ESAB Powercut-1125 Instruction manual

P OW ERC U T 112 5

Plasma Arc Cutting Package

Instruction Manual

This manual provides installation and operation instructions for the following Powercut-1125 cutting packages starting with Serial No. (PB-J120118142).

P/N 0558002791 - 208/230 V, 25' Package P/N 0558002791F - 208/230 V, 25' Package (BL) P/N 0558002792 - 208/230 V, 50' Package P/N 0558002793 - 460 V, 25' Package P/N 0558002794 - 460 V, 50' Package P/N 0558002928 - 575 V, 25' Package

F15-685-D 11/2007

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

CAUTION

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. Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating 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. 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.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

TABLE OF CONTENTS

Section / Title Page

1.0 Safety Precautions ...................................................................................................................................................................5

1.1 Safety - English ................................................................................................................................................................5

1.2 Safety - Spanish ...............................................................................................................................................................9

1.3 Safety - French ...............................................................................................................................................................13

2.0 Description ...............................................................................................................................................................................17

2.1 General ............................................................................................................................................................................ 17

2.2 Scope ............................................................................................................................................................................... 17

2.3 Packages Available ..................................................................................................................................................... 17

2.4 Specications ................................................................................................................................................................ 18

2.5 Optional Accessories .................................................................................................................................................. 20

3.0 Installation ................................................................................................................................................................................21

3.1 General .............................................................................................................................................................................21

3.2 Equipment Required .................................................................................................................................................. 21

3.3 Location .......................................................................................................................................................................... 21

3.4 Inspection ...................................................................................................................................................................... 21

3.5 Primary Electrical Input Connections .................................................................................................................. 21

3.6 Secondary Output Connections ............................................................................................................................ 22

3.7 Connecting POWERCUT-1125 for 200(208)Vac Input .................................................................................... 24

4.0 Operation ..................................................................................................................................................................................27

4.1 Operation ........................................................................................................................................................................27

4.2 PowerCut-1125 Controls........................................................................................................................................... 27

4.3 Cutting with the PT-32 ..............................................................................................................................................28

5.0 Maintenance ............................................................................................................................................................................31

5.1 General ............................................................................................................................................................................ 31

5.2 Inspection and Cleaning .......................................................................................................................................... 31

5.3 PT-32 Torch Consumable Parts ............................................................................................................................... 31

5.4 IGBT Handling and Replacement .......................................................................................................................... 33

5.5 Common Cutting Problems.....................................................................................................................................34

5.6 Troubleshooting .......................................................................................................................................................... 35

5.7 Troubleshooting Guide ............................................................................................................................................. 36

5.8 Reference Voltage Checks ........................................................................................................................................ 40

5.9 Sequence of Operation ............................................................................................................................................. 41

6.0 Replacement Parts .................................................................................................................................................................43

6.1 General .............................................................................................................................................................................43

6.2 Ordering ..........................................................................................................................................................................43

TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS

1.0 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.

PROTECT YOURSELF AND OTHERS -Some welding, cutting, and gouging processes are noisy and require ear protection. The arc, like the sun, emits

ultraviolet (UV) and other radiation and can injure skin and eyes. Hot metal can cause burns. Training in the proper use of the processes and equipment is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any

work area, even if welding helmets, face shields, and goggles are also required.

2. Use a face shield tted with the correct lter and

cover plates to protect your eyes, face, neck, and ears from sparks and rays of the arc when operating or observing operations. Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric-arc or hot metal.

3. Wear ameproof gauntlet type gloves, heavy long-

sleeve shirt, cuess trousers, high-topped shoes, and a welding helmet or cap for hair protection, to protect against arc rays and hot sparks or hot metal. A ameproof apron may also be desirable as protection against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cus, or pockets. Sleeves and collars should be kept buttoned, and open pockets eliminated from the front of clothing.

5. Protect other personnel from arc rays and hot

sparks with a suitable non-ammable partition or curtains.

6. Use goggles over safety glasses when chipping slag

or grinding. Chipped slag may be hot and can y far. Bystanders should also wear goggles over safety glasses.

1.1 Safety - English

FIRES AND EXPLOSIONS -- Heat from ames and arcs can start res. Hot slag or sparks can also cause res and explosions. Therefore:

1. Remove all combustible materials well away from the work area or cover the materials with a protective non-ammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or crevices in oors or wall openings and cause a hidden smoldering re or res on the oor below. Make certain that such openings are protected from hot sparks and metal.“

3. Do not weld, cut or perform other hot work until the workpiece has been completely cleaned so that there are no substances on the workpiece which might produce ammable or toxic vapors. Do not do hot work on closed containers. They may explode.

4. Have re extinguishing equipment handy for instant use, such as a garden hose, water pail, sand bucket, or portable re extinguisher. Be sure you are trained in its use.

5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and create a re hazard.

6. After completing operations, inspect the work area to make certain there are no hot sparks or hot metal which could cause a later re. Use re watchers when necessary.

7. For additional information, refer to NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", available from the National Fire Protection Association, Batterymarch Park, Quincy, MA

02269.

ELECTRICAL SHOCK -- Contact with live electrical parts and ground can cause severe injury or death. DO NOT use AC welding current in damp areas, if movement is conned, or if there is danger of falling.

SECTION 1 SAFETY PRECAUTIONS

1. Be sure the power source frame (chassis) is connected to the ground system of the input power.

2. Connect the workpiece to a good electrical ground.

3. Connect the work cable to the workpiece. A poor or missing connection can expose you or others to a fatal shock.

4. Use well-maintained equipment. Replace worn or damaged cables.

5. Keep everything dry, including clothing, work area, cables, torch/electrode holder, and power source.

6. Make sure that all parts of your body are insulated from work and from ground.

7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand on dry boards or an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

3. Welders should use the following procedures to minimize exposure to EMF:

A. Route the electrode and work cables together.

Secure them with tape when possible.

B. Never coil the torch or work cable around your

body.

C. Do not place your body between the torch and

work cables. Route cables on the same side of your body.

D. Connect the work cable to the workpiece as close

as possible to the area being welded.

E. Keep welding power source and cables as far

away from your body as possible.

FUMES AND GASES -- Fumes and gases, can cause discomfort or harm, particularly in conned spaces. Do not breathe fumes and gases. Shielding gases can cause asphyxiation.

Therefore:

9. Turn o the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specic grounding recommendations. Do not mistake the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS — May be dangerous. Electric current owing through any conductor causes localized Electric and

Magnetic Fields (EMF). Welding and cutting current creates EMF around welding cables and welding machines. Therefore:

1. Welders having pacemakers should consult their

physician before welding. EMF may interfere with some pacemakers.

2. Exposure to EMF may have other health eects which

are unknown.

1. Always provide adequate ventilation in the work area by natural or mechanical means. Do not weld, cut, or gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead, beryllium, or cadmium unless positive mechanical ventilation is provided. Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat irritation while operating, this is an indication that ventilation is not adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not continue to operate if physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specic ventilation recommendations.

SECTION 1 SAFETY PRECAUTIONS

5. WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code

§25249.5 et seq.)

CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release gas. Sudden rupture of cylinder, valve, or relief device can injure or kill. Therefore:

1. Use the proper gas for the process and use the

proper pressure reducing regulator designed to operate from the compressed gas cylinder. Do not use adaptors. Maintain hoses and ttings in good condition. Follow manufacturer's operating instructions for mounting regulator to a compressed gas cylinder.

1. Always have qualied personnel perform the installation, troubleshooting, and maintenance work. Do not perform any electrical work unless you are qualied to perform such work.

2. Before performing any maintenance work inside a power source, disconnect the power source from the incoming electrical power.

3. Maintain cables, grounding wire, connections, power cord, and power supply in safe working order. Do not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such as furnaces, wet conditions such as water puddles, oil or grease, corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position and in good repair.

6. Use equipment only for its intended purpose. Do not modify it in any manner.

2. Always secure cylinders in an upright position by chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure cylinders to work tables or xtures where they may become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and ames. Never strike 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 Jeerson Davis Highway, Arlington, VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death. Therefore:

ADDITIONAL SAFETY INFORMATION -- For more information on safe practices for

electric arc welding and cutting equipment, ask your supplier for a copy of "Precautions and Safe Practices for Arc Welding, Cutting and Gouging", Form 52-529.

The following publications, which are available from the American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon Arc Gouging and Cutting"

SECTION 1 SAFETY PRECAUTIONS

5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal Arc Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.

8. ANSI/AWS F4.1, "Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances."

MEANING OF SYMBOLS - As used throughout this manual: Means Attention! Be Alert! Your safety is involved.

Means immediate hazards which, if not avoided, will result in immediate, serious personal injury or loss of life.

Means potential hazards which could result in personal injury or loss of life.

Means hazards which could result in minor personal injury.

SECTION 1 SEGURIDAD

1.2 Safety - Spanish

ADVERTENCIA: Estas Precauciones de Se-

guridad 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. El no observar las Precauciones de Seguridad puede resultar en daño a la persona o muerte.

PROTEJASE USTED Y A LOS DEMAS-Algunos procesos de soldadura, corte y ranurado son ruidosos y requiren protección para los oídos. El arco,

como el sol , emite rayos ultravioleta (UV) y otras radiaciones que pueden dañar la piel y los ojos. El metal caliente causa quemaduras. EL entrenamiento en el uso propio de los equipos y sus procesos es esencial para prevenir accidentes. Por lo tanto:

1. Utilice gafas de seguridad con protección a los lados

siempre que esté en el área de trabajo, aún cuando esté usando careta de soldar, protector para su cara u otro tipo de protección.

