ESAB PowerCut 900 User manual

Powercut 900

Manual & Mechanized Plasmarc Cutting Package

0558008430 03/2014

Instruction Manual

This manual provides complete instructions for MANUAL & MECHANIZED CONSOLES

2

This equipment will perform in conformity with the description thereof contained in this manual and accompa-

nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-

tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment

should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme-

diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone

or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.

The user of this equipment shall have the sole responsibility for any malfunction which results from improper

use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a ser-

vice facility designated by the manufacturer.

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the

principles of operation and safe practices for arc welding and cutting equipment, we urge

you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and

Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain

this equipment. Do NOT attempt to install or operate this equipment until you have read

and fully understand these instructions. If you do not fully understand these instructions,

contact your supplier for further information. Be sure to read the Safety Precautions be-

fore installing or operating this equipment.

CAUTION

USER RESPONSIBILITY

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

3

TABLE OF CONTENTS

1.0 Safety Precautions ....................................................................................5

1.1 Safety - English ..................................................................................5

1.2 Safety - Spanish .................................................................................9

1.3 Safety - French .................................................................................13

2.0 General ..............................................................................................19

2.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

2.2 Powercut 900 Manual Plasma .................................................................. 20

2.3 Manual Package Ordering Information ..........................................................21

2.4 PT-38 Torch Data ...............................................................................21

2.5 Optional Accessories: .......................................................................... 22

3.0 Installation.......................................................................................... 23

3.1 General ...................................................................................... 23

3.2 Equipment Required........................................................................... 23

3.3 Location....................................................................................... 23

3.4 Inspection..................................................................................... 23

3.5 Primary Input Connections......................................................................24

3.6 Provisions for Automation ......................................................................27

3.7 Secondary Output Connections for Manual Cutting ............................................. 28

3.8 PT-38 Torch Installation ........................................................................ 28

4.0 Operation ...........................................................................................31

4.1 Powercut 900 Controls ........................................................................31

4.2 Cutting with the Powercut 900 using the PT-38 torch............................................ 34

4.3 Stand-o Guide ............................................................................... 36

4.4 Drag Cutting 40 Amp .......................................................................... 36

4.5 Gouging with the Powercut 900 using the PT-38 torch .......................................... 36

4.6 Electrode Wear .................................................................................37

MANUAL PLASMARC CUTTING PACKAGE

Powercut 900

MECHANIZED PLASMARC CUTTING PACKAGE

Powercut 900

2.0 General ..............................................................................................41

2.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

2.2 Powercut 900 Mechanized Plasma...............................................................42

2.3 Mechanized Package Ordering Information......................................................42

2.4 PT-37 Torch Data .............................................................................. 43

2.5 Optional Accessories: .......................................................................... 44

3.0 Installation.......................................................................................... 45

3.1 General ...................................................................................... 45

3.2 Equipment Required........................................................................... 45

3.3 Location....................................................................................... 45

3.4 Inspection..................................................................................... 45

3.5 Primary Input Connections..................................................................... 46

4

TABLE OF CONTENTS

3.6 CNC Interface Connection ..................................................................... 49

3.7 Voltage Divider Adjustment.................................................................... 50

3.8 Secondary Output Connections Mechanized Cutting ............................................51

3.9 PT-37 Torch Installation .........................................................................51

4.0 Operation ...........................................................................................53

4.1 Powercut 900 Controls ........................................................................53

4.2 Cutting with the Powercut 900 using the PT-37 torch............................................ 56

4.3 Electrode Wear ................................................................................ 56

5.0 General ..............................................................................................59

5.1 Inspection and Cleaning ........................................................................59

5.2 Common Cutting Problems .................................................................... 60

5.3 IGBT Handling ..................................................................................61

5.4 Module Replacement ...........................................................................61

6.0 Troubleshooting .................................................................................... 63

6.1 List of Help Codes ............................................................................. 64

7.0 Replacement Parts .................................................................................. 65

7.1 General ....................................................................................... 65

7.2 Ordering ...................................................................................... 65

7.3 Torque Recommendations ..................................................................... 66

7.4 Selecting Air Pressure Units of Measure..........................................................67

7.5 Control/Display Board Assembly ................................................................67

7.6 Primary Power Board Assembly ................................................................ 68

7.7 Secondary Power Board Assembly ............................................................. 69

5

1.0 Safety Precautions

1.1 Safety - English

WARNING: These Safety Precautions are

for your protection. They summarize

precautionary information from the

references listed in Additional Safety

Information section. Before performing any instal-

lation or operating procedures, be sure to read and

follow the safety precautions listed below as well

as all other manuals, material safety data sheets,

labels, etc. Failure to observe Safety Precautions

can result in injury or death.

