ESAB PowerCut 400 Instruction Manual Download

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Valid for serial no. 145-xxx-xxxx

0463 277 001 GB 20121125

PowerCut™ 400
PT-39

Instruction manual

Summary of Contents for PowerCut 400

Page 1: ...GB Valid for serial no 145 xxx xxxx 0463 277 001 GB 20121125 PowerCut 400 PT 39 Instruction manual ...

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Page 5: ... power supply 11 4 3 Input air connection 12 4 4 Connection for return cable 12 4 5 Connection of torch 13 5 OPERATION 14 5 1 Connections 14 5 2 Control devices 15 5 2 1 Symbol key 16 5 3 Installing consumables for the torch 17 5 4 Cutting 18 6 MAINTENANCE 19 6 1 Inspection and cleaning 20 7 TROUBLESHOOTING 20 7 1 Troubleshooting guide 21 8 ORDERING SPARE PARTS 23 DIAGRAM 24 WEAR PARTS 27 ORDER NU...

Page 6: ...f emergency stops S its function S relevant safety precautions S welding and cutting 2 The operator must ensure that S no unauthorised person is stationed within the working area of the equipment when it is started up S no one is unprotected when the arc is struck 3 The workplace must S be suitable for the purpose S be free from drafts 4 Personal safety equipment S Always wear recommended personal...

Page 7: ...tect your eyes and body Use the correct welding screen and filter lens and wear protective clothing S Protect bystanders with suitable screens or curtains FIRE HAZARD S Sparks spatter can cause fire Make sure therefore that there are no inflammable materials nearby NOISE Excessive noise can damage hearing S Protect your ears Use earmuffs or other hearing protection S Warn bystanders of the risk MA...

Page 8: ...s cutting power for severing materials up to 13 mm thickness 2 1 Equipment The power source is supplied with S power cable 3 m S instruction manual S return cable with clamp S plasma cutting torch PT 39 4 6 m supplied as indicated on page 28 S wear part kit for PT 39 3 TECHNICAL DATA PowerCut 400 Mains voltage range 90 280 V 1 50 60 Hz Setting range rated value 110 V 15 25 A 230 V 15 30 A Permitte...

Page 9: ...ILL Take precautionary measures against electric shocks Ensure that all power supplies are disconnected switch off the switch at the wall socket and pull out the equipment s power cable from the socket before making any electrical connections in the power source WARNING It is very important that the chassis is connected to the approved electric protective earth to prevent electric shocks and elect...

Page 10: ...packaging Inspect the equipment for damage that was not immediately apparent upon reception of the delivery Immediately report any damage to the delivery company 2 Check for any loose parts in the packaging Check that the air ducts in the cover s rear panel are not blocked by packaging material that can prevent the air flow through the power source The power source has a carrying handle and can be...

Page 11: ...9 A Fuse anti surge 32 A 16 A NOTE The mains cable areas and fuse sizes as shown above are in accordance with Swedish regulations Use the power source in accordance with the relevant national regulations Supply from power generators The power source can be supplied from different types of generators However some generators may not provide sufficient power for cutting Generators with AVR equivalent...

Page 12: ...compressor may be used The air must be free from polluting particles A pressure regulator is provided to ensure the correct air flow rate on the torch It is set from factory at 4 8 bar 4 4 Connection for return cable Clamp the return cable to the workpiece Be sure the workpiece is connected to an approved earth ground with a properly sized ground cable GB ...

Page 13: ...he torch 1 Turn off the main switch disconnect the power cable and the air supply 2 Open the little left side panel by unscrewing 2 screws 3 Insert the torch end with cable receptacle and air hose through the hole in the front of the power source 4 Connect the violet torch power cable by tightening 1 screw 5 Connect the 2 black torch trigger cables 6 Connect the red torch pilot cable 7 Connect the...

Page 14: ...ndling the equipment can be found on page 6 Read through before you start using the equipment 5 1 Connections 1 Power switch ON OFF 5 Connection for return cable 2 Connection for air 6 Connection for torch 3 Power cable 7 Control devices see chapter 5 2 4 Side panel GB ...

Page 15: ...the thickness of material that can be cut and the quality of a cut at a given speed Special care should be taken to keep the cutting current below 17A when powering the machine from 110V mains supply with a 16A circuit breaker 2 Primary Input Voltage Circuit Breaker Key The symbol explains the yellow field on the output current control Max output current for 110 V and 32A circuit breaker is 25A 3 ...

