powercut-1250_1500_manual & mechanized plas cut pack_0558004285_apr09

Upload: tom-bean

Post on 29-Oct-2015

132 views

Category:

Documents


3 download

TRANSCRIPT

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    1/70

    POWERCUT-1250 / 1500MANUAL & MECHANIZED PLASMARC CUTTING PACKAGE

    0558004285 04/2009

    Installation, Opeation and Sevice Manual

    This manual povides complete instuctions o MANUAL CONSOLES statin with Seial Numbe PJ245, May 2003:

    This manual povides complete instuctions o MECHANIZED CONSOLES statin with Seial Numbe PJ316, May 2003:

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    2/70

    2

    This equipment will perorm in conormity with the description thereo 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. Malunctioning or poorly maintained equipmentshould not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme

    diately. Should such repair or replacement become necessary, the manuacturer recommends that a telephoneor written request or service advice be made to the Authorized Distributor rom whom it was purchased.

    This equipment or any o its parts should not be altered without the prior written approval o the manuacturer.The user o this equipment shall have the sole responsibility or any malunction which results rom improperuse, aulty maintenance, damage, improper repair or alteration by anyone other than the manuacturer or a service acility designated by the manuacturer.

    BE SUrE THIS INOrMATION rEACHES THE OPErATOr.YOU CAN gET ExTrA COPIES THrOUgH YOUr SUPPLIEr.

    These INSTrUCTIONS ae o epeienced opeatos. I you ae not ully amilia with thepinciples o opeation and sae pactices o ac weldin and cuttin equipment, we ueyou to ead ou booklet, Pecautions and Sae Pactices o Ac Weldin, Cuttin, andgouin, om 52529. Do NOT pemit untained pesons to install, opeate, o maintainthis equipment. Do NOT attempt to install o opeate this equipment until you have eadand ully undestand these instuctions. I you do not ully undestand these instuctions,contact you supplie o uthe inomation. Be sue to ead the Saety Pecautions be

    oe installin o opeatin this equipment.

    CAUTION

    USEr rESPONSIBILITY

    rEAD AND UNDErSTAND THE INSTrUCTION MANUAL BEOrE INSTALLINg Or OPErATINg.

    PrOTECT YOUrSEL AND OTHErS!

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    3/70

    3

    SECTION TITLE PAgEPArAgrAPH

    POWErCUT1250/1500 MANUAL PLASMArC CUTTINg PACKAgE

    SECTION 1 DESCrIPTION .......................................................................................................................................................... 131.0 General ....................... ........................ ....................... ........................ ........................ ....................... ........................ ... 131.1 Scope ...................... ........................ ....................... ........................ ........................ ....................... ........................ ....... 131.2 Manual Plasma ........................ ........................ ....................... ........................ ....................... ........................ ........... 15

    SECTION 2 INSTALLATION ........................................................................................................................................................ 192.0 Installation Manual Plasma Cutting Packages ..................... ........................ ....................... ....................... 192.1 General ....................... ........................ ....................... ........................ ........................ ....................... ........................ ... 192.2 Equipment Required ..................... ....................... ........................ ........................ ....................... ........................ ... 192.3 Location ..................... ........................ ....................... ........................ ........................ ....................... ........................ ... 192.4 Inspection ..................... ........................ ....................... ........................ ........................ ....................... ....................... 192.5 Primary Electrical Input Connections Manual Plasma Cutting Packages ....................... .................. 20

    2.6 Secondary Output Connections or Manual Plasma ........................ ........................ ....................... ........... 23SECTION 3 OPErATION .............................................................................................................................................................. 25

    3.0 Operation ...................... ........................ ....................... ........................ ........................ ....................... ....................... 253.1 PowerCut1250 / 1500 Controls ........................ ....................... ........................ ....................... ........................ ... 253.2 PT32EH Torches used with Manual Plasma Only ...................... ........................ ....................... ................... 273.3 PT32EH Possible Cutting Issues ....................... ....................... ........................ ....................... ........................ ... 32

    POWErCUT1250/1500 MECHANIZED PLASMArC CUTTINg PACKAgE

    SECTION 1 DESCrIPTION .......................................................................................................................................................... 351.0 General ....................... ........................ ....................... ........................ ........................ ....................... ........................ ... 351.1 Scope ...................... ........................ ....................... ........................ ........................ ....................... ........................ ....... 35

    1.2 Mechanized Plasma ....................... ....................... ........................ ........................ ....................... ........................ ... 36

    SECTION 2 INSTALLATION ........................................................................................................................................................ 412.0 Installation Mechanized Plasma Cutting Packages ........................ ........................ ....................... ........... 412.1 General ....................... ........................ ....................... ........................ ........................ ....................... ........................ ... 412.2 Equipment Required ..................... ....................... ........................ ........................ ....................... ........................ ... 412.3 Location ..................... ........................ ....................... ........................ ........................ ....................... ........................ ... 412.4 Inspection ..................... ........................ ....................... ........................ ........................ ....................... ....................... 412.5 Primary Electrical Input Connections Mechanized Plas Cutting Packages ........................ .............. 422.6 Secondary Output Connections or Mechanized Plasma ....................... ....................... ........................ ... 45

    SECTION 3 OPErATION .............................................................................................................................................................. 47

    3.0 Operation ...................... ........................ ....................... ........................ ........................ ....................... ....................... 473.1 PowerCut1250 / 1500 Controls ........................ ....................... ........................ ....................... ........................ ... 473.2 PT21AMX Torches used with Mechanized Plasma Only............................. ....................... ....................... 483.3 PT21AMX Possible Cutting Issues ....................... ....................... ........................ ....................... ....................... 50

    TABLE O CONTENTS

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    4/70

    4

    SECTION TITLE PAgEPArAgrAPH

    SECTION 4 MAINTENANCE .......................................................................................................................... 534.0 General ...................... ........................ ....................... ........................ ....................... ........................ ........................ ...... 534.1 Inspection and Cleaning................................ ........................ ....................... ........................ ........................ .......... 534.2 Common Cutting Problems................................................................................................................................... 544.3 IGBT Handling & Replacement .................... ........................ ....................... ........................ ........................ .......... 55

    SECTION 5 TrOUBLESHOOTINg ..................................... ...................................... ..................................... . 575.0 Troubleshooting ........................ ....................... ........................ ....................... ........................ ........................ .......... 575.1 Troubleshooting Guide ...................... ........................ ........................ ....................... ........................ ...................... 585.2 Reerence Voltage Checks ..................... ........................ ........................ ....................... ........................ .................. 625.3 Sequence o Operation ...................... ........................ ........................ ....................... ........................ ...................... 63

    SECTION 6 rEPLACEMENT PArTS .................................. ...................................... ..................................... . 67

    6.0 Replacement Parts ........................ ....................... ........................ ....................... ........................ ........................ ...... 676.1 General ...................... ........................ ....................... ........................ ....................... ........................ ........................ ...... 676.2 Ordering ....................... ........................ ....................... ........................ ....................... ........................ ....................... ... 676.3 IGBT KIT PC1250/1500 replacement .................... ........................ ........................ ....................... ...................... 67

    TABLE O CONTENTS

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    5/70

    5

    SAETY PrECAUTIONS

    Saety Pecautions

    Users o ESAB welding and plasma cutting equipment have the ultimate responsibility or ensuring that

    anyone who works on or near the equipment observes all the relevant saety precautions. Saety precautionsmust meet the requirements that apply to this type o welding or plasma cutting equipment. The ollowingrecommendations should be observed in addition to the standard regulations that apply to the workplace.

    All work must be carried out by trained personnel well acquainted with the operation o the welding or plasmacutting equipment. Incorrect operation o the equipment may lead to hazardous situations which can result ininjury to the operator and damage to the equipment.

    1. Anyone who uses welding or plasma cutting equipment must be amiliar with: its operation location o emergency stops

    its unction relevant saety precautions welding and / or plasma cutting

    2. The operator must ensure that: no unauthorized person stationed within the working area o the equipment when it is started up. no one is unprotected when the arc is struck.

    3. The workplace must: be suitable or the purpose be ree rom drats

    4. Personal saety equipment: Always wear recommended personal saety equipment, such as saety glasses, ame proo

    clothing, saety gloves. Do not wear loose tting items, such as scarves, bracelets, rings, etc., which could become

    trapped or cause burns.

    5. General precautions: Make sure the return cable is connected securely. Work on high voltage equipment may only be caied out by a qualied electician. Appropriate re extinquishing equipment must be clearly marked and close at hand. Lubrication and maintenance must not be carried out on the equipment during operation.

    Class A 400V CE equipment is not intended o use in esidential locations whee the electical powe is povided by thepublic lowvoltae supply system. Thee may be potential diculties in ensuin electomanetic compatibility o Class Aequipment in those locations due to conducted as well as adiated distubances.

    CAUTION

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    6/70

    6

    SAETY PrECAUTIONS

    WELDINg AND PLASMA CUTTINg CAN BE INJUrIOUS TO YOUrSEL ANDOTHErS. TAKE PrECAUTIONS WHEN WELDINg Or CUTTINg. ASK Or

    YOUr EMPLOYErS SAETY PrACTICES WHICH SHOULD BE BASED ONMANUACTUrErS HAZArD DATA.

    ELECTrIC SHOCK Can kill. Install and earth (ground) the welding or plasma cutting unit in accordance with applicable standards. Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing. Insulate yoursel rom earth and the workpiece. Ensure your working stance is sae.

    UMES AND gASES Can be dangerous to health.

    Keep your head out o the umes. Use ventilation, extraction at the arc, or both, to take umes and gases away rom your breathing zoneand the general area.

    ArC rAYS Can injure eyes and burn skin. Protect your eyes and body. Use the correct welding / plasma cutting screen and lter lens and wear

    protective clothing. Protect bystanders with suitable screens or curtains.

    IrE HAZArD Sparks (spatter) can cause re. Make sure thereore that there are no inammable materials nearby.

    NOISE Excessive noise can damage hearing. Protect your ears. Use earmus or other hearing protection. Warn bystanders o the risk.

