ESAB | Powercut 875 | Instruction manual | ESAB Powercut 875 Instruction manual

Powercut 875
Plasma Arc Cutting Package
Instruction Manual
This manual provides installation and operation instructions for the following PowerCut 875 cutting packages starting with Serial No. (PB-J120118142).
P/N 0558002787 - 208/230 V, 25' Package
P/N 0558002788 - 208/230 V, 50' Package
P/N 0558002789 - 460 V, 25' Package
P/N 0558002790 - 460 V, 50' Package
P/N 0558002927 - 575 V, 25' Package
F15-653-J
01 / 2008
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!
2
table of contents
Section / Title
Page
1.0 Safety Precautions...................................................................................................................................................................5
1.1 Safety - English...............................................................................................................................................................5
1.2 Safety - Spanish..............................................................................................................................................................9
1.3 Safety - French............................................................................................................................................................. 13
2.0
Description.............................................................................................................................................................................. 17
2.1 General........................................................................................................................................................................... 17
2.2 Scope.............................................................................................................................................................................. 17
2.3 Packages Available.................................................................................................................................................... 17
2.4 Specifications............................................................................................................................................................... 18
2.5 Optional Accessories................................................................................................................................................. 20
3.0
Installation............................................................................................................................................................................... 21
3.1 General........................................................................................................................................................................... 21
3.2 Equipment Required................................................................................................................................................. 21
3.3 Location......................................................................................................................................................................... 21
3.4 Inspection..................................................................................................................................................................... 21
3.5 Primary Electrical Input Connections................................................................................................................. 22
3.6 Secondary Output Connections........................................................................................................................... 23
3.7 Connecting Powercut 875 for 200(208)Vac Input.......................................................................................... 25
4.0
Operation................................................................................................................................................................................. 27
4.1 Operation...................................................................................................................................................................... 27
4.2 Powercut 875 Controls............................................................................................................................................. 27
4.3 Cutting with the PT-32............................................................................................................................................. 28
4.4 Common Cutting Problems................................................................................................................................... 31
5.0 Maintenance........................................................................................................................................................................... 33
5.1 General........................................................................................................................................................................... 33
5.2 Inspection and Cleaning......................................................................................................................................... 33
5.3 PT-32 Torch Consumable Parts.............................................................................................................................. 34
5.4 IGBT Handling and Replacement......................................................................................................................... 35
5.5 Troubleshooting......................................................................................................................................................... 36
5.6 Troubleshooting Guide............................................................................................................................................ 36
5.7 Reference Voltage Checks....................................................................................................................................... 40
5.8 Sequence of Operation............................................................................................................................................ 41
6.0 Replacement Parts................................................................................................................................................................ 43
6.1 General........................................................................................................................................................................... 43
6.2 Ordering........................................................................................................................................................................ 43
3
table of contents
4
section 1safety precautions
1.0
Safety Precautions
1.1
WARNING: These Safety Precautions are
for your protection. They summarize precautionary information from the references
listed in Additional Safety Information section. Before performing any installation or operating
procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material
safety data sheets, labels, etc. Failure to observe Safety
Precautions can result in injury or death.
Safety - English
FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot
slag or sparks can also cause fires and
explosions. Therefore:
1. Remove all combustible materials well away from
the work area or cover the materials with a protective non-flammable covering. Combustible materials
include wood, cloth, sawdust, liquid and gas fuels,
solvents, paints and coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or
crevices in floors or wall openings and cause a hidden smoldering fire or fires on the floor below. Make
certain that such openings are protected from hot
sparks and metal.“
3. Do not weld, cut or perform other hot work until the
workpiece has been completely cleaned so that there
are no substances on the workpiece which might
produce flammable or toxic vapors. Do not do hot
work on closed containers. They may explode.
4. Have fire extinguishing equipment handy for instant
use, such as a garden hose, water pail, sand bucket,
or portable fire extinguisher. Be sure you are trained
in its use.
5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and
create a fire hazard.
6. After completing operations, inspect the work area
to make certain there are no hot sparks or hot metal
which could cause a later fire. Use fire watchers when
necessary.
7. For additional information, refer to NFPA Standard
51B, "Fire Prevention in Use of Cutting and Welding
Processes", available from the National Fire Protection Association, Batterymarch Park, Quincy, MA
02269.
PROTECT YOURSELF AND OTHERS -Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation
and can injure skin and eyes. Hot metal can cause
burns. Training in the proper use of the processes
and equipment is essential to prevent accidents.
Therefore:
1. Always wear safety glasses with side shields in any
work area, even if welding helmets, face shields, and
goggles are also required.
2. Use a face shield fitted with the correct filter and
cover plates to protect your eyes, face, neck, and
ears from sparks and rays of the arc when operating
or observing operations. Warn bystanders not to
watch the arc and not to expose themselves to the
rays of the electric-arc or hot metal.
3. Wear flameproof gauntlet type gloves, heavy longsleeve shirt, cuffless trousers, high-topped shoes,
and a welding helmet or cap for hair protection, to
protect against arc rays and hot sparks or hot metal.
A flameproof apron may also be desirable as protection against radiated heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cuffs, or pockets. Sleeves and collars should
be kept buttoned, and open pockets eliminated from
the front of clothing.
5. Protect other personnel from arc rays and hot
sparks with a suitable non-flammable partition or
curtains.
6. Use goggles over safety glasses when chipping slag
or grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety
glasses.
ELECTRICAL SHOCK -- Contact with
live electrical parts and ground can
cause severe injury or death. DO NOT
use AC welding current in damp areas,
if movement is confined, or if there is
danger of falling.
5
section 1safety precautions
1. Be sure the power source frame (chassis) is connected to the ground system of the input power.
3. Welders should use the following procedures to
minimize exposure to EMF:
2. Connect the workpiece to a good electrical
ground.
A.Route the electrode and work cables together.
Secure them with tape when possible.
3. Connect the work cable to the workpiece. A poor
or missing connection can expose you or others
to a fatal shock.
B. Never coil the torch or work cable around your
body.
C.Do not place your body between the torch and
work cables. Route cables on the same side of
your body.
4. Use well-maintained equipment. Replace worn or
damaged cables.
5. Keep everything dry, including clothing, work
area, cables, torch/electrode holder, and power
source.
D.Connect the work cable to the workpiece as close
as possible to the area being welded.
E. Keep welding power source and cables as far
away from your body as possible.
6. Make sure that all parts of your body are insulated
from work and from ground.
7. Do not stand directly on metal or the earth while
working in tight quarters or a damp area; stand
on dry boards or an insulating platform and wear
rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the
power.
Therefore:
9. Turn off the power before removing your gloves.
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shielding gases can cause asphyxiation.
1. Always provide adequate ventilation in the work area
by natural or mechanical means. Do not weld, cut, or
gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead, beryllium, or cadmium
unless positive mechanical ventilation is provided.
Do not breathe fumes from these materials.
10. Refer to ANSI/ASC Standard Z49.1 (listed on
next page) for specific grounding recommendations. Do not mistake the work lead for a ground
cable.
2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly
toxic gas, and other irritant gases.
ELECTRIC AND MAGNETIC FIELDS
— May be dangerous. Electric current flowing through any conductor causes localized Electric and
Magnetic Fields (EMF). Welding and
cutting current creates EMF around welding cables
and welding machines. Therefore:
3. If you develop momentary eye, nose, or throat irritation while operating, this is an indication that
ventilation is not adequate. Stop work and take
necessary steps to improve ventilation in the work
area. Do not continue to operate if physical discomfort persists.
1. Welders having pacemakers should consult their
physician before welding. EMF may interfere with
some pacemakers.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specific ventilation recommendations.
2. Exposure to EMF may have other health effects which
are unknown.
6
section 1safety precautions
5.WARNING: This product, when used for welding
or cutting, produces fumes or gases
which contain chemicals known to
the State of California to cause birth
defects and, in some cases, cancer.
(California Health & Safety Code
§25249.5 et seq.)
1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualified to perform such work.
2. Before performing any maintenance work inside a
power source, disconnect the power source from
the incoming electrical power.
3. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do
not operate any equipment in faulty condition.
CYLINDER HANDLING -- Cylinders,
if mishandled, can rupture and violently release gas. Sudden rupture
of cylinder, valve, or relief device can
injure or kill. Therefore:
4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.
1. Use the proper gas for the process and use the
proper pressure reducing regulator designed to
operate from the compressed gas cylinder. Do not
use adaptors. Maintain hoses and fittings in good
condition. Follow manufacturer's operating instructions for mounting regulator to a compressed gas
cylinder.
5. Keep all safety devices and cabinet covers in position
and in good repair.
6. Use equipment only for its intended purpose. Do
not modify it in any manner.
2. Always secure cylinders in an upright position by
chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure
cylinders to work tables or fixtures where they may
become part of an electrical circuit.
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for
electric arc welding and cutting equipment, ask your supplier for a copy of
"Precautions and Safe Practices for Arc
Welding, Cutting and Gouging", Form
52-529.
3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder.
The following publications, which are available from
the American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, are recommended to you:
5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases
in Cylinders", which is available from Compressed
Gas Association, 1235 Jefferson Davis Highway,
Arlington, VA 22202.
