ESAB PowerCut 1300 Instruction Manual
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ESAB PowerCut 1300 Instruction Manual

Manual & mechanized plasmarc cutting package
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PowerCut 1300/1600
Manual & Mechanized Plasmarc Cutting Package
Instruction Manual
This manual provides complete instructions for MANUAL CONSOLES starting with Serial Number PxxJ824xxx, June 2008
This manual provides complete instructions for MECHANIZED CONSOLES starting with Serial Number PxxJ824xxx, June 2008
0558007164
11/2009

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Summary of Contents for ESAB PowerCut 1300

  • Page 1 PowerCut 1300/1600 Manual & Mechanized Plasmarc Cutting Package Instruction Manual This manual provides complete instructions for MANUAL CONSOLES starting with Serial Number PxxJ824xxx, June 2008 This manual provides complete instructions for MECHANIZED CONSOLES starting with Serial Number PxxJ824xxx, June 2008...
  • Page 2 BE SUrE THIS INfOrMATION rEACHES THE OPErATOr. YOU CAN gET ExTrA COPIES THrOUgH YOUr SUPPLIEr. CAUTION 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,”...

  • Page 3: Table Of Contents

    SECTION 4 OPERATION ..................................31 Operation ..................................31 PowerCut 1300/1600 Controls ..........................31 Cutting with the PowerCut 1300/1600 using the PT-38 torch ................34 Stand-off Guide ................................36 Drag Cutting 40 Amp ..............................36 Gouging with the PowerCut 1300/1600 using the PT-38 torch ..............36...
  • Page 4 PT-37 Torch Installation ..............................51 SECTION 4 OPERATION ..................................53 Operation ..................................53 PowerCut 1300/1600 Controls ..........................53 Cutting with the PowerCut 1300/1600 using the PT-37 torch ................56 Electrode Wear ................................56 MAINTENANCE, TrOUBLESHOOTINg, SCHEMATIC DIAgrAMS, rEPLACEMENT PArTS ..57 SECTION 5 MAINTENANCE ................................57 General ....................................59...

  • Page 5: Safety Precautions

    SECTION 1 SAfETY PrECAUTIONS Safety Precautions Safety - English WArNINg: These Safety Precautions are fIrES AND ExPLOSIONS -- Heat from for your protection. They summarize flames and arcs can start fires. Hot precautionary information from the slag or sparks can also cause fires and references listed in Additional Safety explosions.
  • Page 6 SECTION 1 SAfETY PrECAUTIONS 1. Be sure the power source frame (chassis) is con- 3. Welders should use the following procedures to nected to the ground system of the input power. minimize exposure to EMF: 2. Connect the work piece to a good electrical A.
  • Page 7 SECTION 1 SAfETY PrECAUTIONS 5. WArNINg: This product, when used for welding 1. Always have qualified personnel perform the instal- or cutting, produces fumes or gases lation, troubleshooting, and maintenance work. which contain chemicals known to Do not perform any electrical work unless you are the State of California to cause birth qualified to perform such work.
  • Page 8 SECTION 1 SAfETY PrECAUTIONS 5. AWS C5.5 - "Recommended Practices for Gas Tung- MEANINg Of SYMBOLS - As used sten Arc Welding“ throughout this manual: Means Atten- tion! Be Alert! Your safety is involved. 6. AWS C5.6 - "Recommended Practices for Gas Metal Arc Welding"“...

