ESAB | PowerCut 400 | Service manual | ESAB PowerCut 400 User manual

ESAB PowerCut 400 User manual
PowerCut™© 400
Service manual
0740 800 214 20121125
Valid for serial no.145-xxx-xxxx
0740 800 214 20121125
Valid for serial no.145-xxx-xxxx
Table of Contents
1 Read this first . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3 Mechanical design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.1 Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3 Main parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
5 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
6 Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
6.1 No power, main switch not lit, green LED not lit . . . . . . . . . . . . . . . . . . . . . 11
6.2 No power, main switch lit, green LED not lit . . . . . . . . . . . . . . . . . . . . . . . . 11
6.3 No transfer or a short pilot arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.4 PIP LED lit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.5 PIP LED blinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.6 PIP LED blinking, air pressure LED lit and no air at all . . . . . . . . . . . . . . . . 12
6.7 PIP LED blinking, air pressure LED lit and low air pressure . . . . . . . . . . . . 12
6.8 Over temperature LED blinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.9 Fault LED blinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7 Service instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
7.1 Remove the cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.2 Replace the consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.3 Replace the torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.4 Replace the control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.5 Replace the pilot arc board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.6 Replace the fan at the front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.7 Replace the fan at the rear panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.8 Replace the safety switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.9 Replace the display board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.10 Replace the solenoid valve and air sensor . . . . . . . . . . . . . . . . . . . . . . . . . 30
8 At completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
8.1 Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.2 Functional test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Rights reserved to alter specifications without notice.
bp22
1
Rights reserved to alter specifications without notice.
bp22
2
1
Read this first
This service manual is intended for use during service and repair.
Maintenance and repair must be done by an experienced person. Electrical work must
be done by a trained electrician. Use only recommended spare parts.
The wiring diagram can be used as a reference together with the section “Functional
description”. The section “Mechanical design” can be used together with the spare
parts list to identify where the parts are located.
The manual contains details of design changes that have been made up to and
including March 2012.
The PowerCut™ 400 is designed and tested in accordance with Canadian
standard CAN/CSA-E60974-1-00 and American standard UL 60974-1.
On completion of service or repair work, it is the responsibility of the person(s) doing the work to ensure that the product still complies with the
requirements of the above standard.
Note
The unit is tested by ESAB in a general set-up. The responsibility for safety and
function, of the specific set-up, lies with the integrator
CAUTION
Read and understand the instruction manual
before installing or operating.
2
Introduction
The PowerCut 400 is a complete system for manual plasma cutting. It is made for all
types of cutting within production, repair, maintenance and assembly. It can be used
on all electrically conductive materials for example mild steels, stainless steel and aluminium. It delivers cutting power for severing materials up to 0.5” (12.7 mm) thickness. The operating range is from 90 to 280 V AC
S0740 800 214/E20120330/ P34
bp22
3
© ESAB AB 2012
3
Mechanical design
3.1
Front
1
2
3
4
pc400e001
1 Control panel
2 Output current control
3 Torch connection
4 Return cable connection
3.2
Rear
1
2
4
3
pc400e002
1 Power switch ON/OFF
2 Air connection
3 Power connection
4 Side cover
S0740 800 214/E20120330/ P34
bp22
4
© ESAB AB 2012
3.3
Main parts
3
4
2
5
1
6
7
8
9
11 10
pc400e003
1 Control board
2 Pilot arc board
3 Inductors PFC
4 Display board
5 Safety switch
6 Fan, front (Fan, rear not shown in figure)
7 Solenoid valve
8 Air sensor
9 Set air regulator
10 Air regulator
11 Thermal switch control board
(The second thermal switch on the control board are not shown in figure)
S0740 800 214/E20120330/ P34
bp22
5
© ESAB AB 2012
3.4
Control panel
1
20
7
6
25
17
5
4
3
15
PowerCut™ 400
120V 15A
120V 20A
230V 20A
30
A
2
pc400e004
1 Output current control
A control to adjust cutting current from 15A to 30A. The operating range is dependent on the main power supply and the circuit breaker value. See the Primary input
voltage/Circuit breaker key. Special care should be taken to keep the cutting current
below 17A with a main power supply of 120V and a 15A circuit breaker.