    MALUNCTION Call or expert assistance in the event o malunction.

    rEAD AND UNDErSTAND THE INSTrUCTION MANUAL BEOrE INSTALLINg Or OPErATINg.

    PrOTECT YOUrSEL AND OTHErS!

    WArNINg

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    7/70

    7

    PrECAUCIONES DE SEgUrIDAD

    Pecauciones de seuidad

    Los usuarios de los equipos de corte y soldadura ESAB tienen la responsabilidad de asegurar que las personasque trabajan o estn cerca del equipo sigan las normas de seguridad.

    Las precauciones de seguridad deben estar de acuerdo con equipos de corte y soldadura. Las recomendacionesabajo deben ser seguidas adicionalmente a las normas estndar.

    1. Cualquier persona que utilice un equipo de soldadura o corte plasma debe ser amiliar con:su operacinlocalizacin de los paros de emergenciasus uncionesprecauciones de seguridadcorte plasma y soldadura

    2. El operador debe asegurar que:ninguna otra persona este en la rea de trabajo durante el arranque de la maquinaninguna persona este sin proteccin al momento de la partida del arco

    3. La rea de trabajo debe:estar de acuerdo con el trabajoestar libre de corrientes de aire

    4. Equipo de seguridad individual:

    siempre utilice equipos de seguridad, lentes, prendas ignugas, guantes, etc.no utilice artculos sueltos, como buandas, pulseras, anillos, etc.

    5. Precauciones generales:este seguro que el cable de retorno esta bien conectadoel trabajo con alta voltaje debe ser realizado por un tcnico calicado.un extintor de incendios apropiado debe estar acerca de la maquina.lubricacin de la maquina no debe ser realizada durante la operacin.

    El equipo de clase A 400 V CE no est diseado paa su uso enubicaciones esidenciales donde la coiente elctica se suministamediante el sistema de suministo pblico de baja tensin. Puedensui posibles poblemas a la hoa de aantiza la compatibilidadelectomantica con el equipo de clase A en dichas ubicaciones,debido a las petubaciones tanto conducidas como adioelcticas.

    ADVErTENCIA

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    8/70

    8

    PrECAUCIONES DE SEgUrIDAD

    Soldadua y cote plasma puede se atal a usted o otos. Tome laspecauciones de seuidad paa cote plasma y soldadua.

    DESCArgA ELCTrICA puede mata. Instale un cable tiea de acuedo con las nomas No toque pates elcticas o consumibles que estn eneizados. Mantenas aislado del piso y de la pieza de tabajo. Cetique que su situacin de tabajo es seua

    HUMOS Y gASES Son peliosos a su salud Mantena su cabeza alejada de los humos utilice ventilacin o aspiacin paa elimina los humos del ea de tabajo.

    rAYO DEL ArCO. Puede quema la piel o daa los ojos. Potee sus ojos y piel con lentes y opa apopiadas. Poteja las pesonas en la ea de tabajo utilizando una cotina

    PELIgrO DE INCENDIO Chispas pueden povoca incendio. Este seuo que no haan mateiales inamables al ededo dela maquina.

    rUIDO El uido en eceso puede daa los odos. Poteja sus odos. utilice poteccin auicula. Avise las pesonas al ededo sobe el ieso.

    AVErAS Llame a ESAB en caso de una avea con el equipo.

    LEEr Y ENTENDEr EL MANUAL ANTES DE INSTALAr U OPErAr EL EQUIPO.PrOTEJA A USTED Y LOS OTrOS!

    ADVErTENCIA

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    9/70

    9

    PrCAUTIONS DE SCUrIT

    Pcautions de scuit

    Les utilisateurs du matriel de soudage et de coupage plasma ESAB ont la responsabilit ultime d'assurer quetoute personne qui opre ou qui se trouve dans l'aire de travail observe les prcautions de scurit pertinentes.Les prcautions de scurit doivent rpondre aux exigences applicables ce type de matriel de soudage oude coupage plasma. Les recommandations suivantes doivent tre observes en plus des rgles standard qui

    s'appliquent au lieu de travail.

    Tous les travaux doivent tre eectus par un personnel quali possdant de bonnes connaissances par rapportau onctionnement du matriel de soudage et de coupage plasma. Un ontionnement incorrect du matrielpeut produire des situations dangereuses qui peuvent causer des blessures l'oprateur ou des dommages aumatriel.

    1. Toute personne travaillant avec le matriel de soudage ou de coupage plasma doit connatre : son onctionnement; l'emplacement des interrupteurs d'arrt d'urgence; sa onction; les prcautions de scurit pertinentes;

    les procdures de soudage et/ou de coupage plasma.

    2. L'oprateur doit assurer que : seules les personnes autorises travailler sur l'quipement se trouvent dans l'aire de travail lors de la mise

    en marche de l'quipement; toutes les personnes dans l'aire de travail sont protges lorsque l'arc est amorc.

    3. Le lieu de travail doit tre : amnag convenablement pour acqurir le matriel en toute scurit; libre de courants d'air.

    4. quipement de scurit personnelle Vous devez toujours utiliser un quipement de scurit convenable tels que les lunettes de protection, les

    vtement ininammables et des gants de protection. Vous ne devez jamais porter de vtements amples, tels que oulards, bracelets, bagues, etc., qui

    pourraient se prendre dans l'appareil ou causer des brlures.

    5. Prcautions gnrales : Assurezvous que le cble de retour est bien branch. La rparation d'un quipement de haute tension doit te eectue pa un lecticien quali

    seulement. Un quipement d'extinction d'incendie appropri doit tre proximit de l'appareil et l'emplacement doit

    tre clairement indiqu. Vous ne devez jamais procder la lubrication ou l'entretien du matriel lorsque l'appareil est en

    marche.

    Les appaeils de classe A 400 V CE ne sont pas pvus pouune utilisation su des lieu sidentiels o lalimentationlectique povient du seau dalimentation public bassetension. La compatibilit lectomantique des appaeils declasse A dans ces lieu est potentiellement petube en aisondes petubations ayonnes et conduites.

    MISE EN gArDE

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    10/70

    10

    PrCAUTIONS DE SCUrIT

    CHOC LECTrIQUE peut tre mortel. Assurezvous que l'unit de soudage ou de coupage plasma est installe et mise la terre conormment

    aux normes applicables. Ne touchez pas aux pices lectriques sous tension ou les lectrodes si vos mains ne sont pas bien

    protges ou si vos gants ou vos vtements sont humides. Assurezvous que votre corps est bien isol de la mise la terre et de la pice traiter. Assurezvous que votre position de travail est scure.

    VAPEUrS ET gAZ peuvent tre danereux pour la sant. Gardez votre tte loigne des vapeurs. Utilisez un systme de ventilation et/ou d'extraction l'arc pour vacuer les vapeurs et les gaz de votre

    zone respiratoire.

    rAYONS DE L'ArC peuvent endommager la vue ou brler la peau. Protgez vos yeux et votre corps. Utilisez un cran de soudage/coupage plasma convenable quip de

    lentilles teintes et portez des vtements de protection. Protgez les personnes se trouvant dans l'aire de travail l'aide d'un cran ou d'un rideau protecteur

    convenable.

    rISQUE D'INCENDIE Les tincelles (projections) peuvent causer un incendie. Assurezvous qu'il n'y a pas de matriel

    inammable proximit de l'appareil.

    BrUIT un bruit excessi peut endommager la capacit auditive. Protgez vos oreilles. Utilisez des protecteurs d'oreilles ou un autre type de protection auditive. Avertissez les personnes se trouvant dans l'aire de travail de ce risque.

    ONCTIONNEMENT DECTUEUx Dans le cas d'un onctionnement dectueux demandez l'aide d'unepersonne qualie.

    ASSUrEZVOUS DE LIrE ET DE COMPrENDrE LE MANUEL D'UTILISATION AVANTD'INSTALLEr OU D'OPrEr L'UNIT.

    PrOTgEZVOUS ET LES AUTrES !

    AVErTISSEMENT

    LE SOUDAgE ET LE COUPAgE L'ArC PEUVENT CAUSEr DESBLESSUrES L'OPrATEUr OU LES AUTrES PErSONNES SETrOUVANT DANS L'AIrE DE TrAVAIL. ASSUrEZVOUS DEPrENDrE TOUTES LES PrCAUTIONS NCESSAIrES LOrSD'UNE OPrATION DE SOUDAgE OU DE COUPAgE. DEMANDEZ

    VOTrE EMPLOYEUr UNE COPIE DES MESUrES DE SCUrITQUI DOIVENT TrE LABOrES PArTIr DES DONNES DESrISQUE DU ABrICANT.

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    11/70

    11

    POWERCUT-1250 / 1500

    MANUAL PLASMARC CUTTING PACKAGE

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    12/70

    12

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    13/70

    13

    1.0 gENErAL

    The Powercut1250 / 1500 is a compact, completely selcontained plasma cuttingsystem. As shipped, the system is ully assembled and ready to cut ater beingconnected to input power and a source o compressed air (90150 psi / 6.2 to10.3 bar). The Powercut package uses the heavyduty PT32EH (Manual Plasma)

    torch to deliver cutting power or severing materials up to 11/2 inch (38.1mm)thick on the PC1250 and 13/4 inch (45mm) thick on the PC1500. Reer to theollowing pages or descriptions o the Powercut packages available as well asperormance specications.

    1.1 SCOPE

    The purpose o this manual is to provide the operator with all the inormationrequired to install and operate the Powercut plasma arc cutting package. Technical reerence material is also provided to assist in troubleshooting the cuttingpackage.

    Use only the ESAB PT32EH Plasmac

    toch with this console. Use o toches notdesined o use with this console couldceate an ELECTrIC SHOCK HAZArD.

    "DualVoltae" Vesion Back View

    Typical ont View

    SECTION 1 DESCrIPTION

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    14/70

    14

    The PowerCut1250 plasma cutting package combines the

    proven reliability o the PowerCut1250 with the newlydesigned PT32EH torch. The very strong composite casematerial makes the PowerCut1250 an excellent additionto any equipment rental eet. The PT32EH plasma cuttingtorch is designed to provide increased perormance andlonger consumable lie resulting in higher production ratesat lower costs.

