ESAB Powercut-1300/1600 Manual & Mechanized Plasmarc Cutting Package Instruction manual

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Powercut-1300/1600

Manual & Mechanized Plasmarc Cutting Package

Instruction Manual (EN) Manuel d’instructions (FR)

This manual provides complete instructions for MANUAL CONSOLES starting with Serial Number PxxJ824xxx, June 2008

This manual provides complete instructions for MECHANIZED CONSOLES starting with Serial Number PxxJ824xxx, June 2008

0558007595 11/2009

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

CAUTION

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 before installing or operating this equipment.

USER RESPONSIBILITY

This equipment will 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 immediately. 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 service facility designated by the manufacturer.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

TABLE OF CONTENTS

SECTION PAGE

English ................................................................................................................................................................................5

French ..............................................................................................................................................................................51

Powercut-1300/1600

Manual & Mechanized Plasmarc Cutting Package

Instruction Manual (EN)

This manual provides complete instructions for MANUAL CONSOLES starting with Serial Number PxxJ824xxx, June 2008

This manual provides complete instructions for MECHANIZED CONSOLES starting with Serial Number PxxJ824xxx, June 2008

0558007595

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

CAUTION

USER RESPONSIBILITY

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

TABLE OF CONTENTS

SECTION TITLE .........................................................................................................................................PAGE

SECTION 1 Safety Precautions ............................................................................................................................................................ 9

Powercut-1300/1600 MANUAL PLASMARC CUTTING PACKAGE ................................... 11

SECTION 2 DESCRIPTION .................................................................................................................................................................... 13

2.0 General ............................................................................................................................................................................. 13

2.1 Scope................................................................................................................................................................................... 13

2.2 Powercut-1300/1600 Manual Plasma ....................................................................................................................... 14

2.3 Manual Package Ordering Information .................................................................................................................. 15

2.4 PT-38 Torch Data .............................................................................................................................................................15

2.5 Optional Accessories ..................................................................................................................................................... 16

SECTION 3 INSTALLATION .................................................................................................................................................................. 17

3.0 Installation ......................................................................................................................................................................... 17

3.1 General ............................................................................................................................................................................. 17

3.2 Equipment Required ..................................................................................................................................................... 17

3.3 Location .............................................................................................................................................................................17

3.4 Inspection .......................................................................................................................................................................... 17

3.5 Primary Input Connections .........................................................................................................................................18

3.5.1 Input Voltage Changeover - 230/460 Voltage Units ONLY ..............................................................................20

3.5.2 Input Air Connection / Fuse Replacement ............................................................................................................20

3.6 Provisions for Automation ...........................................................................................................................................21

3.7 Secondary Output Connections for Manual Cutting.........................................................................................22

3.8 PT-38 Torch Installation ................................................................................................................................................22

SECTION 4 OPERATION .......................................................................................................................................................................25

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

4.1 Powercut-1300/1600 Controls .................................................................................................................................25

4.2 Cutting with the Powercut-1300/1600 using the PT-38 torch ........................................................................28

4.3 Stand-o Guide ...............................................................................................................................................................30

4.4 Drag Cutting 40 Amp ....................................................................................................................................................30

4.5 Gouging with the Powercut-1300/1600 using the PT-38 torch ...................................................................... 30

4.6 Electrode Wear ................................................................................................................................................................31

TABLE OF CONTENTS

Powercut-1300/1600 MECHANIZED PLASMARC CUTTING PACKAGE .......................33

SECTION 2 DESCRIPTION ....................................................................................................................................................................35

2.0 General .............................................................................................................................................................................35

2.1 Scope................................................................................................................................................................................... 35

2.2 Powercut-1300/1600 Mechanized Plasma .............................................................................................................36

2.3 Mechanized Package Ordering Information ........................................................................................................36

2.4 PT-37 Torch Data .............................................................................................................................................................37

2.5 Optional Accessories ..................................................................................................................................................... 38

SECTION 3 INSTALLATION ..................................................................................................................................................................39

3.0 Installation .........................................................................................................................................................................39

3.1 General .............................................................................................................................................................................39

3.2 Equipment Required .....................................................................................................................................................39

3.3 Location .............................................................................................................................................................................39

3.4 Inspection ..........................................................................................................................................................................35

3.5 Primary Input Connections .........................................................................................................................................40

3.5.1 Input Voltage Changeover - 230/460 Voltage Units ONLY ..............................................................................42

3.5.2 Input Air Connection / Fuse Replacement ............................................................................................................42

3.6 CNC Interface Connection ...........................................................................................................................................43

3.7 Voltage Divider Adjustment .......................................................................................................................................44