2 Primary input voltage/Circuit breaker key
The key explains the yellow field on the Output current control. With a main power
supply of 120V and a 15A circuit breaker it is possible to operate within the yellow
field, 15 - 17 A.
3 Air pressure indicator
The yellow LED indicates that the air pressure is to low.
4 Fault indicator
The blinking yellow LED indicates that the safety switch for the cover is activated and
the power is automatically turned off.
5 Over temperature indicator
The blinking yellow LED indicates that the working temperature has exceeded the
normal values. The LED is turned off when the temperature has decreased to normal.
6 Parts in place (PIP) indicator
The yellow LED indicates parts-in-place error. This means that no nozzle is detected
or that the electrode is not retracting properly.
7 Power ON indicator
The green LED indicates that the power is on.
S0740 800 214/E20120330/ P34
bp22
6
© ESAB AB 2012
4
Technical Data
Mains voltage range
90 - 280 V, 1 ph, 50/60 Hz
Settings range, rated value
120 V: 15 - 25 A
230 V: 15 - 30 A
Permitted load
25% duty cycle 120 V
60% duty cycle 120 V
20% duty cycle 230 V
60% duty cycle 230 V
25 A
19 A
30 A
18 A
Power factor at maximum current
0.99
Efficiency at maximum current
75%
Open-circuit voltage U0
250 V
Operating temperature
-50 to 104 °F (-10 to 40 °C)
Transportation temperature
-68 to 131 °F (-20 to 55 °C)
Sound pressure at no load
< 43 dB (A)
Nominal flow rate
400 cfh at 80 psig
(189 l/min at 5.5 bar)
Dimensions, l × w × h
18.3” × 6.3” × 13.4”
(465 × 160 × 340 mm)
Weight including torch and return
cable
34 lbs (14.5 kg)
Insulation class transformer
H
Enclosure class
IP 23
Duty cycle:
The duty cycle refers to the time as a percentage of a ten-minute period that you can
cut at a certain load without overloading. The duty cycle is valid for 104 °F.
Enclosure class:
The IP code indicates the enclosure class, that is the degree of protection against
penetration by solid objects or water. Equipment marked IP23 is designed for indoor
and outdoor use.
S0740 800 214/E20120330/ P34
bp22
7
© ESAB AB 2012
5
Functional description
The PowerCut 400 is IGBT controlled, operating on the inverter principle. It consists of
three circuit boards, as shown in the circuit diagram. The control board is supplied with
90 - 230 V AC and controls the various functions of the power source. 230 V AC is fed
to the inductors L2, L3 that transforms it to 350 V DC. Further the 350 V DC is fed to
the transformer T1 that convert it to 90 V DC as input voltage to the torch. The control
board also supplies power to the pilot and cutting arc. 18 A and 140/150 V DC is fed
to the pilot arc. The inductor L1 stabilizes the voltage to the pilot and cutting arc. Further the control board supply power through the display board to:
•
the fans, 12 V DC
•
the solenoid valve, 15 V DC
•
the pilot arc board, 17 V DC
The two thermal switches, TERM1 and TERM2, together with the NTC sensor,
TERM3, protects the power source from overheating. They are all attached to the heatsinks on the control board. When the temperature becomes too high the welding current is interrupted and the yellow over temperature LED is lit. The thermal switches and
the NTC sensor are reset when the temperature has decreased to normal.
The display board handles the control signals to and from the power board and the pilot
arc board. The safety switch for the cover is normally closed but opens and turns off
the power if the cover is removed. The yellow fault LED blinks when the safety switch
is opened. The fans start up when the power is turned on, run at full speed for a while
and then slow down until cutting starts. The fan speed depends on the cutting current.
If over temperature is detected, the fans run at high speed until the temperature has
decreased to normal. The potentiometer (output power control) on the display board is
for adjustment of the cutting current.
The display board has LED indicators that show the status of the power unit. The green
LED indicates that the power is on. The yellow LEDs indicate different faults, see “Control panel” in section “Mechanical design”.