Page 16: ...as detected or that the electrode is not retracting properly Turn off the power Check that the components are properly assembled that they are free from excessive damage and that the electrode can slide back and forth with comfortable pressure from one finger Once the source of the error has been corrected turn on the power again 7 Power ON Indicator When the green LED is lit it indicates that the...

Page 17: ... can prevent unnecessary torch damage 1 Tighten electrode and retaining shield cup fully at each consumable change or inspection 2 Check consumable tightness at the beginning of each work period even if everything was working normally at the end of the previous period A Torch body assembly B Baffle C Electrode D Nozzle E Retaining Shield cup F Piston G Electrode Torch body seat See wear parts on p...

Page 18: ...ow allowing the cut to begin 7 To start a cut tilt the torch to prevent molten material from splashing back and damaging the torch When the arc breaks through the workpiece bring the torch to an upright position and proceed to cut 8 When ending a cut the torch switch should be released and the torch lifted off the workpiece immediately upon completion of the cut This is to prevent the pilot arc fr...

Page 19: ...tant to get the optimal performance and lifetime Only those persons who have appropriate electrical knowledge authorized personnel may remove the safety plates WARNING Ensure that the mains voltage supply to the power source has been disconnected externally Switch off the switch at the wall socket before inspecting or working in the power source WARNING Water or oil can collect in the compressed a...

Page 20: ... not damaged or bent 6 Check that all plugs and connections and ground terminals are firmly connected 7 Ensure that all incoming power supplies are disconnected Use goggles and face mask and blow clean the power source internally using dry compressed air at low pressure 7 TROUBLESHOOTING WARNING ELECTRIC SHOCKS CAN KILL Ensure that the mains voltage supply to the power source has been disconnected...

Page 21: ...but the green LED power does not light up S There is no power present S Tripped circuit breaker S Check the power supply S Check the breaker The power source is on but the yellow AIR PRESSURE LED remains lit S The air pressure is low S No air is present S Check that the air filter is not blocked S Increase the air pressure S Check if air is supplied The power source is on but the yellow OVER TEMPE...

Page 22: ...n the incoming line S Check the torch and fit spare parts if necessary S See if the yellow OVER TEMPERATURE LED on the front panel is lit Wait until the power source cools down S See if the yellow AIR PRESSURE LED on the front panel is lit Increase the air pressure S Check whether the air filter is blocked and replace it if necessary S Check the incoming line If an extension is being used ensure t...

Page 23: ...he obligation of the service unit which has carried out the service or repair work to make sure that the product still conforms to the said stan dard PT 39 is designed and tested in accordance with the international and European standard EN 60974 7 It is the obligation of the service unit which has carried out the service or repair work to make sure that the product still conforms to the said stan...

Page 24: ... ESAB AB 2012 Diagram 24 bp28diag ...

Page 25: ... ESAB AB 2012 25 bp28diag ...

Page 26: ... ESAB AB 2012 26 bp28app2 Stainless Steel and Aluminium Cut Speeds Carbon Steel Cut Speeds ...

Page 27: ...o Denomination Notes 0558 010 586 Wear parts kit consisting of 30 Amp for PowerCut 400 3 0558 005 220 Electrode 1 0558 005 217 Gas baffle 30 80 Amp 4 0558 011 620 Nozzle 30 Amp 1 0558 011 886 Retaining cup 1 0558 010 581 Standoff guide assy 3 O ring 301ID 070W Nitrile 1 Grease silicon dow DC 111 1 4 Oz ...

Page 28: ... Ordering no Denomination Type Notes 0700 210 880 Power source for plasma cutting incl torch 4 6m return cable and wear part kit PowerCut 400 90V 280V 1 ph 0558 010 576 Torch PT 39 4 6 m Technical documentation is available on the Internet at www esab com ...

Page 29: ... 29 notes NOTES ...

Page 30: ...D Tel 34 91 878 3600 Fax 34 91 802 3461 SWEDEN ESAB Sverige AB Gothenburg Tel 46 31 50 95 00 Fax 46 31 50 92 22 ESAB international AB Gothenburg Tel 46 31 50 90 00 Fax 46 31 50 93 60 SWITZERLAND ESAB AG Dietikon Tel 41 1 741 25 25 Fax 41 1 740 30 55 UKRAINE ESAB Ukraine LLC Kiev Tel 38 044 501 23 24 Fax 38 044 575 21 88 North and South America ARGENTINA CONARCO Buenos Aires Tel 54 11 4 753 4039 Fa...

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