POWERCUT-1500 PLASMA ARC CUTTING PACKAGE Be sure this information reaches the operator. You can get extra copies through your supplier.
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 welding and cutting equipment, we urge you to read our booklet, "Precautions and Safe Practices for Arc Welding, Cutting, and Gouging," Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this equipment.
USER RESPONSIBILITY This equipment will perform in conformity 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.
SECTION 1 SAFETY PRECAUTIONS WARNING: These Safety Precautions are for your protection. They summarize precautionary information from the references listed in Additional Safety Information section. Before performing any installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death. 5. Do not use equipment beyond its ratings.
SECTION 1 SAFETY PRECAUTIONS EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death. Therefore: FUMES AND GASES -- Fumes and gases, can cause discomfort or harm, particularly in confined spaces. Do not breathe fumes and gases. Shielding gases can cause asphyxiation. Therefore: 1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do not perform any electrical work unless you are qualified to perform such work. 2.
SECTION 1 ADVERTENCIA: Estas Precauciones de Seguridad son para su protección. Ellas hacen resumen de información proveniente de las referencias listadas en la sección "Información Adicional Sobre La Seguridad". Antes de hacer cualquier instalación o procedimiento de operación , asegúrese de leer y seguir las precauciones de seguridad listadas a continuación así como también todo manual, hoja de datos de seguridad del material, calcomanias, etc.
SECTION 1 PRECAUCION DE SEGURIDAD HUMO Y GASES -- El humo y los gases, pueden causar malestar o daño, particularmente en espacios sin ventilación. No inhale el humo o gases. El gas de protección puede causar falta de oxígeno. Por lo tanto: MANTENIMIENTO DEL EQUIPO -- Equipo defectuoso o mal mantenido puede causar daño o muerte. Por lo tanto: 1. Siempre tenga personal cualificado para efectuar l a instalación, diagnóstico, y mantenimiento del equipo.
SECTION 1 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 graves ou mortelles.
SECTION 1 PRÉCAUTIONS DE SÉCURITÉ levage, des câbles de grue ou divers chemins électriques. g. Empêchez l’apparition de toute humidité, notamment sur vos vêtements, à la surface de l’emplacement de travail, des câbles, du porte-électrode et du poste de soudage/coupage. Réparez immédiatement toute fuite d’eau. 4. VENTILATION-- La respiration prolongée des fumées résultant des opérations de soudage/coupage, à l’intérieur, d’un local clos, peut provoquer des malaises et des dommages corporels.
SECTION 1 DESCRIPTION PowerCut-1500 Plasmarc™ Cutting Package The PowerCut 1500 plasma cutting package combines the proven reliability of the PowerCut-875 and 1125 with the newly designed PT-32EH torch. The very strong composite case material makes the PowerCut1500 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.
SECTION 1 DESCRIPTION Optional Accessories: Contents of PT-32 Spare Parts Kit, P/N 0558003062 90 amp Spare Parts Kit ............................................... 0558003062 Plasma Flow Measuring Kit: This valuable troubleshooting tool allows measurement of the actual plasma gas flow through the torch ....................
SECTION 1 DESCRIPTION 1.1 GENERAL Use only The ESAB PT-32 Plasmarc torch with this console. Use of torches not designed for use with this console could create an ELECTRIC SHOCK HAZARD. The Powercut-1500 is a compact, completely self-contained plasma cutting system. As shipped, the system is fully assembled and ready to cut after being connected to input power and a source of compressed air (90-150 psi).
SECTION 2 INSTALLATION 2.1 GENERAL Proper installation is important for satisfactory and trouble-free operation of the PowerCut 1500 cutting package. It is suggested that each step in this section be studied carefully and followed closely. 2.2 EQUIPMENT REQUIRED A source of clean, dry air that supplies 350 cfh at 80 psig is required for the cutting operation. The air supply should not exceed 150 psig (the maximum inlet pressure rating of the air filter-regulator supplied with the package). 2.
SECTION 2 ELECTRIC SHOCK CAN KILL! Before making 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, place the switch in the off position and padlock it to prevent inadvertent tripping . If the connection is made from a fusebox, remove the corresponding fuses and padlock the box cover.
SECTION 2 INSTALLATION 2.6 SECONDARY (OUTPUT) CONNECTIONS (REFER TO FIG. 2-1) The Torch comes factory installed. Figure 2-1. PowerCut 1500 Interconnection Diagram Connect your air supply to the inlet connection of the filter-regulator. Prefiltered DRY AIR SUPPLY (Customer Supplied) (90 to 150 psig max) PRIMARY INPUT POWER CABLE FUSED DISCONNECT BOX Clamp the work cable to the workpiece. Be sure the workpiece is connected to an approved earth ground with a properly sized ground cable.