3.7.1 Output Voltage Sample ................................................................................................................................................44

3.8 Secondary Output Connections for Mechanized Cutting ...............................................................................45

3.9 PT-37 Torch Installation ................................................................................................................................................45

SECTION 4 OPERATION ....................................................................................................................................................................... 47

4.0 Operation ..........................................................................................................................................................................47

4.1 Powercut-1300/1600 Controls ................................................................................................................................. 47

4.2 Cutting with the Powercut-1300/1600 using the PT-37 torch ......................................................................... 50

4.3 Electrode Wear ................................................................................................................................................................50

MAINTENANCE, TROUBLESHOOTING, SCHEMATIC DIAGRAMS, REPLACEMENT PARTS ......... 97

SECTION 5 MAINTENANCE ................................................................................................................................................................97

5.0 General ...............................................................................................................................................................................99

5.1 Inspection and Cleaning ..............................................................................................................................................99

5.2 Common Cutting Problems ......................................................................................................................................100

5.3 IGBT Handling ................................................................................................................................................................101

5.4 Module Replacement ..................................................................................................................................................101

SECTION 6 TROUBLESHOOTING ....................................................................................................................................................103

6.0 Troubleshooting ............................................................................................................................................................103

6.1 List of Help Codes .........................................................................................................................................................104

SECTION 7 REPLACEMENT PARTS..................................................................................................................................................105

7.0 Replacement Parts .......................................................................................................................................................105

7.1 General .............................................................................................................................................................................105

7.2 Ordering ...........................................................................................................................................................................105

7.3 Torque Recommendations ........................................................................................................................................106

7.4 Selecting Air Pressure Units of Measure ...............................................................................................................107

7.5 Control/Display Board Assembly ........................................................................................................................... 107

7.6 Power Board Assembly ...............................................................................................................................................108

Diagrams and Parts List .................................................................................................................... attached packet

SECTION 1 SAFETY PRECAUTIONS

1.0 Safety Precautions

Users of ESAB welding and plasma cutting 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 welding or plasma cutting 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 welding or plasma cutting 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 welding or plasma cutting equipment must be familiar with:

- its operation

- location of emergency stops

- its function

- relevant safety precautions

- welding and / or plasma cutting

2. The operator must ensure that:

- no unauthorized person stationed within the working area of the equipment when it is started up.

- no one is unprotected when the arc is struck.

3. The workplace must:

- be suitable for the purpose

- be free from drafts

4. Personal safety equipment:

- Always wear recommended personal safety equipment, such as safety glasses, ame proof clothing, safety gloves.

- Do not wear loose tting items, such as scarves, bracelets, rings, etc., which could become trapped or cause burns.

5. General precautions:

- Make sure the return cable is connected securely.

- Work on high voltage equipment may only be carried out by a qualied electrician.

- Appropriate re extinquishing equipment must be clearly marked and close at hand.

- Lubrication and maintenance must not be carried out on the equipment during operation.

The following publication, which is available from the Canadian Standards Association, is recommended to you: CSA - W117.2 - "Code for Safety in Welding and Cutting".

SECTION 1 SAFETY PRECAUTIONS

WELDING AND PLASMA CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING OR CUTTING. ASK FOR

WARNING

ELECTRIC SHOCK - Can kill.

- Install and earth (ground) the welding or plasma cutting unit in accordance with applicable standards.

- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

- Insulate yourself from earth and the workpiece.

- Ensure your working stance is safe.

FUMES AND GASES - Can be dangerous to health.

- Keep your head out of the fumes.

- Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone and the general area.

YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANUFACTURERS’ HAZARD DATA.

ARC RAYS - Can injure eyes and burn skin.

- Protect your eyes and body. Use the correct welding / plasma cutting screen and lter lens and wear protective clothing.

- Protect bystanders with suitable screens or curtains.

FIRE HAZARD

- Sparks (spatter) can cause re. Make sure therefore that there are no inammable materials nearby.

NOISE - Excessive noise can damage hearing.

- Protect your ears. Use earmus or other hearing protection.

- Warn bystanders of the risk.

MALFUNCTION - Call for expert assistance in the event of malfunction.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

Powercut-1300/1600

MANUAL PLASMARC CUTTING PACKAGE

SECTION 2 DESCRIPTION

USE THE ESAB PT38 PLASMARC TORCH WITH MANUAL CONSOLES.

WARNING

2.0 General

As shipped, the PowerCut 1300/1600 is fully assembled and ready to cut after being connected to input power and a source of compressed air. The Powercut package uses the heavy-duty PT-38 (Manual Plasma) torch to deliver cutting power for severing materials up to 1-1/2 inch (38 mm) thick on the PC-1300 and 1-3/4 inch (45 mm) thick on the PC-1600. Refer to the following pages for descriptions of the Powercut packages available as well as performance specications.

