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Powercut 700

ESAB Powercut 700 User manual

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  • What is the duty cycle of the Powercut 700?
    What is the maximum cutting thickness for the Powercut 700?
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    What is the operating temperature range for the Powercut 700?
    What is the sound pressure at no load for the Powercut 700?
0740 800 215 20121125 Valid for serial no.145-xxx-xxxx
PowerCut™
©
700
Service manual
0740 800 215 20121125 Valid for serial no.145-xxx-xxxx
bp23 1
Rights reserved to alter specifications without notice
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.2 Green LED lit, torch not working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.3 No action when switching on the power . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.4 Circuit breaker/fuse blows on the external power supply . . . . . . . . . . . . . . 14
6.5 Only the fan is running. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.6 Green LED lit, PIP LED blinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.7 No transfer or a short pilot arc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.8 PIP LED lit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.9 PIP LED lit, air pressure LED lit, no air at all . . . . . . . . . . . . . . . . . . . . . . . . 15
6.10 PIP LED blinking, air pressure LED lit, low air pressure . . . . . . . . . . . . . . . 15
6.11 Over temperature LED blinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.12 Fault LED lit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.13 Fault LED blinking fast. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.14 Fault LED blinking slowly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7 Service instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
7.1 Remove the cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.2 Replace the consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.3 Replace the torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.4 Replace the primary board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.5 Replace the pilot arc board and the secondary board. . . . . . . . . . . . . . . . . 23
7.6 Replace the fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.7 Replace the safety switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.8 Replace the display board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.9 Replace the solenoid valve and air sensor . . . . . . . . . . . . . . . . . . . . . . . . . 27
8 At completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
8.1 Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.2 Functional test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
bp23 2
Rights reserved to alter specifications without notice
bp23 3 Valid for serial no.145-xxx-xxxx
S0740 800 215/E20120330/ P32
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 includ-
ing March 2012.
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.
2Introduction
The PowerCut 700 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 al-
uminium. It delivers cutting power for severing materials up to 5/8” (16 mm) of thick-
ness.
The PowerCut™ 700 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 per-
son(s) doing the work to ensure that the product still complies with the
requirements of the above standard.
CAUTION
Read and understand the instruction manual
before installing or operating.
bp23 4 © ESAB AB 2012
S0740 800 215/E20120330/ P32
3 Mechanical design
3.1 Front
1 Control panel
2 Output current control
3 Power switch 0/I
4 2/4 stroke
5 Torch connection
6 Return cable connection
3.2 Rear
1 Air regulator with air connection
2 Power connection
3 Fuse
2
3
4
1
5
6
pc700e001
6
2
1
pc700e002
bp23 5 Valid for serial no.145-xxx-xxxx
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3.3 Main parts
1 Display board
2 Primary board
3 Solenoid valve
4 Air sensor
5 Safety switch (cover)
6 Air regulator
7 Transformer (auxiliary)
8 Fuse
9 Fan
10 Secondary board
11 Thermal switch, secondary board (Thermal switch, primary board not shown in figure)
12 Pilot arc board
13 Inductor
6
7
9
10
11
12
13
1
8
3
2
4
5
pc700e003
bp23 6 © ESAB AB 2012
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3.4 Control panel
1 Output current control
Knob to adjust the cutting current from 30 A to 50 A. For settings see cut data charts
in the torch manual.
2 Power switch 0/I
Switch to turn the power source on and off.
3 2/4 stroke
Switch to control the function of the torch trigger.
In 2-stroke cutting mode, the torch is activated when the trigger is pressed and de-
activated when the torch trigger is released.
In 4-stroke cutting mode, the torch is activated on first trigger press and deactivated
on the second trigger press.
4 Air pressure indicator
The yellow LED indicates that the air pressure is to low.
5 Fault indicator
The blinking yellow LED indicates that the safety switch for the cover is activated and
the power is automatically turned off.
6 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 nor-
mal.
7 Parts in place (PIP) indicator
The yellow LED indicates a parts-in-place error. This means that no nozzle is detect-
ed or that the electrode is not retracting properly.
