ESAB POWERCUT-1250 Setup guide

POWERCUT-1250 / 1500
MANUAL & MECHANIZED PLASMARC CUTTING PACKAGE
0558004232
Installation, Operation and Service Manual (GB)
This manual provides complete instructions for MANUAL CONSOLES starting with Serial Number PxxJ245xxx, May 2003:
This manual provides complete instructions for MECHANIZED CONSOLES starting with Serial Number PxxJ316xxx, May 2003:

186
This equipment will perform in conformity with the description thereof contained in this manual and accompa-
nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-
tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment
should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme-
diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone
or written request for service advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a ser-
vice facility designated by the manufacturer.
BE SURE THIS INFORMATION REACHES THE OPERATOR.
YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding and cutting equipment, we urge
you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and
Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain
this equipment. Do NOT attempt to install or operate this equipment until you have read
and fully understand these instructions. If you do not fully understand these instructions,
contact your supplier for further information. Be sure to read the Safety Precautions be-
fore installing or operating this equipment.
CAUTION
USER RESPONSIBILITY
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!

187
SECTION TITLE PAGE
PARAGRAPH
POWERCUT-1250/1500 MANUAL PLASMARC CUTTING PACKAGE
SECTION 1 DESCRIPTION.......................................................................................................................................... 193
1.0 General....................................................................................................................................................... 193
1.1 Scope .......................................................................................................................................................... 193
1.2 Manual Plasma ........................................................................................................................................ 194
SECTION 2 INSTALLATION........................................................................................................................................ 199
2.0 Installation - Manual Plasma Cutting Packages........................................................................... 199
2.1 General....................................................................................................................................................... 199
2.2 Equipment Required............................................................................................................................. 199
2.3 Location ..................................................................................................................................................... 199
2.4 Inspection.................................................................................................................................................. 199
2.5 Primary Electrical Input Connections - Manual Plasma Cutting Packages........................ 200
2.6 Secondary Output Connections for Manual Plasma ................................................................. 202
SECTION 3 OPERATION ............................................................................................................................................. 203
3.0 Operation .................................................................................................................................................. 203
3.1 PowerCut-1250 / 1500 Controls ........................................................................................................ 203
3.2 PT-32EH Torches used with Manual Plasma Only ....................................................................... 205
3.3 PT-32EH Possible Cutting Issues........................................................................................................ 210
POWERCUT-1250/1500 MECHANIZED PLASMARC CUTTING PACKAGE
SECTION 1 DESCRIPTION.......................................................................................................................................... 213
1.0 General....................................................................................................................................................... 213
1.1 Scope .......................................................................................................................................................... 213
1.2 Mechanized Plasma............................................................................................................................... 214
SECTION 2 INSTALLATION........................................................................................................................................ 219
2.0 Installation - Mechanized Plasma Cutting Packages ................................................................. 219
2.1 General....................................................................................................................................................... 219
2.2 Equipment Required............................................................................................................................. 219
2.3 Location ..................................................................................................................................................... 219
2.4 Inspection.................................................................................................................................................. 219
2.5 Primary Electrical Input Connections - Mechanized Plas Cutting Packages..................... 220
2.6 Secondary Output Connections for Mechanized Plasma........................................................ 222
SECTION 3 OPERATION ............................................................................................................................................. 225
3.0 Operation .................................................................................................................................................. 225
3.1 PowerCut-1250 / 1500 Controls ........................................................................................................ 225
3.2 PT-21AMX Torches used with Mechanized Plasma Only.......................................................... 226
3.3 PT-21AMX Possible Cutting Issues.................................................................................................... 228
TABLE OF CONTENTS

188
SECTION TITLE PAGE
PARAGRAPH
SECTION 4 MAINTENANCE........................................................................................................... 363
4.0 General....................................................................................................................................................... 355
4.1 Inspection and Cleaning...................................................................................................................... 355
4.2 Common Cutting Problems................................................................................................................ 356
4.3 IGBT Handling & Replacement........................................................................................................... 357
SECTION 5 TROUBLESHOOTING.................................................................................................. 367
5.0 Troubleshooting ..................................................................................................................................... 359
5.1 Troubleshooting Guide ........................................................................................................................ 360
5.2 Reference Voltage Checks ................................................................................................................... 364
5.3 Sequence of Operation ........................................................................................................................ 365
SECTION 6 REPLACEMENT PARTS................................................................................................ 379
TABLE OF CONTENTS