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
7
section 1safety precautions
5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding“
6. AWS C5.6 - "Recommended Practices for Gas Metal
Arc Welding"“
7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."
Meaning of symbols - As used
throughout this manual: Means Attention! Be Alert! Your safety is involved.
Means immediate hazards which,
if not avoided, will result in immediate, serious personal injury
or loss of life.
Means potential hazards which
could result in personal injury or
loss of life.
Means hazards which could result
in minor personal injury.
8
section 1sEGURIDAD
1.2
Safety - Spanish
La escoria puede estar caliente y desprenderse con
velocidad. Personas cercanas deberán usar gafas de
seguridad y careta protectora.
ADVERTENCIA: Estas Precauciones de Seguridad son para su protección. Ellas hacen
resumen de información proveniente de las
referencias listadas en la sección "Información Adicional Sobre La Seguridad". Antes de hacer cualquier
instalación o procedimiento de operación , asegúrese
de leer y seguir las precauciones de seguridad listadas
a continuación así como también todo manual, hoja
de datos de seguridad del material, calcomanias, etc.
El no observar las Precauciones de Seguridad puede
resultar en daño a la persona o muerte.
FUEGO Y EXPLOSIONES -- El calor de
las flamas y el arco pueden ocacionar
fuegos. Escoria caliente y las chispas
pueden causar fuegos y explosiones.
Por lo tanto:
1. Remueva todo material combustible lejos del área
de trabajo o cubra los materiales con una cobija a
prueba de fuego. Materiales combustibles incluyen
madera, ropa, líquidos y gases flamables, solventes,
pinturas, papel, etc.
2. Chispas y partículas de metal pueden introducirse en
las grietas y agujeros de pisos y paredes causando
fuegos escondidos en otros niveles o espacios.
Asegúrese de que toda grieta y agujero esté cubierto
para proteger lugares adyacentes contra fuegos.
3. No corte, suelde o haga cualquier otro trabajo
relacionado hasta que la pieza de trabajo esté totalmente limpia y libre de substancias que puedan
producir gases inflamables o vapores tóxicos. No
trabaje dentro o fuera de contenedores o tanques
cerrados. Estos pueden explotar si contienen vapores
inflamables.
4. Tenga siempre a la mano equipo extintor de fuego para uso instantáneo, como por ejemplo una
manguera con agua, cubeta con agua, cubeta con
arena, o extintor portátil. Asegúrese que usted esta
entrenado para su uso.
5. No use el equipo fuera de su rango de operación. Por
ejemplo, el calor causado por cable sobrecarga en
los cables de soldar pueden ocasionar un fuego.
6. Después de termirar la operación del equipo, inspeccione el área de trabajo para cerciorarse de que las
chispas o metal caliente ocasionen un fuego más
tarde. Tenga personal asignado para vigilar si es
necesario.
7. Para información adicional , haga referencia a la
publicación NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible
a través de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
PROTEJASE USTED Y A LOS DEMAS-Algunos procesos de soldadura, corte
y ranurado son ruidosos y requiren
protección para los oídos. El arco,
como el sol , emite rayos ultravioleta
(UV) y otras radiaciones que pueden dañar la piel
y los ojos. El metal caliente causa quemaduras. EL
entrenamiento en el uso propio de los equipos y
sus procesos es esencial para prevenir accidentes.
Por lo tanto:
1. Utilice gafas de seguridad con protección a los lados
siempre que esté en el área de trabajo, aún cuando esté
usando careta de soldar, protector para su cara u otro
tipo de protección.
2. Use una careta que tenga el filtro correcto y lente para
proteger sus ojos, cara, cuello, y oídos de las chispas y
rayos del arco cuando se esté operando y observando las
operaciones. Alerte a todas las personas cercanas de no
mirar el arco y no exponerse a los rayos del arco eléctrico
o el metal fundido.
3. Use guantes de cuero a prueba de fuego, camisa pesada
de mangas largas, pantalón de ruedo liso, zapato alto al
tobillo, y careta de soldar con capucha para el pelo, para
proteger el cuerpo de los rayos y chispas calientes provenientes del metal fundido. En ocaciones un delantal a
prueba de fuego es necesario para protegerse del calor
radiado y las chispas.
4. Chispas y partículas de metal caliente puede alojarse en
las mangas enrolladas de la camisa , el ruedo del pantalón
o los bolsillos. Mangas y cuellos deberán mantenerse
abotonados, bolsillos al frente de la camisa deberán ser
cerrados o eliminados.
5. Proteja a otras personas de los rayos del arco y chispas
calientes con una cortina adecuada no-flamable como
división.
6. Use careta protectora además de sus gafas de seguridad
cuando esté removiendo escoria o puliendo.
9
CHOQUE ELECTRICO -- El contacto
con las partes eléctricas energizadas
y tierra puede causar daño severo o
muerte. NO use soldadura de corriente alterna (AC) en áreas húmedas,
de movimiento confinado en lugares
estrechos o si hay posibilidad de caer al suelo.
section 1sEGURIDAD
1. Asegúrese de que el chasis de la fuente de poder
esté conectado a tierra através del sistema de
electricidad primario.
2. Conecte la pieza de trabajo a un buen sistema de
tierra física.
3. Conecte el cable de retorno a la pieza de trabajo.
Cables y conductores expuestos o con malas
conexiones pueden exponer al operador u otras
personas a un choque eléctrico fatal.
4. Use el equipo solamente si está en buenas condiciones. Reemplaze cables rotos, dañados o con
conductores expuestos.
5. Mantenga todo seco, incluyendo su ropa, el área de
trabajo, los cables, antorchas, pinza del electrodo,
y la fuente de poder.
6. Asegúrese que todas las partes de su cuerpo están
insuladas de ambos, la pieza de trabajo y tierra.
7. No se pare directamente sobre metal o tierra mientras trabaja en lugares estrechos o áreas húmedas;
trabaje sobre un pedazo de madera seco o una
plataforma insulada y use zapatos con suela de
goma.
8. Use guantes secos y sin agujeros antes de energizar
el equipo.
9. Apage el equipo antes de quitarse sus guantes.
10. Use como referencia la publicación ANSI/ASC
Standard Z49.1 (listado en la próxima página) para
recomendaciones específicas de como conectar el
equipo a tierra. No confunda el cable de soldar a
la pieza de trabajo con el cable a tierra.
3.Los soldadores deberán usar los siguientes procedimientos para minimizar exponerse al EMF:
A.Mantenga el electrodo y el cable a la pieza de
trabajo juntos, hasta llegar a la pieza que usted
quiere soldar. Asegúrelos uno junto al otro con
cinta adhesiva cuando sea posible.
B. Nunca envuelva los cables de soldar alrededor
de su cuerpo.
C.Nunca ubique su cuerpo entre la antorcha y el
cable, a la pieza de trabajo. Mantega los cables a
un sólo lado de su cuerpo.
D.Conecte el cable de trabajo a la pieza de trabajo
lo más cercano posible al área de la soldadura.
E. Mantenga la fuente de poder y los cables de soldar
lo más lejos posible de su cuerpo.
HUMO Y GASES -- El humo y los
gases, pueden causar malestar o
daño, particularmente en espacios
sin ventilación. No inhale el humo
o gases. El gas de protección puede
causar falta de oxígeno. Por lo tanto:
1. Siempre provea ventilación adecuada en el área
de trabajo por medio natural o mecánico. No solde,
corte, o ranure materiales con hierro galvanizado,
acero inoxidable, cobre, zinc, plomo, berílio, o cadmio a menos que provea ventilación mecánica
positiva . No respire los gases producidos por
estos materiales.
2. No opere cerca de lugares donde se aplique substancias químicas en aerosol. El calor de los rayos
del arco pueden reaccionar con los vapores de
hidrocarburo clorinado para formar un fosfógeno,
o gas tóxico, y otros irritant es.
3. Si momentáneamente desarrolla inrritación de
ojos, nariz o garganta mientras est á operando, es
indicación de que la ventilación no es apropiada.
Pare de trabajar y tome las medidas necesarias
para mejorar la ventilación en el área de trabajo.
No continúe operando si el malestar físico persiste.
4. Haga referencia a la publicación ANSI/ASC Standard
Z49.1 (Vea la lista a continuación) para recomendaciones específicas en la ventilación.
CAMPOS ELECTRICOS Y MAGNETICOS - Son peligrosos. La corriente
eléctrica fluye através de cualquier
conductor causando a nivel local
Campos Eléctricos y Magnéticos
(EMF). Las corrientes en el área de corte y soldadura,
crean EMF alrrededor de los cables de soldar y las
maquinas. Por lo tanto:
1. Soldadores u Operadores que use marca-pasos para
el corazón deberán consultar a su médico antes de
soldar. El Campo Electromagnético (EMF) puede
interferir con algunos marca-pasos.
2.Exponerse a campos electromagnéticos (EMF) puede
causar otros efectos de salud aún desconocidos.
10
section 1sEGURIDAD
5.ADVERTENCIA-- Este producto cuando se utiliza para soldaduras o cortes,
produce humos o gases, los
cuales contienen químicos conocidos por el Estado de California de causar defectos en el
nacimiento, o en algunos casos,
Cancer. (California Health &
Safety Code §25249.5 et seq.)
