ESAB Powercut 900 User manual

GB
Valid for serial no. 040-xxx-xxxx0449 549 001 GB 101214
Powercut 900
Instruction manual

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TOCe
Rights reserved to alter specifications without notice.
1 SAFETY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 INTRODUCTION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Equipment 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 TECHNICAL DATA 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 INSTALLATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Delivery check and location 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Mains power supply 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Input air connection 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Connection for return cable 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Connection of torch 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 OPERATION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Connections 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Control devices 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1 Symbol key 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Cutting 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 MAINTENANCE 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Inspection and cleaning 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 FAULT TRACING 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Fault codes 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 ORDERING SPARE PARTS 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGRAM 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDERING NUMBER 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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 ob
served 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 equip
ment. Incorrect operation of the equipment may lead to hazardous situations which can result in in
jury 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 unauthorized 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. Note! Do not use safety gloves when replacing wire.
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 precausions 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 plasma power source Powercut 900 and the plasma cutting torch PT-38 are a
complete and safe plasma cutting system for manual cutting and gouging. It delivers
cutting power for severing materials up to 32 mm thickness.
ESAB's accessories for the product can be found on page 25.
2.1 Equipment
The power source is supplied with:
Smains cable, 3 m
Sinstruction manual
Sreturn cable incl clamp
Splasma cutting torch PT 38, 7.5 m, supplied according to the denomination on
page 24.
3 TECHNICAL DATA
Powercut 900
Mains voltage 3 x 230 V, 400 V $10 % 50/60 Hz
Mains supply Ssc min. 4.0 MVA
Zmax. 0.04 
Setting range 20 – 60 A
Permitted load
60 % duty cycle
100 % duty cycle
60 A / 120 V
50 A / 120 V
Efficiency at maximum current 87 %
Open-circuit voltage U0290 V
Operating temperature –10 to 40 °C
Transportation temperature –20 to 55 °C
Sound pressure at no load < 70 db (A)
Dimensions, l x w x h 630x 322 x 379 mm
Weight 35 kg
Insulation class transformer H
Enclosure class IP 23
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Mains supply, Ssc min
Minimum short circuit power on the network in accordance with IEC 61000-3-12
Mains supply, Zmax
Maximum permissible line impedance of the network in accordance with IEC 61000-3-11.
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 executed 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 prevents 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 equipment under tension 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 with packaging material that can prevent the
air flow through the power source.
The power source has a lifting eyelet and can be lifted easily. Check that the
lifting equipment that is to be used can withstand the weight of the power source.
The weight is stated in the table TECHNICAL DATA, see chapter 3.
WARNING
The product must be lifted as follows:
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 30 cm.
4. An air source that gives clean and dry air, at least 236 l/m at 6.2 bar (90 psig), is
required for cutting. The cutting air pressure must not exceed 10.3 bar
(150 psig), which is the maximum inlet pressure for the filter regulator that is
included in the delivery.
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4.2 Mains 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. The outlet shall have a protectiv earth
connection.
Rating plate with supply connection data
Recommended fuse sizes and minimum cable area
Powercut 900 50 Hz
Mains voltage 230 V/ 400 V
Mains cable area mm 24 G 6
Phase current I1eff 23 A/ 14 A
Fuse, anti-surge 32 A/ 20 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.
WARNING
Make sure the power source is switched off before removing the fuse.
4.3 Input air connection
Connect your air supply to the inlet connection of the filter.
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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
Open the lid on the front panel.
Connect the torch cable receptacle to the panel
receptacle. Check the orientation of the sockets to
ensure a correct fit.
Connect the air hose to the quick-connect fitting.
Place the strain relief in the square cutout in the
front.
Connect the mains cable into the plug on the front
and turn it clockwise until it is secured. Put the lid
back.
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5 OPERATION
General safety regulations for the handling of the equipment can be found on
page 4. Read through before you start using the equipment!
5.1 Connections
1Mains cable 4Torch
2Fuse (2A) 5Return cable with clamp
3Pre-filtered dry air supply
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5.2 Control devices
1Power switch ON/OFF 4Torch trigger/ Gas test trigger
2Output current control 5Pressure regulator
3Display
Power switch - (1)
Turn the knob clockwise to “ON” position for normal operation. Turn the knob
counterclockwise to switch “OFF”.