    Specifcations: PowerCut-1250Cuts 11/4 in. (32mm); severs 11/2 in. (38mm)1 ph. Input .................................................208/230 vac, 1 ph, 50/60 Hz, 67/61 A1 ph. Output .................................................................70 amps @ 60% duty cycle

    3 ph. Input .................................................208/230 vac, 3 ph, 50/60 Hz, 33/29 A.................................................................230/460 vac, 3 ph, 50/60 Hz, 29/20 A.................................................................................400 vac, 3 ph, 50/60 Hz, 18 A..................................................................................575 vac, 3ph, 50/60 Hz, 15 A

    3 ph. Output ..............................................................70 amps @ 100% duty cycle

    Dimensions .................................................................................W = 12.5 (318mm).....................................................................................................H = 16.5 (419mm)........................... .............................. ............................. .............. D = 31.5 (800mm)

    Weight ............................ ............................. .............................. .............. 86 lbs. (39kg)Air Requirements .............................350 ch @ 80 psig (165 l/min @ 5.5 bars)

    TorchPowerCut1250 uses the PT32EH torch. For complete list andbreakdown o parts, reer to Figure 1.1.

    Ordering Inormation:PowerCut1250, 208/230/460 V, 25 (7.6m) PT32EH ............... 0558001933PowerCut1250, 208/230/460 V, 50 (15.2m) PT32EH ............ 0558001934PowerCut1250, 575 V, 25 (7.6m) PT32EH ............................ .... 0558001939PowerCut1250, 575 V, 50 (15.2m) PT 32EH .............................0558001940PowerCut1250, 400 V, CE 25 (7.6m) PT32EH ........................ 0558001936PowerCut1250, 400 V, CE 50 (15.2m) PT32EH ...................... 0558001937PowerCut1250, 460V, 25 (7.6m) PT32EH ............................ ..... 0558005332PowerCut1250, 460V, 50 (15.2m) PT32EH ...............................0558005333

    The components that are included in the Powercut1250 packages (Console,Torch, Spare Parts Kit) may be purchased separately by using the appropriateP/N when placing orders. Individual part numbers are listed below:

    Consoles:

    PowerCut1250 (208)230/460 V, 50/60 Hz, 1/3ph ..................0558001935PowerCut1250 (208)230/460 V, 50/60 Hz, 1/3ph (BL) .......0558001935FPowerCut1250 575 V, 50/60 Hz, 3ph..........................................0558001941PowerCut1250 400 V, CE, 50 Hz, 3ph .........................................0558001938PowerCut1250 460 V, 60 Hz, 3ph ................................................0558005331

    PT32EH Toches:PT32EH Torch, 25t. (7.6m) ............................................................0558003548PT32EH Torch, 50t. (15.2m) ............................ ............................. 0558003549

    Spae Pats Kits: (see section 1.2.3)PT32EH Spare Parts Kit ....................................................................0558003508PT32EH, 400 V Long Heat Shield (LHS), Spare Parts Kit, CE units ..............only ...........................................................................................................0558003560

    1.2 MANUAL PLASMA

    1.2.1 PC-1250 MANUAL PLASMA

    PT-32EH Cut Data-70 AMPS

    Powercut-1250, PT-32EH, 70A Nozzle P/N 0558002618

    Air Pressure - 80 psi, 5/32 Standof

    0.250 (6.35)

    0.500 (12.7)

    0.750 (19.05)

    1.000 (25.4)

    1.250 (31.75)

    1.500 (38.1)

    Inches (mm) IPM (mm/min) IPM (mm/min)

    Max Speeds

    Carbon Steel

    Plate Drop Cut Sever

    131(3327.4)

    50 (1270)

    21 (533.4)

    10 (254)

    6 (152.4)

    --- (---)

    135 (3429)

    53 (1346.2)

    23 (584.2)

    12 (304.8)

    7 (177.8)

    3 (76.2)

    SECTION 1 DESCrIPTION

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    15/70

    15

    Specifcations: PowerCut-1500Cuts 11/2 in. (38mm); severs 13/4 in. (45mm)1 ph. Input .................................................208/230 vac, 1 ph, 50/60 Hz, 82/74 A1 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

    TorchPowerCut1500 uses the PT32EH torch. For complete list andbreakdown o parts, reer to Figure 1.1.

    Ordering Inormation:PowerCut1500, 230/460 V, 25 (7.6m) PT32EH ........................ 0558001942PowerCut1500, 230/460 V, 50 (15.2m) PT32EH ..................... 0558001943PowerCut1500, 575 V, 25 (7.6m) PT32EH ........................... ..... 0558001948PowerCut1500, 575 V, 50 (15.2m) PT 32EH .............................0558001949PowerCut1500, 400 V, CE 25 (7.6m) PT32EH ........................ 0558001945PowerCut1500, 400 V, CE 50 (15.2m) PT32EH ...................... 0558001946PowerCut1500, 460 V, 25 (7.6m) PT32EH ........................... ..... 0558005902PowerCut1500, 460 V, 50 (15.2m) PT 32EH .............................0558005903PowerCut1500, 400 V, 25 (7.6m) PT32EH ............................ ..... 0558007827

    The components that are included in the Powercut1500 packages (Console,Torch, Spare Parts Kit) may be purchased separately by using the appropriateP/N when placing orders. Individual part numbers are listed below:

    The PowerCut1500 plasma cutting package combines theproven reliability o the PowerCut1500 with the newlydesigned PT32EH torch. The very strong composite casematerial makes the PowerCut1500 an excellent addition

    to any equipment rental eet. The PT32EH plasma cuttingtorch is designed to provide increased perormance andlonger consumable lie resulting in higher production ratesat lower costs.

    PT-32EH Cut Data-90 AMPS

    Powercut-1500, PT-32EH, 90A Nozzle P/N 0558002837

    Air Pressure - 80 psi, 5/32 Standof

    1.2.2 PC-1500 MANUAL PLASMA

    0.250 (6.35)

    0.500 (12.7)

    0.750 (19.05)

    1.000 (25.4)

    1.250 (31.75)

    1.500 (38.1)

    151 (3835.4)

    56 (1422.4)

    25 (635)

    16 (406.4)

    11 (279.4)

    7 (177.8)

    153 (3886.2)

    58 (1473.2)

    26 (660.4)

    18 (457.2)

    12 (304.8)

    8 (203.2)

    Inches (mm) IPM (mm/min) IPM (mm/min

    Max Speeds

    Carbon Steel

    Plate Drop Cut Sever

    SECTION 1 DESCrIPTION

    ..................................................................................575 vac, 3ph, 50/60 Hz, 18 A3 ph. Output .................................................................90 amps @ 60% duty cycle

    Dimensions .................................................................................W = 12.5 (318mm).....................................................................................................H = 16.5 (419mm).......................... .............................. ............................. ............... D = 31.5 (800mm)

    Weight ........................... .............................. ............................. ............94 lbs. (42.7kg)Air Requirements .............................350 ch @ 80 psig (165 l/min @ 5.5 bars)

    400V CE Mains Supply .............................. ............................. .... Ssc min

    3.8MVA.......................... .............................. ............................. ........................... Z

    max

    0.042

    400V CE Mains Supply, Ssc min

    Minimum short circuit power on the network in accordance withIEC61000312.

    400V CE Mains Supply, Zma

    Maximum permissible line on the network impedance in accordance

    with IEC61000311.

    Consoles:PowerCut1500 (208)230/460 V, 50/60 Hz, 1/3ph ..................0558003570PowerCut1500 (208)230/460 V, 50/60 Hz, 1/3ph (BL) .........0558003517PowerCut1500 575 V, 50/60 Hz, 3ph..........................................0558001950PowerCut1500 400 V, CE, 50 Hz, 3ph ............................ ............ 0558001947PowerCut1500 460 V, 50/60 Hz, 3ph............................. ............ 0558005900PowerCut1500 400 V, 50 Hz, 3ph ................................................0558007826

    PT32EH Toches:PT32EH Torch, 25t. (7.6m) ............................................................ 0558003548PT32EH Torch, 50t. (15.2m) ......................................................... 0558003549

    Spae Pats Kits: (see section 1.2.3)PT32EH Spare Parts Kit ....................................................................0558003062PT32EH, 400 V Long Heat Shield (LHS), Spare Parts K it, CE units only .....

    ..............................................................................................................0558003557

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    16/70

    16

    Desciption P/N Quantity

    Heat Shield 0558001957 270 amp Nozzle 0558002618 440 amp drag Nozzle 0558002908 1Electrode 0558001969 3Valve Pin 0558001959 1Fuse 2amp, 600vdc 0558001379 1Stando Guide 0558002393 1Wrench 19129 (0558000808) 1Lubricant 17672 (0558000443) 1

    Contents o PT-32EH Spare Parts Kit, 70 amp

    P/N 0558003508

    The PowerCut1250 comes out o the box ready to go. The torch is attached with parts in place, primary cord is attached and the lter/regulator isinstalled. Just hook up the air, power and begin cutting.

    NOTE: Pat numbes in paenthesis apply to "CE"/Euopean units only.

    Heat Shield

    0558001957

    Long Heat Shield

    0558003110

    Valve Pin

    0558001959

    Nozzle

    40 AMP 0558002908 (Drag Cutting)

    50/70 AMP 0558002618

    90 AMP 0558002837

    85W51 (0558003694)

    (Supplied with head)

    Electrode

    0558001969

    PT32EH Torch Head 0558003412

    Desciption P/N Quantity

    Heat Shield 0558001957 290 amp Nozzle 0558002837 440 amp drag Nozzle 0558002908 1Electrode 0558001969 3Valve Pin 0558001959 1Fuse 2amp, 600vdc 0558001379 1

    Stando Guide 0558002393 1Wrench 19129 (0558000808) 1Lubricant 17672 (0558000443) 1

    Contents o PT-32EH Spare Parts Kit, 90 amp

    P/N 0558003062

    The PowerCut1500 comes out o the box ready to go. The torch is attached with parts in place, primary cord is attached and the lter/regulator isinstalled. Just hook up the air, power and begin cutting.