2.1 Scope

The purpose of this manual is to provide the operator with all the information required to install and operate the Powercut plasma arc cutting package. Technical reference material is also provided to assist in troubleshooting the cutting package.

USE OF TORCHES NOT DESIGNED FOR USE WITH THIS CONSOLE COULD CREATE AN ELECTRIC SHOCK HAZARD.

SECTION 2 DESCRIPTION

2.2 PowerCut 1300/1600 Manual Plasma

The PowerCut 1300/1600 plasma cutting package combines the newly redesigned PowerCut 1300/1600 console and PT-38 torch. The PT-38 plasma cutting torch is designed to provide increased performance and longer consumable life resulting in higher production rates at lower costs.

Specications: PowerCut 1300

Cuts 1-1/4 in. (32 mm); severs 1-1/2 in. (38 mm)

1 phase

1 phase Input ............................................................ 208/230 vac, 60 Hz, 57/50 A

Output (1 phase 208 vac) ..................70 amps @ 125vdc - 40% duty cycle

..................60 amps @ 125vdc - 60% duty cycle

..................50 amps @ 125vdc - 100% duty cycle

Output (1 phase 230 vac) ..................70 amps @ 125vdc - 60% duty cycle

...................60 amps @ 125vdc - 100% duty cycle

3 phase

3 phase Input ........................................................... 208/230 vac, 60 Hz, 34/36 A

........................................................................... 460 vac, 60 Hz, 18 A

.....................................................380/400 vac, 50/60 Hz, 19/18 A

........................................................................... 575 vac, 60 Hz, 15 A

Output (3 phase 208 vac) ...................70 amps @ 125vdc - 100% duty cycle

Output (3 phase 230, 460, 575 vac) 70 amps @ 150vdc - 100% duty cycle

Output (3 phase 380-400 vac) ..........70 amps @ 115vdc - 100% duty cycle

Voltage requirements ..........................................................Idle 208V, -2%, +10%

................................................... Cutting 208V, -4%, +15%

...........................Idle 230, 380, 400, 460, 575V, +/- 10%

...................Cutting 230, 380, 400, 460, 575V, +/- 15%

Air Supply Requirements ..............500 cfh @ 90 psig (236 l/min @ 6.2 bars)

CE 380-400 vac .....................................................................................*S

.................................................................................... *Z

Dimensions ................................................................................W = 12.7” (322 mm)

................................................................................ H = 14.9” (379 mm)

................................................................................ D = 27.8” (706 mm)

Weight .................................................................................................90 lbs. (40.8 kg)

sc min

max

4 MVA

0.04 

Specications: PowerCut 1600

Cuts 1-1/2 in. (38 mm); severs 1-3/4 in. (45 mm)

1 phase

1 phase Input ............................................................................. 230 vac, 60 Hz, 79A

1 phase Output ...................................... 90 amps @ 125vdc - 40% duty cycle

....................................... 70 amps @ 125vdc - 60% duty cycle

....................................... 60 amps @ 125vdc - 100% duty cycle

3 phase

3 phase Input ............................................................ 208/230 vac, 60 Hz, 44/47 A

............................................................................ 460 vac, 60 Hz, 23 A

......................................................380/400 vac, 50/60 Hz, 21/20 A

............................................................................ 575 vac, 60 Hz, 20 A

Output (3 phase 208 vac) ...................90 amps @ 125vdc - 60% duty cycle

................... 70 amps @ 125vdc - 100% duty cycle

Output (3 phase 230, 460, 575 vac) 90 amps @ 150vdc - 60% duty cycle 70 amps @ 150vdc - 100% duty cycle

Output (3 phase 380-400 vac) .......... 90 amps @ 115vdc - 60% duty cycle

.......... 70 amps @ 115vdc - 100% duty cycle

Voltage requirements ..........................................................Idle 208V, -2%, +10%

..................................................Cutting 208V, -4%, +15%

..........................Idle 230, 380, 400, 460, 575V, +/- 10%

..................Cutting 230, 380, 400, 460, 575V, +/- 15%

: Minimum short circuit power on the network in accordance with

sc min

IEC61000-3-12.

: Maximum permissible line on the network impedance in accor-

max

dance with IEC61000-3-11.