  • Page 9: Safety - Spanish

    SECTION 1 SEgUrIDAD Safety - Spanish La escoria puede estar caliente y desprenderse con velocidad. Personas cercanas deberán usar ADVErTENCIA: Estas Precauciones de gafas de seguridad y careta protectora. Seguridad son para su protección. Ellas hacen resumen de información prove- fUEgO Y ExPLOSIONES -- El calor de niente de las referencias listadas en la sección las flamas y el arco pueden ocacionar...
  • Page 10 SECTION 1 SEgUrIDAD 1. Asegúrese de que el chasis de la fuente de poder 3. Los soldadores deberán usar los siguientes proced- esté conectado a tierra através del sistema de imientos para minimizar exponerse al EMF: electricidad primario. 2. Conecte la pieza de trabajo a un buen sistema de A.
  • Page 11 SECTION 1 SEgUrIDAD 5. ADVErTENCIA-- Este producto cuando se uti- 1. Siempre tenga personal cualificado para efec- liza para soldaduras o cortes, tuar l a instalación, diagnóstico, y mantenimiento produce humos o gases, los del equipo. No ejecute ningún trabajo eléctrico a cuales contienen químicos menos que usted esté...
  • Page 12 SECTION 1 SEgUrIDAD SIgNIfICADO DE LOS SIMBOLOS Significa el riesgo de un peligro -- Según usted avanza en la lectura potencial que puede resultar en de este folleto: Los Símbolos Sig- serio daño personal o la muerte. nifican ¡Atención! ¡Esté Alerta! Se trata de su seguridad.

  • Page 13: Safety - French

    SECTION 1 SÉCUrITÉ INCENDIES ET ExPLOSIONS -- La Safety - french chaleur provenant des flammes ou de AVErTISSEMENT : Ces règles de sécurité l'arc peut provoquer un incendie. Le ont pour but d'assurer votre protection. laitier incandescent ou les étincelles Ils récapitulent les informations de pré- peuvent également provoquer un caution provenant des références dans...
  • Page 14 SECTION 1 SÉCUrITÉ 1. Assurez-vous que le châssis de la source 3. Les soudeurs doivent suivre les procédures suivantes d'alimentation est branché au système de mise à pour minimiser l'exposition aux champs électriques la terre de l'alimentation d'entrée. et magnétiques : 2.
  • Page 15 SECTION 1 SÉCUrITÉ 5. AVErTISSEMENT : Ce produit, lorsqu'il est utilisé ENTrETIEN DE L'ÉQUIPEMENT -- Un équipe- dans une opération de soudage ou de ment entretenu de façon défectueuse ou coupage, dégage des vapeurs ou des inadéquate peut causer des blessures gaz contenant des chimiques consid- graves ou mortelles.
  • Page 16 SECTION 1 SÉCUrITÉ SIgNIfICATION DES SYMBOLES AVErTISSEMENT Ce symbole, utilisé partout dans ce manuel, Signifie un danger potentiel qui peut entraîner des signifie "Attention" ! Soyez vigilant ! Votre blessures graves ou mortelles. sécurité est en jeu. ATTENTION DANgEr Signifie un danger qui peut entraîner des blessures Signifie un danger immédiat.

  • Page 17: Powercut 1300/1600 Manual Plasmarc Cutting Package

    PowerCut 1300/1600 MANUAL PLASMARC CUTTING PACKAGE...

  • Page 19: Description

    CrEATE AN ELECTrIC SHOCK HAZArD. 2.0 general As shipped, the PowerCut 1300/1600 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 de- liver cutting power for severing materials up to 1-1/2 inch (38 mm) thick on the PC-1300 and 1-3/4 inch (45 mm) thick on the PC-1600.

  • Page 20: Powercut 1300/1600 Manual Plasma

    DESCrIPTION PowerCut 1300/1600 Manual Plasma The PowerCut 1300/1600 plasma cutting package combines the newly redesigned PowerCut 1300/1600 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.

  • Page 21: Manual Package Ordering Information

    575 V PT-38 25 ft (7.6 m) Bilingual ..............................0558007238 575 V PT-38 50 ft (15.2 m) Bilingual ..............................0558007239 The components that are included in the PowerCut 1300/1600 manual packages may be purchased separately by using the appropriate P/N when placing orders. Individual part numbers are listed below:...

  • Page 22: Optional Accessories

    Powercut-900/1300/1600 Water Separator ... p/n 0558007897 Improves air quality by removing water. PowerCut 1300/1600 Mechanized Conversion kit ........p/n 0558007885 Adds automated mechanized capability to an existing manual machine. Refer to mechanized section of this manual for CNC Interface connection. Requires software version 1.04 or higher (displayed during power-up). Refer to Section 4, Subsection 4.1.E1.