    1.2.3 SPArE PArTS / OPTIONAL ACCESSOrIES (PC-1250 / 1500 MANUAL PLASMA)

    Spare Parts Kits:

    Desciption P/N Quantity

    Long Heat Shield (LHS) 0558003110 270 amp Nozzle 0558002618 440 amp drag Nozzle 0558002908 1Electrode 0558001969 3Valve Pin 0558001959 1Fuse 2amp, 600vdc 0558001379 1Stando Guide 0558002393 1Wrench 19129 (0558000808) 1Lubricant 17672 (0558000443) 1

    Contents o PT-32EH (LHS) Spare Parts Kit, 70 amp

    P/N 0558003560, "CE"units only

    Desciption P/N Quantity

    Long Heat Shield (LHS) 0558003110 290 amp Nozzle 0558002837 440 amp drag Nozzle 0558002908 1Electrode 0558001969 3Valve Pin 0558001959 1Fuse 2amp, 600vdc 0558001379 1

    Stando Guide 0558002393 1Wrench 19129 (0558000808) 1Lubricant 17672 (0558000443) 1

    Contents o PT-32EH (LHS) Spare Parts Kit, 90 amp

    P/N 0558003557, "CE" units only

    iue 11. PT32EH Toch

    SECTION 1 DESCrIPTION

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    17/70

    17

    Optional Accessories:70 A Spae Pats Kit ................ .................. ................... .................. .................. ................... ......... 055800350870 A 400 V LHS Spae Pats Kit, "CE" units .................................................................................. 055800356090 A Spae Pats Kit ...................................................................................................................... 055800306290 A 400 V LHS Spae Pats Kit, "CE" units .................................................................................. 0558003557Plasma low Measuin Kit:

    This valuable troubleshooting tool allows measurement o

    the actual plasma gas ow through the torch .................................................................................................................................................. .............................. ............................. .............................. ............................. ......................... 19765 (0558000739)Toch guide Kit:

    This complete kit, in a rugged plastic carrying case, includesattachments or circle and straight line cutting on errous andnonerrous metals,Deluxe, 1 3/4" 42" (44.5mm 1066.8 mm) Radius........................................................................................0558003258Basic, 1 3/4 28 (44.5mm 711.2 mm) Radius ..............................................................................................0558002675

    Stando guideFor proper stando distance when drag cutting .........................................................................................0558002393

    40 amp Da Nozzle ...................................................................................................................................................0558002908gouin Nozzle ...........................................................................................................................................................0558003089Heat Shield gouin .................................................................................................................................................0558003090Da Heat Shield Standad ..................................................................................................................................0558003374Da Heat Shield Heavy Duty ............................................................................................................................0558004206Wheel Kit

    For easy transport o system ..................................................................................................................................0558003060

    Toch WapThis enables operator to store spare parts kit, wrap torchand work cable or easy transport and storage ..............................................................................................0558003059

    NOTE: Pat numbes in paenthesis apply to "CE"/Euopean units only.

    Da Heat Shield StandadMaintains a constant stando, Good lie in most applications ..........................................................................................................................0558003374

    Da Heat Shield Heavy DutyMaintains a constant stando, Long lie, Suitable or piercing ..........................................................................................................................0558004206

    Toch WapThis enables operator to store spare parts kit, wrap torch

    and work cable or easy transport and storage .....................0558003059

    Wheel KitFor easy transport o system ......................................................0558003060

    Powercut shown with Optional Torch Wrapand Spare Parts Kit Holder installed.

    SECTION 1 DESCrIPTION

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    18/70

    18

    SECTION 1 DESCrIPTION

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    19/70

    19

    2.1 gENErAL

    Proper installation is important or satisactory and troubleree operation o thePowerCut cutting package. It is suggested that each step in this section be studiedcareully and ollowed closely.

    2.2 EQUIPMENT rEQUIrED

    A source o clean, dry air that supplies 350 ch (165.2 l/m) at 80 psig (5.5 bar) isrequired or the cutting operation. The air supply should not exceed 150 psig (10.3bar) (the maximum inlet pressure rating o the air lterregulator supplied with thepackage).

    2.3 LOCATIONAdequate ventilation is necessary to provide proper cooling o the PowerCut. Theamount o dirt, dust, and excessive heat to which the equipment is exposed, shouldbe minimized. There should be at least one oot o clearance between the PowerCutpower source and wall or any other obstruction to allow reedom o air movementthrough the power source.

    2.4 INSPECTION

    A. Remove the shipping container and all packing material and inspect or evidence o concealed damage which may not have been apparent upon receipto the PowerCut. Notiy the carrier o any deects or damage at once.

    B. Check container or any loose parts prior to disposing o shipping materials.

    C. Check air louvers and any other openings to ensure that any obstruction isremoved.

    Installin o placin any type o lteindevice will estict the volume o intakeai, theeby subjectin the powe souceintenal components to oveheatin.The waanty is void i any type o ltedevice is used.

    2.0 INSTALLATION - MANUAL PLASMA CUTTINgPACKAgE

    SECTION 2 INSTALLATION

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    20/70

    20

    ELECTrIC SHOCK CAN KILL! Pecautionay measues should be taken to povidemaimum potection aainst electicalshock. Be sue that all powe is o byopenin the line wall disconnect switchand by unpluin the powe cod to theunit when connections ae made inside othe powe souce.

    2.5 PrIMArY ELECTrICAL INPUT CONNECTIONS -MANUAL PLASMA CUTTINg PACKAgE

    The PowerCut1250 / 1500 consoles are equipped with approximately 10t. o

    4conductor input power cable or 3phase connection. I singlephase connection is desired, tape back the red (lt. blue) wire on the input power cable. Connectthe singlephase input to the white and black wires only. When operating thismachine rom a singlephase source, it must be connected to a dedicated 100Amp eed. Due to the higher input current requirements, the duty cycle o themachine is lower than in threephase operation. Single phase duty cycle is 60%or PC1250 and 40% or PC1500.

    Connect your air supply to the inlet connection o the lterregulator.

    CUSTOMER FUSED LINE DISCONNECT SWITCH(See Table 2.3 and WARNING in regards to

    chassis ground in Section 2.5.)

    PRIMARY INPUTPOWER CABLE

    Preltered DRY AIR SUPPLY (Customer Supplied)(90 to 150 psig max)

    (6.2 to 10.3 bars max)

    iue 21. Input Connections

    Red (Lt Blue) NOT USED ON SINGLE PHASE

    White (Brown)

    Black (Black)

    Green (Yellow/Green)

    SECTION 2 INSTALLATION

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    21/70

    21

    Beore connecting to input power, make sure there is a line (wall) disconnectswitch with uses or circuit breakers at the main power panel. You may either usethe actoryinstalled input power cable (4/c, type SO (90 C), 10 t (3.1 m) length)or provide your own input power leads. I you choose to provide your own, makesure they are insulated copper conductors. You must have two (singlephase) orthree (threephase) power leads and one ground wire. The wires may be heavyrubber covered cable or may be run in a solid or exible conduit. Reer to Table21 and 22 or recommended input conductors and line use sizes.

    Table 21. PC1250 recommended Sizeso Input Conductos and Line uses

    Input requiements Input & gnd useVolts Phase Amps Conducto Size

    CU/AWg Amps

    208 1 67A 6 100208 3 33A/Ph. 6 50230 1 61A 6 100230 3 29A/Ph. 6 50460 3 20 6 50400 3 18 6mm2 50575 3 15 10 25

    Table 22. PC1500 recommended Sizeso Input Conductos and Line uses

    Input requiements Input & gnd use

    Volts Phase Amps Conducto Size

    CU/AWg Amps

    208 1 82A 6 100208 3 44A/Ph. 6 80230 1 74A 6 100230 3 40A/Ph. 6 80460 3 27 6 50400 3 24 6mm2 50

    575 3 18 10 50

    Beoe makin any connections to thepowe souce output teminals, makesue that all pimay input powe to thepowe souce is deeneized o at themain disconnect switch and that the inputpowe cable is unplued.

    ELECTrIC SHOCK CAN KILL! Beoe makin

    electical input connections to the powe

    souce, "Machiney Lockout Pocedues"

    should be employed. I the connectionsae to be made om a line disconnect

    switch, place the switch in the o position

    and padlock it to pevent inadvetent

    tippin . I the connection is made om

    a usebo, emove the coespondin

    uses and padlock the bo cove. I it is

    not possible to use padlocks, attach a

    ed ta to the line disconnect switch o

    use bo wanin othes that the cicuit

    is bein woked on.

    The chassis must be connected to an appoved electical ound. ailue to doso may esult in electical shock, seveebuns o death.

    SECTION 2 INSTALLATION

    NOTE !!!400V CE Mains Supply requiements:High power equipment may, due to the primary current drawn rom the mains supply, inuence the power quality o the grid. Thereore connection restrictions or requirements regarding the maximum permissible mains impedance or the required minimum supply capacity at the interace point to the public gridmay apply or some types o equipment (see technical data). In this case it is the responsibility o theinstaller or user o the equipment to ensure, by consultation with the distribution network operator inecessary, that the equipment may be connected.

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    22/70

    22

    2.5.1 INPUT VOLTAgE CHANgEOVEr DUALVOLTAgE UNITS ONLY

    208 230 o 460 Mode

    To simpliy the use o the ESAB Powercut1250 / 1500 with dierent input voltages, it has been equipped with a convenient 230/460 selector switch locatedon the back panel o the unit. Switching between 230 and 460 voltages can bedone by using a athead screwdriver to turn the selector screw.

    The Powercut is also equipped with protective use that will prevent damage tothe power source in the event that the input voltage switch is not set correctlyand the unit is powered on.

    A line (wall) disconnect switch with uses or circuit breakers should be providedat the main power panel (see Table 21 / 22 or use sizes). Theinput power cable o the console may be connected directly to the disconnect switch or you may purchase a proper plug and receptacle rom a local

    electrical supplier. I using plug/receptacle combination, see Table 21 / 22 orrecommended input conductors or connecting receptacle to line disconnectswitch.

