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

88

89
SECTION 2 INSTALLATION
2.1 GENERAL
Properinstallation is important for satisfactory and trouble-free operation of
the PowerCut 1500 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 165 l/m (350 cfh) at 5.5 bar (80 psig)
is required for the cutting operation. The air supply should not exceed 10.3
bar (150 psig) (the maximum inlet pressure rating of the air filter-regulator
supplied with the package).
2.3 LOCATION
AdequateventilationisnecessarytoprovidepropercoolingofthePowerCut
1500. 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 1500 power source and wall or any other
obstruction to allow freedom of air movement through the power source.
2.4 INSPECTION
A. Removetheshippingcontainerandallpackingmaterialandinspectfor
evidence of concealed damage which may not have been apparent
uponreceipt ofthe PowerCut1500. Notify thecarrier ofany defectsor
damage at once.
B. Check container for any loose parts prior to disposing of shipping
materials.
C. Checkairlouversandanyotheropeningstoensurethatanyobstruction
is removed.
2.5 PRIMARY ELECTRICAL INPUT
CONNECTIONS
ThePowerCut1500consolesareequippedwithapproximately3.1m(10ft.)
of 4-conductor input power cable for 3-phase connection.
Installingorplacinganytypeof
filtering device will restrict the
volume of intake air, thereby
subjecting the power source
internal components to over-
heating. Thewarrantyisvoidif
anytypeoffilterdeviceisused.
ELECTRIC SHOCK CAN KILL!
Precautionary measures
should be taken to provide
maximum protection against
electrical shock. Be sure that
all power is off by opening the
line (wall) disconnect switch
and by unplugging the power
cord to the unit when connec-
tions are made inside of the
power source.

90
SECTION 2 INSTALLATION
2.5.1 INPUT VOLTAGE CHANGEOVER
A line (wall) disconnect switch with fuses or circuit breakers should be
provided at the main power panel (see table below for fuse sizes). The
input power cable of the console may be connected directly to the discon-
nect switch or you may purchase a proper plug and receptacle from a local
electrical supplier. If using plug/receptacle combination, see table below
for recommended input conductors for connecting receptacle to line dis-
connect switch.
Table 2-1 Recommended Sizes For
Input Conductors and Line Fuses
Input Requirements Input & Gnd Fuse
Volts Phase Amps Conductor Size
CU Amps
400 3 24 6 mm230
(10 AWG)
Beforemakinganyconnections
to the power source output ter-
minals, make sure that all pri-
mary input power to the power
source is de-energized (off) at
themaindisconnectswitchand
that the input power cable is
unplugged.
ELECTRIC SHOCK CAN KILL!
Before making electrical input
connections to the power
source, "Machinery Lockout
Procedures" should be em-
ployed. If the connections are
to be made from a line discon-
nectswitch,placetheswitchin
the off position and padlock it
topreventinadvertenttripping.
If the connection is made from
a fusebox, remove the corre-
spondingfusesandpadlockthe
box cover. If it is not possible
to use padlocks, attach a red
tagtothelinedisconnectswitch
(or fuse box) warning others
that the circuit is being worked
on.
Thechassismustbeconnected
to an approved electrical
ground. Failure to do so may
result in electrical shock, se-
vere burns or death.

91
SECTION 2 INSTALLATION
Figure 2-1 PowerCut 1500 Interconnection Diagram
2.6 SECONDARY (OUTPUT) CONNECTION
(REFER TO FIGURE BELOW)
The torch comes factory installed.
WORK
SAFETY
GROUND
Prefiltered DRY AIR
SUPPLY (Customer
Supplied)
6.2 to 10.3 bar
(90 to 150 psig max)
Connect your air supply to the inlet connection of the filter-regulator.
PRIMARY INPUT
POWER CABLE
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

92

93
SECTION 3 OPERATION
3.1 OPERATION
3.2 PowerCut 1500 CONTROLS (see figure above)
A. Power Switch. When placed in ON position, the green pilot 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 5.5 bar (80 psig) before cutting
operations. Allowairtoflowforafewminutes. Thisshouldremoveany
condensationthat mayhaveaccumulated duringshutdownperiod. 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
extinguisharcatendofcut,pressandreleasetorchswitchbuttonagain
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 90 amperes.
AD
BC
Figure 3-1A PowerCut 1500 Controls

