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1.  Preliminary release of this manual: 05/2009

2.  08/2009 - Minor changes, Updated replacement parts and schematics.

3.  11/2009 - Added 575V designations in sect 2, added cnc cable in sect 2, updated fig. 3-5, updated 

replacement parts and schematics.

4.  10/2013 - model # changes per J. Magee.

5.  03/2014 - Minor changes to specs per P. Moore.

rEVISION HISTOrY

Summary of Contents for Powercut 900

Page 1: ...Powercut 900 Manual Mechanized Plasmarc Cutting Package 0558008430 03 2014 Instruction Manual This manual provides complete instructions for MANUAL MECHANIZED CONSOLES...

Page 2: ...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 t...

Page 3: ...l 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 off Guide 36 4 4 Drag Cutting 40 Amp 36...

Page 4: ...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...

Page 5: ...ith a suitable non flammable partition or curtains 6 Use goggles over safety glasses when chipping slag or grinding Chipped slag may be hot and can fly far Bystanders should also wear goggles over saf...

Page 6: ...ealtheffectswhich 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...

Page 7: ...s Association 1235 Jefferson Davis Highway Arlington VA 22202 EQUIPMENT MAINTENANCE Faulty or improperly maintained equipment can cause injury or death Therefore 1 Alwayshavequalifiedpersonnelperformt...

Page 8: ...ety 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 finger penetration of s...

Page 9: ...el arco y chis pascalientesconunacortina adecuadano flamable como divisi n 6 Use careta protectora adem s de sus gafas de segu ridad cuando est removiendo escoria o puliendo La escoria puede estar cal...

Page 10: ...2 Exponerseacamposelectromagn ticos EMF puede causar otros efectos de salud a n desconocidos 3 Los soldadores deber n usar los siguientes proced imientos para minimizar exponerse al EMF A Mantenga el...

Page 11: ...MIENTO DEL EQUIPO Equipo defectuoso o mal mantenido puede causar da o o muerte Por lo tanto 1 Siempre tenga personal cualificado para efec tuar l a instalaci n diagn stico y mantenimiento del equipo N...

Page 12: ...n Est Alerta Se trata de su seguridad Significa riesgo inmediato que de no ser evadido puede resultar inmediatamente en serio da o personal o la muerte Significa el riesgo de un peligro potencial que...

Page 13: ...tion Ils r capitulent les informations de pr caution provenant des r f rences dans lasectiondesInformationsdes curit suppl men taires Avantdeproc der l installationoud utiliser l unit assurez vous de...

Page 14: ...ise persiste 4 Consultez ANSI ASC Standard Z49 1 la page suivante pour des recommandations sp cifiques concernant la ventilation 1 Assurez vous que le ch ssis de la source d alimentation est branch au...

Page 15: ...z contenant des chimiques consid res par l tat de la Californie comme tant une cause des malformations cong nitales et dans certains cas du cancer California Health Safety Code 25249 5 et seq MANIPULA...

Page 16: ...Soyez vigilant Votre s curit est en jeu Signifie un danger imm diat La situation peut entra ner des blessures graves ou mortelles Signifieundangerpotentielquipeutentra nerdes blessures graves ou mort...

Page 17: ...17 MANUAL PLASMARC CUTTING PACKAGE Powercut 900...

Page 18: ...18...

Page 19: ...ges for descriptions of the Powercut packages available as well as performance specifications 2 1 Scope The purpose of this manual is to provide the operator with all the information required to insta...

Page 20: ...hat 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 du...

Page 21: ...8 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...

Page 22: ...n 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...

Page 23: ...ed 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...

Page 24: ...E 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 Brow...

Page 25: ...ry 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 Failuret...

Page 26: ...theJ27ControlSupplyVoltagejumperplug violetwire onleftsideoftheunit towardstherearpanel seeFigure 3 2b Remove the cover plug from the J23 208 V header Move J27 jumper from J20 230 V to J23 208 V Place...