    Fuse*

    Input VoltageSelector Switch

    SECTION 2 INSTALLATION

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    23/70

    23

    WORK

    SAFETY GROUND

    2.6 SECONDArY OUTPUT CONNECTIONS Or MANUAL CUTTINg

    The torch comes actory installed.

    Clamp the work cable to the workpiece. Be sure theworkpiece is connected to an approved earth groundwith a properly sized ground cable.

    iue 22. PoweCut Inteconnection Diaam

    SECTION 2 INSTALLATION

    PT32EH

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    24/70

    24

    SECTION 2 INSTALLATION

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    25/70

    25

    3.0 OPErATION

    3.1 PoweCut1250 / 1500 CONTrOLS

    A. Powe Switch. When placed in ON position, the white power light will glowindicating control circuit is energized.

    B. Ai Test Switch. When placed in TEST position, air lterregulator can beadjusted to desired pressure (80 psig / 5.5 bar) beore cutting operations.Allow air to ow or a ew minutes. This should remove any condensationthat may have accumulated during shutdown period. Be sure to placeswitch in OPERATE position beore starting cutting operations.

    C. Tie Lock Switch.

    1. Manual Opeation using the PT32EH torch When placed in LOCK position, this permits releasing torch switch button ater cutting arc has beeninitiated. To extinguish arc at end o cut, press and release torch switchbutton again or pull torch away rom work. When placed in UNLOCKposition, torch switch must be held closed by the operator during theentire cutting operation and then released at the end o cut.

    2. Mechanized Opeation using the PT21AMX torch In mechanizedoperation the Trigger Lock unction disabled. Instead, the switch unctions as an "AutoRestrike" selector. To turn AutoRestrike "on" (gratecutting), place the switch in the up position. To turn AutoRestrike "o"

    (grate cutting), place the switch in the down position.

    A DB C

    iue 31A. PoweCut1250 / 1500 Contols

    TrIggErLOCK

    UNLOCK

    AutoRestrike "on"

    AutoRestrike "o"

    SECTION 3 OPErATION

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    26/70

    26

    iue 31B. PoweCut1250 / 1500 Contols

    D. Output Cuent Contol. Adjustable rom 20 to 70 amperes on Powercut1250.Adjustable rom 20 to 90 amperes on Powercut1500.

    E. Powe "ON" Indicato: Illuminates whenever the ront panel power switchis in the ON position.

    . AC Line Indicato o Hih/Low Line Voltae Indicato: This ault light willblink when the input voltage is outside the + or 15% range o the inputrating.

    g. gas low Indicato: This ault light will blink when the air ow supply is lowor has no back pressure.

    H. ault Indicato: When this light blinks, either the system ailed to initiatea pilot arc ater a number o attempts, or there has been an overcurrentevent within the system. I the light blinks or 10 seconds and then stops,the problem is pilot arc initiation. Check the consumables in the torch.

    I the light continues to blink, and the system does not reset, the ault is anovercurrent event. See troubleshooting section.

    I. Ove Tempeatue Indicato: This ault light will blink to indicate that theduty cycle has been exceeded. Allow the power source to cool down beore

    returning to operation.

    All ault sinals will emain on o a minimum o 10 seconds. I ault cleas,all will eset automatically ecept o ovecuent. To clea ovecuent,the powe must be shut o o 5 seconds and then tuned back on.

    E HF G I

    SECTION 3 OPErATION

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    27/70

    27

    ELECTrIC SHOCK can kill. DoNOToperatetheunitwiththecover

    emoved. DoNOTapplypowertotheunitwhile

    holdin o cayin the unit. DoNOTtouchanytorchpartsforward

    o the toch handle nozzle, heat shield,electode, etc. with powe switchon.

    ArC rAYS can bun eyes and skin;NOISE can damae heain. WearweldinghelmetwithNo.6or7lens

    shade.

    Weareye,ear,andbodyprotection.

    3.2 PT-32EH TOrCH USED WITH MANUALPLASMA ONLY

    3.2.1 CUTTINg WITH THE POWErCUT-1250 / 1500 USINg THEPT-32EH TOrCH (MANUAL PLASMA ONLY)

    Use the ollowing procedures to cut with the PT32EH torch.

    A. Make sure that the wall disconnect switch is on. Turn on the Front PanelPower Switch.

    B. Set Pressure Regulator to 80 psig (5.5 bar).

    C. Hold the torch nozzle approximately 1/8 to 3/16 inch (3.2 to 4.8 mm) abovethe work and tilted at about 15 30. This reduces the chance o spatterentering the nozzle. I the PT32EH's stando guide (P/N 0558002393) isbeing used, the distance between Electrode and Work Piece will be approx.

    3/16" (4.8 mm).

    D. Depress the torch switch. Air should ow rom the torch nozzle.

    E. Two seconds ater depressing the torch switch, the pilot arc should start.The main arc should immediately ollow, allowing the cut to begin. (I usingthe trigger LOCK mode, torch switch may be released ater establishing thecutting arc.) See note.

    NOTE: Tie Lock Switch.

    Manual Opeation usin the PT32EHtoch When placed in LOCK position,this pemits eleasin toch switch button ate cuttin ac has been initiated.To etinuish ac at end o cut, pess and

    elease toch switch button aain o pulltoch away om wok. When placed inUNLOCK position, toch switch must beheld closed by the opeato duin theentie cuttin opeation and then eleasedat the end o cut.

    Position the PoweCut at least 10 eet 3metes om the cuttin aea. Spaks andhot sla om the cuttin opeation candamae the unit.

    Trigger Lock Switch

    SECTION 3 OPErATION

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    28/70

    28

    IMPOrTANT!!!Maintain Pope

    StandO Distance

    3/16 to 1/4 Inch4.8 to 6.4mm

    Powe Output inceases with Stand O Distance!

    iue 32b. Stando vs. Powe Output Duin Cuttin

    CUTDIrECTION

    iue 32a. recommended Toch Anle o 5o to 15o Duin Cuttin

    F. Ater starting the cut, the torch should be maintained at a 515 orward angle. Thisangle is especially useul in helping to create a "drop" cut. When not using the standoguide, the nozzle should be held approximately 1/4 inch (6.4mm) rom the work.

    G. When ending a cut, the torch switch should be released (press and release i usingtrigger LOCK mode) and the torch lited o the workpiece just beore the end o the

    cut. This is to prevent the high requency rom reigniting ater cutting arc extinguishesand causing damage to the nozzle (double arcing).H. For rapid restarts, such as grate or heavy mesh cutting, do not release the torch

    switch. In the postow mode, the arc can be restarted immediately by depressingthe torch switch. This avoids the 2second preow portion o the cutting cycle.

    SECTION 3 OPErATION

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    29/70

    29

    3.2.2 Da Cuttin with the PT32EH Toch / PoweCut packae.

    A. LOW CURRENT AUTODRAG FEATURE

    I drag cutting is desired or thin material under 3/8" (9.5mm) thick, removethe standard 70 / 90 amp nozzle rom the PT32EH torch and install ESAB's40 amp nozzle. Lower the current level setting to be within the AUTODRAG range o 20 to 40 amps (see Auto Drag Scale on ront panel). Thenollow steps in Section 3.2.1. Also reer to PT32EH Instruction Manual No.F15747.

    B. HIGH CURRENT DRAG CUTTINGI drag cutting is desired on materials above 3/8 (9.5mm) thick, be sure thatthe 70 amp / 90 amp nozzle is installed in the PT32EH torch. Attach ESAB'sstando guide and operate as shown in Figure 3.3.

    WHEN THE ARC BREAKSTHROUGH THE WORK, BRINGTHE TORCH TO AN UPRIGHT PO

    SITION AND PROCEED TO CUT.

    TO START A PIERCE, TILT THE TORCH TOPREVENT MOLTEN MATERIAL FROM COMING BACK AGAINST AND DAMAGINGTHE TORCH.

    1

    2

    iue 33. Piecin Technique usin the PT32EH

    Da cuttin, even with lowe cuentlevels may sinicantly educe the lie otoch consumables. Attemptin to DaCut with hihe cuents eate than 40amps may cause immediate catastophicconsumable damae.

    SECTION 3 OPErATION

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    30/70

    30

    i 3.4. Eploded View o PT32EH Toch

    ELECTRODE

    NOZZLE

    SHIELD

    IMPOrTANT!MAKE SHIELD VErY TIgHT!

    VALVE PIN

    *The valve pin is a crucial member o the system. Its unctionis to open the gas ow check valve that is permanentlyassembled within the torch head. I the pin is not correctlyplaced in the electrode, the valve will not open and thesystem will not unction. The valve pin also improves electrode cooling by increasing the velocity o air over the innersurace o the electrode.

    PLACE NOZZLE INTO HEATSHIELD AND THREADTHIS ASSEMBLY TO THETORCH BODY AND HANDTIGHTEN.

    PLACE THE VALVE PIN INTO THE ELEC TRODEAND SCREW THE ELECTRODE INTO THETORCH HEAD AND TIGHTEN SECURELY WITHWRENCH #19129.

    1

    2

    3

    *

    3.2.3 PT32EH TOrCH PArTS INSTALLATION MANUAL PLASMA ONLY

    Make sue powe switch on POWErCUT

    is in O position beoe wokin on thetoch.

    The PT32EH toch head contains a asow check valve that acts in conjunctionwith the ow switch and cicuity withinthe powe souce. This system peventsthe toch om bein eneized with hihvoltae i the toch switch is accidentallyclosed when the shield is emoved. Alwayseplace toch with the with the popetoch manuactued by ESAB since italone contains ESAB's patented saety

    intelock.

    SECTION 3 OPErATION

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    31/70

    31

    iue 35. Installation and Opeation o Stando guide PT32EH ONLY

    THIN GAUGE MATERIALSCAN BE CUT WITH 1/16" (1.6 mm)TORCHTOWORK DISTANCEADJUST TO 3/16" (4.8 mm) FORMATERIALS OVER 1/4" (6.4 mm) THICK

    ADJUST GUIDE BY TURNINGIN A CLOCKWISE DIRECTIONONLY. THIS WILL PREVENTACCIDENTAL LOOSENING

    OF SHIELD.

