ESAB POWERCUT-1500 User manual

POWERCUT-1500

0558003745 102002

Instruction Manual (GB)

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles

ofoperationandsafepracticesforarcweldingandcuttingequipment,weurgeyoutoreadourbooklet,

"PrecautionsandSafePracticesforArcWelding,Cutting,andGouging,"Form52-529. DoNOTpermit

untrainedpersonstoinstall,operate,ormaintain thisequipment. DoNOTattemptto installoroperate

this equipment until you have read and fully understand these instructions. If you do not fully

understandtheseinstructions,contactyoursupplierforfurtherinformation. BesuretoreadtheSafety

Precautions before installing or operating this equipment.

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompanying

labelsand/orinsertswheninstalled,operated,maintainedandrepairedinaccordancewiththeinstructionsprovided.

This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used.

Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair

or replacement become necessary, the manufacturer recommends that a telephone or written request for service

advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The

user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty

maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility

designated by the manufacturer.

Full responsibility for safety of personnel working on or near system rests on user of ESAB Welding

Equipment.

Wrong operation can lead to abnormal situation, injure operator and damage equipment.

All personnel working with welding equipment must be fully familiar with

- handling of equipment

- location of emergency stops

- functions of equipment

- applicable safety regulations

- cutting

Operator must make sure

- no one stays inside work area while machine starts

- no one is unprotected while arc is being struck

Work area must be

- free of machine parts, tools and other objects that can obstruct operator moving within area

- so arranged, that emergency stop buttons are easily accessible

- free from draughts

Personal safety equipment

- always use proper safety equipment such as goggles, non flammable clothing, protective gloves

- never wear loose clothing, belts, bracelets, rings etc., which may catch on equipment or cause burns

Miscellaneous

- only authorised personnel may operate electrical equipment

- check whether return cables are properly fitted and earthen

- requisite fire fighting equipment should be easily available in specially and clearly marked areas

- lubrication and maintenance of welding equipment must not be proceeded during operation.

SAFETY

! WARNING !

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE

PRECAUTIONS WHEN WELDING OR CUTTING. ASK YOUR EMPLOYER FOR SAFETY PRACTICES

THAT SHOULD BE BASED ON MANUFACTURER’S HAZARD DATA.

ELECTRIC SHOCK - Can kill

- Install and earth welding equipment in accordance with obligatory standards.

- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothes.

- Insulate yourself from earth and workpiece.

- Ensure your work position is safe.

FUMES AND GASES - Can be dangerous to your health

- Keep your head away from fumes.

- Use ventilation and/or extraction to keep fumes and gases away from your breathing zone and surroundings.

ARC RAYS - Can injure eyes and burn skin

- Protect your eyes and skin. Use correct welding screens, filter lens and wear protective clothes.

- Protect bystanders with suitable screens or curtains.

FIRE HAZARD

- Sparks (spatter) can cause fire. Make therefore sure there are no inflammable materials nearby.

NOISE - Excessive noise can damage your hearing.

- Protect your ears. Use ear defenders or other hearing protection.

- Warn bystanders of the risk.

MALFUNCTION - Call expert assistance in event of malfunction.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING UNIT

PROTECT YOURSELF AND OTHERS !

SAFETY

TABLE OF CONTENTS

SECTION TITLE PAGE

PARAGRAPH

SECTION 1 DESCRIPTION ................................................................................................. 85

1.1 General ............................................................................................................. 85

1.2 Scope................................................................................................................ 85

1.3 Packages Available .......................................................................................... 85

1.4 Specifications.................................................................................................... 86

SECTION 2 INSTALLATION................................................................................................ 89

2.1 General ............................................................................................................. 89

2.2 Equipment Required ......................................................................................... 89

2.3 Location ............................................................................................................ 89

2.4 Inspection ......................................................................................................... 89

2.5 Primary Electrical Input Connections ................................................................ 89

2.6 Secondary Output Connections ........................................................................ 91

SECTION 3 OPERATION .................................................................................................... 93

3.1 Operation .......................................................................................................... 93

3.2 PowerCut-1500 Controls .................................................................................. 93

3.3 Cutting with the PT-32EH ................................................................................. 95

3.4 Possible Cutting Issues .................................................................................... 98

SECTION 4 MAINTENANCE ............................................................................................... 161

4,1 General ............................................................................................................. 161

4.2 Inspection and Cleaning ................................................................................... 161

4.3 PT-32EH Torch Consumable Parts .................................................................. 161

4.4 IGBT Handling & Replacement......................................................................... 162

SECTION 5 TROUBLESHOOTING ..................................................................................... 163

5.1 Troubleshooting ................................................................................................ 163

5.2 Troubleshooting Guide ..................................................................................... 164

SECTION 6 REPLACEMENT PARTS ................................................................................. 173

SECTION 1 DESCRIPTION

1.1 GENERAL

ThePowercut-1500is acompact, completelyself-containedplasmacutting

system. As shipped, the system is fully assembled and ready to cut after

being connected to input power and a source of compressed air at 6.2-10.3

bar (90-150 psig). The Powercut-1500 package uses the heavy-duty PT-

32EHtorchtodelivercuttingpowerforseveringmaterialsupto38.1mm(1.50")

thick. Refer to the following paragraphs for descriptions of the Powercut-

1500 packages available as well as performance specifications.