2. Use una careta que tenga el ltro correcto y lente

para proteger sus ojos, cara, cuello, y oídos de las chispas y rayos del arco cuando se esté operando y observando las operaciones. Alerte a todas las personas cercanas de no mirar el arco y no exponerse a los rayos del arco eléctrico o el metal fundido.

3. Use guantes de cuero a prueba de fuego, camisa

pesada de mangas largas, pantalón de ruedo liso, zapato alto al tobillo, y careta de soldar con capucha para el pelo, para proteger el cuerpo de los rayos y chispas calientes provenientes del metal fundido. En ocaciones un delantal a prueba de fuego es necesario para protegerse del calor radiado y las chispas.

4. Chispas y partículas de metal caliente puede alojarse

en las mangas enrolladas de la camisa , el ruedo del pantalón o los bolsillos. Mangas y cuellos deberán mantenerse abotonados, bolsillos al frente de la camisa deberán ser cerrados o eliminados.

5. Proteja a otras personas de los rayos del arco y chis-

pas calientes con una cortina adecuada no-amable como división.

6. Use careta protectora además de sus gafas de segu-

ridad cuando esté removiendo escoria o puliendo.

La escoria puede estar caliente y desprenderse con velocidad. Personas cercanas deberán usar gafas de seguridad y careta protectora.

FUEGO Y EXPLOSIONES -- El calor de las amas y el arco pueden ocacionar fuegos. Escoria caliente y las chispas pueden causar fuegos y explosiones. Por lo tanto:

1. Remueva todo material combustible lejos del área de trabajo o cubra los materiales con una cobija a prueba de fuego. Materiales combustibles incluyen madera, ropa, líquidos y gases amables, solventes, pinturas, papel, etc.

2. Chispas y partículas de metal pueden introducirse en las grietas y agujeros de pisos y paredes causando fuegos escondidos en otros niveles o espacios. Asegúrese de que toda grieta y agujero esté cubierto para proteger lugares adyacentes contra fuegos.

3. No corte, suelde o haga cualquier otro trabajo relacionado hasta que la pieza de trabajo esté totalmente limpia y libre de substancias que puedan producir gases inamables o vapores tóxicos. No trabaje dentro o fuera de contenedores o tanques cerrados. Estos pueden explotar si contienen vapores inamables.

4. Tenga siempre 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, inspeccione el área de trabajo para cerciorarse de que las chispas o metal caliente ocasionen un fuego más tarde. Tenga personal asignado para vigilar si es necesario.

7. Para información adicional , haga referencia a la publicación NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", disponible a través de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

CHOQUE ELECTRICO -- El contacto con las partes eléctricas energizadas y tierra puede causar daño severo o muerte. NO use soldadura de corri-

ente alterna (AC) en áreas húmedas, de movimiento connado en lugares estrechos o si hay posibilidad de caer al suelo.

SECTION 1 SEGURIDAD

1. Asegúrese de que el chasis de la fuente de poder esté conectado a tierra através del sistema de electricidad primario.

2. Conecte la pieza de trabajo a un buen sistema de tierra física.

3. Conecte el cable de retorno a la pieza de trabajo. Cables y conductores expuestos o con malas conexiones pueden exponer al operador u otras personas a un choque eléctrico fatal.

4. Use el equipo solamente si está en buenas condiciones. Reemplaze cables rotos, dañados o con conductores expuestos.

5. Mantenga todo seco, incluyendo su ropa, el área de trabajo, los cables, antorchas, pinza del electrodo, y la fuente de poder.

6. Asegúrese que todas las partes de su cuerpo están insuladas de ambos, la pieza de trabajo y tierra.

7. No se pare directamente sobre metal o tierra mientras trabaja en lugares estrechos o áreas húmedas; trabaje sobre un pedazo de madera seco o una plataforma insulada y use zapatos con suela de goma.

8. Use guantes secos y sin agujeros antes de energizar el equipo.

9. Apage el equipo antes de quitarse sus guantes.

10. Use como referencia la publicación ANSI/ASC Standard Z49.1 (listado en la próxima página) para recomendaciones especícas de como conectar el equipo a tierra. No confunda el cable de soldar a la pieza de trabajo con el cable a tierra.

CAMPOS ELECTRICOS Y MAGNETICOS - Son peligrosos. La corriente eléctrica uye através de cualquier conductor causando a nivel local

Campos Eléctricos y Magnéticos (EMF). Las corrientes en el área de corte y soldadura, crean EMF alrrededor de los cables de soldar y las maquinas. Por lo tanto:

1. Soldadores u Operadores que use marca-pasos para

el corazón deberán consultar a su médico antes de soldar. El Campo Electromagnético (EMF) puede interferir con algunos marca-pasos.

2. Exponerse a campos electromagnéticos (EMF) puede

causar otros efectos de salud aún desconocidos.

3. Los soldadores deberán usar los siguientes procedimientos para minimizar exponerse al EMF:

A. Mantenga el electrodo y el cable a la pieza de

trabajo juntos, hasta llegar a la pieza que usted quiere soldar. Asegúrelos uno junto al otro con cinta adhesiva cuando sea posible.

B. Nunca envuelva los cables de soldar alrededor

de su cuerpo.

C. Nunca ubique su cuerpo entre la antorcha y el

cable, a la pieza de trabajo. Mantega los cables a un sólo lado de su cuerpo.

D. Conecte el cable de trabajo a la pieza de trabajo

lo más cercano posible al área de la soldadura.

E. Mantenga la fuente de poder y los cables de soldar

lo más lejos posible de su cuerpo.

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:

1. Siempre provea ventilación adecuada en el área

de trabajo por medio natural o mecánico. No solde, corte, o ranure materiales con hierro galvanizado, acero inoxidable, cobre, zinc, plomo, berílio, o cadmio a menos que provea ventilación mecánica positiva . No respire los gases producidos por estos materiales.

2. No opere cerca de lugares donde se aplique sub-

stancias químicas en aerosol. El calor de los rayos del arco pueden reaccionar con los vapores de hidrocarburo clorinado para formar un fosfógeno, o gas tóxico, y otros irritant es.

3. Si momentáneamente desarrolla inrritación de

ojos, nariz o garganta mientras est á operando, es indicación de que la ventilación no es apropiada. Pare de trabajar y tome las medidas necesarias para mejorar la ventilación en el área de trabajo. No continúe operando si el malestar físico persiste.

4. Haga referencia a la publicación ANSI/ASC Standard

Z49.1 (Vea la lista a continuación) para recomendaciones especícas en la ventilación.

SECTION 1 SEGURIDAD

5. ADVERTENCIA-- Este producto cuando se utiliza para soldaduras o cortes, produce humos o gases, los cuales contienen químicos conocidos por el Estado de California de causar defectos en el nacimiento, o en algunos casos, Cancer. (California Health & Safety Code §25249.5 et seq.)

MANEJO DE CILINDROS-- Los

cilindros, si no son manejados correctamente, pueden romperse y liberar violentamente gases. Rotura repentina del cilindro, válvula, o válvula de escape puede causar daño o muerte. Por lo tanto:

1. Utilize el gas apropiado para el proceso y utilize

un regulador diseñado para operar y reducir la presión del cilindro de gas . No utilice adaptadores. Mantenga las mangueras y las conexiones en buenas condiciones. Observe las instrucciones de operación del manufacturero para montar el regulador en el cilindro de gas comprimido.

2. Asegure siempre los cilindros en posición vertical

y amárrelos con una correa o cadena adecuada para asegurar el cilindro al carro, transportes, tablilleros, paredes, postes, o armazón. Nunca asegure los cilindros a la mesa de trabajo o las piezas que son parte del circuito de soldadura . Este puede ser parte del circuito elélectrico.

3. Cuando el cilindro no está en uso, mantenga la

válvula del cilindro cerrada. Ponga el capote de protección sobre la válvula si el regulador no está conectado. Asegure y mueva los cilindros utilizando un carro o transporte adecuado. Evite el manejo brusco de los

1. Siempre tenga personal cualicado para efectuar l a instalación, diagnóstico, y mantenimiento del equipo. No ejecute ningún trabajo eléctrico a menos que usted esté cualicado para hacer el trabajo.

2. Antes de dar mantenimiento en el interior de la fuente de poder, desconecte la fuente de poder del suministro de electricidad primaria.

3. Mantenga los cables, cable a tierra, conexciones, cable primario, y cualquier otra fuente de poder en buen estado operacional. No opere ningún equipo en malas condiciones.

4. No abuse del equipo y sus accesorios. Mantenga el equipo lejos de cosas que generen calor como hornos, también lugares húmedos como charcos de agua , aceite o grasa, atmósferas corrosivas y las inclemencias del tiempo.

5. Mantenga todos los artículos de seguridad y coverturas del equipo en su posición y en buenas condiciones.

6. Use el equipo sólo para el propósito que fue diseñado. No modique el equipo en ninguna manera.

INFORMACION ADICIONAL DE SEGURIDAD -- Para más información sobre las prácticas de seguridad de los equipos de arco eléctrico para soldar y cortar, pregunte a su suplidor por una copia de "Precautions and Safe Practices for Arc Welding, Cutting and Gouging-Form 52-529.

Las siguientes publicaciones, disponibles através de la American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, son recomendadas para usted:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc Welding"

MANTENIMIENTO DEL EQUIPO -- Equipo defectuoso o mal mantenido puede causar daño o muerte. Por lo tanto:

3. AWS C5.2 - "Recommended Practices for Plasma Arc Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon Arc Gouging and Cutting"

SECTION 1 SEGURIDAD

SIGNIFICADO DE LOS SIMBOLOS

-- Según usted avanza en la lectura de este folleto: Los Símbolos Signican ¡Atención! ¡Esté Alerta! Se trata de su seguridad.