Output current control - (2)
Adjustable from 20 to 60 A. For settings see cut data charts in the torch manual.
Display - (3)
Shows current settings during normal operation. When the unit is initially switched
on, the software version will be briefly displayed.
When the unit is in the “GAS TEST” mode, the display will indicate the air pressure
setting in bar. The setting can be switched to psi by service technicians.
Should a fault condition exist in the normal operation, the display will show a code
number, see chapter 7.1.
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Torch trigger/Gas test switch - (4)
Operating modes:
Normal trigger (CENTER position) - Setting will be used for most cutting and gouging
operations. The torch switch must be held in by the operator during the entire cutting
operation and then released at the end of cut. Recommended for normal cutting,
expanded metal/grate cutting and gouging.
Trigger lock (DOWN position) - allows the torch switch to be released after triggering
and the cutting arc has been initiated. To extinguish the arc at the end of the cut,
press and release the torch switch again or pull the torch away from the work piece.
Not recommended for expanded metal/grate cutting.
Test mode:
Gas test switch (UP position) - The display will indicate flowing air pressure. The air
regulator should be adjusted to recommended pressure before cutting operations.
Allow air to flow for a few minutes. This should remove any condensation that may
have accumulated during a shutdown period. Be sure to place the switch in normal
trigger or trigger lock position before starting any cutting operations.
Pressure regulator - (5)
Regulates torch air pressure. Rotate clockwise to increase and counterclockwise to
decrease.
5.2.1 Symbol key
Power (1) Gas test (4)
Normal trigger (4) Trigger lock (4)
Air pressure (5) Return cable
NOTE! The unit is supplied from the factory with the regulator set to give 5.5 bar (80 psig) to the
torch from a 6.5 bar (95 psig) supply. If the supply pressure to the unit exceeds 6.5 bar (95 psig)up to
the maximum recommended 10.3 bar (150 psig), turn the pressure regulator counterclockwise to
reduce the pressure to the torch to 5.5 bar (80 psig). Follow the gas testing instructions above.
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5.3 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 mains voltage switch to I (On).
4. Flip the toggle switch upwards to gas test mode (GAS TEST). Set the pressure
regulator to 5.5 bar (80 psi).
5. Set the toggle switch to normal mode (CENTER) or trigger lock mode (DOWN).
6. 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. When not using
the stand-off guide, the nozzle should be held approximately 3.2 mm - 6.4 mm
from the work.
7. Depress the torch switch. Air should flow from the torch nozzle.
8. Two seconds after depressing the torch switch, the pilot arc should start. The
main arc should immediately follow, allowing the cut to begin. (If using the
TRIGGER LOCK feature, the torch switch may be released after establishing the
cutting arc.)
9. To start a cut, tilt the torch to prevent molten material from coming back against
and damaging the torch. When the arc breaks through the workpiece, bring the
torch to an upright position and proceed to cut.
10. When ending a cut, the torch switch should be released (press and release if
using TRIGGER LOCK feature) and the torch lifted off the workpiece
immediately upon completion of the cut. This is to prevent the pilot arc from
re-igniting after cutting arc extinguishes and causing damange to the nozzle
(double arcing).
11. For rapid re-starts, such as grate or heavy mesh cutting, do not release the torch
switch. In the postflow mode, the arc can be re-started immediately by
depressing the torch switch. This avoids the 2-second preflow portion of the
cutting cycle.
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6 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
Only those persons who have appropriate electrical knowledge (authorized
personnel) may remove the safety plates.
WARNING
Ensure that the mains voltage supply to the machine 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 himself
attempts any work in the product during the guarantee period in order to rectify any faults.
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. Only use recommended spare parts.
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 a pit which is more
than 1.5 mm deep at its center, 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 .
8. Regularly drain any water from the filter below the air regulators.
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7 FAULT TRACING
WARNING
ELECTRIC SHOCKS CAN KILL Ensure that the mains voltage supply to the
machine 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
No arc. SCheck that the mains power supply switch is
turned on.
