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37

TORCH SWITCH

OPEN

CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH

CLOSE

FAULT OVERLOAD LIGHT

HF CIRCUIT

PILOT ARC

INVERTER

CUTTING ARC (CURRENT)

5.4 SEQUENCE OF OPERATION

A. TRIGGER LOCK “UNLOCK” position

PUSH

RELEASE

ENERGIZE

NOTES:

1.

When the torch switch is pushed during postflow period, the postflow and preflow times are canceled, and the
HF is energized immediately.

2.

When the red fault light comes on, cutting operation should be stopped. The postflow time starts from the
moment the torch switch is released.

20 SEC

Postflow

OPEN

2 SEC.

SECTION 5

TROUBLESHOOTING

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Summary of Contents for POWERCUT-1250

Page 1: ...POWERCUT 1250 1500 PLASMARC CUTTING PACKAGE 0558004106 Instruction Manual ...

Page 2: ...onformity with the description thereof contained in this manual and accompanying labels and or inserts when installed operated maintained and repaired in accordance with the instructions provided This equipment must be checked periodically Malfunctioning or poorly maintained equipment should not be used Parts that are broken missing worn distorted or contaminated should be replaced immediately Sho...

Page 3: ... SECTION 3 OPERATION 19 3 1 Operation 19 3 2 PowerCut 1250 1500 Controls 19 3 3 Cutting with the PT 32EH 21 3 4 Possible Cutting Issues 24 3 5 Common Cutting Problems 25 SECTION 4 MAINTENANCE 27 4 1 General 27 4 2 Inspection and Cleaning 27 4 3 PT 32EH Torch Consumable Parts 27 4 4 IGBT Handling Replacement 28 SECTION 5 TROUBLESHOOTING 31 5 1 Troubleshooting 31 5 2 Troubleshooting Guide 32 5 3 Ref...

Page 4: ...4 TABLE OF CONTENTS ...

Page 5: ...substances on the workpiece which might produce flammable or toxic vapors Do not do hot work on closed containers They may explode 4 Have fire extinguishing equipment handy for instant use such as a garden hose water pail sand bucket or portable fire extinguisher Be sure you are trained in its use 10 98 5 Do not use equipment beyond its ratings For example overloaded welding cable can overheat and...

Page 6: ...trike an arc on a cylinder 5 For additional information refer to CGA Standard P 1 Precautions for Safe Handling of Compressed Gases in Cylinders which is available from Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 EQUIPMENT MAINTENANCE Faulty or improperly maintained equipment can cause injury or death Therefore 1 Always have qualified personnel perform the installa t...

Page 7: ... a la mano equipo extintor de fuego para uso instantáneo como por ejemplo una manguera con agua cubeta con agua cubeta con arena o extintor portátil Asegúrese que usted esta entrenado para su uso 5 No use el equipo fuera de su rango de operación Por ejemplo el calor causado por cable sobrecarga en los cables de soldar pueden ocasionar un fuego 6 Después de termirar la operación del equipo inspecci...

Page 8: ...or no está conectado Asegure y mueva los cilindros utilizando un carro o transporte adecuado Evite el manejo brusco de los cilindros 4 Localize los cilindros lejos del calor chispas y flamas Nunca establezca un arco en el cilindro Las siguientes publicaciones disponibles através de la American Welding Society 550 N W LeJuene Road Mi ami FL 33126 son recomendadas para usted 1 ANSI ASC Z49 1 Safety ...

Page 9: ...loigné de la zone de travail augmente en effet le risque de pas sage d un courant de sortie par des chaînes delevage AVERTISSEMENT Ces règles de sécurité ont pour objet d assurer votre protection Veillez à lire et à observer les précautions énoncées ci dessous avant de monter l équipement ou de commercer à l utiliser Tout défaut d observation de ces précautions risque d entraîner des blessures gra...

Page 10: ...en matière de ventilation indiquées à l alinéa 6 de la norme Z49 1 de l AWS 5 ENTRETIEN DE L ÉQUIPEMENT Un équipement entretenu de façon défectueuse ou inadéquate risque non seulement de réaliser un travail de mauvaise qualité mais chose plus grave encore d entraîner des dommages corporels graves voire mortels en déclenchant des incendies ou des chocs électriques Observez par conséquent les précau...