Signica riesgo inmediato que, de no ser evadido, puede resultar inmediatamente en serio daño personal o la muerte.

Signica el riesgo de un peligro potencial que puede resultar en serio daño personal o la muerte.

Signica el posible riesgo que puede resultar en menores daños a la persona.

SECTION 1 SÉCURITÉ

1.3 Safety - French

AVERTISSEMENT : Ces règles de sécurité

ont pour but d'assurer votre protection. Ils récapitulent les informations de précaution

provenant des références dans la section des Informations de sécurité supplémentaires. Avant de procéder à l'installation ou d'utiliser l'unité, assurezvous de lire et de suivre les précautions de sécurité cidessous, dans les manuels, les ches d'information sur la sécurité du matériel et sur les étiquettes, etc. Tout défaut d'observer ces précautions de sécurité peut entraîner des blessures graves ou mortelles.

PROTÉGEZ-VOUS -- Les processus de soudage, de coupage et de gougeage

produisent un niveau de bruit élevé et exige l'emploi d'une protection auditive. L'arc, tout comme le soleil, émet des rayons ultraviolets en plus d'autre rayons qui peuvent causer des blessures à la peau et les yeux. Le métal incandescent peut causer des brûlures. Une formation reliée à l'usage des processus et de l'équipement est essentielle pour prévenir les accidents. Par conséquent:

1. Portez des lunettes protectrices munies d'écrans la-

téraux lorsque vous êtes dans l'aire de travail, même si vous devez porter un casque de soudeur, un écran facial ou des lunettes étanches.

2. Portez un écran facial muni de verres ltrants et de

plaques protectrices appropriées an de protéger vos yeux, votre visage, votre cou et vos oreilles des étincelles et des rayons de l'arc lors d'une opération ou lorsque vous observez une opération. Avertissez les personnes se trouvant à proximité de ne pas regarder l'arc et de ne pas s'exposer aux rayons de l'arc électrique ou le métal incandescent.

3. Portez des gants ignifugiés à crispin, une chemise

épaisse à manches longues, des pantalons sans rebord et des chaussures montantes an de vous protéger des rayons de l'arc, des étincelles et du métal incandescent, en plus d'un casque de soudeur ou casquette pour protéger vos cheveux. Il est également recommandé de porter un tablier ininammable an de vous protéger des étincelles et de la chaleur par rayonnement.

4. Les étincelles et les projections de métal incandescent

risquent de se loger dans les manches retroussées, les rebords de pantalons ou les poches. Il est recommandé de garder boutonnés le col et les manches et de porter des vêtements sans poches en avant.

5. Protégez toute personne se trouvant à proximité des

étincelles et des rayons de l'arc à l'aide d'un rideau ou d'une cloison ininammable.

6. Portez des lunettes étanches par dessus vos lunettes

de sécurité lors des opérations d'écaillage ou de meulage du laitier. Les écailles de laitier incandescent peuvent être projetées à des distances considérables. L es p er so n ne s se tr o uv an t à p r ox im it é do ive n t é ga l ement porter des lunettes étanches par dessus leur lunettes de sécurité.

INCENDIES ET EXPLOSIONS -- La chaleur provenant des ammes ou de l'arc peut provoquer un incendie. Le laitier incandescent ou les étincelles

peuvent également provoquer un

incendie ou une explosion. Par conséquent :

1. Éloignez susamment tous les matériaux combustibles de l'aire de travail et recouvrez les matériaux avec un revêtement protecteur ininammable. Les matériaux combustibles incluent le bois, les vêtements, la sciure, le gaz et les liquides combustibles, les solvants, les peintures et les revêtements, le papier, etc.

2. Les étincelles et les projections de métal incandescent peuvent tomber dans les ssures dans les planchers ou dans les ouvertures des murs et déclencher un incendie couvant à l'étage inférieur Assurez-vous que ces ouvertures sont bien protégées des étincelles et du métal incandescent.

3. N'exécutez pas de soudure, de coupe ou autre travail à chaud avant d'avoir complètement nettoyé la surface de la pièce à traiter de façon à ce qu'il n'ait aucune substance présente qui pourrait produire des vapeurs inammables ou toxiques. N'exécutez pas de travail à chaud sur des contenants fermés car ces derniers pourraient exploser.

4. Assurez-vous qu'un équipement d'extinction d'incendie est disponible et prêt à servir, tel qu'un tuyau d'arrosage, un seau d'eau, un seau de sable ou un extincteur portatif. Assurez-vous d'être bien instruit par rapport à l'usage de cet équipement.

5. Assurez-vous de ne pas excéder la capacité de l'équipement. Par exemple, un câble de soudage surchargé peut surchauer et provoquer un incendie.

6. Une fois les opérations terminées, inspectez l'aire de travail pour assurer qu'aucune étincelle ou projection de métal incandescent ne risque de provoquer un incendie ultérieurement. Employez des guetteurs d'incendie au besoin.

7. Pour obtenir des informations supplémentaires, consultez le NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", disponible au National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

CHOC ÉLECTRIQUE -- Le contact avec des pièces électriques ou les pièces de mise à la terre sous tension peut causer des blessures graves ou mor-

telles. NE PAS utiliser un courant de soudage c.a. dans un endroit humide, en espace restreint ou si un danger de chute se pose.

SECTION 1 SÉCURITÉ

1. Assurez-vous que le châssis de la source d'alimentation est branché au système de mise à la terre de l'alimentation d'entrée.

2. Branchez la pièce à traiter à une bonne mise de terre électrique.

3. Branchez le câble de masse à la pièce à traiter et assurez une bonne connexion an d'éviter le risque de choc électrique mortel.

4. Utilisez toujours un équipement correctement entretenu. Remplacez les câbles usés ou endommagés.

5. Veillez à garder votre environnement sec, incluant les vêtements, l'aire de travail, les câbles, le porteélectrode/torche et la source d'alimentation.

6. Assurez-vous que tout votre corps est bien isolé de la pièce à traiter et des pièces de la mise à la terre.

7. Si vous devez eectuer votre travail dans un espace restreint ou humide, ne tenez vous pas directement sur le métal ou sur la terre; tenez-vous sur des planches sèches ou une plate-forme isolée et portez des chaussures à semelles de caoutchouc.

8. Avant de mettre l'équipement sous tension, isolez vos mains avec des gants secs et sans trous.

9. Mettez l'équipement hors tension avant d'enlever vos gants.

10. Consultez ANSI/ASC Standard Z49.1 (listé à la page suivante) pour des recommandations spéciques concernant les procédures de mise à la terre. Ne pas confondre le câble de masse avec le câble de mise à la terre.

CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — comportent un risque de danger. Le courant électrique qui passe dans n'importe quel conduc-

teur produit des champs électriques et magnétiques localisés. Le soudage et le courant de coupage créent des champs électriques et magnétiques autour des câbles de soudage et l'équipement. Par conséquent :

1. Un soudeur ayant un stimulateur cardiaque doit

consulter son médecin avant d'entreprendre une opération de soudage. Les champs électriques et magnétiques peuvent causer des ennuis pour certains stimulateurs cardiaques.

2. L'exposition à des champs électriques et magné-

tiques peut avoir des eets néfastes inconnus pour la santé.

3. Les soudeurs doivent suivre les procédures suivantes pour minimiser l'exposition aux champs électriques et magnétiques :

A. Acheminez l'électrode et les câbles de masse

ensemble. Fixez-les à l'aide d'une bande adhésive lorsque possible.

B. Ne jamais enrouler la torche ou le câble de masse

autour de votre corps.

C. Ne jamais vous placer entre la torche et les câbles

de masse. Acheminez tous les câbles sur le même côté de votre corps.

D. Branchez le câble de masse à la pièce à traiter le

plus près possible de la section à souder.

E. Veillez à garder la source d'alimentation pour le

soudage et les câbles à une distance appropriée de votre corps.

LES VAPEURS ET LES GAZ -- peuvent causer un malaise ou des dommages

corporels, plus particulièrement dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le gaz de protection risque de causer l'asphyxie. Par conséquent :

1. Assurez en permanence une ventilation adéquate dans l'aire de travail en maintenant une ventilation naturelle ou à l'aide de moyens mécanique. N'effectuez jamais de travaux de soudage, de coupage ou de gougeage sur des matériaux tels que l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc, le plomb, le berylliym ou le cadmium en l'absence de moyens mécaniques de ventilation ecaces. Ne respirez pas les vapeurs de ces matériaux.

2. N'eectuez jamais de travaux à proximité d'une opération de dégraissage ou de pulvérisation. Lorsque la chaleur

ou le rayonnement de l'arc entre en contact avec les

vapeurs d'hydrocarbure chloré, ceci peut déclencher la formation de phosgène ou d'autres gaz irritants, tous extrêmement toxiques.

3. Une irritation momentanée des yeux, du nez ou de la gorge au cours d'une opération indique que la ventilation n'est pas adéquate. Cessez votre travail an de prendre les mesures nécessaires pour améliorer la ventilation dans l'aire de travail. Ne poursuivez pas l'opération si le malaise persiste.

4. Consultez ANSI/ASC Standard Z49.1 (à la page suivante) pour des recommandations spéciques concernant la ventilation.

SECTION 1 SÉCURITÉ

5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé dans une opération de soudage ou de coupage, dégage des vapeurs ou des gaz contenant des chimiques considéres par l'état de la Californie comme étant une cause des malformations congénitales et dans certains cas, du cancer. (California Health & Safety Code §25249.5 et seq.)

