ESAB Powercut 700 User manual

Brand: ESAB

Model: Powercut 700

Type: User manual

ESAB Powercut 700: Cut like a pro with this versatile and precise plasma cutting system. Suitable for all types of cutting in production, repair, maintenance, and assembly, it delivers a cutting power of up to 50A, allowing you to sever materials up to 5/8” (16mm) thick. Its user-friendly control panel with output current control and 2/4 stroke switch ensures effortless operation. Experience reliable performance and consistent results with the Powercut 700.

Service manual

0740 800 218 GB 20141121 Valid for: Serial no: 248-xxx-xxxx

PowerCut™© 700

TABLE OF CONTENTS

0740 800 218 © ESAB AB 2014

READ THIS FIRST................................................................................................ 4

INTRODUCTION................................................................................................... 5

MECHANICAL DESIGN ....................................................................................... 6

Front ...................................................................................................................... 6

Rear ....................................................................................................................... 6

Main parts ............................................................................................................. 7

Control panel ........................................................................................................ 8

TECHNICAL DATA ............................................................................................... 9

FUNCTIONAL DESCRIPTION ........................................................................... 10

FAULT FINDING ................................................................................................. 13

No power............................................................................................................. 14

Green LED lit, torch not working ......................................................................14

No action when switching on the power..........................................................16

Circuit breaker/fuse blows on the external power supply .............................16

Only the fan is running ......................................................................................17

Green LED lit, PIP LED blinking........................................................................17

No transfer or a short pilot arc .........................................................................17

PIP LED lit ........................................................................................................... 17

PIP LED lit, air pressure LED lit, no air at all ...................................................17

PIP LED blinking, air pressure LED lit, low air pressure................................18

Over temperature LED blinking ........................................................................18

Fault LED is lit .................................................................................................... 19

Fault LED is blinking rapidly.............................................................................19

Fault LED is blinking slowly..............................................................................19

SERVICE INSTRUCTIONS................................................................................. 20

Remove the cover ..............................................................................................21

Replace the consumables ................................................................................. 22

Replace the torch ............................................................................................... 23

Replace the primary board................................................................................24

Replace the pilot arc board and the secondary board ...................................25

Replace the fan................................................................................................... 26

Replace the safety switch .................................................................................27

Replace the display board.................................................................................28

Replace the solenoid valve and air sensor......................................................29

TABLE OF CONTENTS

0740 800 218 © ESAB AB 2014

AT COMPLETION ............................................................................................... 31

Visual inspection................................................................................................31

Functional test.................................................................................................... 32

Rights reserved to alter specifications without notice.

READ THIS FIRST

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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™ 700 is designed and tested accordance with the international and

European standard IEC/EN 60974-1 and 60974-10.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.

INTRODUCTION

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INTRODUCTION

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 aluminium. It delivers

cutting power for severing materials up to 5/8” (16 mm) of thickness.

MECHANICAL DESIGN

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MECHANICAL DESIGN

Front

1. Control panel 4. 2/4 stroke

2. Output current control 5. Torch connection

3. Power switch 0/I 6. Return cable connection

Rear

1. Air connection 3. Fuse

2. Power connection

MECHANICAL DESIGN

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Main parts

1. Display board 8. Fuse

2. Primary board 9. Fan

3. Solenoid valve 10. Secondary board

4. Air sensor 11. Thermal switch, secondary board (Thermal

swith, primary board not shown)

5. Safety switch (cover) 12. Pilot arc board

6. Air regulator 13. Inductor

7. Transformer (auxiliary)

MECHANICAL DESIGN

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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 normal.

7. Parts in place (PIP) indicator

The yellow LED indicates a parts-in-place error. This means that no nozzle is detected or

that the electrode is not retracting properly.

8. Power ON indicator

The green LED indicates that the power is on.