189
SAFETY PRECAUTIONS
Safety Precautions
Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that
anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions
must meet the requirements that apply to this type of welding or plasma cutting equipment. The following
recommendations should be observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well acquainted with the operation of the welding or plasma
cutting equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in
injury to the operator and damage to the equipment.
1. Anyone who uses welding or plasma cutting equipment must be familiar with:
- its operation
- location of emergency stops
- its function
- relevant safety precautions
- welding and / or plasma cutting
2. The operator must ensure that:
- no unauthorized person stationed within the working area of the equipment when it is started up.
- no one is unprotected when the arc is struck.
3. The workplace must:
- be suitable for the purpose
- be free from drafts
4. Personal safety equipment:
- Always wear recommended personal safety equipment, such as safety glasses, ame proof
clothing, safety gloves.
- Do not wear loose tting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions:
- Make sure the return cable is connected securely.
- Work on high voltage equipment may only be carried out by a qualied electrician.
- Appropriate re extinquishing equipment must be clearly marked and close at hand.
- Lubrication and maintenance must not be carried out on the equipment during operation.
-- 4 --
EMCea
WARNING
Read and understand the instruction manual before installing or operating.
Arc welding and cutting can be injurious to yourself and others. Take precausions when welding.
Ask for your employer’s safety practices which should be based on manufacturers’ hazard data.
ELECTRIC SHOCK - Can kill
SInstall and earth the welding unit in accordance with applicable standards.
SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
SInsulate yourself from earth and the workpiece.
SEnsure your working stance is safe.
FUMES AND GASES - Can be dangerous to health
SKeep your head out of the fumes.
SUse ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone
and the general area.
ARC RAYS - Can injure eyes and burn skin.
SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
SProtect bystanders with suitable screens or curtains.
FIRE HAZARD
SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE - Excessive noise can damage hearing
SProtect your ears. Use earmuffs or other hearing protection.
SWarn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
WARNING!
Read and understand the instruction manual before installing
or operating.
CAUTION!
Class A equipment is not intended for use in residential locations where
the electrical power is provided by the public low--voltage supply
system. There may be potential difficulties in ensuring electromagnic
compatibility of class A equipment in those locations, due to conducted
as well as radiated disturbances.
Do not dispose of electrical equipment together with normal waste!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation in accordance with national law, electrical equipment
that has reached the end of its life must be collected separately and returned to an
environmentally compatible recycling facility. As the owner of the equipment, you should
get information on approved collection systems from our local representative.
By applying this European Directive you will improve the environment and human
health!
GB
Class A (400V CE) equipment is not intended for use in resi-
dential locations where the electrical power is provided by the
public low-voltage supply system. There may be potential dif-
culties in ensuring electromagnetic compatibility of Class A
equipment in those locations due to conducted as well as radi-
ated disturbances.
-- 4 --
EMCea
WARNING
Read and understand the instruction manual before installing or operating.
Arc welding and cutting can be injurious to yourself and others. Take precausions when welding.
Ask for your employer’s safety practices which should be based on manufacturers’ hazard data.
ELECTRIC SHOCK - Can kill
SInstall and earth the welding unit in accordance with applicable standards.
SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
SInsulate yourself from earth and the workpiece.
SEnsure your working stance is safe.
FUMES AND GASES - Can be dangerous to health
SKeep your head out of the fumes.
SUse ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone
and the general area.
ARC RAYS - Can injure eyes and burn skin.
SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
SProtect bystanders with suitable screens or curtains.
FIRE HAZARD
SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE - Excessive noise can damage hearing
SProtect your ears. Use earmuffs or other hearing protection.
SWarn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
WARNING!
Read and understand the instruction manual before installing
or operating.
CAUTION!
Class A equipment is not intended for use in residential locations where
the electrical power is provided by the public low--voltage supply
system. There may be potential difficulties in ensuring electromagnic
compatibility of class A equipment in those locations, due to conducted
as well as radiated disturbances.
Do not dispose of electrical equipment together with normal waste!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation in accordance with national law, electrical equipment
that has reached the end of its life must be collected separately and returned to an
environmentally compatible recycling facility. As the owner of the equipment, you should
get information on approved collection systems from our local representative.
By applying this European Directive you will improve the environment and human
health!
GB
CAUTION

