTTOUCHANYTORCHPARTSFORWARDOFTHE

TORCH HANDLE (NOZZLE, HEAT SHIELD, ELECTRODE,

ETC.) WITH POWER SWITCH ON.

ARC RAYS CAN BURN EYES AND SKIN;

NOISE CAN DAMAGE HEARING.

• WEAR WELDING HELMET WITH NO. 6 OR 7 LENS

SHADE.

• WEAREYE,EAR,ANDBODYPROTECTION.

Position the HandyPlasma® 250 at least 10 feet (3 meters)

from the cutting area. Sparks and hot slag from the cut-

ting operation can damage the unit.

3.2 HandyPlasma

®

250 CONTROLS

(FIGURE 3-1)

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

in ON position, the switch becomes illuminated and the

cooling fan will run.

B. Air Pressure Adjustment Control. When main power

switch is turned on and air is owing to the machine,

the air regulator can be adjusted to the desired pres-

sure (65-75 psig / 4.5-5.2 bar) before cutting operations

begin.

NOTE: This pressure adjustment must be made within

15 seconds after the machine is turned on. If this is not

done within the allotted time the main power must be

turned o and back on again to activate the 15 second

preow sequence for air pressure adjustment. See Page

21.

Figure 3-1 HandyPlasma

®

250 Controls

POWER

SWITCH

TEMPERATURE

AIR

WARNING

CAUTION

AIR REGULATOR

CONTROL KNOB

AIR PRESSURE

GAUGE

29

SECTION 3 OPERATION

THE PT-31XL TORCH HEAD CONTAINS A GAS FLOW CHECK

VALVE THAT ACTS IN CONJUNCTION WITH THE FLOW

SWITCH AND CIRCUITRY WITHIN THE POWER SOURCE.

THIS SYSTEM PREVENTS THE TORCH FROM BEING EN-

ERGIZED 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.

3.4 CUTTING WITH THE PT31XL

WEAR THE USUAL PROTECTIVE GLOVES, CLOTHING, AND

HELMET. HELMET WITH FILTER LENS SHADE NO. 6 OR 7

SHOULD PROVIDE ADEQUATE PROTECTION FOR YOUR

EYES.

NEVER TOUCH ANY PARTS FORWARD OF THE TORCH

HANDLE (TIP, HEAT SHIELD, ELECTRODE, ETC.) UNLESS

THE POWER SWITCH IS IN THE OFF POSITION.

CAUTION: Do not depress the torch switch unless the

torch nozzle is touching the workpiece or

within 0.02" (0.51mm) of workpiece.

C. "Over Temperature" LED (Yellow light) - will turn

on if the machine becomes overheated and will turn

o automatically after the machine cools down if the

on/o switch is still on.

"Low Air Flow" LED (Green light) - will turn on during

operation when the air ow is set correctly the LED

will switch o below 15 psig (1.0 bar).

On/O Switch (Orange light) - will light when power

supply is switched on and power is applied.

Air Pressure Gauge (Side Panel) - Shows air pressure

in bars and psi.

3.3 ASSEMBLING PT31XL COMSUMABLE

PARTS

MAKE SURE POWER SWITCH ON POWER SOURCE IS IN

OFF POSITION AND PRIMARY INPUT POWER IS DEEN-

ERGIZED.

Install the electrode, bae, nozzle, and heat shield as shown in

Fig. 3-2. Tighten heat shield snugly but do not overtighten.

BE SURE TO INSTALL THE SWIRL BAFFLE IN THE TORCH.

FAILURE TO DO SO WOULD ALLOW THE NOZZLE (TIP)

TO CONTACT THE ELECTRODE. THIS CONTACT WOULD

PERMIT HIGH VOLTAGE TO BE APPLIED TO THE NOZZLE.

YOUR CONTACT WITH THE NOZZLE OR WORKPIECE

COULD THEN RESULT IN SERIOUS INJURY OR DEATH BY

ELECTRIC SHOCK.

Figure 3-3 Eect of Cutting Speed

TOO FAST TOO SLOW CORRECT

WARNING

Figure 3-2 Assembly of Standard Consumable Parts

NOTE: Nozzles

Marked By

Amperage

18205

Electrode

18785

Bae

Nozzle

15/20A

Heat Shield

20282

19667

30

SECTION 3 OPERATION

WHEN THE ARC BREAKS

THROUGH THE WORK, BRING THE

TORCH TO AN UPRIGHT POSI-

TION AND PROCEED TO CUT.

TO START A PIERCE, TILT THE TORCH

TO PREVENT MOLTEN MATERIAL FROM

COMING BACK AGAINST AND DAMAG-

ING THE TORCH.

1

2

CAUTION: Locate the console at least 10 ft. (3m) from

the cutting work area. Chips and hot slag

from the cutting operation can damage the

console.

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

making control and air pressure adjustments as described

above, proceed as follows:

1. Touch the tip of the torch to the workpiece holding the

torch at about 15- 30° angle to avoid damaging the tip.

2. Depress the torch switch. (Air and high frequency should

energize.)

3. Two seconds after depressing torch switch, the plasma

arc will start cutting.

4. After starting the cut, bring the torch to an upright

position and proceed to cut by dragging the torch

along the workpiece. It may be necessary to cut with a

tip-to-work (stando) distance of up to 0.06" (1.6mm)

due to various material surface conditions.

Figure 3-4 Piercing Technique using the PT-31XL

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

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

is to prevent high frequency from reigniting after cutting

arc extinguishes.

6. In the postow mode, the arc can be restarted immediately

by depressing the torch switch. The two second preow

will automatically cancel.

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