Page 11: ...ance Three year warranty on console One year warranty on torch SECTION 1 DESCRIPTION Specifications PowerCut 1250 Cuts 1 1 4 in 32mm severs 1 1 2 in 38mm 1 ph Input 208 230 vac 1 ph 50 60 Hz 67 61 A 1 ph Output 70 amps 60 duty cycle 3 ph Input 208 230 vac 3 ph 50 60 Hz 33 29 A 230 460 vac 3 ph 50 60 Hz 29 20 A 575 vac 3ph 50 60 Hz 15 A 3 ph Output 70 amps 100 duty cycle Dimensions W 12 5 318mm H 1...

Page 12: ...ity of the PowerCut 1500 with the newly designed PT 32EH torch The very strong composite case material makes the PowerCut 1500 an excellent addition to any equipment rental fleet The PT 32EH plasma cutting torch is designed to provide increased performance and longer consumable life resulting in higher production rates at lower costs Multi input voltage 208 230 460V easily changed on back of machi...

Page 13: ...x ready to go The torch is attached with parts in place primary cord is attached including plug on 230 model and the filter regulator is installed Just hook up the air power and begin cutting Optional Accessories 70 amp Spare Parts Kit 0558003508 90 amp Spare Parts Kit 0558003062 Plasma Flow Measuring Kit This valuable troubleshooting tool allows measurement of the actual plasma gas flow through t...

Page 14: ...mance specifications 1 2 SCOPE The purpose of this manual is to provide the operator with all the information required to install and operate the Powercut plasma arc cutting package Technical reference material is also provided to assist in troubleshooting the cutting package UseonlyTheESABPT 32EHPlasmarc torch with this console Use of torches not designed for use with this console could create an...

Page 15: ...y loose parts prior to disposing of shipping materials C Checkairlouversandanyotheropeningstoensurethatanyobstruction is removed 2 5 PRIMARY ELECTRICAL INPUT CONNECTIONS FIGURE 2 1 The PowerCut 1250 1500 consoles are equipped with approximately 10 ft of 4 conductor input power cable for 3 phase connection If single phase connection is desired tape back the red wire on the input power cable Connect...

Page 16: ... to prevent inadvertent tripping If the connection is made from a fusebox remove the corresponding fuses and padlock the box cover If it is not pos sible to use padlocks attach a red tag to the line disconnect switch or fuse box warning others that the circuit is being worked on The chassis must be connected to an approved electrical ground Failure to do so may result in electrical shock severe bu...

Page 17: ... REFER TO FIG 2 1 The Torch comes factory installed Connect your air supply to the inlet connection of the filter regulator Clamp the work cable to the workpiece Be sure the workpiece is connected to an approved earth ground with a properly sized ground cable FUSED DISCONNECT BOX PRIMARY INPUT POWER CABLE Figure 2 1 PowerCut Interconnection Diagram ...

Page 18: ...18 SECTION 2 INSTALLATION ...

Page 19: ...od Be sure to place switch in OPERATE position before starting cutting operations C Trigger Lock Switch When placed in LOCK position this permits releasing torch switch button after cutting arc has been initiated To extinguish arc at end of cut press and release torch switch button again or pull torch away from work When placed in UNLOCK position torch switch must be held closed by the operator du...

Page 20: ...r there has been an over current event within the system If the light blinks for 10 seconds and then stops the problem is pilot arc initiation Check the consumables in the torch If the light continues to blink and the system does not reset the fault is an over current event See troubleshooting section I Over Temperature Indicator Thisfaultlightwillblinktoindicatethatthe duty cycle has been exceede...

Page 21: ...ishing the cutting arc F After starting the cut the torch should be maintained at a 5 15 forward angle Figure 3 2 This angle is especially useful in helping to create a drop cut When not using the standoff guide the nozzle should be held approximately 1 4 inch from the work CUT DIRECTION Figure 3 2 Recommended Torch Angle of 5 to 15 IMPORTANT Maintain Proper Stand Off Distance 3 16 to 1 4 Inch Pow...

Page 22: ...utting cycle Fig 3 3 Exploded View of PT 32EH Torch ELECTRODE NOZZLE SHIELD IMPORTANT MAKE SHIELD VERY TIGHT VALVE PIN The valve pin is a crucial member of the system Its func tion is to open the gas flow check valve that is perma nently assembled within the torch head If the pin is not correctly placed in the electrode the valve will not open and the system will not function The valve pin also im...

Page 23: ... 6 4 mm 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 16 1 6 mm TO 1 4 6 4 mm TORCH TO WORK GUIDE AGAINST STRAIGHT EDGE OR FREE HAND CUT 3 3 2 INSTALLATION AND USE OF STAND OFF GUIDE ...