SECTION 3 OPERATION B A C D Figure 3-1A. PowerCut 1500 Controls 3.1 OPERATION 3.2 PowerCut 1500 CONTROLS (FIGURE 3-1A) A. Power Switch. When placed in ON position, the green pilot light will glow indicating control circuit is energized. B. Air Test Switch. When placed in Test position, air filter-regulator can be adjusted to desired pressure (80 psig) before cutting operations. Allow air to flow for a few minutes. This should remove any condensation that may have accumulated during shutdown period.
SECTION 3 OPERATION E F G H I Figure 3-1B. PowerCut 1500 Controls 3.2 PowerCut 1500 Indicator Lights (FIGURE 3-1B) E. Power "ON" Indicator: Illuminates whenever the front panel power switch is in the ON position. F. AC Line Indicator or High/Low Line Voltage Indicator: This fault light will blink to indicate that the input voltage is outside the “+ or -” 15% range of the input rating. G.
SECTION 3 OPERATION turned back on. 3.3 CUTTING WITH THE POWERCUT-1500 ELECTRIC SHOCK can kill. • Do NOT operate the unit with the cover removed. • Do NOT apply power to the unit while holding or carrying the unit. • Do NOT touch any torch parts forward of the torch handle (nozzle, heat shield, electrode, etc.) with power switch on. Use the following procedures to cut with the PT-32 torch (Figure 3-4). A. B. C. D. E. ARC RAYS can burn eyes and skin; NOISE can damage hearing.
SECTION 3 OPERATION E. F. held approximately 1/4 inch from the work. 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. This is to prevent the high frequency from reigniting after cutting arc extinguishes and causing damage to the nozzle (double arcing). For rapid re-starts, such as grate or heavy mesh cutting, do not release the torch switch.
SECTION 3 OPERATION 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. THIN GAUGE MATERIALS CAN BE CUT WITH 1/16" (1.6 mm) TORCH-TO-WORK DISTANCE ADJUST TO 3/16" (4.8 mm) FOR MATERIALS OVER 1/4" (6.4 mm) THICK GUIDE AGAINST STRAIGHT EDGE OR FREE-HAND CUT 1/16" (1.6 mm) TO 1/4" (6.
SECTION 3 OPERATION 2 1 WHEN THE ARC BREAKS THROUGH THE WORK, BRING THE TORCH TO AN UPRIGHT POSITION AND PROCEED TO CUT. TO START A PIERCE, TILT THE TORCH TO PREVENT MOLTEN MATERIAL FROM COMING BACK AGAINST AND DAMAGING THE TORCH. Figure 3-5. Piercing Technique using the PT-32 3.4 POSSIBLE CUTTING ISSUES NEW REPLACE ELECTRODE BEFORE PITTING BECOMES DEEPER THAN .06 INCH (1.5 MM) Replace when eroded beyond .06"(1.5mm) Depth. WORN Figure 3-6.
SECTION 3 OPERATION Listed below are common cutting problems followed by the probable cause of each. If problems are determined to be caused by the PowerCut 1500, refer to the maintenance section of this manual. If the problem is not corrected after referring to the maintenance section, contact your ESAB distributor. A. Insufficient Penetration. 1. 2. 3. 4. 5. Current too low. Cutting speed too fast. Damaged cutting nozzle. Improper air pressure. Low air flow rate. B. Main Arc Extinguishes. 1.
SECTION 4 MAINTENANCE 4.1 GENERAL If this equipment does not operate properly, stop work immediately and investigate the cause of the malfunction. Maintenance work must be performed by an experienced person, and electrical work by a trained electrician. Do not permit untrained persons to inspect, clean, or repair this equipment. Use only recommended replacement parts.
SECTION 4 MAINTENANCE HIGH CURRENT CUTTING with STAND-OFF GUIDE If drag cutting is desired on materials above 3/8” thick, be sure that the 90 amp nozzle (P/N 0558002837) is installed in the PT-32 torch. Attach ESAB's stand-off guide (P/N 0558002393) and operate as shown in Figure 3.4. PLACE THE VALVE PIN INTO THE ELECTRODE AND SCREW THE ELECTRODE INTO THE TORCH HEAD AND TIGHTEN SECURELY WITH WRENCH #19129.