Page 27: ...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 interfac...

Page 28: ...ut 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...

Page 29: ...ng 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 cu...

Page 30: ...30 SECTION 3 INSTALLATION...

Page 31: ...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 regu...

Page 32: ...ion that may have accumulated during shutdown period Be sure to place switch in Normal Trigger or Trigger Lock position before starting cutting operations E Display Screen Displays current settings du...

Page 33: ...r assembly of torch consumables Torch nozzle making contact with workpiece at machine power up 10 Feedback improper current sensor failed 11 Primary over current Converter failure 12 Single phase oper...

Page 34: ...pilotarcshouldstart Themainarcshouldimmediatelyfollow allowing the cut to begin If using the trigger LOCK feature torch switch may be released after establishing the cutting arc See note NOTE Trigger...

Page 35: ...from re igniting after cutting arc extinguishes and causing damage to the nozzle double arcing J For rapid re starts such as grate or heavy mesh cutting do not release the torch switch In the postflow...

Page 36: ...reduce the life of torch consumables Attempting to Drag Cut with higher currents greater than 40 amps may cause immediate catastrophic consumable damage WARNING 4 4 Drag Cutting 40 Amp 4 5 Gouging wit...

Page 37: ...the torch For in depth instructions refer to torch manual for complete maintenance and operation 4 6 Electrode Wear Figure 4 6 Electrode Wear Limit REPLACE ELECTRODE BEFORE WEAR BECOMES DEEPER THAN 0...

Page 38: ...38 section 4 operation...

Page 39: ...39 MECHANIZED PLASMARC CUTTING PACKAGE Powercut 900...

Page 40: ...40...

Page 41: ...descrip tions of the Powercut packages available as well as performance specifications 2 1 Scope The purpose of this manual is to provide the operator with all the information required to install and...

Page 42: ...V CNC PT 38 50 ft 15 2m 0558008146 230 V CE CNC PT 37 w o rack 25 ft 7 6 m 0558009222 230 V CE CNC PT 37 w o rack 50 ft 15 2 m 0558009223 460 V CNC PT 37 with rack 25 ft 7 6 m 0558009210 460 V CNC PT...

Page 43: ...5 2 m 0558004861 PT 37 Torch with rack 25 7 6 m 0558004862 PT 37 Torch with rack 50 15 2 m 0558004863 PT 37 Torch w o rack 4 5 1 4 m 0558004894 PT 37 Torch w o rack 17 5 2 m 0558004895 PT 37 Torch w o...

Page 44: ...tch with 25 ft 7 6 m 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 c...

Page 45: ...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 throu...

Page 46: ...chart below CUSTOMER FUSED LINE DISCONNECT SWITCH See Table 3 1 PRIMARY INPUT POWER CABLE Figure 3 1 Input Connections STANDARD UNITS NON CE CE UNITS EUROPE PHASE 3 1 PHASE 3 1 L1 Black Black L1 Brow...

Page 47: ...s 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...

Page 48: ...agejumperplug violetwire onleftsidetowardstherearpanel seeFigure 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...

Page 49: ...connection of the filter 3 5 2 Input Air Connection Power Source CNC PC 900 Start Motion allow For autoMATIC height control Optional input External Current command Corner EXT REF 11 START 15 VDC CORNE...

Page 50: ...s 18 1 ratio 882 ohms 21 1 ratio 750 ohms 20 1 ratio 789 ohms 2 If desired additional minor adjustments of the VDR potentiometer may be made Any adjustments should be performed by a qualified technici...

Page 51: ...the Powercut 900 Torch Lead Access Door Make sure power switch on console is in OFF position and primary input power is de energized WARNING Figure 3 5 Powercut Interconnection Diagram PT 37 Torch Cla...

Page 52: ...ir Hose quick connect fitting 2 Connect the torch cable receptacle to the panel receptacle Check orientation of the sockets to ensure a correct fit 3 Connect the air hose to the quick connect fitting...