    STEEL GUARDSTAND OFF GUIDEP/N 0558002393

    1/16" (1.6 mm) TO1/4" (6.4mm)TORCHTOWORK

    IF GUIDE IS TOO TIGHT ON SHIELD, OPENSLOT WITH SCREWDRIVER.

    IF TOO LOOSE, CLOSE

    SLOT WITH VISE ORLARGE PLIERS.

    GUIDE AGAINSTSTRAIGHT EDGEOR FREEHANDCUT

    SECTION 3 OPErATION

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    32/70

    32

    3.3 PT-32EH POSSIBLE CUTTINg ISSUES

    iue 36. Electode Wea Limit

    NOTE: When replacing the nozzle, always inspect the electrode for wear. If more

    than .06" (1.5mm) of electrode has eroded, 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.

    rEPLACE ELECTrODE BEOrE PITTINgBECOMES DEEPEr THAN .06 INCH 1.5MM

    Replace when eroded beyond.06"(1.5mm) Depth.

    SECTION 3 OPErATION

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    33/70

    33

    POWERCUT-1250 / 1500

    MECHANIZED PLASMARC CUTTING PACKAGE

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    34/70

    34

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    35/70

    35

    1.0 gENErAL

    The Powercut1250 / 1500 is a compact, completely selcontained plasma cutting system. The system is shipped with the PT21AMX mechanized torch. Torchmust be wired to the console beore operation. See section 2.6.1. The system isready to cut ater connections are made to the torch, input power and a sourceo compressed air (90150 psi / 6.2 to 10.3 bar). The mechanized Powercut package uses the PT21AMX mechanized plasma torch to deliver cutting power orsevering materials up to 11/2 inch (38.1mm) thick on the PC1250 and 13/4inch (45mm) thick on PC1500. Reer to the ollowing pages or descriptions othe Powercut packages available as well as perormance specications.

    1.1 SCOPE

    The purpose o this manual is to provide the operator with all the inormationrequired to install and operate the Powercut plasma arc cutting package. Technical reerence material is also provided to assist in troubleshooting the cuttingpackage.

    Use only the ESAB PT21AMx Plasmactoch with this console. Use o toches not

    desined o use with this console couldceate an ELECTrIC SHOCK HAZArD.

    "DualVoltae" Vesion Back View

    Typical ont View

    SECTION 1 DESCrIPTION

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    36/70

    36

    The PowerCut1250 plasma cutting package combines theproven reliability o the PowerCut1250 with the newlydesigned PT21AMX torch. The PT21AMX plasma cutting

    torch is designed to provide increased perormance andlonger consumable lie resulting in higher production ratesat lower costs.

    Specifcations: PowerCut-1250Cuts 11/4 in. (32mm)1 ph. Input .................................................208/230 vac, 1 ph, 50/60 Hz, 67/61 A1 ph. Output .................................................................70 amps @ 60% duty cycle

    3 ph. Input .................................................208/230 vac, 3 ph, 50/60 Hz, 33/29 A.................................................................230/460 vac, 3 ph, 50/60 Hz, 29/20 A.................................................................................400 vac, 3 ph, 50/60 Hz, 18 A..................................................................................575 vac, 3ph, 50/60 Hz, 15 A

    3 ph. Output ..............................................................70 amps @ 100% duty cycle

    Dimensions .................................................................................W = 12.5 (318mm).....................................................................................................H = 16.5 (419mm)........................... .............................. ............................. .............. D = 31.5 (800mm)

    Weight ............................ ............................. .............................. .............. 86 lbs. (39kg)Air Requirements .............................350 ch @ 80 psig (165 l/min @ 5.5 bars)

    TorchPowerCut1250 uses the PT21AMX torch. For complete list andbreakdown o parts, reer to Figure 1.2.

    Ordering Inormation:PowerCut1250, 208/230/460 V, 25 (7.6m) PT21AMX...........0558004185PowerCut1250, 208/230/460 V, 50 (15.2m) PT21AMX ........ 0558004186PowerCut1250, 400 V, CE 25 (7.6m) PT21AMX .................... 0558004187

    PowerCut1250, 400 V, CE 50 (15.2m) PT21AMX..................0558004188PowerCut1250, 208/230/460 V, 25 (7.6m) PT21NR ..............0558005494PowerCut1250, 208/230/460 V, 50 (15.2m) PT21NR ............ 0558005495PowerCut1250, 400 V, CE 25 (7.6m) PT21NR ........................ 0558005496PowerCut1250, 400 V, CE 50 (15.2m) PT21NR ..................... 0558005497

    The components that are included in the Powercut1250 packages (Console,Torch, Spare Parts Kit, Torch Holder Assembly & Interace Cable) may bepurchased separately by using the appropriate P/N when placing orders.Individual part numbers are listed below:

    Consoles:PowerCut1250 (208)230/460 V, 50/60 Hz, 1/3ph ..................0558004189PowerCut1250 400 V, CE, 50 Hz, 3ph .........................................0558004190

    PT21AMx Toches:Without Rack; 50 t. (15.2m) ........................ .............................. ..... 0558003615With Rack; 50 t. (15.2m) ...................................................................0558003614Without Rack; 25 t.(7.6m) ................................................................0558003617With Rack; 25 t. (7.6m) ......................................................................0558003616

    Spae Pats Kits: (see section 1.2.3)PT21AMX Spare Parts Kit (50 Amp) .............................. ...... 21370 (2461001)PT21AMX Spare Parts Kit (70 Amp) .............................21369 (0558000848)

    1.2 MECHANIZED PLASMA

    1.2.1 PC-1250 MECHANIZED PLASMA

    210 (5334)

    101 (2565.4)

    39 (990.6)

    15 (381)

    7 (177.8)

    5 (127)

    PT-21AMX Cut Data-70 AMPS

    Powercut-1250, PT-21AMx, 70A Nozzle P/N 21329 (4485834)

    Air Pressure - 75-85 psi, 3/16" to 1/4 Standof

    0.125 (3.175)

    0.250 (6.35)

    0.500 (12.7)

    0.750 (19.05)

    1.000 (25.4)

    1.250 (31.75)

    190 (4826)

    85 (2159)

    30 (762)

    13 (330.2)

    5 (127)

    3 (76.2)

    NOTE: Pat numbes in paenthesis apply to"CE"/Euopean units.

    SECTION 1 DESCrIPTION

    Inches (mm) IPM (mm/min) IPM (mm/min)

    Max Speeds

    Mild Steel

    Plate Optimum Maximum

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    37/70

    37

    Specifcations: PowerCut-1500Cuts 11/2 in. (38mm)1 ph. Input .................................................208/230 vac, 1 ph, 50/60 Hz, 82/74 A1 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

    The PowerCut1500 plasma cutting package combines theproven reliability o the PowerCut1500 with the newlydesigned PT21AMX torch. The PT21AMX plasma cuttingtorch is designed to provide increased perormance and

    longer consumable lie resulting in higher production ratesat lower costs.

    PT-21AMX Cut Data-90 AMPS

    Powercut-1500, PT-21AMx, 90A Nozzle P/N 0558004269

    Air Pressure - 85 psi, 3/16" to 1/4 Standof

    TorchPowerCut1500 uses the PT21AMX torch. For complete list andbreakdown o parts, reer to Figure 1.2.

    Ordering Inormation:PowerCut1500, 230/460 V, 25 (7.6m) PT21AMX .................... 0558004191PowerCut1500, 230/460 V, 50 (15.2m) PT21AMX ................. 0558004192PowerCut1500, 400 V, CE 25 (7.6m) PT21AMX .................... 0558004193PowerCut1500, 400 V, CE 50 (15.2m) PT21AMX..................0558004194PowerCut1500, 230/460 V, 25 (7.6m) PT21NR .......................0558005490PowerCut1500, 230/460 V, 50 (15.2m) PT21NR ..................... 0558005491PowerCut1500, 400 V, CE 25 (7.6m) PT21NR ........................ 0558005492

    PowerCut1500, 400 V, CE 50 (15.2m) PT21NR ..................... 0558005493

    The components that are included in the Powercut1500 packages may bepurchased separately by using the appropriate P/N when placing orders.Individual part numbers are listed below:

    Consoles:PowerCut1500 (208)230/460 V, 50/60 Hz, 1/3ph ..................0558004195PowerCut1500 400 V, CE, 50 Hz, 3ph ............................ ............ 0558004196

    1.2.2 PC-1500 MECHANIZED PLASMA

    0.250 (6.35)

    0.500 (12.7)

    0.750 (19.05)

    1.000 (25.4)

    1.250 (31.75)

    1.500 (38.1)

    120 (3048)

    49 (1244.6)

    22 (558.8)

    12 (304.8)

    7 (177.8)

    3 (76.2)

    150 (3810)

    55 (1397)

    25 (635)

    13 (330.2)

    9 (228.6)

    5 (127)

    SECTION 1 DESCrIPTION

    Inches (mm) IPM (mm/min) IPM (mm/min)

    Max Speeds

    Mild Steel

    Plate Optimum Maximum

    NOTE: Pat numbes in paenthesis apply to"CE"/Euopean units.

    PT21AMx Toches:Without Rack; 50 t. (15.2m) ............................................................0558003615With Rack; 50 t. (15.2m) ...................................................................0558003614Without Rack; 25 t. (7.6m) ...............................................................0558003617With Rack; 25 t. (7.6m) ......................................................................0558003616

    Spae Pats Kits: (see section 1.2.3)PT21AMX Spare Parts Kit (50 Amp) ............................. ....... 21370 (2461001)PT21AMX Spare Parts Kit (70 Amp) .............................21369 (0558000848)PT21AMX Spare Parts Kit (90 Amp) ......................................................................