Page 24: ...er source may occur Nozzle life is also greatly reduced when using the electrode below the recom mended limit REPLACE ELECTRODE BEFORE PITTING BECOMES DEEPER THAN 06 INCH 1 5 MM Replace when eroded beyond 06 1 5mm Depth NEW WORN 3 3 1 Drag Cutting with the PT 32EH Torch PowerCut package LOW CURRENT AUTO DRAG FEATURE If drag cutting is desired for thin material under 3 8 thick remove the standard 7...

Page 25: ...es it may be impossible to get dross free cuts 1 Current too low 2 Cutting speed too fast or too slow 3 Improper air pressure 4 Faulty nozzle or electrode 5 Low air flow rate D Double Arcing Damaged Nozzle Orifice 1 Low air pressure 2 Damaged cutting nozzle 3 Loose cutting nozzle 4 Heavy spatter accumulation on nozzle E Uneven Arc 1 Damaged cutting nozzle or worn electrode F Unstable Cutting Condi...

Page 26: ...26 SECTION 3 OPERATION ...

Page 27: ...ear on a daily basis Remove spatter or replace if necessary E Make sure cable and hoses are not damaged or kinked F Make sure all plugs fittings and ground connections are tight G With all input power disconnected and wearing proper eye and face protection blow out the inside of the Powercut using low pressure dry compressed air Water or oil occasionally accumulates in compressed air lines Be sure...

Page 28: ...er connected to the system Use soldering irons with grounded tips when soldering to gate termi nals When mounting IGBT modules on a heatsink certain precautions should be taken to prevent any damage against a sudden torque If a sudden torque one sided tightening is applied at only one mounting terminal the ceramic insulation plate or silicon chip inside the module may get dam aged The mounting scr...

Page 29: ...oint Mounting Type Temporary tightening cÎd Final tightening dÎc Four Point Mounting Type Temporary tightening cÎdÎeÎf Final tightening fÎeÎdÎc c c d e Figure 4 2 Screw Fastening Order d f SECTION 4 MAINTENANCE ...

Page 30: ...30 SECTION 4 MAINTENANCE ...

Page 31: ...components and wiring Check for secure terminal connections loose or burned wiring or components bulged or leaking capacitors or any other sign of damage or discoloration The cause of control malfunctions can be found by referring to the sequence of operations and electrical schematic diagram Figure 5 1 and checking the various components A volt ohmmeter will be necessary for some of these checks ...

Page 32: ...en if leaking 3 Does air flow when air test switch is in test position a If not check torch consumables replace if necessary b If above items check OK the problem is internal Take unit to an Authorized Repair Station for repair C The Power light is on but nothing happens when the torch switch is depressed Fault light does not activate NOTE Unplug high frequency connection before attempting to work...

Page 33: ...tch to On position Air should flow through torch If not and air pressure is set at required 80 PSIG check gas Solenoid SOL1 for proper operation d Air Check switch may also be malfunctioning if the air is flowing continuously or putting in the On position does not turn air on 3 Over Temperature indicator The fault light will blink to indicate that the machine has overheated This generally indicate...

Page 34: ...nt then any one of the following may not be working properly a Check the operation of the Thermal Switch TS1 See D 3 a above b Check Air Check switch operation It might be stuck in On position Pilot arc will not initiate if this switch is in the ON position safety reasons c Check air flow switch There may be internal short See D 2 c above d Measure voltage across C5 or C6 capacitor It should be as...

Page 35: ...top when the torch switch is unplugged If yes check and repair the torch If not send unit to an Authorized Repair Station for repair a Check voltage to solenoid coil if present when torch switch is unplugged replace PCB1 If voltage is 0 replace solenoid valve I Main arc is difficult to start 1 The most common reason is worn or missing consumables Check and replace if necessary See Section 3 3 1 2 ...

Page 36: ... Relay LED D1 Gas Solenoid Valve 2 Voltage Test Points Tests are made with power on no arc Disable High Frequency by disconnecting blue wire with black sleeve TP 1 Torch trigger signal TP 4 IGBT s driving signal switching frequency 18 5 KHz TP 5 IGBT s driving signal switching frequency 18 5 KHz TP 7 5 vdc TP 8 15 vdc TP 9 15 vdc TP 10 Ground 54 µs 13vdc 13vdc 0 ...

Page 37: ...LOCK UNLOCK position PUSH RELEASE ENERGIZE NOTES 1 When the torch switch is pushed during postflow period the postflow and preflow times are canceled and the HF is energized immediately 2 When the red fault light comes on cutting operation should be stopped The postflow time starts from the moment the torch switch is released 20 SEC Postflow OPEN 2 SEC SECTION 5 TROUBLESHOOTING ...