Page 53: ...lates 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 fr...

Page 54: ...ce switch in Normal Pilot Arc CENTER position or Continuous Pilot Arc DOWN position before starting cutting opera tions E Display Screen Initially displays the Current Setting during normal operation...

Page 55: ...ece 7 Pilot Arc timeout 5 seconds Cutting process did not begin within the 5 second limit 8 Torch error Improper assembly of torch consumables Torch nozzle making contact with workpiece at machine pow...

Page 56: ...dactsinconjunctionwiththecircuitry withinthepowersourcetopreventthetorchfrombeing energizedwithhighvoltageifthetorchswitchisacciden tally closed when the shield is removed Always replace torch with th...

Page 57: ...57 Powercut 900 MAINTENANCE TROUBLESHOOTING SCHEMATIC DIAGRAMS REPLACEMENT PARTS...

Page 58: ...58...

Page 59: ...suggestions for inspecting and cleaning are as follows A Check work cable for secured connection to workpiece B Check safety earth ground at workpiece and at power source chassis C Check heat shield o...

Page 60: ...it may be impossible to get dross free cuts 1 Current too low 2 Cutting speed too fast or too slow 3 Improper air pressure 4 Faulty nozzle or electrode 5 Low air flow rate D Double Arcing Damaged Noz...

Page 61: ...at from the device It is recommended that a unit manufactured with thermal compound use thermal compound for replacement even if replacement module was shipped with a thermal pad Thermal compound may...

Page 62: ...62 section 5 maintenance...

Page 63: ...l malfunctions can be found by referring to the sequence of operations and electrical sche matic diagram and checking the various components A volt ohmmeter will be necessary for some of these checks...

Page 64: ...ee consecutive times Check replace consumables If problem persists replace repair torch 10 Feedback improper Primarily seen if current sensor has failed Send unit to an Authorized Repair Station for r...

Page 65: ...only Hardware items should be available through local sources Note 7 0 Replacement Parts section 7 replacement parts Model P N DESCRIPTION SCHEMATIC DIAGRAM WIRING DIAGRAM 1 0558008120 PowerCut 900 20...

Page 66: ...6 SW1 22 35 K1 18 18 F1 14 TS1 12 HEATSINK 28 M1 18 WORK GND1 44 44 GND2 14 GND3 Hand GND A B C D E F G H J 25 GND K L 12 PCB1 POTENTIOMETERS 14 PCB2 3 14 PCB2 TB1 2 44 PCB2 J16 25 PCB3 TB4 44 PCB3 TB...

Page 67: ...used 3 Verify SW2 1 2 dip switches are in the open position for proper operation SW1 1 2 SW2 1 2 open 1 2 psi open 1 2 BAR open 1 2 open 1 2 7 4 Selecting Air Pressure Units of Measure 7 5 Control Dis...

Page 68: ...switches Settings 1 Verify SW1 1 2 dip switches are in the closed position for proper operation open 1 2 Important Note This replacement pc board may have a 10 32 fine stud for J16 Earlier PowerCut m...

Page 69: ...ivider Trimpot mechanized versions Important Note This replacement pc board may have 10 32 fine studs for TB3 TB5 and TB6 Earlier PowerCut machines and replacement pc boards have 10 24 course studs Ca...

Page 70: ...70 notes...

Page 71: ...es Updated replacement parts and schematics 3 11 2009 Added 575V designations in sect 2 added cnc cable in sect 2 updated fig 3 5 updated replacement parts and schematics 4 10 2013 model changes per J...

Page 72: ...5557 Hours 7 30 AM to 3 30 PM EST Repair Estimates Repair Status F WELDING EQUIPMENT TRAINING Telephone 843 664 4428 Fax 843 679 5864 Hours 7 30 AM to 4 00 PM EST Training School Information and Regi...

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