PROTECT YOURSELF AND OTHERS --

Some welding, cutting, and gouging

processes are noisy and require ear

protection. The arc, like the sun, emits

ultraviolet (UV) and other radiation and can injure

skin and eyes. Hot metal can cause burns. Training

in the proper use of the processes and equipment

is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in

any work area, even if welding helmets, face

shields, and goggles are also required.

2. Use a face shield tted with the correct lter and

cover plates to protect your eyes, face, neck, and

ears from sparks and rays of the arc when oper-

ating or observing operations. Warn bystanders

not to watch the arc and not to expose themselves

to the rays of the electric-arc or hot metal.

3. Wear ameproof gauntlet type gloves, heavy

long-sleeve shirt, cuess trousers, high-topped

shoes, and a welding helmet or cap for hair

protection, to protect against arc rays and hot

sparks or hot metal. A ameproof apron may also

be desirable as protection against radiated heat

and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cus, or pockets. Sleeves and collars

should be kept buttoned, and open pockets

eliminated from the front of clothing.

5. Protect other personnel from arc rays and hot

sparks with a suitable non-ammable partition

or curtains.

6. Use goggles over safety glasses when chipping

slag or grinding. Chipped slag may be hot and

can y far. Bystanders should also wear goggles

over safety glasses.

FIRES AND EXPLOSIONS -- Heat from

ames and arcs can start res. Hot

slag or sparks can also cause res and

explosions. Therefore:

1. Remove all combustible materials well away from

the work area or cover the materials with a pro-

tective non-ammable covering. Combustible

materials include wood, cloth, sawdust, liquid

and gas fuels, solvents, paints and coatings,

paper, etc.

2. Hot sparks or hot metal can fall through cracks

or crevices in oors or wall openings and cause a

hidden smoldering re or res on the oor below.

Make certain that such openings are protected

from hot sparks and metal.“

3. Do not weld, cut or perform other hot work until

the work piece has been completely cleaned so

that there are no substances on the work piece

which might produce ammable or toxic vapors.

Do not do hot work on closed containers. They

may explode.

4. Have re extinguishing equipment handy for

instant use, such as a garden hose, water pail,

sand bucket, or portable re extinguisher. Be

sure you are trained in its use.

5. Do not use equipment beyond its ratings. For

example, overloaded welding cable can overheat

and create a re hazard.

6. After completing operations, inspect the work

area to make certain there are no hot sparks or

hot metal which could cause a later re. Use re

watchers when necessary.

7. For additional information, refer to NFPA Stan-

dard 51B, "Fire Prevention in Use of Cutting and

Welding Processes", available from the National

Fire Protection Association, Battery march Park,

Quincy, MA 02269.

ELECTRICAL SHOCK -- Contact with

live electrical parts and ground can

cause severe injury or death. DO

NOT use AC welding current in damp

areas, if movement is conned, or if there is danger

of falling.

SECTION 1 SAFETY PRECAUTIONS

6

1. Be sure the power source frame (chassis) is con-

nected to the ground system of the input power.

2. Connect the work piece to a good electrical

ground.

3. Connect the work cable to the work piece. A poor

or missing connection can expose you or others

to a fatal shock.

4. Use well-maintained equipment. Replace worn or

damaged cables.

5. Keep everything dry, including clothing, work

area, cables, torch/electrode holder, and power

source.

6. Make sure that all parts of your body are insulated

from work and from ground.

7. Do not stand directly on metal or the earth while

working in tight quarters or a damp area; stand

on dry boards or an insulating platform and wear

rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the

power.

9. Turn o the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on

next page) for specic grounding recommenda-

tions. Do not mistake the work lead for a ground

cable.

ELECTRIC AND MAGNETIC FIELDS

— May be dangerous. Electric cur-

rent owing through any conduc-

tor causes localized Electric and

Magnetic Fields (EMF). Welding and

cutting current creates EMF around welding cables

and welding machines. Therefore:

1. Welders having pacemakers should consult their

physician before welding. EMF may interfere with

some pacemakers.

