ESAB PowerCut 400 User manual

GB
Valid for serial no. 145-xxx-xxxx0463 277 001 GB 20121125
PowerCut™ 400
PT-39
Instruction manual

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TOCe
Rights reserved to alter specifications without notice.
APPLICATIONS 24.......................................................
1 SAFETY 6...........................................................
2 INTRODUCTION 8...................................................
2.1 Equipment 8................................................................
3 TECHNICAL DATA 8.................................................
4 INSTALLATION 9....................................................
4.1 Delivery check and location 10.................................................
4.2 Primary power supply 11......................................................
4.3 Input air connection 12........................................................
4.4 Connection for return cable 12.................................................
4.5 Connection of torch 13........................................................
5 OPERATION 14.......................................................
5.1 Connections 14..............................................................
5.2 Control devices 15...........................................................
5.2.1 Symbol key 16..........................................................
5.3 Installing consumables for the torch 17..........................................
5.4 Cutting 18...................................................................
6 MAINTENANCE 19....................................................
6.1 Inspection and cleaning 20....................................................
7 TROUBLESHOOTING 20..............................................
7.1 Troubleshooting guide 21......................................................
8 ORDERING SPARE PARTS 23.........................................
DIAGRAM 24............................................................
WEAR PARTS 27........................................................
ORDER NUMBER 28.....................................................

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1 SAFETY
Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on or
near the equipment observes all the relevant safety precautions. Safety precautions must meet the
requirements that apply to this type of equipment. The following recommendations should be
observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well-acquainted with the operation of the
equipment. Incorrect operation of the equipment may lead to hazardous situations which can result
in injury to the operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with:
Sits operation
Slocation of emergency stops
Sits function
Srelevant safety precautions
Swelding and cutting
2. The operator must ensure that:
Sno unauthorised person is stationed within the working area of the equipment when it is
started up.
Sno-one is unprotected when the arc is struck
3. The workplace must:
Sbe suitable for the purpose
Sbe free from drafts
4. Personal safety equipment
SAlways wear recommended personal safety equipment, such as safety glasses, flame-proof
clothing, safety gloves.
SDo not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions
SMake sure the return cable is connected securely.
SWork on high voltage equipment may only be carried out by a qualified electrician.
SAppropriate fire extinquishing equipment must be clearly marked and close at hand.
SLubrication and maintenance must not be carried out on the equipment during operation.
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WARNING
Read and understand the instruction manual before installing or operating.
Arc welding and cutting can be injurious to yourself and others. Take precautions when welding and
cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard
data.
ELECTRIC SHOCK - Can kill
SInstall and earth the unit in accordance with applicable standards.
SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
SInsulate yourself from earth and the workpiece.
SEnsure your working stance is safe.
FUMES AND GASES - Can be dangerous to health
SKeep your head out of the fumes.
SUse ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone
and the general area.
ARC RAYS - Can injure eyes and burn skin.
SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
SProtect bystanders with suitable screens or curtains.
FIRE HAZARD
SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE - Excessive noise can damage hearing
SProtect your ears. Use earmuffs or other hearing protection.
SWarn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
WARNING
Do not use the power source for thawing frozen pipes.
CAUTION
Class A equipment is not intended for use in residential locations where
the electrical power is provided by the public low-voltage supply system.
There may be potential difficulties in ensuring electromagnetic
compatibility of class A equipment in those locations, due to conducted
as well as radiated disturbances.
CAUTION
This product is solely intended for plasma cutting.
CAUTION
Read and understand the instruction manual before
installing or operating.
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Dispose of electronic equipment at the recycling facility!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation in accordance with national law, electrical and/or
electronic equipment that has reached the end of its life must be disposed of at a
recycling facility.
As the person responsible for the equipment, it is your responsibility to obtain
information on approved collection stations.
For further information contact the nearest ESAB dealer.
ESAB can provide you with all necessary cutting protection and accessories.
2 INTRODUCTION
The PowerCut 400 is a complete system for manual plasma cutting. It delivers
cutting power for severing materials up to 13 mm thickness.