MANIPULATION DES CYLINDRES -La manipulation d'un cylindre, sans observer les précautions nécessaires, peut produire des fissures et un

échappement dangereux des gaz. Une brisure soudaine du cylindre, de la soupape ou du dispositif de surpression peut causer des blessures graves ou mortelles. Par conséquent :

1. Utilisez toujours le gaz prévu pour une opération

et le détendeur approprié conçu pour utilisation sur les cylindres de gaz comprimé. N'utilisez jamais d'adaptateur. Maintenez en bon état les tuyaux et les raccords. Observez les instructions d'opération du fabricant pour assembler le détendeur sur un cylindre de gaz comprimé.

2. Fixez les cylindres dans une position verticale, à

l'aide d'une chaîne ou une sangle, sur un chariot manuel, un châssis de roulement, un banc, un mur, une colonne ou un support convenable. Ne xez jamais un cylindre à un poste de travail ou toute autre dispositif faisant partie d'un circuit électrique.

3. Lorsque les cylindres ne servent pas, gardez les

soupapes fermées. Si le détendeur n'est pas branché, assurez-vous que le bouchon de protection de la soupape est bien en place. Fixez et déplacez les cylindres à l'aide d'un chariot manuel approprié. Toujours manipuler les cylindres avec soin.

4. Placez les cylindres à une distance appropriée

de toute source de chaleur, des étincelles et des ammes. Ne jamais amorcer l'arc sur un cylindre.

5. Pour de l'information supplémentaire, consultez

CGA Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", mis à votre disposition par le Compressed Gas Association, 1235 Jeerson Davis Highway, Arlington, VA 22202.

ENTRETIEN DE L'ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou inadéquate peut causer des blessures graves ou mortelles. Par conséquent :

1. Efforcez-vous de toujours confier les tâches d'installation, de dépannage et d'entretien à un personnel qualié. N'eectuez aucune réparation électrique à moins d'être qualié à cet eet.

2. Avant de procéder à une tâche d'entretien à l'intérieur de la source d'alimentation, débranchez l'alimentation électrique.

3. Maintenez les câbles, les ls de mise à la terre, les branchements, le cordon d'alimentation et la source d'alimentation en bon état. N'utilisez jamais un équipement s'il présente une défectuosité quelconque.

4. N'utilisez pas l'équipement de façon abusive. Gardez l'équipement à l'écart de toute source de chaleur, notamment des fours, de l'humidité, des aques d'eau, de l'huile ou de la graisse, des atmosphères corrosives et des intempéries.

5. Laissez en place tous les dispositifs de sécurité et tous les panneaux de la console et maintenez-les en bon état.

6. Utilisez l'équipement conformément à son usage prévu et n'eectuez aucune modication.

INFORMATIONS SUPPLÉMENTAIRES RELATIVES À LA SÉCURITÉ -- Pour obtenir de l'information supplémentaire sur les règles de sécurité à observer pour l'équipement de soudage à l'arc électrique et le coupage, demandez un exemplaire du livret "Precautions and Safe Practices for Arc Welding, Cutting and Gouging", Form 52-529.

Les publications suivantes sont également recommandées et mises à votre disposition par l'American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126 :

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon Arc Gouging and Cutting"

SECTION 1 SÉCURITÉ

SIGNIFICATION DES SYMBOLES Ce symbole, utilisé partout dans ce manuel, signie "Attention" ! Soyez vigilant ! Votre sécurité est en jeu.

DANGER

Signie un danger immédiat. La situation peut entraîner des blessures graves ou mortelles.

AVERTISSEMENT

Signie un danger potentiel qui peut entraîner des blessures graves ou mortelles.

ATTENTION

Signie un danger qui peut entraîner des blessures corporelles mineures.

SECTION 2 DESCRIPTION

2.1 GENERAL

The Powercut is a compact, completely self-contained plasma cutting system. As

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.

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). The Powercut-1125 package uses the heavy-duty PT-32 torch to deliver cutting power for severing materials up to 1-1/4 inch thick. Refer to the following paragraphs for descriptions of the Powercut-1125 packages available as well as performance specications.

2.2 SCOPE

The purpose of this manual is to provide the operator with all the information required to install and operate the Powercut-1125 plasma arc cutting package. Technical reference material is also provided to assist in troubleshooting the cutting package.

2.3 PACKAGES AVAILABLE

2.3.1 Manual Cutting Packages

Powercut-1125 packages listed on the front cover and below, includes the following components:

PT-32 Torches:

PT-32 Torch, 75

PT-32 Spare Parts Kit (see below) ..........................................................................0558002822

Powercut-1125 Console/Power Source ..................................................................See below

PT-32 Spare Parts Kit, P/N 0558002822, Contents:

Quantity Part Number Description

4 0558002618 50-70 Amp Nozzle 1 0558002908 40 Amp Nozzle 3 0558001969 Electrode 2 0558001957 Heat Shield 1 0558001959 Valve Pin 1 0558002393 Stand O Guide 1 19129 Wrench 1 17672 Lubricant

Depending on the choice of input power, each package includes the following appropriate PowerCut-1125 Console/Power Source:

head, 25-ft. ...................................................................................0558001971

head, 50-ft. ..................................................................................0558001972

Powercut-1125 Consoles:

208/230 V, 50/60 Hz, 1/3-ph .......................................................................... P/N 0558002192

460 V, 50/60 Hz, 3-phase ................................................................................. P/N 0558002193

575 V, 60 Hz, 3-phase ........................................................................................ P/N 0558002924

208/230 V, 50/60 Hz, 1/3-ph (bilingual) ..................................................... P/N 0558003369

Powercut-1125 Manual Cutting Packages:

208/230 V, 25' Package ....................................................................................P/N 0558002791

208/230 V, 25' Package (bilingual) .............................................................P/N 0558002791F

208/230 V, 50' Package ....................................................................................P/N 0558002792

460 V, 25' Package ............................................................................................. P/N 0558002793

460 V, 50' Package ............................................................................................. P/N 0558002794

575 V, 25' Package ............................................................................................. P/N 0558002928

SECTION 2 DESCRIPTION

2.4 SPECIFICATIONS

Table 2-2. PowerCut-1125 Specications

Rated Inputs Rated Outputs

Phases Volts Amps Power

Factor

One 208 64

73% 60% 70

230 68

73% 60% 70

*Duty Cycle

Output Amps @ 120V DC

Open Circuit Voltage

280V DC 280V DC

270V DC 270V DC

Eciency

86%

Three 208 28 93% 60% 70 285V DC 89%

230 25 93% 60% 70 275V DC 89% 460 14 88% 60% 70 275V DC 89% 575 11 87% 60% 70 260V DC 89%

*Duty cycle is based on a 10-minute period; therefore, a 70% duty cycle means the power source may operate for 7 minutes with a cool down period of 3 minutes. 100% duty cycle means the power source may operate continuously.

Current Capacity PT-32 80 A DCSP Air Requirements PT-32 320 cfh @ 65 - 75 psig

(150 l/min @ 4.5 - 5.2 bars)

Dimensions Length

w/handles

20.3 (516 mm)

30.0 (750 mm) Height 16.38 (410 mm) Width

w/o opt. storage

13.1 (328 mm)

16.1 (403 mm) w/ opt. torch storage

Weight of PowerCut-1125 System 87 lbs (39.5 kg) Shipping Weight 102 lbs (46.4 kg)

SECTION 2 DESCRIPTION

Table 2-3. PT-32 Torch Specications

Current Capacity (100% Duty) Length of Service Lines Weight 25 ft. 50 ft.

PT-32 CUTTING SPEEDS

AIR @ 70 PSI and OUTPUT CURRENT 40AMPS

Cutting Material Thickness (In.) Speed (IPM)

Carbon Steel 1/16 200 1/8 98 1/4 36 3/8 18 1/2 11

Stainless Steel 1/16 138 1/8 58 1/4 18 3/8 10 1/2 6

90 A DCSP 25 ft. or 50 ft.

5.2 lbs (2.4kg)

9.6 lbs (4.4 kg)

3.031" (76 mm)

8" (200 mm)

75°

1.08" (25.20 mm)

1.16" (25.41 mm)

Figure 2-1. PT-32 Dimensions

Aluminum 1/16 200

1/8 110 1/4 48 3/8 17 1/2 14

Figure 2-2. PT-32/POWERCUT-875 Cutting Performance

IMPORTANT!!!

Maintain Proper

Stand-O Distance

3/16 to 1/4 Inch

Power Output increases with Stand O Distance!

Figure 2-3. PT-32/POWERCUT-875 Cutting Performance

SECTION 2 DESCRIPTION

2.5 OPTIONAL ACCESSORIES

1. Torch Wrap/Spare Parts Kit Holder, P/N 0558003013 Units can be mounted to either side of machine using the two upper mounting positions of the end cap handles.

2. Wheel Cart, P/N 0558003014

This 3 7/8" high cart has front and rear heavy duty swivel caster to make it easier to roll the PowerCut-875 around the

job site.

SECTION 3 INSTALLATION

3.1 GENERAL

Proper installation is important for satisfactory and trouble-free operation of the

Installing or placing any type of ltering device will restrict the volume of intake air, thereby subjecting the power source internal components to overheating. The warranty is void if any type of lter device is used.

Powercut-1125 cutting package. It is suggested that each step in this section be studied carefully and followed closely.

3.2 EQUIPMENT REQUIRED

A source of clean, dry air that supplies 360 cfh at 75 psig is required for the cutting operation. The air supply should not exceed 150 psig (the maximum inlet pressure rating of the air lter-regulator supplied with the package). A Brass 45O 1/4" NPT Female x 1/4" NPT Male Street Elbow is recommended for attaching the air hose to the regulator . This elbow will provide greater clearance around the handle. (See replacement parts for ordering information or obtain from a hardware supplier.)

3.3 LOCATION

Adequate ventilation is necessary to provide proper cooling of the Powercut-1125. The amount of dirt, dust, and excessive heat to which the equipment is exposed, should be minimized. There should be at least one foot of clearance between the Powercut-1125 power source and wall or any other obstruction to allow freedom of air movement through the power source.