2. Exposure to EMF may have other health eects which

are unknown.

3. Welders should use the following procedures to

minimize exposure to EMF:

A. Route the electrode and work cables together.

Secure them with tape when possible.

B. Never coil the torch or work cable around your

body.

C. Do not place your body between the torch and

work cables. Route cables on the same side of

your body.

D. Connect the work cable to the work piece as close

as possible to the area being welded.

E. Keep welding power source and cables as far

away from your body as possible.

FUMES AND GASES -- Fumes and

gases, can cause discomfort or harm,

particularly in conned spaces. Do

not breathe fumes and gases. Shield-

ing gases can cause asphyxiation.

Therefore:

1. Always provide adequate ventilation in the work area

by natural or mechanical means. Do not weld, cut, or

gouge on materials such as galvanized steel, stain-

less steel, copper, zinc, lead, beryllium, or cadmium

unless positive mechanical ventilation is provided.

Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying opera-

tions. The heat or arc rays can react with chlorinated

hydrocarbon vapors to form phosgene, a highly

toxic gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat ir-

ritation while operating, this is an indication that

ventilation is not adequate. Stop work and take

necessary steps to improve ventilation in the work

area. Do not continue to operate if physical discom-

fort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)

for specic ventilation recommendations.

SECTION 1 SAFETY PRECAUTIONS

7

5. WARNING: This product, when used for welding

or cutting, produces fumes or gases

which contain chemicals known to

the State of California to cause birth

defects and, in some cases, cancer.

(California Health & Safety Code

§25249.5 et seq.)

CYLINDER HANDLING -- Cylinders,

if mishandled, can rupture and vio-

lently release gas. Sudden rupture

of cylinder, valve, or relief device can

injure or kill. Therefore:

1. Use the proper gas for the process and use the

proper pressure reducing regulator designed to

operate from the compressed gas cylinder. Do not

use adaptors. Maintain hoses and ttings in good

condition. Follow manufacturer's operating instruc-

tions for mounting regulator to a compressed gas

cylinder.

2. Always secure cylinders in an upright position by

chain or strap to suitable hand trucks, undercar-

riages, benches, walls, post, or racks. Never secure

cylinders to work tables or xtures where they may

become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have

valve protection cap in place if regulator is not con-

nected. Secure and move cylinders by using suitable

hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and ames.

Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,

"Precautions for Safe Handling of Compressed Gases

in Cylinders", which is available from Compressed

Gas Association, 1235 Jeerson Davis Highway,

Arlington, VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or

improperly maintained equipment can

cause injury or death. Therefore:

1. Always have qualied personnel perform the instal-

lation, troubleshooting, and maintenance work.

Do not perform any electrical work unless you are

qualied to perform such work.

2. Before performing any maintenance work inside a

power source, disconnect the power source from

the incoming electrical power.

3. Maintain cables, grounding wire, connections, power

cord, and power supply in safe working order. Do

not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep

equipment away from heat sources such as furnaces,

wet conditions such as water puddles, oil or grease,

corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position

and in good repair.

6. Use equipment only for its intended purpose. Do

not modify it in any manner.

ADDITIONAL SAFETY INFORMATION -- For

more information on safe practices for

electric arc welding and cutting equip-

ment, ask your supplier for a copy of

"Precautions and Safe Practices for Arc

Welding, Cutting and Gouging", Form

52-529.

The following publications, which are available from

the American Welding Society, 550 N.W. LeJuene Road,

Miami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc

Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc

Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon

Arc Gouging and Cutting"

SECTION 1 SAFETY PRECAUTIONS

8

5. AWS C5.5 - "Recommended Practices for Gas Tung-

sten Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal

Arc Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Hand-

book.

8. ANSI/AWS F4.1, "Recommended Safe Practices for

Welding and Cutting of Containers That Have Held

Hazardous Substances."

Means immediate hazards which,

if not avoided, will result in im-

mediate, serious personal injury

or loss of life.

Means potential hazards which

could result in personal injury or

loss of life.

Means hazards which could result

in minor personal injury.