Page 38: ...on ENERGIZE NOTES 1 When the torch switch is pushed during postflow period the postflow time isreset thepreflowtimeiscanceled andtheHFisenergizedimmediately 2 When the red fault light comes on cutting operation should be stopped The postflow time starts from the moment the torch switch is released 3 FAULTlightisonduringsecond turn off triggeronly Thisdoesnotaffect performance in any way PREFLOW 2 ...

Page 39: ...39 Powercut 1250 1500 Schematic Diagram D 0558003510 A ...

Page 40: ...40 SECTION 5 TROUBLESHOOTING ...

Page 41: ...used with this equipment The use of non ESAB parts may void your warranty Replacement parts may be ordered from your ESAB distributor or from ESAB Welding Cutting Products Attn Customer Service Dept P O Box 100545 411 S Ebenezer Road Florence SC 29501 0545 Be sure to indicate any special shipping instructions when ordering replace ment parts To order parts by phone contact ESAB at 1 843 664 5540 O...

Page 42: ...558001818 Knob 1 37 Diam 4 1 0558003390M Panel Front Silkscreen PC 1250 1 0558003391M Panel Front Silkscreen PC 1500 5 1 0558003001 Work Cable 6 AWG 6 1 13733935 Panel Receptacle 7 2 0558002780 Foot Plasma Tube 8 1 0558002581 Strain Relief Input NPT 9 1 0558001916 Plasma Tube End Cover 1 2 3 3 4 6 5 7 8 9 Front View Powercut 1250 1500 ...

Page 43: ...0 160 PSI WHT CB 3 1 0558002446 Switch 40A S2 4 1 0558003075 Fuse 2A 600VAC F1 5 1 97W63 Connector Cable Grip 6 1 0558003002 Cable Input Power 10Ft 7 1 951182 Fan 230V 50 60 Hz 233CFM M1 8 1 0558002994 Finger Guard 1 5MM 06 IN SECTION 6 REPLACEMENT PARTS 1 Rear View Powercut 1250 1500 2 3 4 5 6 7 8 ...

Page 44: ...20 OHMS R12 15 3 2 951185 Diode Module FDS 100A 600V D7 D8 4 2 0558003367 Transducer Current 100A T5 T7 5 1 0558002576 Relay SPST 24V w MAG K2 6 1 952233 Inductor Output PC 1250 L2 1 0558002455 Inductor Output PC 1500 L2 7 1 0558002189 Switch Pressure 25 GPN PS1 8 1 0558002482 SOL AY 1 8 NPTF Port 3 16 BARB SOL1 9 1 0558003105 Switch Pressure High FS1 1 5 6 2 3 Resistors Hidden by Bar 4 7 8 9 ...

Page 45: ... RES WW AHNI 50W 3 K 10 OHM R6 R7 4 4 951161 CAPC Metpoly 20 0 UF 400VDC C11 C14 5 1 38240 PCB Power PCB5 6 1 38229 PCB HI Freq PCB2 7 1 952232 Input Inductor PC 1250 L1 1 0558002438 Input Inductor PC 1500 L1 8 1 0558002449 Transformer Hi Freq T8 9 1 38224 PCB IGBT Driver PCB7 10 2 0558003106 Cap 2000 UF 450VDC PC 1250 C5 C6 2 0558002435 Cap 3100 UF 450VDC PC 1500 C5 C6 1 2 3 Behind Bar 4 5 10 Ass...

Page 46: ...k PCB6 2 1 38238 PCB Display PCB3 3 1 38237 PCB Control PCB1 4 1 38242 PCB In Rush Control PCB4 5 1 950710 Switch Thermal 131 F TS2 6 1 952938 Relay SS 660V 10A Q4 7 1 0558003389 Transformer Control T6 Upper Left Side Internal View Powercut 1250 1500 SECTION 6 REPLACEMENT PARTS 7 6 ...

Page 47: ...47 ...

Page 48: ...452 Part Numbers Technical Applications Hours 8 00 AM to 5 00 PM EST Performance Features Technical Specifications EquipmentRecommendations D LITERATURE REQUESTS Telephone 843 664 5562 Fax 843 664 5548 Hours 7 30 AM to 4 00 PM EST E WELDING EQUIPMENT REPAIRS Telephone 843 664 4487 Fax 843 664 5557 Repair Estimates Repair Status Hours 7 30 AM to 3 30 PM EST F WELDING EQUIPMENT TRAINING Telephone 84...

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