ESAB POWERCUT-1250 Installation, Operation And Service Manual Download Page 1

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POWERCUT-1250 / 1500

MANUAL & MECHANIZED PLASMARC CUTTING PACKAGE

0558004232

Installation, Operation and Service Manual (GB)

This manual provides complete instructions for MANUAL CONSOLES starting with Serial Number PxxJ245xxx, May 2003:

This manual provides complete instructions for MECHANIZED CONSOLES starting with Serial Number PxxJ316xxx, May 2003:

Summary of Contents for POWERCUT-1250

Page 1: ...2 Installation Operation and Service Manual GB This manual provides complete instructions for MANUAL CONSOLES starting with Serial Number PxxJ245xxx May 2003 This manual provides complete instructions for MECHANIZED CONSOLES starting with Serial Number PxxJ316xxx May 2003 ...

Page 2: ...s from improper use faulty maintenance damage improper repair or alteration by anyone other than the manufacturer or a ser vice facility designated by the manufacturer Be sure this information reaches the operator You can get extra copies through your supplier These INSTRUCTIONS are for experienced operators If you are not fully familiar with the principles of operation and safe practices for arc ...

Page 3: ...203 3 2 PT 32EH Torches used with Manual Plasma Only 205 3 3 PT 32EH Possible Cutting Issues 210 POWERCUT 1250 1500 MECHANIZED PLASMARC CUTTING PACKAGE SECTION 1 DESCRIPTION 213 1 0 General 213 1 1 Scope 213 1 2 Mechanized Plasma 214 SECTION 2 INSTALLATION 219 2 0 Installation Mechanized Plasma Cutting Packages 219 2 1 General 219 2 2 Equipment Required 219 2 3 Location 219 2 4 Inspection 219 2 5 ...

Page 4: ...ction and Cleaning 355 4 2 Common Cutting Problems 356 4 3 IGBT Handling Replacement 357 SECTION 5 TROUBLESHOOTING 367 5 0 Troubleshooting 359 5 1 Troubleshooting Guide 360 5 2 Reference Voltage Checks 364 5 3 Sequence of Operation 365 SECTION 6 REPLACEMENT PARTS 379 TABLE OF CONTENTS ...

Page 5: ...S Sparks spatter can cause fire Make sure therefore that there are no inflammable materials nearby NOISE Excessive noise can damage hearing S Protect your ears Use earmuffs or other hearing protection S Warn bystanders of the risk MALFUNCTION Call for expert assistance in the event of malfunction PROTECT YOURSELF AND OTHERS WARNING Read and understand the instruction manual before installing or op...

Page 6: ...our head out of the fumes Use ventilation extraction at the arc or both to take fumes and gases away from your breathing zone and the general area ARC RAYS Can injure eyes and burn skin Protect your eyes and body Use the correct welding plasma cutting screen and filter lens and wear protective clothing Protect bystanders with suitable screens or curtains FIRE HAZARD Sparks spatter can cause fire M...

Page 7: ...191 POWERCUT 1250 1500 MANUAL PLASMARC CUTTING PACKAGE ...

Page 8: ...192 ...

Page 9: ...h 45mm thick on the PC 1500 Refer to the following pages for descriptions of the Powercut packages available as well as performance specifications 1 1 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 Tech nical reference material is also provided to assist in troubleshooting the cutting pack...

Page 10: ...575 V 50 15 2m PT 32EH 0558001940 PowerCut 1250 400 V CE 25 7 6m PT 32EH 0558001936 PowerCut 1250 400 V CE 50 15 2m PT 32EH 0558001937 PowerCut 1250 460 V 25 7 6m PT 32EH 0558005332 PowerCut 1250 460 V 50 15 2m PT 32EH 0558005333 ThecomponentsthatareincludedinthePowercut 1250packages Console Torch SparePartsKit maybepurchasedseparatelybyusingtheappropriate P N when placing orders Individual part n...

