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POWERCUT-1250 / 1500

1. 12 5 318mm Powercut 1 500 PT 32EH 90A Nozzle P N 0558002837 M S H 16 5 419mm _ AA A Don am Air Pressure 80 psi 5 32 Standoff WVU m ee een 94 lbs 42 7kg Air Requirements 350 80 psig 165 l min 5 5 bars Max Speeds Carbon Steel Supply S Plate Drop Cut Sever inimum short circuit power on the network in accordance wit Inches mm IPM mm min IPM mm min 400V CE Mains Supply Z 0 250 6 35 151 3835 4 153 3886 2 Maximum permissible line on the network impedance in accordance 0 500 12 7 56 1422 4 58 1473 2 with IEC61000 3 11 0 750 19 05 25 635 26 660 4 1 000 25 4 16 406 4 18 457 2 Torch 1 250 31 75 11 279 4 12 304 8 PowerCut 1500 uses the PT 32EH torch For complete list and 1 500 38 1 7 177 8 8 203 2 breakdown of parts refer to Figure 1 1 Ordering Information PowerCut 1500 230 460 V 25 7 6m 2 0558001942 PowerCut 1500 230 460 V 50 15 2m PT 32EH 0558001943 Consoles PowerCut 1500 575 V 25 7 6m 32 0558001948 PowerCut 1500 208 230 460 V 50 60 Hz 1 3 ph 0558003570 PowerCut 1500 575 V 50 15 2m PT 32EH 0558001949 PowerCut 1500 208 230 460 V 50 60 Hz 1 3 ph BL
2. 0558004190 PT 21AMX Torches Without Rack 50 ft 15 20 ondaa 0558003615 With Rack 50 ft 0558003614 Without Rack 25 ft 7 6M 0558003617 With Rack 25 ft 0558003616 Spare Parts Kits see section 1 2 3 PT 21AMX Spare Parts Kit 50 21370 2461001 21 Spare Parts Kit 70 21369 0558000848 DESCRIPTION PT 21AMX Cut Data 70 AMPS Powercut 1250 PT 21AMX 70A Nozzle P N 21329 4485834 Air Pressure 75 85 psi 3 16 to 1 4 Standoff Max Speeds Mild Steel Plate Optimum Maximum Inches mm IPM mm min IPM mm min 0 125 3 175 190 4826 210 5334 0 250 6 35 85 2159 101 2565 4 0 500 12 7 30 762 39 990 6 0 750 19 05 13 330 2 15 381 1 000 25 4 5 127 7 177 8 1 250 31 75 3 76 2 5 127 NOTE Part numbers in parenthesis apply to CE European units 36 SECTION 1 DESCRIPTION 1 2 2 1500 MECHANIZED PLASMA The PowerCut 1500 plasma cutting package combines the proven reliability of the PowerCut 1500 with the newly designed PT 21AMX torch The PT 21AMX plasma cutting torch is designed to provide increased performance and longer consumable life resulting in higher production rates at lower costs Specifications PowerCut 1500 Cuts 1 1 2 in 38mm TOR OE een 208 230 vac 1 ph 50 60 Hz 82 74 A A A
3. 0558005331 PT 32EH Torches PT 32EH Torch 25 ft 7 6m 0558003548 PT 32EH Torch 50 ft 15 21 0558003549 Spare Parts Kits see section 1 2 3 PI 32EH Spare Parte Kit nun 0558003508 PT 32EH 400 V Long Heat Shield LHS Spare Parts Kit CE units M 0558003560 14 SECTION 1 DESCRIPTION 1 2 2 PC 1500 MANUAL PLASMA The PowerCut 1500 plasma cutting package combines the proven reliability of the PowerCut 1500 with the newly designed PT 32EH torch The very strong composite case material makes the PowerCut 1500 an excellent addition to any equipment rental fleet The PT 32EH plasma cutting torch is designed to provide increased performance and longer consumable life resulting in higher production rates at lower costs Specifications PowerCut 1500 Cuts 1 1 2 in 38mm severs 1 3 4 in 45mm TORIO DU rat 208 230 vac 1 ph 50 60 Hz 82 74 A ISSUED 90 amps 40 duty cycle 3 ph NEUE ae 208 230 vac 3 ph 50 60 Hz 44 40 A 230 460 vac 3 ph 50 60 Hz 40 27 A 400 3ph 50 60 Hz 26 A 400V Mains Supply nenn aa Sen 3 8MVA 2 0 0420 ME 575 vac 3ph 50 60 Hz 18 A PT 32EH Cut Data 90 AMPS S ph QUT dre 90 amps 60 duty cycle
4. 90 amps 40 duty cycle 3 DID ne 208 230 vac 3 ph 50 60 Hz 44 40 A 230 460 vac 3 ph 50 60 Hz 40 27 A 400 vac 3ph 50 60 Hz 26 A 400V CE Mains SUDDIV aan Sen 3 8MVA Z x 0 0420 een 575 vac 3ph 50 60 Hz 18 A Spic nennen 90 amps 60 duty cycle NOTE Part numbers in parenthesis apply to CE European units DIMENSIONS een ee W 12 5 318mm H 16 5 419mm l D 31 5 800mm Weight 94 Ibs 42 7kg PT 21AMX Cut Data 90 AMPS Air Requirements 350 80 psig 165 l min 5 5 bars Powercut 1500 PT 21AMX 90A Nozzle P N 0558004269 Air Pressure 85 psi 3 16 to 1 4 Standoff 400V CE Mains Supply S min Minimum short circuit power on the network in accordance with IEC61000 3 12 Max Speeds Mild Steel 400V CE Mains Supply 2 Maximum permissible line on the network impedance in accordance Plate Optimum Maximum with IEC61000 3 1 1 Inches mm IPM mm min IPM mm min 0 250 6 35 120 3048 150 3810 Torch 0 500 12 7 49 1244 6 55 1397 PowerCut 1500 uses the PT 21AMX torch For complete list and breakdown of parts refer to Figure 1 2 0 750 19 05 22 558 8 25 635 1 000 25 4 12 304 8 13 3302 Ordering Information 1 250 31 75 7 1778
5. a O II E AE A E OA A S Primary Electrical Input Connections Manual Plasma Cutting lt Secondary Output Connections for Manual Plasma sn OPERATION ne ee re RPS HON ER t PowerCut 1250 1 a a eminence PT 32EH Torches used with Manual Plasma Only nn PT 32EH Possible Cutting SU nennen POWERCUT 1250 1500 MECHANIZED PLASMARC CUTTING PACKAGE DESCRIPTION na ee me SS INSTALLATION an an Installation Mechanized Plasma Cutting Packages ss na oid Re QUISO NIRE Nu RUM NIE edo p o Su Primary Electrical Input Connections Mechanized Plas Cutting lt Secondary Output Connections for Mechanized Plasma ss OP RATION 9 eset P wercut 12530 7 T500 CONTO a PT 21AMX Torches used with Mechanized Plasma Only 21 Possible Cutting ISSUES nina nme PAGE TABLE OF CONTENTS SECTION TITLE PAGE PARAGRAPH SECTION 4 MAINTENANCE Escrita 53 4 0 53 4 1 inspection and 53 4 2 54 4 3 IGBI Handling coment 55 SECTION 5 TROUBLESHOOTING iria ais 37 5 0 CIN ee ne 57 5 1 TTOUDIESHOOHNG Ul
6. d ESAB EF POWERCUT 1250 1500 MANUAL amp MECHANIZED PLASMARC CUTTING PACKAGE Installation Operation and Service Manual This manual provides complete instructions for MANUAL CONSOLES starting with Serial Number PxxJ245xxx May 2003 This manual provides complete instructions for MECHANIZED CONSOLES starting with Serial Number PxxJ316xxx May 2003 0558004285 04 2009 BE SURE THIS INFORMATION REACHES THE OPERATOR YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER 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 Form 52 529 Do NOT permit untrained persons to install operate or maintain this equipment Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions If you do not fully understand these instructions contact your supplier for further information Be sure to read the Safety Precautions be fore installing or operating this equipment USER RESPONSIBILITY This equipment will perform in conformity with the description thereof contained in this manual and accompa nying labels and or inserts when installed operated maintained and repaired in accordance with the instruc tions provided This equipment must be checked periodically Malf
7. un equipo de soldadura corte plasma debe ser familiar con 5 operaci n localizaci n de los paros de emergencia sus funciones precauciones de seguridad corte plasma y soldadura 2 Eloperador debe asegurar que ninguna otra persona este en la rea de trabajo durante el arranque de la maquina ninguna persona este sin protecci n al momento de la partida del arco 3 La rea de trabajo debe estar de acuerdo con el trabajo estar libre de corrientes de aire 4 Equipo de seguridad individual siempre utilice equipos de seguridad lentes prendas ign fugas guantes etc no utilice art culos sueltos como bufandas pulseras anillos etc 5 Precauciones generales este seguro que el cable de retorno esta bien conectado el trabajo con alta voltaje debe ser realizado por un t cnico calificado un extintor de incendios apropiado debe estar acerca de la maquina lubricaci n de la maquina no debe ser realizada durante la operaci n A ADVERTENCIA El equipo de clase A 400 V CE no est disenado para su uso en ubicaciones residenciales donde la corriente electrica se suministra mediante el sistema de suministro p blico de baja tensi n Pueden surgir posibles problemas a la hora de garantizar la compatibilidad electromagnetica con el equipo de clase A en dichas ubicaciones debido las perturbaciones tanto conducidas como radioel ctricas PRECAUCIONES DE SEGURIDAD ADVERTENCIA Soldadura y corte plasma
8. 0558003517 PowerCut 1500 400 V CE 25 7 6m 2 0558001945 PowerCut 1500 575 V 50 60 Hz 3 0558001950 PowerCut 1500 400 V CE 50 15 2m PT 32EH 0558001946 PowerCut 1500 400 V CE 50 HZ 3 0558001947 PowerCut 1500 460 V 25 7 60m PT 32EH 0558005902 PowerCut 1500 460 V 50 60 Hz 3 0558005900 PowerCut 1500 460 V 50 15 2m PT 2 0558005903 PowerCut 1500 400 V 50 Hz 3 ph sss 0558007826 PowerCut 1500 400 V 25 7 6m 2 0558007827 PT 32EH Torches Thecomponentsthatare included in the Powercut 1500 packages Console PT 32EH Torch 25 ft 07 O11 0558003548 Torch Spare Parts Kit may be purchased separately by using the appropriate PT 32EH Torch 50 f6 15 2010 un 0558003549 P N when placing orders Individual part numbers are listed below Spare Parts Kits see section 1 2 3 PT 32EH Spare Parts Kit een 0558003062 PT 32EH 400 V Long Heat Shield LHS Spare Parts Kit CE units only EN 0558003557 15 SECTION 1 DESCRIPTION 1 2 3 SPARE PARTS OPTIONAL ACCESSORIES PC 1250 1500 MANUAL PLASMA Spare PartsKits Contents of PT 32EH Spare Parts Kit 70 amp Contents of PT 32EH LHS Spare
9. 3 3 PT 21AMX POSSIBLE CUTTING ISSUES Replace when eroded beyond 06 1 5mm Depth A ET REPLACE ELECTRODE BEFORE PITTING BECOMES DEEPER THAN 06 INCH 1 5 MM Figure 3 1 Electrode Wear Limit NOTE When replacing the nozzle always inspect the electrode for wear If more than 06 1 5mm of electrode has eroded replace the electrode If the electrode is used beyond this recommended wear limit damage to the torch and power source may occur Nozzle life is also greatly reduced when using the electrode below the recommended limit 50 POWERCUT 1250 1500 MAINTENANCE TROUBLESHOOTING SCHEMATIC DIAGRAMS REPLACEMENT PARTS 52 SECTION 4 MAINTENANCE 4 0 GENERAL If this equipment does not operate properly stop work immediately and investigate the cause of the malfunction Maintenance work must be performed by an experienced person and electrical work by a trained electrician Do not permit untrained persons to inspect clean or repair this equipment Use only recommended replacement parts Be sure that the wall disconnect switch or wall circuit breaker is open before at tempting any inspection or work inside of the Powercut 4 1 INSPECTION AND CLEANING Frequent inspection and cleaning of the PowerCut is recommended for safety and proper operation Some suggestions for inspecting and cleaning are as follows A Check work cable for secured connection to workpiece Check safety