ELECTRIC SHOCK CAN KILL! Precautionary measures should be taken to provide maximum protection against electrical shock. Be sure that all power is o by opening the line (wall) disconnect switch and by unplugging the power cord to the unit when connections are made inside of the power source.

Be sure that the power source is properly congured for your input power supply. DO NOT connect a power source congured for 208/230 V to a 460 V input power supply. Damage to the machine may occur.

3.4 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-1125. Notify the carrier of any defects or damage at once.

B. Check container for any loose parts prior to disposing of shipping materials.

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

removed.

3.5 PRIMARY ELECTRICAL INPUT CONNECTIONS FIGURE 31

NOTE: If using 200(208) V input power, the Powercut-1125 must be reconnected for

200 V use as directed in Section 3.7 and Fig. 3-2.

The Powercut-1125 consoles are equipped with a 10-ft, 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.

NOTE: The 208/230 V models are equipped with a plug for single-phase connection only.

The plug is mounted to a 4-conductor cable. If 3-phase connection is desired, remove and discard the plug and proceed as described above.

SECTION 3 INSTALLATION

Table 3-1. Recommended Sizes For

Input Conductors and Line Fuses

Input Requirements Input & Gnd Fuse Volts Phase Amps Conductor Size CU/AWG Amps

208 1 64A 4 90 208 3 28A/Ph. 10 50 230 1 58A 4 90 230 3 25A/Ph. 10 40 460 3 14 10 25 575 3 11 10 20

3.6 SECONDARY OUTPUT CONNECTIONS REFER TO FIG. 31

Before making any connections to the power source output terminals, make sure that all primary input power to the power source is deenergized (o) at the main disconnect switch and that the input power cable is unplugged.

1. For operator safety, the torch connections are located on the output terminal board behind the lower portion of the front panel. Remove access cover to output terminal compartment from lower front panel of power source.

2. Thread the power cable, pilot arc cable and switch lead of the PT-32 through the open bushing of the cover. Connect power cable to the torch tting (lefthand threads); attach the pilot arc cable connection to the Pilot Arc bulkhead adaptor; and plug in the switch lead to the torch switch receptable on the output terminal. Make sure the power and pilot arc cable connections are wrench-tight. Make sure plug of switch lead is rmly inserted in place.

3. Reassemble the access cover to the power source.

4. Connect your air supply to the inlet connection of the lter-regulator.

5. 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 INSTALLATION

TORCH PILOT ARC CONNECTION

TORCH SWITCH

ADAPTOR

TORCH POWER

CABLE

CONNECTION

WORK

View With Access Cover Removed

Allow at least 10 ft. (3m)

between work and power source

SAFETY GROUND

ACCESS FOR CNC INTERFACE CONNECTIONS. (See Detail “A”)

CUSTOMER FUSED LINE DISCONNECT SWITCH (See Table 3-1 and WARNING in regards to chassis ground)

ACCESS COVER FOR TORCH CONNECTION

Use a Brass 45O 1/4" NPT Female x 1/4" NPT Male Street Elbow for better clearance around the handle.

PT-32

Preltered AIR SUPPLY (Customer Supplied) (90 to 150 psig max)

INPUT POWER CABLE

(See Table 3-1)

NOTE: The 208/230 V models are equipped with a plug for single-

phase connection only. The plug is mounted to a 4-conductor cable. If 3-phase connection is desired, remove and discard the plug and refer to Sect. 3.5.

Figure 3-1. Powercut-1125 Interconnection Diagram

SECTION 3 INSTALLATION

3.7 CONNECTING POWERCUT1125 FOR 200208 VAC INPUT

The Powercut-1125 power source with 200/230 vac, 1-phase input capability is factory set for 230 vac input. If using 200(208) vac input, the Powercut-1125 must be reconnected as follows before connecting to your input power:

1. Remove rear handle, slide left side panel out.

2. Locate the Input Bridge (IBR) and TB5 terminal block (see Fig. 3-2) on the left side towards the rear panel. Disconnect the gray lead from TB5-2 and then connect it to TB5-1. (See Diagram on inside of lower panel).

3. Locate the output bridge (D2) on left side towards the front panel (see Fig. 3-2). Disconnect and swap leads X2 and X3 from the main transformer. For 200(208) vac input, X2 is connected to TB3 and X3 is connected to terminal 3 of D2. Make sure the connections are rmly tightened.

4. Leave all other wires the same.

5. Reinstall cover and connect the Powercut-1125 to 208 vac input power.

SECTION 3 INSTALLATION

Do NOT change any other wires.

Figure 3-2. Original Factory Setup for 230 Vac Input on

Power Source with 200/230 Vac Input Power Capability

SECTION 3 INSTALLATION

SECTION 4 OPERATION

4.1 OPERATION

4.2 Powercut-1125 CONTROLS (FIGURE 4-2)

• DoNOToperatetheunitwiththe

ELECTRIC SHOCK can kill.

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.

ARC RAYS can burn eyes and skin; NOISE can damage hearing.

• WearweldinghelmetwithNo.6or7

lens shade.

• Weareye,ear,andbodyprotection.

Position the Powercut-1125 at least 10 feet (3 meters) from the cutting area. Sparks and hot slag from the cutting operation can damage the unit.

A. Power Switch (located on rear panel). When placed in ON position, the green

pilot light will glow indicating control circuit is energized and the cooling fan will run.

B. Output Current Control. Adjustable from 20 to 60 amperes.

C. Air Test Switch. When placed in Test position, air lter-regulator can be ad-

justed to desired pressure (65-75 psig) before cutting operations. Allow air to ow for a few minutes. This should remove any condensation that may have accumulated during shutdown period. Be sure to place switch in OPERATE position before starting cutting operations.

D. 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 during the entire cutting operation and then released at the end of cut.

E. Fault Light. Will glow amber under the following conditions and operations

will come to a complete stop.

Flow Fault: The fault light will be mostly on but will ick o for about 1/10th of a second every second. This indicates that the air ow supply is low or has no back pressure.

Over Temperature: The fault light will be mostly o but will ick on for about 1/10th of a second every second. This indicates that the duty cycle has been exceeded. Allow the power source to cool down before returning to operate.

High/Low Line Voltage: The fault light will rapidly blink on and o (ve times per second). This indicates that the input voltage is outside the “+ or -” 15% range of the input rating.

Over-Current: The fault light will be on continuously. This indicates that input current has been exceeded.

All fault signals will remain on for a minimum of 10 seconds. If fault clears, all will reset automatically except for over-current. To clear over-current, the power must be shut o for 5 seconds and then turned back on.

SECTION 4 OPERATION

4.3 CUTTING WITH THE PT32

Use the following procedures to cut with the PT-32 torch (Figure 4-1).

A. Hold the torch nozzle approximately 1/8 to 3/16 inch above the work and tilted at about 15 - 30°. This reduces the

chance of spatter entering the nozzle. If the PT-32's stando guide P/N 0558002393 is being used, the distance between

Electrode and Work Piece will be approx. 3/16-inch. B. Depress the torch switch. Air should ow from the torch nozzle. C. Two seconds after depressing the torch switch, the pilot arc should start. The main arc should immediately follow, al-

lowing the cut to begin. (If using the trigger LOCK mode, torch switch may be released after establishing the cutting

arc.) D. After starting the cut, the torch should be maintained at a 5-15° forward angle. This angle is especially useful in helping

to create a "drop" cut. When not using the stando guide, the nozzle should be held approximately 1/4 inch from the

work. E. When ending a cut, the torch switch should be released (press and release if using trigger LOCK mode) and lifted o

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).

F. For rapid re-starts, such as grate or heavy mesh cutting, do not release the torch switch. In the postow mode, the arc

can be re-started immediately by depressing the torch switch. This avoids the 2-second preow portion of the cutting

cycle.

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.

Piercing Technique using the PT-32

Figure 4-1. Cutting Diagrams

CUT

DIRECTION

Recommended Torch Angle

of 5° to 15°

SECTION 4 OPERATION

AIR

PRESSURE

GAUGE

AIR TEST SWITCH

POWER LIGHT

(WHITE)

FAULT LIGHT

(AMBER)

CURRENT CONTROL

KNOB

TRIGGER LOCK

REAR VIEW

FUSE (3A)

SWITCH

AIR REGULATOR CONTROL KNOB

POWER ON-OFF (I-O) SWITCH

Figure 4-2. Powercut-1125 Controls

NOTE: When replacing the nozzle, always inspect the electrode for wear. If more than .06" of electrode Hafnium 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. Refer to Figure 4-3.

NEW

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

REPLACE ELECTRODE BEFORE PITTING BECOMES DEEPER THAN .06 INCH (1.5 MM)

WORN

Figure 4-3. Electrode Wear Limit

4.3.1. Drag Cutting with the PT-32/PowerCut -1125 System

LOW CURRENT AUTO-DRAG FEATURE

If drag cutting is desired for thin material under 3/8" thick, remove the standard 50-70 amp nozzle (P/N 0558002618) from the

PT-32 torch and install ESAB's 40 amp nozzle (P/N 0558002908). Lower the current level setting to be within the AUTO-DRAG

range of 20 to 40 amps (see Auto Drag Scale on front panel). Then follow steps in Section 4.3. Also refer to PT-32 Instruction

Manual No. F-15-440.

HIGH CURRENT DRAG CUTTING

If drag cutting is desired on materials above 3/8” thick, be sure that the 50-70 amp nozzle (P/N 0558002618) is installed in

the PT-32 torch. Attach ESAB's stand-o guide (P/N 0558002393) and operate as shown in Figure 4.4.

