Powercut Plasma 1600

SECTION 4
F.
OPERATION
After starting the cut, the torch should be maintained at a 5-15° forward angle. This angle is especially useful in helping
to create a "drop" cut. When not using the stand-off guide, the nozzle should be held approximately 1/8" - 1/4" (3.2
mm - 6.4 mm) from the work.
IMPORTANT!!!
Maintain Proper
Stand-Off Distance
5˚ to 15˚
Power Output increases
with Stand-off Distance!
1/8" - 1/4"
(3.2 - 6.4 mm)
CUT DIRECTION
Power Output increases with Stand Off
Distance!
Figure 4-4a. Proper Torch Angle
G.
H.
Figure 4-4b. Stand-off vs. Power Output
When ending a cut, the torch switch should be released (press and release if using TRIGGER LOCK feature) and the
torch lifted off the workpiece immediately upon completion of the cut. This is to prevent the pilot arc from re-igniting
after cutting arc extinguishes and causing 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.
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
35
SECTION 4
WARNING
OPERATION
DRAG CUTTING, EVEN WITH LOWER CURRENT LEVELS MAY SIGNIFICANTLY REDUCE THE LIFE OF TORCH CONSUMABLES. ATTEMPTING
TO DRAG CUT WITH HIGHER CURRENTS GREATER THAN 40 AMPS
MAY CAUSE IMMEDIATE CATASTROPHIC CONSUMABLE DAMAGE.
4.2.1 PT-38 Stand-off Guide
Drag Cutting with the PT-38 Torch.
If drag cutting is desired, attach ESAB's stand-off guide by removing the standard heat shield and installing the threaded
heat shield with stand-off guide.
Replace standard heat shield
with stand-off guide
Stand-off guide
Guide against
straight edge or
free-hand cut.
Figure 4-6. Installation and Operation of Stand-off Guide (PT-38 ONLY)
For thin material, under 3/8" (9 mm), insert ESAB's 40 amp nozzle, low current baffle and standard heat shield;
set current level to 40 amps and begin cutting.
Baffle
36
Electrode Nozzle
Heat Shield
SECTION 4
OPERATION
WARNING
MAKE SURE POWER SWITCH ON POWERCUT IS IN OFF POSITION BEFORE WORKING ON THE TORCH.
WARNING
THE PT-38 TORCH HEAD ACTS IN CONJUNCTION WITH THE CIRCUITRY
WITHIN THE POWER SOURCE TO PREVENT 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 SAFETY INTERLOCK.
CAUTION
REPLACE ELECTRODE BEFORE WEAR BECOMES DEEPER THAN .060"
INCH (1.5 MM)
4.3
Electrode Wear
If the electrode has a pit which is more than .06" (1.5mm) deep at its center, it must be replaced. This is done by
unscrewing the electrode in a counter-clockwise direction from the piston. 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.
WORN
NEW
Figure 4-8. Electrode Wear Limit
For in depth instructions refer to torch manual for complete maintenance and operation.
37
SECTION 4
OPERATION
38
Powercut-1300/1600
MECHANIZED PLASMARC CUTTING PACKAGE
39
40
SECTION 2
WARNING
DESCRIPTION
USE THE ESAB PT-37 PLASMARC TORCH WITH MECHANIZED CONSOLES. USE OF TORCHES NOT DESIGNED FOR USE WITH THIS CONSOLE COULD CREATE AN ELECTRIC SHOCK HAZARD.
2.0 General
The Powercut-1300/1600 is a compact, 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 /
6.2 - 10.3 bar). The Powercut package uses the heavy-duty PT-37 (Mechanized 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 specifications.
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.
41
SECTION 2
2.2
DESCRIPTION
Powercut-1300/1600 Mechanized Plasma
The Powercut-1300/1600 plasma cutting package combines the newly redesigned Powercut-1300/1600 console and PT-38
torch. The PT-37 plasma cutting torch is designed to provide increased performance and longer consumable life resulting
in higher production rates at lower costs.
Specifications: Powercut-1300
Cuts 1-1/4 in. (32 mm); severs 1-1/2 in. (38 mm)
1 ph. Input .................................................208/230 vac, 1 ph, 50/60 Hz, 74/63 A
1 ph. Output .................................................................70 amps @ 60% duty cycle
3 ph. Input .................................................208/230 vac, 3 ph, 50/60 Hz, 39/31 A
.................................................................230/460 vac, 3 ph, 50/60 Hz, 31/20 A
..................................................................................400 vac, 3ph, 50/60 Hz, 26 A
..................................................................................575 vac, 3ph, 50/60 Hz, 18 A
3 ph. Output .............................................................. 70 amps @ 100% duty cycle
Dimensions ................................................................................W = 12.7” (322 mm)
................................................................................................... H = 14.9” (379 mm)
................................................................................................... D = 27.8” (706 mm)
Weight .................................................................................................90 lbs. (40.8 kg)
Air Requirements .............................500 cfh @ 90 psig (236 l/min @ 6.2 bars)
Specifications: Powercut-1600
Cuts 1-1/2 in. (38 mm); severs 1-3/4 in. (45 mm)
1 ph. Input ..................................................................230 vac, 1 ph, 50/60 Hz, 82A
1 ph. Output .................................................................90 amps @ 40% duty cycle
3 ph. Input .................................................208/230 vac, 3 ph, 50/60 Hz, 47/41 A
.................................................................230/460 vac, 3 ph, 50/60 Hz, 41/25 A
..................................................................................400 vac, 3ph, 50/60 Hz, 28 A
..................................................................................575 vac, 3ph, 50/60 Hz, 20 A
3 ph. Output .................................................................90 amps @ 40% duty cycle
Dimensions ................................................................................W = 12.7” (322 mm)
................................................................................................... H = 14.9” (379 mm)
................................................................................................... D = 27.8” (706 mm)
Weight .................................................................................................90 lbs. (40.8 kg)
Air Requirements .............................500 cfh @ 90 psig (236 l/min @ 6.2 bars)
2.3
Package Ordering Information
The components that are included in the Powercut-1300/1600 mechanized packages may be purchased separately by using the appropriate P/N when placing orders. Individual part numbers are listed below:
Available Packages:
Powercut-1300:
208-230/460 V CNC PT-37 with rack 25 ft (7.6 m)............................................................................................................................. 0558008172
208-230/460 V CNC PT-37 w/o rack 25 ft (7.6 m) .............................................................................................................................. 0558008170
208-230/460 V CNC PT-37 with rack 50 ft (15.2 m) .......................................................................................................................... 0558008173
208-230/460 V CNC PT-37 w/o rack 50 ft (15.2 m) ........................................................................................................................... 0558008171
208-230/460 V Hand Switch PT-37 with rack 25 ft (7.6 m) ............................................................................................................ 0558008178
208-230/460 V Hand Switch PT-37 with rack 50 ft (15.2 m).......................................................................................................... 0558008179
208-230/460 V CNC PT-38 25 ft (7.6m) ................................................................................................................................................. 0558008182
208-230/460 V CNC PT-38 50 ft (15.2m)............................................................................................................................................... 0558008183
Powercut-1600:
208-230/460 V CNC PT-37 with rack 25 ft (7.6 m)............................................................................................................................. 0558008176
208-230/460 V CNC PT-37 w/o rack 25 ft (7.6 m) .............................................................................................................................. 0558008174
208-230/460 V CNC PT-37 with rack 50 ft (15.2 m) .......................................................................................................................... 0558008177
208-230/460 V CNC PT-37 w/o rack 50 ft (15.2 m) ........................................................................................................................... 0558008175
208-230/460 V CNC PT-38 25 ft (7.6m) ................................................................................................................................................. 0558008184
208-230/460 V CNC PT-38 50 ft (15.2m)............................................................................................................................................... 0558008185
208-230/460 V Hand Switch PT-37 with rack 25 ft (7.6 m) ............................................................................................................ 0558008180
208-230/460 V Hand Switch PT-37 with rack 50 ft (15.2 m).......................................................................................................... 0558008181
42
SECTION 2
DESCRIPTION
Available Consoles:
Powercut-1300:
208-230/460 V Mechanized Console .................................................................................................................................................... 0558007881
400 V CE Mechanized Console ................................................................................................................................................................ 0558007882
Powercut-1600:
208-230/460 V Mechanized Console .................................................................................................................................................... 0558007883
400 V CE Mechanized Console ................................................................................................................................................................ 0558007884
PT-37 Torches:
PT-37 Torch with rack 4.5' (1.4 m)............................................................................................................................................................ 0558004860
PT-37 Torch with rack 17' (5.2 m)............................................................................................................................................................. 0558004861
PT-37 Torch with rack 25' (7.6 m)............................................................................................................................................................. 0558004862
PT-37 Torch with rack 50' (15.2 m) .......................................................................................................................................................... 0558004863
PT-37 Torch w/o rack 4.5' (1.4 m) ............................................................................................................................................................. 0558004894
PT-37 Torch w/o rack 17' (5.2 m) .............................................................................................................................................................. 0558004895
PT-37 Torch w/o rack 25' (7.6 m) .............................................................................................................................................................. 0558004896
PT-37 Torch w/o rack 50' (15.2 m) ........................................................................................................................................................... 0558004897
WARNING
2.4
DO NOT USE OXYGEN WITH THIS TORCH! A HAZARDOUS FIRE MAY
RESULT.
PT-37 Torch Data
Powercut-1300/1600 mechanized plasma cutting packages use the PT-37 torch. For dimensions and breakdown of parts,
refer to torch manual.
43
SECTION 2
2.5
DESCRIPTION
Optional Accessories:
Torch Holder Assembly............................................................... 0558005926
Remote Hand Control Switch with 25 ft. (7.6m) lead for PT-37 ...............
........................................................................................................... 0558008349
Gas Flow Measuring Kit:
This valuable troubleshooting tool allows measurement of the actual
air gas flow through the torch ....... 19765("CE" units - 0558000739)
Powercut-1300/1600 Water Separator:
Improves air quality by removing water .................................0558007897
Powercut-1300/1600 Mechanized Conversion kit:
Adds mechanized capability to an existing manual machine .................
...................................................................................................0558007885
44
SECTION 3
WARNING
3.0
Installation
3.1
General
INSTALLATION
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.
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 filter-regulator
supplied with the package).
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.
45
SECTION 3
WARNING
3.5
INSTALLATION
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.
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 threephase operation. Single-phase duty cycle
is 60% for PC-1300 and 40% for PC-1600.
STANDARD UNITS
CE UNITS
(NON-CE)
(EUROPE)
PHASE
3
1
PHASE
3
1
L1
Black
L2
Red
Black
L1
Brown
Brown
-
L2
Black
-
L3
White
White
L3
Gray
Gray
GND
Green
Green
GND
Green/Yel
Green/Yel
CUSTOMER FUSED LINE DISCONNECT SWITCH
(See Table 3-1)
PRIMARY INPUT
POWER CABLE
Figure 3-1. Input Connections
46
SECTION 3
INSTALLATION
WARNING
ELECTRIC SHOCK CAN KILL! BEFORE MAKING ELECTRICAL INPUT CONNECTIONS TO THE POWER SOURCE, "MACHINERY LOCKOUT PROCEDURES" SHOULD BE EMPLOYED. IF THE CONNECTIONS ARE TO BE
MADE FROM A LINE DISCONNECT SWITCH, PLACE THE SWITCH IN THE
OFF POSITION AND PADLOCK IT TO PREVENT INADVERTENT TRIPPING.
IF THE CONNECTION IS MADE FROM A FUSEBOX, REMOVE THE CORRESPONDING FUSES AND PADLOCK THE BOX COVER. IF IT IS NOT POSSIBLE TO USE PADLOCKS, ATTACH A RED TAG TO THE LINE DISCONNECT
SWITCH (OR FUSE BOX) WARNING OTHERS THAT THE CIRCUIT IS BEING
WORKED ON.
WARNING
THE CHASSIS MUST BE CONNECTED TO AN APPROVED ELECTRICAL
GROUND. FAILURE TO DO SO MAY RESULT IN ELECTRICAL SHOCK, SEVERE BURNS OR DEATH.
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.
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 (three-phase) power leads and one
ground wire. The wires may be heavy rubber covered cable or may be run in a solid or flexible conduit. Refer to
Table 3-2 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
PowerCut-1600
Input & Gnd
Conductors
Line
Fuse
Volts
Phase
Amps
Cu / Awg
Amps
208
1
74
6
100
208
3
39
6
230
1
63
6
230
3
31
6
50
2
Input Requirements
Input & Gnd
Conductors
Line
Fuse
Volts
Phase
Amps
Cu / Awg
Amps
60
208
3
47
6
70
100
230
1
82
6
100
230
3
41
6
60
400
3
26
6 mm
40
400
3
28
6 mm
40
460
3
20
10
30
460
3
25
10
40
575
3
18
10
30
575
3
20
10
30
47
2
SECTION 3
INSTALLATION
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 different input voltages, it has been equipped with a 230/460
volt selector switch located on the rear panel of the unit. Switching between 230 and 460 voltages can be done
by using a flathead 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
Replace fuse with Slo-Blo, 2 Amp, 600 V only
WARNING
Pre-filtered DRY AIR SUPPLY (Customer Supplied)
(90 - 150 psig max)
(6.2 - 10.3 bars max)
MAKE SURE THE POWER
SOURCE IS SWITCHED OFF
BEFORE REMOVING FUSE.
Figure 3-2. Input Connections / Fuse Replacement
3.5.2 INPUT AIR CONNECTION
Connect your air supply to the inlet connection of the filter-regulator.
48
SECTION 3
3.6
INSTALLATION
CNC Interface Connection (Mechanized)
Power Source
CNC
START
CORNER
EXT. REF
MOTION
ALLOW
FOR
AHC
START
#13
M
M
5
START
+15 VDC
#14
N
N
4
+ 15 VDC
CORNER/EXT. REF
#5
E
E
6
CORNER/EXT. REF
ARC ON COM
#7
G
G
7 (ARC ON)
ARC ON
#9
I
I
8 (ARC ON)
VDR +
#3
C
C
RED
VDR -
#8
H
H
BLK
(+)
(-)
OPTIONAL
CURRENT REF-
#10
J
J
3
CURRENT REF+
#12
L
L
2
#4
D
D
#6
F
F
#11
K
K
FAULT
#1
A
A
9
FAULT
#2
B
B
10
SPARES
OPTIONAL
INPUT
NO
CONNECTION
Figure 3-3. Mechanical Cutting Interface Diagram
CNC Interface Connection
49
EXTERNAL
CURRENT
COMMAND
SECTION 3
3.7
INSTALLATION
SECONDARY OUTPUT CONNECTIONS FOR MECHANIZED Cutting
PT-37 Torch
Torch Cable
Clamp the work cable to
the workpiece. Be sure the
workpiece is connected
to an approved earth
ground with a properly
sized ground cable.
SAFETY GROUND
Figure 3-4. Powercut Interconnection Diagram
50
SECTION 3
WARNING
3.8
INSTALLATION
MAKE SURE POWER SWITCH ON CONSOLE IS IN OFF POSITION AND
PRIMARY INPUT POWER IS DE-ENERGIZED.
PT-37 Torch Lead Installation
1. Open torch lead access door on the front panel of the Powercut-1300/1600.
Torch Lead
Access
Door
2. Connect the power cable male receptacle to the female receptacle.
Check orientation of the sockets so as to ensure a correct fit.
Power Cable Female
Receptacle
Power Cable Male
Receptacle
3. Connect the air hose to the quick-connect fitting. Place the strain relief in the square cutout in the front of
the console. Line up the groove of the strain relief with the half square cutout area.
square cutout
strain relief
Air Hose quickconnect fitting
51
SECTION 3
INSTALLATION
4. Insert work cable into plug on the front of the console and turn
clockwise until secure.
5. Replace torch lead access door. Refer to the data in the cut data
tables, Section 4, Operation, for torch cutting parameters.
Work Cable
Torch Lead Access Door
52
SECTION 4
OPERATION
WARNING
ELECTRIC SHOCK CAN KILL.
t%0/0501&3"5&5)&6/*58*5)5)&$07&33&.07&%
t%0/05"11-:108&3505)&6/*58)*-&)0-%*/(03$"33:ING THE UNIT.
t%0/05506$)"/:503$)1"354'038"3%0'5)&503$)
HANDLE (NOZZLE, HEAT SHIELD, ELECTRODE, ETC.) WITH POWER
SWITCH ON.
4.0
Operation
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 cut gas pressure.
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.
C
A
B
Figure 4-1. Powercut 1300/1600 Controls
53
SECTION 4
D.
OPERATION
Torch Trigger / Gas Test Switch
Note:
The torch trigger positions are converted to mechanized logic on the mechanized consoles.
Cutting modes:
Normal Pilot Arc (CENTER position) - The pilot arc will not re-strike automatically. Requires a new start signal. This
setting is recommended for standard plate cutting.
Continuous Pilot Arc (DOWN position) - The pilot arc will re-strike automatically. Examples for usage of this setting
are expanded metal and grate cutting.
Test Mode:
Gas Test Switch (UP position) - The display screen will indicate air pressure reading and the air filter-regulator can
be adjusted to desired pressure 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 Normal Pilot Arc
(CENTER position) or Continuous Pilot Arc (DOWN 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
briefly 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.
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.
E
UP position
CENTER position
DOWN position
D
Toggle Switch detail
F
(Codes shown on
non -"CE" units only)
Figure 4-2. Powercut 1300/1600 Controls
54
SECTION 4
OPERATION
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 off for 5 seconds and then turned back on.
F.
Help Codes (See Section 6, Troubleshooting):
1.
2.
3.
4.
5.
6.
7.
8.
10.
11.
12.
13.
14.
Line voltage, idle +/- 15 % - line voltage has fluctuated +/- 15 %.
Line voltage, cutting +/- 20 % - line voltage has fluctuated +/- 20 %.
Control bias, +/- 15 V bias split - Control transformer supplying insuffient voltage to the control circuit.
Thermal switch - Switch opens due to excessive heat within the unit.
Pressure - Insuffient air pressure being supplied.
Fail to fire - Arc failed to transfer to workpiece.
Pilot Arc timeout (~ 5 seconds) - Cutting process did not begin within the 5 second limit.
Torch error - Improper assembly of torch consumables.
Feedback improper - current sensor may be disconnected.
Primary over-current - Converter failure.
Single phase operation, shutdown - Exceeded single phase duty cycle rating.
OCV (open circuit voltage) failure - Voltage or current not detected when test (PIP) is performed.
Ambient temperature - Make sure adequate air flow 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.
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 air was removed.
55
SECTION 4
OPERATION
WARNING
MAKE SURE POWER SWITCH ON POWERCUT IS IN OFF POSITION BEFORE WORKING ON THE TORCH.
WARNING
THE PT-37 TORCH HEAD ACTS IN CONJUNCTION WITH THE CIRCUITRY
WITHIN THE POWER SOURCE TO PREVENT 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 SAFETY INTERLOCK.
4.2
Cutting with the Powercut-1300/1600 using the PT-37 torch
A. For in depth instructions refer to torch manual for complete maintenance and operation.
B. Periodically check torch head assembly. Replace if worn or damaged.
C. Torch cable should be inspected periodically. If there are any cuts through the protective sheath or wire
insulation, replace the cable.
CAUTION
4.3
REPLACE ELECTRODE BEFORE WEAR BECOMES DEEPER THAN .060"
INCH (1.5 MM)
Electrode Wear
If the electrode has a pit which is more than .06" (1.5mm) deep at its center, it must be replaced. This is done by
unscrewing the electrode in a counter-clockwise direction from the piston. 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.
WORN
NEW
Figure 4-8. Electrode Wear Limit
56
Powercut-1300/1600
MAINTENANCE
TROUBLESHOOTING
SCHEMATIC DIAGRAMS
REPLACEMENT PARTS
57
58
SECTION 5
WARNING
5.0
MAINTENANCE
BE SURE THAT THE WALL DISCONNECT SWITCH OR WALL CIRCUIT
BREAKER IS OPEN BEFORE ATTEMPTING ANY INSPECTION OR WORK
INSIDE OF THE POWERCUT.
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.
5.1
Inspection and Cleaning
Frequent inspection and cleaning of the Powercut 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
using low-pressure dry compressed air.
WARNING
H.
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.
Occasionally, bleed all water from the filter beneath the air filter-regulator.
59
SECTION 5
5.2
MAINTENANCE
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, 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.
1. Current too low.
2. Cutting speed too fast.
3. Damaged cutting nozzle.
4. Improper air pressure.
5. Low air flow rate.
B. Main Arc Extinguishes.
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. Current too low.
2. Cutting speed too fast or too slow.
3. Improper air pressure.
4. Faulty nozzle or electrode.
5. Low air flow rate.
D. Double Arcing. (Damaged Nozzle Orifice.)
1. Low air pressure.
2. Damaged cutting nozzle.
3. Loose cutting nozzle.
4. Heavy spatter accumulation on nozzle.
E.
Uneven Arc.
1. Damaged cutting nozzle or worn electrode.
F.
Unstable Cutting Conditions.
1. Incorrect cutting speed.
2. Loose cable or hose connections.
3. Electrode and/or cutting nozzle in poor condition.
G. Main Arc Does Not Strike.
1. Worn electrode.
2. Loose connections.
3. Work cable not attached.
H. Poor Consumable Life.
1. Improper gas pressure.
2. Contaminated air supply.
3. Low air flow rate.
60
SECTION 5
5.3
MAINTENANCE
IGBT Handling
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 precautions application to FETs should
be followed.
Other handling precautions that should also be observed are as follows:
t
t
t
5.4
6TFHSPVOEFEXPSLTUBUJPOXJUIHSPVOEFEøPPSTBOEHSPVOEFEXSJTUTUSBQTXIFOIBOEMJOHEFWJDFT
6TFBΩ resistor in series with the gate when performing curve tracer tests.
/FWFSJOTUBMMEFWJDFTJOUPTZTUFNTXJUIQPXFSDPOOFDUFEUPUIFTZTUFN
Module Replacement
When mounting 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 5-1. Also, care must be taken to achieve maximum
contact (i.e. minimum contact thermal resistance) for the best heat dissipation.
Application of a thermal compound / pad on the contact surface improves its thermal conductivity. Use Dow-340 Heat Sink
Compound or equivalent. See Replacement Parts section for the required pad.
A torque wrench should be used. Tighten mounting and terminal screws per Torque Requirements shown in Subsection 7.3.
If device is over-torqued, the device can be damaged like the above “one-sided tightening”.

Two-Point Mounting Type
Initial tightening  è‚
Final tightening  ‚è

Four-Point Mounting Type
Initial tightening  è‚èƒè„
Final tightening  „èƒè‚è
ƒ
‚
„
‚
Figure 5-1 Screw Fastening Order
61
SECTION 5
MAINTENANCE
62
SECTION 6
TROUBLESHOOTING
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.
6.0
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 and checking the various components. A volt-ohmmeter will be necessary for some of these
checks.
63
SECTION 6
6.1
TROUBLESHOOTING
List of Help Codes
Code
Error
Cause
Solution
1
Line voltage, idle +/- 15 %
Supply line voltage either dropped or
exceeded nominal input setting.
Check voltage supply.
2
Line voltage, cutting +/- 20 %
Supply line voltage either dropped or
exceeded nominal input setting during
a cut.
Check voltage supply.
3
Control bias, +/- 15 V bias split
Control transformer not supplying the
proper voltage to the control circuit
Check transformer and control
board. Send unit to an Authorized
Repair Station for repair.
4
Thermal switch
Switch open - unit overheated.
Allow unit to cool down, check for
adequate ventilation.
5
Pressure
Air pressure is outside of proper range.
Check air supply and pressure setting.
6
Fail to fire
Arc did not transfer. Arc will repeatedly
"pop" out 3 consecutive times.
Check/replace consumables.
7
Pilot Arc time out (~ 5 seconds)
Pilot arc exceeded 5 second limit .
Transfer within 5 second limit.
Check ground cable.
8
Torch error
Electrode in contact with nozzle (failed
to separate).
Check/replace consumables. If
problem persists replace/repair
torch.
10
Feedback improper
Primarily seen if current sensor is
unplugged.
Check cable and connection
between current sensor board and
control board. Send unit to an Authorized Repair Station for repair.
11
Primary over-current
Converter failure.
Send unit to an Authorized Repair
Station for repair.
12
Single phase operation, shutdown
Exceeded single phase duty cycle
rating.
Operate within proper duty cycle
rating.
13
OCV (open circuit voltage)
failure
Voltage or current not detected when
test (PIP) is performed.
Send unit to an Authorized Repair
Station for repair.
14
Cabinet temperature
Too high, outside of operating limits.
Check ventilation around 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.
Check bus charger. Send unit to an
Authorized Repair Station for repair.
20
PIP (Parts in place) no retract
Piston did not retract when air applied.
Check/clean consumables.
Check air supply.
21
PIP (Parts in place) no continuity
Piston did not drop back in place when
air was removed.
Check/clean consumables. Ensure
proper installation of consumables.
64
SECTION 7
REPLACEMENT PARTS
7.0
Replacement Parts
7.1
General
Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on
the unit nameplate.
7.2
Ordering
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.