TECHNICAL DATA

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TECHNICAL DATA

Mains voltage range 400 V ±10%, 3 ph, 50/60 Hz

Setting range 30 - 50 A

Permitted load:

30% duty cycle 50 A

60% duty cycle 37 A

100% duty cycle 30 A

Power factor at maximum current 0.75

Efficiency at maximum current 85%

Open-circuit voltage U

320 V

Operating temperature -10 to 40 °C

Transportation temperature -20 to 55 °C

Sound pressure at no load < 70 dB (A)

Nominal flow rate 189 l/min at 4.8 bar

Dimensions, l × w × h 600 × 210 × 380 mm

Weight including torch and return cable 25.5 kg

Insulation class transformer H

Enclosure class IP 23

Application class

Duty cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or

cut at a certain load without overloading. The duty cycle is valid for 40°C/104°F.

Enclosure class

The IP code indicates the enclosure class, i. e. the degree of protection against penetration

by solid objects or water.

Equipment marked IP23 is intended for indoor and outdoor use.

Application class

The symbol indicates that the power source is designed for use in areas with increased

electrical hazard.

FUNCTIONAL DESCRIPTION

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FUNCTIONAL DESCRIPTION

The PowerCut 700 is IGBT-controlled, operating on the inverter half-bridge principle. It

consists of seven circuit boards, as shown in the circuit diagram. The primary board is

supplied with 400 V AC and together with the secondary board it energizes the different parts

of the power source.

The primary board converts the 400 V AC to 570 V DC that is fed to the transformers T1 and

T2 on the secondary board. The output from T1 and T2 is about 300 V DC (peak).

The fan and the transformer are protected with the fuse F1.

The auxiliary transformer converts the 400 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

temperature 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 trig- ger is pressed and

deactivated 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

components 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 22 V AC 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

correctly installed in the torch or that the torch parts in place are retracted. If the PIP led

indicator is blinking, there is continuity.

FUNCTIONAL DESCRIPTION

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FUNCTIONAL DESCRIPTION

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FAULT FINDING

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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.

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.

FAULT FINDING

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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.

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 mV and more.

If they are incorrect, replace the primary board, see section “Replace the primary board”

in chapter “Service instructions”. If correct continue with step 3.

FAULT FINDING

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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 section “Replace the primary board” in chapter “Service instructions”. If correct

continue with step 4.

FAULT FINDING

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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 section “Replace the

secondary board” in chapter “Service instructions”.

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, see instructions in section

“Replace the pilot arc board” in chapter “Service instructions”.

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.

FAULT FINDING

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1. Replace the primary board, see instructions in section “Replace the primary board” in

chapter “Service instructions”.

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

diagram and the labels on the transformer.

The input should be 230 V AC.

The outputs should be 9, 18 and 24 V AC.

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 section “Replace the torch” in chapter “Service instructions”.

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, replace

the pilot arc board, see instructions in section “Replace the pilot arc board” in chapter

“Service instructions”.

PIP LED lit

The green LED and the PIP LED are lit. The torch is not working.

1. Check and replace the consumables on the torch. See section “Replace the

consumables” in chapter “Service instructions”.

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

manometer 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.

FAULT FINDING

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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, see instructions in section

“Replace the air sensor” in chapter “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 section

“Replace the solenoid valve” in chapter “Service instructions”.

If there is no voltage, replace the display board, see instructions in section “Replace the

display board” in chapter “Service instructions”.

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 the air pressure is

low. 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, see instructions in section

“Replace the air sensor” in chapter “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 section

“Replace the solenoid valve” in chapter “Service instructions”.

If there is no voltage, replace the display board, see instructions in section “Replace the

display board” in chapter “Service instructions”.

Over temperature LED blinking

The green LED is lit the over temperature LED is blinking. 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 problems

between the pilot arch and cutting arc? Replace the pilot arc board.

FAULT FINDING

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Fault LED is lit

Check the torch switch button.

Fault LED is blinking rapidly

Check the safety switch and replace if damaged, see instructions in section “Replace the

safety switch” in chapter “Service instructions”.

Fault LED is blinking slowly

Check or replace the Pilot Arc Board or the Display Board, see instructions in sections

“Replace the pilot arc board and the secondary board” and “Replace the display board” in

chapter “Service instructions”.

SERVICE INSTRUCTIONS

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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 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.

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.

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

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ESAB Powercut 700 User manual

ESAB Powercut 700 User manual

ESAB Powercut 700 User manual

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