Air Supply Requirements ..............500 cfh @ 90 psig (236 l/min @ 6.2 bars)

CE 380-400 vac ....................................................................................*S

................................................................................... *Z

Dimensions ................................................................................W = 12.7” (322 mm)

................................................................................ H = 14.9” (379 mm)

................................................................................ D = 27.8” (706 mm)

Weight .................................................................................................90 lbs. (40.8 kg)

Duty Cycle: The duty cycle refers to the time as a percentage of a ten-minute period that you can cut at a certain load without overheating. The duty cycle is valid for 40 degrees C.

sc min

max

4 MVA

0.04 

SECTION 2 DESCRIPTION

2.3 Package Ordering Information

Powercut-1300:

208-230/460 V PT-38 25 ft (7.6 m) ...................................................................................................................................................... 0558007221

208-230/460 V PT-38 50 ft (15.2 m) .................................................................................................................................................... 0558007222

208-230/460 V PT-38 25 ft (7.6 m) BL ..............................................................................................................................................0558007221F

380-400 V CE PT-38 25 ft (7.6 m) ........................................................................................................................................................0558007225

380-400 V CE PT-38 50 ft (15.2 m) ...................................................................................................................................................... 0558007226

400 V PT-38 25 ft (7.6 m) .........................................................................................................................................................................0558007635

460 V PT-38 25 ft (7.6 m) ........................................................................................................................................................................ 0558008321

460 V PT-38 50 ft (15.2 m) .....................................................................................................................................................................0558008322

575 V PT-38 25 ft (7.6 m) BL .................................................................................................................................................................. 0558007228

575 V PT-38 50 ft (15.2 m) BL ................................................................................................................................................................ 0558007229

Powercut-1600:

208-230/460 V PT-38 25 ft (7.6 m) .......................................................................................................................................................0558007231

208-230/460 V PT-38 50 ft (15.2 m) .................................................................................................................................................... 0558007232

208-230/460 V PT-38 25 ft (7.6 m) BL .............................................................................................................................................. 0558007231F

380-400 V CE PT-38 25 ft (7.6 m) ........................................................................................................................................................0558007235

380-400 V CE PT-38 50 ft (15.2 m) ...................................................................................................................................................... 0558007236

460 V PT-38 25 ft (7.6 m) BL .................................................................................................................................................................. 0558008324

460 V PT-38 50 ft (15.2 m) BL ...............................................................................................................................................................0558008325

The components that are included in the Powercut-1300/1600 manual packages may be purchased separately by using the appropriate P/N when placing orders. Individual part numbers are listed below:

Consoles:

Powercut-1300:

208-230/460 V Console..........................................................................................................................................................................0558007220

208-230/460 V Console BL ..................................................................................................................................................................0558007220F

380-400 V CE Console ............................................................................................................................................................................ 0558007224

400 V Console............................................................................................................................................................................................0558007634

460 V Console............................................................................................................................................................................................0558008320

575 V Console BL ...................................................................................................................................................................................... 0558007227

Powercut-1600:

208-230/460 V Console BL ..................................................................................................................................................................0558007230F

PT-38 Torches:

PT-38 Torch, 25' (7.6 m) ..........................................................................................................................................................................0558006786

PT-38 Torch, 50' (15.2 m) ....................................................................................................................................................................... 0558006787

2.4 PT-38 Torch Data

Powercut-1300/1600 manual plasma cutting packages use the PT-38 torch. For dimensions and breakdown of parts, refer to torch manual.

SECTION 2 DESCRIPTION

2.5 Optional Accessories:

Powercut-900/1300/1600 Cart ....................................................p/n 0558007898

Enables operator to easily transport the power source , work cable and power cord.

Gas Flow Measuring Kit .............p/n 19765 ("CE" units - 0558000739)

Valuable troubleshooting tool allows measurement of the actual air ow through the torch.

Powercut-900/1300/1600 Water Separator ...........p/n 0558007897

Improves air quality by removing water.

Powercut-1300/1600 Mechanized Conversion kit .....................................p/n 0558007885

Adds automated mechanized capability to an existing manual machine. Refer to mechanized section of this manual for CNC Interface connection. Requires software version 1.04 or higher (displayed during power-up). Refer to Section 4, Subsection 4.1.E1. Contact factory for any required software updates.

Remote Hand Switch with 25 ft. (7.6m) lead ............... p/n 0558008349

Enables non-automated mechanized cutting using the PT-37 torch. Can be used on machines equipped with or without CNC interface connection pigtail. Connects to the torch cable receptacle through the front panel access door strain relief.

SECTION 3 INSTALLATION

INSTALLING OR PLACING ANY TYPE OF FILTERING DEVICE WILL RE STRICT THE VOLUME OF INTAKE AIR, THEREBY SUBJECTING THE

WARNING

3.0 Installation

3.1 General

Proper installation is important for satisfactory and trouble-free operation of the Powercut cutting package. It is suggested that each step in this section be studied carefully and followed closely.