Model # P/N
DESCRIPTION
SCHEMATIC DIAGRAM
WIRING DIAGRAM
1
0558007220
PC-1300 230/460v
0558007542
0558007543
2
0558007230
PC-1600 230/460v
0558007542
0558007543
3
0558007220F
PC-1300 230/460v BL
0558007542
0558007543
4
0558007230F
PC-1600 230/460v BL
0558007542
0558007543
5
0558007881
PC-1300 Mech 230/460v
0558007542
0558007543
6
0558007883
PC-1600 Mech 230/460v
0558007542
0558007543
7
0558008320
PC-1300 460v
0558008326
0558008327
8
0558008323
PC-1600 460v
0558008326
0558008327
9
0558007227
PC-1300 575v BL
0558007544
0558007545
10
0558007237
PC-1600 575v BL
0558007544
0558007545
11
0558007634
PC-1300 400v
0558007546
0558007547
12
0558007636
PC-1600 400v
0558007546
0558007547
13
0558007224
PC-1300 400v CE
0558007546
0558007547
14
0558007234
PC-1600 400v CE
0558007546
0558007547
15
0558007882
PC-1300 Mech 400v CE
0558007546
0558007547
16
0558007884
PC-1600 Mech 400v CE
0558007546
0558007547
65
SECTION 7
7.3
REPLACEMENT PARTS
Torque Recommendations
RECOMMENDED TORQUES ( IN/LBS ±10% )
SYMBOL / DESCRIPTION
MOUNT
TERMINAL
BR101
36
44
Q101,102
36
36
Q103
25
36
D101,102
28
22
C101-104
-
25
R2,5,7,10,12,14,15
6
-
SW1
22
35
SW2
6
25 / 18
K1 (PC-1600 230/460V)
18
40
K1 (All Others)
18
18
TS1,2
12
-
HEATSINK
28
-
M1
18
-
WORK
44
44
-
44
BUSSBAR DIODE (-)
PCB2
PCB2 - TB1,2,3,4,7
PCB2 - TB8, J18, PI
PCB7
P3,20,21
P1,44
SHEETMETAL EXTRUDED
14
-
-
44
-
25
18
7
-
2.5
-
4.5
28
-
SHEETMETAL PLAIN
14
-
END CAP / HANDLE
44
-
TORCH WRAP
12
-
66
SECTION 7
7.4
REPLACEMENT PARTS
Selecting Air Pressure Units of Measure
1. Set SW1-1 dip switch for desired air pressure units of measure.
t PSI - “OPEN”
t BAR - Not Open
2. SW1-2 is not used.
3. Verify SW2 - 1,2 dip switches are in the “open” position for proper operation.
CONTROL/DISPLAY BOARD ASSEMBLY
P/N 0558038317
open
1 2
open
1 2
BAR
PSI
67
open
1 2
open
1 2
SW2-1,2
SW1-1,2
NOTES
68
REVISION HISTORY
1.
2.
3.
4.
5.
6.
Preliminary release of this manual is 05/2007.
Released FOR BETA USE ONLY 06/2007.
Released FOR BETA USE ONLY 09/2007.
Released FOR BETA USE ONLY 04/2008.
Official release 07/2008.
08/2008 - minor changes, updated replacement parts and schematics, CN #083140.
69
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES
A.
CUSTOMER SERVICE QUESTIONS:
Telephone: (800)362-7080 / Fax: (800) 634-7548
Order Entry
Product Availability
Pricing
Hours: 8:00 AM to 7:00 PM EST
Order Information Returns
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
Part Numbers
Technical Applications
Specifications
Hours: 8:00 AM to 5:00 PM EST
Equipment Recommendations
LITERATURE REQUESTS:
Telephone: (843) 664-5562 / Fax: (843) 664-5548
Hours: 7:30 AM to 4:00 PM EST
D.
E.
F.
G.
H.
WELDING EQUIPMENT REPAIRS:
Telephone: (843) 664-4487 / Fax: (843) 664-5557
Repair Estimates Repair Status
Hours: 7:30 AM to 3:30 PM EST
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
WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-123
Hours: 7:30 AM to 4:00 PM EST
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
Material Safety Data Sheets
Warranty Registration
Instruction Literature Download Library
Distributor Locator
Global Company Information
Press Releases
Customer Feedback & Support
0558007164
08/2008