1. Siempre tenga personal cualificado para efectuar l a instalación, diagnóstico, y mantenimiento
del equipo. No ejecute ningún trabajo eléctrico a
menos que usted esté cualificado para hacer el
trabajo.
2. Antes de dar mantenimiento en el interior de la
fuente de poder, desconecte la fuente de poder
del suministro de electricidad primaria.
3. Mantenga los cables, cable a tierra, conexciones,
cable primario, y cualquier otra fuente de poder
en buen estado operacional. No opere ningún
equipo en malas condiciones.
4. No abuse del equipo y sus accesorios. Mantenga
el equipo lejos de cosas que generen calor como
hornos, también lugares húmedos como charcos
de agua , aceite o grasa, atmósferas corrosivas y
las inclemencias del tiempo.
5. Mantenga todos los artículos de seguridad y
coverturas del equipo en su posición y en buenas
condiciones.
6. Use el equipo sólo para el propósito que fue
diseñado. No modifique el equipo en ninguna
manera.
MANEJO DE CILINDROS-- Los
cilindros, si no son manejados
correctamente, pueden romperse y liberar violentamente
gases. Rotura repentina del
cilindro, válvula, o válvula de
escape puede causar daño o
muerte. Por lo tanto:
1. Utilize el gas apropiado para el proceso y utilize
un regulador diseñado para operar y reducir la
presión del cilindro de gas . No utilice adaptadores. Mantenga las mangueras y las conexiones
en buenas condiciones. Observe las instrucciones
de operación del manufacturero para montar el
regulador en el cilindro de gas comprimido.
INFORMACION ADICIONAL DE SEGURIDAD -- Para más información sobre las
prácticas de seguridad de los equipos de
arco eléctrico para soldar y cortar, pregunte
a su suplidor por una copia de "Precautions
and Safe Practices for Arc Welding, Cutting
and Gouging-Form 52-529.
2. Asegure siempre los cilindros en posición vertical
y amárrelos con una correa o cadena adecuada
para asegurar el cilindro al carro, transportes, tablilleros, paredes, postes, o armazón. Nunca asegure
los cilindros a la mesa de trabajo o las piezas que
son parte del circuito de soldadura . Este puede ser
parte del circuito elélectrico.
Las siguientes publicaciones, disponibles através de
la American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, son recomendadas para usted:
3. Cuando el cilindro no está en uso, mantenga la
válvula del cilindro cerrada. Ponga el capote de
protección sobre la válvula si el regulador no
está conectado. Asegure y mueva los cilindros
utilizando un carro o transporte adecuado. Evite
el manejo brusco de los
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
MANTENIMIENTO DEL EQUIPO -- Equipo
defectuoso o mal mantenido puede
causar daño o muerte. Por lo tanto:
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
11
section 1sEGURIDAD
SIGNIFICADO DE LOS sImbolOs
-- Según usted avanza en la lectura
de este folleto: Los Símbolos Significan ¡Atención! ¡Esté Alerta! Se
trata de su seguridad.
Significa riesgo inmediato que,
de no ser evadido, puede resultar
inmediatamente en serio daño
personal o la muerte.
Significa el riesgo de un peligro
potencial que puede resultar en
serio daño personal o la muerte.
Significa el posible riesgo que
puede resultar en menores daños
a la persona.
12
section 1sÉCURITÉ
1.3
Safety - French
INCENDIES ET EXPLOSIONS -- La
chaleur provenant des flammes ou de
l'arc peut provoquer un incendie. Le
laitier incandescent ou les étincelles
peuvent également provoquer un
incendie ou une explosion. Par conséquent :
AVERTISSEMENT : Ces règles de sécurité
ont pour but d'assurer votre protection. Ils
récapitulent les informations de précaution
provenant des références dans la section
des Informations de sécurité supplémentaires. Avant
de procéder à l'installation ou d'utiliser l'unité, assurezvous de lire et de suivre les précautions de sécurité cidessous, dans les manuels, les fiches d'information sur la
sécurité du matériel et sur les étiquettes, etc. Tout défaut
d'observer ces précautions de sécurité peut entraîner
des blessures graves ou mortelles.
1. Éloignez suffisamment tous les matériaux combustibles de l'aire de travail et recouvrez les matériaux
avec un revêtement protecteur ininflammable. Les
matériaux combustibles incluent le bois, les vêtements, la sciure, le gaz et les liquides combustibles,
les solvants, les peintures et les revêtements, le
papier, etc.
2. Les étincelles et les projections de métal incandescent peuvent tomber dans les fissures dans
les planchers ou dans les ouvertures des murs et
déclencher un incendie couvant à l'étage inférieur
Assurez-vous que ces ouvertures sont bien protégées
des étincelles et du métal incandescent.
3. N'exécutez pas de soudure, de coupe ou autre travail à chaud avant d'avoir complètement nettoyé la
surface de la pièce à traiter de façon à ce qu'il n'ait
aucune substance présente qui pourrait produire
des vapeurs inflammables ou toxiques. N'exécutez
pas de travail à chaud sur des contenants fermés
car ces derniers pourraient exploser.
4. Assurez-vous qu'un équipement d'extinction
d'incendie est disponible et prêt à servir, tel qu'un
tuyau d'arrosage, un seau d'eau, un seau de sable
ou un extincteur portatif. Assurez-vous d'être bien
instruit par rapport à l'usage de cet équipement.
5. Assurez-vous de ne pas excéder la capacité de
l'équipement. Par exemple, un câble de soudage
surchargé peut surchauffer et provoquer un incendie.
6. Une fois les opérations terminées, inspectez l'aire de
travail pour assurer qu'aucune étincelle ou projection de métal incandescent ne risque de provoquer
un incendie ultérieurement. Employez des guetteurs
d'incendie au besoin.
7. Pour obtenir des informations supplémentaires,
consultez le NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible au
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
PROTÉGEZ-VOUS -- Les processus de
soudage, de coupage et de gougeage
produisent un niveau de bruit élevé et
exige l'emploi d'une protection auditive. L'arc, tout
comme le soleil, émet des rayons ultraviolets en plus
d'autre rayons qui peuvent causer des blessures à la
peau et les yeux. Le métal incandescent peut causer
des brûlures. Une formation reliée à l'usage des
processus et de l'équipement est essentielle pour
prévenir les accidents. Par conséquent:
1. Portez des lunettes protectrices munies d'écrans latéraux lorsque vous êtes dans l'aire de travail, même
si vous devez porter un casque de soudeur, un écran
facial ou des lunettes étanches.
2. Portez un écran facial muni de verres filtrants et de
plaques protectrices appropriées afin de protéger
vos yeux, votre visage, votre cou et vos oreilles des
étincelles et des rayons de l'arc lors d'une opération
ou lorsque vous observez une opération. Avertissez
les personnes se trouvant à proximité de ne pas regarder l'arc et de ne pas s'exposer aux rayons de l'arc
électrique ou le métal incandescent.
3. Portez des gants ignifugiés à crispin, une chemise
épaisse à manches longues, des pantalons sans rebord
et des chaussures montantes afin de vous protéger des
rayons de l'arc, des étincelles et du métal incandescent,
en plus d'un casque de soudeur ou casquette pour
protéger vos cheveux. Il est également recommandé
de porter un tablier ininflammable afin de vous protéger des étincelles et de la chaleur par rayonnement.
4. Les étincelles et les projections de métal incandescent
risquent de se loger dans les manches retroussées,
les rebords de pantalons ou les poches. Il est recommandé de garder boutonnés le col et les manches et
de porter des vêtements sans poches en avant.
5. Protégez toute personne se trouvant à proximité des
étincelles et des rayons de l'arc à l'aide d'un rideau ou
d'une cloison ininflammable.
6. Portez des lunettes étanches par dessus vos lunettes
de sécurité lors des opérations d'écaillage ou de
meulage du laitier. Les écailles de laitier incandescent
peuvent être projetées à des distances considérables.
Les personnes se trouvant à proximité doivent également porter des lunettes étanches par dessus leur
lunettes de sécurité.
CHOC ÉLECTRIQUE -- Le contact avec
des pièces électriques ou les pièces
de mise à la terre sous tension peut
causer des blessures graves ou mortelles. NE PAS utiliser un courant de
soudage c.a. dans un endroit humide, en espace
restreint ou si un danger de chute se pose.
13
section 1sÉCURITÉ
1. Assurez-vous que le châssis de la source
d'alimentation est branché au système de mise à
la terre de l'alimentation d'entrée.
2. Branchez la pièce à traiter à une bonne mise de
terre électrique.
3. Branchez le câble de masse à la pièce à traiter et
assurez une bonne connexion afin d'éviter le risque
de choc électrique mortel.
4. Utilisez toujours un équipement correctement
entretenu. Remplacez les câbles usés ou endommagés. 5. Veillez à garder votre environnement sec, incluant
les vêtements, l'aire de travail, les câbles, le porteélectrode/torche et la source d'alimentation.
6. Assurez-vous que tout votre corps est bien isolé
de la pièce à traiter et des pièces de la mise à la
terre.
7. Si vous devez effectuer votre travail dans un espace
restreint ou humide, ne tenez vous pas directement sur le métal ou sur la terre; tenez-vous sur
des planches sèches ou une plate-forme isolée et
portez des chaussures à semelles de caoutchouc.
8. Avant de mettre l'équipement sous tension, isolez
vos mains avec des gants secs et sans trous.
9. Mettez l'équipement hors tension avant d'enlever
vos gants.
10. Consultez ANSI/ASC Standard Z49.1 (listé à
la page suivante) pour des recommandations
spécifiques concernant les procédures de mise à
la terre. Ne pas confondre le câble de masse avec
le câble de mise à la terre.
3. Les soudeurs doivent suivre les procédures suivantes
pour minimiser l'exposition aux champs électriques
et magnétiques :
A.Acheminez l'électrode et les câbles de masse
ensemble. Fixez-les à l'aide d'une bande adhésive
lorsque possible.
B. Ne jamais enrouler la torche ou le câble de masse
autour de votre corps.
C.Ne jamais vous placer entre la torche et les câbles
de masse. Acheminez tous les câbles sur le même
côté de votre corps.
D.Branchez le câble de masse à la pièce à traiter le
plus près possible de la section à souder.
E. Veillez à garder la source d'alimentation pour le
soudage et les câbles à une distance appropriée
de votre corps.
LES VAPEURS ET LES GAZ -- peuvent
causer un malaise ou des dommages
corporels, plus particulièrement
dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le
gaz de protection risque de causer
l'asphyxie. Par conséquent :
1. Assurez en permanence une ventilation adéquate
dans l'aire de travail en maintenant une ventilation naturelle ou à l'aide de moyens mécanique.
N'effectuez jamais de travaux de soudage, de
coupage ou de gougeage sur des matériaux tels que
l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc,
le plomb, le berylliym ou le cadmium en l'absence
de moyens mécaniques de ventilation efficaces. Ne
respirez pas les vapeurs de ces matériaux.
2. N'effectuez jamais de travaux à proximité d'une
opération de dégraissage ou de pulvérisation. Lorsque la chaleur
ou le rayonnement de l'arc entre en contact avec les
vapeurs d'hydrocarbure chloré, ceci peut déclencher
la formation de phosgène ou d'autres gaz irritants,
tous extrêmement toxiques.
3. Une irritation momentanée des yeux, du nez ou de la
gorge au cours d'une opération indique que la ventilation n'est pas adéquate. Cessez votre travail afin
de prendre les mesures nécessaires pour améliorer
la ventilation dans l'aire de travail. Ne poursuivez
pas l'opération si le malaise persiste.
4. Consultez ANSI/ASC Standard Z49.1 (à la page
suivante) pour des recommandations spécifiques
concernant la ventilation.
CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — comportent un risque de
danger. Le courant électrique qui
passe dans n'importe quel conducteur produit des champs électriques
et magnétiques localisés. Le soudage et le courant de coupage créent des champs électriques
et magnétiques autour des câbles de soudage et
l'équipement. Par conséquent :
1. Un soudeur ayant un stimulateur cardiaque doit
consulter son médecin avant d'entreprendre une
opération de soudage. Les champs électriques et
magnétiques peuvent causer des ennuis pour certains stimulateurs cardiaques.
2. L'exposition à des champs électriques et magnétiques peut avoir des effets néfastes inconnus pour
la santé.
14
section 1sÉCURITÉ
5.AVERTISSEMENT : Ce produit, lorsqu'il est utilisé
dans une opération de soudage ou de
coupage, dégage des vapeurs ou des
gaz contenant des chimiques considéres par l'état de la Californie comme
étant une cause des malformations
congénitales et dans certains cas, du
cancer. (California Health & Safety
Code §25249.5 et seq.)
ENTRETIEN DE L'ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou
inadéquate peut causer des blessures
graves ou mortelles. Par conséquent :
1. Efforcez-vous de toujours confier les tâches
d'installation, de dépannage et d'entretien à un
personnel qualifié. N'effectuez aucune réparation
électrique à moins d'être qualifié à cet effet.
2. Avant de procéder à une tâche d'entretien à
l'intérieur de la source d'alimentation, débranchez
l'alimentation électrique.
3. Maintenez les câbles, les fils de mise à la terre,
les branchements, le cordon d'alimentation et la
source d'alimentation en bon état. N'utilisez jamais un équipement s'il présente une défectuosité
quelconque.
4. N'utilisez pas l'équipement de façon abusive. Gardez
l'équipement à l'écart de toute source de chaleur,
notamment des fours, de l'humidité, des flaques
d'eau, de l'huile ou de la graisse, des atmosphères
corrosives et des intempéries.
5. Laissez en place tous les dispositifs de sécurité et
tous les panneaux de la console et maintenez-les
en bon état.
6. Utilisez l'équipement conformément à son usage
prévu et n'effectuez aucune modification.
MANIPULATION DES CYLINDRES -La manipulation d'un cylindre, sans
observer les précautions nécessaires,
peut produire des fissures et un
échappement dangereux des gaz.
Une brisure soudaine du cylindre, de la soupape ou
du dispositif de surpression peut causer des blessures graves ou mortelles. Par conséquent :
1. Utilisez toujours le gaz prévu pour une opération
et le détendeur approprié conçu pour utilisation
sur les cylindres de gaz comprimé. N'utilisez jamais
d'adaptateur. Maintenez en bon état les tuyaux et
les raccords. Observez les instructions d'opération
du fabricant pour assembler le détendeur sur un
cylindre de gaz comprimé.
2. Fixez les cylindres dans une position verticale, à
l'aide d'une chaîne ou une sangle, sur un chariot
manuel, un châssis de roulement, un banc, un mur,
une colonne ou un support convenable. Ne fixez
jamais un cylindre à un poste de travail ou toute autre
dispositif faisant partie d'un circuit électrique.
3. Lorsque les cylindres ne servent pas, gardez les
soupapes fermées. Si le détendeur n'est pas branché, assurez-vous que le bouchon de protection de
la soupape est bien en place. Fixez et déplacez les
cylindres à l'aide d'un chariot manuel approprié.
Toujours manipuler les cylindres avec soin.
4. Placez les cylindres à une distance appropriée
de toute source de chaleur, des étincelles et des
flammes. Ne jamais amorcer l'arc sur un cylindre.
5. Pour de l'information supplémentaire, consultez
CGA Standard P-1, "Precautions for Safe Handling
of Compressed Gases in Cylinders", mis à votre disposition par le Compressed Gas Association, 1235
Jefferson Davis Highway, Arlington, VA 22202.
INFORMATIONS SUPPLÉMENTAIRES RELATIVES À LA SÉCURITÉ -- Pour obtenir de
l'information supplémentaire sur les règles
de sécurité à observer pour l'équipement
de soudage à l'arc électrique et le coupage,
demandez un exemplaire du livret "Precautions and Safe Practices for Arc Welding,
Cutting and Gouging", Form 52-529.
Les publications suivantes sont également recommandées et mises à votre disposition par l'American Welding
Society, 550 N.W. LeJuene Road, Miami, FL 33126 :
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
15
section 1sÉCURITÉ
SIGNIFICATION DES SYMBOLES
Ce symbole, utilisé partout dans ce manuel,
signifie "Attention" ! Soyez vigilant ! Votre
sécurité est en jeu.
DANGER
Signifie un danger immédiat. La situation peut
entraîner des blessures graves ou mortelles.
AVERTISSEMENT
Signifie un danger potentiel qui peut entraîner des
blessures graves ou mortelles.
ATTENTION
Signifie un danger qui peut entraîner des blessures
corporelles mineures.
16
section 2description
2.1 General
The PowerCut is a compact, completely self-contained plasma cutting system. As shipped, the system is fully assembled and
ready to cut after being connected to input power and a source of compressed air (90-150 psi). The PowerCut 875 package
uses the heavy-duty PT-32 torch to deliver cutting power for severing materials up to 1-1/4 inch thick. Refer to the following
paragraphs for descriptions of the Powercut 875 packages available as well as performance specifications.
2.2 scope
The purpose of this manual is to provide the operator with all the information required to install and operate the PowerCut 875
plasma arc cutting package. Technical reference material is also provided to assist in troubleshooting the cutting package.
WARNING
Use only The ESAB PT-32 Plasmarc torch with this console.
Use of torches not designed for use with this console
could create an ELECTRIC SHOCK HAZARD.
2.3 Packages Available
2.3.1 Manual Cutting Packages
PowerCut 875 packages listed on the front cover and below, includes the following components:
PT-32 Torch, 75o head, 25’ (7.6m)................................................................................................................................................0558001971
PT-32 Torch, 75o head, 50’ (15.2m) ............................................................................................................................................0558001972
PT-32 Spare Parts Kit (see Table 2-1)..........................................................................................................................................0558002822
PowerCut 875 Console/Power Source..........................................................................................................................................See below
Depending on the choice of input power, each package includes the following appropriate Powercut 875 Console/Power
Source:
208/230 V, 50/60 Hz, 1 or 3-phase......................................................................................................................................P/N 0558002190
460 V, 50/60 Hz, 3-phase.......................................................................................................................................................P/N 0558002191
575 V, 60 Hz, 3-Phase..............................................................................................................................................................P/N 0558002923
PowerCut 875 Manual Cutting Packages:
208/230 V, 25’ (7.6m) Package.............................................................................................................................................P/N 0558002787
208/230 V, 50’ (15.2m) Package...........................................................................................................................................P/N 0558002788
460 V, 25’ (7.6m) Package......................................................................................................................................................P/N 0558002789
460 V, 50’ (15.2m) Package....................................................................................................................................................P/N 0558002790
575 V, 25’ (7.6m) Package......................................................................................................................................................P/N 0558002927
Table 2-1. PT-32 Spare Parts Kit, P/N 0558002822, Contents
Quantity
Part Number
Description
4
0558002618
50-70 Amp Nozzle
1
0558002908
40 Amp Nozzle
3
0558001969
Electrode
2
0558001957
Heat Shield
1
0558001959
Valve Pin
1
0558002393
Stand Off Guide
1
19129
Wrench
1
17672
Lubricant
17
section 2description
2.4 Specifications
Table 2-2. Powercut 875 Specifications
Rated
Output
60% Duty Cycle*
60 A @ 100 V dc
100% Duty Cycle*
50 A @ 104 V dc
Output Current Range
20 to 60 Amperes
Open Circuit Voltage
275 V dc
Rated Primary Input
@
7.2 kW Max. Output Power
60 A @ 120 Vdc
208/230 V ac, 50/60 Hz, 3-phase
26/24 A/phase
208/230 V ac, 50/60 Hz, 1-phase
55/49 A
460 V ac, 50/60 Hz, 3-phase
11 A/phase
575 V ac, 50/60 Hz, 3-phase
9 A/phase
Power Factor @ 60 Amperes Output
74% (208/230 V, 1-phase)
90% (208/230 V, 3-phase)
92% (460 & 575 V, 3-phase)
Efficiency @ 60 Amperes Output
90% Typical
Current Capacity
PT-32
80 A DCSP
Air Requirements
PT-32
320 cfh @ 75 psig
(151 l/min @ 5.2 bars)
Dimensions
Length
30.3” (770 mm)
Height
16.5” (419 mm)
Width
w/o opt. storage
12.5” (318 mm)
w/ opt. torch storage
15.5” (394 mm)
Weight of Powercut 875 System
87 lbs (39.5 kg)
Shipping Weight
112 lbs (51 kg)
*Duty cycle is based on a 10-minute period; therefore, a 60-percent duty cycle means the power source may operate for 6 minutes with a cool down period of 4 minutes and a 100-percent duty cycle means the power source may operate continuously.
18
section 2description
Table 2-3. PT-32 Torch Specifications
Current Capacity (100% Duty)
Length of Service Lines
Weight
25’ (7.6m)
50’ (15.2m)
90 A DCSP
25 ft. or 50 ft.
3.031"
(77mm)
75°
5.2 lbs (2.4kg)
9.6 lbs (4.4 kg)
1.16"
(27mm)
Figure 2-1. PT-32 Dimensions
PT-32 CUTTING SPEEDS
AIR @ 70 PSI and OUTPUT CURRENT 40AMPS
Material
Thickness (In.)
Cutting
Speed (IPM)
Carbon Steel
1/16
1/8
1/4
3/8
1/2
200
98
36
18
11
Stainless Steel
1/16
1/8
1/4
3/8
1/2
138
58
18
10
6
Aluminum
1/16
1/8
1/4
3/8
1/2
200
110
48
17
14
IMPORTANT!!!
Maintain Proper
Stand-Off Distance
3/16 to 1/4 Inch
Figure 2-2. PT-32/Powercut 875 Cutting Performance
Power Output increases with Stand Off Distance!
Figure 2-3. PT-32/Powercut 875 Cutting Performance
19
section 2description
2.5 OPTIONAL ACCESSORIES
1. Torch Wrap/Spare Parts Kit Holder, P/N 0558003013
Units can be mounted to either side of machine using the two upper mounting positions of the end cap handles.
2. Wheel Cart, P/N 0558003014
This 3 7/8" high cart has front and rear heavy duty swivel caster to make it easier to roll the Powercut 875 around the
job site.
20
section 3installation
3.1 General
Proper installation is important for satisfactory and trouble-free operation of the PowerCut 875 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 360 cfh at 75 psig is required for the cutting operation. The air supply should not exceed
150 psig (the maximum inlet pressure rating of the air filter-regulator supplied with the package). A Brass 45° 1/4" NPT Female
x 1/4" NPT Male Street Elbow is recommended for attaching the air hose to the regulator . This elbow will provide greater
clearance around the handle. (See Figure 6-7 on Page 47) for ordering information or obtain from a Hardware Supplier.
3.3 Location
Adequate ventilation is necessary to provide proper cooling of the PowerCut 875. 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 875 power source and wall or any other obstruction to allow freedom of air movement through the power
source.
WARNING
Installing or placing any type of filtering device will restrict the volume of intake air, thereby subjecting the
power source internal components to overheating. The
warranty is void if any type of filter device is used.
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 875. 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.
WARNING
ELECTRIC SHOCK CAN KILL! Precautionary measures should
be taken to provide maximum protection against electrical 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.
21
section 3installation
3.5 Primary Electrical Input Connections (Figure 3-1)
The PowerCut 875 consoles are equipped with a 10 ft (3.0 m), 4-conductor input power cable for 3-phase connection. If
single-phase connection is desired, tape back the red wire on the input power cable.
NOTE: The 208/230 V models are equipped with a plug for single-phase connection only. The plug is mounted to a 4-conductor
cable. If 3-phase connection is desired, remove and discard the plug and proceed as described above.
caution
Be sure that the power source is properly configured for
your input power supply. DO NOT connect a power source
configured for 208/230 V to a 460 V input power supply. Damage to the machine may occur.
NOTE: If using 200(208) V input power, the PowerCut 875 must be reconnected for 200 V use as directed in Section 3.7 and Fig.
3-2.
A line (wall) disconnect switch with fuses or circuit breakers should be provided at the main power panel (see Fig. 3-1 and
Table 3-1 for fuse sizes). The input power cable of the console may be connected directly to the disconnect switch or you
may purchase a proper plug and receptacle from a local electrical supplier. If using plug/receptacle combination, see Table
3-1 for recommended input conductors for connecting receptacle to line disconnect switch.
WARNING
The chassis must be connected to an approved electrical
ground. Failure to do so may result in electrical shock,
severe burns or death.
Table 3-1. Recommended Sizes For
Input Conductors and Line Fuses
Input Requirements
Volts
PhaseAmps
Input & Gnd
Fuse
Conductor
Size
208
208
230
230
460
575
1
3
1
3
3
3
CU/AWGAmps
55A
26A/Ph.
49A
24A/Ph.
11
9
6
6
6
6
10
10
22
80
50
80
50
25
20
section 3installation
3.6 SECONDARY (OUTPUT) CONNECTIONS (Refer to Fig. 3-1)
1. For operator safety, the torch connections are located on the output terminal board behind the lower portion of the
front panel. Remove access cover to output terminal compartment from lower front panel of power source.
2. Thread the power cable, pilot arc cable and switch lead of the PT-32 through the open bushing of the cover. Connect
power cable to the torch fitting (left-hand threads); attach the pilot arc cable connection to the Pilot Arc bulkhead
adaptor; and plug in the switch lead to the torch switch receptacle on the output terminal. Make sure the power and
pilot arc cable connections are wrench-tight. Make sure plug of switch lead is firmly inserted in place.
3. Reassemble the access cover to the power source.
4. Connect your air supply to the inlet connection of the filter-regulator.
5. Clamp the work cable to the workpiece. Be sure the workpiece is connected to an approved earth ground with a properly
sized ground cable.
WARNING
Before making any connections to the power source output terminals, make sure that all primary input power to
the power source is deenergized (off) at the main disconnect switch and that the input power cable is unplugged.
23
section 3installation
Allow at least 10 ft. (3m)
between work and power source
WORK
SAFETY GROUND
ACCESS COVER FOR
TORCH CONNECTION
ACCESS FOR CNC INTERFACE CONNECTIONS.
(See Detail “A”)
Use a Brass 45° 1/4" NPT Female x 1/4" NPT
Male Street Elbow for better clearance around
the handle.
PT-32
Prefiltered AIR SUPPLY
(Customer Supplied)
(90 to 150 psig max)
CUSTOMER FUSED LINE DISCONNECT
SWITCH (See Table 3.1 and WARNING
in regards to chassis ground in Section
3.5.)
INPUT POWER CABLE
(See Table 3.1)
NOTE: The 208/230 V models are equipped with a plug for
single-phase connection only. The plug is mounted to
a 4-conductor cable. If 3-phase connection is desired,
remove and discard the plug and refer to Sect. 3.5.
Figure 3-1. PowerCut 875 Interconnection Diagram
24
section 3installation
3.7 Connecting PowerCut 875 for 200(208) Vac Input
The PowerCut 875 power source with 200/230 vac, 1-phase input capability is factory set for 230 vac input. If using 200(208)
vac input, the PowerCut 875 must be reconnected as follows before connecting to your input power:
1. Remove rear handle, slide left side panel out.
2. Locate the Input Bridge (IBR) and TB5 terminal block (see Fig. 1) on the left side towards the rear panel. Disconnect the
gray lead from TB5-2 and then connect it to TB5-1. (See Diagram on inside of lower panel).
3. Locate the output bridge (D1) on left side towards the front panel (see Fig. 2). Disconnect and swap leads X2 and X3
from the main transformer. For 200(208) vac input, X2 is connected to TB3 and X3 is connected to terminal 3 of D1.
Make sure the connections are firmly tightened.
4. Leave all other wires the same.
5. Reinstall cover and connect the PowerCut 875 to 208 vac input power.
ELECTRIC SHOCK CAN KILL! Precautionary measures should
be taken to provide maximum protection against electrical 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 200(208) VAC Input.
WARNING
Fig. 3-2a
Fig. 3-2b
GRY
TB5
(IBR)
INPUT
BRIDGE
R
FROM MAIN TRANSFORMER
X3
R2
BLK
+
BLK
GRY
S G
T +
OUTPUT BRIDGE
(D1)
~
1
~
2
~3
Figure 3-2. Original Factory Setup for 230 Vac Input on
Power Source with 200/230 Vac Input Power Capability
25
X1
TB3
X2
section 3installation
26
section 4
operation
4.1 Operation
4.2 PowerCut 875 CONTROLS (FIGURE 4-1)
A.
Power Switch (located on rear panel). When placed in ON position, the white pilot light will glow indicating control
circuit is energized and the cooling fan will run.
B.Output Current Control. Adjustable from 20 to 60 amperes.
C.Air Test Switch/Air Regulator. When placed in Test position, air filter-regulator can be adjusted to desired pressure
(65-75 psig) before cutting operations. Allow air to flow for a few minutes. This should remove any condensation that
may have accumulated during shutdown period. Be sure to place switch in OPERATE position before starting cutting
operations.
D.
Trigger Lock Switch. When placed in LOCK position, this permits releasing 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 UNLOCK position, torch switch must be held closed by the operator during the entire cutting
operation and then released at the end of cut.
E.
Fault Light. (see label illustration below) Will glow amber under the following conditions and operations will come
to a complete stop.
Flow Fault: The fault light will be mostly on but will flick off for about 1/10th of a second every second. This indicates
that the air flow supply is low or has no back pressure.
Over Temperature: The fault light will be mostly off but will flick on for about 1/10th of a second every second. This
indicates that the duty cycle has been exceeded. Allow the power source to cool down before returning to operate.
High/Low Line Voltage: The fault light will rapidly blink on and off (five times per second). This indicates that the
input voltage is outside the “+ or -” 15% range of the input rating.
Over-Current: The fault light will be on continuously. This indicates that input current has been exceeded.
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 off for 5 seconds and then turned back on.
F.Air Pressure Gauge: Recommended air pressure should be set to 70 psi.
27
section 4
operation
FAULT LIGHT
(AMBER)
POWER LIGHT
(WHITE)
FUSE (3A)
AIR REGULATOR
CONTROL KNOB
CURRENT
CONTROL
KNOB
AIR
PRESSURE
GAUGE
POWER ON-OFF
(I-O) SWITCH
AIR TEST
SWITCH
TRIGGER LOCK
SWITCH
Figure 4-1. PowerCut 875 Controls
WARNING
caution
ELECTRIC SHOCK can kill.
• Do NOT operate the unit with the cover removed.
• 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.
Position the PowerCut 875 at least 10 feet (3 meters) from the
cutting area. Sparks and hot slag from the cutting operation can damage the unit.
4.3 Cutting with the PT-32
WARNING
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
• Wear welding helmet with No. 6 or 7 lens shade.
• Wear eye, ear, and body protection.
Use the following procedures to cut with the PT-32 torch (Figure 4-5).
A.
Hold the torch nozzle approximately 1/8 to 3/16 inch above the work and tilted at about 15 - 30°. This reduces the chance
of spatter entering the nozzle. If the PT-32's standoff tool (P/N 0558002393) is being used, the difference between the
electrode and workpiece is approximately 3/16-inch.
B.
Depress the torch switch. Air should flow from the torch nozzle.
28
section 4
operation
CUT
DIRECTION
Figure 4-2. Recommended Torch Angle of
5° to 15°
F.
C.
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 mode, torch switch may be released
after establishing the cutting arc.)
D.
After starting the cut, the torch should be maintained at a 5-15°
forward angle (Figure 4-2). This angle is especially useful in helping
to create a "drop" cut. When not using the standoff guide, the nozzle
should be held approximately 1/4 inch from the work.
E.
When ending a cut, the torch switch should be released (press and
release if using trigger LOCK mode) and lifted off the workpiece just
before the end of the cut. This is to prevent the high frequency from
reigniting after cutting arc extinguishes and causing damage to the
nozzle (double arcing).
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.
caution
REPLACE ELECTRODE BEFORE PITTING BECOMES DEEPER THAN .06
INCH (1.5 MM)
NEW
Replace when eroded beyond
.06"(1.5mm) Depth.
WORN
Figure 4-3. Electrode Wear Limit
NOTE: When replacing the nozzle, always inspect the electrode for wear. If more than .06" of electrode Hafnium has eroded,
replace the electrode. 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. Refer to Figure
4-3.
4.3.1. Drag Cutting with the PT-32/PowerCut 875 System
If dragging cutting is desired, attach ESAB's standoff guide (P/N 0558002393). Then follow steps in Section 4.3. If drag
cutting is desired for thin material, under 3/8", remove 70 amp nozzle from torch head, insert ESAB's 40 amp nozzle (P/N
0558002908). Lower current level to 40 amps or lower, (see Auto Drag Scale on front panel). Then follow steps in Section 4.3.
Also refer to PT-32 Instruction Manual No. F-15-440.
29
section 4
operation
Drag cutting, even with lower current levels may significantly reduce the life of torch
consumables. Attempting to Drag Cut with higher currents (70 amps) may cause immediate
catastrophic consumable damage.
NOTICE
ADJUST GUIDE BY TURNING
IN A CLOCKWISE DIRECTION
ONLY. THIS WILL PREVENT
ACCIDENTAL LOOSENING
OF SHIELD.
STEEL GUARD
STAND OFF GUIDE
P/N 0558002393
IF GUIDE IS TOO TIGHT ON
SHIELD, OPEN SLOT WITH
SCREWDRIVER.
GUIDE AGAINST
STRAIGHT EDGE
OR FREE-HAND
CUT
THIN GAUGE MATERIALS
CAN BE CUT WITH 1/16" (1.6 mm)
TORCH-TO-WORK DISTANCE
ADJUST TO 3/16" (4.8 mm) FOR
MATERIALS OVER 1/4" (6.4 mm) THICK
1/16" (1.6 mm) TO
1/4" (6.4 mm)
TORCH-TO-WORK
Figure 4-4. Installation and Operation of Steel Heat Shield Guards
30
IF TOO LOOSE, CLOSE
SLOT WITH VISE OR
LARGE PLIERS.
section 4
operation
2
1
WHEN THE ARC BREAKS
THROUGH THE WORK, BRING
THE TORCH TO AN UPRIGHT POSITION AND PROCEED TO CUT.
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-32
4.4 Common Cutting Problems
Listed below are common cutting problems followed by the probable cause of each. If problems are determined to be
caused by the PowerCut 875, refer to the maintenance section of this manual. If the problem is not corrected after referring
to the maintenance section, contact your ESAB distributor.
A. Insufficient Penetration.
E.Uneven Arc.
1.
2.
3.
4.
5.
Current too low.
Cutting speed too fast.
Damaged cutting nozzle.
Improper air pressure.
Low air flow rate.
1. Damaged cutting nozzle or worn electrode.
F.Unstable Cutting Conditions.
B. Main Arc Extinguishes.
G. Main Arc Does Not Strike.
1. Cutting speed too slow.
2. Worn electrode.
C. Dross Formation. (In some materials and thicknesses,
it may be impossible to get dross-free cuts.)
1.
2.
3.
4.
5.
Current too low.
Cutting speed too fast or too slow.
Improper air pressure.
Faulty nozzle or electrode.
Low air flow rate.
1.
2.
3.
4.
1. Worn electrode.
2. Loose connections.
3. Worn cable not attached.
H. Poor Consumable Life.
D. Double Arcing. (Damaged Nozzle Orifice.)
1. Incorrect cutting speed.
2. Loose cable or hose connections.
3. Electrode and/or cutting nozzle in poor condition.
Low air pressure.
Damaged cutting nozzle.
Loose cutting nozzle.
Heavy spatter accumulation on nozzle.
31
1. Improper gas pressure.
2. Contaminated air supply.
3. Low air flow rate.
section 4
operation
32
section 5maintenance
5.1 General
If this equipment does not operate properly, stop work immediately and investigate the cause of the malfunction. Maintenance work must be performed by an experienced person, and electrical work by a trained electrician. Do not permit
untrained persons to inspect, clean, or repair this equipment. Use only recommended replacement parts.
WARNING
Be sure that the wall disconnect switch or wall circuit
breaker is open before attempting any inspection or work
inside of the PowerCut 875.
5.2 Inspection and Cleaning
Frequent inspection and cleaning of the PowerCut 875 is recommended for safety and proper operation. Some suggestions
for inspecting and cleaning are as follows:
A.
B.
C.
D.
E.
F.
G.
Check work cable for secured connection to workpiece.
Check safety earth ground at workpiece and at power source chassis.
Check heat shield on torch. It should be replaced if damaged.
Check the torch electrode and cutting nozzle for wear on a daily basis. Remove spatter or replace if necessary.
Make sure cable and hoses are not damaged or kinked.
Make sure all plugs, fittings, and ground connections are tight.
With all input power disconnected, and wearing proper eye and face protection, blow out the inside of the PowerCut
875 using low-pressure dry compressed air.
H.
Occasionally, bleed all water from the filter beneath the air filter-regulator.
caution
Water or oil occasionally accumulates in compressed air lines. Be
sure to direct the first blast of air away from the equipment to avoid
damage to the PowerCut 875.
NOTE:
Schematics and Wiring Diagrams on 279.4mm x 431.8mm
(11” x 17”) paper are included inside the back cover of this manual.
33
section 5maintenance
5.3 PT-32 Torch Consumable Parts
To assemble the consumable parts, refer to Figure 5-1.
A. Place nozzle, swirl baffle, electrode, and valve pin into the shield as shown.
B. Thread assembly to the torch body and hand tighten. Always make sure the shield is very tight before cutting.
WARNING
WARNING
Make sure power switch on PowerCut 875 is in OFF position
before working on the torch.
The PT-32 torch head contains a gas flow check valve that
acts in conjunction with the flow switch and circuitry
within the power source. This system prevents the torch
from being energized with high voltage if the torch switch
is accidentally closed when the shield is removed. Always
replace torch with the proper torch manufactured by
ESAB since it alone contains ESAB's patented safety interlock.
PLACE THE VALVE PIN INTO THE ELECTRODE AND
SCREW THE ELECTRODE INTO THE TORCH HEAD
AND TIGHTEN SECURELY WITH WRENCH #19120.
1
* VALVE PIN
2
ELECTRODE
NOZZLE
SHIELD
PLACE NOZZLE INTO HEAT
SHIELD AND THREAD
THIS ASSEMBLY TO THE
TORCH BODY AND HAND
TIGHTEN.
IMPORTANT!
MAKE SHIELD VERY TIGHT!
valve pin is a crucial member of the system. Its function is to open the gas flow check valve that
* The
is permanently assembled within the torch head. If the pin is not correctly placed in the electrode,
the valve will not open and the system will not function. The valve pin also improves electrode
cooling by increasing the velocity of air over the inner surface of the electrode.
Figure 5-1. Assembly of PT-32 Torch Front End Parts
34
3
section 5maintenance
5.4
IGBT Handling & Replacement
Since IGBT gates are insulated from any other conducting region, care should be taken to prevent static build up, which
could possibly damage gate oxides. All IGBT modules are shipped from the factory with conductive foam contacting the
gate and emitter sense pins.
Always ground parts touching gate pins during installation. In general, standard ESD predictions application to FETs should
be followed.
Other handling precautions that should also be observed are as follows:
•
•
•
•
Use grounded work station with grounded floors and grounded wrist straps when handling devices.
Use a 100W resistor in series with the gate when performing curve tracer tests.
Never install devices into systems with power connected to the system.
Use soldering irons with grounded tips when soldering to gate terminals.
When mounting IGBT modules on a heatsink, certain precautions should be taken to prevent any damage against a sudden
torque. If a sudden torque (“one-sided tightening”) is applied at only one mounting terminal the ceramic insulation plate or
silicon chip inside the module may get damaged.
The mounting screws are to be fastened in the order shown in Figure 5-2. Also, care must be taken to achieve maximum
contact (i.e. minimum contact thermal resistance) for the best heat dissipation.
Application of a thermal pad on the contact surface improves it thermal conductivity. See Replacement Parts section for
the required pad.
A torque wrench should be used. Tighten mounting screws to 28 in-lbs; wire connecting screws to 19 in-lbs. If torque is too
heavy, the device can damage like the above “one-sided tightening”.

Four-Point Mounting Type
Temporary tightening  
Final tightening  
Two-Point Mounting Type
Temporary tightening  
Final tightening  





Figure 5-2. Screw Fastening Order
35
section 5maintenance
5.5
Troubleshooting
Check the problem against the symptoms in the following troubleshooting guide. The remedy may be quite simple. If the
cause cannot be quickly located, shut off the input power, open up the unit, and perform a simple visual inspection of all the
components and wiring. Check for secure terminal connections, loose or burned wiring or components, bulged or leaking
capacitors, or any other sign of damage or discoloration.
The cause of control malfunctions can be found by referring to the sequence of operations and electrical schematic diagram
(Figure 5-1) and checking the various components. A volt-ohmmeter will be necessary for some of these checks.
WARNING
ELECTRIC SHOCK CAN KILL! Be sure that all primary power to
the machine has been externally disconnected. Open the
line (wall) disconnect switch or circuit breaker before attempting inspection or work inside of the power source.
WARNING
Voltages in plasma cutting equipment are high enough
to cause serious injury or possibly death. Be particularly
careful around equipment when the covers are removed.
NOTE: Before checking voltages in the circuit, disconnect the power from the high frequency generator to avoid damaging your voltmeter.
5.6
Troubleshooting GUIDE
A. Power Light (PL1) does not come on.
1. Visually inspect the machine for any damage.
2. Check if the cooling fan is running. If not, then check the following :
a. Check if the machine power cord is plugged to the input power receptacle.
b. Measure the input power at the receptacle. If not present, then check the wall disconnect switch and it’s fuses.
c. Check Fuse (F1). If fuse is ok, then check the input circuit breaker (CB1) for proper operation. Replace if defective.
3. If above items check OK , the problem is internal. Send unit to an Authorized Repair Station for repair.
a. If the cooling fan is running, then measure voltage between pins P2-11 and P2-14 of the control board
(should be 115 VAC). If there is no voltage, then replace transformer T2.
b. If the voltage is present, then the pilot light may be burnt out.
B. No Air Flow
1. Check air inlet supply. Unit requires 360 CFH at 75 psig.
2. Check air hose and connections. Tighten if leaking.
3. Does air flow when “air test” switch is in test position?
a. If not, check torch consumables, replace if necessary.
b. If above items check OK , the problem is internal. Take unit to an Authorized Repair Station for repair.
36
section 5maintenance
C. The Power light is on, but nothing happens when the torch switch is depressed. Fault light does not
activate.
NOTE: Unplug high frequency connection before attempting to work on this problem.
1. Check the Pilot Arc fuse (F2) located on the rear panel. An open fuse will indicate a short in the torch. If the fuse is all
right, then check the following:
a. With the machine power on, depress the torch switch. On the control board the LED 1 should be lit as long as the
switch is depressed. If not then check:
i.
Turn power off to the machine. Unplug Control board. Put an ohmmeter across P5-1 and P5-2 to take resistance reading. Depress torch switch. Meter should read a short. If not, then one of the following is not working properly:
ii. Torch switch or the leads. Unplug the torch switch leads at the machine. Put a meter across the two plug
pins. Should read a short when the torch switch is depressed. If not, then either broken switch leads or malfunctioning switch.
b. Check T2 transformer secondary voltages at the plugs P1 and P2. Refer to system schematic. Replace the transformer if the correct secondary voltages are not present.
c. If everything above checks out all right, then the PCB1 Control Board should be replaced.
D. Fault light activates when torch switch is closed.
The Fault circuit is used to monitor conditions necessary for the safe operation of the PowerCut 875. The fault light
will glow amber under the following conditions and operations will come to a complete stop:
1. High/Low line voltage. The Fault Light will rapidly blink on and off (5 times per second). This indicates that the input voltage is outside the “+” or “-” 15% safe operating range rating.
2. Flow fault - The fault light will be mostly on but will blink off for 1/10th of a second every second. This indicates that
the air flow is low or there is no flow to the pressure switch.
a. Check the air pressure at the machine regulator. It should be adjusted to 65 psig. If no air pressure, check the air
at the supply point. Also, check for any obstructions in the air hose.
b. Air flow may be blocked at the torch tip. Check the torch consumables. Also check for any obstructions in the
torch leads.
NOTE: If above items check OK, the problem is internal. Send unit to an Authorized Repair Station for repair.
c. Put the ‘Air Check’ switch to On position. Air should flow through torch. To check if the pressure switch is open,
put voltmeter leads between P1-12 and P1-1. It should read about 5 VDC. When the pressure switch closes, the
voltage will drop to zero volts.
d. Air Check switch may also be malfunctioning if the air is flowing continuously or if putting in the On position
does not turn air on.
3.Over Temperature. The fault light will be mostly off but will blink on for 1/10 of a second, every second. This generally indicates that the duty cycle has been exceeded. Allow the power source to cool before returning to operate.
a. Thermal switch may be open. It will open if the temperature at the IGBT base reaches 94°C. With the machine
power off, check the continuity between P1-1 and P1-2 of the control board. If the switch is OK, then the ohmmeter should read a direct short. If not then it should read open.
37
section 5maintenance
b. If the switch is malfunctioning, replace it. Clean the surface of the heat sink before installing the switch. 4. Over Current. The fault light will be on continuously. This indicates that the input current to the main transformer
has exceeded preset limits.
a. To check if the output is shorted, measure the resistance by putting the ohmmeter leads (make sure to disconnect HI Frequency leads):”+” of the meter to Torch “+” output terminal and Work “-” lead of the meter to the “-”
output terminal. Reading should be about 2 K Ohms. Reverse the voltmeter leads, the resistance reading should
be less than 1.5 K Ohms.
b. If the resistance reading is different than above, check the torch, the output bridge and Filter Board (PCB-5).
E.Air is On but nothing happens when torch switch is operated.
1. Check the pilot arc fuse located on the rear panel. If it is open, nothing will happen when the torch switch is depressed.
2. Check the torch. Make sure that the valve pin is installed and the heat shield is very tight.
3. Check to assure high frequency is present at the torch. If not, then listen for high frequency at the high frequency
generator. It is located on the bottom/right side of the unit. The high frequency gap is set between 0.028" to 0.031”
Disconnect HI FREQUENCY leads. Check for 115 volt supply to the high frequency unit between P2-12 & P2-13 of
the control board with torch switch closed.
4. With HI FREQUENCY leads disconnected, measure open circuit voltage. It should be 275 VDC between “Work” and
“Torch” terminals. If it is not present then any one of the following may not be working properly:
a. Check the operation of the Thermal Switch. See D.3.a. above.
b. Check Air Check switch operation. It might be stuck in On position. Pilot arc will not initiate if this switch is in the
ON position. (safety reasons)
c. Check air flow switch. There may be internal short. See D.2.c above.
d.
Measure voltage across C1 or C2 capacitor. It should be as follows:
approx. 325 VDC for the 208/230 volt unit.
approx. 280 VDC to 325 VDC for the 460 volt unit
approx. 410 VDC for the 575 volt unit
If not, one of following could be malfunctioning:
1). Check the capacitors C1 and C2 for any damage.
2.) Check input bridge/SCR Module (IBR) This can be checked without taking it out of the circuit using an
volt/ohmeter. Replace it if found malfunctioning. Follow bridge installation instructions.
3.) Check Inrush current resistor, R10 and SCR1. Both are located on the input bridge heat sink. Replace it if
malfunctioning.
e. IGBTs (2 on 230 V, and 1 on the 460 V units) may be blown. See IGBT installation procedure. Before replacing IGBTs, make sure to check the zener diodes and pico fuses on the IGBT driver boards.
38
section 5maintenance
F.High Frequency and Pilot Arc are on but Main Arc does not transfer.
1. Make sure work clamp is connected to work material.
2. Check the torch. Replace consumables if necessary.
3. Make sure the current setting potentiometer is set above 20 amps. If it is, set below 20 amps, then HI FREQUENCY
will go on and off at 5 sec intervals.
G. Poor Cutting Performance.
1. Check air supply regulator . It should be adjusted to 65-75 psig.
2. The air supplied to the torch should be free of oil and water.
3. Make sure the consumables in the torch are acceptable.
4. Check open circuit voltage. See E.4 above.
5. Check the output. Use a calibrated current probe capable of measuring 100 amps in the presence of high frequency.
H. Air does not shut off.
1. Check air test, the gas solenoid valve is energized when the switch is in the “on” position.
2. Does air flow stop when the torch switch is unplugged? If yes, check and repair the torch. If not, send unit to an Authorized Repair Station for repair.
a. Check voltage to solenoid coil, if present when torch switch is unplugged, replace PCB1. If voltage is “0”, replace
solenoid valve.
I. Main arc is difficult to start.
1.
2.
3.
4.
5.
The most common reason is worn or missing consumables. Check and replace if necessary.
Input air must be clean and dry.
Input air pressure must be at least 75 psig.
Torch connections must be tight.
Work cable and clamp must be in good condition and must make a good electrical connection to the material to be
cut.
6. If above items check OK , the problem is internal. Send unit to an Authorized Repair Station for repair.
a. Missing or weak pilot arc. Check pilot arc fuse, open circuit voltage, pilot arc resistors and pilot arc wiring.
b. Inoperative starter board (PCB-5).
39
section 5maintenance
5.7
REFERENCE VOLTAGE CHECKS
A. Control Board Assembly (PCB1)
1. LED’s
LED-1
LED-2
LED-3
- Torch Switch
- High Frequency
- Gas Solenoid Valve
2. Voltage Test Points
Tests are made with power on - no arc.
Disable High Frequency by disconnecting blue wire with black sleeve
TP-0
TP-1
TP-2
TP-3
TP-4
TP-9
TP-10
-
-
-
-
-
-
-
Ground
+15 vdc
+12 vdc
-12 vdc
+5 vdc
IGBT’s driving signal - switching frequency = 16 KHz
IGBT’s driving signal - switching frequency = 16 KHz
For 208/230 VAC input, the IGBT off time is 3msec.
For /460/ VAC input, the IGBT off time is 6msec.
Figure 5-3. IGBT Gating Signal
40
section 5maintenance
5.8
Sequence of Operation
A. TRIGGER LOCK “UNLOCK” position
TORCH SWITCH
PUSH
GAS SOLENOID VALVE
RELEASE
OPEN
2 SEC.
PREFLOW
CLOSE
10 SEC
Postflow
PRESSURE SWITCH
FAULT OVERLOAD LIGHT
HF CIRCUIT
INVERTER
CUTTING ARC (CURRENT)
CLOSE
OPEN
ENERGIZE
NOTES:
1.
When the torch switch is pushed during postflow period, the postflow and preflow times are canceled, and the
HF is energized immediately.
2.
When the amber fault light comes on, cutting operation should be stopped. The postflow time starts from the
moment the torch switch is released.
41
section 5maintenance
B.
TRIGGER LOCK "LOCK" position
TORCH SWITCH
PUSH RELEASE
PUSH
GAS SOLENOID VALVE
OPEN
RELEASE
CLOSE
PREFLOW
2 SEC.
10 SEC
Postflow
CLOSE
PRESSURE SWITCH
POSTFLOW
OPEN
FAULT LIGHT
ENERGIZE
HF CIRCUIT
INVERTER
CUTTING ARC (CURRENT)
NOTES:
1.
When the torch switch is pushed during postflow period, the postflow and preflow times are canceled, and the HF is
energized immediately.
2.
When the red fault light comes on, cutting operation should be stopped. The postflow time starts from the moment
the torch switch is released.
3.
FAULT light is on during second "turn-off" trigger only. This does not affect performance in any way.
42
section 6
replacement parts
6.0Replacement Parts
6.1General
Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on
the unit nameplate.
6.2Ordering
To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this
equipment. The use of non-ESAB parts may void your warranty.
Replacement parts may be ordered from your ESAB Distributor.
Be sure to indicate any special shipping instructions when ordering replacement parts.
Refer to the Communications Guide located on the back page of this manual for a list of customer service phone
numbers.
Note
Bill of material items that have blank part numbers are provided for customer information only.
Hardware items should be available through local sources.
43
section 6
replacement parts
44
section 6
replacement parts
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section 6
replacement parts
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section 6
replacement parts
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section 6
replacement parts
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section 6
replacement parts
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section 6
replacement parts
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section 6
replacement parts
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section 6
replacement parts
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section 6
replacement parts
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section 6
replacement parts
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revision history
1. "C" Revision - 10/2003 - Based on CN# 013326, apparently missed update when CN was released.
Updates include various changes to the Replacement Parts section and wiring / schematic diagrams have been replaced.
2. "D" Revision - 03/2004 - Based on CN# 043028. Updated Schematic 0558002486 on Page 37 to Revision B.
3. "E" Revision - 05/2005 - Based on CN# 053013. Updated Replacement Parts section, figure 6-2, added regulator filter p/n 0558005394 note. Updated format.
4. Revision 08/2005 - Made various updates per D. Smith and in replacement parts section, ADDED finger guard p/n 0558005659 per CN-053103.
5. Revision 12/2005 - Updated all rear view pics & removed regulator filter p/n 0558005394 note per D. Smith.
6. Revision 04 / 2006 - Updated entire Replacement Parts subsection per ECN #063058.
7. Revision 08/2007: Added Fault Light Indicator Chart to section 3.
8. Revision 12/2007 - Updated entire Replacement Parts subsection.
9. Revision 01 / 2008 - Updated Table 2-2, Powercut 875 Specifications in Subsection 2.4, Specifications.
55
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES
A.
CUSTOMER SERVICE QUESTIONS:
Telephone: (800)362-7080 / Fax: (800) 634-7548
Hours: 8:00 AM to 7:00 PM EST
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B.
ENGINEERING SERVICE:
Telephone: (843) 664-4416 / Fax : (800) 446-5693
Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting
C.
TECHNICAL SERVICE:
Telephone: (800) ESAB-123/ Fax: (843) 664-4452
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Hours: 8:00 AM to 5:00 PM EST
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D.
LITERATURE REQUESTS:
Telephone: (843) 664-5562 / Fax: (843) 664-5548
Hours: 7:30 AM to 4:00 PM EST
E.
WELDING EQUIPMENT REPAIRS:
Telephone: (843) 664-4487 / Fax: (843) 664-5557
Repair Estimates Repair Status
Hours: 7:30 AM to 3:30 PM EST
F.
WELDING EQUIPMENT TRAINING
Telephone: (843)664-4428 / Fax: (843) 679-5864
Training School Information and Registrations
Hours: 7:30 AM to 4:00 PM EST
G.
WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST
H.
TECHNICAL ASST. CONSUMABLES:
Telephone : (800) 933-7070
Hours: 7:30 AM to 5:00 PM EST
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123
Fax: (843) 664-4462
Hours: 7:30 AM to 5:00 PM EST
or
visit us on the web at http://www.esabna.com
The ESAB web site offers
Comprehensive Product Information
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F15-653-J
01 / 2008
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