94
Figure 3-1B PowerCut 1500 Controls
3.2 PowerCut 1500 Indicator Lights (see figure above)
E. Power "ON" Indicator: Illuminates whenever the front panel power
switch is in the ON position.
F. AC Line Indicatoror High/LowLineVoltage Indicator: Thisfaultlight
willblinktoindicatethattheinputvoltageisoutsidethe“+or-”15%range
of the input rating.
G. Gas Flow Indicator: This fault light will blink to indicate that the air flow
supply is low or has no back pressure.
H. FaultIndicator: Whenthislightblinks,eitherthesystemfailedtoinitiate
apilotarc after a number of attempts, or there has been an over-current
eventwithinthesystem.Ifthelightblinksfor 10secondsandthen stops,
then the problem is pilot arc initiation. Check the consumables in the
torch.
Ifthelightcontinuestoblink,andthesystemdoesnotreset,thenthefault
is an over-current event. One likely source of an over-current fault is a
nozzletoelectrodeshort.Turnoffthemachineandinspectthetorchand
its consumables. Replace the consumables as needed. Turn the ma-
chine back on. If the problem occurs again, the machine may require
service.
I. OverTemperatureIndicator:Thisfaultlightwillblinktoindicatethatthe
duty cycle has been exceeded. Allow the power source to cool down
before returning to operation.
Allfault signals willremain on for aminimum of 10seconds. 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

95
SECTION 3 OPERATION
3.3 CUTTING WITH THE POWERCUT-1500
Use the following procedures to cut with the PT-32EH torch (see ex-
ploded view of PT-32EH torch).
A. Makesurethatthewalldisconnectswitchison.Turnonthefrontpanel
power switch.
B. Set pressure regulator to 5.5 bar (80 psig).
C. Hold the torch nozzle approximately 3.2 to 4.8 mm (1/8 to 3/16 inch)
above the work and tilted at about 15 - 30°. This reduces the chance
ofspatterenteringthenozzle.Ifthe PT-32EH'sstandoff guideis being
used, the distance between electrode and work piece will be approx.
4.8mm(3/16inch). Depressthetorchswitch. Air shouldflowfromthe
torch nozzle.
E. Two seconds after depressing the torch switch, the pilot arc should
start.Themainarcshouldimmediatelyfollow,allowingthecuttobegin.
(If using the trigger LOCK mode, torch switch may be released after
establishing the cutting arc.)
F. Afterstartingthecut,thetorchshouldbemaintainedata5-15°forward
angle (see figure below). This angle is especially useful in helping to
create a "drop" cut. When not using the standoff guide, the nozzle
should be held approximately 6.4 mm (1/4 inch) from the work.
Figure 3-2 Recommended Stand-off and Torch Angle
ELECTRIC SHOCK can kill.
ž Do NOT operate the unit with
the cover removed.
ž Do NOT apply power to the
unit while holding or carry-
ing the unit.
ž Do NOT touch any torch
parts forward of the torch
handle (nozzle, heat shield,
electrode, etc.) with power
switch on.
ARC RAYS can burn eyes and
skin;
NOISE can damage hearing.
ž WearweldinghelmetwithNo.
6 or 7 lens shade.
ž Wear eye, ear, and body pro-
tection.
Position the PowerCut 1500 at
least3meters(10feet)fromthe
cutting area. Sparks and hot
slagfromthecuttingoperation
can damage the unit.
IMPORTANT!!!
Maintain Proper
Stand-Off Distance
4.8 to 6.4 mm
(3/16" to 1/4")
Power Output increases with Stand Off Distance!
Standoff vs.
Power Output
CUT
DIRECTION