SECTION 4 MAINTENANCE 4.4 IGBT Handling & Replacement Since IGBT gates are insulated from any other conducting region, care should be taken to prevent static build up, which could possibly damage gate oxides. All IGBT modules are shipped from the factory with conductive foam contacting the gate and emitter sense pins. Always ground parts touching gate pins during installation. In general, standard ESD precautions application to FETs should be followed.
SECTION 4 MAINTENANCE c Two-Point Mounting Type Temporary tightening cÎd d Final tightening dÎc c e f d Four-Point Mounting Type Temporary tightening cÎdÎeÎf Final tightening fÎeÎdÎc Figure 4-2.
SECTION 5 TROUBLESHOOTING 5.1TROUBLESHOOTING ELECTRIC SHOCK CAN KILL! Be sure that all primary power to the machine has been externally disconnected. Open the line (wall) disconnect switch or circuit breaker before attempting inspection or work inside of the power source. Check the problem against the symptoms in the following troubleshooting guide. The remedy may be quite simple.
SECTION 5 TROUBLESHOOTING 5.2TROUBLESHOOTING GUIDE A. Power Light does not come on. 1. Visually inspect the machine for any damage. 2. Check following: a. Check if the machine power cord is plugged into the input power receptacle. b. Measure the input power at the receptacle. If not present, then check the wall disconnect switch and it’s fuses. c. Check Fuse (F1). 3. If above items check OK , the problem is internal. Send unit to an Authorized Repair Station for repair. a.
SECTION 5 TROUBLESHOOTING Refer to system schematic. Replace the transformer if the correct secondary voltages are not present. 3. If everything above checks out all right, then the PCB1 Control Board should be replaced. D. Fault light activates when torch switch is closed. The machine monitor conditions necessary for the safe operation of the Powercut-1500. The fault lights will glow under the following conditions and operations will come to a stop. 1. High/Low line voltage.
SECTION 5 TROUBLESHOOTING c. b. To check if the output is shorted, measure the resistance by putting the ohmmeter leads across the output. Put the black lead to the "work" terminal and the red lead to the torch electrode terminal. The reading should be about 2K OHMs. If the resistance reading is different than above, check the torch, the output bridge and Start-up Board (PCB-6). E. Air is On but nothing happens when torch switch is operated. 1. Check the torch.
SECTION 5 TROUBLESHOOTING F. High Frequency and Pilot Arc are on but Main Arc does not transfer. 1. Make sure work clamp is connected to work material. 2. Check the torch. Replace consumables if necessary. G. Poor Cutting Performance. 1. Check air supply regulator . It should be adjusted to 80 psig. 2. The air supplied to the torch should be free of oil and water. 3. Make sure the consumables in the torch are acceptable. 4. Check open circuit voltage. See E.3 above. 5. Check the output.
SECTION 5 TROUBLESHOOTING 5.3 REFERENCE VOLTAGE CHECKS A. Control Board Assembly (PCB1) 1. LED’s LED- (D9)LED- (D4)LED- (D1)- 2. Torch Switch Pilot Arc Relay Gas Solenoid Valve Voltage Test Points Tests are made with power on - no arc. Disable High Frequency by disconnecting blue wire with black sleeve TP-1 TP-4 TP-5 TP-7 TP-8 TP-9 TP-10 - Torch trigger signal IGBT’s driving signal - switching frequency = 18.5 KHz IGBT’s driving signal - switching frequency = 18.
SECTION 5 TROUBLESHOOTING 5.4 SEQUENCE OF OPERATION A. TRIGGER LOCK “UNLOCK” position PUSH TORCH SWITCH RELEASE OPEN CLOSE GAS SOLENOID VALVE PREFLOW 2 SEC. 20 SEC Postflow FLOW SWITCH CLOSE OPEN FAULT OVERLOAD LIGHT HF CIRCUIT ENERGIZE PILOT ARC INVERTER CUTTING ARC (CURRENT) 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.
SECTION 5 B. TROUBLESHOOTING TRIGGER LOCK "LOCK" position PUSH RELEASE PUSH RELEASE TORCH SWITCH OPEN GAS SOLENOID VALVE 2 SEC. CLOSE PREFLOW 20 SEC Postflow OPEN CLOSE FLOW SWITCH FAULT LIGHT ENERGIZE HF CIRCUIT PILOT ARC INVERTER CUTTING ARC (CURRENT) NOTES: 1. When the torch switch is pushed during postflow period, the postflow time is reset, the preflow time is canceled, and the HF is energized immediately. 2. When the red fault light comes on, cutting operation should be stopped.