10. 41 SECTION 2 INSTALLATION 2 5 PRIMARY ELECTRICAL INPUT CONNECTIONS MECHANIZED PLASMA CUTTING PACKAGE PIN WARNING ELECTRIC SHOCK CAN KILL Precaution ary measures should be taken to provide maximum protection against electrical The PowerCut 1250 1500 consoles are equipped with approximately 10 ft of 4 conductorinputpower cablefor 3 phase connection Ifsingle phase connection is desired tape back the red It blue wire on the input power cable Connect the shock Be sure that all power 15 off by single phase input to the white and black wires only When operating this machine opening the line wall disconnect switch from a single phase source it must be connected to a dedicated 100 Amp feed and by unplugging the power cord to the Due to the higher input current requirements the duty cycle of the machine is unitwhen connections are made inside of lower than in three phase operation the power source Connect your air supply to the inlet connection of the filter regulator Prefiltered DRY AIR SUPPLY Customer Supplied 90 to 150 psig max ua 6 2 to 10 3 bars max 8 H Voltage Divider ___ 9 Arc On signal from PS to CNC Relay Closing Start signal from CNC to PS Relay Closing P N 57002249 PRIMARY INPUT POWER CABLE el Red Lt Blue NOT USED ON SINGLE PHASE White Brown Black Black Green Yellow Green CUSTOMER FUSED LINE DISCONNECT SWITCH See Table
11. one is unprotected when the arc is struck 3 The workplace must be suitable for the purpose be free from drafts 4 Personal safety equipment Always wear recommended personal safety equipment such as safety glasses flame proof clothing safety gloves Do not wear loose fitting items such as scarves bracelets rings etc which could become trapped or cause burns 5 General precautions Make sure the return cable is connected securely Work on high voltage equipment may only be carried out by a qualified electrician Appropriate fire extinguishing equipment must be clearly marked and close at hand Lubrication and maintenance must not be carried out on the equipment during operation Class A 400V CE equipment is not intended for use in resi dential locations where the electrical power is provided by the public low voltage supply system There may be potential dif ficulties in ensuring electromagnetic compatibility of Class A equipment in those locations due to conducted as well as radi ated disturbances SAFETY PRECAUTIONS WELDING AND PLASMA CUTTING CAN BE INJURIOUS TO YOURSELF AND WARN NG OTHERS TAKE PRECAUTIONS WHEN WELDING OR CUTTING ASK FOR YOUR EMPLOYER S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANUFACTURERS HAZARD DATA ELECTRIC SHOCK Can kill Install and earth ground the welding or plasma cutting unit in accordance with applicable standards Do not touch live elec
12. Currenttoo 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 Nozzle Orifice 1 Low air pressure 2 Damaged cutting nozzle 3 Loose cutting nozzle 4 Heavy spatter accumulation on nozzle E Uneven Arc 1 Damaged cutting nozzle or worn electrode F Unstable Cutting Conditions 1 Incorrect cutting speed 2 Loose cable or hose connections 3 Electrode and or cutting nozzle in poor condition G Main Arc Does Not Strike 1 Worn electrode 2 Loose connections 3 Work cable not attached H Poor Consumable Life 1 Improper gas pressure 2 Contaminated air supply 3 Low air flow rate 54 SECTION 4 MAINTENANCE 4 3 IGBT KIT PC 1250 1500 HANDLING AND REPLACEMENT P N 0558008966 PART NUMBER TY DESCRIPTION 0558006151 2 IGBT DUAL 150A 600V 38224 1 PCB IGBT DRIVER 05512020 4 SCREW SKT HEX M5 X 20 BLK 05W01055 4 WASHER FLAT 5 64302920 4 WASHER LOCK 10 0558003084 1 COMPOUND HEATSINK AOS WHITE 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 Always ground parts touching gate pins during installation In general standard ESD precau tions should be followed Other handling precautions that s
13. ready to cut after connections are made to the torch input power and a source of compressed air 90 150 psi 6 2 to 10 3 bar The mechanized Powercut pack age uses the PT 21 AMX mechanized plasma torch to deliver cutting power for severing materials up to 1 1 2 inch 38 1mm thick on the PC 1250 and 1 3 4 inch 45mm thick on PC 1500 Refer to the following pages for descriptions of the Powercut packages available as well as performance specifications 1 1 SCOPE The purpose of this manual is to provide the operator with all the information required to install and operate the Powercut plasma arc cutting package Tech nical reference material is also provided to assist in troubleshooting the cutting package Dual Voltage Version Back View 35 SECTION 1 12 MECHANIZED PLASMA 1 2 1 PC 1250 MECHANIZED PLASMA The PowerCut 1250 plasma cutting package combines the proven reliability of the PowerCut 1250 with the newly designed 21 torch The PT 21AMX plasma cutting torch is designed to provide increased performance and longer consumable life resulting in higher production rates at lower costs Specifications PowerCut 1250 Cuts 1 1 4 in 32mm 1 ph ae 208 230 vac 1 ph 50 60 Hz 67 61 A 1 ph eine 70 amps 60 duty cycle 3 ph Itt 208 230 vac 3 ph 50 60 Hz 33 29 A HH 230 460 vac 3 ph 50 60 Hz 29 20 A P v 400 vac 3 ph 50 60 Hz 1
14. the power source This system prevents the torch from being energized with high voltage if the torch switch is accidentally closedwhenthe shieldisremoved Always replace torch with the with the proper torch manufactured by ESAB since it alone contains ESAB s patented safety interlock OPERATION 3 2 3 PT 32EH TORCH PARTS INSTALLATION MANUAL PLASMA ONLY PLACE THE VALVE PIN INTO THE ELECTRODE AND SCREW THE ELECTRODE INTO THE TORCH HEAD AND TIGHTEN SECURELY WITH WRENCH 19129 PN ELECTRODE NOZZLE _ SHIELD PLACE NOZZLE INTO HEAT SHIELD AND THREAD THIS ASSEMBLY TO THE TORCH BODY AND HAND TIGHTEN IMPORTANT MAKE SHIELD VERY TIGHT The valve pin is a crucial member of the system Its function is to open the gas flow check valve that is permanently assembled within the torch head If the pin is not correctly placed in the electrode the valve will not open and the system will not function The valve pin also improves elec trode cooling by increasing the velocity of air over the inner surface of the electrode Fig 3 4 Exploded View of PT 32EH Torch 30 SECTION 3 OPERATION ADJUST GUIDE BY TURNING IN A CLOCKWISE DIRECTION ONLY THIS WILL PREVENT 774555 ACCIDENTAL LOOSENING OF SHIELD IF GUIDE IS TOO TIGHT ON SHIELD OPEN SLOT WITH SCREWDRIVER STEEL GUARD STAND OFF GUIDE P N 0558002393 THIN GAUGE MATERIALS CAN BE CUT WITH 1 16
15. 3429 breakdown of parts refer to Figure 1 1 0 500 12 7 50 1270 53 1346 2 Ordering Information 0 750 19 05 21 533 4 23 584 2 PowerCut 1250 208 230 460 V 25 7 6m 2 0558001933 1 000 25 4 10 254 12 304 8 PowerCut 1250 208 230 460 V 50 15 2m PT 32EH 0558001934 PowerCut 1250 575 V 25 7 6m PT 32EH 0558001939 1 250 31 75 6 152 4 7 177 8 PowerCut 1250 575 V 50 15 2m PT 32EH 0558001940 1 500 38 1 3 76 2 PowerCut 1250 400 V CE 25 7 6m PT 32EH 0558001936 PowerCut 1250 400 V CE 50 15 2m PT 32EH 0558001937 PowerCut 1250 460V 25 7 6m 2 0558005332 PowerCut 1250 460V 50 15 2m PT 32EH 0558005333 Thecomponentsthatareincludedinthe Powercut 1250 packages Console Torch Spare Parts Kit may be purchased separately by using the appropriate P N when placing orders Individual part numbers are listed below Consoles PowerCut 1250 208 230 460 V 50 60 Hz 1 3 ph 0558001935 PowerCut 1250 208 230 460 V 50 60 Hz 1 3 ph BL 0558001935F PowerCut 1250 575 V 50 60 Hz 3 0558001941 PowerCut 1250 400 V CE 50 Hz 3 0558001938 PowerCut 1250 460 V 60 Hz 3 P
16. Feedback amp Support ESAB Welding amp Cutting Products PO Box 100545 Florence SC 29501 0545 EEE ESAB EP 0558004285 04 2009
17. Parts Kit 70 amp P N 0558003508 P N 0558003560 CE units only Description P N Quantity Description P N Quantity Heat Shield 0558001957 2 Long Heat Shield LHS 0558003110 2 70 amp Nozzle 0558002618 4 70 amp Nozzle 0558002618 4 40 amp drag Nozzle 0558002908 1 40 amp drag Nozzle 0558002908 1 Electrode 0558001969 3 Electrode 0558001969 3 Valve Pin 0558001959 1 Valve Pin 0558001959 1 Fuse 2amp 600vdc 0558001379 1 Fuse 2amp 600vdc 0558001379 1 Stand off Guide 0558002393 1 Stand off Guide 0558002393 1 Wrench 19129 0558000808 1 Wrench 19129 0558000808 1 Lubricant 17672 0558000443 1 Lubricant 17672 0558000443 1 The PowerCut 1250 comes out of the box ready to go The torch is attached with parts in place primary cord is attached and the filter regulator is installed Just hook up the air power and begin cutting NOTE Part numbers in parenthesis apply to CE European units only Contents of PT 32EH Spare Parts Kit 90 amp Contents of PT 32EH LHS Spare Parts Kit 90 amp P N 0558003062 P N 0558003557 CE units only Description P N Quantity Description P N Quantity Heat Shield 0558001957 2 Long Heat Shield LHS 0558003110 2 90 amp Nozzle 0558002837 4 90 amp Nozzle 0558002837 4 40 amp drag Nozzle 0558002908 1 40 amp drag Nozzle 0558002908 1 Electrode 0558001969 3 Electrode 0558001969 3 Valve Pin 0558001959 1 Valve Pin 0558001959 1 Fuse 2amp 600vdc 0558001379 1 Fuse 2amp 600vdc 0558001379 1 Stand off Guide 0558002393 1 Stand off
18. earth ground at workpiece and at power source chassis Check heat shield on torch It should be replaced if damaged D Check the torch electrode and cutting nozzle for wear on a daily basis Remove spatter or replace if necessary Make sure cable and hoses are not damaged or kinked Make sure all plugs fittings and ground connections are tight With all input power disconnected and wearing proper eye and face protection blow out the inside of the Powercut using low pressure dry compressed air rum Water or oil occasionally accumulates in compressed air lines Be sure to direct the first blast of air away from the equipment to avoid damage to the Powercut Occasionally bleed all water from the filter beneath the air filter regulator 53 SECTION 4 4 2 MAINTENANCE 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 1 Current too low 2 Cutting speed too fast 3 Damaged cutting nozzle 4 Improper air pressure 5 Low air flow rate B Main Arc Extinguishes 1 Cutting speed too slow 2 Worn electrode C DrossFormation In some materials and thicknesses it may be impossible to get dross free cuts 1
19. puede ser fatal a usted otros Tome las precauciones de seguridad para corte plasma y soldadura DESCARGA ELECTRICA puede matar Instale un cable tierra de acuerdo con las normas Notoque partes el ctricas consumibles que est n energizados Mantengas aislado del piso la pieza de trabajo Certifique que su situaci n de trabajo es segura HUMOS Y GASES Son peligrosos a su salud Mantenga su cabeza alejada de los humos utilice ventilaci n o aspiraci n para eliminar los humos del rea de trabajo RAYO DEL ARCO Puede quemar la piel o danar los ojos Protege sus ojos y piel con lentes y ropa apropiadas Proteja las personas en la rea de trabajo utilizando una cortina PELIGRO DE INCENDIO Chispas pueden provocar incendio Este seguro que no hagan materiales inflamables al rededor de la maquina RUIDO El ruido en exceso puede los o dos Proteja sus o dos utilice protecci n auricular Avise las personas al rededor sobre el riesgo AVER AS Llame a ESAB en caso de una aver a con el equipo LEER Y ENTENDER EL MANUAL ANTES DE INSTALAR U OPERAR EL EQUIPO PROTEJA A USTED Y LOS OTROS PRECAUTIONS DE SECURITE Precautions de s curit Les utilisateurs du mat riel de soudage et de coupage plasma ESAB ont la responsabilit ultime d assurer que toute personne qui ou qui se trouve dans l aire de travail observe les pr cautions de s curit pertinentes
20. 1 6 mm TORCH TO WORK DISTANCE ADJUST TO 3 16 4 8 mm FOR MATERIALS OVER 1 4 6 4 mm THICK 1 16 1 6 mm TO 1 4 6 4mm TORCH TO WORK GUIDE AGAINST STRAIGHT EDGE OR FREE HAND CUT IF TOO LOOSE CLOSE SLOT WITH VISE OR LARGE PLIERS Figure 3 5 Installation and Operation of Stand off Guide PT 32EH ONLY 31 SECTION 3 3 3 PT 32EH POSSIBLE CUTTING ISSUES Replace when eroded beyond 06 1 5mm Depth A A CU A REPLACE ELECTRODE BEFORE PITTING LC BECOMES DEEPER THAN 06 INCH 1 5 Figure 3 6 Electrode Wear Limit NOTE When replacing the nozzle always inspect the electrode for wear If more than 06 1 5mm of electrode has eroded replace the electrode If the electrodeis used beyondthis recommended wear limit damagetothetorch and power source may occur Nozzle life is also greatly reduced when using the electrode below the recommended limit 32 POWERCUT 1250 1500 MECHANIZED PLASMARC CUTTING PACKAGE 34 SECTION 1 Armea Use only the ESAB PT 21AMX Plasmarc torch with this console Use of torches not designed for use with this console could create an ELECTRIC SHOCK HAZARD Typical Front View DESCRIPTION 1 0 GENERAL The Powercut 1250 1500 is a compact completely self contained plasma cut ting system The system is shipped with the PT 21AMX mechanized torch Torch must be wired to the console before operation See section 2 6 1 The system is
21. 1 PC 1250 MANUAL PLASMA The PowerCut 1250 plasma cutting package combines the proven reliability of the PowerCut 1250 with the newly designed PT 32EH torch The very strong composite case material makes the PowerCut 1250 an excellent addition to any equipment rental fleet The PT 32EH plasma cutting torch is designed to provide increased performance and longer consumable life resulting in higher production rates at lower costs Specifications PowerCut 1250 Cuts 1 1 4 in 32mm severs 1 1 2 in 38mm ee 208 230 1 50 60 2 67 61 T pl aserrada 70 amps 60 duty cycle 3 ph ID 208 230 3 ph 50 60 Hz 33 29 etree 230 460 vac 3 ph 50 60 Hz 29 20 A ncaa 400 vac 3 ph 50 60 Hz 18 A a 575 vac 3ph 50 60 Hz 15 PT 32EH Cut Data 70 AMPS 3 ph ON DU anne 70 amps 100 duty cycle Powercut 1250 PT 32EH 70A Nozzle P N 0558002618 DIMENSIONS W 12 5 318mm EE MM 16 5 419mm Air Pressure 80 psi 5 32 Standoff D 31 5 800mm LU a ee 86 Ibs 39kg Max Speeds Air Requirements 350 80 psig 165 l min 5 5 bars Carbon Steel Plate Drop Cut Sever Torch Inches mm IPM mm min IPM mm min PowerCut 1250 uses the PT 32EH torch For complete list and 0 250 6 35 131 3327 4 135
22. 2 3 and WARNING in regards to chassis ground in Section 2 5 Figure 2 1 Input Connections 42 SECTION 2 A IE ELECTRICSHOCKCANKILL Beforemaking electrical input connections to the power source Machinery Lockout Procedures should be employed If the connections are to be made from a line disconnect switch place the switch in the off position and padlock it to prevent inadvertent tripping If the connection is made from a fusebox remove the corresponding fuses and padlock the box cover If it is not possible to use padlocks attach a red tag to the line disconnect switch or fuse box warning others that the circuit is being worked on ARENT The chassis must be connected to an ap proved electrical ground Failure to do so may result in electrical shock severe burns or death A WARNING Before making any connections to the power source output terminals make sure that all primary input power to the power source is deenergized off at the main disconnect switch andthatthe input power cable is unplugged A INPUT VOLTAGE SELECTOR NOT POWER ON OFF SWITCH USE POWER SWITCH ON FRONT PANEL TO TURN 6 ON AND OFF INSTALLATION Before connecting to input power make sure there is a line wall disconnect switch with fuses or circuit breakers at the main power panel You may either use the factory installed input power cable 4 c type SO 90 C 10 ft 3 1 m length or provide your own
23. 40 Torch Body Assembly 21359 4485850 NOTE Part numbers in parenthesis apply to CE European units only Figure 1 2 PT 21AMX Torch Cutting Parameters for the PT 21AMX Torch 90AMP Data Nozzle P N 0558004269 Heat Shield P N 21326 4485831 Metal Air Arc Pierce Thickness Pressure Voltage Time 0251 6 8 6 s mo o 050 13 85 6 188 5 120 03 075 19 85 6 188 5 125 10 1 00 25 85 6 250 6 130 275 1 25 32 85 6 250 6 140 NR 1 50 38 85 6 2550 6 145 NR indicates piercing is not recommended Travel Speed Metal Feri Mild Stee Aluminum Stainless Maximum Optimum Maximum Optimum Maximum Optimum 25 6 150 3810 120 3048 125 3175 105 2667 88 22352 80 2022 1 25 00 25 13 3302 3048 20 58 15 381 10 24 8 2032 50 38 5 17 3 762 10 254 7 1778 3 762 3 762 m 5 5 3 5 39 SECTION 1 DESCRIPTION Cutting Parameters for the PT 21AMX Torch 70AMP Data Nozzle P N 21329 4485834 Heat Shield P N 21326 4485831 Metal Air Arc Pierce Thickness Pressure Voltage Time 250 6 75 5 188 5 110 02 _ 500 13 85 6 188 5 115 06 750 19 85 6 188 5 125 23 1 000 25 85 6 1 2501 6 135 NR 1 250 32 85 6 1250 6 150 NR NR indicates piercing is not rec
24. 5838 19497 4485843 488157 4485841 17672 0558000443 21375 4485842 93750006 4485651 950272 0558004270 Quantity WY U VI N Quantity gt gt gt OUT gt Quantity WY gt gt UU DESCRIPTION SPARE PARTS OPTIONAL ACCESSORIES PC 1250 1500 MECHANIZED PLASMA Optional Accessories Torch Holder Assembly 16V83 0558004250 50 amp Spare Parts Kit nennen 21370 2461001 70 amp Spare Parts Kit wessen nn 21369 0558000848 90 amp Spare Parts 0558004271 0558004277 CNG Cabe nen 57002249 Plasma Flow Measuring Kit This valuable troubleshooting tool allows measurement of the actual plasma gas flow through the torch 19765 0558000739 NOTE Part numbers in parenthesis apply to CE European units only Torch Holder AV t 0558005926 Remote Hand Control Switch with 25 ft 7 6m lead for 2 assssesesssssssssnsensnenenennenennnennnnenenenennenenenenene 0558003612 Plasma Flow Measuring Kit 19765 0558000739 38 SECTION 1 DESCRIPTION Electrode 21150 0558004262 Heat Shield 70 90 amp 21326 4485831 30 50 amp 21447 4485832 Tube 21374 4485838 O Ring 488157 4485841 Cutting Nozzle see appropriate spare parts kit for p n Insulator 21373 4485837 Electrode Adaptor Assembly 21332 44858
25. 8A cas 575 vac 3ph 50 60 Hz 15 A 3 ph OWUEDUE nia 70 amps 100 duty cycle W 12 5 318mm ee ee H 16 5 419mm nn D 31 5 800mm laser ne 86 lbs 39kg Air Requirements 350 80 psig 165 l min 5 5 bars Torch PowerCut 1250 uses the PT 21AMX torch For complete list and breakdown of parts refer to Figure 1 2 Ordering Information PowerCut 1250 208 230 460 V 25 7 6m PT 21AMX 0558004185 PowerCut 1250 208 230 460 V 50 15 2m PT 21AMX 0558004186 PowerCut 1250 400 V CE 25 7 6m PT 21 AMX 0558004187 PowerCut 1250 400 V 50 15 2m 21 0558004188 PowerCut 1250 208 230 460 V 25 7 6m PT 21NR 0558005494 PowerCut 1250 208 230 460 V 50 15 2m 21 8 0558005495 PowerCut 1250 400 V CE 25 7 6m PT 21NR 0558005496 PowerCut 1250 400 V CE 50 15 2m PT 21NR 0558005497 Thecomponentsthatareincluded in the Powercut 1250 packages Console Torch Spare Parts Kit Torch Holder Assembly amp Interface Cable may be purchased separately by using the appropriate P N when placing orders Individual part numbers are listed below Consoles PowerCut 1250 208 230 460 V 50 60 Hz 1 3 ph 0558004189 PowerCut 1250 400 V CE 50 Hz 3
26. 9 228 6 PowerCut 1500 230 460 V 25 7 6m 21 0558004191 5 127 PowerCut 1500 230 460 V 50 15 2m 21 0558004192 1 500 38 1 76 2 127 PowerCut 1500 400 V CE 25 7 6m 21 0558004193 PowerCut 1500 400 V CE 50 15 2m 21 0558004194 PowerCut 1500 230 460 V 25 7 6m 21 0558005490 owerCut 6m P TZ TNR 2 4 Without Rack 15 2 HPV ea 0558003615 PowerCut 1500 400 V CE 50 15 2m PT 21NR 0558005493 With Rack 50 ft 15 2m s 0558003614 Without Rack 25 TE amaia 0558003617 The componentsthatare included in the Powercut 1500 packages may be With Rack 25 ft 7 61 s 0558003616 purchased separately by using the appropriate P N when placing orders Individual part numbers are listed below Spare Parts Kits see section 1 2 3 Consoles PT 21AMX Spare Parts Kit 50 21370 2461001 PowerCut 1500 208 230 460 V 50 60 Hz 1 3 ph 0558004195 een n D PowerCut 1500 400 V CE 50 Hz 3 0558004196 P A 37 SECTION 1 1 2 3 Contents of PT 21 AMX Spare Parts Kit P N 21370 2461001 50 Amp Description Heat Shield 50 A Cutting Nozzle 50 A Electrode Electrode Insulator Electrode Holder Assy Baffl
27. ARC RAYS can burn eyes and skin NOISE can damage hearing Wearwelding helmet with No 6or7 lens shade Wear eye ear and body protection NOTE Trigger Lock Switch Manual Operation using the PT 32EH torch When placed in LOCK position this permits releasing torch switch but ton after cutting arc has been initiated To extinguish arc at end of cut press and release torch switch button again or pull torch away from work When placed in UNLOCK position torch switch must be held closed by the operator during the entire cutting operationandthenreleased at the end of cut A Position the PowerCut at least 10 feet 3 meters from the cutting area Sparks and hot slag from the cutting operation can damage the unit 3 2 1 OPERATION PT 32EH TORCH USED WITH MANUAL PLASMA ONLY CUTTING WITH THE POWERCUT 1250 1500 USING THE PT 32EH TORCH MANUAL PLASMA ONLY Use the following procedures to cut with the PT 32EH torch A Make sure that the wall disconnect switch is on Turn on the Front Panel Power Switch Set Pressure Regulator to 80 psig 5 5 bar Hold the torch nozzle approximately 1 8 to 3 16 inch 3 2 to 4 8 mm above the work and tilted at about 15 30 This reduces the chance of spatter entering the nozzle If the PT 32EH s stand off guide P N 0558002393 is being used the distance between Electrode and Work Piece will be approx 3 16 4 8 mm Depress the torch switch Air should f
28. E peut tre mortel Assurez vous que l unit de soudage ou de coupage plasma est install e et mise la terre conform ment aux normes applicables Ne touchez pas aux pi ces lectriques sous tension ou les lectrodes si vos mains ne sont pas bien prot g es ou si vos gants ou vos v tements sont humides Assurez vous que votre corps est bien isol de la mise la terre et de la pi ce traiter Assurez vous que votre position de travail est s cure VAPEURS ET GAZ peuvent tre danereux pour la sant Gardez votre t te loign e des vapeurs Utilisez un syst me de ventilation et ou d extraction l arc pour vacuer les vapeurs et les gaz de votre zone respiratoire RAYONS DE L ARC peuvent endommager la vue ou br ler la peau Prot gez vos yeux et votre corps Utilisez un cran de soudage coupage plasma convenable quip de lentilles teint es et portez des v tements de protection Prot gez les personnes se trouvant dans l aire de travail l aide d un cran ou d un rideau protecteur convenable RISQUE D INCENDIE Les tincelles projections peuvent causer un incendie Assurez vous qu il n y a pas de mat riel inflammable proximit de l appareil BRUIT un bruit excessif peut endommager la capacit auditive Prot gez vos oreilles Utilisez des protecteurs d oreilles ou un autre type de protection auditive Avertissez les personnes se trouvant dans l aire de travail de ce risque FONCT
29. Guide 0558002393 1 Wrench 19129 0558000808 1 Wrench 19129 0558000808 1 Lubricant 17672 0558000443 1 Lubricant 17672 0558000443 1 The PowerCut 1500 comes out of the box ready to go The torch is attached with parts in place primary cord is attached and the filter regulator is installed Just hook up the air power and begin cutting 85W51 0558003694 Supplied with head Valve Pin PE PT 32EH Torch Head 0558003412 0558001969 6 Heat Shield 0558001957 Nozzle Long Shield 40 AMP 0558002908 Drag Cutting 0558003110 50 70 AMP 0558002618 90 AMP 0558002837 Figure 1 1 PT 32EH Torch 16 SECTION 1 DESCRIPTION Optional Accessories 70 Spare Parts Kit un 0558003508 70 400 V LHS Spare Parts Kit UNIS asnicar 0558003560 90A Spare Parts nt ste nn tenons 0558003062 90 A 400 V LHS Spare Parts Kit CE iio ia 0558003557 Plasma Flow Measuring Kit This valuable troubleshooting tool allows measurement of the actual plasma gas flow through the torches C 19765 0558000739 Torch Guide Kit This complete kit in a rugged plastic carrying case includes attachments for circle and straight line cutting on ferrous and non ferrous metals Deluxe 1 3 4 42 44 5mm 1066 8 mm roots 0558003258 Basic 13 4 28 44 5mm 711 2 mm RadiUS nues 0558002675 Stand off Guide For prope
30. ING TRIGGER LOCK LOCK position Manual Cutting Only with PT 32EH Torch PUSH RELEASE PUSH RELEASE TORCH SWITCH 1 GLOSE GAS SOLENOID VALVE PREFLOW 2 5 mem dp POSTFLOW Postflow CLOSE OPEN FLOW SWITCH i tt 1 a FAULT LIGHT 1 ENERGIZE CIRCUIT 0 INVERTER Lr e LL CUTTING ARC CURRENT NOTES 1 When the torch switch is pushed during postflow period the postflow time is reset the preflow time is canceled and the HF is energized immediately 2 When the red fault light comes on cutting operation should be stopped The postflow time starts from the moment the torch switch is released 3 FAULI light is on during second turn off trigger only This does not affect performance in any way 64 SECTION 5 TROUBLESHOOTING NOTE Schematics on 279 4mm x 431 8mm 11 x 17 paper are included inside the back cover of this manual 65 SECTION 5 TROUBLESHOOTING 66 SECTION 6 REPLACEMENT PARTS 6 0 Replacement Parts 6 1 General Always provide the serial number of the unit on which the parts will be used The serial number is stamped on the unit nameplate 6 2 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 you
31. IONNEMENT D FECTUEUX Dans le cas d un fonctionnement d fectueux demandez l aide d une personne qualifi e ASSUREZ VOUS DE LIRE ET DE COMPRENDRE LE MANUEL D UTILISATION AVANT D INSTALLER OU D OP RER L UNIT PROT GEZ VOUS ET LES AUTRES 10 POWERCUT 1250 1500 MANUAL PLASMARC CUTTING PACKAGE SECTION 1 WARNING Use only the ESAB PT 32EH Plasmarc torch with this console Use of torches not designed for use with this console could create an ELECTRIC SHOCK HAZARD DESCRIPTION 1 0 GENERAL The Powercut 1250 1500isacompact completely self contained plasma cutting system As shipped the system is fully assembled and ready to cut after being connected to input power and a source of compressed air 90 150 psi 6 2 to 10 3 bar The Powercut package uses the heavy duty PT 32EH Manual Plasma torch to deliver cutting power for severing materials up to 1 1 2 inch 38 1mm thick on the PC 1250 and 1 3 4 inch 45mm thick on the PC 1500 Refer to the following pages for descriptions of the Powercut packages available as well as performance specifications 1 1 SCOPE The purpose of this manual is to provide the operator with all the information required to install and operate the Powercut plasma arc cutting package Tech nical reference material is also provided to assist in troubleshooting the cutting package Typical Front View Dual Voltage Version Back View SECTION 1 DESCRIPTION 12 MANUAL PLASMA 1 2
32. Les pr cautions de s curit doivent r pondre aux exigences applicables ce type de mat riel de soudage ou de coupage plasma Les recommandations suivantes doivent tre observ es en plus des r gles standard qui s appliquent au lieu de travail Tous les travaux doivent tre effectu s par un personnel qualifi poss dant de bonnes connaissances par rapport au fonctionnement du mat riel de soudage et de coupage plasma Un fontionnement incorrect du mat riel peut produire des situations dangereuses qui peuvent causer des blessures l op rateur ou des dommages au mat riel 1 Toute personne travaillant avec le mat riel de soudage ou de coupage plasma doit connaitre son fonctionnement l emplacement des interrupteurs d arr t d urgence sa fonction les pr cautions de s curit pertinentes les proc dures de soudage et ou de coupage plasma 2 L op rateur doit assurer que seules les personnes autoris es travailler sur l quipement se trouvent dans l aire de travail lors de la mise en marche de l quipement toutes les personnes dans l aire de travail sont prot g es lorsque l arc est amorc 3 Le lieu de travail doit tre am nag convenablement pour acqu rir le mat riel en toute s curit libre de courants d air 4 quipement de s curit personnelle Vous devez toujours utiliser un quipement de s curit convenable tels que les lunettes de protection les v tement ininflammable
33. NSTALLATION MANUAL PLASMA CUTTING PACKAGE 2 1 GENERAL Proper installation is important for satisfactory and trouble free operation of the PowerCut cutting package It is suggested that each step in this section be studied carefully and followed closely 2 2 EQUIPMENT REQUIRED A source of clean dry air that supplies 350 cfh 165 2 at 80 psig 5 5 bar is required for the cutting operation The air supply should not exceed 150 psig 10 3 bar the maximum inlet pressure rating of the air filter regulator supplied with the package 2 3 LOCATION Adequate ventilation is necessary to provide proper cooling of the PowerCut The amount of dirt dust and excessive heat to which 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 movement through the power source 2 4 INSPECTION A Remove the shipping container and all packing material and inspect for evi dence of concealed damage which may not have been apparent upon receipt of the PowerCut Notify the carrier of any defects or damage at once Check container for any loose parts prior to disposing of shipping materials C Check air louvers and any other openings to ensure that any obstruction is removed SECTION 2 PIN WARNING ELECTRIC SHOCK CAN KILL Precaution ary measures should be taken to provide maximum protection against electr
34. PUT VOLTAGE CHANGEOVER DUAL VOLTAGE UNITS ONLY 208 230 or 460 Mode To simplify the use of the ESAB Powercut 1250 1500 with different input voltages it has been equipped with a convenient 230 460 selector switch located on the back panel of the unit Switching between 230 and 460 voltages can be done by using a flathead screwdriver to turn the selector screw The Powercut is also equipped with protective fuse that will prevent damage to the power source in the event that the input voltage switch is not set correctly and the unit is powered on A line wall disconnect switch with fuses or circuit breakers should be provided at the main power panel see Table 2 1 2 2 for fuse sizes The input power cable of the console may be connected directly to the disconnect switch or you may purchase a proper plug and receptacle from a local electrical supplier If using plug receptacle combination see Table 2 1 2 2 for recommended input conductors for connecting receptacle to line disconnect switch Input Voltage Selector Switch Fuse 44 SECTION 2 INSTALLATION 2 6 SECONDARY OUTPUT CONNECTIONS FOR MECHANIZED CUTTING TORCH CABLE 000 00 CQO A Clamp the work cable to the a workpiece Be sure the workpiece isconnectedtoanapproved earth SAFETY GROUND ground with a properly sized ground cable Figure 2 4 PowerCut Interconnection Diagram 2 6 1 MECHANIZED TORCH INSTALLATION Use the followin
35. UESTIONS 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 B ENGINEERING SERVICE Telephone 843 664 4416 Fax 800 446 5693 Hours 7 30 AM to 5 00 PM EST Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting TECHNICAL SERVICE Telephone 800 ESAB 123 Fax 843 664 4452 Hours 8 00 AM to 5 00 PM EST Part Numbers Technical Applications Specifications Equipment Recommendations D LITERATURE REQUESTS Telephone 843 664 5562 Fax 843 664 5548 Hours 7 30 AM to 4 00 EST WELDING EQUIPMENT REPAIRS Telephone 843 664 4487 Fax 843 664 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 Registrations WELDING PROCESS ASSISTANCE Telephone 800 ESAB 123 Hours 7 30 AM to 4 00 PM EST H TECHNICAL ASST CONSUMABLES Telephone 800 933 7070 Hours 7 30 AM to 5 00 PM EST IF YOU DO NOT KNOW WHOM TO CALL Telephone 800 ESAB 123 Fax 843 664 4462 Hours 7 30 AM to 5 00 PM EST or visit us on the web at http www esabna com The ESAB web site offers Comprehensive Product Information Material Safety Data Sheets Warranty Registration Instruction Literature Download Library Distributor Locator Global Company Information Press Releases Customer
36. a gas flow check valve that acts in conjunction with the flow switch and circuitry within the power source This system prevents the torch from being energized with high voltage if the torch switch is accidentally closed when the shield is removed Always replace torch with the NOTE Part numbers in parenthesis apply to CE European units only OPERATION 3 2 PT 21AMX TORCH USED WITH MECHANIZED PLASMA ONLY 1 The seat comes assembled to the front end of the torch If the seat becomes damaged the torch body must be replaced DO NOT attempt to remove the seat from torch body 2 Electrode holder assembly p n 21332 4485840 includes the baffle tube p n 21374 4485838 If baffle tube becomes damaged it can be replaced by un threading the damaged tube out of the holder Use small hex end of the wrench p n 21375 4485842 in hex broach on the tube Tighten tube secure ly but do not over tighten Electrode Holder Assembly Baffle Tube ES gt Wrench 3 Install the electrode insulator p n 21373 4485837 onto electrode holder assembly p n 21332 4485840 and then thread electrode p n 21150 0558004262 onto the electrode holder assembly Assemble electrode firmly by hand Do not use wrenches or pliers These three parts combined are the electrode assembly D 4 u 21332 4485840 21373 4485837 21150 0558004262 48 SECTION 3 NOTE Part numbers in parenthesis app
37. cuit is energized Air Test Switch When placed in TEST position air filter regulator can be adjusted to desired pressure 80 psig 5 5 bar before cutting operations Allow air to flow for a few minutes This should remove any condensation that may have accumulated during shutdown period Be sure to place switch in OPERATE position before starting cutting operations Trigger Lock Switch 1 Manual Operation using the PT 32EH torch When placed in LOCK posi tion this permits releasing torch switch button after cutting archas been initiated To extinguish arc at end of cut press and release torch switch button again or pull torch away from work When placed in UNLOCK position torch switch must be held closed by the operator during the entire cutting operation and then released at the end of cut 2 Mechanized Operation using the PT 21AMX torch In mechanized operation the Trigger Lock function disabled Instead the switch func tions as an Auto Restrike selector To turn Auto Restrike on grate cutting place the switch in the up position To turn Auto Restrike off grate cutting place the switch in the down position TRIGGER LOCK O I UNLOCK Auto Restrike off Auto Restrike on 25 SECTION 3 OPERATION Figure 3 1B PowerCut 1250 1500 Controls Output Current Control Adjustablefrom 2010 70 amperes on Powercut 1250 Adjustable from 20 to 90 amperes on Powercut 1500 Power ON Indicator llluminates
38. e Tube Pilot Arc Adaptor O ring Lubricant 1 Seat Baffle Wrench Hex Key Wrench Tool Box STD P N CE P N 21447 4485832 21330 4485833 21150 0558001617 21373 4485837 21332 4485840 21374 4485838 19497 4485843 488157 4485841 17672 0558000443 21375 4485842 93750006 4485651 950272 0558004270 Contents of PT 21 AMX Spare Parts Kit P N 21369 0558000848 70 Amp Description Heat Shield 70 90 A Heat Shield 50 A Cutting Nozzle 50 A Cutting Nozzle 70 A Electrode Electrode Insulator Electrode Holder Assy Baffle Tube Pilot Arc Adaptor O ring Lubricant 1 Seat Baffle Wrench Hex Key Wrench Tool Box STD P N CE P N 21326 4485831 21447 4485832 21330 4485833 21329 4485834 21150 0558001617 21373 4485837 21332 4485840 21374 4485838 19497 4485843 488157 4485841 17672 0558000443 21375 4485842 93750006 4485651 950272 0558004270 Contents of PT 21AMX Spare Parts Kit P N 0558004271 0558004277 90 Amp Description Heat Shield 70 90 A Heat Shield 50 A Cutting Nozzle 50 A Cutting Nozzle 70 A Cutting Nozzle 90 A Electrode Electrode Insulator Electrode Holder Assy Baffle Tube Pilot Arc Adaptor O ring Lubricant 1 Seat Baffle Wrench Hex Key Wrench Tool Box STD P N CE P N 21326 4485831 21447 4485832 21330 4485833 21329 4485834 0558004269 21150 0558001617 21373 4485837 21352 4485840 21374 448
39. epress the torch switch On the control board the LED 1 should be lit as long as the switch is depressed If not then check a Turn power off to the machine Unplug Control board Put an ohmmeter across J3 3 and J3 4 to take resistance reading Depress torch switch Meter should read a short If not then one of the following is not working properly b Torch switch or the leads Unplug the torch switch leads at the machine Put a meter across the two plug pins Meter should read a short when the torch switch is de pressed If not then either there are broken switch leads or a malfunctioning switch 58 SECTION5 D TROUBLESHOOTING Check transformer secondary voltages at the output diode modules Refer to system schematic Replace the transformer module if the correct secondary voltages are not present If everything above checks out all right then the PCB1 Control Board should be replaced Fault light activates when torch switch is closed The machine monitors conditions necessary for the safe operation of the Powercut The fault lights will glow under the following conditions and operations will come to a stop 1 High Low line voltage The AC LINE light will blink to indicate that the input voltage is outside the 15 range of the nominal voltage Gas Flow indicator The fault light will blink to indicate that the air flow is low or that the torch is not providing any back pressure a Check the air pressure at the
40. g procedures to install the PT 21AMX torch A Remove torch connection cover from front panel Cover is held in place by two screws If strain relief connector is present remove before con necting the PT 21AMX torch a Strain Relief Connector Torch Connection Cover 45 SECTION 2 INSTALLATION Remove nut torch cable assembly C Insert torch cable assembly through opening in cover D Re attach cable nut and tighten E Pull an adequate amount of hose through the cover to allow ease of hose connections F Attach hoses and tighten G Slide cover back into place and tighten screws 46 SECTION 3 3 0 OPERATION 3 1 PowerCut 1250 1500 CONTROLS NOTE See Section 3 1 C for complete operation instructions NOTE Trigger Lock Switch Mechanized Operation using the PT 21AMX torch In mechanized operation the Trigger Lock function disabled In stead the switch functions as an Auto Restrike selector To turn Auto Restrike on gratecutting placetheswitchinthe up position To turn Auto Restrike off place the switch in the down position Trigger Lock Switch TRIGGER g as Auto Restrike on Grate cutting LOCK O I UNLOCK Auto Restrike off Standard cutting 47 SECTION 3 PIN WARNING Make sure power switch onthe POWERCUT is in the OFF position before working on the torch The PT 21 AMX torch head contains
41. h frequency PC Board PCB 2 Connector J2 to avoid damaging your voltmeter 57 SECTION5 TROUBLESHOOTING 5 1 TROUBLESHOOTING GUIDE A Power Light does not come on 1 Visually inspect the machine for any damage 2 Check following a Check if the machine power cord is plugged into the input power receptacle b Measure the input power at the receptacle If not present then check the wall dis connect switch and it s fuses C Check Fuse F1 3 If above items check the problem is internal Send unit to an Authorized Repair Sta tion for repair a Ensure that ribbon cable is connected to main PCB 1 and front panel PCB 3 b Measure voltage between pins P7 5 and P7 6 of the control board If there is no voltage then replace Control Transformer T6 C Ifthe voltage is present then the pilot light may be burnt out B No Air Flow 1 Check air inlet supply Unit requires 350 cfh at 80psig 165 1 5 5 bars 2 Check air hose and connections Tighten if leaking 3 Does air flow when air test switch is in test position a If not check torch consumables replace if necessary b If above items check the problem is internal Take unit to an Authorized Repair Station for repair C The Power light is on but nothing happens when the torch switch is depressed Fault light does not activate NOTE Unplug high frequency connection before attempting to work on this problem 1 With the machine power on d
42. hould also be observed are as follows Use grounded work station with grounded floors and grounded wrist straps when handling devices Usea 1000 resistor in series with the gate when performing curve tracer tests e Never install devices into systems with power connected to the system Module Replacement When mounting modules on a heatsink certain precautions should be taken to prevent any damage against a sudden torque If a sudden torque one sided tightening is applied at only one mounting terminal the ceramic insulation plate or silicon chip inside the module may get damaged The mounting screws are to be fastened in the order shown Also care must be taken to achieve maximum contact i e minimum contact thermal resistance for the best heat dissipation A torque wrench should be used Tighten mounting and terminal screws per Torque Requirements shown in illustration below If device is over torqued the device can be damaged like the above one sided tightening Application of a Thermal Compound or Thermal Pad on the contact surface is required to properly remove heat from the device It is recommended that a unit manufactured with a thermal pad use thermal compound for replacement Thermal compound may always be used as a replacement for a pad Never use both compound and a pad Thoroughly remove any residual material from the mating surfaces Use supplied Heat Sink Compound or equivalent Apply a thin layer 005
43. ical shock Be sure that all power is off by opening the line wall disconnect switch and by unplugging the power cord to the unitwhen connections are made inside of the power source Prefiltered DRY AIR SUPPLY Customer Supplied 90 to 150 psig max 6 2 to 10 3 bars max CUSTOMER FUSED LINE DISCONNECT SWITCH See Table 2 3 and WARNING in regards to chassis ground in Section 2 5 Red Lt Blue NOT USED ON SINGLE PHASE White Brown Black Black Green Yellow Green 79 INSTALLATION 2 5 PRIMARY ELECTRICAL INPUT CONNECTIONS MANUAL PLASMA CUTTING PACKAGE The PowerCut 1250 1500 consoles are equipped with approximately 10 ft of 4 conductor input power cable for 3 phase connection If single phase connec tion is desired tape back the red It blue wire on the input power cable Connect the single phase input to the white and black wires only When operating this machine from a single phase source it must be connected to a dedicated 100 Amp feed Due to the higher input current requirements the duty cycle of the machine is lower than in three phase operation Single phase duty cycle is 60 for PC 1250 and 40 for PC 1500 Connect your air supply to the inlet connection of the filter regulator PRIMARY INPUT POWER CABLE a Figure 2 1 Input Connections 20 SECTION 2 A EI ELECTRICSHOCKCANKILL Beforemaking electrical input connections to the power source Machinery Lockout Procedures sh
44. input power leads If you choose to provide your own make sure they are insulated copper conductors You must have two single phase or three three phase power leads and one ground wire The wires may be heavy rubber covered cable or may be run in a solid or flexible conduit Refer to Table 2 3 and 2 4 for recommended input conductors and line fuse sizes Table 2 3 PC 1250 Recommended Sizes For Input Conductors and Line Fuses Input Requirements Input amp Gnd Fuse Volts Phase Amps Conductor Size CU AWG Amps 67A 33A Ph 61A 29A Ph Table 2 4 PC 1500 Recommended Sizes For Input Conductors and Line Fuses Input Requirements Input amp Gnd Fuse Volts Phase Amps Conductor Size CU AMG Amps 82A 6 44A Ph 6 74A 6 40A Ph 6 27 6 24 6mm 18 10 NOTE 400V CE Mains Supply Requirements High power equipment may due to the primary current drawn from the mains supply influence the pow er quality ofthe grid Therefore connection restrictions or requirements regarding the maximum permis sible mains impedance or the required minimum supply capacity at the interface point to the public grid may apply for some types of equipment see technical data In this case it is the responsibility of the installer or user of the equipment to ensure by consultation with the distribution network operator if necessary that the equipment may be connected SECTION 2 INSTALLATION 2 5 1 IN
45. it Switching between 230 and 460 voltages can be done by using a flathead screwdriver to turn the selector screw The Powercut is also equipped with protective fuse that will prevent damage to the power source in the event that the input voltage switch is not set correctly and the unit is powered on Aline wall disconnect switch with fuses or circuit breakers should be provided at the main power panel see Table 2 1 2 2 for fuse sizes The input power cable of the console may be connected directly to the discon nect switch or you may purchase a proper plug and receptacle from a local electrical supplier If using plug receptacle combination see Table 2 1 2 2 for recommended input conductors for connecting receptacle to line disconnect switch Input Voltage Selector Switch Fuse 22 SECTION 2 INSTALLATION 2 6 SECONDARY OUTPUT CONNECTIONS FOR MANUAL CUTTING The torch comes factory installed Clamp the work cable to the workpiece Be sure the workpiece is connected to an approved earth ground with a properly sized ground cable WORK nt SAFETY GROUND wv PT 32EH Figure 2 2 PowerCut Interconnection Diagram 23 SECTION 2 INSTALLATION 24 SECTION 3 3 0 3 1 OPERATION A B D Figure 3 1A PowerCut 1250 1500 Controls OPERATION PowerCut 1250 1500 CONTROLS Power Switch When placed in ON position the white power light will glow indicating control cir
46. loa ani 58 5 2 Reference Voltage Checks ais 62 5 3 seguence o Operatii _________________ 63 SECTION 6 REPEACEMENT PARTS scsi aia 67 6 0 Replacement NOH UII EN Iu 67 6 1 GENE sn 67 6 2 CCC 67 6 3 IGBT PC 1250 1500 Te place men transicion acond 67 SAFETY PRECAUTIONS Safety Precautions Users of ESAB welding and plasma cutting 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 welding or plasma cutting 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 welding or plasma cutting 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 welding or plasma cutting equipment must be familiar with its operation location of emergency stops its function relevant safety precautions welding and or plasma cutting 2 The operator must ensure that unauthorized person stationed within the working area of the equipment when it is started up
47. low from the torch nozzle Two seconds after depressing the torch switch the pilot arc should start The main arc should immediately follow allowing the cut to begin If using the trigger LOCK mode torch switch may be released after establishing the cutting arc See note Trigger Lock Switch 27 SECTION 3 OPERATION F After starting the cut the torch should be maintained at a 5 15 forward angle This angle is especially usefulinhelpingtocreatea drop cut When not using the stand off guide the nozzle should be held approximately 1 4 inch 6 4mm from the work CUT DIRECTION IMPORTANTI Maintain Proper Stand Off Distance 3 16 to 1 4 Inch 4 8 to 6 4mm 7 Power Output increases with Stand Distance Figure 3 2b Stand off vs Power Output During Cutting G When ending cut torch switch should be released press and release if using trigger LOCK mode and the torch lifted off the workpiece just before the end of the cut This is to prevent the high frequency from reigniting after cutting arc extinguishes and causing damage to the nozzle double arcing H For rapid re starts such as grate or heavy mesh cutting do not release the torch switch In the postflow mode the arc can be re started immediately by depressing the torch switch This avoids the 2 second preflow portion of the cutting cycle 28 SECTION 3 caution Drag cutting even with lower current levels may significan
48. ly to CE European units only OPERATION 4 Install nozzle onto the electrode assembly by inserting small shoulder on electrode insulator into nozzle s rear opening Place nozzle and electrode assembly into the heat shield If front end of the torch is facing down as normal in a setup the nozzle and electrode assembly can be stacked in the heat shield and then assembled to the torch Be sure to use proper heat shield and nozzle combination 5 Apply a thin film of lubricant p n 17672 0558000443 to O ring p n 488157 4485841 O ring Lubricant 6 Tighten heat shield fully to hold the parts in firm contact with each other and to the torch head Fully means at least 3 16 4 8mm rotation after electrode seat contacts electrode holder To connect PT 21AMX torch to the console connect the power cable of the torch to the NEG terminal and pilot arc cable to the POS terminal of the unit using pilot arc adaptor p n 19497 4485843 supplied with spare parts kit A separate remote control switch cable is required for connecting to the switch receptacle on the console The front end of the torch contains a gas flow check valve that acts in conjunction with the circuitry provided in the power supply This patented system provides a safety interlock preventing the torch from being accidentally energized with high voltage when the heat shield is removed and the torch switch is accidentally closed 49 SECTION 3
49. machine regulator It should be adjusted to 80 psig 5 5 bars If no air pressure check the air at the supply point Also check for any obstruc tions in the air hose b Air flow may be blocked at the torch tip Check the torch consumables see Figure 3 4 Also check for any obstructions in the torch leads NOTE If above items check OK the problem is internal Send unit to an Authorized Repair Station for repair c Put the Air Check switch to On position Air should flow through torch If not and air pressure is set at required 80 psig 5 5 bars check gas Solenoid SOL1 for proper operation d Air Check switch may also be malfunctioning if the air is flowing continuously or put ting in the On position does not turn air on Over Temperature indicator The fault light will blink to indicate that the machine has overheated This generally indicates that the air flow has been blocked Clear blockage and allow the power source to cool before operating a Thermal Switch TS1 may be open It will open if the heat sink temperature reaches 80 C With the machine power off check the continuity between P6 7 and P6 8 of the control board If the switch is OK then the ohmmeter should read a direct short If not then it should read open b Ifthe switch is malfunctioning replace it Clean the surface of the heat sink before installing the switch Fault Indicator When this light blinks either the system failed to initiate a pilo
50. n Work and Torch terminals If it is not present then any one of the following may not be working properly a Checkthe operation of the Thermal Switch TS1 See D 3 a above b CheckAir Check switch operation It might be stuck in On position Pilot arc will not initiate if this switch is in the ON position safety reasons Check air flow switch There may be internal short See D 2 c above d Measure voltage across C5 or C6 capacitor It should be as follows approx 325 VDC with 230 V supplied the 230 460 volt unit approx 294 VDC with 208 V supplied to the 230 460 volt unit approx 325 VDC with 460 V supplied to the 230 460 volt unit approx 282 VDC with 400 V supplied to the 400 volt unit approx 400 VDC with 575 V supplied to the 575 volt unit If not one of following could be malfunctioning 1 Check capacitors C5 and for any damage 2 Check input bridge SCR Module This can be checked without taking it out of the circuit using an volt ohmeter Replace it if found malfunctioning Follow bridge installation instructions 3 Check Inrush current resistor R1 located on the Input Bridge Heatsink and SCR O1 Replace if malfunctioning e IGBTs may be damaged See IGBT installation procedure Before replacing IGBTs make sure to check the zener diodes and pico fuses on the IGBT driver boards 60 SECTION5 WY TROUBLESHOOTING High Frequency and Pilot Arc are on but Main Arc d
51. nominal between mating surfaces Initial tightening 03 2 Final tightening 2 3 D os Two Point Mounting Type fe 36 in lbs 4 1 newton meters 36 in lbs 4 1 newton meters Screw Fastening Order and Torque 55 SECTION 4 MAINTENANCE 56 SECTION5 TROUBLESHOOTING 5 0 TROUBLESHOOTING A RGIS ELECTRIC SHOCK CAN KILL Be sure that all primary power to the machine has been ex ternally disconnected Open the line wall disconnect switch or circuit breaker before attempting inspection or work inside of the power source Check the problem against the symptoms in the following troubleshooting guide The remedy may be quite simple If the cause cannot be quickly located shut off the input power open up the unit and perform a simple visual inspection of all the components and wiring Check for secure terminal connections loose or burned wiring or components bulged or leaking capacitors or any other sign of damage or discoloration The cause of control malfunctions can be found by referring to the sequence of operations and electrical schematic diagram and checking the various components A volt ohmmeter will be necessary for some of these checks A WARNING Voltages in plasma cutting equipment are high enough to cause serious injury or pos sibly death Be particularly careful around equipment when the covers are removed NOTE Before checking voltages in the circuit disconnect the power from the hig
52. oes not transfer Make sure work clamp is connected to work material Check the torch Replace consumables if necessary Poor Cutting Performance Check air supply regulator It should be adjusted to 80 psig 5 5 bars The air supplied to the torch should be free of oil and water Make sure the consumables in the torch are acceptable Check open circuit voltage See E 3 above Check the output Use a calibrated current probe capable of measuring 100 amps in the presence of high frequency Air does not shut off Check air test the gas solenoid valve is energized when the switch is in the on position Does air flow stop when the torch switch is unplugged If yes check and repair the torch If not send unit to an Authorized Repair Station for repair a Check voltage to solenoid coil if present when torch switch is unplugged replace PCB1 If voltage is 0 replace solenoid valve Main arc is difficult to start The most common reason is worn or missing consumables Check and replace if neces Sary Input air must be clean and dry Input air pressure must be at least 85 psig 5 7 bars Torch connections must be tight Work cable and clamp must be in good condition and must make a good electrical con nection to the material to be cut If above items check the problem is internal Send unit to an Authorized Repair Sta tion for repair a Missing or weak pilot arc Check pilot arc fuse open circuit voltage and
53. ommended Travel Speed Mild Steel Aluminum Stainless Optimum Maximum Optimum Maximum Optimum n pm pm 125 3 210 5334 190 4826 205 5207 185 4699 91 23114 80 202 2159 100 2540 90 2286 61 15494 55 1397 3302 25 635 20 508 12 3048 9 2286 127 12 3048 9 2286 7 1778 6 1524 762 9 2286 5 127 3 762 3 762 Metal Thickness 40 50AMP Data Nozzle P N 21330 4485833 Heat Shield P N 21447 4485832 Metal Air Arc Pierce Arc Thickness Pressure Voltage Time Current 6063 2 75 s s 3 m o 4 s s 6 125 3 110 02 0250 6 s 6 s 120 04 0375 10 ss 6 188 5 125 06 NR 0 500 13 s5 6 188 5 135 087NR NR indicates piercing is not recommended Travel Speed Mild Steel Aluminum Stainless Maximum Optimum Maximum Optimum Maximum Optimum in 1 110 1 Metal Thickness 112 28448 100 2540 141 35814 110 2794 79 20066 75 1905 063 0250 6 71 18034 66 16764 83 21082 77 19558 37 9398 30 762 0 5001 13 21 5334 18 4572 13 3302 9 2286 11 2794 8 2032 NOTE Part numbers in parenthesis apply to CE European units only 40 SECTION 2 A rum Installing or placing any type of filtering device will restrict the volume of intake air thereby subjecting the
54. or may be run in a solid or flexible conduit Refer to Table 2 1 and 2 2 for recommended input conductors and line fuse sizes Table 2 1 PC 1250 Recommended Sizes For Input Conductors and Line Fuses SD ECS Vots Phase Amps Conductor Size cumwc __ Amps 67A 33A Ph 61A 29A Ph 20 15 Table 2 2 1500 Recommended Sizes For Input Conductors and Line Fuses InputRequirements Input amp Gnd Fuse vos phase Amps conductor size L CUAWG Amps 82A 44A Ph 74A 40A Ph 27 24 18 NOTE 400V CE Mains Supply Requirements High power equipment may due to the primary current drawn from the mains supply influence the pow er quality of the grid Therefore connection restrictions or requirements regarding the maximum permis sible mains impedance or the required minimum supply capacity at the interface point to the public grid may apply for some types of equipment see technical data In this case it is the responsibility of the installer or user of the equipment to ensure by consultation with the distribution network operator if necessary that the equipment may be connected SECTION 2 INSTALLATION 2 5 1 INPUT VOLTAGE CHANGEOVER DUAL VOLTAGE UNITS ONLY 208 230 or 460 Mode To simplify the use of the ESAB Powercut 1250 1500 with different input volt ages it has been equipped with a convenient 230 460 selector switch located on the back panel of the un
55. ould be employed If the connections are to be made from a line disconnect switch place the switch in the off position and padlock it to prevent inadvertent tripping If the connection is made from a fusebox remove the corresponding fuses and padlock the box cover If it is not possible to use padlocks attach a red tag to the line disconnect switch or fuse box warning others that the circuit is being worked on IN WARNING The chassis must be connected to an ap proved electrical ground Failure to do so may result in electrical shock severe burns or death WARNING Before making any connections to the power source output terminals make sure that all primary input power to the power source is deenergized off at the main disconnectswitchandthattheinput power cable is unplugged A INPUT VOLTAGE SELECTOR NOT POWER ON OFF SWITCH USE POWER SWITCH ON FRONT PANEL TO TURN 6 ON AND OFF INSTALLATION Before connecting to input power make sure there is a line wall disconnect switch with fuses or circuit breakers the main power panel You may either use the factory installed input power cable 4 c type SO 90 C 10 ft 3 1 m length or provide your own input power leads If you choose to provide your own make sure they are insulated copper conductors You must have two single phase or three three phase power leads and one ground wire The wires may be heavy rubber covered cable
56. pilot arc wir ing b Inoperative Start up Board PCB 6 61 SECTION5 TROUBLESHOOTING 5 2 REFERENCE VOLTAGE CHECKS A Control Board Assembly PCB1 1 LED s LED D9 Torch Switch LED D4 Pilot Arc Relay LED D1 Gas Solenoid Valve 2 Voltage Test Points Tests are made with power on no arc Disable High Frequency by disconnecting blue wire with black sleeve TP 1 Torch trigger signal TP 4 IGBT s driving signal switching frequency 18 5 KHz TP 5 IGBT s driving signal switching frequency 18 5 KHz TP 7 5 TP 8 15 TP 9 15 TP 10 Ground 54 us 13vdc 13vdc Figure 5 1 IGBT Gating Signal 62 SECTION 5 TROUBLESHOOTING 5 3 SEQUENCE OF OPERATION A TRIGGER LOCK UNLOCK position Applies to PT 21AMX and PT 32EH Torches PUSH RELEASE TORCH SWITCH t OPEN CLOSE GAS SOLENOID VALVE 771 1 2 PREFLOW 20 SEC Postflow OPEN FLOW SWITCH CLOSE d FAULT OVERLOAD LIGHT HF CIRCUIT y ENERGIZE PILOT ARC CUTTING CURRENT NOTES 1 When torch switch is pushed during postflow period the postflow and preflow times canceled and the HF is energized immediately 2 When the red fault light comes on cutting operation should be stopped The postflow time starts from the moment the torch switch is released 63 SECTION5 TROUBLESHOOT
57. power source internal components to overheating The warranty is void if any type of filter device is used INSTALLATION 2 0 INSTALLATION MECHANIZED PLASMA CUTTING PACKAGE 2 1 GENERAL Proper installation is important for satisfactory and trouble free operation of the PowerCut cutting package It is suggested that each step in this section be studied carefully and followed closely 2 2 EQUIPMENT REQUIRED A source of clean dry air that supplies 350 cfh at 80 psig 165 1 i m 5 5 bars is required for the cutting operation The air supply should not exceed 150 psig 10 3 bars the maximum inlet pressure rating of the air filter regulator supplied with the package 2 3 LOCATION Adequate ventilation is necessary to provide proper cooling of the PowerCut The amount of dirt dust and excessive heat to which 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 movement through the power source 2 4 INSPECTION A Remove the shipping container and all packing material and inspect for evidence of concealed damage which may not have been apparent upon receipt of the PowerCut Notify the carrier of any defects or damage at once B Check container for any loose parts prior to disposing of shipping materi als C Check air louvers and any other openings to ensure that any obstruction is removed
58. r stand off distance when drag cutting sn 0558002393 40 amp Drag Nozzle EO OO 0558002908 Gouging NO2ZZIG ne otto o 0558003089 Heat Shield Gouging unseren 0558003090 Drag Heat Shield Standard ss 0558003374 Drag Heat Shield Heavy Duty sn 0558004206 Wheel Kit 0558003060 Torch Wrap This enables operator to store spare parts kit wrap torch and work cable for easy transport and Storage nina 0558003059 NOTE Part numbers in parenthesis apply to CE European units only Drag Heat Shield Standard Maintains a constant stand off Good life in most applications 0558003374 Torch Wrap This enables operator to store spare parts kit wrap torch and work cable for easy transport and storage 0558003059 Drag Heat Shield Heavy Duty Maintains a constant stand off Long life Suitable for piercing 0558004206 Powercut shown with Optional Torch Wrap Wheel Kit and Spare Parts Kit Holder installed For easy transport of System 0558003060 17 SECTION 1 DESCRIPTION SECTION 2 A ENS Installing or placing any type of filtering device will restrict 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 2 0 I
59. r 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 numbers Note Bill of material items that have blank part numbers are provided for customer information only Hardware items should be available through local sources 6 3 IGBT KIT PC 1250 1500 REPLACEMENT P N 0558008966 PART NUMBER TY DESCRIPTION 0558006151 2 IGBT DUAL 150A 600V 38224 1 PCB IGBT DRIVER 05512020 4 SCREW SKT HEX M5 X 20 BLK 05W01055 4 WASHER FLAT M5 64302920 4 WASHER LOCK 10 0558003084 1 COMPOUND HEATSINK AOS WHITE 6 NOTES 68 10 11 12 13 14 15 16 17 REVISION HISTORY Original release of this manual is 05 2003 Revision 11 2003 changed panel views to show updated voltage switch Revision 04 2004 Updated schematic diagram on page 66 per change notice 043018 Revision 05 2004 In the Replacement Parts Section changed bom item 42 from 38131 to 0558038276 See DNECO 043086 Revision 10 2004 Updated schematics on Pages 65 and 67 per change notice 043236 Revision 12 2004 Schematics moved to 11 x 17 pages in back of manual Revision 01 2005 Changed main transformer module from 0558003377 to 0558005313 CN 053002 Revision 06 2005 added Air Line Filter Regulator p n 0558005394 note in Replacemen
60. s et des gants de protection Vous ne devez jamais porter de v tements amples tels que foulards bracelets bagues etc qui pourraient se prendre dans l appareil ou causer des br lures 5 Pr cautions g n rales Assurez vous que le c ble de retour est bien branch La r paration d un quipement de haute tension doit tre effectu e par un lectricien qualifi seulement Un quipement d extinction d incendie appropri doit tre proximit de l appareil et l emplacement doit tre clairement indiqu Vous ne devez jamais proc der la lubrification ou l entretien du mat riel lorsque l appareil est en marche Les appareils de classe A 400 V CE ne sont pas pr vus pour une utilisation sur des lieux r sidentiels o l alimentation lectrique provient du r seau d alimentation public basse tension La compatibilit lectromagn tique des appareils de classe A dans ces lieux est potentiellement perturb e en raison des perturbations rayonn es et conduites PRECAUTIONS DE SECURITE LE SOUDAGE ET LE COUPAGE PEUVENT CAUSER DES BLESSURES L OP RATEUR OU LES AUTRES PERSONNES SE TROUVANT DANS LAIRE DE TRAVAIL ASSUREZ VOUS DE AVERTISSEMENT PRENDRE TOUTES LES PRECAUTIONS NECESSAIRES LORS D UNE OPERATION DE SOUDAGE OU DE COUPAGE DEMANDEZ VOTRE EMPLOYEUR COPIE DES MESURES DE SECURITE QUI DOIVENT ETRE ELABOREES PARTIR DES DONNEES DES RISQUE DU FABRICANT CHOC ELECTRIQU
61. t Parts section per CN 053013 Revision 08 2005 In replacement parts section updated finger guard from p n 0558002994 to p n 0558005659 amp cover torch connection from p n 0558002464M to 0558005658 per CN 053103 Revision 12 2005 Updated front rear views In replacement parts section p n table 2 32 chgd p n from 951800 to 0558005462 Removed Air Line Filter Regulator p n 0558005394 NOTE in Replacement Parts section Revision 01 2006 Changed p n 0558003075 to p n 0558001379 per DNECO 053179 Revision 03 2006 Added 0555001935F to the Console list in Subsection 1 2 1 Added 0558005902 and 0558005903 to the Ordering Information list in Subsection 1 2 2 Added 0558003517 and 0558005900 to the Console list in Subsection 1 2 2 Added 0558005331 and 0558005900 to the BOM charts in Section 6 Replacement Parts Refer to ECN 063042 and PA 6900 05 24 Revision 05 2006 Updated P Ns in Replacement Parts Tables per ECN 063080 Revision 12 2006 Changed Torch Holder Assy p n from 16V83 0558004250 to 0558005926 and updated picture Revision 12 2007 Added 400V harmonics info to PC 1500 pages Updated replacement parts section Revision 03 2008 Updated replacement parts section per ECN 083042 Revision 04 2009 Updated replacement parts section per ECN 093066 and updated IGBT info 69 ESAB Welding amp Cutting Products Florence SC Welding Equipment COMMUNICATION GUIDE CUSTOMER SERVICES A CUSTOMER SERVICE Q
62. t arc after a number of attempts or there has been an over current event within the system a Ifthe light blinks for 10 seconds and then stops then the problem is pilot arc initia tion Check the consumables in the torch b Ifthe light continues to blink and the system does not reset then the fault is an over current event One likely source of an over current fault is a nozzle to electrode short Turn off the machine and inspect the torch and its consumables Replace the consumables as needed Turn the machine back on If the problem occurs again the machine may require service 59 SECTION5 TROUBLESHOOTING c To check if the output is shorted measure the resistance by putting the ohmmeter leads across the output Put the black lead to the work terminal and the red lead to the torch electrode terminal The reading should be about 2K OHMs b Ifthe resistance reading is different than above check the torch the output bridge and Start up Board PCB 6 Air is On but nothing happens when torch switch is operated Check the torch Make sure that the valve pin is installed and the heat shield is very tight Check to assure high frequency is present at the torch Disconnect HI FREQUENCY leads Check for 575 volt supply to the high frequency unit between P2A 1 amp P2A 3 of the High Fre quency Board PCB2 with torch switch closed With HI FREQUENCY leads disconnected measure open circuit voltage It should be 320 VDC be twee
63. tly reduce the life of torch consumables Attempting to Drag Cut with higher currents greater than 40 amps may causeimmediatecatastrophic consumable damage OPERATION Drag Cutting with the 32 Torch PowerCut package LOW CURRENT AUTO DRAG FEATURE If drag cutting is desired for thin material under 3 8 9 5mm thick remove the standard 70 90 amp nozzle from the PT 32EH torch and install ESAB s 40 amp nozzle Lower the current level setting to be within the AUTO DRAG range of 20 to 40 amps see Auto Drag Scale on front panel Then follow steps in Section 3 2 1 Also refer to PT 32EH Instruction Manual No F 15 747 HIGH CURRENT DRAG CUTTING If drag cutting is desired on materials above 3 8 9 5mm thick be sure that the 70 amp 90 amp nozzle is installed in the PT 32EH torch Attach ESAB s stand off guide and operate as shown in Figure 3 3 2 WHEN THE 2 BREAKS Za Am THROUGH THE WORK BRING THETORCH TO AN UPRIGHT PO AND PROCEED CUT ki 11 13 SS 1 TOSTARTA PIERCE TILT THE TORCH PREVENT MOLTEN MATERIAL FROM ING BACK AGAINST AND DAMAGING THE TORCH Figure 3 3 Piercing Technique using the PT 32EH 29 SECTION 3 A WARNING Make sure power switch on POWERCUT is in OFF position before working on the torch The PT 32EH torch head contains a gas flow check valve that acts in conjunction with the flow switch and circuitry within
64. trical parts or electrodes with bare skin wet gloves or wet clothing Insulate yourself from earth and the workpiece Ensure your working stance is safe FUMES AND GASES Can be dangerous to health Keep your head out of the fumes Use 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 Protect your eyes and body Use the correct welding plasma cutting screen and filter lens and wear protective clothing Protect bystanders with suitable screens or curtains FIRE HAZARD Sparks spatter can cause fire Make sure therefore that there are no inflammable materials nearby NOISE Excessive noise can damage hearing Protect your ears Use earmuffs or other hearing protection Warn bystanders of the risk MALFUNCTION Call for expert assistance in the event of malfunction READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING PROTECT YOURSELF AND OTHERS PRECAUCIONES DE SEGURIDAD Precauciones de seguridad Los usuarios de los equipos de corte y soldadura ESAB tienen la responsabilidad de asegurar que las personas que trabajan o estan cerca del equipo sigan las normas de seguridad Las precauciones de seguridad deben estar de acuerdo con equipos de corte y soldadura Las recomendaciones abajo deben ser seguidas adicionalmente a las normas estandar 1 Cualquier persona que
65. unctioning or poorly maintained equipment should not be used Parts that are broken missing worn distorted or contaminated should be replaced imme diately Should such repair or replacement become necessary the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased This equipment or any of its parts should not be altered without the prior written approval of the manufacturer The user of this equipment shall have the sole responsibility for any malfunction which results 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 READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING PROTECT YOURSELF AND OTHERS SECTION PARAGRAPH SECTION 1 1 0 1 1 1 2 SECTION 2 2 0 2 1 2 2 2 3 2 4 23 2 6 SECTION 3 3 0 3 1 2 3 3 SECTION 1 1 0 1 1 1 2 SECTION 2 2 0 2 1 22 2 3 2 4 2 5 2 6 SECTION 3 3 0 3 1 2 2 3 3 TABLE CONTENTS TITLE POWERCUT 1250 1500 MANUAL PLASMARC CUTTING PACKAGE DESCRIPTION ee an CSS eee ie ee gt INSTALLATION den mn a amant Installation Manual Plasma Cutting Packages nn a a de E En Equipment Required ss GER ee A
66. whenever the front panel power switch isinthe ON position AC Line Indicator or High Low Line Voltage Indicator This fault light will blink when the input voltage is outside the or 15 range of the input rating Gas Flow Indicator This fault light will blink when the air flow supply is low or has no back pressure Fault Indicator When this light blinks either the system failed to initiate a pilot arc after a number of attempts or there has been an over current event within the system If the light blinks for 10 seconds and then stops the problem is pilot arc initiation Check the consumables in the torch If the light continues to blink and the system does not reset the fault is an over current event See troubleshooting section Over Temperature Indicator This fault light will blink to indicate that the duty cycle has been exceeded Allow the power source to cool down before returning to operation Allfault signals will remain on fora 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 26 SECTION 3 I amu ELECTRIC SHOCK can kill Do NOT operate the unit with the cover removed Do NOT apply power to the unit while holding or carrying the unit Do NOT touch any torch parts forward of the torch handle nozzle heat shield electrode etc with power switch on NA AT

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