    ..................................................................................0558004271 (0558004277)

    ..................................................................................575 vac, 3ph, 50/60 Hz, 18 A

    3 ph. Output .................................................................90 amps @ 60% duty cycle

    Dimensions .................................................................................W = 12.5 (318mm).....................................................................................................H = 16.5 (419mm).......................... .............................. ............................. ............... D = 31.5 (800mm)

    Weight ........................... .............................. ............................. ............94 lbs. (42.7kg)Air Requirements .............................350 ch @ 80 psig (165 l/min @ 5.5 bars)

    400V CE Mains Supply .................................................. ............. Ssc min

    3.8MVA......................... .............................. ............................. ........................... Z

    max0.042

    400V CE Mains Supply, Ssc min

    Minimum short circuit power on the network in accordance withIEC61000312.

    400V CE Mains Supply, Zma

    Maximum permissible line on the network impedance in accordancewith IEC61000311.

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    38/70

    38

    Optional Accessories:Torch Holder Assembly ......................... ............................ 16V83 (0558004250)

    50 amp Spare Parts Kit ..............................................................21370 (2461001)70 amp Spare Parts Kit .......................................................21369 (0558000848)90 amp Spare Parts Kit ..........................................0558004271 (0558004277)

    CNC Cable 50' .............................................................................................57002249

    Plasma Flow Measuring KitThis valuable troubleshooting tool allows measurement o the actualplasma gas ow through the torch ........................... .... 19765 (0558000739)

    NOTE: Pat numbes in paenthesis apply to"CE"/Euopean units only.

    1.2.3 SPArE PArTS / OPTIONAL ACCESSOrIES (PC-1250 / 1500 MECHANIZED PLASMA)

    Torch Holder Assy ................................................................................0558005926

    Desciption STD P/N CE P/N Quantity

    Heat Shield (50 A) 21447 (4485832) 2Cutting Nozzle (50 A) 21330 (4485833) 5Electrode 21150 (0558001617) 5Electrode Insulator 21373 (4485837) 1Electrode Holder Assy 21332 (4485840) 1Bafe Tube 21374 (4485838) 1Pilot Arc Adaptor 19497 (4485843) 1Oring 488157 (4485841) 5Lubricant (1 oz.) 17672 (0558000443) 1Seat/Bafe Wrench 21375 (4485842) 1HexKey Wrench 93750006 (4485651) 1Tool Box 950272 (0558004270) 1

    Contents o PT-21AMX Spare Parts Kit,P/N 21370 (2461001) 50 Amp

    Desciption STD P/N CE P/N Quantity

    Heat Shield (70/90 A) 21326 (4485831) 2Heat Shield (50 A) 21447 (4485832) 1Cutting Nozzle (50 A) 21330 (4485833) 5Cutting Nozzle (70 A) 21329 (4485834) 5Electrode 21150 (0558001617) 5Electrode Insulator 21373 (4485837) 1Electrode Holder Assy 21332 (4485840) 1Bafe Tube 21374 (4485838) 1Pilot Arc Adaptor 19497 (4485843) 1Oring 488157 (4485841) 5Lubricant (1 oz.) 17672 (0558000443) 1Seat/Bafe Wrench 21375 (4485842) 1HexKey Wrench 93750006 (4485651) 1Tool Box 950272 (0558004270) 1

    Contents o PT-21AMX Spare Parts Kit,

    P/N 21369 (0558000848) 70 Amp

    Desciption STD P/N CE P/N Quantity

    Heat Shield (70/90 A) 21326 (4485831) 2Heat Shield (50 A) 21447 (4485832) 1Cutting Nozzle (50 A) 21330 (4485833) 5Cutting Nozzle (70 A) 21329 (4485834) 5Cutting Nozzle (90 A) 0558004269 5Electrode 21150 (0558001617) 5Electrode Insulator 21373 (4485837) 1Electrode Holder Assy 21332 (4485840) 1Bafe Tube 21374 (4485838) 1Pilot Arc Adaptor 19497 (4485843) 1Oring 488157 (4485841) 5Lubricant (1 oz.) 17672 (0558000443) 1Seat/Bafe Wrench 21375 (4485842) 1HexKey Wrench 93750006 (4485651) 1Tool Box 950272 (0558004270) 1

    Contents o PT-21AMX Spare Parts Kit,

    P/N 0558004271 (0558004277) 90 Amp

    Remote Hand Control Switch with 25 t. (7.6m)lead or PT21AMX .........................................................................0558003612

    Plasma Flow Measuring Kit ..............................................19765 (0558000739)

    SECTION 1 DESCrIPTION

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    39/70

    39

    Heat Shield70/90 amp 21326 (4485831)30/50 amp 21447 (4485832)

    Bafe Tube 21374 (4485838)

    Electrode Adaptor Assembly 21332 (4485840)

    Insulator 21373 (4485837)

    Electrode 21150 (0558004262)

    Torch Body Assembly 21359 (4485850)

    ORing 488157 (4485841)

    Cutting Nozzle (see appropriatespare parts kit or p/n)

    iue 12. PT21AMx Toch

    Cuttin Paametes o the PT21AMx Toch90AMP Data, Nozzle P/N 0558004269,

    Heat Shield P/N 21326 4485831

    NR indicates piercing is not recommended

    Pierce

    Time

    Metal

    Thickness

    6

    13

    19

    25

    32

    38

    Air

    Pressure

    psig

    Stand-Of

    in. mm

    Arc

    Voltage

    DC Volts seconds

    0.25

    0.50

    0.75

    1.00

    1.25

    1.50

    barmmin.85

    85

    85

    85

    85

    85

    5

    5

    5

    6

    6

    6

    .188

    .188

    .188

    .250

    .250

    .250

    6

    6

    6

    6

    6

    6

    Optimum

    Mild Steel Aluminum Stainless

    Maximum

    Travel Speed

    ipm (mm/min) ipm (mm/min)OptimumMaximum

    ipm (mm/min) ipm (mm/min)OptimumMaximum

    ipm (mm/min) ipm (mm/min

    110

    120

    125

    130

    140

    145

    0.1

    0.3

    1.0

    2.75

    NR

    NR

    Metal

    Thickness

    6

    13

    19

    25

    32

    38

    0.25

    0.50

    0.75

    1.00

    1.25

    1.50

    mmin. 15055

    25

    13

    9

    5

    3810

    1397

    635

    330.2

    228.6

    127

    120

    49

    22

    12

    7

    3

    3175

    1549.4

    889

    508

    330.2

    254

    3048

    1244.6

    558.8

    304.8

    177.8

    76.2

    105

    51

    31

    15

    10

    7

    125

    61

    35

    20

    13

    10

    2667

    1295.4

    787.4

    381

    254

    177.8

    88

    37

    15

    10

    7

    3

    2235.2

    939.8

    381

    254

    177.8

    76.2

    80

    31

    13

    8

    5

    3

    2032

    787.4

    330.2

    203.2

    127

    76.2

    (NOTE: Pat numbes in paenthesisapply to "CE"/Euopean units only.

    SECTION 1 DESCrIPTION

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    40/70

    40

    Cuttin Paametes o the PT21AMx Toch

    Pierce

    Time

    Metal

    Thickness

    3

    6

    13

    19

    25

    32

    Air

    Pressure

    psig

    Stand-Of

    in. mm

    Arc

    Voltage

    DC Volts seconds.125

    .250

    .500

    .750

    1.000

    1.250

    barmmin.75

    75

    85

    85

    85

    85

    5

    5

    5

    5

    6

    6

    .188

    .188

    .188

    .188

    .250

    .250

    5

    5

    6

    6

    6

    6

    Optimum

    Mild Steel Aluminum Stainless

    Maximum

    Travel Speed

    ipm (mm/min) ipm (mm/min)

    OptimumMaximum

    ipm (mm/min) ipm (mm/min)

    OptimumMaximum

    ipm (mm/min) ipm (mm/min

    105

    110

    115

    125

    135

    150

    0.1

    0.2

    0.6

    2.3

    NR

    NR

    Metal

    Thickness

    mmin.210

    101

    39

    15

    7

    5

    5334

    2565.4

    990.6

    381

    177.8

    127

    190

    85

    30

    13

    5

    3

    5207

    2540

    990.6

    635

    304.8

    228.6

    4826

    2159

    762

    330.2

    127

    76.2

    185

    90

    31

    20

    9

    5

    205

    100

    39

    25

    12

    9

    4699

    2286

    787.4

    508

    228.6

    127

    91

    61

    23

    12

    7

    3

    2311.4

    1549.4

    584.2

    304.8

    177.8

    76.2

    80

    55

    20

    9

    6

    3

    2032

    1397

    508

    228.6

    152.4

    76.2

    NR indicates piercing is not recommended

    PierceTime

    MetalThickness

    2

    3

    5

    6

    10

    13

    AirPressure

    psig

    Stand-Of

    in. mm

    ArcVoltage

    DC Volts seconds

    0.063

    0.125

    0.188

    0.250

    0.375

    0.500

    barmmin.75

    75

    85

    85

    85

    85

    3

    3

    3

    5

    5

    5

    .125

    .125

    .125

    .188

    .188

    .188

    5

    5

    6

    6

    6

    6

    Optimum

    Mild Steel Aluminum Stainless

    Maximum

    Travel Speed

    ipm (mm/min) ipm (mm/min)OptimumMaximum

    ipm (mm/min) ipm (mm/min)OptimumMaximum

    ipm (mm/min) ipm (mm/min

    110

    110

    110

    120

    125

    135

    0

    0.1

    0.2

    0.4

    0.6 / NR

    0.8 / NR

    MetalThickness

    mmin.170

    112

    111

    71

    43

    21

    4318

    2844.8

    2819.4

    1803.4

    1092.2

    533.4

    155

    100

    102

    66

    40

    18

    4089.4

    3581.4

    2667

    2108.2

    939.8

    330.2

    3937

    2540

    2590.8

    1676.4

    1016

    457.2

    150

    110

    93

    77

    31

    9

    161

    141

    105

    83

    37

    13

    3810

    2794

    2362.2

    1955.8

    787.4

    228.6

    141

    79

    57

    37

    15

    11

    3581.4

    2006.6

    1447.8

    939.8

    381

    279.4

    130

    75

    50

    30

    10

    8

    330.2

    1905

    1270

    762

    254

    203.2

    70AMP Data, Nozzle P/N 21329 4485834, Heat Shield P/N 21326 4485831

    40/50AMP Data, Nozzle P/N 21330 4485833, Heat Shield P/N 21447 4485832

    .125

    .250

    .500

    .750

    1.000

    1.250

    3

    6

    13

    19

    25

    32

    ArcCurrent

    amps

    40

    40

    50

    50

    50

    50

    2

    3

    5

    6

    10

    13

    0.063

    0.125

    0.188

    0.250

    0.375

    0.500

    NR indicates piercing is not recommended

    NOTE: Pat numbes in paenthesis apply to "CE"/Euopean units only.