SECTION 1 SAFETY PRECAUTIONS

MEANING OF SYMBOLS - As used

throughout this manual: Means Atten-

tion! Be Alert! Your safety is involved.

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

water. Protection is provided against touch with a nger, penetration of solid objects greater than 12mm and

against spraying water up to 60 degrees from vertical. Equipment marked IP23S may be stored, but is not in-

tended to be used outside during precipitation unless sheltered.

Enclosure Class

This product is solely intended for plasma cutting. Any other

use may result in personal injury and / or equipment damage.

CAUTION

15°

Maximum

Tilt Allowed

CAUTION

If equipment is placed on a surface that

slopes more than 15°, toppling over may oc-

cur. Personal injury and / or signicant dam-

age to equipment is possible.

CAUTION

To avoid personal injury and/or equipment

damage, lift using method and attachment

points shown here.

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2.0 General

As shipped, the PowerCut 900 is fully assembled and ready to cut after being connected to input power and a

source of compressed air. The Powercut package uses the heavy-duty PT-38 (Manual Plasma) torch to deliver cut-

ting power for severing materials up to 1-1/4 inch (32 mm) thick. Refer to the following pages for descriptions of

the Powercut packages available as well as performance specications.

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.

USE THE ESAB PT38 PLASMARC TORCH WITH MANUAL CONSOLES.

USE OF TORCHE S NOT DESIGN ED FOR USE WITH THIS CONSOLE COULD

CREATE AN ELECTRIC SHOCK HAZARD.

SECTION 2 DESCRIPTION

WARNING

20

SECTION 2 DESCRIPTION

Specications: Powercut 900

Cuts 1 inch (25 mm); severs 1-1/4 inch (32 mm)

The Powercut 900 plasma cutting package combines the newly redesigned Powercut 900 console and PT-38 torch. The

PT-38 plasma cutting torch is designed to provide increased performance and longer consumable life resulting in higher

production rates at lower costs.

2.2 Powercut 900 Manual Plasma

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 overheating. The duty

cycle is valid for 40 degrees C.

1 phase

1 phase Input ............................................................ 208/230 vac, 60 Hz, 56/47 A

Output ....................................................... 60 amps @ 120vdc - 60% duty cycle

................................................................ 50 amps @ 120vdc - 100% duty cycle

3 phase

3 phase Input ............................................................ 208/230 vac, 60 Hz, 28/23 A

......................................................................230 vac, 50/60 Hz, 23 A

............................................................................ 460 vac, 60 Hz, 12 A

...................................................... 380/400 vac, 50/60 Hz, 13/12 A

...............................................................................575 vac, 60 Hz, 9 A

Output ...................................................... 60 amps @ 120vdc - 60% duty cycle

......................................................50 amps @ 120vdc - 100% duty cycle

Voltage Requirements .............. Idle 208, 230, 380, 400, 460, 575V, +/- 10%

....... Cutting 208, 230, 380, 400, 460, 575V, +/- 15%

Air Supply Requirements ..............500 cfh @ 90 psig (236 l/min @ 6.2 bars)

CE 400 vac .......................................................................................... *S

sc min

2.3 MVA

........................................................................................................... *Z

max

0.068 Ω

Dimensions ................................................................................W = 12.7” (322 mm)

................................................................................ H = 14.9” (379 mm)

................................................................................ D = 24.8” (630 mm)

Weight .................................................................................................78 lbs. (35.4 kg)

21

SECTION 2 DESCRIPTION

2.4 PT-38 Torch Data

Powercut 900 manual plasma cutting packages

use the PT-38 torch. For dimensions and break-

down of parts, refer to torch manual.

2.3 Manual Package Ordering Information

Powercut 900:

208/230 V PT-38 25 ft (7.6 m) ................................................................................................................................................................ 0558008121

208/230 V PT-38 50 ft (15.2 m) .............................................................................................................................................................0558008122

230 V CE PT-38 25 ft (7.6 m) ...................................................................................................................................................................0558008124

230 V CE PT-38 50 ft (15.2 m) ................................................................................................................................................................0558008125

380-400 V CE PT-38 25 ft (7.6 m) .........................................................................................................................................................0558008136

380-400 V CE PT-38 50 ft (15.2 m) .......................................................................................................................................................0558008137

400 V PT-38 25 ft (7.6 m) .........................................................................................................................................................................0558008134

