ESAB POWERCUT-1250 Instruction Manual
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ESAB POWERCUT-1250 Instruction Manual

Plasmarc cutting package
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POWERCUT-1250 / 1500
PLASMARC CUTTING PACKAGE
Instruction Manual
0558004106

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Summary of Contents for ESAB POWERCUT-1250

  • Page 1 POWERCUT-1250 / 1500 PLASMARC CUTTING PACKAGE Instruction Manual 0558004106...
  • Page 2 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,"...

  • Page 3: Table Of Contents

    Primary Electrical Input Connections ..............15 Secondary Output Connections ................ 17 SECTION 3 OPERATION ....................19 Operation ......................19 PowerCut-1250 / 1500 Controls ................ 19 Cutting with the PT-32EH ................. 21 Possible Cutting Issues ..................24 Common Cutting Problems ................25 SECTION 4 MAINTENANCE ....................
  • Page 4 TABLE OF CONTENTS...

  • Page 5: Safety Precautions

    SAFETY PRECAUTIONS 5. Do not use equipment beyond its ratings. For example, WARNING: hese Safety Precautions are for overloaded welding cable can overheat and create a fire your protection. They summarize precautionary hazard. information from the references listed in Addi- 6.
  • Page 6 SAFETY PRECAUTIONS FUMES AND GASES -- Fumes and EQUIPMENT MAINTENANCE -- Faulty or gases, can cause discomfort or harm, improperly maintained equipment can particularly in confined spaces. Do cause injury or death. Therefore: not breathe fumes and gases. Shield- ing gases can cause asphyxiation. 1.
  • Page 7 PRECAUCION DE SEGURIDAD ADVERTENCIA: No use el equipo fuera de su rango de operación. Por ejemplo, el Estas Precauciones de Seguridad calor causado por cable sobrecarga en los cables de soldar son para su protección. Ellas hacen resumen de pueden ocasionar un fuego. información proveniente de las referencias listadas en 6.
  • Page 8 PRECAUCION DE SEGURIDAD HUMO Y GASES -- El humo y los gases, MANTENIMIENTO DEL EQUIPO -- Equipo pueden causar malestar o daño, defectuoso o mal mantenido puede particularmente espacios causar daño o muerte. Por lo tanto: ventilación. No inhale el humo o gases. El 1.
  • Page 9 PRÉCAUTIONS DE SÉCURITÉ a. Éloigner suffisamment tous les matériaux combus- AVERTISSEMENT: Ces règles de sécurité ont pour objet tibles du secteur où l’on exécute des soudures ou des d’ assurer votre protection. Veillez à lire et à observer les coupes à l’arc, à moins de les recouvrir complètement précautions énoncées ci-dessous avant de monter l’...
  • Page 10 52529 “Precautions and Safe Practices for Arc Weld- danger d’explosion; ce ventilateur ne fonctionne que ing, Cutting and Gouging” publié par ESAB. Nous si l’interrupteur correspondant du panneau avant se conseillons également de consulter les publications trouve placé...

  • Page 11: Description

    1 ph. Output .......... 70 amps @ 60% duty cycle PowerCut-1250, 400 V, “CE” 50’ PT-32EH ....0558001937 The components that are included in the Powercut-1250 packages may 3 ph. Input ......208/230 vac, 3 ph, 50/60 Hz, 33/29 A be purchased separately by using the appropriate P/N when placing ...........

  • Page 12: Ordering Information

    PowerCut-1500, 400 V, “CE” 50’ PT-32EH ....0558001946 ............575 vac, 3ph, 50/60 Hz, 18 A The components that are included in the Powercut-1250 packages 3 ph. Output ........... 90 amps @ 60% duty cycle may be purchased separately by using the appropriate P/N when placing orders.

  • Page 13: Optional Accessories

    17672 Gouging Nozzle ............0558003089 Heat Shield Gouging ..........0558003090 The PowerCut-1250 comes out of the box ready to go. The torch is Drag Heat Shield ............0558003374 attached with parts in place, primary cord is attached and the filter/ Wheel Kit regulator is installed.

  • Page 14: General

    SECTION 1 DESCRIPTION 1.1 GENERAL The Powercut-1250 / 1500 is a compact, completely self-contained plasma Use only The ESAB PT-32EH Plasmarc cutting system. As shipped, the system is fully assembled and ready to cut torch with this console. Use of torches...

  • Page 15: Installation

    CONNECTIONS (FIGURE 2-1) ELECTRIC SHOCK CAN KILL! Precau- tionary measures should be taken to The PowerCut-1250 / 1500 consoles are equipped with approximately 10- provide maximum protection against ft. of 4-conductor input power cable for 3-phase connection. If single-phase electrical shock. Be sure that all power is off by opening the line (wall) discon- connection is desired, tape back the red wire on the input power cable.
  • Page 16 200 - 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.

  • Page 17: Secondary Output Connections

    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...
  • Page 18 SECTION 2 INSTALLATION...

  • Page 19: Operation

    Output Current Control. Adjustable from 20 to 70 amperes on Powercut-1250. Adjustable from 20 to 90 amperes on Powercut-1500.
  • Page 20 SECTION 3 OPERATION 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.