PowerCut 400 uses compressed air as gas for plasma. The power source is supplied
with components for air regulation and distribution. An air regulator is provided to ensure the correct air flow rate on the torch. A set air regulator can be used for pressure
adjustments. An air sensor and a solenoid valve is used for control of the air pressure
and flow. Normally the air sensor is closed. It opens when the air pressure is less than
3.5 bar. The solenoid valve is supplied with 15 V DC and normally open. It closes and
switches off the airflow if the voltage drops. An air pressure fault is indicated on the
control panel.
S0740 800 214/E20120330/ P34
bp22
8
© ESAB AB 2012
S0740 800 214/E20120330/ P34
bp22
9
© ESAB AB 2012
FAN
FAN
INDUCTOR
INDUCTOR
230V AC
12V DC
0V DC
12V DC
0V DC
SAFETY SWITCH
( COVER )
MAIN SWITCH
POWER
ON
THERMISTOR
OVER
TEMP.
FAULT
NTC SENSOR
POTENTIOMETER
AIR
PRESSURE
DISPLAY BOARD
0700 210 008
PIP
THERMISTOR
PCB CONTROL PFC
CONTROL BOARD
0700 210 014
140/150V DC
18A
90V DC
to Torch
350V DC
SOLENOID VALVE
AIR SENSOR
3,5 Bar
TORCH ON/OFF
TORCH PIP
PILOT ARC
15V DC
0V DC
SWPILOT
CPILOT
+17V DC
INDUCTOR
TRANSFORMER
PILOT ARC BOARD
0700 210 027
pc400e005
PIP
6
Fault finding
This section lists the most common symptoms and fault indications. Fault indications
are displayed on the front panel by the LEDs. Several LEDs can be active at the same
time. Remember that the yellow Fault LED always blinks when the power source is
turned on and the cover is removed.
Safety precautions
WARNING
Work on high voltage installations must be carried out by authorized personnel only.
WARNING
Personnel working with the equipment must be aware of the fact that high
voltage is present in the equipment. Parts with high voltage are not accessible during normal operation. If the cover is opened for maintenance or
other reason, parts connected to mains such as connection terminals may
be exposed.
CAUTION
Electrostatic discharge (ESD). Sensitive components such as
integrated circuits may be damaged by static electricity.
CAUTION
Use an approved antistatic wrist strap to avoid damage to sensitive components. Use the original packaging during transportation and storage of
sensitive components.
Required conditions
Make sure that the mains power supply and air supply are turned off and disconnected
when fault finding the power source.
For certain measurements it is necessary to turn on the power and air supply, make
sure that necessary safety preparations are done to avoid accidents and injury.
Use an approved antistatic wrist strap to avoid damage to sensitive components.
The accuracy of measuring instruments shall be class 2.5 as a minimum, except for
the measurement of insulation resistance, where the accuracy of the instruments is not
specified but shall be taken in account for the measurement.
The voltmeter shall have an internal resistance of at least 1Mohm.
S0740 800 214/E20120330/ P34
bp22
10
© ESAB AB 2012
6.1
No power, main switch not lit, green LED not lit
The main switch is set to ON. The main switch is not lit and the green LED on the front
panel is not lit.
1 Check the fuse/circuit breaker for the external power supply.
2 Check the external power supply.
3 Check the input cable and plug.
4 Check the main switch on the power source and the wires to the switch. Measure
between the input cables L1 and L2, see the circuit diagram in section “Functional
description”. If there is power, replace the control board, see instructions “Replace
the control board” in section “Service instructions”.
6.2
No power, main switch lit, green LED not lit
The main switch is set to ON and is lit but the green LED on the control panel is not lit.
1 Check the wires from the main switch to the control board and the flat connector between the control board and the display board.
2 If the wires and the flat connector are correct, replace the control board. See
“Replace the control board” in section “Service instructions”.
6.3
No transfer or a short pilot arc
The main switch is set to ON and the green LED is lit. No transfer or the pilot arc turns
off quickly when the torch trigger is pressed.
1 Check the return cable to the power source for damage and that it is attached
correctly to the workpiece.