    SECTION 1 DESCrIPTION

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    41/70

    41

    2.1 gENErAL

    Proper installation is important or satisactory and troubleree operation othe PowerCut cutting package. It is suggested that each step in this section bestudied careully and ollowed closely.

    2.2 EQUIPMENT rEQUIrED

    A source o clean, dry air that supplies 350 ch at 80 psig (165.1 i/m @ 5.5 bars)is required or the cutting operation. The air supply should not exceed 150 psig(10.3 bars) (the maximum inlet pressure rating o the air lterregulator suppliedwith the package).

    2.3 LOCATION

    Adequate ventilation is necessary to provide proper cooling o the PowerCut.The amount o dirt, dust, and excessive heat to which the equipment is exposed,should be minimized. There should be at least one oot o clearance betweenthe PowerCut power source and wall or any other obstruction to allow reedomo air movement through the power source.

    2.4 INSPECTION

    A. Remove the shipping container and all packing material and inspect orevidence o concealed damage which may not have been apparent uponreceipt o the PowerCut. Notiy the carrier o any deects or damage atonce.

    B. Check container or any loose parts prior to disposing o shipping materials.

    C. Check air louvers and any other openings to ensure that any obstructionis removed.

    Installin o placin any type o lteindevice will estict the volume o intakeai, theeby subjectin the powe souceintenal components to oveheatin.The waanty is void i any type o ltedevice is used.

    2.0 INSTALLATION - MECHANIZED PLASMA CUTTINgPACKAgE

    SECTION 2 INSTALLATION

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    42/70

    42

    ELECTrIC SHOCK CAN KILL! Pecautionay measues should be taken to povidemaimum potection aainst electical

    shock. Be sue that all powe is o byopenin the line wall disconnect switchand by unpluin the powe cod to theunit when connections ae made inside othe powe souce.

    2.5 PrIMArY ELECTrICAL INPUT CONNECTIONS -MECHANIZED PLASMA CUTTINg PACKAgE

    The PowerCut1250 / 1500 consoles are equipped with approximately 10t. o4conductor input power cable or 3phase connection. I singlephase connectionis desired, tape back the red (lt. blue) wire on the input power cable. Connect the

    singlephase input to the white and black wires only. When operating this machinerom a singlephase source, it must be connected to a dedicated 100 Amp eed.Due to the higher input current requirements, the duty cycle o the machine islower than in threephase operation.

    Connect your air supply to the inlet connection o the lterregulator.

    CUSTOMER FUSED LINE DISCONNECT SWITCH(See Table 2.3 and WARNING in regards to

    chassis ground in Section 2.5.)

    PRIMARY INPUTPOWER CABLE

    Preltered DRY AIR SUPPLY (Customer Supplied)(90 to 150 psig max)(6.2 to 10.3 bars max)

    NUMBER PIN CONNECTION8 H Voltage Divider ()3 C Voltage Divider (+)9 I Arc On signal rom PS7 G to CNC, Relay Closing

    14 N Start signal rom CNC13 M to PS, Relay Closing

    P/N 57002249

    iue 21. Input Connections

    Red (Lt Blue) NOT USED ON SINGLE PHASE

    White (Brown)

    Black (Black)

    Green (Yellow/Green)

    To CNC machineH

    IgN

    M

    C

    SECTION 2 INSTALLATION

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    43/70

    43

    Beoe makin any connections to thepowe souce output teminals, makesue that all pimay input powe to thepowe souce is deeneized o at the

    main disconnect switch and that the inputpowe cable is unplued.

    ELECTrIC SHOCK CAN KILL! Beoe makin

    electical input connections to the powe

    souce, "Machiney Lockout Pocedues"

    should be employed. I the connectionsae to be made om a line disconnect

    switch, place the switch in the o position

    and padlock it to pevent inadvetent

    tippin . I the connection is made om

    a usebo, emove the coespondin

    uses and padlock the bo cove. I it is

    not possible to use padlocks, attach a

    ed ta to the line disconnect switch o

    use bo wanin othes that the cicuit

    is bein woked on.

    The chassis must be connected to an appoved electical ound. ailue to doso may esult in electical shock, seveebuns o death.

    Beore connecting to input power, make sure there is a line (wall) disconnectswitch with uses or circuit breakers at the main power panel. You may either usethe actoryinstalled input power cable (4/c, type SO (90 C), 10 t (3.1 m) length)or provide your own input power leads. I you choose to provide your own, makesure they are insulated copper conductors. You must have two (singlephase) or

    three (threephase) power leads and one ground wire. The wires may be heavyrubber covered cable or may be run in a solid or exible conduit. Reer to Table23 and 24 or recommended input conductors and line use sizes.

    Table 23. PC1250 recommended Sizeso Input Conductos and Line uses

    Input requiements Input & gnd use

    Volts Phase Amps Conducto Size

    CU/AWg Amps

    208 1 67A 6 100208 3 33A/Ph. 6 50

    230 1 61A 6 100230 3 29A/Ph. 6 50460 3 20 6 50400 3 18 6mm2 50575 3 15 10 25

    Table 24. PC1500 recommended Sizeso Input Conductos and Line uses

    Input requiements Input & gnd use

    Volts Phase Amps Conducto Size

    CU/AWg Amps

    208 1 82A 6 100

    208 3 44A/Ph. 6 80230 1 74A 6 100230 3 40A/Ph. 6 80460 3 27 6 50400 3 24 6mm 50575 3 18 10 50

    SECTION 2 INSTALLATION

    NOTE !!!400V CE Mains Supply requiements:High power equipment may, due to the primary current drawn rom the mains supply, inuence the power quality o the grid. Thereore connection restrictions or requirements regarding the maximum permissible mains impedance or the required minimum supply capacity at the interace point to the public gridmay apply or some types o equipment (see technical data). In this case it is the responsibility o theinstaller or user o the equipment to ensure, by consultation with the distribution network operator inecessary, that the equipment may be connected.

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    44/70

    44

    2.5.1 INPUT VOLTAgE CHANgEOVEr DUALVOLTAgE UNITS ONLY

    208 230 o 460 ModeTo simpliy the use o the ESAB Powercut1250 / 1500 with dierent input voltages,it has been equipped with a convenient 230/460 selector switch located on the back

    panel o the unit. Switching between 230 and 460 voltages can be done by usinga athead screwdriver to turn the selector screw.

    The Powercut is also equipped with protective use that will prevent damage tothe power source in the event that the input voltage switch is not set correctly andthe unit is powered on.

    A line (wall) disconnect switch with uses or circuit breakers should be provided atthe main power panel (see Table 21 / 22 or use sizes). Theinput power cable o the console may be connected directly to the disconnect switchor you may purchase a proper plug and receptacle rom a local electrical supplier.I using plug/receptacle combination, see Table 21 / 22 or recommended inputconductors or connecting receptacle to line disconnect switch.

    Fuse*

    Input VoltageSelector Switch

    SECTION 2 INSTALLATION

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    45/70

    45

    2.6 SECONDArY OUTPUT CONNECTIONS Or MECHANIZED CUTTINg

    Clamp the work cable to theworkpiece. Be sure the workpieceis connected to an approved earthground with a properly sizedground cable.

    iue 24. PoweCut Inteconnection Diaam

    2.6.1 MECHANIZED TOrCH INSTALLATION

    Use the ollowing procedures to install the PT21AMX torch.

    A. Remove torch connection cover rom ront panel. Cover is held in placeby two screws. I strain relie connector is present, remove beore connecting the PT21AMX torch.

    SAFETY GROUND

    PT21 AMX

    TORCH CABLE

    Strain Relie Connector

    Torch Connection Cover

    SECTION 2 INSTALLATION

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    46/70

    46

    B. Remove nut on torch cable assembly.

    Nut

    C. Insert torch cable assembly through opening in cover.

    D. Reattach cable nut and tighten.

    E. Pull an adequate amount o hose through the cover to allow ease o hoseconnections.

    F. Attach hoses and tighten.

    G. Slide cover back into place and tighten screws.

    SECTION 2 INSTALLATION

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    47/70

    47

    3.0 OPErATION

    3.1 PoweCut1250 / 1500 CONTrOLS

    NOTE: See Section 3.1.C, o complete opeation instuctions

    Trigger Lock Switch

    TrIggErLOCK

    UNLOCK

    AutoRestrike "on" (Grate cutting)

    AutoRestrike "o" (Standard cutting)

    NOTE: Tie Lock Switch.

    Mechanized Opeation usin the PT21AMx toch In mechanized opeationthe Tie Lock unction disabled. Instead, the switch unctions as an "Autorestike" selecto. To tun Autorestike"on" ate cuttin, place the switch in theup position. To tun Autorestike "o",place the switch in the down position.

    SECTION 3 OPErATION

  • 7/14/2019 Powercut-1250_1500_Manual & Mechanized Plas Cut Pack_0558004285_Apr09

    48/70

    48

    3.2 PT-21AMx TOrCH USED WITH MECHANIZEDPLASMA ONLY

    1. The seat comes assembled to the ront end o the torch. I the seat becomesdamaged, the torch body must be replaced. DO NOT attempt to remove the

    seat rom torch body.

    2. Electrode holder assembly p/n 21332 (4485840) includes the bafe tube p/n21374 (4485838). I bafe tube becomes damaged, it can be replaced by unthreading the d