Page 11: ...owerCut 1500 208 230 460 V 50 60 Hz 1 3 ph BL 0558003517 PowerCut 1500 575 V 50 60 Hz 3 ph 0558001950 PowerCut 1500 400 V CE 50 Hz 3 ph 0558001947 PowerCut 1500 460 V 50 60 Hz 3 ph 0558005900 PowerCut 1500 400 V 50 Hz 3 ph 0558007826 The PowerCut 1500 plasma cutting package combines the proven reliability of the PowerCut 1500 with the newly designed PT 32EH torch The very strong composite case mat...

Page 12: ...00vdc 0558001379 1 Stand off Guide 0558002393 1 Wrench 19129 0558000808 1 Lubricant 17672 0558000443 1 Contents of PT 32EH Spare Parts Kit 90 amp P N 0558003062 The PowerCut 1500 comes out of the box ready to go The torch is attached with parts in place primary cord is attached and the filter regulator is installed Just hook up the air power and begin cutting 1 2 3 SPARE PARTS OPTIONAL ACCESSORIES...

Page 13: ...mp Drag Nozzle 0558002908 Gouging Nozzle 0558003089 Heat Shield Gouging 0558003090 Drag Heat Shield Standard 0558003374 Drag Heat Shield Heavy Duty 0558004206 Wheel Kit For easy transport of system 0558003060 Torch Wrap This enables operator to store spare parts kit wrap torch and work cable for easy transport and storage 0558003059 NOTE Part numbers in parenthesis apply to CE European units only ...

Page 14: ...198 section 1 description ...

Page 15: ...ized There should be at least one foot of clearance between the PowerCut power source and wall or any other obstruction to allow freedom of air movement through the power source 2 4 Inspection A Remove the shipping container and all packing material and inspect for evidence of concealed damage which may not have been apparent upon receipt of the PowerCut Notify the carrier of any defects or damage...

Page 16: ...er cable Connect the single phaseinputtothewhiteandblackwiresonly Whenoperatingthismachine from a single phase source it must be connected to a dedicated 100 Amp feed Due to the higher input current requirements the duty cycle of the machine is lower than in three phase operation Single phase duty cycle is 60 for PC 1250 and 40 for PC 1500 Connect your air supply to the inlet connection of the fil...

Page 17: ...hat all primary input power to the power source is deenergized off at the maindisconnectswitchandthattheinput power cable is unplugged ELECTRICSHOCKCANKILL Beforemaking electrical input connections to the power source Machinery Lockout Procedures should be employed If the connections are to be made from a line disconnect switch placetheswitchintheoffposition and padlock it to prevent inadvertent t...

Page 18: ... Manual Cutting The torch comes factory installed Clamp the work cable to the workpiece Be sure the workpiece is connected to an approved earth ground with a properly sized ground cable Figure 2 2 PowerCut Interconnection Diagram PT 32EH section 2 installation ...

Page 19: ... LOCK position this permits releasing torch switch button after cutting arc has been initiated To extinguish arc at end of cut press and release torch switch button again or pull torch away from work When placed in UNLOCK position torch switch must be held closed by the operator during the entire cutting operation and then released at the end of cut 2 MechanizedOperation using the PT 21AMX torch I...

Page 20: ...ailed to initiate a pilot arc after a number of attempts or there has been an over current event within the system If the light blinks for 10 seconds and then stops the problem is pilot arc initiation Check the consumables in the torch If the light continues to blink and the system does not reset the fault is an over current event See troubleshooting section I Over Temperature Indicator This fault...

Page 21: ...zzle If the PT 32EH s stand off guide P N 0558002393 is being used the distance between Electrode and Work Piece will be approx 3 16 4 8 mm D Depress the torch switch Air should flow from the torch nozzle E Two seconds after depressing the torch switch the pilot arc should start The main arc should immediately follow allowing the cut to begin If using the trigger LOCK mode torch switch may be rele...

Page 22: ...e the nozzle should be held approximately 1 4 inch 6 4mm from the work G When ending a cut the torch switch should be released press and release if using trigger LOCK mode and the torch lifted off the workpiece just before the end of the cut Thisistopreventthehighfrequencyfromreignitingaftercuttingarcextinguishes and causing damage to the nozzle double arcing H For rapid re starts such as grate or...

