Prest-O-Lite 550 Manuale utente

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

Prest-O-Lite® 550 Plasma Cutter

Instruction Manual

Installation, Operation and Service

Form No: 0558006082 03 / 2007

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

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

tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment

should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme-

diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone

or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.

The user of this equipment shall have the sole responsibility for any malfunction which results from improper

use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a ser-

vice facility designated by the manufacturer.

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the

principles of operation and safe practices for arc welding and cutting equipment, we urge

you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and

Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain

this equipment. Do NOT attempt to install or operate this equipment until you have read

and fully understand these instructions. If you do not fully understand these instructions,

contact your supplier for further information. Be sure to read the Safety Precautions be-

fore installing or operating this equipment.

CAUTION

USER RESPONSIBILITY

TABLE OF CONTENTS

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

1.1 Safety - English...............................................................................................................................................................5

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

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

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

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

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

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

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

3.0 Installation...................................................................................................................................................................................21

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

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

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

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

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

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

3.7 Connecting Prest-O-Lite®550................................................................................................................................ 23

4.0 Operation.................................................................................................................................................................................... 25

4.1 Operation...................................................................................................................................................................... 25

4.2 Prest-O-Lite® 550 Controls...................................................................................................................................... 25

4.3 Assembling PT-31XL Consumable Parts............................................................................................................ 26

4.4 Cutting with the PT-31XL........................................................................................................................................ 26

4.5 Operating Techniques.............................................................................................................................................. 28

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

5.0 Maintenance...............................................................................................................................................................................29

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

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

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

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

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

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

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

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

7.1 General ...........................................................................................................................................................................37

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

Section / Title Page

TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS

1.0 Safety Precautions 1.1 Safety - English

WARNING: These Safety Precautions are

for your protection. They summarize pre-

cautionaryinformationfromthereferences

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,

materialsafetydatasheets,labels,etc.Failuretoobserve

Safety Precautions can result in injury or death.

PROTECT YOURSELF AND OTHERS --

Some welding, cutting, and gouging

processes are noisy and require ear

protection.Thearc,likethesun,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

workarea,evenifweldinghelmets,faceshields,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.

Aﬂameproofapronmayalsobe desirableas protec-

tion against radiated heat and sparks.

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

trouser cuﬀs, or pockets. Sleeves and collars should

bekeptbuttoned,andopenpocketseliminatedfrom

the front of clothing.

5. Protect other personnel from arc rays and hot

sparks with a suitable non-ﬂammable partition or

curtains.

6. Usegogglesoversafety glasseswhen chippingslag

orgrinding.Chipped slagmaybehot andcan ﬂy far.

Bystanders should also wear goggles over safety

glasses.

FIRES AND EXPLOSIONS -- Heat from

ﬂames and arcs can start ﬁres. Hot

slag or sparks can also cause ﬁres and

explosions. Therefore:

1. Remove all combustible materials well away from

the work area or cover the materials with a protec-

tivenon-ﬂammablecovering.Combustiblematerials

include wood, cloth, sawdust, liquid and gas fuels,

solvents, paints and coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or

crevices in ﬂoors or wall openings and cause a hid-

densmolderingﬁreorﬁresontheﬂoorbelow.Make

certain that such openings are protected from hot

sparks and metal.“

3. Donotweld,cutorperformother hotworkuntilthe

workpiecehasbeencompletelycleanedsothatthere

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. Haveﬁreextinguishingequipmenthandyforinstant

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

orportableﬁreextinguisher.Be sureyouaretrained

in its use.

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

ample, overloaded welding cable can overheat and

create a ﬁre hazard.

6. After completing operations, inspect the work area

tomake certain thereareno hot sparks or hot metal

whichcouldcausealaterﬁre.Useﬁrewatcherswhen

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

causesevereinjuryor death.DONOT

useACweldingcurrentindampareas,

if movement is conﬁned, or if there is

danger of falling.

SECTION 1 SAFETY PRECAUTIONS

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

nected to the ground system of the input power.

2. Connect the workpiece to a good electrical

ground.

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

or missing connection can expose you or others

to a fatal shock.

4. Use well-maintained equipment. Replace worn or

damaged cables.

5. Keep everything dry, including clothing, work

area, cables, torch/electrode holder, and power

source.

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

from work and from ground.

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

working in tight quarters or a damp area; stand

on dry boards or an insulating platform and wear

rubber-soled shoes.

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

power.

9. Turn oﬀ the power before removing your gloves.

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

next page) for speciﬁc grounding recommenda-

tions. Do not mistake the work lead for a ground

cable.

ELECTRIC AND MAGNETIC FIELDS

— May be dangerous. Electric cur-

rent ﬂowing through any conduc-

tor causes localized Electric and

MagneticFields(EMF).Welding and

cuttingcurrentcreatesEMFaroundweldingcables

and welding machines. Therefore:

1. Welders having pacemakers should consult their

physician before welding. EMF may interfere with

some pacemakers.