460 V PT-38 25 ft (7.6 m) .........................................................................................................................................................................0558008128

460 V PT-38 50 ft (15.2 m) ......................................................................................................................................................................0558008129

575 V PT-38 25 ft (7.6 m) Bilingual ......................................................................................................................................................0558008132

The components that are included in the Powercut 900 manual packages may be purchased separately by using the ap-

propriate P/N when placing orders. Individual part numbers are listed below:

Consoles:

Powercut 900:

208/230 V Console ..................................................................................................................................................................................0558008120

230 V CE Console .....................................................................................................................................................................................0558008123

380-400 V CE Console ............................................................................................................................................................................0558008135

400 V Console............................................................................................................................................................................................0558008133

460 V Console............................................................................................................................................................................................0558008127

575 V Console Bilingual ......................................................................................................................................................................... 0558008131

PT-38 Torches:

PT-38 Torch, 25' (7.6 m) .......................................................................................................................................................................... 0558006786

PT-38 Torch, 50' (15.2 m) ....................................................................................................................................................................... 0558006787

22

SECTION 2 DESCRIPTION

2.5 Optional Accessories:

Powercut 900/1300/1600 Cart ............................................p/n 0558007898

Enables operator to easily transport the power source , work cable and power

cord.

Powercut 900/1300/1600 Water Separator .....p/n 0558007897

Improves air quality by removing water.

Powercut 900 Mechanized Conversion kit ...... p/n 0558008284

Adds automated mechanized capability to an existing manual machine. Refer to mechanized section of this manual for

CNC Interface connection.

Gas Flow Measuring Kit ............. p/n 19765 ("CE" units - 0558000739)

Valuable troubleshooting tool allows measurement of the actual air

ow through the torch.

Remote Hand Switch with 25 ft. (7.6m) lead ............... p/n 0558008349

50 ft. (15.2m) lead ............ p/n 0558009277

Enables non-automated mechanized cutting using the PT-37 torch.

Can be used on machines equipped with or without CNC interface

connection pigtail. Connects to the torch cable receptacle through

the front panel access door strain relief.

23

3.1 General

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 regulator sup-

plied 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 move-

ment through the power source.

3.4 Inspection

A. Remove the shipping container and all packing material and inspect for evidence of concealed dam-

age 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.

INSTALLING OR PLACING ANY TYPE OF FILTERING DEVICE WILL RE

STRICT THE VOLUME OF INTAKE AIR, THEREBY SUBJECTING THE

POWER SOURCE INTERNAL COMPONENTS TO OVERHEATING. THE

WARRANTY IS VOID IF ANY TYPE OF FILTER DEVICE IS USED.

3.0 Installation

SECTION 3 INSTALLATION

WARNING

24

ELECTRIC SHOCK CAN KILL! PRECAUTIONARY MEASURES SHOULD

BE TAKEN TO PROVIDE MAXIMUM PROTECTION AGAINST ELECTRI

CAL 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.

3.5 Primary Input Connections

The Powercut 900 consoles are equipped with approximately 8 ft. (2.4 m) 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.

CUSTOMER FUSED LINE DISCONNECT SWITCH

(See Table 3-1)

PRIMARY INPUT

POWER CABLE

Figure 3-1. Input Connections

SECTION 3 INSTALLATION

WARNING

STANDARD UNITS

(NON-CE)

CE UNITS

(EUROPE)

PHASE 3 1 PHASE 3 1

L1 Black Black L1 Brown Brown

L2 Red - L2 Black -

L3 White White L3 Gray Gray

GND Green Green GND Green/Yel Green/Yel

INSULATE UNUSED POWER CORD

CONDUCTOR WHEN CONNECTING

FOR SINGLE PHASE.

WARNING

NOTE: The 208/230 vac, 60 Hz models are equipped with a plug for single-phase connection only. The plug is congured NEMA

6-50P (50A 250 V) and mounted to a 4-conductor cable. If 3-phase connection is desired, remove and discard the plug

and proceed as described above.

NOTE: If using 208 vac input power, the PC-900 must be reconnected for 208 vac input as directed in Section 3.5.1.

25

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), 8 ft (2.4

m) length) or provide your own input power leads. If you choose to provide your own, make sure they are insu-

lated copper conductors. You must have two (single-phase) or three (3 phase) power leads and one ground wire.