3.2 Equipment Required

A source of clean, dry air that supplies 500 cfh (236 l/m) at 90 psig (6.2 bar) is required for the cutting operation. The air supply should not exceed 150 psig (10.3 bar) (the maximum inlet pressure rating of the air lter-regulator supplied with the package).

POWER SOURCE INTERNAL COMPONENTS TO OVERHEATING. THE WARRANTY IS VOID IF ANY TYPE OF FILTER DEVICE IS USED.

3.3 Location

Adequate ventilation is necessary to provide proper cooling of the Powercut. 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 clearance between the Powercut power source and wall or any other obstruction to allow freedom of air movement through the power source.

3.4 Inspection

A. Remove the shipping container and all packing material and inspect for evidence of concealed damage

which may not have been apparent upon receipt of the Powercut. Notify the carrier of any defects or damage at once.

B. Check container for any loose parts prior to disposing of shipping materials.

C. Check air louvers and any other openings to ensure that any obstruction is removed.

SECTION 3 INSTALLATION

ELECTRIC SHOCK CAN KILL! PRECAUTIONARY MEASURES SHOULD BE TAKEN TO PROVIDE MAXIMUM PROTECTION AGAINST ELECTRI

WARNING

3.5 Primary Input Connections

The Powercut-1300/1600 consoles are equipped with approximately 10 ft. of 4-conductor input power cable for 3 phase connection. If single-phase connection is desired, cap the unused wire on the input power cable per chart below. When operating this machine from a single-phase source, it must be connected to a dedicated 100 amp feed. Due to the higher input current requirements, the duty cycle of the machine is lower than in 3 phase operation. See specication section or rating plate.

CAL SHOCK. BE SURE THAT ALL POWER IS OFF BY OPENING THE LINE WALL DISCONNECT SWITCH AND BY UNPLUGGING THE POWER CORD TO THE UNIT WHEN CONNECTIONS ARE MADE INSIDE OF THE POWER SOURCE.

STANDARD UNITS

(NON-CE)

PHASE 3 1 PHASE 3 1

L1 Black Black L1 Brown Brown L2 Red - L2 Black L3 White White L3 Gray Gray

GND Green Green GND Green/Yel Green/Yel

CE UNITS

(EUROPE)

WARNING

INSULATE UNUSED POWER CORD

CONDUCTOR WHEN CONNECTING

FOR SINGLE PHASE.

PRIMARY INPUT

POWER CABLE

CUSTOMER FUSED LINE DISCONNECT SWITCH

(See Table 3-1)

Figure 3-1. Input Connections

SECTION 3 INSTALLATION

ELECTRIC SHOCK CAN KILL! BEFORE MAKING ELECTRICAL INPUT CON NECTIONS TO THE POWER SOURCE, "MACHINERY LOCKOUT PRO CEDURES" SHOULD BE EMPLOYED. IF THE CONNECTIONS ARE TO BE MADE FROM A LINE DISCONNECT SWITCH, PLACE THE SWITCH IN THE

WARNING

OFF POSITION AND PADLOCK IT TO PREVENT INADVERTENT TRIPPING. IF THE CONNECTION IS MADE FROM A FUSEBOX, REMOVE THE CORRE SPONDING FUSES AND PADLOCK THE BOX COVER. IF IT IS NOT POSSI BLE TO USE PADLOCKS, ATTACH A RED TAG TO THE LINE DISCONNECT SWITCH OR FUSE BOX WARNING OTHERS THAT THE CIRCUIT IS BEING WORKED ON.

THE CHASSIS MUST BE CONNECTED TO AN APPROVED ELECTRICAL GROUND. FAILURE TO DO SO MAY RESULT IN ELECTRICAL SHOCK, SE VERE BURNS OR DEATH.

BEFORE MAKING ANY CONNECTIONS TO THE POWER SOURCE OUT PUT TERMINALS, MAKE SURE THAT ALL PRIMARY INPUT POWER TO THE POWER SOURCE IS DEENERGIZED OFF AT THE MAIN DISCON NECT SWITCH AND THAT THE INPUT POWER CABLE IS UNPLUGGED.

Before connecting to input power, make sure there is a line (wall) disconnect switch with fuses or circuit breakers at the main power panel. You may either use the factory-installed input power cable (4/c, type SO (90 °C), 10 ft (3.1 m) length) or provide your own input power leads. If you choose to provide your own, make sure they are insulated copper conductors. You must have two (single-phase) or three (3 phase) power leads and one ground wire. The wires may be heavy rubber covered cable or may be run in a solid or exible conduit. Refer to Table 3-1 for recommended input conductors and line fuse sizes.