2 Check the connections inside the power source.
3 If the connections are correct, replace the pilot arc board, see instructions in
“Replace the pilot arc board” in section “Service instructions”.
6.4
PIP LED lit
The green LED is lit and the PIP LED is lit.
1 Check and replace the consumables on the torch. See “Replace the consumables”
in section “Service instructions”.
6.5
PIP LED blinking
The green LED is lit and the PIP LED is blinking.
1 Check and replace the Torch. See “Replace the torch” in section “Service instructions”.
S0740 800 214/E20120330/ P34
bp22
11
© ESAB AB 2012
6.6
PIP LED blinking, air pressure LED lit and no air at all
Symptom:
The green LED is lit, the air pressure LED is lit and the PIP LED starts blinking after a
few seconds.
1 Check the external air supply.
2 Check external air hoses and connections for damage or leakage.
3 Check the air pressure and flow in the power source with a portable pressure meter.
4 Check the air hoses inside the power source for loose connections, damage and
leakage.
5 Check the air sensor. Measure the continuity over the connectors on the air sensor.
If the air sensor is open (no continuity), replace the air sensor, see instructions “Replace the solenoid valve and air sensor” in section “Service instructions”. If the air
sensor is closed (continuity), it is working.
6 Check the solenoid valve. Measure the voltage over the connectors on the solenoid
valve. The value should be 15 V DC.
If not, measure over pin 7 and 8 on the connector J3 on the display board. If there is
voltage on the display board, replace the solenoid valve, see instructions in “Replace
the solenoid valve and air sensor” in section “Service instructions”.
If there is no voltage, replace the display board, see instructions in “Replace the display board” in section “Service instructions”.
6.7
PIP LED blinking, air pressure LED lit and low air pressure
1 Check the external air supply.
2 Check external air hoses and connections for leakage, dirt or damage.
3 Measure the air flow and the air pressure. At least 23.8 gallon/m (90 l/m) and 70 psi
(4.8 bar) is required for cutting.
4 Check the air hoses inside the power source for loose connections, damage and
leakage.
5 Check the air regulator for leakage, dirt or damage.
6 Check the air sensor. Measure the continuity over the connectors on the air sensor.
If the air sensor is open (no continuity), replace the air sensor, se instructions “Replace the solenoid valve and air sensor” in section “Service instructions”. If the air
sensor is closed (continuity) it is working.
7 Check the solenoid valve. Measure the voltage over the connectors on the solenoid
valve. The value should be 15 V DC.
If not, measure over pin 7 and 8 on the connector J3 on the display board. If there is
voltage on the display board, replace the solenoid valve, see instructions in “Replace
the solenoid valve and air sensor” in section “Service instructions”.
S0740 800 214/E20120330/ P34
bp22
12
© ESAB AB 2012
If there is no voltage, replace the display board, see instructions in “Replace the display board” in section “Service instructions”.
6.8
Over temperature LED blinking
1 The duty cycle is to long. Wait for a while to let the fans cool down the equipment.
2 Does the overtemperature indication appear frequently? Check the fans. Are they
running without problems? If not, replace the faulty fan.
3 Check the thermial switches. Measure the continuity. If any of them are open replace
the faulty thermal switch. If closed they are ok.
4 Does the overtemperature indication appear frequently together with transfer problems between the pilot arc and cutting arc? Replace the pilot arc board.
6.9
Fault LED blinking
1 The fault LED indicates that the cover is removed and that the safety switch is activated. The power is turned off.
2 Check the safety switch and replace if damaged, see instructions “Replace the safety switch” in section “Service instructions”.
S0740 800 214/E20120330/ P34
bp22
13
© ESAB AB 2012
7
Service instructions
The following section describes the procedures to replace the most common parts of
the power source.
Safety precautions
WARNING
Work on high voltage installations must be carried out by authorized personnel only.
WARNING
Personnel working with the equipment must be aware of the fact that high
voltage is present in the equipment. Parts with high voltage are not accessible during normal operation. If the cover is opened for maintenance or
other reason, parts connected to mains such as connection terminals may
be exposed.
CAUTION
Electrostatic discharge (ESD). Sensitive components such as
integrated circuits may be damaged by static electricity.