SECTION 4 OPERATION

Drag cutting, even with lower current levels may signicantly reduce the life of torch consumables.

NOTICE

STEEL GUARD STAND OFF GUIDE P/N 0558002393

Attempting to Drag Cut with higher currents (70 amps) may cause immediate catastrophic consumable damage.

ADJUST GUIDE BY TURNING IN A CLOCKWISE DIRECTION ONLY. THIS WILL PREVENT ACCIDENTAL LOOSENING OF SHIELD.

GUIDE AGAINST STRAIGHT EDGE OR FREE-HAND CUT

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

1/16" (1.6 mm) TO 1/4" (6.4 mm) TORCH-TO-WORK

IF GUIDE IS TOO TIGHT ON SHIELD, OPEN SLOT WITH SCREWDRIVER.

IF TOO LOOSE, CLOSE SLOT WITH VISE OR LARGE PLIERS.

Figure 4-4. Installation and Operation of Steel Heat Shield Guards

SECTION 5 MAINTENANCE

5.1 GENERAL

If this equipment does not operate properly, stop work immediately and investi-

Be sure that the wall disconnect switch

or wall circuit breaker is open before at-

tempting any inspection or work inside of

the Powercut-1125.

gate 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.

5.2 INSPECTION AND CLEANING

Frequent inspection and cleaning of the Powercut-1125 is recommended for safety and proper operation. Some suggestions for inspecting and cleaning are as follows:

Water or oil occasionally accumulates in

compressed air lines. Be sure to direct the

rst blast of air away from the equipment

to avoid damage to the Powercut-1125.

Make sure power switch on Powercut-1125

is in OFF position before working on the

torch.

The PT-32 torch head contains a gas ow

check valve that acts in conjunction with

the ow switch and circuitry within the

power source. This system prevents the

torch from being energized with high

voltage if the torch switch is accidentally

closed when the shield is removed. Always

replace torch with the proper torch manu-

factured by ESAB since it alone contains

ESABs patented safety interlock.

A. Check work cable for secured connection to workpiece. B. Check safety earth ground at workpiece and at power source chassis. C. Check heat shield on torch. It should be replaced if damaged. D. Check the torch electrode and cutting nozzle for wear on a daily basis. Re-

move spatter or replace if necessary. E. Make sure cable and hoses are not damaged or kinked. F. Make sure all plugs, ttings, and ground connections are tight. G. With all input power disconnected, and wearing proper eye and face pro-

tection, blow out the inside of the Powercut-1125 using low-pressure dry

compressed air. H. Occasionally, bleed all water from the lter beneath the air lter-regulator.

5.3 PT32 TORCH CONSUMABLE PARTS

To assemble the consumable parts, refer to Figure 5-1.

A. Place nozzle, electrode, and valve pin into the shield as shown.

B. Thread assembly to the torch body and hand tighten. Always make sure the

shield is very tight before cutting.

SECTION 5 MAINTENANCE

PLACE THE VALVE PIN INTO THE ELECTRODE AND SCREW THE ELECTRODE INTO THE TORCH HEAD AND TIGHTEN SECURELY WITH WRENCH #19120.

VALVE PIN

ELECTRODE

NOZZLE

SHIELD

PLACE NOZZLE INTO HEAT SHI EL D AND THR EA D THI S ASS EMBLY TO THE TORCH BODY AND HAND TIGHTEN.

IMPORTANT!

MAKE SHIELD VERY TIGHT!

The valve pin is a crucial member of the system. Its function

is to open the gas ow check valve that is permanently 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 improves electrode cooling by increasing the velocity of air over the inner surface of the electrode.

Figure 5-1. Assembly of PT-32 Torch Front End Parts

SECTION 5 MAINTENANCE

5.4 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 emmiter sense pins.

Always ground parts touching gate pins during installation. In general, standard ESD precautlions application to FETs should be followed.

Other handling precautions that should also be observed are as follows:

• Usegroundedworkstationwithgroundedoorsandgroundedwriststrapswhenhandlingdevices.

• Usea100Wresistorinserieswiththegatewhenperformingcurvetracertests.

• Neverinstalldevicesintosystemswithpowerconnectedtothesystem.

• Usesolderingironswithgroundedtipswhensolderingtogateterminals.

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 damaged.

The mounting screws are to be fastened in the order shown in Figure 5-2. Also, care must be taken to achieve maximum contact (i.e. minimum contact thermal resistance) for the best heat dissipation.

Application of a thermal pad on the contact surface improves it thermal conductivity. See Replacement Parts section for the required pad.

A torque wrench should be used. Tighten mounting screws to 28 in-lbs; wire connecting screws to 19 in-lbs. If torque is too heavy, the device can damage like the above “one-sided tightening”.

Two-Point Mounting Type



Temporary tightening  

 Final tightening  















Four-Point Mounting Type

 Temporary tightening    Final tightening  



Figure 5-2. Screw Fastening Order

SECTION 5 MAINTENANCE

5.5 COMMON CUTTING PROBLEMS

Listed below are common cutting problems followed by the probable cause of each. If problems are determined to be caused by the Powercut-1125, 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. Insucient Penetration.

1. Current too low.

2. Cutting speed too fast.

3. Damaged cutting nozzle.

4. Improper air pressure.

5. Low air ow rate.

B. Main Arc Extinguishes.

1. Cutting speed too slow.

2. Worn electrode.

C. Dross Formation. (In some materials and thicknesses, 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 ow rate.

D. Double Arcing. (Damaged Nozzle Orice.)

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 Conditions.

1. Incorrect cutting speed.

2. Loose cable or hose connections.

3. Electrode and/or cutting nozzle in poor condition.

G. Main Arc Does Not Strike.

1. Worn electrode.

2. Loose connections.

3. Work cable not attached.

H. Poor Consumable Life.

1. Improper gas pressure.

2. Contaminated air supply.

3. Low air ow rate.

SECTION 5 MAINTENANCE

5.6 TROUBLESHOOTING

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.

Voltages in plasma cutting equipment are high enough to cause serious injury or possibly death. Be particularly careful around equipment when the covers are removed.

Check the problem against the symptoms in the following troubleshooting guide. The remedy may be quite simple. If the cause cannot be quickly located, shut o the input power, open up the unit, and perform a simple visual inspection of all the 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, electrical schematic diagrams and checking the various components. A volt-ohmmeter will be necessary for some of these checks.

NOTE

Before checking voltages in the circuit, disconnect the power from the high frequency generator to avoid damaging your voltmeter.

NOTE:

Schematics and Wiring Diagrams on 11” x 17”

paper are included

inside the back cover of this manual.

SECTION 5 MAINTENANCE

5.7 TROUBLESHOOTING GUIDE

A. Power Light (PL1) does not come on.

1. Visually inspect the machine for any damage.

2. Check if the cooling fan is running. If not, then check the following :

a. Check if the machine power cord is plugged to 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). If fuse is ok, then check the input circuit breaker (CB1) for proper operation. Replace if defec-

tive.

3. If above items check OK , the problem is internal. Send unit to an Authorized Repair Station for repair.

a. If the cooling fan is running, then measure voltage between pins P2-11 and P2-14 of the control board

(should be 115 VAC). If there is no voltage, then replace transformer T2.

b. If the voltage is present, then the pilot light may be burnt out.

B. No Air Flow

A. Check air inlet supply. Unit requires 360 CFH at 75 psig.

B. Check air hose and connections. Tighten if leaking.

C. Does air ow 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 on this problem.

1. Check the Pilot Arc fuse (F2) located on the rear panel. An open fuse will indicate a short in the torch. If the fuse is all right, then check the following:

a. With the machine power on, depress the torch switch. On the control board the LED 1 should be lit as long as the

switch is depressed. If not then check:

SECTION 5 MAINTENANCE

i. Turn power o to the machine. Unplug Control board. Put an ohmmeter across P5-1 and P5-2 to take resis-

tance reading. Depress torch switch. Meter should read a short. If not, then one of the following is not working properly:

ii. Torch switch or the leads. Unplug the torch switch leads at the machine. Put a meter across the two plug

pins. Should read a short when the torch switch is depressed. If not, then either broken switch leads or malfunctioning switch.

b. Check T2 transformer secondary voltages at the plugs P1 and P2. Refer to system schematic. Replace the trans-

former if the correct secondary voltages are not present.

c. 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 Fault circuit is used to monitor conditions necessary for the safe operation of the Powercut-1125. The fault light

will glow amber under the following conditions and operations will come to a complete stop:

1. High/Low line voltage. The Fault Light will rapidly blink on and o (5 times per second). This indicates that the in-

put voltage is outside the “+” or “-” 15% safe operating range rating.

2. Flow fault - The fault light will be mostly on but will blink o for 1/10th of a second every second. This indicates that

the air ow is low or there is no ow to the pressure switch.

a. Check the air pressure at the machine regulator. It should be adjusted to 65 psig. If no air pressure, check the air

at the supply point. Also, check for any obstructions in the air hose.

b. Air ow may be blocked at the torch tip. Check the torch consumables. Also check for any obstructions in the

torch leads.

NOTE: If above items check OK , the problem is internal. send unit to an Authorized Repair Station for repair. c.. Put the ‘Air Check’ switch to On position. Air should ow through torch. To check if the pressure switch is open,

put voltmeter leads between P1-12 and P1-1. It should read about 5 VDC. When the pressure switch closes, the voltage will drop to zero volts.

d. Air Check switch may also be malfunctioning if the air is owing continuously or if putting in the On position

does not turn air on.