  • Page 23: Installation

    SECTION 3 INSTALLATION INSTALLINg Or PLACINg ANY TYPE Of fILTErINg DEVICE WILL rE- WArNINg 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. Installation general Proper installation is important for satisfactory and trouble-free operation of the Powercut cutting package.

  • Page 24: Primary Input Connections

    POWEr SOUrCE. Primary Input Connections The PowerCut 1300/1600 consoles are equipped with approximately 10 ft. 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. When operating this machine from a single-phase source, it must be connected to a dedicated 100 amp feed.
  • Page 25 Refer to Table 3-1 for recommended input conductors and line fuse sizes. Table 3-1. (PowerCut 1300/1600) recommended Sizes for Input Conductors and Line fuses...

  • Page 26: Input Voltage Changeover - 230/460 Voltage Units Only

    208 - 230 or 460 Mode To simplify the use of the PowerCut 1300/1600 with different input voltages, it has been equipped with a 230/460 voltage selector switch located on the rear panel of the unit. Switching between 230 and 460 voltages can be done by using a flathead screwdriver.

  • Page 27: Provisions For Automation

    SECTION 3 INSTALLATION Provisions for Automation 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 0558007885.

  • Page 28: Secondary Output Connections For Manual Cutting

    3-3. Powercut Interconnection Diagram SAFETY GROUND WArNINg MAKE SUrE POWEr SWITCH ON CONSOLE IS IN Off POSITION AND PrIMArY INPUT POWEr IS DE-ENErgIZED. PT-38 Torch Installation Open torch lead access door on the front panel of the PowerCut 1300/1600. Torch Lead Access Door...
  • Page 29 SECTION 3 INSTALLATION Connect the torch cable receptacle to the panel receptacle. Check orientation of the sockets to ensure a correct fit. Panel Receptacle Torch Cable Male Receptacle Connect the air hose to the quick-connect fitting. Place the strain relief in the square cutout in the front of the console.
  • Page 30 SECTION 3 INSTALLATION...

  • Page 31: Operation

    80 psig (5.5 bar). Follow TEST MODE instructions, see 4.1.D. Pressure is indicated on the display screen. Output Current Control. Adjustable from 20 to 70 amperes on PowerCut 1300. Adjustable from 20 to 90 amperes on PowerCut 1600. For settings refer to cut data charts in the torch manual.
  • Page 32 "Help Code" menu on the front panel (non-"CE" units only) or in Section 4.1.F and in Troubleshooting Section 6.1. UP position CENTER position DOWN position Toggle Switch detail (Codes shown on Domestic and Bi-lingual units only) figure 4-2. Powercut 1300/1600 Controls...
  • Page 33 SECTION 4 OPErATION Note: All fault signals will remain on for a minimum of 10 seconds. If fault clears, all will reset automatically except for over-current. To clear over-current, the power must be shut off for 5 seconds and then turned back on.

  • Page 34: Cutting With The Powercut 1300/1600 Using The Pt-38 Torch

    CUTTINg ArEA. SPArKS AND HOT SLAg frOM THE CUTTINg OPErA- TION CAN DAMAgE THE UNIT. Cutting with the PowerCut 1300/1600 using the PT-38 torch Use the following procedures to cut with the PT-38 torch. Make sure that the wall disconnect switch is on and air is supplied to machine.
  • Page 35 SECTION 4 OPErATION After starting the cut, the torch should be maintained at a 5-15° forward angle. This angle is especially useful in helping to create a "drop" cut. When not using the stand-off guide, the nozzle should be held approximately 1/8" - 1/4" (3.2 mm - 6.4 mm) from the work.

  • Page 36: Stand-Off Guide

    TO DrAg CUT WITH HIgHEr CUrrENTS grEATEr THAN 40 AMPS MAY CAUSE IMMEDIATE CATASTrOPHIC CONSUMABLE DAMAgE. Stand-off guide Drag Cutting 40 Amp gouging with the PowerCut 1300/1600 using the PT-38 torch For in depth instructions refer to torch manual for complete maintenance and operation.

  • Page 37: Electrode Wear

    ENErgIZED WITH HIgH VOLTAgE If THE TOrCH SWITCH IS ACCIDEN- TALLY CLOSED WHEN THE SHIELD IS rEMOVED. ALWAYS rEPLACE TOrCH WITH THE PrOPEr TOrCH MANUfACTUrED BY ESAB SINCE IT ALONE CONTAINS ESAB'S SAfETY INTErLOCK. rEPLACE ELECTrODE BEfOrE WEAr BECOMES DEEPEr THAN .060"...
  • Page 38 SECTION 4 OPErATION...
  • Page 39 PowerCut 1300/1600 MECHANIZED PLASMARC CUTTING PACKAGE...

  • Page 41: Powercut 1300/1600 Mechanized Plasmarc Cutting Package

    SOLE COULD CrEATE AN ELECTrIC SHOCK HAZArD. 2.0 general As shipped, the PowerCut 1300/1600 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-37 (Mechanized Plasma) torch to deliver cutting power for severing materials up to 1 inch (25 mm) thick on the PC-1300 and 1-1/4 inch (32 mm) thick on the PC-1600.

  • Page 42: Section 2

    DESCrIPTION PowerCut 1300/1600 Mechanized Plasma The PowerCut 1300/1600 plasma cutting package combines the newly redesigned PowerCut 1300/1600 console and PT-37 torch. The PT-37 plasma cutting torch is designed to provide increased performance and longer consumable life resulting in higher production rates at lower costs.

  • Page 43: Description

    SECTION 2 DESCrIPTION Mechanized Package Ordering Information The components that are included in the PowerCut 1300/1600 mechanized packages may be purchased separately by using the ap- propriate P/N when placing orders. Individual part numbers are listed below: Available Packages: Powercut 1300: Powercut 1600: 208-230/460 V CNC PT-37 with rack 25 ft (7.6 m) ......0558008170...

  • Page 44: Powercut 1300/1600 Mechanized Plasma

    Powercut-900/1300/1600 Water Separator ... p/n 0558007897 Improves air quality by removing water. PowerCut 1300/1600 Mechanized Conversion kit ........p/n 0558007885 Adds automated mechanized capability to an existing manual machine. Refer to mechanized section of this manual for CNC Interface connection. Requires software version 1.04 or higher (displayed during power-up). Refer to Section 4,...

  • Page 45: Installation

    SECTION 3 INSTALLATION INSTALLINg Or PLACINg ANY TYPE Of fILTErINg DEVICE WILL rE- WArNINg 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. Installation general Proper installation is important for satisfactory and trouble-free operation of the Powercut cutting package.

  • Page 46: Primary Input Connections

    POWEr SOUrCE. Primary Input Connections The PowerCut 1300/1600 consoles are equipped with approximately 10 ft. 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. When operating this machine from a single-phase source, it must be connected to a dedicated 100 amp feed.

  • Page 47: Section 3

    Refer to Table 3-2 for recommended input conductors and line fuse sizes. Table 3-1. (PowerCut 1300/1600) recommended Sizes for Input Conductors and Line fuses...

  • Page 48: Input Voltage Changeover - 230/460 Voltage Units Only

    208 - 230 or 460 Mode To simplify the use of the PowerCut 1300/1600 with different input voltages, it has been equipped with a 230/460 voltage selector switch located on the rear panel of the unit. Switching between 230 and 460 voltages can be done by using a flathead screwdriver.

  • Page 49: Cnc Interface Connection

    SECTION 3 INSTALLATION CNC Interface Connection Power Source PC-1300/1600 STArT (P1-5) STArT STArT +15 VDC (P1-4) + 15 VDC COrNEr COrNEr / ExT rEf (P1-6) ExT rEf COrNEr / ExT rEf ArC ON COMMON (P1-7) (ArC ON) MOTION ArC ON (P1-8) (ArC ON) ALLOW...

  • Page 50: Voltage Divider Adjustment

    SECTION 3 INSTALLATION WArNINg MAKE SUrE POWEr SWITCH ON CONSOLE IS IN Off POSITION AND PrIMArY INPUT POWEr IS DE-ENErgIZED. Voltage Divider Adjustment It may be necessary to adjust the Voltage Divider or VDR to match the particular height control system. There are two default settings for the PowerCut models as shipped from the factory: •...

  • Page 51: Secondary Output Connections For Mechanized Cutting

    3-4. Powercut Interconnection Diagram WArNINg MAKE SUrE POWEr SWITCH ON CONSOLE IS IN Off POSITION AND PrIMArY INPUT POWEr IS DE-ENErgIZED. PT-37 Torch Installation Open torch lead access door on the front panel of the PowerCut 1300/1600. Torch Lead Access Door...

  • Page 52: Section 3

    SECTION 3 INSTALLATION Connect the torch cable receptacle to the panel receptacle. Check orientation of the sockets to ensure a correct fit. Panel Receptacle Torch Cable Male Receptacle Connect the air hose to the quick-connect fitting. Place the strain relief in the square cutout in the front of the console.

  • Page 53: Operation

    80 psig (5.5 bar). Follow TEST MODE instructions, see 4.1.D. Pressure is indicated on the display screen. Output Current Control. Adjustable from 20 to 70 amperes on PowerCut 1300. Adjustable from 20 to 90 amperes on PowerCut 1600. For settings refer to cut data charts in the torch manual.

  • Page 54: Section 4

    "Help Code" menu on the front panel (non-"CE" units only) or in Section 4.1.F and in Troubleshooting Section 6.1. UP position CENTER position DOWN position Toggle Switch detail (Codes shown on Domestic and Bi-lingual units only) figure 4-2. Powercut 1300/1600 Controls...

  • Page 55: Section 4

    SECTION 4 OPErATION Note: All fault signals will remain on for a minimum of 10 seconds. If fault clears, all will reset automatically except for over-current. To clear over-current, the power must be shut off for 5 seconds and then turned back on. Help Codes (See Section 6.1, Troubleshooting for Causes and Solutions): Line voltage, idle +/- 15 % - line voltage has fluctuated +/- 15 %.

  • Page 56: Cutting With The Powercut 1300/1600 Using The Pt-37 Torch

    TOrCH WITH THE PrOPEr TOrCH MANUfACTUrED BY ESAB SINCE IT ALONE CONTAINS ESAB'S SAfETY INTErLOCK. Cutting with the PowerCut 1300/1600 using the PT-37 torch A. Make sure that the wall disconnect switch is on and air is supplied to machine.

  • Page 57: Maintenance Troubleshooting Schematic Diagrams Replacement Parts

    PowerCut 1300/1600 MAINTENANCE TROUBLESHOOTING SCHEMATIC DIAGRAMS REPLACEMENT PARTS...

  • Page 59: General

    SECTION 5 MAINTENANCE BE SUrE THAT THE WALL DISCONNECT SWITCH Or WALL CIrCUIT WArNINg BrEAKEr IS OPEN BEfOrE ATTEMPTINg ANY INSPECTION Or WOrK INSIDE Of THE POWErCUT. general If this equipment does not operate properly, stop work immediately and investigate the cause of the malfunc- tion.

  • Page 60: Common Cutting Problems

    Listed below are common cutting problems followed by the probable cause of each. If problems are determined to be caused by the Powercut, refer to the maintenance section of this manual. If the problem is not corrected after referring to the maintenance section, contact your ESAB distributor. A. Insufficient Penetration.

  • Page 61: Igbt Handling

    SECTION 5 MAINTENANCE IgBT Handling Since IGBT gates are insulated from any other conducting region, care should be taken to prevent static build up, which could possibly damage gate oxides. All IGBT modules are shipped from the factory with conductive foam contacting the gate and emitter sense pins.
  • Page 62 SECTION 5 MAINTENANCE...

  • Page 63: Troubleshooting

    SECTION 6 TrOUBLESHOOTINg ELECTrIC SHOCK CAN KILL! BE SUrE THAT ALL PrIMArY POWEr TO WArNINg THE MACHINE HAS BEEN ExTErNALLY DISCONNECTED. OPEN THE LINE (WALL) DISCONNECT SWITCH Or CIrCUIT BrEAKEr BEfOrE AT- TEMPTINg INSPECTION Or WOrK INSIDE Of THE POWEr SOUrCE. VOLTAgES IN PLASMA CUTTINg EQUIPMENT ArE HIgH ENOUgH WArNINg TO CAUSE SErIOUS INJUrY Or POSSIBLY DEATH.

  • Page 64: List Of Help Codes

    SECTION 6 TrOUBLESHOOTINg List of Help Codes Code Error Cause Solution Line voltage, idle +/- 15 % Supply line voltage either dropped or Check voltage supply. exceeded nominal input setting while idle. Line voltage, cutting +/- 20 % Supply line voltage either dropped or ex- Check voltage supply.

  • Page 65: Replacement Parts

    Ordering To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this equipment. The use of non-ESAB parts may void your warranty. Replacement parts may be ordered from your ESAB Distributor. Be sure to indicate any special shipping instructions when ordering replacement parts. Refer to the Communications Guide located on the back page of this manual for a list of customer service phone num- bers.

  • Page 66: Torque Recommendations

    SECTION 7 rEPLACEMENT PArTS Torque recommendations rECOMMENDED TOrQUES ( IN/LBS ±10% ) SYMBOL / DESCrIPTION MOUNT TErMINAL BR101 Q101,102,103 D101,102 C101-104 R2,5,7,10,12,14,15 25 / 18 K1 (PC-1600 230/460V) K1 (All Others) TS1,2 HEATSINK WORK , GND1 BUSSBAR DIODE (-) PCB1 - POTENTIOMETERS PCB2 PCB2 - TB1,2,3,4,7 PCB2 - TB8, J18, P1...

  • Page 67: Selecting Air Pressure Units Of Measure

    SECTION 7 rEPLACEMENT PArTS Selecting Air Pressure Units of Measure 1. Set SW1-1 dip switch for desired air pressure units of measure. • PSI - “OPEN” • BAR - Not Open 2. SW1-2 is not used. 3. Verify SW2 - 1,2 dip switches are in the “open” position for proper operation. Control/Display Board Assembly CONTrOL/DISPLAY BOArD ASSEMBLY P/N 0558038317...

  • Page 68: Power Board Assembly

    SECTION 7 rEPLACEMENT PArTS Power Board Assembly POWEr BOArD ASSEMBLY P/N 0558038315, 0558038323, 0558038346, 0558038347, 0558038379, 0558038380 Before installation: 1. Disconnect input power to machine. 2. Verify position of dip switches. Settings: open 1. Verify SW1 - 1,2 dip switches are in the “closed” position for proper operation. J18 stud TB-8 stud Voltage Divider Trimpot...
  • Page 69 rEVISION HISTOrY Preliminary release of this manual is 05/2007. Released FOR BETA USE ONLY 06/2007. Released FOR BETA USE ONLY 09/2007. Released FOR BETA USE ONLY 04/2008. Official release 07/2008. 08/2008 - Minor changes, Updated replacement parts and schematics. 10/2008 - Updated specifications, Updated replacement parts and schematics. Revision 11/2008 - New 575 V Control Transformer, added plug to fan assembly, updated replacement parts and schematics.
  • Page 70 ESAB Welding & Cutting Products, florence, SC Welding Equipment COMMUNICATION gUIDE - CUSTOMEr SErVICES CUSTOMER SERVICE QUESTIONS: Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST Order Entry Product Availability Pricing Order Information Returns ENGINEERING SERVICE:...

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