The wires may be heavy rubber covered cable or may be run in a solid or exible conduit. Ensure the ground lead

is suciently long inside the machine. In an event where the power cord is pulled from the machine, the ground

lead must not break from the ground connection before the power leads have broken from their connection.

Refer to Table 3-1 for recommended input conductors and line fuse sizes.

BEFORE MAKING ANY CONNECTIONS TO THE POWER SOURCE OUT

PUT TERMINALS, MAKE SURE THAT ALL PRIMARY INPUT POWER TO

THE POWER SOURCE IS DEENERGIZED OFF AT THE MAIN DISCON

NECT SWITCH AND THAT THE INPUT POWER CABLE IS UNPLUGGED.

THE CHASSIS MUST BE CONNECTED TO AN APPROVED ELECTRICAL

GROUND. FAILURE TO DO SO MAY RESULT IN ELECTRICAL SHOCK, SE

VERE BURNS OR DEATH.

SECTION 3 INSTALLATION

WARNING

Table 3-1. (Powercut 900)

Recommended Sizes For Input Conductors and Line Fuses

PowerCut 900

Input Requirements Input & Gnd

Conductors

Line

Fuse

Volts Phase Amps Cu / Awg Amps

208 1 56 6 75

208 3 28 6 35

230 1 47 6 60

230 3 23 6 30

230(CE) 3 23 6 mm

2

30

400 3 14 10 20

380(CE) 3 15 6 mm

2

20

400(CE) 3 14 6 mm

2

20

460 3 12 10 20

575 3 9 10 15

ELECTRIC SHOCK CAN KILL! BEFORE MAKING ELECTRICAL INPUT CON

NECTIONS TO THE POWER SOURCE, "MACHINERY LOCKOUT PRO

CEDURES" 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 CORRE

SPONDING FUSES AND PADLOCK THE BOX COVER. IF IT IS NOT POSSI

BLE TO USE PADLOCKS, ATTACH A RED TAG TO THE LINE DISCONNECT

SWITCH OR FUSE BOX WARNING OTHERS THAT THE CIRCUIT IS BEING

WORKED ON.

26

3.5.1 INPUT VOLTAGE CHANGEOVER - 208/230 VOLTAGE 60 Hz UNITS ONLY

208 or 230 Mode

SECTION 3 INSTALLATION

The PowerCut 900, 208/230 vac, 60 Hz model, is factory set for 230 vac input. If using 208 vac input, the PowerCut 900 must

be reconnected as follows before connecting to your input power:

1. Remove cover.

2. Locate the Output Diode Bridge (BR102) (see Figure 3.2A) on the left side of the unit, towards the front panel. Discon-

nect and exchange the X2 and X3 leads only. Leave other smaller wire in place. For 208 vac input, X2 is connected to

BR102-2 and X3 is connected to BR102-3. Ensure the connections are rmly tightened to 22 in/lbs (2.5 Nm).

3. Locate the J27 Control Supply Voltage jumper plug (violet wire) on left side of the unit, towards the rear panel (see Figure

3.2b). Remove the cover plug from the J23 (208 V) header. Move J27 jumper from J20 (230 V) to J23 (208 V). Place the

cover plug on the J20 (230 V) header.

4. Reinstall cover and connect the PowerCut 900 to 208 vac input power.

ELECTRIC SHOCK CAN KILL! PRECAUTIONARY MEASURES SHOULD

BE TAKEN TO PROVIDE MAXIMUM PROTECTION AGAINST ELECTRI

CAL SHOCK. BE SURE THAT ALL POWER IS OFF BY OPENING THE LINE

WALL DISCONNECT SWITCH AND BY UNPLUGGING THE POWER

CORD TO THE UNIT WHEN RECONNECTING FOR 208 VAC INPUT.

WARNING

Figure 3-2. Original Factory Setup for 230 vac Input on

Power Source with 208/230 vac, 60 Hz Input Power Capability

BR102

Figure 3-2b.

208 vac

Figure 3-2a.

208 vac

Disconnect and

exchange the

X2 and X3 leads

only.