8 Power ON indicator
The green LED indicates that the power is on.
40
35
30
45
50
A
PowerCut™ 700
8
7
6
5
4
1
2
3
pc700e004
bp23 7 Valid for serial no.145-xxx-xxxx
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4 Technical Data
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.
Mains voltage range 230 V ±15%, 1 ph, 50/60 Hz
Setting range 30 - 50 A
Permitted load:
25% duty cycle
60% duty cycle
100% duty cycle
50 A
37 A
30 A
Power factor at maximum current 0.75
Efficiency at maximum current 80%
Open-circuit voltage U
0
320 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 < 49 dB (A)
Nominal flow rate 400 cfh at 80 psig
(189 l/min at 5.5 bar)
Dimensions, l × w × h 22” × 8.3” × 15”
(557 × 211 × 380 mm)
Weight including torch and
return cable
47 lbs (21.3 kg)
Insulation class transformer H
Enclosure class IP 23
bp23 8 © ESAB AB 2012
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5 Functional description
The PowerCut 700 is IGBT-controlled, operating on the inverter principle. It consists of four cir-
cuit boards, as shown in the circuit diagram. The primary board is supplied with 230 V AC and
controls together with the secondary board the various functions of the power source.
The primary board converts the 230 V AC to 350 V DC that is fed to the transformers T1 and
T2 on the secondary board. The output from T1 and T2 is 24 V DC.
The secondary board supply 24 V DC to the pilot arc board, the display board and the torch.
230 V AC is also distributed to the fan MV1 and the auxiliary transformer TR1. The fan and the
transformer are protected with the fuse F1.
The auxiliary transformer converts the 230 V AC to 9, 18 and 24 V AC. The 9 V AC is fed to the
torch trigger, 18 V AC to the display board and 24 V AC to the solenoid valve.
The two thermal switches, not shown in the circuit diagram, attached to the heat sinks of the
primary and secondary board protects the power source from overheating. When the tempera-
ture becomes too high the welding current is interrupted and the yellow over temperature LED
is lit. The thermal switches are reset when the temperature has decreased to normal.
The display board handles the control signals to and from the primary 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 trigger lock controls the function of the torch trigger. It has two positions 2-stroke or 4-
stroke. In 2-stroke cutting mode, the torch is activated when the trigger is pressed and deacti-
vated when the torch trigger is released. In 4-stroke cutting mode, the torch is activated on first
trigger press and deactivated on the second trigger press.
The fan starts up when the power is turned on and then goes at full speed all the time.
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 of the PowerCut 700”.
PowerCut 700 uses compressed air as gas for plasma. The power source is supplied with com-
ponents for air regulation and distribution. An air regulator with manometer regulates the air
flow rate on the torch. 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 to low, that is less
than 3.5 bar. The solenoid valve is supplied with 15 V DC and normally open. It closes and
switches of the airflow if the voltage drop. An air pressure fault is indicated on the control panel.
The Torch Parts-In Place (PIP) function is checked by a microprocessor every time the power
source is turned on. When the power source is turned on the continuity is checked. If the PIP
led indicator is lit, there is no continuity. It indicates that the electrode and nozzle are not cor-
rectly installed in the torch or that the torch parts-in place are retracted. If the PIP led indicator
is blinking, there is continuity.
bp23 9 © ESAB AB 2012
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230V AC
FUSE
TRANSFORMER
(AUXILARY)
230V AC
350V DC
24V DC
PRIMARY BOARD
0700 210 131
POWER
ON
PIP FAULT AIR
PRESSURE
OVER
TEMP.