Table 3-1. (Powercut-1300/1600)

Recommended Sizes For Input Conductors and Line Fuses

PowerCut 1300

Input Requirements Input & Gnd

Conductors

Volts Phase Amps Cu / Awg Amps

208 1 57 6 75 208 3 34 6 45 230 1 50 6 70 230 3 36 6 50

400 3 18 10 25 380(CE) 3 19 6 mm 400(CE) 3 18 6 mm

460 3 18 10 25

575 3 15 10 20

Line Fuse

25 25

Input Requirements Input & Gnd

Volts Phase Amps Cu / Awg Amps

208 3 44 6 60 230 1 79 6 100 230 3 47 6 60

400 3 20 10 30 380(CE) 3 21 6 mm 400(CE) 3 20 6 mm

460 3 23 10 30

575 3 20 10 30

PowerCut 1600

Conductors

Line Fuse

30 30

SECTION 3 INSTALLATION

ELECTRIC SHOCK CAN KILL! PRECAUTIONARY MEASURES SHOULD BE TAKEN TO PROVIDE MAXIMUM PROTECTION AGAINST ELECTRI

WARNING

3.5.1 INPUT VOLTAGE CHANGEOVER - 230/460 VOLTAGE UNITS ONLY

208 - 230 or 460 Mode

To simplify the use of the Powercut-1300/1600 with dierent input voltages, it has been equipped with a 230/460 voltage selector switch located on the rear panel of the unit. Switching between 230 and 460 voltages can be done by using a athead screwdriver. You will hear two clicks when switching between 230 and 460 positions. Do not allow switch to remain in the center position. This switch should never be changed when machine power is on. Damage could result.

Input Voltage Selector Switch

CAL SHOCK. BE SURE THAT ALL POWER IS OFF BY OPENING THE LINE WALL DISCONNECT SWITCH AND BY UNPLUGGING THE POWER CORD TO THE UNIT WHEN RECONNECTING FOR 208 VAC INPUT.

Replace fuse with Slo-Blo, 2 Amp, 600 V only

Pre-ltered DRY AIR SUPPLY (Customer Supplied)

(90 - 150 psi / 6.2 - 10.3 bars)

Figure 3-2. Input Connections / Fuse Replacement

3.5.2 INPUT AIR CONNECTION

Connect your air supply to the inlet connection of the lter-regulator.

WARNING

MAKE SURE THE POWER

SOURCE IS SWITCHED OFF

BEFORE REMOVING FUSE.

SECTION 3 INSTALLATION

3.6 Provisions for Automation

A mechanized version of the Powercut is available with a full automation interface, which allows the unit to communicate with an external control on a Cutting Machine or Robot. (See section 2.3 - Mechanized Package ordering information).

The manual version of the Powercut can be upgraded with the full automation interface by installing a mechanized conversion kit p/n 0558007885. (See section 2.5 - Optional accessories).

Two standard provisions are included within all Powercuts to allow the unit to work with a simple interface used by some Cutting Machine Manufacturers.

1) Trigger Interconnect - Some Cutting Machines connect directly to the plasma start circuit, in series with the plasma unit’s torch switch. A convenient connection point has been provided for this purpose. The Powercut trigger circuit includes a male / female spade interconnection, which may be used to connect the external control cable. This connection is in series with the torch switch, which means both the torch switch and the external control circuit will have to close in order to start the plasma system.

2) Output Voltage Sample - Some Cutting Machines sample the full output voltage of the plasma system to control the torch height and to determine when to start moving. The full output voltage is available within the machine on a pair of insulated male spade terminals.

Cut tie wrap. Remove sleeve and voltage pickup insulators.1.

Output Voltage Sample

Trigger Interconnect

SECTION 3 INSTALLATION

3.7 Secondary Output Connections for Manual Cutting

The PT-38 torch comes factory installed with the manual packages.

Clamp the work cable to the workpiece. Be sure the workpiece is connected to an approved earth ground with a properly sized ground cable.

PT-38 Cutting Torch

WORK

SAFETY

GROUND

MAKE SURE POWER SWITCH ON CONSOLE IS IN OFF POSITION AND

WARNING

PRIMARY INPUT POWER IS DEENERGIZED.

3.8 PT-38 Torch Installation

Open torch lead access door on the front panel of the Powercut-1300/1600.1.

Figure 3-3. Powercut Interconnection Diagram

Torch Lead Access Door

SECTION 3 INSTALLATION

Connect the torch cable receptacle to the panel receptacle. Check 2. orientation of the sockets to ensure a correct t.