190
SAFETY PRECAUTIONS
WELDING AND PLASMA CUTTING CAN BE INJURIOUS TO YOURSELF AND
OTHERS. TAKE PRECAUTIONS WHEN WELDING OR CUTTING. ASK FOR
YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE BASED ON
MANUFACTURERS’ HAZARD DATA.
ELECTRIC SHOCK - Can kill.
- Install and earth (ground) the welding or plasma cutting unit in accordance with applicable standards.
- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
- Insulate yourself from earth and the workpiece.
- Ensure your working stance is safe.
FUMES AND GASES - Can be dangerous to health.
- Keep your head out of the fumes.
- Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone
and the general area.
ARC RAYS - Can injure eyes and burn skin.
- Protect your eyes and body. Use the correct welding / plasma cutting screen and lter lens and wear
protective clothing.
- Protect bystanders with suitable screens or curtains.
FIRE HAZARD
- Sparks (spatter) can cause re. Make sure therefore that there are no inammable materials nearby.
NOISE - Excessive noise can damage hearing.
- Protect your ears. Use earmus or other hearing protection.
- Warn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
WARNING

191
POWERCUT-1250 / 1500
MANUAL PLASMARC CUTTING PACKAGE

192

193
1.0 GENERAL
ThePowercut-1250/1500isacompact,completelyself-containedplasmacutting
system. As shipped, the system is fully assembled and ready to cut after being
connected to input power and a source of compressed air (90-150 psi / 6.2 to
10.3 bar).The Powercut package uses the heavy-duty PT-32EH (Manual Plasma)
torch to deliver cutting power for severing materials up to 1-1/2 inch (38.1mm)
thick on the PC-1250 and 1-3/4 inch (45mm) thick on the PC-1500. Refer to the
following pages for descriptions of the Powercut packages available as well as
performance specications.
1.1 SCOPE
The purpose of this manual is to provide the operator with all the information
required to install and operate the Powercut plasma arc cutting package. Tech-
nical reference material is also provided to assist in troubleshooting the cutting
package.
Use only the ESAB PT-32EH Plasmarc
torchwiththisconsole.Useoftorchesnot
designed for use with this console could
create an ELECTRIC SHOCK HAZARD.
"Single Voltage" Version Back View
Typical Front View
SECTION 1 DESCRIPTION

194
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 eet. The PT-32EH plasma cutting
torch is designed to provide increased performance and
longer consumable life resulting in higher production rates
at lower costs.
Specications: 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
.................................................................................400 vac, 3 ph, 50/60 Hz, 18 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 = 31.5”(800mm)
Weight.....................................................................................................86 lbs. (39kg)
Air Requirements .............................350 cfh @ 80 psig (165 l/min @ 5.5 bars)
Torch
PowerCut-1250 uses the PT-32EH torch. For complete list and
breakdown of parts, refer to Figure 1.1.
OrderingInformation:
PowerCut-1250, 208/230/460V, 25’(7.6m) PT-32EH...............0558001933
PowerCut-1250, 208/230/460V, 50’(15.2m) PT-32EH............0558001934
PowerCut-1250, 575V, 25’ (7.6m) PT-32EH................................0558001939
PowerCut-1250, 575V, 50’(15.2m) PT- 32EH.............................0558001940
PowerCut-1250, 400V,“CE”25’(7.6m) PT-32EH........................0558001936
PowerCut-1250, 400V,“CE”50’(15.2m) PT-32EH......................0558001937
PowerCut-1250, 460V, 25’ (7.6m) PT-32EH................................0558005332
PowerCut-1250, 460V, 50’(15.2m) PT- 32EH.............................0558005333
ThecomponentsthatareincludedinthePowercut-1250packages(Console,
Torch,SparePartsKit)maybepurchasedseparatelybyusingtheappropriate
P/N when placing orders. Individual part numbers are listed below:
Consoles:
PowerCut-1250 (208)230/460V, 50/60 Hz, 1/3-ph..................0558001935
PowerCut-1250 (208)230/460V, 50/60 Hz, 1/3-ph (BL) .......0558001935F
PowerCut-1250 575V, 50/60 Hz, 3-ph..........................................0558001941
PowerCut-1250 400V, CE, 50 Hz, 3-ph.........................................0558001938
PowerCut-1250 460V, 60 Hz, 3-ph................................................0558005331
PT-32EH Torches:
PT-32EH Torch, 25-ft. (7.6m) ............................................................0558003548
PT-32EH Torch, 50-ft. (15.2m) .........................................................0558003549
Spare Parts Kits: (see section 1.2.3)
PT-32EH Spare Parts Kit ....................................................................0558003508
PT-32EH, 400 V Long Heat Shield (LHS), Spare Parts Kit, CE units ..............
only...........................................................................................................0558003560
1.2 MANUAL PLASMA
1.2.1 PC1250 MANUAL PLASMA
PT-32EH Cut Data-70 AMPS
Powercut-1250, PT-32EH, 70A Nozzle P/N 0558002618
Air Pressure - 80 psi (5.5 bar), 5/32”(4.0 mm)Stando
0.250 (6.35)
0.500 (12.7)
0.750 (19.05)
1.000 (25.4)
1.250 (31.75)
1.500 (38.1)
131 (3327.4)
50 (1270)
21 (533.4)
10 (254)
6 (152.4)
--- (---)
135 (3429)
53 (1346.2)
23 (584.2)
12 (304.8)
7 (177.8)
3 (76.2)
SECTION 1 DESCRIPTION
Plate Drop Cut Sever
Inches (mm) IPM (mm/min) IPM (mm/min)
Max Speeds
Carbon Steel

195
Specications: PowerCut-1500
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
400V CE Mains Supply ................................................................ Ssc min 3.8MVA
................................................................................................................ Zmax 0.042Ω
..................................................................................575 vac, 3ph, 50/60 Hz, 18 A
3 ph. Output.................................................................90 amps @ 60% duty cycle
Dimensions .................................................................................W = 12.5”(318mm)
.....................................................................................................H = 16.5”(419mm)
.................................................................................................... D = 31.5”(800mm)
Weight..................................................................................................94 lbs. (42.7kg)
Air Requirements .............................350 cfh @ 80 psig (165 l/min @ 5.5 bars)
Torch
PowerCut-1500 uses the PT-32EH torch. For complete list and
breakdown of parts, refer to Figure 1.1.
OrderingInformation:
PowerCut-1500, 230/460V, 25’(7.6m) PT-32EH........................0558001942
PowerCut-1500, 230/460V, 50’(15.2m) PT-32EH.....................0558001943
PowerCut-1500, 575V, 25’ (7.6m) PT-32EH................................0558001948
PowerCut-1500, 575V, 50’(15.2m) PT- 32EH.............................0558001949
PowerCut-1500, 400V,“CE”25’(7.6m) PT-32EH........................0558001945
PowerCut-1500, 400V,“CE”50’(15.2m) PT-32EH......................0558001946
PowerCut-1500, 460V, 25’ (7.6m) PT-32EH................................0558005902
PowerCut-1500, 460V, 50’(15.2m) PT- 32EH.............................0558005903
PowerCut-1500, 400V, 25’(7.6m) PT-32EH.................................0558007827
ThecomponentsthatareincludedinthePowercut-1500packages(Console,
Torch,SparePartsKit)maybepurchasedseparatelybyusingtheappropriate
P/N when placing orders. Individual part numbers are listed below:
Consoles:
PowerCut-1500 (208)230/460V, 50/60 Hz, 1/3-ph..................0558003570
PowerCut-1500 (208)230/460V, 50/60 Hz, 1/3-ph (BL) .........0558003517
PowerCut-1500 575V, 50/60 Hz, 3-ph..........................................0558001950
PowerCut-1500 400V, CE, 50 Hz, 3-ph........................................0558001947
PowerCut-1500 460V, 50/60 Hz, 3-ph..........................................0558005900
PowerCut-1500 400V, 50 Hz, 3-ph................................................0558007826
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 eet. The PT-32EH plasma cutting
torch is designed to provide increased performance and
longer consumable life resulting in higher production rates
at lower costs.
PT-32EH Cut Data-90 AMPS
Powercut-1500, PT-32EH, 90A Nozzle P/N 0558002837
Air Pressure - 80 psi (5.5 bar) , 5/32”(4.0 mm)Stando
1.2.2 PC1500 MANUAL PLASMA
0.250 (6.35)
0.500 (12.7)
0.750 (19.05)
1.000 (25.4)
1.250 (31.75)
1.500 (38.1)
151 (3835.4)
56 (1422.4)
25 (635)
16 (406.4)
11 (279.4)
7 (177.8)
153 (3886.2)
58 (1473.2)
26 (660.4)
18 (457.2)
12 (304.8)
8 (203.2)
SECTION 1 DESCRIPTION
Plate Drop Cut Sever
Inches (mm) IPM (mm/min) IPM (mm/min)
Max Speeds
Carbon Steel
PT-32EH Torches:
PT-32EH Torch, 25-ft. (7.6m)............................................................ 0558003548
PT-32EH Torch, 50-ft. (15.2m)......................................................... 0558003549
Spare Parts Kits: (see section 1.2.3)
PT-32EH Spare Parts Kit ....................................................................0558003062
PT-32EH, 400 V Long Heat Shield (LHS), Spare Parts Kit, CE units ..............
only...........................................................................................................0558003557
400V CE Mains Supply, Ssc min
Minimum short circuit power on the network in accordance with
IEC61000-3-12.
400V CE Mains Supply, Zmax
Maximum permissible line on the network impedance in accordance
with IEC61000-3-11.