2.1 Equipment
The power source is supplied with:
Spower cable, 3 m
Sinstruction manual
Sreturn cable with clamp
Splasma cutting torch PT-39, 4.6 m, supplied as indicated on page 28
Swear part kit for PT-39.
3 TECHNICAL DATA
PowerCut 400
Mains voltage range 90 - 280 V , 1 ~, 50/60 Hz
Setting range, rated value 110 V: 15 – 25 A
230 V: 15 –30 A
Permitted load
25 % duty cycle 110 V
60 % duty cycle 110 V
20 % duty cycle 230V
60 % duty cycle 230 V
25 A
19 A
30 A
18 A
Power factor at maximum current 0.99
Efficiency at maximum current 75 %
Open-circuit voltage U0250 V
Operating temperature -10 to 40 °C
Transportation temperature -20 to 55 °C
Sound pressure at no load < 43 db (A)
Nominal flow rate 189 l/min at 4.8 bar
Dimensions, l x w x h 465 x 160 x 340 mm
Weight including torch and return cable 14.5 kg
Insulation class transformer H
Enclosure class IP 23
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Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or cut at
a certain load without overloading. The duty cycle is valid for 40°C.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Equipment marked IP23 is designed for indoor and outdoor use.
4 INSTALLATION
The installation must be carried out by a professional.
Correct installation is very important for trouble-free operation and good cutting
results. Carefully read and follow each step in this chapter.
WARNING
ELECTRIC SHOCKS CAN KILL Take precautionary measures against electric
shocks. Ensure that all power supplies are disconnected –switch off the switch at
the wall socket and pull out the equipment's power cable from the socket before
making any electrical connections in the power source.
WARNING
It is very important that the chassis is connected to the approved electric protective
earth, to prevent electric shocks and electrical accidents. Ensure that protective
earth is not connected to any phase conductors by mistake.
WARNING
Poor connections or failure to connect the return cable to the workpiece can result
in fatal electric shock.
WARNING
Air filter devices may not be used –installation or mounting of any form of air filter
device obstructs the cold air flow and causes a risk of overheating. The warranty is
invalidated if any type of air filter is used.
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WARNING
Do NOT start the equipment with the cover removed.
Do NOT connect the power source with the main switch in ON position or when you
are holding it or carrying it.
Do NOT touch any of the torch's parts when the power supply is on.
CAUTION
This product is intended for industrial use. In a domestic environment this product may
cause radio interference. It is the user's responsibility to take adequate precautions.
CAUTION
Place the power source at least 3 metres from the cutting area as sparks and slag spray
can damage the power source
4.1 Delivery check and location
1. Remove the packaging. Inspect the equipment for damage that was not
immediately apparent upon reception of the delivery. Immediately report any
damage to the delivery company.
2. Check for any loose parts in the packaging. Check that the air ducts in the
cover's rear panel are not blocked by packaging material that can prevent the air
flow through the power source.
The power source has a carrying handle and can be lifted easily.
3. Position the power source so that its cooling air inlets and outlets are not
obstructed. Minimum permitted distance to wall or other obstruction is
1 m.
4. An air source that gives clean and dry air, at least 189 l/m at 4.8 bar, is
required for cutting. The cutting air pressure must not exceed 6 bar, which is the
maximum inlet pressure for the filter regulator that is included in the delivery.
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4.2 Primary power supply
Make sure that the power source is connected to the correct supply voltage and that
it is protected by the correct fuse rating. A protective earth connection must be made
in accordance with regulations.
Rating plate with supply
connection data
WARNING
Make sure the power source is switched off before removing the fuse.
Recommended fuse sizes and minimum cable area
Powercut 400
Mains voltage 110 V 1~ 230 V 1~
Mains cable area 3G2.5 3G2.5
Phase current I1eff 16 A 9 A
Fuse, anti-surge 32 A 16 A
NOTE! The mains cable areas and fuse sizes as shown above are in accordance with Swedish
regulations. Use the power source in accordance with the relevant national regulations.
Supply from power generators
The power source can be supplied from different types of generators. However,
some generators may not provide sufficient power for cutting. Generators with AVR,
equivalent or better type of regulation with a min rated power of 6 kW are
recommended to supply the power source within it's full capacity.