3. Over Temperature. The fault light will be mostly o but will blink on for 1/10 of a second, every second. This gener-

ally indicates that the duty cycle has been exceeded. Allow the power source to cool before returning to operate.

a. Thermal switch may be open. It will open if the temperature at the IGBT base reaches 94oC. With the machine

power o, check the continuity between P1-1 and P1-2 of the control board. If the switch is OK, then the ohmmeter should read a direct short. If not then it should read open.

SECTION 5 MAINTENANCE

b. If the switch is malfunctioning, replace it. Clean the surface of the heat sink before installing the switch.

4. Over Current. The fault light will be on continuously. This indicates that the input current to the main transformer has exceeded preset limits.

a. To check if the output is shorted, measure the resistance by putting the ohmmeter leads (make sure to discon-

nect HI Frequency leads):”+” of the meter to Torch “+” output terminal and Work “-” lead of the meter to the “-” output terminal. Reading should be about 2 K Ohms. Reverse the voltmeter leads, the resistance reading should be less than 1.5 K Ohms.

b. If the resistance reading is dierent than above, check the torch, the output bridge and Filter Board (PCB-5).

E. Air is On but nothing happens when torch switch is operated.

1. Check the pilot arc fuse located on the rear panel. If it is open, nothing will happen when the torch switch is depressed.

2. Check the torch. Make sure that the valve pin is installed and the heat shield is very tight.

3. Check to assure high frequency is present at the torch. If not, then listen for high frequency at the high frequency generator. It is located on the bottom/right side of the unit. The high frequency gap is set between 0.028" to 0.031” Disconnect HI FREQUENCY leads. Check for 115 volt supply to the high frequency unit between P2-12 & P2-13 of the control board with torch switch closed.

4. With HI FREQUENCY leads disconnected, measure open circuit voltage. It should be 275 VDC between “Work” and “Torch” terminals. If it is not present then any one of the following may not be working properly:

a. Check the operation of the Thermal Switch. 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 ow switch. There may be internal short. See D.2.c above. d. Measure voltage across C1 or C2 capacitor. It should be as follows:

approx. 325 VDC for the 208/230 volt unit. approx. 280 VDC to 325 VDC for the 460 volt unit approx. 410 VDC for the 575 volt unit

If not, one of following could be malfunctioning:

1). Check the capacitors C1 and C2 for any damage.

2.) Check input bridge/SCR Module (IBR) This can be checked without taking it out of the circuit using an

volt/ohmeter. Replace it if found malfunctioning. Follow bridge installation instructions.

3.) Check Inrush current resistor, R10 and SCR1. Both are located on the input bridge heat sink. Replace it if

malfunctioning.

e. IGBTs (2 on 230 V, and 1 on the 460 V units) may be blown. See IGBT installation procedure. Before replacing IG-

BTs, make sure to check the zener diodes and pico fuses on the IGBT driver boards.

SECTION 5 MAINTENANCE

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.

3. Make sure the current setting potentiometer is set above 20 amps. If it is, set below 20 amps, then HI FREQUENCY will go on and o at 5 sec intervals.

G. Poor Cutting Performance.

1. Check air supply regulator . It should be adjusted to 65-75 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.4 above.

5. Check the output. Use a calibrated current probe capable of measuring 100 amps in the presence of high frequency.

H. Air does not shut o.

1. Check air test, the gas solenoid valve is energized when the switch is in the “on” position.

2. Does air ow stop 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 dicult to start.

1. The most common reason is worn or missing consumables. Check and replace if necessary.

2. Input air must be clean and dry.

3. Input air pressure must be at least 75 psig.

4. Torch connections must be tight.

5. Work cable and clamp must be in good condition and must make a good electrical connection to the material to be cut.

6. If above items check OK, the problem is internal. Send unit to an Authorized Repair Station for repair.

a. Missing or weak pilot arc. Check pilot arc fuse, open circuit voltage, pilot arc resistors and pilot arc wiring. b. Inoperative starter board (PCB-5).

SECTION 5 MAINTENANCE

5.8 TROUBLESHOOTING GUIDE

A. Control Board Assembly (PCB1)

1. LED’s

LED-1 - Torch Switch LED-2 - High Frequency LED-3 - 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-0 - Ground TP-1 - +15 vdc TP-2 - +12 vdc TP-3 - -12 vdc TP-4 - +5 vdc TP-9 - IGBT’s driving signal - switching frequency = 16 KHz TP-10 - IGBT’s driving signal - switching frequency = 16 KHz

For 208/230 VAC input, the IGBT o time is 3msec.

For /460/ VAC input, the IGBT o time is 6msec.

Figure 5.3. IGBT Gating Signal

SECTION 5 MAINTENANCE

5.9 SEQUENCE OF OPERATION

A. TRIGGER LOCK “UNLOCK” position

PUSH RELEASE

TORCH SWITCH

OPEN CLOSE GAS SOLENOID VALVE

PREFLOW

PRESSURE SWITCH CLOSE

FAULT OVERLOAD LIGHT

HF CIRCUIT

INVERTER

CUTTING ARC (CURRENT)

2 SEC.

ENERGIZE

10 SEC

Postow

OPEN

NOTES:

1. When the torch switch is pushed during postow period, the postow and preow times are canceled, and the HF is energized immediately.

2. When the amber fault light comes on, cutting operation should be stopped. The postow time starts from the moment the torch switch is released.

SECTION 5 MAINTENANCE

B. TRIGGER LOCK "LOCK" position

PUSH RELEASE PUSH RELEASE TORCH SWITCH

OPEN CLOSE GAS SOLENOID VALVE

2 SEC.

PREFLOW

10 SEC

Postow

PRESSURE SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER

CUTTING ARC (CURRENT)

ENERGIZE

POSTFLOW

OPEN

NOTES:

1. When the torch switch is pushed during postow period, the postow and preow times are canceled, and the HF is energized immediately.

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

3. FAULT light is on during second "turn-o" trigger only. This does not aect performance in any way.

SECTION 6 REPLACEMENT PARTS

6.0 Replacement Parts

6.1 General

Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on the unit nameplate.

6.2 Ordering

To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this equipment. The use of non-ESAB parts may void your warranty.

Replacement parts may be ordered from your ESAB Distributor.

Be sure to indicate any special shipping instructions when ordering replacement parts.

Refer to the Communications Guide located on the back page of this manual for a list of customer service phone numbers.

Note

Bill of material items that have blank part numbers are provided for customer information only.

Hardware items should be available through local sources.

SECTION 6 REPLACEMENT PARTS

Fig. 6-1. Powercut-1125 Power Source, Front View

Item Qty. Part Circuit No. Req. No. Description Symbol

1 1 634518 SWITCH TOGGLE SPST 2 POS 15 A 125 V S3 1 951474 SWITCH SEAL BLACK

2 1 951526 LAMP NEON WHITE PL1 3 1 951754 LAMP LED YEL 12 V PL2 4 1 673213 SWITCH TOGGLE SPST 2 POS 15 A 125 V S3

1 951474 SWITCH SEAL BLACK 5 1 13730611 KNOB,SKIRT 1 0558001176 POT 10,3W R1 6 1 0558005498M DOOR, ACCESS 7 2 0558002780 FOOT, PLASMA TUBE 8 2 0558002581 STRAIN RELIEF INPUT NPT1 9 4 61328089 SCREW, STLZPC 0.250-20X0.75 10 1 952207 HOLE PLUG NYLON 11 1 0558002184M PANEL, FRONT PC-1125 12 2 61328091 SCREW, STLZPC 0.250-20X1.75 13 2 0558001916 PLASMA TUBE END COVER 14 1 21711 GAUGE, 1.50 160PSI WHITE 1 993426 GROMMET, RUBBER 1.50 ID X 1.76 OD

SECTION 6 REPLACEMENT PARTS

Optional

7,9

Fig. 6-2. Powercut-1125 Power Source, Rear View

Item Qty. Part Circuit No. Req. No. Description Symbol

1 1 8952136 FUSE HOLDER 1 8952559 FUSE 3A FAST ACTING F1 2 1 954940 LABEL, RATING PC-1125 208/230V 1 954939 LABEL, RATING PC-1125 460V 1 954963 LABEL, RATING PC-1125 575V 3 1 21710 FILTER, REGULATOR AIR LINE 4 1 950512 45O ELBOW, 1/4" NPT FEMALE X 1/4" NPT MALE (Optional) 5 1 2091514 LABEL, WARNING 1 954707 LABEL, WARNING 1 954994 LABEL, DANGER HIGH VOLTAGE 1 955269 LABEL, SYMBOL READ CAUTION 1 954953 LABEL, PT-32 TORCH 6 1 0558002188 SWITCH, POWER 600V / 70A S1 7 2 0558002581 STRAIN RELIEF INPUT NPT1 8 1 13730763 SERIAL CODE PLATE 9 1 37573 INPUT POWER CABLE, 6FT. 4-COND. 6AWG w/PLUG (208/230V) 1 37574 INPUT POWER CABLE, 6FT. 4-COND. 6AWG w/PLUG (460/575V) 10 1 0558005659 FINGER GUARD

SECTION 6 REPLACEMENT PARTS

19,20,21

15, 25

17, 23, 24

Fig. 6-3. Powercut-1125 Power Source, Left Side View (208/230)

SECTION 6 REPLACEMENT PARTS

Item Qty. Part Circuit

No. Req. No. Description Symbol

Fig. 6-3. Powercut-1125 Power Source, Left Side View (208/230) cont'd

25 1 951314 CAPACITOR .022uf 1KV C10

23 1 2062282 CAPACITOR .22uf 1KV (See Wiring Diagram) C19

24 3 951321 METAL OXIDE VARISTOR 275V (See Wiring Diagram) MOV1, 2, 3

22 2 0558002169 FITTING, BARB, 1/4 HOSE, 1/8 NPTF

21 1 0558002628 NUT, RETAINING

20 1 0558002187 FITTING, BARB, 1/4 HOSE, 1/8 NPTM

19 1 0558002189 PRESSURE SWITCH 24V SPST PS1

(Includes PAD - 952280)

17 1 952235 MODULE, INPUT BRIDGE/SCR IBR

18 2 950487 TERM. BLOCK 2 POS 20A TB1,5

12 1 952255 CAPACITOR 40UF 400VDC C4

14 1 17250010 RESISTOR FIXED 50W 10 OHM R10

6 AR 90858025 TUBING 1/4” NYLOBRAID

7 1 0558002482 SOL AY 3/16 BARB 1/8 NPTM PORT SOL

8 1 952208 STANDOFF, INSULATING, NYLON TB3

AR 994674 GROMMET STRIP

5 2 952237 CAPACITOR 1800UF 450VDC W/NUT C1,2

1 1 36731 BUSBAR (NEG.)

4 2 0558001177 PCB ASSY MOSFET/IGBT DRVR BRD PCB2,3

2 1 36730 BUSBAR (POS.)

3 1 950711 SWITCH,THERMAL 194 DEG. TB3

(Includes PAD - 951193)

(Includes PAD - 951518)

11 4 17721020 RES. 25W 1% 20 OHMS R3,4,5,6

10 2 951185 BRIDGE 100ADC 100NS 600V D1, 2

9 1 13730583 TERM. BUSHING .687”

(Includes PAD - 951191)

(Includes PAD - 951194)

16 2 952873 IGBT 600V 200A SER H Q1,2

15 1 17750010 RESISTOR 50W 3% 10 OHM R7

13 1 32858 TRANSFORMER ASSY. CURRENT T4

SECTION 6 REPLACEMENT PARTS

19,20,21

Fig. 6-4. Powercut-1125 Power Source, Left Side View (460/575V)

SECTION 6 REPLACEMENT PARTS

Item Qty. Part Circuit

No. Req. No. Description Symbol

Fig. 6-4. Powercut-1125 Power Source, Left Side View (460/575)

22 2 0558002169 FITTING, BARB, 1/4 HOSE, 1/8 NPTF

21 1 0558002628 NUT, RETAINING

20 1 0558002187 FITTING, BARB, 1/4 HOSE, 1/8 NPTM

19 1 0558002189 PRESSURE SWITCH 24V SPST PS1

(Includes PAD - 952280)

17 1 952235 MODULE, INPUT BRIDGE/SCR IBR

18 2 950487 TERM. BLOCK 2 POS 20A TB1,5

6 AR 90858025 TUBING 1/4” NYLOBRAID

7 1 0558002482 SOL AY 3/16 BARB 1/8 NPTM PORT SOL

8 1 952208 STANDOFF, INSULATING, NYLON TB3

AR 994674 GROMMET STRIP

2 952562 CAPACITOR 1800UF 500VDC (575V)

5 2 952237 CAPACITOR 1800UF 450VDC W/NUT (460V) C1,2

4 2 0558001197 PCB ASSY MOSFET/IGBT DRVRBRD PCB2,3

1 951892 CAPACITOR 0.68UF 1200VDC (575V)

3 1 951964 CAPACITOR 2UF 800VCD (460V) C16

1 1 36733 BUSBAR (NEG.)

2 1 950711 SWITCH,THERMAL 194 DEG. TB3

(Includes PAD - 951518)

10 2 951185 BRIDGE 100ADC 100NS 600V D1, 2

(Not used on 575V)

9 1 13730583 TERM. BUSHING .687”

12 1 952255 CAPACITOR 40UF 400VDC (460V) C4

11 4 17721020 RES. 25W 1% 20 OHMS R3,4,5,6

(Includes PAD - 951833)

1 951831 MODULE DUAL IGBT 200A, 1400V (575V)

16 2 951205 MODULE DUAL IGBT 200A, 1200V (460V) Q1

15 1 17750010 RESISTOR 50W 3% 10 OHM R7

13 1 32958 TRANSFORMER ASSY. CURRENT T4

14 1 17250010 RESISTOR FIXED 50W 10 OHM R10

1 952585 CAPACITOR 20UF 600VDC (575V)

(Includes PAD - 951193)

SECTION 6 REPLACEMENT PARTS

18,19,20 8

15,16

1,13

Fig. 6-5. Powercut-1125 Power Source, Right Side View (208/230)

SECTION 6 REPLACEMENT PARTS

Item Qty. Part Circuit

No. Req. No. Description Symbol 1 1 831488 PC BRD AY SHUNT BRD PCB4

2 1 37603 TRANSFORMER ASSY MAIN 230/460V T1

3 1 8952232 INDUCTOR PFC L2

5 2 37753BK BRKT RES DUAL

6 2 950908 CABLE TIE, PUSH-MOUNT

4 2 17300012 RESISTER 300W 12 OHM R11,12

7 1 835940 TRANSFORMER ASSY. CONTROL T2

9 1 0558002175B BRACKET, TRANSFORMER MOUNTING

8 2 950487 TERMINAL BLOCK 2 POS 20A TB1,5

10 1 37669 REACTOR ASSY. HIGH FREQ. T3

11 1 2142496 TUBING, PVC .0625 ID

12 1 38214 CONTROL BOARD ASSY. PCB1

13 1 951515 CAPACITOR .047uf 660VAC C23

14 1 952233 INDUCTOR OUTPUT L1

15 1 36431 SPARK GAPASSY. SG

17 1 951179 TRANSFORMER HI VOLTAGE T5

16 2 951342 CAPACITOR 2500pf 15KV C13, 14

19 1 952557 CAPACITOR .82uf 630VDC (See Wiring Diagram) C21, 22

18 1 673458 CONTACTOR 3 POLE 110 VAC 40A

Fig. 6-5. Powercut-1125 Power Source, Right Side View (208/230) cont'd

20 2 17130433 RESISTOR, CM FILM AL 1W 330K (See Wiring Diagram) R13

SECTION 6 REPLACEMENT PARTS

3, 20, 21

8, 22, 23

15,17

1,13

Fig. 6-6. Powercut-1125 Power Source, Right Side View (460/575 V)

SECTION 6 REPLACEMENT PARTS

Item Qty. Part Circuit

No. Req. No. Description Symbol

1 1 31488 PC BRD AY SHUNT BRD PCB4

2 1 37603 TRANSFORMER ASSY MAIN (460V) T1

Fig. 6-6. PowerCut-1125 Power Source, Right Side View (460/575 V) cont'd

23 1 952204 CAPACITOR .01UF 250VAC (See Wiring Diagram)

22 2 672348 CAPACITOR .01UF 1KV (See Wiring Diagram)

21 2 17130433 RESISTOR CM FILM AL 1W 330K (See Wiring Diagram) R13

19 1 38039 START-UP BOARD ASS'Y PCB5

20 2 952557 CAPACITOR .82UF 630VDC (See Wiring Diagram) C21

18 1 952213 REACTOR 3PH LINE 12A L2

17 2 951342 CAPACITOR 2500pf 15KV C13, 14

15 1 36431 SPARK GAPASSY. SG

16 1 951179 TRANSFORMER HI VOLTAGE T5

12 1 38214 CONTROL BOARD ASSY. PCB1

13 1 951515 CAPACITOR .047uf 660VAC C23

14 1 952233 INDUCTOR OUTPUT L1

10 1 37669 REACTOR ASSY. HIGH FREQ. T3

11 1 2142496 TUBING, PVC .0625 ID

9 1 0558002175B BRACKET, TRANSFORMER MOUNTING

7 1 32914 TRANSFORMER ASSY. CONTROL T2

5 2 37753BK BRKT RES DUAL

4 2 17300012 RESISTER 300W 12 OHM R11,12

1 36599 TRANSFORMER ASSY MAIN (575V)

3 1 673458 CONTACTOR 3 POLE 110VAC 40A K1

8 2 950487 TERMINAL BLOCK 2 POS 20A TB1,5

6 2 950908 CABLE TIE, PUSH-MOUNT

SECTION 6 REPLACEMENT PARTS

Fig. 6-7. Powercut-1125 (208/230V) Power Source, Top View with PCB1 and Shelf Removed

Item Qty. Part Circuit No. Req. No. Description Symbol

2 1 952026 TERM. BLOCK 7 POS 25 A TB4 1 2 17240310 RESISTOR 10 K 25 W R2, 15 3 1 951182 FAN AC AXIAL M1

SECTION 6 REPLACEMENT PARTS

Fig. 6-8. Powercut-1125 (460V) Power Source, Top View with PCB1 and Shelf Removed

Item Qty. Part Circuit No. Req. No. Description Symbol

1 1 952026 TERM. BLOCK 7 POS 25 A TB4 2 2 17240310 RESISTOR 10 K 25 W R2, 15 3 1 951182 FAN AC AXIAL M1

NOTES

REVISION HISTORY

The "A" edition of this manual (6/2001) updated parts information. 1.

The "B" edition of this manual (9/2001) introduces the 575V version of the PowerCut-1125 along with 2. its Schematic/ Wiring Diagrams and additional parts information. New Optional Accessories, Section

1.5, are also included in this edition.

Revision C - 05/2005 - added Air Line Filter Regulator p/n 0558005394 note in Replacement Parts sec-3. tion per CN #053013. Updated format.

Revision 08/2005 - Made various updates per D. Smith and in replacement parts section, ADDED 4. nger guard p/n 0558005659 per CN-053103.

Revision 12/2005 - Removed Air Line Filter Regulator p/n 0558005394 note in Replacement Parts sec-5. tion per D. Smith.

Revision 11/2007 - Added p/n's 0558003369 and 0558002791F to section 6. 2.3 Packages Available. Updated replacement parts section to show new label p/n's.

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