D-0558003108-B Powercut-1500 Schematic Diagram
SECTION 6 REPLACEMENT PARTS A. REPLACEMENT PARTS Replacement Parts are illustrated on the following figures. When ordering replacement parts, order by part number and part name, as illustrated on the figure. Always provide the series or serial number of the unit on which the parts will be used. The serial number is stamped on the unit nameplate. B. ORDERING To assure proper operation, it is recommended that only genuine ESAB parts and products be used with this equipment.
SECTION 6 REPLACEMENT PARTS 2 3 4 1 11 9, 10 5 7 6 8 Front View - Powercut-1500 Item No. Qty. 1 2 3 4 5 6 7 8 9 10 11 1 2 1 1 1 1 1 2 1 1 1 Part No. Description 36107 951474 954942 0558001818 0558002461M 0558003001 13733935 0558002780 0558002581 950435 0558002464M SW Pwr Disc 600V Switch Seal Black Overlay Front Panel Powercut-1500 Knob 1.37 Diam Panel Front Work Cable #6 AWG Panel Receptacle Foot Plasma Tube Strain Relief Input NPT Locknut, 1.
SECTION 6 REPLACEMENT PARTS 3 2 4 1 5 6 7 8 Rear View - Powercut-1500 Item No. Qty. 1 2 3 4 5 6 7 8 1 1 1 1 1 1 1 1 Part No. Description 21710 21711 0558002446 0558003075 97W63 0558003002 951182 0558002994 Regulator Air Line *808-02 Gauge 1.50 *160 PSI WHT CB Switch 40A Fuse 2A 600VAC, Fast Acting Only Connector Cable Grip Cable Input Power, 10Ft. Fan 230V 50/60 Hz 233CFM Finger Guard 1.5MM (.06 IN.
SECTION 6 REPLACEMENT PARTS 3 2 4 5 1 6 Internal View - Powercut-1500 Lower Left Side Item No. Qty. 1 2 3 4 5 6 2 4 2 2 1 1 Part No.
SECTION 6 REPLACEMENT PARTS 3 2 1 Internal View - Powercut-1500 Left Side Rear Item No. Qty. 1 2 3 1 1 1 Part No. Description 0558002482 0558002189 0558003105 SOL AY 1/8 NPTF Port 3/16 BARB Switch Pressure .
SECTION 6 REPLACEMENT PARTS 3 1 2 Internal View - Powercut-1500 Left Side Sub-Assembly Item No. Qty. 1 2 3 1 2 1 Part No.
SECTION 6 REPLACEMENT PARTS 1 2 3 4 7 6 5 Internal View - Powercut-1500 Right Side Item No. Qty. 1 2 3 4 5 6 7 1 1 2 2 4 1 1 Part No. Description Symbol 0558002434 17750050 0558003182 17750051 951161 38206 38229 3PH BR Rect. w/out Thyristor RES WW 50W 50 OHM Module Dual IGBT 200A 600V RES WW AHNI 50W 3%K 10 OHM CAPC Metpoly *20.
SECTION 6 REPLACEMENT PARTS 2 1 5 (Located Under Lip) 3 4 Internal View - Powercut-1500 Right Side Sub-Assembly Item No. Qty. 1 2 3 4 5 4 1 1 1 1 Part No.
SECTION 6 REPLACEMENT PARTS 1 JP4 2 JP1 4 3 5 Upper Left Side Internal View - Powercut-1500 Item No. Qty. 1 2 3 4 5 1 1 1 1 1 Part No.
SECTION 6 REPLACEMENT PARTS 2 1 Internal View - Powercut-1500 Front Left Side Item No. 1 2 Qty. Part No.
Instruction Manual Changes The "A" edition (3/02) of the manual covers the following: 1. Schematic Diagram upgraded from 0558003108 to 0558003108-A. 2. PCB Start-Up Network (P/N 38200) replaced with (P/N 38131) in parts list on page 34.
ESAB Welding & Cutting Products, Florence, SC Welding Equipment COMMUNICATION GUIDE - CUSTOMER SERVICES A. CUSTOMER SERVICE QUESTIONS: Telephone: (800)362-7080 / Fax: (800) 634-7548 Order Entry Product Availability Pricing Delivery Order Changes Saleable Goods Returns Shipping Information Hours: 8:00 AM to 7:00 PM EST B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693 Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM EST Warranty Returns Authorized Repair Stations C.