96
SECTION 3 OPERATION
G. When ending a cut, the torch switch should be released (press and
releaseifusingtriggerLOCKmode)andthetorchliftedofftheworkpiece
justbeforetheendofthecut. Thisisto preventthehigh frequencyfrom
reigniting after cutting arc extinguishes and causing damage to the
nozzle (double arcing).
H. Forrapidre-starts,suchasgrate orheavymesh cutting,donot release
the torch switch. In the postflow mode, the arc can be re-started
immediately by depressing the torch switch. This avoids the 2-second
preflow portion of the cutting cycle.
HEAT SHIELD
0558003110
NOZZLE
40A 0558002908
90A 0558002837
ELECTRODE
0558001969
VALVE PIN
00558001959
O-RING
SUPPLIED
WITH HEAD
0558003694
Fig 3.3 Exploded View of PT-32EH Torch

97
THIN GAUGE MATERIALS
CAN BE CUT WITH 1.6 mm (1/16")
TORCH-TO-WORK DISTANCE
ADJUST TO 4.8 mm (3/16") FOR
MATERIALS OVER 6.4 mm (1/4")
THICK
ADJUST GUIDE BY TURNING
IN A CLOCKWISE DIRECTION
ONLY. THIS WILL PREVENT
ACCIDENTAL LOOSENING
OF SHIELD.
STEEL GUARD
STAND OFF GUIDE
P/N 0558002393
IF GUIDE IS TOO
TIGHT ON SHIELD,
OPEN SLOT WITH
SCREWDRIVER.
IF TOO LOOSE, CLOSE
SLOT WITH VISE OR
LARGE PLIERS.
1.6 mm (1/16") TO
6.4 mm (1/4")
TORCH-TO-WORK
GUIDE AGAINST
STRAIGHT EDGE
OR FREE-HAND
CUT
Figure 3-4 Installation and Operation of Steel Heat Shield Guards
SECTION 3 OPERATION

98
SECTION 3 OPERATION
WHEN THE ARC BREAKS
THROUGH THE WORK,
BRING THE TORCH TO AN
UPRIGHT POSITION AND
PROCEED TO CUT.
TO START A PIERCE, TILT THE
TORCH TO PREVENT MOLTEN
MATERIAL FROM COMING BACK
AGAINST AND DAMAGING THE
TORCH.
1
2
Figure 3-5 Piercing Technique using the PT-32EH
3.4 POSSIBLE CUTTING ISSUES
Drag cutting, even with lower
currentlevelsmaysignificantly
reduce the life of torch
consumables. Attempting to
Drag Cut with higher currents
(40 amps) may cause immedi-
ate catastrophic consumable
damage.
Figure 3-6. Electrode Wear Limit
NOTE: When replacing the nozzle, always inspect the electrode for wear.
Ifmorethan1.6mm(.06")ofelectrodeHafniumhaseroded,replace
the electrode. If the electrode is used beyond this recommended
wear limit, damage to the torch and power source may occur.
Nozzle life is also greatly reduced when using the electrode below
the recommended limit. Refer to exploded view of PT-32EH torch.
REPLACE ELECTRODE
BEFORE PITTING BECOMES
DEEPER THAN 1.6 MM
(0.06 INCH)
Replace when eroded
beyond .06"(1.6mm) depth
NEW WORN
3.3.1. Drag Cutting with PT-32EH torch / PowerCut 1500 package.
LOW CURRENT AUTO-DRAG FEATURE
If drag cutting is desired for thin material under 9.5 mm (3/8") thick, remove
the standard 90 amp nozzle from the PT-32EH torch and install ESAB's 40
amp nozzle. Lower the current level setting to be within the AUTO-
DRAG range of 20 to 40 amps (see Auto Drag Scale on front panel).
Then follow steps in "Cutting with the PowerCut-1500" section. Also refer
to PT-32EH Instruction Manual No. F15-440.
HIGH CURRENT DRAG CUTTING
Ifdragcuttingisdesiredonmaterialsabove9.5mm(3/8”)thick,besurethat
the 90 amp nozzle is installed in the PT-32EH torch. Attach ESAB's stand-
offguide andoperateperheatshieldguardinstallationandoperationfigure.