196
Description P/N Quantity
Heat Shield 0558001957 2
70 amp Nozzle 0558002618 4
40 amp drag Nozzle 0558002908 1
Electrode 0558001969 3
Valve Pin 0558001959 1
Fuse 2amp, 600vdc 0558001379 1
Stand-o Guide 0558002393 1
Wrench 19129 (0558000808) 1
Lubricant 17672 (0558000443) 1
Contents of PT-32EH Spare Parts Kit, 70 amp
P/N 0558003508
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 lter/regulator is
installed. Just hook up the air, power and begin cutting.
(NOTE: Part numbers in parenthesis apply to "CE"/European units only.)
Heat Shield
0558001957
Long Heat Shield
0558003110
Valve Pin
0558001959
Nozzle
40 AMP - 0558002908 (Drag Cutting)
50/70 AMP - 0558002618
90 AMP - 0558002837
85W51 (0558003694)
(Supplied with head)
Electrode
0558001969
PT-32EH Torch Head - 0558003412
Description P/N Quantity
Heat Shield 0558001957 2
90 amp Nozzle 0558002837 4
40 amp drag Nozzle 0558002908 1
Electrode 0558001969 3
Valve Pin 0558001959 1
Fuse 2amp, 600vdc 0558001379 1
Stand-o Guide 0558002393 1
Wrench 19129 (0558000808) 1
Lubricant 17672 (0558000443) 1
Contents of PT-32EH Spare Parts Kit, 90 amp
P/N 0558003062
The PowerCut-1500 comes out of the box ready to go. The torch is attached with parts in place, primary cord is attached and the lter/regulator is
installed. Just hook up the air, power and begin cutting.
1.2.3 SPARE PARTS / OPTIONAL ACCESSORIES PC1250 / 1500 MANUAL PLASMA
SparePartsKits:
Description P/N Quantity
Long Heat Shield (LHS) 0558003110 2
70 amp Nozzle 0558002618 4
40 amp drag Nozzle 0558002908 1
Electrode 0558001969 3
Valve Pin 0558001959 1
Fuse 2amp, 600vdc 0558001379 1
Drag Heat Shield 0558004206 1
Wrench 19129 (0558000808) 1
Lubricant 17672 (0558000443) 1
Contents of PT-32EH (LHS) Spare Parts Kit, 70 amp
P/N 0558003560, "CE"units only
Description P/N Quantity
Long Heat Shield (LHS) 0558003110 2
90 amp Nozzle 0558002837 4
40 amp drag Nozzle 0558002908 1
Electrode 0558001969 3
Valve Pin 0558001959 1
Fuse 2amp, 600vdc 0558001379 1
Drag Heat Shield 0558004206 1
Wrench 19129 (0558000808) 1
Lubricant 17672 (0558000443) 1
Contents of PT-32EH (LHS) Spare Parts Kit, 90 amp
P/N 0558003557, "CE" units only
Figure 1-1. PT-32EH Torch
SECTION 1 DESCRIPTION