Page 23: ...RAG CUTTING Ifdragcuttingisdesiredonmaterialsabove3 8 9 5mm thick besurethat the 70 amp 90 amp nozzle is installed in the PT 32EH torch Attach ESAB s stand off guide and operate as shown in Figure 3 3 WHEN THE ARC BREAKS THROUGH THE WORK BRING THE TORCH TO AN UPRIGHT PO SITION AND PROCEED TO CUT TO START A PIERCE TILT THE TORCH TO PREVENT MOLTEN MATERIAL FROM COM ING BACK AGAINST AND DAMAGING THE ...

Page 24: ... THIS ASSEMBLY TO THE TORCH BODY AND HAND TIGHTEN PLACETHEVALVEPININTOTHEELECTRODE AND SCREW THE ELECTRODE INTO THE TORCHHEADANDTIGHTENSECURELYWITH WRENCH 19129 3 2 3 PT 32EH TORCH PARTS INSTALLATION MANUAL PLASMA ONLY Make sure power switch on POWERCUT is in OFF position before working on the torch The PT 32EH torch head contains a gas flow check valve that acts in conjunction with the flow switc...

Page 25: ...S OVER 1 4 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 1 16 1 6 mm TO 1 4 6 4mm TORCH TO WORK IF GUIDE IS TOO TIGHT ON SHIELD OPEN SLOT WITH SCREWDRIVER IF TOO LOOSE CLOSE SLOT WITH VISE OR LARGE PLIERS GUIDE AGAINST STRAIGHT EDGE OR FREE HAND CUT section 3 operation ...

Page 26: ... 1 5mm of electrode has eroded replace the electrode If the electrodeisusedbeyondthisrecommendedwearlimit damagetothetorch andpowersourcemayoccur Nozzlelifeisalsogreatlyreducedwhenusing the electrode below the recommended limit REPLACE ELECTRODE BEFORE PITTING BECOMES DEEPER THAN 06 INCH 1 5 MM Replace when eroded beyond 06 1 5mm Depth section 3 operation ...

Page 27: ...211 POWERCUT 1250 1500 MECHANIZED PLASMARC CUTTING PACKAGE ...

Page 28: ...212 ...

Page 29: ...rials up to 1 1 2 inch 38 1mm thick on the PC 1250 and 1 3 4 inch 45mm thick on PC 1500 Refer to the following pages for descriptions of the Powercut packages available as well as performance specifications 1 1 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 Tech nical reference material is...

Page 30: ... V 50 15 2m PT 21NR 0558005495 400 V CE 25 7 6m PT 21NR 0558005496 400 V CE 50 15 2m PT 21NR 0558005497 ThecomponentsthatareincludedinthePowercut 1250packages Console Torch Spare Parts Kit Torch Holder Assembly Interface Cable may be purchased separately by using the appropriate P N when placing orders Individual part numbers are listed below Consoles PowerCut 1250 208 230 460 V 50 60 Hz 1 3 ph 05...

Page 31: ...2m PT 21AMX 0558004194 230 460 V 25 7 6m PT 21NR 0558005490 230 460 V 50 15 2m PT 21NR 0558005491 400 V CE 25 7 6m PT 21NR 0558005492 400 V CE 50 15 2m PT 21NR 0558005493 ThecomponentsthatareincludedinthePowercut 1500packagesmaybe purchased separately by using the appropriate P N when placing orders Individual part numbers are listed below Consoles PowerCut 1500 208 230 460 V 50 60 Hz 1 3 ph 05580...

Page 32: ...eld 70 100 A 21326 4485831 2 Heat Shield 50 A 21447 4485832 1 Cutting Nozzle 50 A 21330 4485833 5 Cutting Nozzle 70 A 21329 4485834 5 Electrode 21150 0558004262 5 Electrode Insulator 21373 4485837 1 Electrode Holder Assy 21332 4485840 1 Baffle Tube 21374 4485838 1 Pilot Arc Adaptor 19497 4485843 1 O ring 488157 4485841 5 Lubricant 1 oz 17672 0558000443 1 Seat Baffle Wrench 21375 4485842 1 Hex Key ...