Panel Receptacle

Torch Cable Male Receptacle

Connect the air hose to the quick-connect tting. Place the strain relief in the square cutout in the front of 3. the console. Line up the groove of the strain relief with the half square cutout area.

square cutout

Air Hose quickconnect tting

Insert work cable into plug on the front of the console and turn 4. clockwise until secure.

Replace 5. torch lead access door.

Torch Lead Access Door

strain relief

Work Cable

SECTION 3 INSTALLATION

SECTION 4 OPERATION

ELECTRIC SHOCK CAN KILL.

• Do NoT operaTe The uNiT wiTh The cover removeD.

WARNING

4.0 Operation

The PowerCut 1300/1600 will automatically tailor the arc for Normal cutting, Expanded metal / Grate cutting, and Gouging operations. No manual switching is required.

4.1 PowerCut 1300/1600 Controls

A. Power Switch. Turn knob clockwise to "ON" position for normal operation. Turn knob counterclockwise to switch

"OFF".

B. Pressure Regulator. Regulates torch air pressure. Rotate clockwise to increase and counterclockwise to decrease.

The unit is shipped from the factory with the regulator adjusted to deliver 80 psig (5.5 bar) to the torch from a 95 psig (6.5 bar) supply. If supply pressure to the machine is greater than 95 psig (6.5 bar) up to the maximum recommended 150 psig (10.3 bar), rotate pressure regulator knob counterclockwise to reduce the pressure delivered to the torch back to 80 psig (5.5 bar). Follow TEST MODE instructions, see 4.1.D.

• Do NoT apply power To The uNiT while holDiNg or carryiNg The uNiT.

• Do NoT Touch aNy Torch parTs forwarD of The Torch haNDle (Nozzle,

HEAT SHIELD, ELECTRODE, ETC. WITH POWER SWITCH ON.

Note:

Pressure is indicated on the display screen.

C. Output Current Control. Adjustable from 20 to 70 amperes on PowerCut 1300. Adjustable from 20 to 90 amperes on

PowerCut 1600. For settings refer to cut data charts in the torch manual.

Figure 4-1. Powercut 1300/1600 Controls

SECTION 4 OPERATION

D. Torch Trigger / Gas Test Switch

Operating modes: Normal Trigger (CENTER position) - Setting will be used for most cutting and gouging operations. 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 cut, press and release torch switch again or pull torch away from work. Not recommended for expanded metal / grate cutting.

Test Mode: Gas Test Switch (UP position) - The display screen will indicate owing air pressure. The air regulator should be ad-

justed to recommended pressure before cutting operations. Allow air to ow for a few minutes. This should remove any condensation that may have accumulated during shutdown period. Be sure to place switch in Normal Trigger or

Trigger Lock position before starting cutting operations.

E. Display Screen: Displays current settings during normal operation.

1. Power-up Indication: When unit is initially switched on the Model, PIP (Parts in Place), Software version will be

briey displayed. Display will then show Current Setting.

2. Gas Test: When unit is in the "GAS TEST" mode the display will indicate air pressure setting in psi/bar.

UP position

CENTER position DOWN position

Toggle Switch detail

Figure 4-2. Powercut 1300/1600 Controls

F (Codes shown on Domestic and Bi-lingual units only)

SECTION 4 OPERATION

3. Fault Indication: Should a fault condition exist in normal operation, the display will show a code number. Refer to

the "Help Code" menu on the front panel (non-"CE" units only) or in Section 4.1.F and in Troubleshooting Section 6.1.

Note:

All fault signals will remain on for a minimum of 10 seconds. If fault clears, all will reset automatically

except for over-current. To clear over-current, the power must be shut o for 5 seconds and then turned

back on.

F. Help Codes (See Section 6.1, Troubleshooting for Causes and Solutions):

1. Line voltage, idle +/- 15 % - line voltage has uctuated +/- 15 %.

2. Line voltage, cutting +/- 20 % - line voltage has uctuated +/- 20 %.

3. Control bias, +/- 15 V bias split - Control transformer supplying insuent voltage to the control circuit.

4. Thermal switch - Switch opens due to excessive heat within the unit.

5. Pressure - Incorrect air pressure being supplied. Minimum 60 psi / maximum 95 psi.

6. Fail to re - Arc failed to transfer to workpiece.

7. Pilot Arc timeout (~ 5 seconds) - Cutting process did not begin within the 5 second limit.

8. Torch error - Improper assembly of torch consumables. Torch nozzle making contact with workpiece at machine power-up.

10. Feedback improper - current sensor failed.

11. Primary over-current - Converter failure.

12. Single phase operation, shutdown - Exceeded single phase duty cycle rating.

13. OCV (open circuit voltage) failure - Voltage or current not detected when test (PIP) is performed.

14. Ambient temperature - Make sure adequate air ow is around all sides of unit. Check air louvers and any other openings to ensure that any obstruction is removed.