CAUTION
Use an approved antistatic wrist strap to avoid damage to sensitive components. Use the original packaging during transportation and storage of
sensitive components.
Required conditions
Make sure that the power supply and the air supply are turned off and disconnected
during service on the power source.
For certain measurements it is necessary to turn on the power and air supply, make
sure that necessary safety preparations are done to avoid accidents and injury.
Use an approved antistatic wrist strap to avoid damage to sensitive components.
S0740 800 214/E20120330/ P34
bp22
14
© ESAB AB 2012
Support equipment and consumables
Support equipment and consumables needed for the replacements are listed below:
ESD equipment
Bit holder
Torx driver bits
20, 25
Hex sockets bits
6,7
Adjustable spanner
A set of shaft spanners
6, 7, 10, 13, 24
Nut driver and a set of bits
A socket wrench set
A pair of pliers
Extractor for mini-fit connectors
Crosshead screwdriver
PH2 × 100, PH0 × 75
A slotted screwdriver
Thread locker of medium strength
S0740 800 214/E20120330/ P34
bp22
15
© ESAB AB 2012
7.1
Remove the cover
2
3
pc400e018
1 Make sure that the mains power supply and air supply are turned off and
disconnected.
2 Remove the screws that hold the cover.
3 Disconnect the earth connection.
S0740 800 214/E20120330/ P34
bp22
16
© ESAB AB 2012
7.2
Replace the consumables
pctorch001
1 Make sure that the mains power supply and air supply are turned off and
disconnected.
2 Make sure that the consumables are not hot.
3 Disconnect the consumables.
4 Put the replacement consumables in position and tighten them.
5 Go to section “At completion” and follow the instructions.
S0740 800 214/E20120330/ P34
bp22
17
© ESAB AB 2012
7.3
Replace the torch
3
2
pc400e006
1 Remove the cover, see “Remove the cover”.
2 Disconnect the power and air supply connectors.
3 Disconnect the torch cable and pull it out.
4 Install the replacement torch in the reverse order.
5 Go to section “At completion” and follow the instructions.
S0740 800 214/E20120330/ P34
bp22
18
© ESAB AB 2012
7.4
Replace the control board
3
3
2
pc400e007
1 Remove the cover, see instructions in “Remove the cover”.
2 Remove the protection sheet.
3 Remove the screws on the holder.
4
4
pc400e008
4 Loosen and remove the holder.
S0740 800 214/E20120330/ P34
bp22
19
© ESAB AB 2012
5
5
pc400e009
5 Remove the screws that hold the control board.
S0740 800 214/E20120330/ P34
bp22
20
© ESAB AB 2012
9
6
7
8
pc400e010
6 Disconnect the connectors on the power switch and to the inductors.
7 Disconnect the connectors on the display board.
8 Disconnect the earth connection.
9 Lift and tilt the board carefully. Disconnect the connectors to the control board.
10 Install the replacement board in the reverse order.
11 Go to section “At completion” and follow the instructions.
S0740 800 214/E20120330/ P34
bp22
21
© ESAB AB 2012
7.5
Replace the pilot arc board
2
3
4
3
3
4
pc400e011
1 Remove the cover, see “Remove the cover”
2 Put the power source on the side.
3 Disconnect the three connectors on the pilot arc board.
4 Remove the two screws that hold the pilot arc board.
5 Install the replacement pilot arc board in the reverse order.
6 Go to section “At completion” and follow the instructions.
S0740 800 214/E20120330/ P34
bp22
22
© ESAB AB 2012
7.6
Replace the fan at the front panel
2
3
5
4
pc400e012
1 Remove the cover, see “Remove the cover”.
2 Disconnect the connectors on the display board.
3 Disconnect the torch connectors.
4 Loosen and remove the torch cable.
5 Loosen the return cable connection. Make sure that the cable can move
easily through the bushing.
