ESAB PowerCut 400 User manual

Valid for serial no. 145-xxx-xxxx0463 277 001 GB 20121125

PowerCut™ 400

PT-39

Instruction manual

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TOCe

Rights reserved to alter specifications without notice.

APPLICATIONS 24.......................................................

1 SAFETY 6...........................................................

2 INTRODUCTION 8...................................................

2.1 Equipment 8................................................................

3 TECHNICAL DATA 8.................................................

4 INSTALLATION 9....................................................

4.1 Delivery check and location 10.................................................

4.2 Primary 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 NUMBER 28.....................................................

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1 SAFETY

Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on or

near the equipment observes all the relevant safety precautions. Safety precautions must meet the

requirements that apply to this type of equipment. The following recommendations should be

observed in addition to the standard regulations that apply to the workplace.

All work must be carried out by trained personnel well-acquainted with the operation of the

equipment. Incorrect operation of the equipment may lead to hazardous situations which can result

in injury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:

Sits operation

Slocation of emergency stops

Sits function

Srelevant safety precautions

Swelding and cutting

2. The operator must ensure that:

Sno unauthorised person is stationed within the working area of the equipment when it is

started up.

Sno-one is unprotected when the arc is struck

3. The workplace must:

Sbe suitable for the purpose

Sbe free from drafts

4. Personal safety equipment

SAlways wear recommended personal safety equipment, such as safety glasses, flame-proof

clothing, safety gloves.

SDo not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautions

SMake sure the return cable is connected securely.

SWork on high voltage equipment may only be carried out by a qualified electrician.

SAppropriate fire extinquishing equipment must be clearly marked and close at hand.

SLubrication and maintenance must not be carried out on the equipment during operation.

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WARNING

Read and understand the instruction manual before installing or operating.

Arc welding and cutting can be injurious to yourself and others. Take precautions when welding and

cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard

data.

ELECTRIC SHOCK - Can kill

SInstall and earth the unit in accordance with applicable standards.

SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

SInsulate yourself from earth and the workpiece.

SEnsure your working stance is safe.

FUMES AND GASES - Can be dangerous to health

SKeep your head out of the fumes.

SUse ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone

and the general area.

ARC RAYS - Can injure eyes and burn skin.

SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.

SProtect bystanders with suitable screens or curtains.

FIRE HAZARD

SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE - Excessive noise can damage hearing

SProtect your ears. Use earmuffs or other hearing protection.

SWarn bystanders of the risk.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

WARNING

Do not use the power source for thawing frozen pipes.

CAUTION

Class A equipment is not intended for use in residential locations where

the electrical power is provided by the public low-voltage supply system.

There may be potential difficulties in ensuring electromagnetic

compatibility of class A equipment in those locations, due to conducted

as well as radiated disturbances.

CAUTION

This product is solely intended for plasma cutting.

CAUTION

Read and understand the instruction manual before

installing or operating.

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Dispose of electronic equipment at the recycling facility!

In observance of European Directive 2002/96/EC on Waste Electrical and Electronic

Equipment and its implementation in accordance with national law, electrical and/or

electronic equipment that has reached the end of its life must be disposed of at a

recycling facility.

As the person responsible for the equipment, it is your responsibility to obtain

information on approved collection stations.

For further information contact the nearest ESAB dealer.

ESAB can provide you with all necessary cutting protection and accessories.

2 INTRODUCTION

The PowerCut 400 is a complete system for manual plasma cutting. It delivers

cutting power for severing materials up to 13 mm thickness.

2.1 Equipment

The power source is supplied with:

Spower cable, 3 m

Sinstruction manual

Sreturn cable with clamp

Splasma cutting torch PT-39, 4.6 m, supplied as indicated on page 28

Swear 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

Permitted load

25 % duty cycle 110 V

60 % duty cycle 110 V

20 % duty cycle 230V

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 U0250 V

Operating temperature -10 to 40 °C

Transportation temperature -20 to 55 °C

Sound pressure at no load < 43 db (A)

Nominal flow rate 189 l/min at 4.8 bar

Dimensions, l x w x h 465 x 160 x 340 mm

Weight including torch and return cable 14.5 kg

Insulation class transformer H

Enclosure class IP 23

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Duty cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or cut at

a certain load without overloading. The duty cycle is valid for 40°C.

Enclosure class

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

objects or water. Equipment marked IP23 is designed for indoor and outdoor use.

4 INSTALLATION

The installation must be carried out by a professional.

Correct installation is very important for trouble-free operation and good cutting

results. Carefully read and follow each step in this chapter.

WARNING

ELECTRIC SHOCKS CAN KILL 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 electrical accidents. Ensure that protective

earth is not connected to any phase conductors by mistake.

WARNING

Poor connections or failure to connect the return cable to the workpiece can result

in fatal electric shock.

WARNING

Air filter devices may not be used –installation or mounting of any form of air filter

device obstructs the cold air flow and causes a risk of overheating. The warranty is

invalidated if any type of air filter is used.

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WARNING

Do NOT start the equipment with the cover removed.

Do NOT connect the power source with the main switch in ON position or when you

are holding it or carrying it.

Do NOT touch any of the torch's parts when the power supply is on.

CAUTION

This product is intended for industrial use. In a domestic environment this product may

cause radio interference. It is the user's responsibility to take adequate precautions.

CAUTION

Place the power source at least 3 metres from the cutting area as sparks and slag spray

can damage the power source

4.1 Delivery check and location

1. Remove the 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 lifted easily.

3. Position the power source so that its cooling air inlets and outlets are not

obstructed. Minimum permitted distance to wall or other obstruction is

1 m.

4. An air source that gives clean and dry air, at least 189 l/m at 4.8 bar, is

required for cutting. The cutting air pressure must not exceed 6 bar, which is the

maximum inlet pressure for the filter regulator that is included in the delivery.

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