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