ESAB POWERCUT-1500 User manual

POWERCUT-1500
0558003745 102002
Instruction Manual (GB)

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles
ofoperationandsafepracticesforarcweldingandcuttingequipment,weurgeyoutoreadourbooklet,
"PrecautionsandSafePracticesforArcWelding,Cutting,andGouging,"Form52-529. DoNOTpermit
untrainedpersonstoinstall,operate,ormaintain thisequipment. DoNOTattemptto installoroperate
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
labelsand/orinsertswheninstalled,operated,maintainedandrepairedinaccordancewiththeinstructionsprovided.
This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used.
Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair
or replacement become necessary, the manufacturer recommends that a telephone or written request for service
advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The
user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty
maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility
designated by the manufacturer.

Full responsibility for safety of personnel working on or near system rests on user of ESAB Welding
Equipment.
Wrong operation can lead to abnormal situation, injure operator and damage equipment.
All personnel working with welding equipment must be fully familiar with
- handling of equipment
- location of emergency stops
- functions of equipment
- applicable safety regulations
- cutting
Operator must make sure
- no one stays inside work area while machine starts
- no one is unprotected while arc is being struck
Work area must be
- free of machine parts, tools and other objects that can obstruct operator moving within area
- so arranged, that emergency stop buttons are easily accessible
- free from draughts
Personal safety equipment
- always use proper safety equipment such as goggles, non flammable clothing, protective gloves
- never wear loose clothing, belts, bracelets, rings etc., which may catch on equipment or cause burns
Miscellaneous
- only authorised personnel may operate electrical equipment
- check whether return cables are properly fitted and earthen
- requisite fire fighting equipment should be easily available in specially and clearly marked areas
- lubrication and maintenance of welding equipment must not be proceeded during operation.
SAFETY

! WARNING !
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE
PRECAUTIONS WHEN WELDING OR CUTTING. ASK YOUR EMPLOYER FOR SAFETY PRACTICES
THAT SHOULD BE BASED ON MANUFACTURER’S HAZARD DATA.
ELECTRIC SHOCK - Can kill
- Install and earth welding equipment in accordance with obligatory standards.
- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothes.
- Insulate yourself from earth and workpiece.
- Ensure your work position is safe.
FUMES AND GASES - Can be dangerous to your health
- Keep your head away from fumes.
- Use ventilation and/or extraction to keep fumes and gases away from your breathing zone and surroundings.
ARC RAYS - Can injure eyes and burn skin
- Protect your eyes and skin. Use correct welding screens, filter lens and wear protective clothes.
- Protect bystanders with suitable screens or curtains.
FIRE HAZARD
- Sparks (spatter) can cause fire. Make therefore sure there are no inflammable materials nearby.
NOISE - Excessive noise can damage your hearing.
- Protect your ears. Use ear defenders or other hearing protection.
- Warn bystanders of the risk.
MALFUNCTION - Call expert assistance in event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING UNIT
PROTECT YOURSELF AND OTHERS !
SAFETY

TABLE OF CONTENTS
SECTION TITLE PAGE
PARAGRAPH
SECTION 1 DESCRIPTION ................................................................................................. 85
1.1 General ............................................................................................................. 85
1.2 Scope................................................................................................................ 85
1.3 Packages Available .......................................................................................... 85
1.4 Specifications.................................................................................................... 86
SECTION 2 INSTALLATION................................................................................................ 89
2.1 General ............................................................................................................. 89
2.2 Equipment Required ......................................................................................... 89
2.3 Location ............................................................................................................ 89
2.4 Inspection ......................................................................................................... 89
2.5 Primary Electrical Input Connections ................................................................ 89
2.6 Secondary Output Connections ........................................................................ 91
SECTION 3 OPERATION .................................................................................................... 93
3.1 Operation .......................................................................................................... 93
3.2 PowerCut-1500 Controls .................................................................................. 93
3.3 Cutting with the PT-32EH ................................................................................. 95
3.4 Possible Cutting Issues .................................................................................... 98
SECTION 4 MAINTENANCE ............................................................................................... 161
4,1 General ............................................................................................................. 161
4.2 Inspection and Cleaning ................................................................................... 161
4.3 PT-32EH Torch Consumable Parts .................................................................. 161
4.4 IGBT Handling & Replacement......................................................................... 162
SECTION 5 TROUBLESHOOTING ..................................................................................... 163
5.1 Troubleshooting ................................................................................................ 163
5.2 Troubleshooting Guide ..................................................................................... 164
SECTION 6 REPLACEMENT PARTS ................................................................................. 173
83