15. Bus charger failure - Primary bus not up to voltage.

19. Torch trigger early engagement - Torch trigger depressed at power up.

20. PIP (Parts in place) no retract - Piston did not retract when air applied.

21. PIP (Parts in place) no continuity - Piston did not drop back in place when signal to solenoid was removed.

SECTION 4 OPERATION

ARC RAYS CAN BURN EYES AND SKIN;

WARNING

4.2 Cutting with the Powercut-1300/1600 using the PT-38 torch

Use the following procedures to cut with the PT-38 torch.

A. Make sure that the wall disconnect switch is on and air is supplied to machine.

B. Turn on the front panel power switch.

C. Flip toggle switch upward to place unit in "GAS TEST" mode. Set Pressure Regulator to 80 psig (5.5 bar).

D. Place unit in Normal Trigger (CENTER position) or Trigger Lock (DOWN position).

NOISE CAN DAMAGE HEARING.

• wear welDiNg helmeT wiTh No. 6 or 7 leNs shaDe.

• wear eye, ear, aND boDy proTecTioN.

POSITION THE POWERCUT AT LEAST 10 FEET 3 METERS FROM THE CUTTING AREA. SPARKS AND HOT SLAG FROM THE CUTTING OPERA TION CAN DAMAGE THE UNIT.

E. Hold the torch nozzle approximately 1/8 - 1/4 inch (3.2 - 6.4 mm) above the work and tilted at about 5 -15°. This reduces

the chance of spatter entering the nozzle. If the PT-38's 90A stand-o guide is being used, the distance between nozzle and work piece will be approximately 1/4" (6.4 mm).

F. Depress the torch switch. Air should ow from the torch nozzle.

G. 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, torch switch may be released after establishing the cutting arc.) See note.

NOTE: Trigger Lock Mode.

Manual Operation using the PT-38 torch - When placed in TRIGGER LOCK position, this permits re-

leasing torch switch button after cutting arc has been initiated. To extinguish arc at end of cut, press and release torch switch button again or pull torch away from work. When placed in NORMAL TRIGGER position, torch switch must be held closed by the operator during the entire cutting operation and then

released at the end of cut.

Torch Trigger / Gas Test Switch

Figure 4-3. Torch Trigger / Gas Test Switch

SECTION 4 OPERATION

H. 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-o guide, the nozzle should be held approximately 1/8" - 1/4" (3.2 mm - 6.4 mm) from the work.

IMPORTANT!!!

5˚ to 15˚

CUT DIRECTION

Maintain Proper

Stand-O Distance

Power Output increases

with Stand-o Distance!

1/8" - 1/4"

(3.2 - 6.4 mm)

Figure 4-4a. Proper Torch Angle

Figure 4-4b. Stand-o vs. Power Output

I. When ending a cut, the torch switch should be released (press and release if using TRIGGER LOCK feature) and the

torch lifted o the workpiece immediately upon completion of the cut. This is to prevent the pilot arc from re-igniting after cutting arc extinguishes and causing damage to the nozzle (double arcing).

J. For rapid re-starts, such as grate or heavy mesh cutting, do not release the torch switch. In the postow mode, the arc

can be re-started immediately by depressing the torch switch. This avoids the 2-second preow portion of the cutting cycle.

2. WHEN THE ARC BREAKS THROUGH THE WORK, BRING THE TORCH TO AN UPRIGHT POSITION AND PROCEED TO CUT.

1. TO START A PIERCE, TILT THE TORCH TO PREVENT MOLTEN MATERIAL FROM COMING BACK AGAINST AND DAMAGING THE TORCH.

Figure 4-5. Piercing Technique using the PT-38

SECTION 4 OPERATION

DRAG CUTTING, EVEN WITH LOWER CURRENT LEVELS MAY SIGNIFI

WARNING

4.3 Stand-o Guide

Refer to torch manual.

4.4 Drag Cutting 40 Amp

Refer to torch manual.

4.5 Gouging with the Powercut 900 using the PT-38 torch

Refer to torch manual.

CANTLY REDUCE THE LIFE OF TORCH CONSUMABLES. ATTEMPTING TO DRAG CUT WITH HIGHER CURRENTS GREATER THAN 40 AMPS MAY CAUSE IMMEDIATE CATASTROPHIC CONSUMABLE DAMAGE.

+ 80 hidden pages

ESAB Powercut-1300/1600 Manual & Mechanized Plasmarc Cutting Package Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual