ESAB | POWERCUT-1250 | Instruction manual | ESAB POWERCUT-1250 Instruction manual

POWERCUT-1250 / 1500
PLASMARC CUTTING PACKAGE
Instruction Manual
0558004106
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 before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual
and accompanying labels and/or inserts when installed, operated, maintained and repaired in
accordance with the instructions provided. This equipment must be checked periodically.
Malfunctioning or poorly maintained equipment should not be used. Parts that are broken,
missing, worn, distorted or contaminated should be replaced immediately. 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 service facility designated by the manufacturer.
2
TABLE OF CONTENTS
SECTION
PARAGRAPH
TITLE
PAGE
SECTION 1
1.1
1.2
DESCRIPTION ................................................................................................. 11
General ............................................................................................................. 14
Scope ................................................................................................................ 14
SECTION 2
2.1
2.2
2.3
2.4
2.5
2.6
INSTALLATION ................................................................................................
General .............................................................................................................
Equipment Required .........................................................................................
Location ............................................................................................................
Inspection .........................................................................................................
Primary Electrical Input Connections ................................................................
Secondary Output Connections ........................................................................
15
15
15
15
15
15
17
SECTION 3
3.1
3.2
3.3
3.4
3.5
OPERATION ....................................................................................................
Operation ..........................................................................................................
PowerCut-1250 / 1500 Controls ........................................................................
Cutting with the PT-32EH .................................................................................
Possible Cutting Issues ....................................................................................
Common Cutting Problems ...............................................................................
19
19
19
21
24
25
SECTION 4
4.1
4.2
4.3
4.4
MAINTENANCE ...............................................................................................
General .............................................................................................................
Inspection and Cleaning ...................................................................................
PT-32EH Torch Consumable Parts ..................................................................
IGBT Handling & Replacement .........................................................................
27
27
27
27
28
SECTION 5
5.1
5.2
5.3
5.4
TROUBLESHOOTING .....................................................................................
Troubleshooting ................................................................................................
Troubleshooting Guide .....................................................................................
Reference Voltage Checks ...............................................................................
Sequence of Operation .....................................................................................
31
31
32
36
37
SECTION 6
REPLACEMENT PARTS ................................................................................. 41
3
TABLE OF CONTENTS
4
SAFETY PRECAUTIONS
5. Do not use equipment beyond its ratings. For example,
overloaded welding cable can overheat and create a fire
hazard.
6. After completing operations, inspect the work area to make
certain there are no hot sparks or hot metal which could
cause a later fire. Use fire watchers when necessary.
7. For additional information, refer to NFPA Standard 51B, "Fire
Prevention in Use of Cutting and Welding Processes", available from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
WARNING: These Safety Precautions are for
your protection. They summarize precautionary
information from the references listed in Additional Safety Information section. Before performing any installation or operating procedures,
be sure to read and follow the safety precautions listed below
as well as all other manuals, material safety data sheets,
labels, etc. Failure to observe Safety Precautions can result
in injury or death.
PROTECT YOURSELF AND OTHERS -Some welding, cutting, and gouging processes are noisy and require ear protection. The arc, like the sun, emits ultraviolet (UV) and other radiation and can injure skin and eyes.
Hot metal can cause burns. Training in the proper use of
the processes and equipment is essential to prevent
accidents. Therefore:
ELECTRICAL SHOCK -- Contact with live
electrical parts and ground can cause severe injury or death. DO NOT use AC welding current in damp areas, if movement is
confined, or if there is danger of falling.
1. Be sure the power source frame (chassis) is connected to
the ground system of the input power.
2. Connect the workpiece to a good electrical ground.
3. Connect the work cable to the workpiece. A poor or missing
connection can expose you or others to a fatal shock.
4. Use well-maintained equipment. Replace worn or damaged cables.
5. Keep everything dry, including clothing, work area, cables,
torch/electrode holder, and power source.
6. Make sure that all parts of your body are insulated from
work and from ground.
7. Do not stand directly on metal or the earth while working in
tight quarters or a damp area; stand on dry boards or an
insulating platform and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for
specific grounding recommendations. Do not mistake the
work lead for a ground cable.
1. Always wear safety glasses with side shields in any work
area, even if welding helmets, face shields, and goggles
are also required.
2. Use a face shield fitted with the correct filter and cover
plates to protect your eyes, face, neck, and ears from
sparks and rays of the arc when operating or observing
operations. Warn bystanders not to watch the arc and not
to expose themselves to the rays of the electric-arc or hot
metal.
3. Wear flameproof gauntlet type gloves, heavy long-sleeve
shirt, cuffless trousers, high-topped shoes, and a welding
helmet or cap for hair protection, to protect against arc
rays and hot sparks or hot metal. A flameproof apron may
also be desirable as protection against radiated heat and
sparks.
4. Hot sparks or metal can lodge in rolled up sleeves, trouser
cuffs, or pockets. Sleeves and collars should be kept
buttoned, and open pockets eliminated from the front of
clothing
5. Protect other personnel from arc rays and hot sparks with
a suitable non-flammable partition or curtains.
6. Use goggles over safety glasses when chipping slag or
grinding. Chipped slag may be hot and can fly far. Bystanders should also wear goggles over safety glasses.
ELECTRIC AND MAGNETIC FIELDS — May
be dangerous. Electric current flowing
through any conductor causes localized
Electric and Magnetic Fields (EMF). Welding and cutting current creates EMF around
welding cables and welding machines.
Therefore:
FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot slag or
sparks can also cause fires and explosions. Therefore:
1. Welders having pacemakers should consult their physician
before welding. EMF may interfere with some pacemakers.
2. Exposure to EMF may have other health effects which are
unknown.
3. Welders should use the following procedures to minimize
exposure to EMF:
A. Route the electrode and work cables together. Secure
them with tape when possible.
B. Never coil the torch or work cable around your body.
C. Do not place your body between the torch and work
cables. Route cables on the same side of your body.
D. Connect the work cable to the workpiece as close as
possible to the area being welded.
E. Keep welding power source and cables as far away from
your body as possible.
1. Remove all combustible materials well away from the
work area or cover the materials with a protective nonflammable covering. Combustible materials include wood,
cloth, sawdust, liquid and gas fuels, solvents, paints and
coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or crevices
in floors or wall openings and cause a hidden smoldering
fire or fires on the floor below. Make certain that such
openings are protected from hot sparks and metal.“
3. Do not weld, cut or perform other hot work until the
workpiece has been completely cleaned so that there are
no substances on the workpiece which might produce
flammable or toxic vapors. Do not do hot work on closed
containers. They may explode.
4. Have fire extinguishing equipment handy for instant use,
such as a garden hose, water pail, sand bucket, or
portable fire extinguisher. Be sure you are trained in its
use.
5
10/98
SAFETY PRECAUTIONS
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shielding gases can cause asphyxiation.
Therefore:
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do not
perform any electrical work unless you are qualified to
perform such work.
2. Before performing any maintenance work inside a power
source, disconnect the power source from the incoming
electrical power.
3. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do not
operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position
and in good repair.
6. Use equipment only for its intended purpose. Do not
modify it in any manner.
1. Always provide adequate ventilation in the work area by
natural or mechanical means. Do not weld, cut, or gouge
on materials such as galvanized steel, stainless steel,
copper, zinc, lead, beryllium, or cadmium unless positive mechanical ventilation is provided. Do not breathe
fumes from these materials.
2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly toxic
gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat irritation
while operating, this is an indication that ventilation is not
adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not continue to
operate if physical discomfort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specific ventilation recommendations.
5. WARNING: This product, when used for welding or
cutting, produces fumes or gases which
contain chemicals known to the State of
California to cause birth defects and, in
some cases, cancer. (California Health &
Safety Code §25249.5 et seq.)
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for electric arc welding and cutting equipment, ask
your supplier for a copy of "Precautions and
Safe Practices for Arc Welding, Cutting and
Gouging", Form 52-529.
The following publications, which are available from the
American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding“
6. AWS C5.6 - "Recommended Practices for Gas Metal Arc
Welding"“
7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."
CYLINDER HANDLING -- Cylinders, if
mishandled, can rupture and violently
release gas. Sudden rupture of cylinder, valve, or relief device can injure or
kill. Therefore:
2.
3.
4.
5.
1.
Use the proper gas for the process and use the proper pressure reducing regulator
designed to operate from the compressed gas cylinder.
Do not use adaptors. Maintain hoses and fittings in good
condition. Follow manufacturer's operating instructions
for mounting regulator to a compressed gas cylinder.
Always secure cylinders in an upright position by chain
or strap to suitable hand trucks, undercarriages, benches,
walls, post, or racks. Never secure cylinders to work
tables or fixtures where they may become part of an
electrical circuit.
When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.
Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder.
For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases in
Cylinders", which is available from Compressed Gas
Association, 1235 Jefferson Davis Highway, Arlington,
VA 22202.
MEANING OF SYMBOLS - As used throughout this manual: Means Attention! Be Alert!
Your safety is involved.
Means immediate hazards which, if
not avoided, will result in immediate,
serious personal injury or loss of life.
Means potential hazards which could
result in personal injury or loss of life.
Means hazards which could result in
minor personal injury.
6
SP98-10
PRECAUCION DE SEGURIDAD
ADVERTENCIA: Estas Precauciones de Seguridad
son para su protección. Ellas hacen resumen de
información proveniente de las referencias listadas en
la sección "Información Adicional Sobre La Seguridad".
Antes de hacer cualquier instalación o procedimiento
de operación , asegúrese de leer y seguir las
precauciones de seguridad listadas a continuación así como también
todo manual, hoja de datos de seguridad del material, calcomanias,
etc. El no observar las Precauciones de Seguridad puede resultar en
daño a la persona o muerte.
PROTEJASE USTED Y A LOS DEMAS-Algunos procesos de soldadura, corte y
ranurado son ruidosos y requiren
protección para los oídos. El arco, como el
sol , emite rayos ultravioleta (UV) y otras
radiaciones que pueden dañar la piel y los ojos. El metal
caliente causa quemaduras. EL entrenamiento en el uso
propio de los equipos y sus procesos es esencial para
prevenir accidentes. Por lo tanto:
1. Utilice gafas de seguridad con protección a los lados siempre que
2.
3.
4.
5.
6.
esté en el área de trabajo, aún cuando esté usando careta de
soldar, protector para su cara u otro tipo de protección.
Use una careta que tenga el filtro correcto y lente para proteger sus
ojos, cara, cuello, y oídos de las chispas y rayos del arco cuando
se esté operando y observando las operaciones. Alerte a todas las
personas cercanas de no mirar el arco y no exponerse a los rayos
del arco eléctrico o el metal fundido.
Use guantes de cuero a prueba de fuego, camisa pesada de
mangas largas, pantalón de ruedo liso, zapato alto al tobillo, y
careta de soldar con capucha para el pelo, para proteger el cuerpo
de los rayos y chispas calientes provenientes del metal fundido.
En ocaciones un delantal a prueba de fuego es necesario para
protegerse del calor radiado y las chispas.
Chispas y partículas de metal caliente puede alojarse en las
mangas enrolladas de la camisa , el ruedo del pantalón o los
bolsillos. Mangas y cuellos deberán mantenerse abotonados,
bolsillos al frente de la camisa deberán ser cerrados o eliminados.
Proteja a otras personas de los rayos del arco y chispas calientes
con una cortina adecuada no-flamable como división.
Use careta protectora además de sus gafas de seguridad cuando
esté removiendo escoria o puliendo. La escoria puede estar caliente
y desprenderse con velocidad. Personas cercanas deberán usar
gafas de seguridad y careta protectora.
FUEGO Y EXPLOSIONES -- El calor de las
flamas y el arco pueden ocacionar fuegos.
Escoria caliente y las chispas pueden
causar fuegos y explosiones. Por lo tanto:
1. Remueva todo material combustible lejos del área de trabajo o
cubra los materiales con una cobija a prueba de fuego. Materiales
combustibles incluyen madera, ropa, líquidos y gases flamables,
solventes, pinturas, papel, etc.
2. Chispas y partículas de metal pueden introducirse en las grietas y
agujeros de pisos y paredes causando fuegos escondidos en otros
niveles o espacios. Asegúrese de que toda grieta y agujero esté
cubierto para proteger lugares adyacentes contra fuegos.
3. No corte, suelde o haga cualquier otro trabajo relacionado hasta
que la pieza de trabajo esté totalmente limpia y libre de substancias
que puedan producir gases inflamables o vapores tóxicos. No
trabaje dentro o fuera de contenedores o tanques cerrados. Estos
pueden explotar si contienen vapores inflamables.
4. Tenga siempre a la mano equipo extintor de fuego para uso
instantáneo, como por ejemplo una manguera con agua, cubeta
con agua, cubeta con arena, o extintor portátil. Asegúrese que
usted esta entrenado para su uso.
7
5. No use el equipo fuera de su rango de operación. Por ejemplo, el
calor causado por cable sobrecarga en los cables de soldar
pueden ocasionar un fuego.
6. Después de termirar la operación del equipo, inspeccione el área
de trabajo para cerciorarse de que las chispas o metal caliente
ocasionen un fuego más tarde. Tenga personal asignado para
vigilar si es necesario.
7. Para información adicional , haga referencia a la publicación
NFPA Standard 51B, "Fire Prevention in Use of Cutting and
Welding Processes", disponible a través de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
CHOQUE ELECTRICO -- El contacto con
las partes eléctricas energizadas y tierra
puede causar daño severo o muerte. NO
use soldadura de corriente alterna (AC)
en áreas húmedas, de movimiento
confinado en lugares estrechos o si hay
posibilidad de caer al suelo.
1. Asegúrese de que el chasis de la fuente de poder
2.
3.
4.
5.
6.
7.
8.
9.
10.
esté
conectado a tierra através del sistema de electricidad primario.
Conecte la pieza de trabajo a un buen sistema de tierra física.
Conecte el cable de retorno a la pieza de trabajo. Cables y
conductores expuestos o con malas conexiones pueden exponer
al operador u otras personas a un choque eléctrico fatal.
Use el equipo solamente si está en buenas condiciones.
Reemplaze cables rotos, dañados o con conductores expuestos.
Mantenga todo seco, incluyendo su ropa, el área de trabajo, los
cables, antorchas, pinza del electrodo, y la fuente de poder.
Asegúrese que todas las partes de su cuerpo están insuladas
de ambos, la pieza de trabajo y tierra.
No se pare directamente sobre metal o tierra mientras trabaja
en lugares estrechos o áreas húmedas; trabaje sobre un
pedazo de madera seco o una plataforma insulada y use
zapatos con suela de goma.
Use guantes secos y sin agujeros antes de energizar el equipo.
Apage el equipo antes de quitarse sus guantes.
Use como referencia la publicación ANSI/ASC Standard Z49.1
(listado en la próxima página) para recomendaciones específicas
de como conectar el equipo a tierra. No confunda el cable de
soldar a la pieza de trabajo con el cable a tierra.
CAMPOS ELECTRICOS Y MAGNETICOS
- Son peligrosos. La corriente eléctrica
fluye através de cualquier conductor
causando a nivel local Campos Eléctricos
y Magnéticos (EMF). Las corrientes en el
área de corte y soldadura, crean EMF
alrrededor de los cables de soldar y las
maquinas. Por lo tanto:
1. Soldadores u Operadores que use marca-pasos para el corazón
deberán consultar a su médico antes de soldar. El Campo
Electromagnético (EMF) puede interferir con algunos marcapasos.
2. Exponerse a campos electromagnéticos (EMF) puede causar
otros efectos de salud aún desconocidos.
3. Los soldadores deberán usar los siguientes procedimientos para
minimizar exponerse al EMF:
A. Mantenga el electrodo y el cable a la pieza de trabajo juntos,
hasta llegar a la pieza que usted quiere soldar. Asegúrelos
uno junto al otro con cinta adhesiva cuando sea posible.
B. Nunca envuelva los cables de soldar alrededor de su cuerpo.
C. Nunca ubique su cuerpo entre la antorcha y el cable, a la pieza
de trabajo. Mantega los cables a un sólo lado de su cuerpo.
D. Conecte el cable de trabajo a la pieza de trabajo lo más
cercano posible al área de la soldadura.
E. Mantenga la fuente de poder y los cables de soldar lo más
lejos posible de su cuerpo.
PRECAUCION DE SEGURIDAD
HUMO Y GASES -- El humo y los gases,
pueden causar malestar
o daño,
particularmente en espacios sin
ventilación. No inhale el humo o gases. El
gas de protección puede causar falta de
oxígeno. Por lo tanto:
MANTENIMIENTO DEL EQUIPO -- Equipo
defectuoso o mal mantenido puede
causar daño o muerte. Por lo tanto:
1. Siempre tenga personal cualificado para efectuar l
a
instalación, diagnóstico, y mantenimiento
del
equipo. No ejecute ningún trabajo eléctrico a menos
que usted esté cualificado para hacer el trabajo.
2. Antes de dar mantenimiento en el interior de la
fuente de poder, desconecte la fuente de poder del
suministro de electricidad primaria.
3. Mantenga los cables, cable a tierra, conexciones,
cable primario, y cualquier otra fuente de poder en
buen estado operacional. No opere ningún equipo en
malas condiciones.
4. No abuse del equipo y sus accesorios. Mantenga el
equipo lejos de cosas que generen calor como
hornos, también lugares húmedos como charcos de
agua , aceite o grasa, atmósferas corrosivas y las
inclemencias del tiempo.
5. Mantenga todos los artículos de seguridad y coverturas
del equipo en su posición y en buenas condiciones.
6. Use el equipo sólo para el propósito que fue diseñado.
No modifique el equipo en ninguna manera.
INFORMACION ADICIONAL DE SEGURIDAD
-- Para más información sobre las prácticas de
seguridad de los equipos de arco eléctrico
para soldar y cortar, pregunte a su suplidor por
una copia de "Precautions and Safe Practices
for Arc Welding, Cutting and Gouging-Form 52529.
Las siguientes publicaciones, disponibles através de la
American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, son recomendadas para usted:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
5. AWS C5.5 - "Recommended Practices for Gas Tungsten
Arc Welding“
6. AWS C5.6 - "Recommended Practices for Gas Metal Arc
Welding"“
7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."
1. Siempre provea ventilación adecuada en el área de
trabajo por medio natural o mecánico. No solde, corte, o
ranure materiales con hierro galvanizado, acero inoxidable,
cobre, zinc, plomo, berílio, o cadmio a menos que provea
ventilación mecánica positiva . No respire los gases
producidos por estos materiales.
2. No opere cerca de lugares donde se aplique substancias
químicas en aerosol. El calor de los rayos del arco pueden
reaccionar con los vapores de hidrocarburo clorinado para
formar un fosfógeno, o gas tóxico, y otros irritant es.
3. Si momentáneamente desarrolla inrritación de ojos, nariz
o garganta mientras est á operando, es indicación de que
la ventilación no es apropiada. Pare de trabajar y tome
las medidas necesarias para mejorar la ventilación en
el área de trabajo. No continúe operando si el malestar
físico persiste.
4. Haga referencia a la publicación ANSI/ASC Standard
Z49.1 (Vea la lista a continuación) para recomendaciones
específicas en la ventilación.
5. ADVERTENCIA-- Este producto cuando se utiliza para
soldaduras o cortes, produce humos
o gases, los cuales contienen
químicos conocidos por el Estado
de California de causar defectos en el
nacimiento, o en algunos casos, Cancer. (California Health & Safety Code
§25249.5 et seq.)
MANEJO DE CILINDROS-- Los
cilindros, si no son manejados
correctamente, pueden romperse y
liberar violentamente gases. Rotura
repentina del cilindro, válvula, o
válvula de escape puede causar daño
o muerte. Por lo tanto:
1. Utilize el gas apropiado para el proceso y utilize un
regulador diseñado para operar y reducir la presión del
cilindro de gas . No utilice adaptadores. Mantenga las
mangueras y las conexiones en buenas condiciones.
Observe las instrucciones de operación del manufacturero
para montar el regulador en el cilindro de gas comprimido.
2. Asegure siempre los cilindros en posición vertical y
amárrelos con una correa o cadena adecuada
para
asegurar el cilindro al carro, transportes, tablilleros, paredes,
postes, o armazón. Nunca asegure los cilindros a la mesa
de trabajo o las piezas que son parte del circuito de
soldadura . Este puede ser parte del circuito elélectrico.
3. Cuando el cilindro no está en uso, mantenga la válvula del
cilindro cerrada. Ponga el capote de protección sobre la
válvula si el regulador no está conectado. Asegure y
mueva los cilindros utilizando un carro o transporte
adecuado. Evite el manejo brusco de los cilindros.
4. Localize los cilindros lejos del calor, chispas, y flamas.
Nunca establezca un arco en el cilindro.
SIGNIFICADO DE LOS SIMBOLOS -- Según
usted avanza en la lectura de este folleto:
Los Símbolos Significan ¡Atención! ¡Esté
Alerta! Se trata de su seguridad.
Significa riesgo inmediato que, de no ser
evadido, puede resultar inmediatamente
en serio daño personal o la muerte.
Significa el riesgo de un peligro potencial
que puede resultar en serio daño personal o la muerte.
Significa el posible riesgo que puede
resultar en menores daños a la persona.
8
PRÉCAUTIONS DE SÉCURITÉ
a. Éloigner suffisamment tous les matériaux combustibles du secteur où l’on exécute des soudures ou des
coupes à l’arc, à moins de les recouvrir complètement
d’une bâche non-inflammable. Ce type de matériaux
comprend notamment le bois, les vêtements, la sciure,
l’essence, le kérosène, les peintures, les solvants, le
gaz naturel, l’acétylène, le propane et autres substances combustibles semblables.
b. Les étincelles ou les projections de métal incandescent peuvent tomber dans des fissures du plancher ou
dans des ouvertures des murs et y déclencher une
ignition lente cachée. Veiller à protéger ces ouvertures
des étincelles et des projections de métal.
c. N’exécutez pas de soudures, de coupes, d’opérations
de gougeage ou autres travaux à chaud à la surface
de barils, bidons, réservoirs ou autres contenants
usagés, avant de les avoir nettoyés de toute trace de
substance susceptible de produire des vapeurs
inflammables ou toxiques.
d. En vue d’assurer la prévention des incendies, il
convient de disposer d’un matériel d’extinction prêt à
servir immédiatement, tel qu’un tuyau d’arrosage, un
seau à eau, un seau de sable ou un extincteur portatif.
e. Une fois le travail à l’arc terminé, inspectez le secteur
de façon à vous assurer qu’aucune étincelle ou projection de métal incandescent ne risque de provoquer
ultérieurement un feu.
3. CHOC ÉLECTRIQUE-- Le gougeage à l’arc et à l’arc
au plasma exige l’emploi de tensions à vide
relativement importantes; or, celles-ci risquent de
causer des dommages corporels graves et même
mortels en cas d’utilisation inadéquate. La gravité du
choc électrique reçu dépend du chemin suivi par le
courant à travers le corps humain et de son intensité.
a. Ne laissez jamais de surfaces métalliques sous tension venir au contact direct de la peau ou de
vêtements humides. Veillez à porter des gants bien
secs.
b. Si vous devez effectuer un travail sur une surface
métallique ou dans un secteur humide, veillez à assurer votre isolation corporelle en portant des gants secs
et des chaussures à semelles de caoutchouc et en
vous tenant sur une planche ou une plate-forme
sèche.
c. Mettez toujours à la terre le poste de soudage/coupage
en le reliant par un câble à une bonne prise de terre.
d. N’utilisez jamais de câbles usés ou endommagés. Ne
surchargez jamais le câble. Utilisez toujours un
équipement correctement entretenu.
e. Mettez l’équipement hors tension lorsqu’il n’est pas en
service. une mise à la masse accidentelle peut en effet
provoquer une surchauffe de l’équipement et un danger d’incendie. Ne pas enrouler ou passer le câble
autour d’une partie quelconque du corps.
f. Vérifiez si le câble de masse est bien relié à la pièce en
un point aussi proche que possible de la zone de
travail. Le branchement des câbles de masse à
l’ossature du bâtiment ou en un point éloigné de la
zone de travail augmente en effet le risque de passage d’un courant de sortie par des chaînes delevage
AVERTISSEMENT: Ces règles de sécurité ont pour objet
d’ assurer votre protection. Veillez à lire et à observer les
précautions énoncées ci-dessous avant de monter l’
équipement ou de commercer à l’utiliser. Tout défaut
d’observation de ces précautions risque d’entraîner des
blessures graves ou mortelles.
1. PROTECTION INDIVIDUELLE-- Les brûlures de la
peau et des yeux dues au rayonnement de l’arc
électrique ou du métal incandescent, lors du soudage
au plasma ou à l’électrode ou lors du gougeage à
l’arc, peuvent s’avérer plus graves que celles
résultant d’une exposition prolongée au soleil. Aussi
convient-il d’observer les précautions suivantes:
a. Portez un écran facial adéquat muni des plaques
protectrices et des verres filtrants appropriés afin de
vous protéger les yeux, le visage, le cou et les oreilles
des étincelles et du rayonnement de l’arc électrique
lorsque vous effectuez des soudures ou des coupes
ou lorsque vous en observez l’exécution.
AVERTISSEZ les personnes se trouvant à proximité
de façon à ce qu’elles ne regardent pas l’arc et à ce
qu’elles ne s’exposent pas à son rayonnement, ni à
celui du métal incandescent.
b. Portez des gants ignifugés à crispins, une tunique
épaisse à manches longues, des pantalons sans
rebord, des chaussures à embout d’acier et un
casque de soudage ou une calotte de protection, afin
d’éviter d’exposer la peau au rayonnement de l’arc
électrique ou du métal incandescent. ll est également
souhaitable d’utiliser un tablier ininflammable de
façon à se protéger des étincelles et du rayonnement
thermique.
c. Les étincelles ou les projections de métal incandescent risquent de se loger dans des manches
retroussées, des bords relevés de pantalons ou dans
des poches. Aussi convient-il de garder boutonnés le
col et les manches et de porter des vêtements sans
poches à l’avant.
d. Protégez des étincelles et du rayonnement de l’arc
électrique les autres personnes travaillant à proximité
à l’aide d’un écran ininflammable adéquat.
e. Ne jamais omettre de porter des lunettes de sécurité
lorsque vous vous trouvez dans un secteur où l’on
effectue des opérations de soudage ou de coupage à
l’arc. Utilisez des lunettes de sécurité à écrans ou
verres latéraux pour piquer ou meûler le laitier. Les
piquetures incandescentes de laitier peuvent être
projetées à des distances considérables. Les
personnes se trouvant à proximité doivent également
porter des lunettes de protection.
f. Le gougeage à l’arc et le soudage à l’arc au plasma
produisent un niveau de bruit extrêmement élevé (de
100 à 114 dB) et exigent par conséquent l’emploi de
dispositifs appropriés de protection auditive.
2. PRÉVENTION DES INCENDES-- Les projections de
laitier incandescent
ou d’étincelles peuvent
provoquer de graves incendies au contact de
matériaux combustibles solides, liquides ou gazeux.
Aussi faut-il observer les précautions suivantes:
9/97
9
PRÉCAUTIONS DE SÉCURITÉ
des câbles de grue ou divers chemins électriques.
g. Empêchez l’apparition de toute humidité, notamment
sur vos vêtements, à la surface de l’emplacement de
travail, des câbles, du porte-électrode et du poste de
soudage/coupage. Réparez immédiatement toute
fuite d’eau.
4. VENTILATION-- La respiration prolongée des fumées
résultant des opérations de soudage/coupage, à
l’intérieur, d’un local clos, peut provoquer des malaises et des dommages corporels. Aussi convient-il
d’observer les précautions suivantes:
a. Assurez en permanence une aération adéquate de
l’emplacement de travail en maintenant une ventilation naturelle ou à l’aide de moyens mécaniques.
N’effectuez jamais de travaux de soudage ou de
coupage sur des matériaux de zinc, de plomb, de
beryllium ou de cadmium en l’absence de moyens
mécaniques de ventilation capables d’empêcher
l’inhalation des fumées dégagées par ces matériaux.
b. N’effectuez jamais de travaux de soudage ou de
coupage à proximité de vapeurs d’hydrocarbure
chloré résultant d’opérations voisines de dégraissage
ou de pulvérisation. La chaleur dégagée ou le
rayonnement de l’arc peut déclencher la formation de
phosgène -- gaz particulièrement toxique -- et d’autres
gaz irritants, à partir des vapeurs de solvant.
c. Une irritation momentanée des yeux, du nez ou de la
gorge constatée au cours de l’utilisation de
l’équipement dénote un défaut de ventilation. Arrêtezvous de travailler afin de prendre les mesures nécessaires à l’amélioration de la ventilation. Ne poursuivez
pas l’opération entreprise si le malaise persiste.
d. Certaines commandes comportent des canalisations
où circule de l’hydrogène. L’armoire de commande est
munie d’un ventilateur destiné à empêcher la formation de poches d’hydrogène, lesquelles présentent un
danger d’explosion; ce ventilateur ne fonctionne que
si l’interrupteur correspondant du panneau avant se
trouve placé en position ON (Marche). Veillez à
manœuvrer cette commande en vérifiant si le
couvercle est bien en place, de façon à assurer
l’efficacité de la ventilation ainsi réalisée. Ne jamais
débrancher le ventilateur.
e. Les fumées produites par l’opération de soudage ou
de coupage peuvent s’avérer toxiques. Aussi est-il
nécessaire de disposer en permanence d’un dispositif
adéquat de ventilation de type aspirant, afin d’éliminer du voisinage de l’opérateur tout dégagement de
fumée visible.
f. Consultez les recommandations particulières en
matière de ventilation indiquées à l’alinéa 6 de la
norme Z49.1 de l’AWS.
5. ENTRETIEN DE L’ÉQUIPEMENT-- Un équipement
entretenu de façon défectueuse ou inadéquate risque
non seulement de réaliser un travail de mauvaise
qualité mais, chose plus grave encore, d’entraîner des
dommages corporels graves, voire mortels en
déclenchant des incendies ou des chocs électriques.
Observez par conséquent les précautions suivantes:
a. Efforcez-vous de toujours confier à un personnel qualifié l’installation, le dépannage et l’entretien du poste
de soudage et de coupage. N’effectuez aucune
réparation électrique sur l’équipement à moins d’être
qua-lifié à cet effet.
b. Ne procédez jamais à une tâche d’entretien
quelconque à l’intérieur du poste de soudage/
coupage, avant d’avoir débranché l’alimentation
électrique.
c. Maintenez en bon état de fonctionnement les câbles,
le câble de masse, les branchements, le cordon
d’alimentation et le poste de soudage/coupage.
N’utilisez jamais le poste ou l’équipement s’il présente
une défectuosité quelconque.
d. Prenez soin du poste de soudage et de coupage et des
équipements accessoires. Gardez-les à l’écart des
sources de charleur, notamment des fours, de
l’humidité, des flaques d’eau maintenez-les à l’abri des
traces d’huile ou de graisse, des atmosphères corrosives et des intempéries.
e. Laissez en place tous les dispositifs de sécurité et tous
les panneaux de l’armoire de commande en veillant à
les garder en bon état.
f. Utilisez le poste de soudage/coupage conformément à
son usage prévu et n’effectuez aucune modification.
6. INFORMATIONS COMPLÉMENTAIRES RELATIVES
À LA SÉCURITÉ-Pour obtenir des informations complémentaires sur les
règles de sécurité à observer pour le montage et
l’utilisation d’équipements de soudage et de coupage
électriques et sur les méthodes de travail
recommandées, demandez un exemplaire du livret N°
52529 “Precautions and Safe Practices for Arc Welding, Cutting and Gouging” publié par ESAB. Nous
conseillons également de consulter les publications
sui-vantes, tenues à votre disposition par l’American
Welding Society, 550 N.W. LeJuene Road, Miami, FL
32126:
a. “Safety in Welding and Cutting” AWS Z49.1
b. “Recommended Safe Practices for Gas-Shielded Arc
Welding “AWS A6. 1.
c. “Safe Practices for Welding and Cutting Containers
That Have Held Combustibles” AWS-A6.0.
d. “Recommended Safe Practices for Plasma Arc Cutting”
AWS-A6. 3.
e. “Recommended Safe Practices for Plasma Arc Welding” AWS-C5. 1.
f. “Recommended Safe Practices for Air Carbon Arc
Gouging and Cutting” AWS-C5. 3.
g. “Code For Safety in Welding and Cutting”
CSA-Standard W117. 2.
9/97
10
SECTION 1
DESCRIPTION
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.
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
Multi input voltage (208)230/460V, easily changed on
back of machine.
Cuts 1-1/4 inch.
Designed for rugged treatment and outdoor use
makes the PowerCut an excellent choice for rental
fleet and construction site uses.
More performance features than any other machine
in its class.
Delivers big machine cutting power in a rugged,
lightweight package.
Pilot arc start facilitates starting on painted and coated
metals.
Long-life consumables and repairable torch minimize
operating costs.
Arrives ready to cut, with torch connected and frontend parts in place, for the ultimate in operator
convenience.
Trigger lock-in for long-cut operator comfort.
Built in line conditioner – handles poor power lines.
Auto Drag feature allows torch to drag on workpiece
without damage to the nozzle for easy template
following.
For longer nozzle life while drag cutting, a 40 amp
nozzle is available (P/N 0558002908).
Self protectant against improper input voltage.
Multiple troubleshooting lights on front panel.
Excellent gouging performance.
Three year warranty on console.
One year warranty on torch.
PT-32EH Cut Data-70 AMPS
Powercut-1250, PT-32EH, 70A Nozzle P/N 0558002618
Air Pressure - 80 psi, 5/32” Standoff
Max Speeds
Carbon Steel
(Inches)
(IPM)
Sever
(IPM)
0.250
0.500
0.750
131
50
21
135
53
23
1.000
1.250
10
6
12
7
1.500
----
3
Plate
Torch
Drop Cut
PowerCut-1250 uses the PT-32EH torch. For complete list
and breakdown of parts, refer to PT-32EH data page.
Ordering Information:
Specifications: PowerCut-1250
Cuts 1-1/4 in. (32mm); severs 1-1/2 in. (38mm)
1 ph. Input ............................. 208/230 vac, 1 ph, 50/60 Hz, 67/61 A
1 ph. Output .......................................... 70 amps @ 60% duty cycle
3 ph. Input .............................. 208/230 vac, 3 ph, 50/60 Hz, 33/29 A
........................................... 230/460 vac, 3 ph, 50/60 Hz, 29/20 A
........................................................ 575 vac, 3ph, 50/60 Hz, 15 A
3 ph. Output ......................................... 70 amps @ 100% duty cycle
Dimensions ........................................................ W = 12.5” (318mm)
........................................................................ H = 16.5” (419mm)
........................................................................... D = 32” (813mm)
Weight ........................................................................ 86 lbs. (39kg)
Air Requirements ..... 350 cfh @ 80 psig (165 l/min @ 4.8-5.2 bars)
11
PowerCut-1250, 208/230/460 V, 25’ PT-32EH ............. 0558001933
PowerCut-1250, 208/230/460 V, 50’ PT-32EH ............. 0558001934
PowerCut-1250, 575 V, 25’ PT-32EH .......................... 0558001939
PowerCut-1250, 575 V, 50’ PT- 32EH .......................... 0558001940
PowerCut-1250, 400 V, “CE” 25’ PT-32EH ................... 0558001936
PowerCut-1250, 400 V, “CE” 50’ PT-32EH ................... 0558001937
The components that are included in the Powercut-1250 packages 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 575 V, 50/60 Hz, 3-ph....................... 0558001941
PowerCut-1250 400 V, CE, 50 Hz, 3-ph ..................... 0558001938
PT-32EH Torches:
PT-32EH Torch, 75o head, 25-ft. ................................ 0558003548
PT-32EH Torch, 75o head, 50-ft. ................................ 0558003549
PT-32EH Spare Parts Kit (see Table 1-1) .................. 0558003508
SECTION 1
DESCRIPTION
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.
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
■
Multi input voltage (208)230/460V, easily changed on
back of machine.
Cuts 1-1/2 inch.
Designed for rugged treatment and outdoor use
makes the PowerCut an excellent choice for rental
fleet and construction site uses.
More performance features than any other machine
in its class.
Delivers big machine cutting power in a rugged,
lightweight package.
Pilot arc start facilitates starting on painted and coated
metals.
Long-life consumables and repairable torch minimize
operating costs.
Arrives ready to cut, with torch connected and frontend parts in place, for the ultimate in operator
convenience.
Trigger lock-in for long-cut operator comfort.
Built in line conditioner – handles poor power lines.
Auto Drag feature allows torch to drag on workpiece
without damage to the nozzle for easy template
following.
For longer nozzle life while drag cutting, a 40 amp
nozzle is available (P/N 0558002908).
Self protectant against improper input voltage.
Multiple troubleshooting lights on front panel.
Excellent gouging performance.
Three year warranty on console.
One year warranty on torch.
PT-32EH Cut Data-90 AMPS
Powercut-1500, PT-32EH, 90A Nozzle P/N 0558002837
Air Pressure - 80 psi, 5/32” Standoff
Max Speeds
Carbon Steel
(IPM)
151
Sever
(IPM)
153
0.500
0.750
56
25
58
26
1.000
1.250
1.500
16
11
7
18
12
8
Plate
(Inches)
0.250
Torch
Drop Cut
PowerCut-1500 uses the PT-32EH torch. For complete list
and breakdown of parts, refer to PT-32EH data page.
Specifications: PowerCut-1500
Ordering Information:
Cuts 1-1/2 in. (38mm); severs 1-3/4 in. (45mm)
1 ph. Input .............................. 208/230 vac, 1 ph, 50/60 Hz, 82/74 A
1 ph. Output ........................................... 90 amps @ 40% duty cycle
3 ph. Input .............................. 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
........................................................ 575 vac, 3ph, 50/60 Hz, 18 A
3 ph. Output ........................................... 90 amps @ 60% duty cycle
Dimensions ........................................................ W = 13.1” (328mm)
w/ optional Torch Storage ............................... W= 16.1" (403mm)
........................................................................ H = 16.5” (419mm)
........................................................................ D = 32.5” (826mm)
Weight ..................................................................... 94 lbs. (42.7kg)
Shipping Weight ..................................................... 109 lbs. (49.5kg)
Air Requirements ............ 360 cfh @ 75 psig (170 l/min @ 5.2 bars)
12
PowerCut-1500, 230/460 V, 25’ PT-32EH .................... 0558001942
PowerCut-1500, 230/460 V, 50’ PT-32EH .................... 0558001943
PowerCut-1500, 575 V, 25’ PT-32EH .......................... 0558001948
PowerCut-1500, 575 V, 50’ PT- 32EH .......................... 0558001949
PowerCut-1500, 400 V, “CE” 25’ PT-32EH ................... 0558001945
PowerCut-1500, 400 V, “CE” 50’ PT-32EH ................... 0558001946
The components that are included in the Powercut-1250 packages
may be purchased separately by using the appropriate P/N when
placing orders. Individual part numbers are listed below:
Consoles:
PowerCut-1500 (208)230/460 V,
50/60 Hz, 1/3-ph ..................................................... 0558003570
PowerCut-1500 575 V, 50/60 Hz, 3-ph ....................... 0558001950
PowerCut-1500 400 V, CE, 50 Hz, 3-ph .................... 0558001947
PT-32EH Torches:
PT-32EH Torch, 90o head, 25-ft. ............................... 0558003548
PT-32EH Torch, 90o head, 50-ft. ............................... 0558003549
PT-32EH Spare Parts Kit (see Table 1-1) ................. 0558003062
SECTION 1
DESCRIPTION
Optional Accessories:
Contents of PT-32EH Spare Parts Kit, P/N 0558003508
Description
P/N
Heat Shield
70 amp Nozzle
40 amp drag Nozzle
Electrode
Valve Pin
Fuse 2amp, 600vdc
Stand-off Guide
Wrench
Lubricant
0558001957
0558002618
0558002908
0558001969
0558001959
0558003075
0558002393
19129
17672
70 amp Spare Parts Kit ............................................... 0558003508
90 amp Spare Parts Kit ............................................... 0558003062
Plasma Flow Measuring Kit:
This valuable troubleshooting tool allows measurement of
the actual plasma gas flow through the torch ................... 19765
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, 1 3/4" - 42" Radius, Deluxe ...... 0558003258
Basic, 1/34” - 28” Radius ......................................... 0558002675
Stand-off Guide
For proper stand-off distance when drag cutting ...... 0558002393
40 amp Drag Nozzle ................................................. 0558002908
Gouging Nozzle .......................................................... 0558003089
Heat Shield Gouging ................................................ 0558003090
Drag Heat Shield ........................................................ 0558003374
Wheel Kit
For easy transport of system ................................... 0558003060
Torch Wrap
This enables operator to store spare parts kit, wrap torch
and work cable for easy transport and storage ......... 0558003059
Quantity
2
4
1
3
1
1
1
1
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.
Contents of PT-32 Spare Parts Kit, P/N 0558003062
Description
P/N
Heat Shield
90 amp Nozzle
40 amp drag Nozzle
Electrode
Valve Pin
Fuse 2amp, 600vdc
Stand-off Guide
Wrench
Lubricant
0558001957
0558002837
0558002908
0558001969
0558001959
0558003075
0558002393
19129
17672
Quantity
2
4
1
3
1
1
1
1
1
Torch Wrap
This enables operator to store spare parts kit, wrap torch
and work cable for easy transport and storage .......... 0558003059
The PowerCut-1500 comes out of the box ready to go. The torch is
attached with parts in place, primary cord is attached (including plug
on 230 model), and the filter/regulator is installed. Just hook up the
air, power and begin cutting.
O-Ring - 85W51
(Supplied with head)
Valve Pin
0558001959
Electrode
0558001969
Heat Shield
0558001957
Wheel Kit
For easy transport of system .................................... 0558003060
PT-32EH Torch Head - 0558003412
Nozzle
40 AMP - 0558002908 (Drag Cutting)
50/70 AMP - 0558002618
90 AMP - 0558002837
Powercut shown with Optional Torch Wrap
and Spare Parts Kit Holder installed.
13
SECTION 1
DESCRIPTION
1.1 GENERAL
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.
The Powercut-1250 / 1500 is a compact, 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 (90150 psi). The Powercut package uses the heavy-duty PT-32EH torch to deliver
cutting power for severing materials up to 1-1/2 inch thick. Refer to the
following paragraphs for descriptions of the Powercut packages available as
well as performance specifications.
1.2 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.
Technical reference material is also provided to assist in troubleshooting the
cutting package.
PT-32EH DRAG MODE CUTTING SPEEDS
AIR @ 80PSI and OUTPUT CURRENT 40AMPS
Thickness
(In.)
Cutting
Speed (IPM)
Carbon Steel
1/16
1/8
1/4
3/8
1/2
200
98
36
18
11
Stainless Steel
1/16
1/8
1/4
3/8
1/2
138
58
18
10
6
Aluminum
1/16
1/8
1/4
3/8
1/2
200
110
48
17
14
Material
14
SECTION 2
INSTALLATION
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 is required for the
cutting operation. The air supply should not exceed 150 psig (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
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.
ELECTRIC SHOCK CAN KILL! Precautionary measures should be taken to
provide maximum protection against
electrical shock. Be sure that all power
is off by opening the line (wall) disconnect switch and by unplugging the
power cord to the unit when connections are made inside of the power
source.
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
materials.
C.
Check air louvers and any other openings to ensure that any obstruction
is removed.
2.5 PRIMARY ELECTRICAL INPUT
CONNECTIONS (FIGURE 2-1)
The PowerCut-1250 / 1500 consoles are equipped with approximately 10ft. of 4-conductor input power cable for 3-phase connection. If single-phase
connection is desired, tape back the red 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.
CUSTOMER FUSED LINE DISCONNECT SWITCH
(See Table 2.1 and WARNING in regards to chassis ground in Section 2.5.)
15
SECTION 2
ELECTRIC SHOCK CAN KILL! Before
making 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.
The chassis must be connected to an
approved electrical ground. Failure to
do so may result in electrical shock,
severe burns or death.
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 and that
the input power cable is unplugged.
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 (No. 6 AWG, 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 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
Input Requirements
Volts
Phase
208
208
230
230
460
575
1
3
1
3
3
3
Amps
67A
33A/Ph.
61A
29A/Ph.
20
15
Input & Gnd
Fuse
Conductor
Size
CU/AWG
Amps
6
6
6
6
6
10
100
50
100
50
50
25
Table 2-2. (PC-1500) Recommended Sizes For
Input Conductors and Line Fuses
Input Requirements
Volts
Phase
208
208
230
230
460
575
1
3
1
3
3
3
Amps
82A
44A/Ph.
74A
40A/Ph.
27
18
Input & Gnd
Fuse
Conductor
Size
CU/AWG
Amps
6
6
6
6
6
10
100
80
100
80
50
50
2.5.1 INPUT VOLTAGE CHANGEOVER
200 - 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. 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
Input Voltage
Selector Switch
INPUT VOLTAGE SELECTOR
NOT POWER
ON - OFF SWITCH
Fuse*
USE POWER SWITCH ON FRONT
PANEL TO TURN
ON AND OFF
provided at the main power panel (see Fig. 2-1 and 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.
16
SECTION 2
INSTALLATION
2.6 SECONDARY (OUTPUT) CONNECTIONS (REFER TO
FIG. 2-1)
The Torch comes factory installed.
Connect your air supply to the inlet connection of the filter-regulator.
Prefiltered DRY AIR
SUPPLY (Customer
Supplied)
(90 to 150 psig max)
PRIMARY INPUT
POWER CABLE
FUSED
DISCONNECT
BOX
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
SAFETY
GROUND
PT-32EH
Figure 2-1. PowerCut Interconnection Diagram
17
SECTION 2
INSTALLATION
18
SECTION 3
OPERATION
B
A
C
D
Figure 3-1A. PowerCut-1250 / 1500 Controls
3.1 OPERATION
3.2 PowerCut-1250 / 1500 CONTROLS
A.
Power Switch. When placed in ON position, the white power light will
glow indicating control circuit is energized.
B.
Air Test Switch. When placed in TEST position, air filter-regulator can
be adjusted to desired pressure (80 psig) 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.
C.
Trigger Lock Switch. When placed in LOCK position, this permits
releasing torch switch button 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
operation and then released at the end of cut.
D.
Output Current Control. Adjustable from 20 to 70 amperes on
Powercut-1250. Adjustable from 20 to 90 amperes on Powercut-1500.
19
SECTION 3
OPERATION
E
F
G
H
I
Figure 3-1B. PowerCut-1250 / 1500 Controls
E. Power "ON" Indicator: Illuminates whenever the front panel power
switch is in the ON position.
F. 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.
G. Gas Flow Indicator: This fault light will blink when the air flow supply is
low or has no back pressure.
H. 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.
I.
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.
All fault signals will remain on for a minimum of 10 seconds. If fault
clears, all will reset automatically except for over-current. To clear
over-current, the power must be shut off for 5 seconds and then
turned back on.
20
SECTION 3
OPERATION
3.3 CUTTING WITH THE POWERCUT-1250 / 1500
Use the following procedures to cut with the PT-32EH torch.
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.
A.
B.
C.
D.
E.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
• Wear welding helmet with No. 6 or 7
lens shade.
• Wear eye, ear, and body protection.
F.
Make sure that the wall disconnect switch is on. Turn on the Front
Panel Power Switch.
Set Pressure Regulator to 80 psig.
Hold the torch nozzle approximately 1/8 to 3/16 inch above the work and
tilted at about 15 - 30°. This reduces the chance of spatter entering the
nozzle. If the PT-32EH's standoff guide (P/N 0558002393) is being
used, the distance between Electrode and Work Piece will be approx.
3/16-inch.
Depress the torch switch. Air should flow 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.)
After starting the cut, the torch should be maintained at a 5-15° forward
angle (Figure 3-2). This angle is especially useful in helping to create
a "drop" cut. When not using the standoff guide, the nozzle should be
held approximately 1/4 inch from the work.
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.
CUT
DIRECTION
Figure 3-2. Recommended Torch Angle of 5° to 15°
IMPORTANT!!!
Maintain Proper
Stand-Off Distance
3/16 to 1/4 Inch
Power Output increases with Stand Off Distance!
21
Standoff vs. Power Output
SECTION 3
OPERATION
G.
H.
When ending a cut, the 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).
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.
3.3.1
PT-32EH TORCH PARTS INSTALLATION
PLACE THE VALVE PIN INTO THE
ELECTRODE AND SCREW THE
ELECTRODE INTO THE TORCH HEAD
AND TIGHTEN SECURELY WITH
WRENCH #19129.
1
*VALVE
PIN
ELECTRODE
NOZZLE
SHIELD
2
PLACE NOZZLE INTO
HEAT SHIELD AND
THREAD THIS ASSEMBLY TO THE TORCH
BODY AND HAND
TIGHTEN.
3
IMPORTANT!
MAKE SHIELD VERY
TIGHT!
valve pin is a crucial member of the system. Its func* The
tion 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 electrode cooling by increasing the velocity of air
over the inner surface of the electrode.
Fig 3.3. Exploded View of PT-32EH Torch
22
SECTION 3
3.3.2
OPERATION
INSTALLATION AND USE OF STAND-OFF GUIDE
ADJUST GUIDE BY TURNING
IN A CLOCKWISE DIRECTION
ONLY. THIS WILL PREVENT
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" (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" (6.4 mm)
TORCH-TO-WORK
GUIDE AGAINST
STRAIGHT EDGE
OR FREE-HAND
CUT
IF TOO LOOSE, CLOSE
SLOT WITH VISE OR
LARGE PLIERS.
Figure 3-4. Installation and Operation of Stand-off Guides
23
SECTION 3
OPERATION
2
1
WHEN THE ARC BREAKS
THROUGH THE WORK,
BRING THE TORCH TO AN
UPRIGHT POSITION AND
PROCEED TO CUT.
TO START A PIERCE, TILT THE
TORCH TO PREVENT MOLTEN
MATERIAL FROM COMING BACK
AGAINST AND DAMAGING THE
TORCH.
Figure 3-5. Piercing Technique using the PT-32EH
3.4 POSSIBLE CUTTING ISSUES
NEW
Replace when eroded
beyond
.06"(1.5mm) Depth.
WORN
REPLACE ELECTRODE BEFORE
PITTING BECOMES DEEPER THAN
.06 INCH (1.5 MM)
Figure 3-6. Electrode Wear Limit
NOTE: When replacing the nozzle, always inspect the electrode for wear. If
more than .06" of electrode Hafnium 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.
3.3.1. Drag Cutting with the PT-32EH Torch / PowerCut package.
Drag cutting, even with lower current
levels may significantly reduce the life
of torch consumables. Attempting to
Drag Cut with higher currents greater
than (40 amps) may cause immediate
catastrophic consumable damage.
LOW CURRENT AUTO-DRAG FEATURE
If drag cutting is desired for thin material under 3/8" thick, remove the
standard 70 / 90 amp nozzle from the PT-32EH torch and install ESAB's 40
amp nozzle (P/N 0558002908). 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 (3.3). Also refer to PT-32EH
Instruction Manual No. F-15-440.
HIGH CURRENT DRAG CUTTING
If drag cutting is desired on materials above 3/8” thick, be sure that the 70 amp
(P/N 0558002618) / 90 amp nozzle (P/N 0558002837) is installed in the PT32EH torch. Attach ESAB's stand-off guide (P/N 0558002393) and operate
as shown in Figure 3.4.
24
SECTION 3
OPERATION
3.5 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.
2.
3.
4.
5.
Current too low.
Cutting speed too fast.
Damaged cutting nozzle.
Improper air pressure.
Low air flow rate.
B. Main Arc Extinguishes.
1. Cutting speed too slow.
2. Worn electrode.
C. Dross Formation. (In some materials and thicknesses, it may be
impossible to get dross-free cuts.)
1.
2.
3.
4.
5.
Current too low.
Cutting speed too fast or too slow.
Improper air pressure.
Faulty nozzle or electrode.
Low air flow rate.
D. Double Arcing. (Damaged Nozzle Orifice.)
1.
2.
3.
4.
Low air pressure.
Damaged cutting nozzle.
Loose cutting nozzle.
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.
25
SECTION 3
OPERATION
26
SECTION 4
MAINTENANCE
4.1 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 attempting any inspection or work inside of the
Powercut.
4.2 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.
B.
C.
D.
E.
F.
G.
Check work cable for secured connection to workpiece.
Check safety earth ground at workpiece and at power source chassis.
Check heat shield on torch. It should be replaced if damaged.
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.
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.
H.
Occasionally, bleed all water from the filter beneath the air filterregulator.
4.3 PT-32EH TORCH CONSUMABLE PARTS
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 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 proper torch manufactured by ESAB
since it alone contains ESAB's patented safety interlock.
To assemble the torch consumable parts, refer to Figure 3.3 .
27
SECTION 4
MAINTENANCE
4.4 IGBT Handling & Replacement
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 precautions application to FETs should be followed.
Other handling precautions that should also be observed are as follows:
•
•
•
•
Use grounded work station with grounded floors and grounded wrist
straps when handling devices.
Use a 100Ω resistor in series with the gate when performing curve
tracer tests.
Never install devices into systems with power connected to the
system.
Use soldering irons with grounded tips when soldering to gate terminals.
When mounting IGBT 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 in Figure 4-2.
Also, care must be taken to achieve maximum contact (i.e. minimum
contact thermal resistance) for the best heat dissipation.
Application of a thermal pad on the contact surface improves its thermal
conductivity. See Replacement Parts section for the required pad.
A torque wrench should be used. Tighten mounting screws to 28 in-lbs;
wire connecting screws to 19 in-lbs. If torque is too heavy, the device can
damage like the above “one-sided tightening”.
28
SECTION 4
MAINTENANCE
c
Two-Point Mounting Type
Temporary tightening  cÎd
Final tightening  dÎc
d
c
Four-Point Mounting Type
Temporary tightening 
cÎdÎeÎf
Final tightening  fÎeÎdÎc
e
f
d
Figure 4-2. Screw Fastening Order
29
SECTION 4
MAINTENANCE
30
SECTION 5
TROUBLESHOOTING
5.1 TROUBLESHOOTING
ELECTRIC SHOCK CAN KILL! Be sure that all primary power to the
machine has been externally 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 (Figure 5-1) and
checking the various components. A volt-ohmmeter will be necessary for
some of these checks.
Voltages in plasma cutting equipment are high enough to cause
serious injury or possibly death. Be particularly careful around
equipment when the covers are removed.
NOTE
Before checking voltages in the circuit, disconnect the power from the
high frequency PC Board (PCB-2, Connector J2) to avoid damaging your
voltmeter.
31
SECTION 5
TROUBLESHOOTING
5.2 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 disconnect switch and it’s fuses.
c. Check Fuse (F1).
3. If above items check OK , the problem is internal. Send unit to an
Authorized Repair Station 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. If the 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.
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 OK , 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, depress 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 depressed. If not, then
either there are broken switch leads or a malfunctioning
switch.
32
SECTION 5
TROUBLESHOOTING
2. 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.
3. If everything above checks out all right, then the PCB1 Control Board
should be replaced.
D. 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.
2. 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 machine regulator. It should be
adjusted to 80 psig. If no air pressure, check the air at the supply
point. Also, check for any obstructions in the air hose.
b. Air flow may be blocked at the torch tip. Check the torch
consumables (see Figure 3.3). 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, check
gas Solenoid (SOL1) for proper operation.
d. Air Check switch may also be malfunctioning if the air is flowing
continuously or putting in the On position does not turn air on.
3. 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. If the switch is malfunctioning, replace it. Clean the surface of the
heat sink before installing the switch.
4. 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.
a. If the light blinks for 10 seconds and then stops, then the problem
is pilot arc initiation. Check the consumables in the torch.
b. If the light continues to blink, and the system does not reset, then
the fault is an over-current event. One likely source of an overcurrent fault is a nozzle to electrode short. Turn off the machine
and inspect the torch and its consumables. Replace the
33
SECTION 5
TROUBLESHOOTING
c.
b.
consumables as needed. Turn the machine back on. If the
problem occurs again, the machine may require service.
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.
If the resistance reading is different than above, check the torch,
the output bridge and Start-up Board (PCB-6).
E. Air is On but nothing happens when torch switch is operated.
1. Check the torch. Make sure that the valve pin is installed and the heat
shield is very tight.
2. 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 & P2A-3 of the High Frequency Board
(PCB2) with torch switch closed.
3. With HI FREQUENCY leads disconnected, measure open circuit
voltage. It should be 320 VDC between “Work” and “Torch” terminals.
If it is not present then any one of the following may not be working
properly:
a. Check the operation of the Thermal Switch (TS1). See D.3.a.
above.
b. Check Air 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)
c. 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 to 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. 400 VDC with 575 V supplied to the 575 volt unit
If not, one of following could be malfunctioning:
1). Check the capacitors C5 and C6 for any damage.
2.) Check input bridge/SCR Module (BR1) 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 (Q1). 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.
34
SECTION 5
TROUBLESHOOTING
F.
High Frequency and Pilot Arc are on but Main Arc does not
transfer.
1. Make sure work clamp is connected to work material.
2. Check the torch. Replace consumables if necessary.
G. Poor Cutting Performance.
1. Check air supply regulator . It should be adjusted to 80 psig.
2. The air supplied to the torch should be free of oil and water.
3. Make sure the consumables in the torch are acceptable.
4. Check open circuit voltage. See E.3 above.
5. Check the output. Use a calibrated current probe capable of
measuring 100 amps in the presence of high frequency.
H. Air does not shut off.
1. Check air test, the gas solenoid valve is energized when the switch is
in the “on” position.
2. 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.
I.
Main arc is difficult to start.
1. The most common reason is worn or missing consumables. Check
and replace if necessary. See Section 3.3.1.
2. Input air must be clean and dry.
3. Input air pressure must be 80 psig.
4. Torch connections must be tight.
5. Work cable and clamp must be in good condition and must make a
good electrical connection to the material to be cut.
6. If above items check OK , the problem is internal. Send unit to an
Authorized Repair Station for repair.
a. Missing or weak pilot arc. Check pilot arc fuse, open circuit
voltage and pilot arc wiring.
b. Inoperative Start-up Board (PCB-6).
35
SECTION 5
TROUBLESHOOTING
5.3 REFERENCE VOLTAGE CHECKS
A. Control Board Assembly (PCB1)
1.
LED’s
LED- (D9)LED- (D4)LED- (D1)-
2.
Torch Switch
Pilot Arc Relay
Gas Solenoid Valve
Voltage Test Points
Tests are made with power on - no arc.
Disable High Frequency by disconnecting blue wire with black
sleeve
TP-1 TP-4 TP-5 TP-7 TP-8 TP-9 TP-10 -
Torch trigger signal
IGBT’s driving signal - switching frequency = 18.5 KHz
IGBT’s driving signal - switching frequency = 18.5 KHz
+5 vdc
+15 vdc
-15 vdc
Ground
54 µs
13vdc
0
13vdc
Figure 5.1 IGBT Gating Signal
36
SECTION 5
TROUBLESHOOTING
5.4 SEQUENCE OF OPERATION
A. TRIGGER LOCK “UNLOCK” position
PUSH
TORCH SWITCH
RELEASE
OPEN
CLOSE
GAS SOLENOID VALVE
PREFLOW
2 SEC.
20 SEC
Postflow
FLOW SWITCH
CLOSE
OPEN
FAULT OVERLOAD LIGHT
HF CIRCUIT
ENERGIZE
PILOT ARC
INVERTER
CUTTING ARC (CURRENT)
NOTES:
1.
When the torch switch is pushed during postflow period, the postflow and preflow times are 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.
37
SECTION 5
B.
TROUBLESHOOTING
TRIGGER LOCK "LOCK" position
PUSH
RELEASE
PUSH
RELEASE
TORCH SWITCH
OPEN
GAS SOLENOID VALVE
2 SEC.
CLOSE
PREFLOW
20 SEC
POSTFLOW
CLOSE
Postflow
OPEN
FLOW SWITCH
FAULT LIGHT
ENERGIZE
HF CIRCUIT
PILOT ARC
INVERTER
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.
FAULT light is on during second "turn-off" trigger only. This does not affect
performance in any way.
38
39
D-0558003510-A
Powercut-1250 / 1500 Schematic Diagram
SECTION 5
TROUBLESHOOTING
40
SECTION 6
REPLACEMENT PARTS
A. REPLACEMENT PARTS
Replacement Parts are illustrated on the following figures. When ordering
replacement parts, order by part number and part name, as illustrated on the
figure. Always provide the series or serial number of the unit on which the
parts will be used. The serial number is stamped on the unit nameplate.
B. ORDERING
To assure proper operation, it is recommended that only genuine ESAB parts
and products be used with this equipment. The use of non-ESAB parts may
void your warranty.
Replacement parts may be ordered from your ESAB distributor or from:
ESAB Welding & Cutting Products
Attn: Customer Service Dept.
P.O. Box 100545, 411 S. Ebenezer Road
Florence, SC 29501-0545
Be sure to indicate any special shipping instructions when ordering replacement parts.
To order parts by phone, contact ESAB at 1-843-664-5540. Orders may also
be faxed to 1-800-634-7548. Be sure to indicate any special shipping instructions when ordering replacement parts.
Refer to the Communication Guide located on the last page of this manual
for a list of customer service phone numbers.
41
SECTION 6
REPLACEMENT PARTS
2
3
3
1
9
8
4
5
7
6
Front View - Powercut-1250 / 1500
Item
No.
1
2
3
4
5
6
7
8
9
Qty.
1
2
1
1
1
1
1
2
1
1
Part
No.
Description
36107
951474
0558001818
0558003390M
0558003391M
0558003001
13733935
0558002780
0558002581
0558001916
SW Pwr Disc 600V
Switch Seal Black
Knob 1.37 Diam
Panel Front Silkscreen (PC-1250)
Panel Front Silkscreen (PC-1500)
Work Cable #6 AWG
Panel Receptacle
Foot Plasma Tube
Strain Relief Input NPT
Plasma Tube End Cover
42
Symbol
S1
SECTION 6
REPLACEMENT PARTS
3
2
4
1
5
6
7
8
Rear View - Powercut-1250 / 1500
Item
No.
Qty.
1
2
3
4
5
6
7
8
1
1
1
1
1
1
1
1
Part
No.
Description
21710
21711
0558002446
0558003075
97W63
0558003002
951182
0558002994
Regulator Air Line *808-02
Gauge 1.50 *160 PSI WHT CB
Switch 40A
Fuse 2A 600VAC
Connector Cable Grip
Cable Input Power, 10Ft.
Fan 230V 50/60 Hz 233CFM
Finger Guard 1.5MM (.06 IN.)
43
Symbol
S2
F1
M1
SECTION 6
REPLACEMENT PARTS
3
2
4
9
Resistors Hidden by Bar
5
1
7
8
6
Internal View - Powercut-1250 / 1500
Lower Left Side
Item
No.
1
2
3
4
5
6
7
8
9
Qty.
1
4
2
2
1
1
1
1
1
1
Part
No.
Description
0558003377
17721020
951185
0558003367
0558002576
952233
0558002455
0558002189
0558002482
0558003105
Transformer Main, Module
RES WWFAHT 25W 1% 20 OHMS
Diode Module FDS 100A 600V
Transducer Current 100A
Relay SPST 24V w/MAG
Inductor Output (PC-1250)
Inductor Output (PC-1500)
Switch Pressure .25 GPN
SOL AY 1/8 NPTF Port 3/16 BARB
Switch Pressure High
44
Symbol
T2, T4
R12-15
D7, D8
T5, T7
K2
L2
L2
PS1
SOL1
FS1
SECTION 6
REPLACEMENT PARTS
1
2
3 (Behind Bar)
9 (Located under lip
8
6
5
7 (Located behind 6) 10 (Assembled to 5)
4
Internal View - Powercut-1250 / 1500
Right Side
Item
No.
1
2
3
4
5
6
7
8
9
10
Qty.
1
1
2
2
2
4
1
1
1
1
1
1
2
2
Part
No.
Description
Symbol
952871
0558002434
0558003379
0558003182
17750051
951161
38240
38229
952232
0558002438
0558002449
38224
0558003106
0558002435
3PH BR Rect. w/out Thyristor (PC-1250)
3PH BR Rect. w/out Thyristor (PC-1500)
Module Dual IGBT 150A 600V (PC-1250)
Module Dual IGBT 200A 600V (PC-1500)
RES WW AHNI 50W 3%K 10 OHM
CAPC Metpoly *20.0***UF 400VDC
PCB Power
PCB HI Freq
Input Inductor (PC-1250)
Input Inductor (PC-1500)
Transformer Hi Freq
PCB IGBT Driver
Cap 2000 UF 450VDC (PC-1250)
Cap 3100 UF 450VDC (PC-1500)
BR1
BR1
Q2, Q3
Q2, Q3
R6, R7
C11-C14
PCB5
PCB2
L1
L1
T8
PCB7
C5,C6
C5,C6
45
SECTION 6
REPLACEMENT PARTS
7
1
2
3
5
4
6
Upper Left Side Internal View - Powercut-1250 / 1500
Item
No.
Qty.
1
2
3
4
5
6
7
1
1
1
1
1
1
1
Part
No.
Description
38131
38238
38237
38242
950710
952938
0558003389
PCB Start-up Network
PCB Display
PCB Control
PCB In Rush Control
Switch Thermal 131°F
Relay SS 660V 10A
Transformer Control
46
Symbol
PCB6
PCB3
PCB1
PCB4
TS2
Q4
T6
47
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES
A. CUSTOMER SERVICE QUESTIONS: Telephone: (800)362-7080 / Fax: (800) 634-7548
Order Entry
Product Availability
Pricing
Delivery
Order Changes
Saleable Goods Returns
Shipping Information
Hours: 8:00 AM to 7:00 PM EST
B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693
Welding Equipment Troubleshooting
Hours: 7:30 AM to 5:00 PM EST
Warranty Returns
Authorized Repair Stations
C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452
Part Numbers
Technical Applications
Hours: 8:00 AM to 5:00 PM EST
Performance Features Technical Specifications
Equipment Recommendations
D. LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548
Hours: 7:30 AM to 4:00 PM EST
E. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4487 / Fax: (843) 664-5557
Repair Estimates
Repair Status
Hours: 7:30 AM to 3:30 PM EST
F. WELDING EQUIPMENT TRAINING:
Telephone: (843)664-4428 / Fax: (843) 679-5864
Training School Information and Registrations
Hours: 7:30 AM to 4:00 PM EST
G. 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) 664-4452/ Web:http://www.esab.com
Hours: 7:30 AM to 5:00 PM EST
12/02
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