84

85
SECTION 1 DESCRIPTION
1.1 GENERAL
ThePowercut-1500is acompact, 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 at 6.2-10.3
bar (90-150 psig). The Powercut-1500 package uses the heavy-duty PT-
32EHtorchtodelivercuttingpowerforseveringmaterialsupto38.1mm(1.50")
thick. Refer to the following paragraphs for descriptions of the Powercut-
1500 packages available as well as performance specifications.
1.2 SCOPE
Thepurposeofthismanualistoprovidetheoperatorwithall theinformation
required to install and operate the Powercut-1500 plasma arc cutting
package. Technical reference material is also provided to assist in trouble-
shooting the cutting package.
1.3 PACKAGES AVAILABLE
1.3.1 Manual Cutting Packages
Powercut-1500 packages listed on the front cover and below, includes the
following components:
Powercut 1500 Manual Cutting Packages:
PowerCut-1500 400 V, "CE" 7.6 m (25 ft.) PT-32EH ............ P/N 0558001945
PowerCut-1500 400 V, "CE" 15.2 m (50 ft.) PT-32EH .......... P/N 0558001946
The components that are included in the Powercut-1500 packages may be
purchased separately by using the appropriate P/N when placing orders.
Individual part numbers are listed below:
Console:
PowerCut-1500 400 V, 3-ph, 50/60Hz, 24A .......................... P/N 0558001947
PT-32EH Torches:
PT-32EH Torch, 90o, 7.6 m (25 ft.) ........................................ P/N 0558003548
PT-32EH Torch, 90o, 15.2 m (50 ft.)...................................... P/N 0558003549
PT-32EH Spare Parts Kit (see table below) .......................... P/N 0558003557
Table 1-1 PT-32EH 90Amp Spare Parts Kit, P/N 0558003557, Contents
0558002837
0558002908
0558001969
0558003110
0558001959
0558002393
0558000808
0558000443
0558003075
4
1
3
2
1
1
1
1
1
Part Number
90 Amp Nozzle
40 Amp Nozzle
Electrode
Heat Shield
Valve Pin
Stand Off Guide
Wrench
Lubricant
Fuse 2Amp 600VAC
Description Quantity
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.

86
SECTION 1 DESCRIPTION
1.4 SPECIFICATIONS
Table 1-2 PowerCut-1500 Specifications
* Duty cycle is based on a 10-minute period: therefore, a 60% duty cycle means the power source may operate for
6 minutes with a cool down period of 4 minutes. 100% duty cycle means the power source may operate continu-
ously.
Rated Inputs Rated Outputs
Phases Volts Amps Power
Factor * Duty Cycle Output
Amps
Open
Circuit
Voltage Efficiency
Three 400 24
18 86%
81% 60%
100% 90A @ 127Vdc 75A @ 120Vdc 278 Vdc
278 Vdc 88% 87%
Length 648 mm (25.50")
w/handles 813 mm (32.00")
Height 416 mm (16.38")
Dimensions of Console Width w/o opt. storage 333 mm (13.10")
w/ opt. torch storage 409 mm (16.10")
Weight of PowerCut-1500 42.7 kg (94 lbs)
System Shipping Weight 49.5 kg (109 lbs)

87
SECTION 1 DESCRIPTION
Table 1-3 PT-32EH Torch Specifications
Figure 1-1 PT-32EH Dimensions
Current Capacity (100% Duty)
Air Requirements
Length of Service Lines
Weight
7.6 m (25ft.)
15.2 m (50ft.)
90 A DCSP
165 l/min @ 5.5 bar
(350 cfh @ 80 psig)
7.6 m (25ft.) or 15.2 m (50ft.)
2.4 kg (5.2 lbs)
4.4 kg (9.6 lbs)
Cutting Speed
Material Thickness mm (in.) mm/m (ipm)
Carbon Steel 1.6 (1/16) 5,080 (200)
3.2 (1/8) 2,489 (98)
6.4 (1/4) 914 (36)
9.5 (3/8) 457 (18)
12.7 (1/2) 279 (11)
Stainless Steel 1.6 (1/16) 3,505 (138)
3.2 (1/8) 1,473 (58)
6.4 (1/4) 457 (18)
9.5 (3/8) 254 (10)
12.7 (1/2) 152 (6)
Aluminum 1.6 (1/16) 5,080 (200)
3.2 (1/8) 2,794 (110)
6.4 (1/4) 1,219 (48)
9.5 (3/8) 432 (17)
12.7 (1/2) 356 (14)
Figure 1-2 PT-32EH / POWERCUT-1500 Cutting Performance
PT-32EH DRAG MODE CUTTING SPEEDS
AIR @ 5.5 BAR (80 PSIG) and OUTPUT CURRENT 40 AMPS
PT-32EH CUT SPEED - CARBON
STEEL
0
1000
2000
3000
4000
6.4mm 12.7mm 19.1mm 25.4mm 31.8mm 38.1mm
Material Thickness
Cut Speed, mm/m
90 Amps
70 Amps
60 Amps

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