ESAB POWERCUT-1250 User manual

POWERCUT-1250 / 1500
PLASMARC CUTTING PACKAGE
0558004106
Instruction Manual

2
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
understandtheseinstructions,contactyoursupplierforfurtherinformation. BesuretoreadtheSafety
Precautions before installing or operating this equipment.
BE SURE THIS INFORMATION REACHES THE OPERATOR.
YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.
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 malfunc-
tion which results from improper use, faulty maintenance, damage, improper repair or alter-
ation by anyone other than the manufacturer or a service facility designated by the manufac-
turer.

3
TABLE OF CONTENTS
SECTION TITLE PAGE
PARAGRAPH
SECTION 1 DESCRIPTION ................................................................................................. 11
1.1 General ............................................................................................................. 14
1.2 Scope................................................................................................................ 14
SECTION 2 INSTALLATION................................................................................................ 15
2.1 General ............................................................................................................. 15
2.2 Equipment Required ......................................................................................... 15
2.3 Location ............................................................................................................ 15
2.4 Inspection ......................................................................................................... 15
2.5 Primary Electrical Input Connections ................................................................ 15
2.6 Secondary Output Connections ........................................................................ 17
SECTION 3 OPERATION .................................................................................................... 19
3.1 Operation .......................................................................................................... 19
3.2 PowerCut-1250 / 1500 Controls........................................................................ 19
3.3 Cutting with the PT-32EH ................................................................................. 21
3.4 Possible Cutting Issues .................................................................................... 24
3.5 Common Cutting Problems ............................................................................... 25
SECTION 4 MAINTENANCE ............................................................................................... 27
4.1 General ............................................................................................................. 27
4.2 Inspection and Cleaning ................................................................................... 27
4.3 PT-32EH Torch Consumable Parts .................................................................. 27
4.4 IGBT Handling & Replacement ......................................................................... 28
SECTION 5 TROUBLESHOOTING ..................................................................................... 31
5.1 Troubleshooting ................................................................................................ 31
5.2 Troubleshooting Guide ..................................................................................... 32
5.3 Reference Voltage Checks ............................................................................... 36
5.4 Sequence of Operation ..................................................................................... 37
SECTION 6 REPLACEMENT PARTS ................................................................................. 41

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TABLE OF CONTENTS

5
WARNING: These Safety Precautions are for
your protection. They summarize precautionary
information from the references listed in Addi-
tional Safety Information section. Before per-
forming 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 pro-
cesses are noisy and require ear protec-
tion. The arc, like the sun, emits ultravio-
let (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:
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. By-
standers should also wear goggles over safety glasses.
FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot slag or
sparks can also cause fires and explo-
sions. Therefore:
1. Remove all combustible materials well away from the
work area or cover the materials with a protective non-
flammable 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.
10/98
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", avail-
able from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
ELECTRICAL SHOCK -- Contact with live
electrical parts and ground can cause se-
vere injury or death. DO NOT use AC weld-
ing 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 dam-
aged 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.
ELECTRIC AND MAGNETIC FIELDS — May
be dangerous. Electric current flowing
through any conductor causes localized
Electric and Magnetic Fields (EMF). Weld-
ingand cutting currentcreates EMF around
welding cables and welding machines.
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.
SAFETY PRECAUTIONS

6
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shield-
ing gases can cause asphyxiation.
Therefore:
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 posi-
tive mechanical ventilation is provided. Do not breathe
fumes from these materials.
2. Do not operate near degreasing and spraying opera-
tions. 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 im-
prove 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.)
CYLINDER HANDLING -- Cylinders, if
mishandled, can rupture and violently
release gas. Sudden rupture of cylin-
der, valve, or relief device can injure or
kill. Therefore:
1. Use the proper gas for the pro-
cess 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.
2. 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.
3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not con-
nected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder.
5. 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.
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
1. Always have qualified personnel perform the installa-
tion, 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.
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for elec-
tric 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, Mi-
ami, 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 Tung-
sten Arc Welding“
6. AWS C5.6 - "Recommended Practices for Gas Metal Arc
Welding"“
7. AWS SP - "Safe Practices" - Reprint, Welding Hand-
book.
8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."
MEANING OF SYMBOLS - As used through-
out 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.
SP98-10
SAFETY PRECAUTIONS

7
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
esté en el área de trabajo, aún cuando esté usando careta de
soldar, protector para su cara u otro tipo de protección.
2. 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.
3. 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.
4. 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.
5. Proteja a otras personas de los rayos del arco y chispas calientes
con una cortina adecuada no-flamable como división.
6. 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.
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 esté
conectado a tierra através del sistema de electricidad primario.
2. Conecte la pieza de trabajo a un buen sistema de tierra física.
3. 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.
4. Use el equipo solamente si está en buenas condiciones.
Reemplaze cables rotos, dañados o con conductores expuestos.
5. Mantenga todo seco, incluyendo su ropa, el área de trabajo, los
cables, antorchas, pinza del electrodo, y la fuente de poder.
6. Asegúrese que todas las partes de su cuerpo están insuladas
de ambos, la pieza de trabajo y tierra.
7. 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.
8. Use guantes secos y sin agujeros antes de energizar el equipo.
9. Apage el equipo antes de quitarse sus guantes.
10. 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
causandoa nivellocalCampos 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 marca-
pasos.
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

8
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:
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, Can-
cer. (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.
Las siguientes publicaciones, disponibles através de la
American Welding Society, 550 N.W. LeJuene Road, Mi-
ami, 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 Hand-
book.
8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."
Significa riesgo inmediato que, de no ser
evadido, puede resultar inmediatamente
en serio daño personal o la muerte.
Significael riesgo deun peligropotencial
que puede resultar en serio daño per-
sonal o la muerte.
Significa el posible riesgo que puede
resultar en menores daños a la persona.
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 52-
529.
SIGNIFICADO DE LOS SIMBOLOS -- Según
usted avanza en la lectura de este folleto:
Los Símbolos Significan ¡Atención! ¡Esté
Alerta! Se trata de su seguridad.
PRECAUCION DE SEGURIDAD