S0740 800 214/E20120330/ P34
bp22
23
© ESAB AB 2012
6
7
9
8
8
9
pc400e013
6 Remove the screws that hold the front panel and remove the front panel.
7 Release the mini-fit connectors on the fan connector with an extractor.
8 Remove the two screws that hold the fan plate to the front panel.
9 Remove the two screws that hold the fan to the plate.
10 Fit the mini-fit connectors of the replacement fan into the fan connector. The red
wire connector into position 1 and the black wire connector into position 2.
11 Install the fan in the reverse order.
12 Go to section “At completion” and follow the instructions.
S0740 800 214/E20120330/ P34
bp22
24
© ESAB AB 2012
7.7
Replace the fan at the rear panel
2
3
2
4
5
5
6
pc400e014
1 Remove the cover, see “Remove the cover”.
2 Disconnect the air pressure hose.
3 Disconnect the two connectors on the power switch.
4 Disconnect the fan contact.
5 Remove the earth connection.
6 Remove the two screws that hold the rear panel and remove the rear panel.
S0740 800 214/E20120330/ P34
bp22
25
© ESAB AB 2012
7
7
7
8
10
9
9
10
pc400e015
7 Remove the nuts that hold the plate with the air regulator and the power switch.
8 Remove the plate with the air regulator and the power switch.
9 Remove the two screws that hold the fan plate to the rear panel.
10 Remove the two screws that hold the fan to the fan plate.
11 Remove the fan.
12 Install the replacement fan in the reverse order.
13 Go to section “At completion” and follow the instructions.
S0740 800 214/E20120330/ P34
bp22
26
© ESAB AB 2012
7.8
Replace the safety switch
2
3
pc400e016
1 Remove the cover, see “Remove the cover”.
2 Remove the two connectors.
3 Remove the two screws and bolts.
4 Remove the switch.
5 Install the replacement switch in the reverse order.
6 Go to section “At completion” and follow the instructions.
S0740 800 214/E20120330/ P34
bp22
27
© ESAB AB 2012
7.9
Replace the display board
2
3
pc400e019
1 Remove the cover, see “Remove the cover”.
2 Disconnect the upper connectors on the display board.
3 Remove the two screws that hold the display board to the front panel.
S0740 800 214/E20120330/ P34
bp22
28
© ESAB AB 2012
4
pc400e017
4 Remove carefully the display board and disconnect the remaining connectors.
5 Install the replacement display board in the reverse order.
6 Go to section “At completion” and follow the instructions.
S0740 800 214/E20120330/ P34
bp22
29
© ESAB AB 2012
7.10
Replace the solenoid valve and air sensor
2
3
pc400p001
1 Remove the cover, see “Remove the cover”.
2 Disconnect the air hoses and the fan connector.
3 Disconnect the connectors on the air sensor and loosen the set air regulator with
a spanner.
S0740 800 214/E20120330/ P34
bp22
30
© ESAB AB 2012
4
5
7
pc400p002
4 Remove the air sensor and solenoid assembly from the elbow fitting with two
spanners. One to loosen the assembly and one to keep one end fixed.
5 Disconnect the connectors on the inside of the solenoid valve.
6 Fasten the air sensor and the solenoid valve assembly in a vice.
7 Loosen and replace the applicable part.
8 Inspect and make sure that the parts are clean before installation.
9 Put a small amount of thread locker on the threads and assemble the parts.
10 Make sure that the connections are tightly fitted.
11 Install the assembly in the reverse order.
12 Go to section “At completion” and follow the instructions.
S0740 800 214/E20120330/ P34
bp22
31
© ESAB AB 2012
8
At completion
After repair, inspection and test
Inspection and test shall be done after repair according to manufacturers instructions
and local regulations. They are:
•
Visual inspection
•
Functional test
General requirements
Test of plasma cutting power sources can be hazardous and shall be done by an expert in the field of electrical repair, preferably also familiar with plasma cutting, welding
and allied processes.
Test shall be done at an ambient air temperature between 50 to 104 °F (10° C to 40°
C) on a dry and cleaned plasma cutting power source.
8.1
Visual inspection
Disconnect the cutting power source from the mains supply. During visual inspection,
each safety related function judged as relevant by the test personnel, shall be checked
for correct operation.