2. ExposuretoEMFmayhaveotherhealtheﬀectswhich

are unknown.

3. Welders should use the following procedures to

minimize exposure to EMF:

A. Route the electrode and work cables together.

Secure them with tape when possible.

B. Never coil the torch or work cable around your

body.

C. Do not place your body between the torch and

work cables. Route cables on the same side of

your body.

D. Connecttheworkcabletotheworkpieceasclose

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,cancausediscomfortorharm,

particularly in conﬁned spaces. Do

notbreathefumesandgases.Shield-

ing gases can cause asphyxiation.

Therefore:

1. Alwaysprovideadequateventilationintheworkarea

bynaturalormechanicalmeans.Donotweld,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. Donotoperateneardegreasingandsprayingopera-

tions.Theheatorarcrayscanreactwith 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. RefertoANSI/ASCStandardZ49.1(seelistingbelow)

for speciﬁc ventilation recommendations.

SECTION 1 SAFETY PRECAUTIONS

5. WARNING: Thisproduct,whenusedforwelding

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

ofcylinder,valve,or reliefdevicecan

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.Followmanufacturer'soperatinginstruc-

tions for mounting regulator to a compressed gas

cylinder.

2. Always secure cylinders in an upright position by

chain or strap to suitable hand trucks, undercar-

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

cylinders to work tables or ﬁxtures where they may

become part of an electrical circuit.

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

valve protection cap in place if regulator is not con-

nected.Secureandmovecylindersbyusingsuitable

hand trucks. Avoid rough handling of cylinders.

4. Locatecylindersawayfromheat,sparks,andﬂames.

Never strike an arc on a cylinder.

5. Foradditionalinformation,refertoCGAStandardP-1,

"PrecautionsforSafeHandlingofCompressedGases

in Cylinders", which is available from Compressed

Gas Association, 1235 Jeﬀerson Davis Highway,

Arlington, VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or

improperly maintained equipment can

cause injury or death. Therefore:

1. Alwayshavequaliﬁedpersonnelperformtheinstal-

lation, troubleshooting, and maintenance work.

Do not perform any electrical work unless you are

qualiﬁed to perform such work.

2. Before performing any maintenance work inside a

power source, disconnect the power source from

the incoming electrical power.

3. Maintaincables,groundingwire,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

equipmentawayfromheatsourcessuchasfurnaces,

wet conditions such as water puddles, oil or grease,

corrosive atmospheres and inclement weather.

5. Keepallsafetydevicesandcabinetcoversinposition

and in good repair.

6. Use equipment only for its intended purpose. Do

not modify it in any manner.

ADDITIONALSAFETYINFORMATION--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

theAmericanWeldingSociety,550N.W.LeJueneRoad,

Miami, FL 33126, are recommended to you:

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

2. AWSC5.1- "RecommendedPracticesforPlasmaArc

Welding"

3. AWSC5.2- "RecommendedPracticesforPlasmaArc

Cutting"

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

Arc Gouging and Cutting"

SECTION 1 SAFETY PRECAUTIONS

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

sten Arc Welding“

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

Arc Welding"“

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

book.

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

Welding and Cutting of Containers That Have Held

Hazardous Substances."

MEANING OF SYMBOLS - As used

throughout this manual: Means Atten-

tion! Be Alert! Your safety is involved.

Meansimmediatehazardswhich,

if not avoided, will result in im-

mediate, serious personal injury

or loss of life.

Means potential hazards which

could result in personal injury or

loss of life.

Meanshazardswhichcouldresult

in minor personal injury.

SECTION 1 SEGURIDAD

1.2 Safety - Spanish

ADVERTENCIA: Estas Precauciones de Se-

guridad son para su protección. Ellas hacen

resumen de información proveniente de las

referencias listadas en la sección "Información Adi-

cional Sobre La Seguridad". Antes de hacer cualquier

instalación o procedimiento de operación , asegúrese

de leer y seguir las precauciones de seguridad listadas

a continuación así como también todo manual, hoja

de datos de seguridad del material, calcomanias, etc.

El no observar las Precauciones de Seguridad puede

resultar en daño a la persona o muerte.

PROTEJASE USTED Y A LOS DEMAS--

Algunosprocesosdesoldadura,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. Utilicegafasdeseguridadconprotecciónaloslados

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,

zapatoaltoaltobillo,y caretadesoldarconcapucha

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. Chispasypartículasdemetalcalientepuedealojarse

en las mangas enrolladas de la camisa , el ruedo del

pantalón o los bolsillos. Mangas y cuellos deberán

mantenerse abotonados, bolsillos al frente de la

camisa deberán ser cerrados o eliminados.

5. Proteja a otras personas de los rayos del arco y chis-

pascalientesconunacortina adecuadano-ﬂamable

como división.

6. Usecaretaprotectoraademásdesus gafas desegu-

ridad cuando esté removiendo escoria o puliendo.

La escoria puede estar caliente y desprenderse con

velocidad. Personas cercanas deberán usar gafas

de seguridad y careta protectora.

FUEGO Y EXPLOSIONES -- El calor de

lasﬂamas 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

pruebadefuego.Materialescombustibles incluyen

madera,ropa, líquidos y gases ﬂamables,solventes,

pinturas, papel, etc.

2. Chispasypartículasdemetalpuedenintroducirseen

las grietas y agujeros de pisos y paredes causando

fuegos escondidos en otros niveles o espacios.

Asegúresedequetodagrietayagujeroestécubierto

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.Estospuedenexplotarsicontienenvapores

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. Nouseelequipofueradesurangodeoperación.Por

ejemplo, el calor causado por cable sobrecarga en

los cables de soldar pueden ocasionar un fuego.

6. Despuésdetermirarlaoperacióndelequipo,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

conlasparteseléctricas energizadas

y tierra puede causar daño severo o

muerte. NO use soldadura de corri-

ente alterna (AC) en áreas húmedas,

de movimiento conﬁnado en lugares estrechos o

si hay posibilidad de caer al suelo.

SECTION 1 SEGURIDAD

1. Asegúrese de que el chasis de la fuente de poder

esté conectado a tierra através del sistema de

electricidad primario.

2. Conecte la pieza de trabajo a un buen sistema de

tierra física.

3. Conecte el cable de retorno a la pieza de trabajo.

Cables y conductores expuestos o con malas

conexiones pueden exponer al operador u otras

personas a un choque eléctrico fatal.

4. Use el equipo solamente si está en buenas condi-

ciones. Reemplaze cables rotos, dañados o con

conductores expuestos.

5. Mantengatodoseco,incluyendosuropa,eláreade

trabajo, los cables, antorchas, pinza del electrodo,

y la fuente de poder.

6. Asegúresequetodas laspartes desu cuerpo están

insuladas de ambos, la pieza de trabajo y tierra.

7. Noseparedirectamentesobremetalotierramien-

trastrabaja enlugares estrechoso áreashúmedas;

trabaje sobre un pedazo de madera seco o una

plataforma insulada y use zapatos con suela de

goma.

8. Useguantessecosysinagujerosantesdeenergizar

el equipo.

9. Apage el equipo antes de quitarse sus guantes.

10. Use como referencia la publicación ANSI/ASC

StandardZ49.1(listado enla próximapágina) para

recomendacionesespecíﬁcasdecomoconectarel

equipo a tierra. No confunda el cable de soldar a

la pieza de trabajo con el cable a tierra.

CAMPOS ELECTRICOS Y MAGNETI-

COS - Son peligrosos. La corriente

eléctrica ﬂuye através de cualquier

conductor causando a nivel local

Campos Eléctricos y Magnéticos

(EMF). Lascorrienteseneláreadecorteysoldadura,

crean EMF alrrededor de los cables de soldar y las

maquinas. Por lo tanto:

1.Soldadoresu Operadoresqueuse marca-pasospara

el corazón deberán consultar a su médico antes de

soldar. El Campo Electromagnético (EMF) puede

interferir con algunos marca-pasos.

2.Exponerseacamposelectromagnéticos(EMF)puede

causar otros efectos de salud aún desconocidos.

3.Los soldadores deberán usar los siguientes proced-

imientos para minimizar exponerse al EMF:

A. Mantenga el electrodo y el cable a la pieza de

trabajo juntos, hasta llegar a la pieza que usted

quiere soldar. Asegúrelos uno junto al otro con

cinta adhesiva cuando sea posible.

B. Nunca envuelva los cables de 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. Mantengalafuentedepoderyloscablesdesoldar

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 pormedionaturalomecánico.Nosolde,

corte, o ranure materiales con hierro galvanizado,

acero inoxidable, cobre, zinc, plomo, berílio, o cad-

mio a menos que provea ventilación mecánica

positiva . No respire los gases producidos por

estos materiales.

2. No opere cerca de lugares donde se aplique sub-

stancias químicas en aerosol. El calor de los rayos

del arco pueden reaccionar con los vapores de

hidrocarburo clorinado paraformarun fosfógeno,

o gas tóxico, y otros irritant es.

3. Si momentáneamente desarrolla inrritación de

ojos, nariz o garganta mientras est á operando, es

indicación de que la ventilación no es apropiada.

Pare de trabajar y tome las medidas necesarias

para mejorar la ventilación en el área de trabajo.

No continúe operando si el malestar físico per-

siste.

4. Hagareferenciaalapublicación ANSI/ASC Standard

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

daciones especíﬁcas en la ventilación.

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