9
a. Éloigner suffisamment tous les matériaux combus-
tibles 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 sub-
stances combustibles semblables.
b. Les étincelles ou les projections de métal incandes-
cent 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 projec-
tion 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 ten-
sion 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 assu-
rer 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 dan-
ger 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 pas-
sage 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 incandes-
cent 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
PRÉCAUTIONS DE SÉCURITÉ

10
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 mal-
aises 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 ventila-
tion 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. Arrêtez-
vous de travailler afin de prendre les mesures néces-
saires 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 forma-
tion 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’élimi-
ner 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 qua-
lifié 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 corro-
sives 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 Weld-
ing, 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 Weld-
ing” 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
PRÉCAUTIONS DE SÉCURITÉ

11
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 front-
end 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.
SECTION 1 DESCRIPTION
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)
Torch
PowerCut-1250 uses the PT-32EH torch. For complete list
and breakdown of parts, refer to PT-32EH data page.
Ordering Information:
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, 75ohead, 25-ft. ................................ 0558003548
PT-32EH Torch, 75ohead, 50-ft. ................................ 0558003549
PT-32EH Spare Parts Kit (see Table 1-1) .................. 0558003508
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
Plate Drop Cut Sever
(Inches) (IPM) (IPM)
0.250 131 135
0.500 50 53
0.750 21 23
1.000 10 12
1.250 6 7
1.500 ---- 3

12
Specifications: 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
........................................................ 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)
Torch
PowerCut-1500 uses the PT-32EH torch. For complete list
and breakdown of parts, refer to PT-32EH data page.
Ordering Information:
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, 90ohead, 25-ft. ............................... 0558003548
PT-32EH Torch, 90ohead, 50-ft. ............................... 0558003549
PT-32EH Spare Parts Kit (see Table 1-1) ................. 0558003062
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 front-
end 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.
SECTION 1 DESCRIPTION
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
Plate Drop Cut Sever
(Inches) (IPM) (IPM)
0.250 151 153
0.500 56 58
0.750 25 26
1.000 16 18
1.250 11 12
1.500 7 8

13
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 0558003075 1
Stand-off Guide 0558002393 1
Wrench 19129 1
Lubricant 17672 1
Contents of PT-32EH Spare Parts Kit, 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 filter/
regulator is installed. Just hook up the air, power and begin cutting.
SECTION 1 DESCRIPTION
Heat Shield
0558001957
Valve Pin
0558001959
Nozzle
40 AMP - 0558002908 (Drag Cutting)
50/70 AMP - 0558002618
90 AMP - 0558002837
O-Ring - 85W51
(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 0558003075 1
Stand-off Guide 0558002393 1
Wrench 19129 1
Lubricant 17672 1
Contents of PT-32 Spare Parts Kit, 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 (including plug
on 230 model), and the filter/regulator is installed. Just hook up the
air, power and begin cutting.
Optional Accessories:
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
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 Optional Torch Wrap
and Spare Parts Kit Holder installed.

14
SECTION 1 DESCRIPTION
1.1 GENERAL
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 (90-
150 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.
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.
Thickness Cutting
Material (In.) Speed (IPM)
Carbon Steel 1/16 200
1/8 98
1/4 36
3/8 18
1/2 11
Stainless Steel 1/16 138
1/8 58
1/4 18
3/8 10
1/2 6
Aluminum 1/16 200
1/8 110
1/4 48
3/8 17
1/2 14
PT-32EH DRAG MODE CUTTING SPEEDS
AIR @ 80PSI and OUTPUT CURRENT 40AMPS

15
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
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. Checkair 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 10-
ft. 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.
Installing or placing any type of filter-
ing device will restrict the volume of
intakeair,thereby subjecting the power
source internal components to over-
heating. The warranty is void if any
type of filter device is used.
ELECTRIC SHOCK CAN KILL! Precau-
tionary measures should be taken to
provide maximum protection against
electrical shock. Be sure that all power
is off by opening the line (wall) discon-
nect switch and by unplugging the
power cord to the unit when connec-
tions are made inside of the power
source.
CUSTOMER FUSED LINE DISCONNECT SWITCH
(See Table 2.1 and WARNING in regards to chassis ground in Section 2.5.)

16
SECTION 2 INSTALLATION
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
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 recep-
tacle to line disconnect switch.
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.
Input Voltage
Selector Switch
Fuse*
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
linedisconnect 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 pos-
sible 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 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
provideyourown,makesure 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.
INPUT VOLTAGE SELECTOR
NOT POWER
ON - OFF SWITCH
USE POWER SWITCH ON FRONT
PANEL TO TURN
ON AND OFF
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
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
575 3 18 10 50

17
SECTION 2 INSTALLATION
WORK
SAFETY
GROUND
PT-32EH
Prefiltered DRY AIR
SUPPLY (Customer
Supplied)
(90 to 150 psig max)
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.
Clamp the work cable to the
workpiece. Be sure the
workpiece is connected to an
approved earth ground with a
properly sized ground cable.
FUSED
DISCONNECT
BOX
PRIMARY INPUT
POWER CABLE
Figure 2-1. PowerCut Interconnection Diagram

18
SECTION 2 INSTALLATION

19
SECTION 3 OPERATION
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 condensa-
tion 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.
AD
BC
Figure 3-1A. PowerCut-1250 / 1500 Controls

20
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.
SECTION 3 OPERATION
EH
FG
I