  • Page 21: Cutting With The Pt-32Eh

    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. Make sure that the wall disconnect switch is on. Turn on the Front • Do NOT operate the unit with the Panel Power Switch.
  • Page 22 SECTION 3 OPERATION 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).
  • Page 23 SECTION 3 OPERATION 3.3.2 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"...

  • Page 24: Possible Cutting Issues

    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 Drag cutting, even with lower current amp nozzle (P/N 0558002908). Lower the current level setting to be levels may significantly reduce the life of torch consumables.

  • Page 25: Common Cutting Problems

    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.
  • Page 26 SECTION 3 OPERATION...

  • Page 27: Maintenance

    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.

  • Page 28: Igbt Handling & Replacement

    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 conduc- tive foam contacting the gate and emitter sense pins.
  • Page 29 SECTION 4 MAINTENANCE Two-Point Mounting Type Temporary tightening  Final tightening  Four-Point Mounting Type Temporary tightening  Final tightening  Figure 4-2. Screw Fastening Order...
  • Page 30 SECTION 4 MAINTENANCE...

  • Page 31: Troubleshooting

    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.

  • Page 32: Troubleshooting Guide

    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.
  • Page 33 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.
  • Page 34 SECTION 5 TROUBLESHOOTING consumables as needed. Turn the machine back on. If the problem occurs again, the machine may require service. 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"...
  • Page 35 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.

  • Page 36: Reference Voltage Checks

    SECTION 5 TROUBLESHOOTING 5.3 REFERENCE VOLTAGE CHECKS A. Control Board Assembly (PCB1) LED’s LED- (D9)- Torch Switch LED- (D4)- Pilot Arc Relay LED- (D1)- 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 - Torch trigger signal TP-4 - IGBT’s driving signal - switching frequency = 18.5 KHz...

  • Page 37: Sequence Of Operation

    SECTION 5 TROUBLESHOOTING 5.4 SEQUENCE OF OPERATION A. TRIGGER LOCK “UNLOCK” position PUSH RELEASE TORCH SWITCH OPEN CLOSE GAS SOLENOID VALVE PREFLOW 2 SEC. 20 SEC Postflow OPEN FLOW SWITCH CLOSE FAULT OVERLOAD LIGHT HF CIRCUIT ENERGIZE PILOT ARC INVERTER CUTTING ARC (CURRENT) NOTES: When the torch switch is pushed during postflow period, the postflow and preflow times are canceled, and the...
  • Page 38 SECTION 5 TROUBLESHOOTING TRIGGER LOCK "LOCK" position PUSH RELEASE PUSH RELEASE TORCH SWITCH OPEN CLOSE GAS SOLENOID VALVE PREFLOW 2 SEC. 20 SEC Postflow POSTFLOW CLOSE OPEN FLOW SWITCH FAULT LIGHT ENERGIZE HF CIRCUIT PILOT ARC INVERTER CUTTING ARC (CURRENT) NOTES: 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.
  • Page 40 SECTION 5 TROUBLESHOOTING...

  • Page 41: Replacement Parts

    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 &...
  • Page 42 SECTION 6 REPLACEMENT PARTS Front View - Powercut-1250 / 1500 Item Part Qty. Description Symbol 36107 SW Pwr Disc 600V 951474 Switch Seal Black 0558001818 Knob 1.37 Diam 0558003390M Panel Front Silkscreen (PC-1250) 0558003391M Panel Front Silkscreen (PC-1500) 0558003001 Work Cable #6 AWG...
  • Page 43 SECTION 6 REPLACEMENT PARTS Rear View - Powercut-1250 / 1500 Item Part Qty. Description Symbol 21710 Regulator Air Line *808-02 21711 Gauge 1.50 *160 PSI WHT CB 0558002446 Switch 40A 0558003075 Fuse 2A 600VAC 97W63 Connector Cable Grip 0558003002 Cable Input Power, 10Ft.
  • Page 44 SECTION 6 REPLACEMENT PARTS Resistors Hidden by Bar Internal View - Powercut-1250 / 1500 Lower Left Side Item Part Qty. Description Symbol 0558003377 Transformer Main, Module T2, T4 17721020 RES WWFAHT 25W 1% 20 OHMS R12-15 951185 Diode Module FDS 100A 600V...
  • Page 45 SECTION 6 REPLACEMENT PARTS 3 (Behind Bar) 9 (Located under lip 7 (Located behind 6) 10 (Assembled to 5) Internal View - Powercut-1250 / 1500 Right Side Item Part Qty. Description Symbol 952871 3PH BR Rect. w/out Thyristor (PC-1250) 0558002434 3PH BR Rect.
  • Page 46 SECTION 6 REPLACEMENT PARTS Upper Left Side Internal View - Powercut-1250 / 1500 Item Part Qty. Description Symbol 38131 PCB Start-up Network PCB6 38238 PCB Display PCB3 38237 PCB Control PCB1 38242 PCB In Rush Control PCB4 950710 Switch Thermal 131°F...
  • Page 48 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.

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Powercut-1500

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