197
OptionalAccessories:
70 A Spare Parts Kit ........................................................................................................................................0558003508
70 A 400 V LHS Spare Parts Kit, "CE" units.....................................................................................................0558003560
90 A Spare Parts Kit.........................................................................................................................................0558003062
90 A 400 V LHS Spare Parts Kit, "CE" units.....................................................................................................0558003557
Plasma Flow Measuring Kit:
This valuable troubleshooting tool allows measurement of
the actual plasma gas ow through the torch...................................................................................................... 19765 (0558000739)
Torch Guide Kit:
This complete kit, in a rugged plastic carrying case, includes
attachments for circle and straight line cutting on ferrous and
non-ferrous metals, 1 3/4" - 42" (44.5mm - 1066.8 mm) Radius,
Deluxe...................................................................................................................................................................................................0558003258
Basic, 1 3/4”- 28” (44.5mm - 711.2 mm) Radius .....................................................................................................................0558002675
Stand-o Guide
For proper stand-o distance when drag cutting ................................................................................................................0558002393
40 amp Drag Nozzle ..........................................................................................................................................................................0558002908
Gouging Nozzle ..................................................................................................................................................................................0558003089
Heat Shield Gouging ........................................................................................................................................................................0558003090
Drag Heat Shield (Standard) .........................................................................................................................................................0558003374
Drag Heat Shield (Heavy Duty) ...................................................................................................................................................0558004206
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
(NOTE: Part numbers in parenthesis apply to "CE"/European units only.)
Drag Heat Shield (Standard)
Maintains a constant stand-o, Good life in most applications ............
..............................................................................................................0558003374
Drag Heat Shield (Heavy Duty)
Maintains a constant stand-o, Long life, Suitable for piercing ............
..............................................................................................................0558004206
Torch Wrap
This enables operator to store spare parts kit, wrap torch
and work cable for easy transport and storage..................0558003059
Wheel Kit
For easy transport of system......................................................0558003060
Powercut shown with OptionalTorch Wrap
and Spare Parts Kit Holder installed.
SECTION 1 DESCRIPTION

198
SECTION 1 DESCRIPTION

199
2.1 GENERAL
Proper installation is important for satisfactory and trouble-free operation of
the PowerCut cutting package. It is suggested that each step in this section be
studied carefully and followed closely.
2.2 EQUIPMENT REQUIRED
A source of clean, dry air that supplies 350 cfh (165.2 l/m) at 80 psig (5.5 bar) is
required for the cutting operation. The air supply should not exceed 150 psig
(10.3 bar) (the maximum inlet pressure rating of the air lter-regulator supplied
with the package).
2.3 LOCATION
Adequate ventilation is necessary to provide proper cooling of the PowerCut.
Theamount of dirt,dust, and excessiveheatto which the equipment is exposed,
should be minimized. There should be at least one foot of clearance between
the PowerCut power source and wall or any other obstruction to allow freedom
of air movement through the power source.
2.4 INSPECTION
A. Remove the shipping container and all packing material and inspect for
evidence of concealed damage which may not have been apparent upon
receipt of the PowerCut. Notify the carrier of any defects or damage at
once.
B. Check container for any loose parts prior to disposing of shipping materi-
als.
C. Check air louvers and any other openings to ensure that any obstruction
is removed.
Installing or placing any type of ltering
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 lter
device is used.
2.0 INSTALLATION  MANUAL PLASMA CUTTING
PACKAGE
SECTION 2 INSTALLATION

200
ELECTRIC SHOCK CAN KILL! Precaution-
ary measures should be taken to provide
maximum protection against electrical
shock. Be sure that all power is o by
opening the line (wall) disconnect switch
and by unplugging the power cord to the
unitwhenconnectionsaremadeinsideof
the power source.
2.5 PRIMARY ELECTRICAL INPUT CONNECTIONS 
MANUAL PLASMA CUTTING PACKAGE
The PowerCut-1250 / 1500 consoles are equipped with approximately 10-ft. of
4-conductorinputpowercablefor3-phaseconnection.Ifsingle-phaseconnection
is desired, tape back the red (lt. blue) wire on the input power cable. Connect the
single-phaseinputtothewhiteandblackwiresonly.Whenoperatingthismachine
from a single-phase source, it must be connected to a dedicated 100 Amp feed.
Due to the higher input current requirements, the duty cycle of the machine is
lower than in three-phase operation. Single phase duty cycle is 60% for PC-1250
and 40% for PC-1500.
Connect your air supply to the inlet connection of the lter-regulator.
CUSTOMER FUSED LINE DISCONNECT SWITCH
(See Table 2.3 and WARNING in regards to
chassis ground in Section 2.5.)
PRIMARY INPUT
POWER CABLE
Preltered DRY AIR SUPPLY (Customer Supplied)
(90 to 150 psig max)
(6.2 to 10.3 bars max)
Figure 2-1. Input Connections
Red (Lt Blue) NOT USED ON SINGLE PHASE
White (Brown)
Black (Black)
Green (Yellow/Green)
SECTION 2 INSTALLATION