Move J27 jumper

from: J20 (230 V)

to: J23 (208 V)

27

Figure 3-3. Input Connections / Fuse Replacement

Pre-ltered DRY AIR SUPPLY (Customer Supplied)

(90 - 150 psi / 6.2 - 10.3 bars)

Replace fuse with Slo-Blo, 2 Amp, 600 V only

MAKE SURE THE POWER

SOURCE IS SWITCHED OFF

BEFORE REMOVING FUSE.

WARNING

SECTION 3 INSTALLATION

Connect your air supply to the inlet connection of the lter.

3.5.2 Input Air Connection / Fuse Replacement

3.6 Provisions for Automation

1. Cut tie wrap. Remove sleeve and voltage pickup insulators.

Trigger Interconnect

Output Voltage Sample

A mechanized version of the Powercut is available with a full automation interface, which allows the unit to communicate with an ex-

ternal control on a Cutting Machine or Robot. (See section 2.3 - Mechanized Package ordering information).

The manual version of the Powercut can be upgraded with the full automation interface by installing a mechanized conversion kit p/n

0558008284. (See section 2.5 - Optional accessories).

Two standard provisions are included within all Powercuts to allow the unit to work with a simple interface used by some Cutting Ma-

chine Manufacturers.

1) Trigger Interconnect - Some Cutting Machines connect directly to the plasma start circuit, in series with the plasma unit’s torch

switch. A convenient connection point has been provided for this purpose. The Powercut trigger circuit includes a male / female

spade interconnection, which may be used to connect the external control cable. This connection is in series with the torch switch,

which means both the torch switch and the external control circuit will have to close in order to start the plasma system.

2) Output Voltage Sample - Some Cutting Machines sample the full output voltage of the plasma system to control the torch height

and to determine when to start moving. The full output voltage is available within the machine on a pair of insulated male spade

terminals.

28

SECTION 3 INSTALLATION

3.8 PT-38 Torch Installation

1. Open torch lead access door on the front panel of the Powercut 900.

MAKE SURE POWER SWITCH ON CONSOLE IS IN OFF POSITION AND

PRIMARY INPUT POWER IS DEENERGIZED.

WARNING

Torch Lead

Access

Door

3.7 Secondary Output Connections for Manual Cutting

Figure 3-4. Powercut Interconnection Diagram

WORK

SAFETY

GROUND

PT-38 Cutting Torch

The PT-38 torch comes factory installed with the

manual packages.

Clamp the work cable to the workpiece. Be sure

the workpiece is connected to an approved earth

ground with a properly sized ground cable.

29

Air Hose quick-

connect tting

2. Connect the torch cable receptacle to the panel receptacle. Check

orientation of the sockets to ensure a correct t.

3. Connect the air hose to the quick-connect tting. 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.

Torch Cable Male

Receptacle

strain relief

square cutout

Panel Receptacle

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.

Torch Lead Access Door

Work Cable

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31

SECTION 4 OPERATION

WARNING

ELECTRIC SHOCK CAN KILL.

• Do NoT operaTe The uNiT wiTh The cover removeD.

• Do NoT apply power To The uNiT while holDiNg or carryiNg The uNiT.

• D o NoT Touch aNy Torch par T s forwarD of Th e Torch haNDle (Noz z l e ,

HEAT SHIELD, ELECTRODE, ETC. WITH POWER SWITCH ON.

A

C

B

4.0 Operation

The PowerCut 900 will automatically tailor the arc for Normal cutting, Expanded metal / Grate cutting,

and Gouging operations. No manual switching is required.

4.1 Powercut 900 Controls

A. Power Switch. Turn knob clockwise to "ON" position for normal operation. Turn knob counterclockwise to

switch "OFF".

B. Pressure Regulator. Regulates torch air pressure. Rotate clockwise to increase and counterclockwise to de-

crease.

Note:

The unit is shipped from the factory with the regulator adjusted to deliver 80 psig (5.5 bar) to the torch

from a 95 psig (6.5 bar) supply. If supply pressure to the machine is greater than 95 psig (6.5 bar) up to the

maximum recommended 150 psig (10.3 bar), rotate pressure regulator knob counterclockwise to reduce

the pressure delivered to the torch back to 80 psig (5.5 bar). Follow TEST MODE instructions, see 4.1.D.

Pressure is indicated on the display screen.

C. Output Current Control. Adjustable from 20 to 60 amperes. For settings refer to cut data charts in the torch

manual.

Figure 4-1. Powercut 900 Controls

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