DISPLAY BOARD
0700 210 140
PILOT ARC
BOARD
0700 210 135
SECONDARY INVERTER
BOARD
0700 210 115
PCB INTERFACE
OPTIONAL
PIP
+
C
D
A
B
EVA1
24VAC
9VAC
J2
J2
L1
J8
J7J1
1
2
3
4
5
6
1
2
3
4
1
1
1
1
1
1
2
2
1
3
4
1
2
3
4
5
6
7
8
9
10
1
1
1
1
1
1
2
3
4
5
6
1
1
1
2
3
4
5
6
DC BA
7
8
9
10
1
2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
5
6
7
8
9
10
11
12
13
14
12
6
11
5
10
4
9
3
8
2
7
1
J1
F1
TR1
MV1
230V
0V
0V
9V
18V
24V
0V
0V
1
1
1
1
J2
J3
J3
J7
J6
J6
J5
J4
J3
J10
J1
J1 J2
J3
T1
T2
HS1
R13
J6
J8
J9
I
II
III
J4
S2
S3
J3
J5
J1
J7
J5
J3
J1
J2-A
J4-A
J6-A
PILOT1
SAFETY SWITCH
( COVER )
2/4 STROKE
9VAC1
9VAC2
18VAC1
18VAC2
24VAC1
24VAC2
MAIN SWITCH
FAN
SOLENOID VALVE
INDUCTOR
TRANSFORMER
TRANSFORMER
14
13
12
11
10
9
8
7
6
5
4
3
2
1
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
11
12
PILOT
POTENTIOMETER
TORCH ON/OFF
POWER
TORCH SWITCH
pc700e005
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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 per-
sonnel 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 acces-
sible during normal operation. If the cover is opened for maintenance or
other reason, parts connected to mains such as connection terminals may
be exposed.
WARNING
High voltage is accumulated in capacitors after power has been switched
off. Always wait at least five minutes after the power is switched off, before
starting any work with the power source.
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 com-
ponents. 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 ESD equipment 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.
bp23 11 Valid for serial no.145-xxx-xxxx
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6.1 No power
The main switch is set to I. The green LED on the front panel is not lit and the power
source is not working.
1 Check the fuse in the power source. If the fuse is blown and there is power supply
to the power source, it is possible to hear the sound of the relay on the primary board
when the main switch is set to I.
2 Check the fuse/circuit breaker of the external power supply.
3 Check the external power supply.
6.2 Green LED lit, torch not working
The main switch is set to I. The green LED is lit and the torch is not working.
1 Turn off and disconnect the mains power supply and wait for five minutes.
2 Measure on the IGBTs on the primary board with a multimeter in diode test mode.
Value should be 400 or more.
If they are incorrect, replace the primary board, see “Replace the primary board” in
section “Service instructions”. If correct continue with step 3.
pc700e013
2 2
2 2
bp23 12 © ESAB AB 2012
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3 Measure on the primary bridge on the primary board with a multimeter in diode test
mode. Value should be 400 to 500 mV. If they are incorrect, replace the primary
board, see “Replace the primary board” in section “Service instructions”. If correct
continue with step 4.
pc700e015
3 3 3
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4 Measure on any of the diodes on the secondary board. Use a multimeter in diode
test mode. Value should be 300 to 400 mV.
If the value is incorrect, replace the secondary board, see “Replace the secondary
board” in section “Service instructions”.
pc700e014
bp23 14 © ESAB AB 2012
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6.3 No action when switching on the power
The main switch is set to I. The green LED lit and no sound of relay on pilot arc board
when turning the main switch to I.
1 Check the connections inside the power source.
2 If the connections are correct, replace the pilot arc board, se instructions in “Replace
the pilot arc board” in section “Service instructions”.
6.4 Circuit breaker/fuse blows on the external power supply
The circuit breaker/fuse on the external power supply blows when the power source is
turned on.
1 Replace the primary board, see instructions in “Replace the primary board” in sec-
tion “Service instructions”.
6.5 Only the fan is running
The main switch is set to I but only the fan is running.
1 Check the auxiliary transformer. Make sure that the connections are correctly fitted.
Measure the voltage on the auxiliary transformer input and output, see the wiring di-
agram and the labels on the transformer.
The input should be 230 V AC.
The outputs should be 9, 18 and 24 V AC.
6.6 Green LED lit, PIP LED blinking
The main switch is set to I. The green LED is lit and the PIP LED is blinking. The torch
is not working.
1 Replace the torch, see “Replace the torch” in section “Service instructions”.
6.7 No transfer or a short pilot arc
The main switch is set to I 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.