201
Before connecting to input power, make sure there is a line (wall) disconnect
switch with fuses or circuit breakers at the main powerpanel.You may either use
the factory-installed input power cable (4/c, type SO (90 °C), 10 ft (3.1 m) length)
orprovide yourown input powerleads. If youchoose to provideyour 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 exible 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 Input & Gnd Fuse
Volts Phase Amps Conductor Size
CU/AWG Amps
208 1 67A 6 100
208 3 33A/Ph. 6 50
230 1 61A 6 100
230 3 29A/Ph. 6 50
460 3 20 6 50
400 3 18 6mm250
575 3 15 10 25
Table 2-2. ( PC-1500 ) Recommended Sizes
For Input Conductors and Line Fuses
Input Requirements Input & Gnd Fuse
Volts Phase Amps Conductor Size
CU/AWG Amps
208 1 82A 6 100
208 3 44A/Ph. 6 80
230 1 74A 6 100
230 3 40A/Ph. 6 80
460 3 27 6 50
400 3 24 6mm250
575 3 18 10 50
Before making any connections to the
power source output terminals, make
sure that all primary input power to the
power source is deenergized (o) at the
maindisconnectswitchandthattheinput
power cable is unplugged.
ELECTRICSHOCKCANKILL!Beforemaking
electrical input connections to the power
source, "Machinery Lockout Procedures"
should be employed. If the connections
are to be made from a line disconnect
switch,placetheswitchintheo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 ap-
proved electrical ground. Failure to do
so may result in electrical shock, severe
burns or death.
SECTION 2 INSTALLATION
NOTE !!!
400V CE Mains Supply Requirements:
High power equipment may, due to the primary current drawn from the mains supply, inuence the pow-
er quality of the grid. Therefore connection restrictions or requirements regarding the maximum permis-
sible mains impedance or the required minimum supply capacity at the interface point to the public grid
may apply for some types of equipment (see technical data). In this case it is the responsibility of the
installer or user of the equipment to ensure, by consultation with the distribution network operator if
necessary, that the equipment may be connected.

202
WORK
SAFETY GROUND
2.6 SECONDARY OUTPUT CONNECTIONS FOR MANUAL CUTTING
The torch comes factory installed.
Clamp the work cable to the workpiece. Be sure
the workpiece is connected to an approved earth
ground with a properly sized ground cable.
Figure 2-2. PowerCut Interconnection Diagram
PT-32EH
SECTION 2 INSTALLATION

203
3.0 OPERATION
3.1 PowerCut-1250 / 1500 CONTROLS
A. Power Switch. When placed in ON position, the white power light will glow indicat-
ing control circuit is energized.
B. Air Test Switch. When placed in TEST position, air lter-regulator can be adjusted
to desired pressure (80 psig / 5.5 bar) before cutting operations. Allow air to ow 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.
1. Manual Operation using the PT-32EH torch - 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.
2. MechanizedOperation using the PT-21AMX torch - In mechanized operation the
Trigger Lock function disabled. Instead, the switch functions as an "Auto-Restrike"
selector. To turn Auto-Restrike "on" (grate cutting), place the switch in the up
position. To turn Auto-Restrike "o" (grate cutting), place the switch in the down
position.
A DB C
Figure 3-1A. PowerCut-1250 / 1500 Controls
TRIGGER
LOCK
UNLOCK
Auto-Restrike "on"
Auto-Restrike "o"
SECTION 3 OPERATION

204
Figure 3-1B. PowerCut-1250 / 1500 Controls
D. OutputCurrentControl. Adjustablefrom20to70amperesonPowercut-1250.Adjustable
from 20 to 90 amperes on Powercut-1500.
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 FlowIndicator:This fault light will blink when the air ow 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
resetautomaticallyexceptforover-current.Toclear over-current,thepowermust be
shut o for 5 seconds and then turned back on.
E HF G I
SECTION 3 OPERATION