ESAB PowerCut 400 User manual
- Category
- Welding System
- Type
- User manual
ESAB PowerCut 400 is an air plasma cutting machine for manual cutting. It makes all types of cuts on electrically conductive materials up to 0.5” (12.7 mm) thick. Adjust the cutting current between 15 and 30 amps depending on the main power supply and circuit breaker. It features a control board that manages various functions, a pilot arc board, and a display board that handles communication between the user and the machine. The PowerCut 400 is designed for indoor and outdoor use.
ESAB PowerCut 400 is an air plasma cutting machine for manual cutting. It makes all types of cuts on electrically conductive materials up to 0.5” (12.7 mm) thick. Adjust the cutting current between 15 and 30 amps depending on the main power supply and circuit breaker. It features a control board that manages various functions, a pilot arc board, and a display board that handles communication between the user and the machine. The PowerCut 400 is designed for indoor and outdoor use.
0740 800 214 20121125 Valid for serial no.145-xxx-xxxx
PowerCut™
©
400
Service manual
0740 800 214 20121125 Valid for serial no.145-xxx-xxxx
bp22 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, 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
bp22 2
Rights reserved to alter specifications without notice.
bp22 3 © ESAB AB 2012
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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.
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 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 al-
uminium. It delivers cutting power for severing materials up to 0.5” (12.7 mm) thick-
ness. The operating range is from 90 to 280 V AC
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 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.
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3 Mechanical design
3.1 Front
1 Control panel
2 Output current control
3 Torch connection
4 Return cable connection
3.2 Rear
1 Power switch ON/OFF
2 Air connection
3 Power connection
4 Side cover
1
2
3
4
1
2
3
4
pc400e002
pc400e001
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3.3 Main parts
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)
4
1
2
5
3
6
7
8
10
11
9
pc400e003
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3.4 Control panel
1 Output current control
A control to adjust cutting current from 15A to 30A. The operating range is depend-
ent 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 nor-
mal.
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.
120V 15A
20
17
15
25
30
A
PowerCut™ 400
120V 20A
230V 20A
7
6
5
4
3
1
2
pc400e004
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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 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 U
0
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
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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. Fur-
ther 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 heat-
sinks on the control board. When the temperature becomes too high the welding cur-
rent 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 “Con-
trol 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 en-
sure 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.
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pc400e005
PCB CONTROL PFC
PIP
350V DC
230V AC
90V DC
to Torch
140/150V DC
18A
NTC SENSOR
INDUCTOR
TRANSFORMER
INDUCTOR
SAFETY SWITCH
( COVER )
FAN
FAN
INDUCTOR
MAIN SWITCH
THERMISTOR THERMISTOR
+17V DC
15V DC
0V DC
SOLENOID VALVE
CPILOT
POWER
ON
PIP FAULT
POTENTIOMETER
AIR
PRESSURE
OVER
TEMP.
SWPILOT
PILOT ARC
TORCH PIP
AIR SENSOR
3,5 Bar
TORCH ON/OFF
CONTROL BOARD
0700 210 014
PILOT ARC BOARD
0700 210 027
DISPLAY BOARD
0700 210 008
12V DC
0V DC
12V DC
0V DC
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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.
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 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.
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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 be-
tween 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 instruc-
tions”.
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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 “Re-
place 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 dis-
play 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 “Re-
place 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”.
bp22 13 © ESAB AB 2012
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If there is no voltage, replace the display board, see instructions in “Replace the dis-
play 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 prob-
lems 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 acti-
vated. The power is turned off.
2 Check the safety switch and replace if damaged, see instructions “Replace the safe-
ty switch” in section “Service instructions”.
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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 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.
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 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.
bp22 15 © ESAB AB 2012
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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
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7.1 Remove the cover
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.
pc400e018
3
2
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7.2 Replace the consumables
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.
pctorch001
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7.3 Replace the torch
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.
pc400e006
2
3
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ESAB PowerCut 400 User manual
- Category
- Welding System
- Type
- User manual
ESAB PowerCut 400 is an air plasma cutting machine for manual cutting. It makes all types of cuts on electrically conductive materials up to 0.5” (12.7 mm) thick. Adjust the cutting current between 15 and 30 amps depending on the main power supply and circuit breaker. It features a control board that manages various functions, a pilot arc board, and a display board that handles communication between the user and the machine. The PowerCut 400 is designed for indoor and outdoor use.
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