1.2 SCOPE

Thepurposeofthismanualistoprovidetheoperatorwithall theinformation

required to install and operate the Powercut-1500 plasma arc cutting

package. Technical reference material is also provided to assist in trouble-

shooting the cutting package.

1.3 PACKAGES AVAILABLE

1.3.1 Manual Cutting Packages

Powercut-1500 packages listed on the front cover and below, includes the

following components:

Powercut 1500 Manual Cutting Packages:

PowerCut-1500 400 V, "CE" 7.6 m (25 ft.) PT-32EH ............ P/N 0558001945

PowerCut-1500 400 V, "CE" 15.2 m (50 ft.) PT-32EH .......... P/N 0558001946

The components that are included in the Powercut-1500 packages may be

purchased separately by using the appropriate P/N when placing orders.

Individual part numbers are listed below:

Console:

PowerCut-1500 400 V, 3-ph, 50/60Hz, 24A .......................... P/N 0558001947

PT-32EH Torches:

PT-32EH Torch, 90o, 7.6 m (25 ft.) ........................................ P/N 0558003548

PT-32EH Torch, 90o, 15.2 m (50 ft.)...................................... P/N 0558003549

PT-32EH Spare Parts Kit (see table below) .......................... P/N 0558003557

Table 1-1 PT-32EH 90Amp Spare Parts Kit, P/N 0558003557, Contents

0558002837

0558002908

0558001969

0558003110

0558001959

0558002393

0558000808

0558000443

0558003075

Part Number

90 Amp Nozzle

40 Amp Nozzle

Electrode

Heat Shield

Valve Pin

Stand Off Guide

Wrench

Lubricant

Fuse 2Amp 600VAC

Description Quantity

Use only The ESAB PT-32EH

Plasmarc torch with this

console. Use of torches not

designed for use with this

console could create an

ELECTRIC SHOCK HAZARD.

SECTION 1 DESCRIPTION

1.4 SPECIFICATIONS

Table 1-2 PowerCut-1500 Specifications

* Duty cycle is based on a 10-minute period: therefore, a 60% duty cycle means the power source may operate for

6 minutes with a cool down period of 4 minutes. 100% duty cycle means the power source may operate continu-

ously.

Rated Inputs Rated Outputs

Phases Volts Amps Power

Factor * Duty

Cycle Output

Amps

Open

Circuit

Voltage Efficiency

Three 400 24

18 86%

81% 60%

100% 90A @ 127Vdc

75A @ 120Vdc 278 Vdc

278 Vdc 88%

87%

Length 648 mm (25.50")

w/handles 813 mm (32.00")

Height 416 mm (16.38")

Dimensions of Console Width w/o opt. storage 333 mm (13.10")

w/ opt. torch storage 409 mm (16.10")

Weight of PowerCut-1500 42.7 kg (94 lbs)

System Shipping Weight 49.5 kg (109 lbs)

SECTION 1 DESCRIPTION

Table 1-3 PT-32EH Torch Specifications

Figure 1-1 PT-32EH Dimensions

Current Capacity (100% Duty)

Air Requirements

Length of Service Lines

Weight

7.6 m (25ft.)

15.2 m (50ft.)

90 A DCSP

165 l/min @ 5.5 bar

(350 cfh @ 80 psig)

7.6 m (25ft.) or 15.2 m (50ft.)

2.4 kg (5.2 lbs)

4.4 kg (9.6 lbs)

Cutting Speed

Material Thickness mm (in.) mm/m (ipm)

Carbon Steel 1.6 (1/16) 5,080 (200)

3.2 (1/8) 2,489 (98)

6.4 (1/4) 914 (36)

9.5 (3/8) 457 (18)

12.7 (1/2) 279 (11)

Stainless Steel 1.6 (1/16) 3,505 (138)

3.2 (1/8) 1,473 (58)

6.4 (1/4) 457 (18)

9.5 (3/8) 254 (10)

12.7 (1/2) 152 (6)

Aluminum 1.6 (1/16) 5,080 (200)

3.2 (1/8) 2,794 (110)

6.4 (1/4) 1,219 (48)

9.5 (3/8) 432 (17)

12.7 (1/2) 356 (14)

Figure 1-2 PT-32EH / POWERCUT-1500 Cutting Performance

PT-32EH DRAG MODE CUTTING SPEEDS

AIR @ 5.5 BAR (80 PSIG) and OUTPUT CURRENT 40 AMPS

PT-32EH CUT SPEED - CARBON

STEEL

1000

2000

3000

4000

6.4mm 12.7mm 19.1mm 25.4mm 31.8mm 38.1mm

Material Thickness

Cut Speed, mm/m

90 Amps

70 Amps

60 Amps

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