Page 33: ...seconds 0 25 0 50 0 75 1 00 1 25 1 50 bar mm in 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 Optimum Maximum ipm mm min ipm mm min Optimum Maximum 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 mm in 150 55 25 13 ...

Page 34: ...bar mm in 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 Optimum Maximum ipm mm min ipm mm min Optimum Maximum 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 Metal Thickness mm in 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 ...

Page 35: ...zed There should be at least one foot of clearance between the PowerCut power source and wall or any other obstruction to allow freedom of air movement through the power source 2 4 Inspection A Remove the shipping container and all packing material and inspect for evidence of concealed damage which may not have been apparent upon receipt of the PowerCut Notify the carrier of any defects or damage ...

Page 36: ...operatingthismachine from a single phase source it must be connected to a dedicated 100 Amp feed Due to the higher input current requirements the duty cycle of the machine is lower than in three phase operation Connect your air supply to the inlet connection of the filter regulator CUSTOMER FUSED LINE DISCONNECT SWITCH See Table 2 3 and WARNING in regards to chassis ground in Section 2 5 PRIMARY I...

Page 37: ...uctors You must have two single phase or three three phase power leads and one ground wire The wires may be heavy rubber covered cable or may be run in a solid or flexible conduit Refer to Table 2 3 and 2 4 for recommended input conductors and line fuse sizes Table 2 3 PC 1250 Recommended Sizes For Input Conductors and Line Fuses Input Requirements Input Gnd Fuse Volts Phase Amps Conductor Size CU...

Page 38: ...N Use the following procedures to install the PT 21AMX torch A Remove torch connection cover from front panel Cover is held in place by two screws If strain relief connector is present remove berfore connecting the PT 21AMX torch Installation Operation and Maintenance Manual for the SHADOW GANTRY SHAPE CUTTING MACHINE 411 S Ebenezer Road Florence SC 29501 0545 SAFETY GROUND PT 21 AMX TORCH CABLE S...

Page 39: ...h cable assembly through opening in cover D Re attach cable nut and tighten E Pull an adequate amount of hose through the cover to allow ease of hose connections F Attach hoses and tighten G Slide cover back into place and tighten screws section 2 installation ...

Page 40: ...224 section 2 installation ...

Page 41: ...g Auto Restrike off Standard cutting NOTE Trigger Lock Switch Mechanized Operation using the PT 21AMX torch In mechanized operation the Trigger Lock function disabled In stead the switch functions as an Auto Restrike selector To turn Auto Restrike on gratecutting placetheswitchinthe up position To turn Auto Restrike off place the switch in the down position section 3 operation ...

Page 42: ...de holder assembly p n 21332 4485840 and then thread electrode p n 21150 0558004262 onto the electrode holder assembly Assemble electrode firmly by hand Do not use wrenches or pliers These three parts combined are the electrode assembly Baffle Tube Electrode Holder Assembly MakesurepowerswitchonthePOWERCUT is in the OFF position before working on the torch The PT 21 AMX torch head contains a gas f...

Page 43: ...eld is removed and the torch switch is accidentally closed 6 Tighten heat shield fully to hold the parts in firm contact with each other and tothetorchhead Fully meansatleast3 16 4 8mm rotationafterelectrode seat contacts electrode holder 5 Apply a thin film of lubricant p n 17672 0558000443 to O ring p n 488157 4485841 4 Install nozzle onto the electrode assembly by inserting small shoulder on el...

Page 44: ...6 1 5mm of electrode has eroded replace the electrode If the electrodeisusedbeyondthisrecommendedwearlimit damagetothetorch andpowersourcemayoccur Nozzlelifeisalsogreatlyreducedwhenusing the electrode below the recommended limit REPLACE ELECTRODE BEFORE PITTING BECOMES DEEPER THAN 06 INCH 1 5 MM Replace when eroded beyond 06 1 5mm Depth section 3 operation ...

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