2 Check the connections inside the power source. If the connections are correct, re-
place the pilot arc board, se instructions in “Replace the pilot arc board” in section
“Service instructions”.
6.8 PIP LED lit
The green LED is lit and the PIP LED is lit. The torch is not working.
1 Check and replace the consumables on the torch. See “Replace the consumables”
in section “Service instructions”.
bp23 15 Valid for serial no.145-xxx-xxxx
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6.9 PIP LED lit, air pressure LED lit, no air at all
The green LED, the PIP LED and the air pressure LED are lit. The torch is not working.
1 Check the external air supply.
2 Check external air hoses and connections for damage or leakage.
3 Check the manometer on the air regulator. If there is external air supply but the ma-
nometer shows zero, replace the air regulator.
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 set air regulator for leakage, dirt or damage.
7 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 “Re-
place the air sensor” in section “Service instructions”. If the air sensor is closed
(continuity), it is working.
8 Check the solenoid valve. Measure the voltage over the connectors on the solenoid
valve. The value should be 24 V AC.
If not, measure over pin 2 and 8 on the connector J2 on the display board. If there is
voltage on the display board, replace the solenoid valve, see instructions in “Replace
the solenoid valve” in section “Service instructions”.
If there is no voltage, replace the display board, see instructions in “Replace the dis-
play board” in section “Service instructions”.
6.10 PIP LED blinking, air pressure LED lit, low air pressure
The green LED is lit, the PIP LED is blinking, the air pressure LED lit and low air pres-
sure. The torch is not working.
1 Check the external air supply.
2 Check external air hoses and connections for leakage, dirt or damage.
3 Check the pressure gauge on the air regulator. At least 70 psi (4.8 bar) is required
for cutting.
If there is external air supply of at least 70 psi (4.8 bar) and 23.8 gallon/m (90 l/m)
but not possible to adjust the pressure on the air regulator, replace the air regulator.
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 set air regulator for leakage, dirt or damage.
7 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 “Re-
bp23 16 © ESAB AB 2012
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place the air sensor” in section “Service instructions”. If the air sensor is closed
(continuity), it is working.
8 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 2 and 8 on the connector J2 on the display board. If there is
voltage on the display board, replace the solenoid valve, see instructions in “Replace
the solenoid valve” in section “Service instructions”.
If there is no voltage, replace the display board, see instructions in “Replace the dis-
play board” in section “Service instructions”.
6.11 Over temperature LED blinking
The green LED is lit the over temperature LED is blinkning. The torch is not working.
1 The duty cycle is too high. Wait for a while to let the fans cool down the equipment.
2 Does the over temperature indication appear frequently? Check the fan, is it running
without problems? If not, replace the fan.
3 Check the thermal switches at normal temperature. Measure the continuity. If any of
them are open replace the damaged thermal switch.
4 Does the over temperature indication appear frequently together with transfer prob-
lems between the pilot arch and cutting arc? Replace the pilot arc board.
6.12 Fault LED lit
Check the torch switch button.
6.13 Fault LED blinking fast
Check the safety switch and replace if damaged, see instructions “Replace the safety
switch” in section “Service instructions”.
6.14 Fault LED blinking slowly
Check or replace the pilot arch board or the display board, se instructions “Replace the
pilot arc board...” or “Replace the display board” in section “Service instructions”.
bp23 17 Valid for serial no.145-xxx-xxxx
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7 Service instructions
The following section describes the replacements procedures of the most common
parts of the power source.
Safety precautions
WARNING
Work on high voltage installations must be carried out by authorized per-
sonnel 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 acces-
sible during normal operation. If the cover is opened for maintenance or
other reason, parts connected to mains such as connection terminals may
be exposed.
WARNING
High voltage is accumulated in capacitors after power has been switched
off. Always wait at least five minutes after the power is switched off, before
starting any work with the power source.
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 com-
ponents. 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 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.
bp23 18 © ESAB AB 2012
S0740 800 215/E20120330/ P32
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
Crosshead screwdriver PH2 × 100, PH0 × 75
A slotted screwdriver
Thread locker of medium strength
Silicone protective coating
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