SCheck that the current supply and return
cables are correctly connected.
SCheck that the correct current value is set.
The current is interrupted during cutting. SCheck whether the thermal overload trips
have operated.
SCheck the mains power supply fuses.
The thermal cut-out trips frequently. SMake sure that you are not exceeding the
rated data for the power source (i.e. that the
unit is not being overloaded).
Poor cutting performance. SCheck that the current supply and return
cables are correctly connected.
SCheck that the correct current value is set.
SCheck that the correct electrode is being
used.
SCheck the mains power supply fuses.
If you cannot locate the problem switch off the incoming power supply, open the unit
and check all components and conductors visually. Look for swollen or leaking
condensers and other signs of damage or discolouration.
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7.1 Fault codes
Should a fault condition exist in normal operation, the display will show a code
number. All fault signals will remain on for a minimum of 10 seconds. If the fault is
cleared, all will reset automatically except for over-current. To clear over-current, the
power must be shut off for 5 seconds and then turned back on.
Code Problem Cause Solution
1Mains voltage, idle +/–15 % Incoming mains voltage may
have fallen below or risen
above the set nominal value.
Check the mains voltage.
2Mains voltage, cutting +/–20
%
Incoming mains voltage may
have fallen below or risen
above the set nominal value
during ongoing cutting.
Check the mains voltage.
3Operating pre-tensioning, +/–
15 V pre-tensioning
distribution
The operating circuit
transformer does not supply
the correct voltage to the
operating circuits.
Check the transformer and
control board.
4Thermal switches Thermal switches off –
equipment overheated.
Let the equipment cool.
Check that the ventilation is
adequate.
5 Pressure The air pressure is outside
the permitted interval., min
5.1 bar and max 6.5 bar.
Check the supply
compressed air and pressure
setting.
6The arc does not strike. Arc transfer could not occur. Check the ground lead.
7Pilot arc time limit (approx 5
seconds) exceeded.
The cutting process did not
begin with the 5 second limit.
Start within 5 seconds:
8Torch fault The electrode touches the
nozzle (cannot separate).
Check/replace consumables.
10 Reconnection problem. The problem primarily occurs
if the hall sensor is not
connected.
Check the cable connection
between the current sensor
board and the control board.
Check the torch for a short
circuit between the nozzle
and the work piece.
Remove any scrap from the
front section of the torch.
11 Over current on the primary
side.
Converter fault. Send the unit to the
authorised service workshop
for repair.
12 Phase drop, switch off, on
the primary side (mains
supply)
Exceeded single phase duty
cycle rating
Check the mains power
supply fuses.
13 Open circuit voltage fault Neither voltage nor current
could be detected at
automatic Parts In Place
(PIP) check of consumables.
Send the unit to the
authorised service workshop
for repair.
14 Overtemperature in the
apparatus sheath.
The temperature is higher
than the permitted
operational limit.
Check the ventilation around
the unit.
Check the cooling air gaps
and ensure that any
obstacles are removed from
there.
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Code SolutionCauseProblem
15 Bus charging fault Under voltage on the primary
bus.
Check the bus charger.
19 Torch trigger early
engagement
Torch trigger depressed at
power up.
Check the trigger.
20 No return at PIP (Parts In
Place) check of consum
ables.
The piston was not
withdrawn when air was
released.
Check/clean consumables.
Check the compressed air
supply.
21 No unbroken current path at
PIP (Parts In Place) check of
consumables.
The piston did not fall back
when the air supply was
removed.
Check/clean consumables.
8 ORDERING SPARE PARTS
Repair and electrical work should be performed by an authorized ESAB serviceman.
Use only ESAB original spare and wear parts.
Powercut 900 is designed and tested in accordance with the international and Europe
an standards 60974-1 and 60974-10. It is the obligation of the service unit which has
carried out the service or repair work to make sure that the product still conforms to
the said standard.
Always provide the serial number of the unit on which the parts will be used. The
serialnumber is stamped on the units rating plate.
Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication.
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Diagram
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