ESAB PowerCut 700 PT-39 User manual

GB
Valid for serial no. 145-xxx-xxxx0463 339 001 GB 20121125
PowerCut™ 700
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........................................................
4.5.1 Disconnecting the Torch 14...............................................
4.5.2 Connecting the Torch 14..................................................
5 OPERATION 15.......................................................
5.1 Connections 15..............................................................
5.2 Control devices 16...........................................................
5.2.1 Symbol key 17..........................................................
5.3 Installing consumables for the torch 18..........................................
5.4 Cutting 19...................................................................
6 MAINTENANCE 20....................................................
6.1 Inspection and cleaning 21....................................................
7 TROUBLESHOOTING 21..............................................
7.1 Troubleshooting guide 22......................................................
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 700 is a complete system for manual plasma cutting. It delivers
cutting power for severing materials up to 20 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, 7.5 m, supplied as indicated on page 28
Swear part kit for PT-39.
3 TECHNICAL DATA
PowerCut 700
Mains voltage 400 V $10 %, 3-ph, 50/60 Hz
Setting range 30 – 50 A
Permitted load
30 % duty cycle
60 % duty cycle
100% duty cycle
50 A
37 A
30 A
Power factor at max current 0.75
Efficiency at maximum current 85 %
Open-circuit voltage U0320 V
Operating temperature -10 to 40 °C
Transportation temperature -20 to 55 °C
Sound pressure at no load < 70 db (A)
Nominal flow rate 189 l/min at 4.8 bar
Dimensions, l x w x h 600 x 210 x 380 mm
Weight incl torch and return cable 25.5 kg
Insulation class transformer H
Enclosure class IP 23
Application class
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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.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
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 is at the bottom plate
WARNING
Make sure the power source is switched off before removing the fuse.
Recommended fuse sizes and minimum cable area
Powercut 700
Mains voltage 400 V 3-ph
Mains cable area 4G2.5
Phase current I1eff 6.5 A
Fuse, anti-surge 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 welding. Generators with
AVR, equivalent or better type of regulation with a min rated power of 10.8 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. Set the pressure with the knob on the top of the regulator.
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
To allow quick and easy separation of the torch from the power supply, the Power
Cut 700 is equipped with a unique quick disconnect solution.
Before connecting or disconnecting the torch, there are some safety rules to keep in
mind.
SIf the connector is loose or damaged, the system should not be operated until it
has been repaired by a qualified professional. Always make sure that the
connection is firm and properly locked in place.
SNever, under any circumstances, disconnect the torch while the equipment is on.
The system should be unplugged, or otherwise disconnected from power, prior
to servicing.
SUsers should never pull the power supply by its cables, or do anything that might
damage the cable or connector. The connector is designed to withstand wear
from regular use, but excessive abuse can render the connector unusable.
SLike the power supply itself, the connector should never be operated in or near
standing water. Additionally, if the connector’s silicon moisture seal is absent or
damaged, users should not operate the system.
SThe gas connection is lubricated to ensure a smooth connection, but the
electrical connector should never be lubricated. Users should take care to keep
the electrical connections clean and dry.
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4.5.1 Disconnecting the Torch
Always obey the safety rules above.
1. Disconnect the power at the wall or unplug the power supply.
2. Press the nylon tab on the torchside connector.
3. Pull the two halves apart while keeping the tab depressed.
4.5.2 Connecting the Torch
Always obey the safety rules above.
1. Disconnect the power at the wall or unplug the power supply.
2. Press the release button on the female gas connector to ensure that the locking
mechanism is not engaged.
3. Align the gas connectors and engage them.
4. Align the electrical connections and engage them.
5. Press the two halves together until a click sound indicates that the gas
connectors are locked together.
6. Tug lightly on the connector to ensure that it is properly locked in place.
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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
1Connection for air 4Connection for torch
2Connection for power cable 5Control devices, see chapter 5.2
3Connection for return cable with clamp 6Fuse.
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5.2 Control devices
1Power switch 0/1 5Over temperature indicator, yellow
22/4 stroke 6Parts in Place (PIP), yellow
3Air pressure indicator, yellow 7Power ON indicator, green
4Fault indicator, yellow 8Output current control
1 Power switch
Turn the knob clockwise to “1”position for normal operation. Turn the knob
anti-clockwise to “0” to switch off the power source.
2 2/4 stroke
When in 2-stroke cutting mode, the torch activates when the trigger is pressed, and
deactivates when the trigger is released. In 4-stroke mode, the torch activates on the
first trigger press, after which it can be released for increased comfort during long
cuts. The torch is then deactivated by pressing the trigger again.
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.
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.
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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.
8 Output current control
Adjustable from 30 to 50 A. For settings see cut data charts in the torch manual.
5.2.1 Symbol key
Power Air
Temperature Fault
PIP Parts in Place 2-stroke
4-stroke
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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. (If working in the
4-stroke mode, the torch switch may be released after establishing the cutting
arc.)
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 30 - 50A. 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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