ESAB Powercut-1250 Plasma Arc Cutting Package Instruction manual

POWERCUT-1250

PLASMA ARC CUTTING PACKAGE

Instruction Literature

15-737 082002

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles
of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet,
"Precautions and Safe Practices for Arc Welding, Cutting, and Gouging," Form 52-529. Do NOT permit
untrained persons to install, operate, or maintain this equipment. 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.

2

TABLE OF CONTENTS

SECTION TITLE PAGE

PARAGRAPH

SECTION 1 DESCRIPTION ................................................................................................. 10

1.1 General ............................................................................................................. 10

1.2 Scope ................................................................................................................ 10

1.3 Packages Available ........................................................................................... 10

1.4 Specifications .................................................................................................... 11

SECTION 2 INSTALLATION ................................................................................................ 13

2.1 General ............................................................................................................. 13

2.2 Equipment Required ......................................................................................... 13

2.3 Location ............................................................................................................ 13

2.4 Inspection.......................................................................................................... 13

2.5 Primary Electrical Input Connections................................................................. 13

2.6 Secondary Output Connections......................................................................... 15

SECTION 3 OPERATION ..................................................................................................... 16

3.1 Operation .......................................................................................................... 16

3.2 PowerCut-1250 Controls ................................................................................... 16

3.3 Cutting with the PT-32EH .................................................................................. 18

3.4 Possible Cutting Issues ..................................................................................... 21

SECTION 4 MAINTENANCE................................................................................................ 22

4,1 General ............................................................................................................. 22

4.2 Inspection and Cleaning .................................................................................... 22

4.3 PT-32EH Torch Consumable Parts ................................................................... 22

4.4 IGBT Handling & Replacement ......................................................................... 24

SECTION 5 TROUBLESHOOTING ..................................................................................... 26

5.1 Troubleshooting ................................................................................................ 26

5.2 Troubleshooting Guide ...................................................................................... 27

SECTION 6 REPLACEMENT PARTS .................................................................................. 36

3

SECTION 1 SAFETY PRECAUTIONS

WARNING: These Safety Precautions are for

your protection. They summarize precautionary
information from the references listed in Addi­tional Safety Information section. Before per-

forming 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 protec-

tion. 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 fitted with the correct filter 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 flameproof gauntlet type gloves, heavy long-sleeve

shirt, cuffless 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 flameproof apron may
also be desirable as protection against radiated heat and
sparks.

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

cuffs, 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-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag or

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

FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot slag or
sparks can also cause fires and explo­sions. Therefore:

1. Remove all combustible materials well away from the

work area or cover the materials with a protective non­flammable 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 floors or wall openings and cause a hidden smoldering
fire or fires on the floor 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
flammable or toxic vapors. Do not do hot work on closed
containers. They may explode.

4. Have fire extinguishing equipment handy for instant use,

such as a garden hose, water pail, sand bucket, or
portable fire extinguisher. Be sure you are trained in its
use.

5. Do not use equipment beyond its ratings. For example,
overloaded welding cable can overheat and create a fire
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 fire. Use fire 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
confined, or if there is danger of falling.

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.

9. Turn off the power before removing your gloves.

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

ELECTRIC AND MAGNETIC FIELDS — May
be dangerous. Electric current flowing
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 effects which are
unknown.

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.

4

10/98

SECTION 1 SAFETY PRECAUTIONS

FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shield­ing gases can cause asphyxiation.
Therefore:

1. Always 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 specific ventilation recommendations.

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

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 fittings in good
condition. Follow manufacturer's operating instructions
for mounting regulator to a compressed gas cylinder.

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 fixtures 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 flames.
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 Jefferson Davis Highway, Arlington,
VA 22202.

§25249.5 et seq.)

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

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

2. 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.

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"

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.

5

SP98-10

SECTION 1 PRECAUCION DE SEGURIDAD

ADVERTENCIA: Estas Precauciones de Seguridad

son para su protección. Ellas hacen resumen de
información proveniente de las referencias listadas en
la sección "Información Adicional Sobre La Seguridad".
Antes de hacer cualquier instalación o procedimiento

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.

de operación , asegúrese de leer y seguir las

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:

Utilice gafas de seguridad con protección a los lados siempre que

1.

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 filtro 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 chispas calientes

con una cortina adecuada no-flamable como división.

6. Use careta protectora además de sus gafas de seguridad 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
flamas y el arco pueden ocacionar fuegos.
Escoria caliente y las chispas pueden
causar fuegos y explosiones. Por lo tanto:

Remueva todo material combustible lejos del área de trabajo o

1.

cubra los materiales con una cobija a prueba de fuego. Materiales
combustibles incluyen madera, ropa, líquidos y gases flamables,
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 inflamables o vapores tóxicos. No
trabaje dentro o fuera de contenedores o tanques cerrados. Estos
pueden explotar si contienen vapores inflamables.

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 corriente alterna (AC)
en áreas húmedas, de movimiento
confinado en lugares estrechos o si hay
posibilidad de caer al suelo.

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 específicas
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
fluye 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 marca­pasos.

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.

6

SECTION 1 PRECAUCION DE SEGURIDAD

HUMO Y GASES -- El humo y los gases,
pueden causar malestar o daño,
particularmente en espacios sin
ventilación. No inhale el humo o gases. El
gas de protección puede causar falta de
oxígeno. Por lo tanto:

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 substancias
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
específicas en la ventilación.