During visual inspection, the following listed items shall be checked:
1 Torch holder, cutting current return clamp;
•
•
•
•
missing or defective insulation
defective connections
defective, damaged switches
other damage
2 Mains supply;
•
•
•
•
•
defective, damaged cable
deformed, faulty plug
broken or thermally damaged plug pins
ineffective cable anchorage
cables and plugs unsuitable for the intended use and performance
3 Cutting circuit;
•
•
•
•
defective damaged cable
deformed, faulty or thermally damaged couple/sockets
ineffective cable anchorage
cables and coupler unsuitable for the intended use and performance
S0740 800 214/E20120330/ P34
bp22
32
© ESAB AB 2012
4 Enclosure;
•
•
•
•
•
•
missing or damaged parts
unauthorised modifications
cooling opening blocked
signs of overload and improper use
missing of defective protective covers
conductive objects put in the enclosure
5 Controls and indicators;
•
•
•
defective switches and lamps
defective pressure regulator or manometer
incorrect fuse
6 General condition;
•
•
•
8.2
defective air hoses and connections
poor legibility of markings and labelling
other damage or signs of improper use
Functional test
Do a functional test to make sure that the powers source is working in a proper way.
1 Prepare a working area with a workpiece.
2 Connect the mains power and air supply to the power source.
3 Connect the return cable to the workpiece.
4 Turn on the power and check that the green LED is lit on the front panel.
5 Check the function of the power source by cutting a workpiece.
S0740 800 214/E20120330/ P34
bp22
33
© ESAB AB 2012
ESAB subsidiaries and representative offices
Europe
THE NETHERLANDS
ESAB Nederland B.V.
Amersfoort
Tel: +31 33 422 35 55
Fax: +31 33 422 35 44
North and South America
BELGIUM
S.A. ESAB N.V.
Brussels
Tel: +32 2 745 11 00
Fax: +32 2 745 11 28
NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
BRAZIL
ESAB S.A.
Contagem-MG
Tel: +55 31 2191 4333
Fax: +55 31 2191 4440
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: +971 4 887 21 11
Fax: +971 4 887 22 63
BULGARIA
ESAB Kft Representative Office
Sofia
Tel/Fax: +359 2 974 42 88
POLAND
ESAB Sp.zo.o.
Katowice
Tel: +48 32 351 11 00
Fax: +48 32 351 11 20
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
Africa
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 8 310 960
Fax: +351 1 859 1277
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
SOUTH AFRICA
ESAB Africa Welding & Cutting Ltd.
Durbanvill 7570 - Cape Town
Tel: +27 (0)21 975 8924
DENMARK
Aktieselskabet ESAB
Herlev
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
ROMANIA
ESAB Romania Trading SRL
Bucharest
Tel: +40 316 900 600
Fax: +40 316 900 601
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 57 48
Distributors
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
RUSSIA
LLC ESAB
Moscow
Tel: +7 (495) 663 20 08
Fax: +7 (495) 663 20 09
Asia/Pacific
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 2326 3000
Fax: +86 21 6566 6622
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 218
SPAIN
ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
INDONESIA
P.T. ESABindo Pratama
Jakarta
Tel: +62 21 460 0188
Fax: +62 21 461 2929
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
ESAB international AB
Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
JAPAN
ESAB Japan
Tokyo
Tel: +81 45 670 7073
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
SWITZERLAND
ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
MALAYSIA
ESAB (Malaysia) Snd Bhd
USJ
Tel: +603 8023 7835
Fax: +603 8023 0225
ITALY
ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: +39 02 97 96 8.1
Fax: +39 02 97 96 87 01
UKRAINE
ESAB Ukraine LLC
Kiev
Tel: +38 (044) 501 23 24
Fax: +38 (044) 575 21 88
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 6861 43 22
Fax: +65 6861 31 95
AUSTRIA
ESAB Ges.m.b.H
Vienna-Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: +82 55 269 8170
Fax: +82 55 289 8864
EGYPT
ESAB Egypt
Dokki-Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
AUSTRALIA
ESAB South Pacific
Archerfield BC QLD 4108
Tel: +61 1300 372 228
Fax: +61 7 3711 2328
www.esab.com
© ESAB AB
120330
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising