Prest-O-Lite 380, Instruction Manual

Page 1: ...Prest O Lite 380 Plasma Cutter P N 0558006057 230 V 1 Phase 50 60 Hz Form No 0558006081 03 2007 Prest O Lite 380 Plasma Cutter Instruction Manual Installation Operation and Service ...

Page 2: ...ll 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 ...

Page 3: ...Work Lead Connection 17 2 7 PT 31XL Torch Consumables Installation 20 SECTION 3 OPERATION 21 3 1 Operation 22 3 2 Prest O Lite 380 Controls 22 3 3 Assembling PT 31XL Consumable Parts 23 3 4 Cutting with the PT 31XL 23 3 5 Operating Techniques 25 3 6 Common Cutting Problems 25 SECTION 4 MAINTENANCE 27 4 1 General 27 4 2 Inspection and Cleaning 27 4 3 Flow Switch 27 4 4 PT 31XL Torch Maintenance 28 ...

Page 4: ... TABLE OF CONTENTS ...

Page 5: ...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 over loaded welding cable can overheat and create a fire h...

Page 6: ...strike an arc on a cylinder 5 Foradditionalinformation refertoCGAStandardP 1 Precau tions for Safe Handling of Compressed Gases in Cylinders which is available from Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 EQUIPMENT MAINTENANCE Faulty or improperly main tained equipment can cause injury or death Therefore 1 Always have qualified personnel perform the installation ...

Page 7: ...manoequipoextintordefuego parausoinstantáneo 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 causadoporcablesobrecargaenloscablesdesoldarpuedenocasionar un fuego 6 Después de termirar la operación del equipo inspeccione el área de trabajo...

Page 8: ...el capote de protección sobre la válvula si el regulador no está conectado Asegure y mueva los cilindros utilizando uncarrootransporteadecuado Eviteelmanejobrusco de los Las siguientes publicaciones disponibles através de la American Welding Society 550 N W LeJuene Road Miami FL 33126 son recomendadas para usted 1 ANSI ASC Z49 1 Safety in Welding and Cutting 2 AWS C5 1 Recommended Practices for Pl...

Page 9: ...rver les précautions énoncées ci dessous avant de monter l équipement ou de commercer à l utiliser Tout défaut d observation de ces précau tions risque d entraîner des blessures graves ou mortelles 1 PROTECTIONINDIVIDUELLE Lesbrûluresdelapeauetdes yeux dues au rayonnement de l arc électrique ou du métal incandescent lors du soudage au plasma ou à l électrode ou lors du gougeage à l arc peuvent s a...

Page 10: ...articulières en matière de ventilation indiquées à l alinéa 6 de la norme Z49 1 de l AWS 5 ENTRETIEN DE L éQUIPEMENT Un équipement entretenu de façon défectueuse ou inadéquate risque non seulement de réaliser un travail de mauvaise qualité mais chose plus grave encore d entraîner des dommages corporels graves voire mortels en déclenchant des incendies ou des chocs électriques Observez par conséque...

Page 11: ...roubleshooting the Cutter 1 3 SYSTEM AVAILABLE Prest O Lite 380 Plasma Cutter P N 0558006057 includes Console with Regulator and Work Cable PT 31XL Torch 15 ft 4 6m 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 15 ft...

Page 12: ...fle 0558006189 1 Heat Shield 0558006185 1 Lubricant 1 4 oz 17672 1 NOTE PT 31XL Torch Assembly P N 0558004482 is supplied with the nozzle electrode swirl baffle and heat shield assembled as part of the Prest O Lite 380 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 6...

Page 13: ...rch Table 1 3 PT 31XL Torch Specifications PT 31XL Torch Current Capacity 50A DCSP Shipping Wgt 1 5 lbs 0 68 kg Length of Service Lines 15 ft 4 6 m Figure 1 1 PT 31XL Dimensions PT 31XL Torch Assembly P N 0558004482 is supplied with the nozzle electrode swirl baffle and heat shield as sembled ...

Page 14: ...14 SECTION 1 DESCRIPTION ...

Page 15: ...d with the package 2 3 Location Adequateventilationisnecessarytoprovidepropercooling of the Prest O Lite 380 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 clear ance between the Prest O Lite 380 power source and wall or any other obstruction to allow freedom of air movement through the power source Installi...

Page 16: ...SCONNECT SWITCH See Table 2 1 PLUG customer supplied NEMA 6 30 rating minimum RECEPTACLE NEMA 6 30 rating minimum Receptacle to match plug Prefiltered AIR SUPPLY Customer Supplied 90 to 150 psig max See Table 2 1 and WARNING in regards to chassis ground in Section 2 5 2 5 Primary Electrical Input Connections ...

Page 17: ... 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 fitting 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 Removethemachin...

Page 18: ...TION 2 INSTALLATION WORK CABLE SAFETY GROUND PT 31XL WORK between work and power source Allow at least 10 ft 3 m Figure 2 3 Prest O Lite 380 Secondary Interconnection Diagram 2 6 SECONDARY OUTPUT CONNECTIONS ...

Page 19: ...D 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 ...

Page 20: ...nch but do NOT overtighten 2 7 PT 31XL Torch CONSUMABLES Installation Figure 2 6 Assembly of XT Consumable Parts NOTE Nozzles Marked By Amperage 0558006190 Plunger Seat 0558006191 Electrode 0558006192 0558006189 Baffle Nozzle Heat Shield 0558006185 30 40A 0558006187 1 To disassemble the front end hold the torch with the shield in an upright position This will prevent the nozzle electrode and swirl...

Page 21: ...tor to 65 psi 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 off and back on again to activate the 15 second preflow sequence for air pressure adjustment 2 Set output current from 15 to 30 amperes to suit cutting conditions prior to operation of th...

Page 22: ... the green pilot light will glow indicat ing control circuit is energized and the cooling fan will run B Output Current Control Adjustable from 15 to 30 amperes to suit cutting conditions Set output current tosuitcuttingconditionspriortooperationofmachine See Page 22 C AirPressureAdjustmentControl Whenmainpower switch is turned on and air is flowing to the machine theairregulatorcanbeadjustedtothe...

Page 23: ...on off switch is still on LowAirFlow LED Greenlight willturnonduring operation when the air flow is set correctly the LED will switch off below 15psi 1 bar On Off Switch LED Green light will light when power supply is switched on and power is applied LED will turn off when switch is in OFF position AirPressureGauge SidePanel Showsairpressure in bars and psi 3 3 ASSEMBLING PT 31XL COMSUMABLE PARTS ...

Page 24: ...0 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 atip to work standoff distanceofupto1 16 dueto various material s...

Page 25: ... connections 3 Electrode and or cutting nozzle in poor condi tion G Main Arc Does Not Strike 1 Loose connections 2 Missing torch parts 3 Air pressure too high or too low 4 Work lead not properly connected H Poor Consumable Life 1 Improper air pressure 2 Contaminated air supply NOTE The speeds given here are typical for best quality cuts Your actual speeds may vary depending on material composition...

Page 26: ...26 SECTION 3 OPERATION ...

Page 27: ...aged or kinked F Make sure all fittings and ground connections are tight G Withallinputpowerdisconnected andwearingproper eye and face protection blow out the inside of the Prest O Lite 380 using low pressure dry compressed air H Wateroroiloccasionallyaccumulatesinthebowlofthe air pressure regulator To drain bowl turn machine off with air supplied to the machine then push upward on the button loca...

Page 28: ... cuts through the protective sheath or if gas leaks are noted replace the damaged component By following Steps 1 2 and 3 in Subsection 4 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...

Page 29: ...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 1 2 3 Slide switch and band from handle Snip leads at splice to replace switch Unscrew handle and power cable from head 4 5 POWER CABLE AND SWITCH DISASSEMBLY SEQUENCE ...

Page 30: ...30 SECTION 4 MAINTENANCE WORK LEAD CONNECTION TORCH CONNECTION ...

Page 31: ...e line wall disconnect switch or circuit breaker beforeattemptinginspectionorworkinsideofthepower source Check the problem against the symptoms in the following troubleshooting guide The remedy may be quite simple If thecausecannotbequicklylocated shutofftheinputpower open up the unit and perform a simple visual inspection of all the components and wiring Check for secure termi nal connections loo...

Page 32: ...t Is air adjusted to 65 70 psig 4 5 4 8 bar Yes No Adjust Does air come on when main power turned on Yes No No electrode in torch No valve pin in torch Replace electrode Check continuity of torch switch Replace valve pin OK No Replace torch switch Repair replace power source ...

Page 33: ...f Does arc start when nozzle contacts work without depressing torch switch Yes No Check for short in torch switch or torch switch leads Does air flow even when Prest O Lite 380 power switch is OFF Yes No Replace Repair replace control solenoid valve PCB ...

Page 34: ...itch light not energized Is switch ON Yes No Turn on switch Is input power plug in receptacle Yes No Insert plug Is cooling fan turning No Check voltage at receptacle and input power line No Check main fuses Replace main power switch Yes Yes ...

Page 35: ...t overheated LED turns off when unit cools down Yes No Is cooling air flowing Duty cycle exceeded 35 30 A Yes No or 100 21 A output Repair power source Repair fan F No current output Is input voltage within 10 of units input rating Yes No See D sequence Repair replace Inverter ...

Page 36: ...ER CUTTING ARC CURRENT ENERGIZE 10 14 SEC ONDS Postflow OPEN SECTION 5 TROUBLESHOOTING NOTES 1 Whenthetorchswitchisdepressedduringpostflowperiod thepostflowandpreflowtimesarecanceled and the HF is energized immediately The postflow time starts from the moment the torch switch is released 5 3 SEQUENCE OF OPERATION 2 SECONDS ...

Page 37: ...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 ba...

Page 38: ...38 SECTION 6 REPLACEMENT PARTS 23 22 21 rear front front rear front rear rear front front rear rear front 3 5 4 6 10 8 7 9 17 13 11 18 12 15 16 19 20 24 25 380 PLASMA CUTTER 380 PLASMA CUTTER ...

Page 39: ...uage 0558002768 19 Work Cable w clamp 0700156013 18 Solenoid Valve Assy 0558002764 17 On Off Switch 0700156012 16 Bottom Plate 0700156014 15 Inverter PCB 0700156011 14 PT 31 Torch Assy 0558004482 13 Flow Switch Assy 951202 12 EMC Filter 0558002746 11 Fan Grid 0558002739 10 Fan 0558002738 9 Air Gauge Filter Assy 0558002767 8 Power Cable 0558003342 7 Air Nipple 1 8 0700156006 6 HF Generator 07001560...

Page 40: ... Torches PT 31XL Torch Assembly 15 lines P N 0558004482 Assembled w 30 40A high performance consumables used on Prest O Lite 380 FEMALE TORCH CONNECTION P N 0558004947 USED ON HANDY PLASMA 380 When ordering The PT 31XL Torch Assembly for use on the Handy Plasma 380 P N 0558004947 must ALSO be orDEred PLUNGER 0558006192 ELECTRODE 0558006190 SWIRL BAFFLE 0558006189 NOZZLE Tip HEAT SHIELD 0558006185 ...

Page 41: ...41 Notes ...

Page 42: ...Notes ...

Page 43: ...Revision History Original release 06 2006 03 2007 Revised Title Page layout text ...

Page 44: ...pair 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 66...