Start with generator:
1) Start the generator
2) Turn on the power source by mains switch ON
Stop with generator
3) Turn off the power source by mains switch OFF
4) Stop the generator
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4.3 Input air connection
Connect your air supply to the inlet connection of the filter. Any cylinder of
compressed air or air from a compressor may be used. The air must be free from
polluting particles. A pressure regulator is provided to ensure the correct air flow rate
on the torch. It is set from factory at 4.8 bar.
4.4 Connection for return cable
Clamp the return cable to the workpiece. Be sure the workpiece is connected to an
approved earth ground with a properly sized ground cable.
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4.5 Connection of torch
The installation must be carried out by a professional.
ATorch power cable, violet
BTorch trigger cables, black
CAir hose to quick-connect fitting
DTorch pilot cable, red
The power source is equipped with a quick-disconnect solution for connecting and
disconnecting the torch.
1. Turn off the main switch, disconnect the power cable and the air supply.
2. Open the little left side panel by unscrewing 2 screws.
3. Insert the torch end with cable receptacle and air hose through the hole in the
front of the power source.
4. Connect the violet torch power cable by tightening 1 screw.
5. Connect the 2 black torch trigger cables.
6. Connect the red torch pilot cable.
7. Connect the air hose to the fitting.
8. Close the little left side panel.
9. Connect the power cable and turn on the main switch.
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5 OPERATION
General safety regulations for handling the equipment can be found on
page 6. Read through before you start using the equipment!
5.1 Connections
1Power switch ON/OFF 5Connection for return cable
2Connection for air 6Connection for torch
3Power cable 7Control devices, see chapter 5.2
4Side panel
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5.2 Control devices
1Knob for setting of current 5Over temperature indicator, yellow
2Primary input voltage/Circuit breaker key 6Parts In Place (PIP), yellow
3Air pressure indicator, yellow 7Power ON indicator, green
4Fault indicator, yellow
1 Output current control
Output current control can vary the cutting current from 15A to 30A. Adjusting the
current will affect the power consumed by the machine, the thickness of material that
can be cut, and the quality of a cut at a given speed. Special care should be taken to
keep the cutting current below 17A when powering the machine from 110V mains
supply with a 16A circuit breaker.
2 Primary Input Voltage/Circuit Breaker Key
The symbol explains the yellow field on the output current control. Max output
current for 110 V and 32A circuit breaker is 25A.
3 Air Pressure Indicator
The yellow LED indicates that the air pressure is too low.
4 Fault Indicator
The flashing yellow LED indicates that the safety switch for the cover is activated
and the power is automatically turned off.
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5 Over Temperature Indicator
When the yellow LED is lit, the working temperature has exceeded the normal
values. It is turned off when the temperature is normal.
6 Parts in Place (PIP)
When the yellow LED is lit, it indicates that there is a parts-in-place error. This
means that no nozzle was detected, or that the electrode is not retracting properly.
Turn off the power. Check that the components are properly assembled, that they
are free from excessive damage, and that the electrode can slide back and forth with
comfortable pressure from one finger. Once the source of the error has been
corrected, turn on the power again.
7 Power ON Indicator
When the green LED is lit, it indicates that the power is on.
5.2.1 Symbol key
Power Air
Temperature Fault
PIP Parts in Place Power supply
Read the manual
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5.3 Installing consumables for the torch
Proper use of the torch within rated operating conditions (especially arc current and
gas flow rate) and correct installation of consumable parts can prevent unnecessary
torch damage.
1. Tighten electrode and retaining/shield cup fully at each consumable change or
inspection.
2. Check consumable tightness at the beginning of each work period, even if
everything was working normally at the end of the previous period.
ATorch body assembly
BBaffle
CElectrode
DNozzle
ERetaining/Shield cup
FPiston
GElectrode/Torch body seat
See wear parts on page 27.
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5.4 Cutting
1. Set the switch (wall socket or similar) to on.
2. Check that the compressor is connected to the power source.
3. Set the power switch to I (On).
4. After starting the cut, the torch should be maintained at a 5 - 15° forward angle.
This angle is especially useful in helping to create a “drop”cut. The torch can be
operated with the nozzle dragging on the plate or with up to 6.35 mm standoff.
The ideal standoff is 3.2 mm. Standoff guides are available to simplify
maintaining the gap, see wear parts on page 27.
5. Depress the torch switch. Air should flow from the torch nozzle.
6. Two seconds after depressing the torch switch, the pilot arc should start. The
main arc should immediately follow, allowing the cut to begin.
7. To start a cut, tilt the torch to prevent molten material from splashing back and
damaging the torch. When the arc breaks through the workpiece, bring the torch
to an upright position and proceed to cut.
8. When ending a cut, the torch switch should be released and the torch lifted off
the workpiece immediately upon completion of the cut. This is to prevent the pilot
arc from re-igniting after the cutting arc has extinguished and causing damage to
the nozzle (double arcing).
9. For rapid re-starts on machines that support grate cutting mode, do not release
the torch switch. The torch will automatically return to pilot arc mode after each
cut and transfer back to main arc, when the torch is positioned over the next
working surface. When working without grate cutting mode, simply release and
re-press the trigger during the postflow to restart the arc without a delay for
preflow.
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Speed
Typically, manual plasma cutting speeds are limited by the sever speed. This
indicates the maximum speed you will be able to move the torch along the cut while
still penetrating the work piece. However, for applications that require a cleaner cut,
it may be important to cut closer to the quality speed.
If the cut is made too quickly, significant quantities of molten metal can form dross on
the underside of the cut. While most slag formed from carbon steel will easily chip
off, it can be a nuisance. Quality speeds are selected to keep dross formation to a
minimum.
On page 26 data shows the maximum cutting speeds possible for the power source
at 15 - 30A. Quality cut speed recommendations are also listed for steel.
Note that when the torch is used at its limits, the quality of the cut suffers.
6 MAINTENANCE
Regular maintenance is important to get the optimal performance and lifetime.
Only those persons who have appropriate electrical knowledge (authorized
personnel) may remove the safety plates.
WARNING
Ensure that the mains voltage supply to the power source has been disconnected
externally. Switch off the switch at the wall socket before inspecting or working in
the power source.
WARNING
Water or oil can collect in the compressed air lines. Always direct the first stream of
air away from the equipment, to prevent damage.
CAUTION
All guarantee undertakings from the supplier cease to apply if the customer attempts any
work to rectify any faults in the product during the guarantee period.
If the equipment does not work correctly, stop work immediately and determine the
cause of the problem. Maintenance work may only be carried out by persons with
the applicable knowledge. Electrical work may only be carried out by authorised
electricians. Never allow persons other than those with the applicable knowledge to
check, clean or repair the equipment. Use only ESAB original spare and wear parts.
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6.1 Inspection and cleaning
The following points on the power source should be checked and/or cleaned
regularly.
1. Check the return cable connection to the work piece.
2. Check that the protective earth from the work piece is securely connected to the
power source chassis earth.
3. Check the torch heat shield. Replace it if it is damaged.
4. Check the electrode and the nozzle for wear daily. Remove any splash, replace
the electrode and nozzle as necessary. If the electrode has pitting which is more
than 3.2 mm deep at its centre, it must be replaced. If the electrode is used
beyond this recommended wear limit, damage to the torch and power source
may occur. Nozzle life is also greatly reduced when using the electrode below
the recommended limit.
5. Check that the cables or hoses are not damaged or bent.
6. Check that all plugs and connections and ground terminals are firmly connected.
7. Ensure that all incoming power supplies are disconnected. Use goggles and face
mask and blow clean the power source internally using dry compressed air at
low pressure .
7 TROUBLESHOOTING
WARNING
ELECTRIC SHOCKS CAN KILL! Ensure that the mains voltage supply to the power
source has been disconnected externally. Switch off the switch at the mains
socket before inspecting or working in the power source.
WARNING
Plasma cutting equipment uses extremely high voltages that can cause severe
injury or even death. Observe extreme caution when working with the covers
removed.
Try these recommended checks and inspections before sending for an authorized
service technician.
Type of fault Corrective action
Insufficient penetration SCurrent too low
SCutting speed too fast
SDamaged cutting nozzle
SImproper air pressure
SLow air flow rate
Main arc extinguishes. SCutting speed too slow
SWorn electrode
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