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 cilindros.

4. Localize los cilindros lejos del calor, chispas, y flamas.
Nunca establezca un arco en el cilindro.

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

1. Siempre tenga personal cualificado para efectuar l
a instalación, diagnóstico, y mantenimiento del
equipo. No ejecute ningún trabajo eléctrico a menos
que usted esté cualificado 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 modifique 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"

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

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

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."

SIGNIFICADO DE LOS SIMBOLOS -- Según
usted avanza en la lectura de este folleto:
Los Símbolos Significan ¡Atención! ¡Esté
Alerta! Se trata de su seguridad.

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

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

Significa el posible riesgo que puede
resultar en menores daños a la persona.

7

SECTION 1 PRÉCAUTIONS DE SÉCURITÉ

AVERTISSEMENT: Ces règles de sécurité ont pour objet
d’ assurer votre protection. Veillez à lire et à observer les
précautions énoncées ci-dessous avant de monter l’
équipement ou de commercer à l’utiliser. Tout défaut
d’observation de ces précautions risque d’entraîner des
blessures graves ou mortelles.

1. PROTECTION INDIVIDUELLE-- Les brûlures de la
peau et des yeux dues au rayonnement de l’arc
électrique ou du métal incandescent, lors du soudage
au plasma ou à l’électrode ou lors du gougeage à
l’arc, peuvent s’avérer plus graves que celles
résultant d’une exposition prolongée au soleil. Aussi
convient-il d’observer les précautions suivantes:

a. Portez un écran facial adéquat muni des plaques

protectrices et des verres filtrants appropriés afin de
vous protéger les yeux, le visage, le cou et les oreilles
des étincelles et du rayonnement de l’arc électrique
lorsque vous effectuez des soudures ou des coupes
ou lorsque vous en observez l’exécution.

AVERTISSEZ les personnes se trouvant à proximité

de façon à ce qu’elles ne regardent pas l’arc et à ce
qu’elles ne s’exposent pas à son rayonnement, ni à
celui du métal incandescent.

b. Portez des gants ignifugés à crispins, une tunique

épaisse à manches longues, des pantalons sans
rebord, des chaussures à embout d’acier et un
casque de soudage ou une calotte de protection, afin
d’éviter d’exposer la peau au rayonnement de l’arc
électrique ou du métal incandescent. ll est également
souhaitable d’utiliser un tablier ininflammable de
façon à se protéger des étincelles et du rayonnement
thermique.

c. Les étincelles ou les projections de métal incandes-

cent risquent de se loger dans des manches
retroussées, des bords relevés de pantalons ou dans
des poches. Aussi convient-il de garder boutonnés le
col et les manches et de porter des vêtements sans
poches à l’avant.

d. Protégez des étincelles et du rayonnement de l’arc

électrique les autres personnes travaillant à proximité
à l’aide d’un écran ininflammable adéquat.

e. Ne jamais omettre de porter des lunettes de sécurité

lorsque vous vous trouvez dans un secteur où l’on
effectue des opérations de soudage ou de coupage à
l’arc. Utilisez des lunettes de sécurité à écrans ou
verres latéraux pour piquer ou meûler le laitier. Les
piquetures incandescentes de laitier peuvent être
projetées à des distances considérables. Les
personnes se trouvant à proximité doivent également
porter des lunettes de protection.

f. Le gougeage à l’arc et le soudage à l’arc au plasma

produisent un niveau de bruit extrêmement élevé (de
100 à 114 dB) et exigent par conséquent l’emploi de
dispositifs appropriés de protection auditive.

2. PRÉVENTION DES INCENDES-- Les projections de
laitier incandescent ou d’étincelles peuvent
provoquer de graves incendies au contact de
matériaux combustibles solides, liquides ou gazeux.
Aussi faut-il observer les précautions suivantes:

a. Éloigner suffisamment tous les matériaux combus-

tibles du secteur où l’on exécute des soudures ou des
coupes à l’arc, à moins de les recouvrir complètement
d’une bâche non-inflammable. Ce type de matériaux
comprend notamment le bois, les vêtements, la sciure,
l’essence, le kérosène, les peintures, les solvants, le
gaz naturel, l’acétylène, le propane et autres sub­stances combustibles semblables.

b. Les étincelles ou les projections de métal incandes-

cent peuvent tomber dans des fissures du plancher ou
dans des ouvertures des murs et y déclencher une
ignition lente cachée. Veiller à protéger ces ouvertures
des étincelles et des projections de métal.

c. N’exécutez pas de soudures, de coupes, d’opérations

de gougeage ou autres travaux à chaud à la surface
de barils, bidons, réservoirs ou autres contenants
usagés, avant de les avoir nettoyés de toute trace de
substance susceptible de produire des vapeurs
inflammables ou toxiques.

d. En vue d’assurer la prévention des incendies, il

convient de disposer d’un matériel d’extinction prêt à
servir immédiatement, tel qu’un tuyau d’arrosage, un
seau à eau, un seau de sable ou un extincteur portatif.

e. Une fois le travail à l’arc terminé, inspectez le secteur

de façon à vous assurer qu’aucune étincelle ou projec­tion de métal incandescent ne risque de provoquer
ultérieurement un feu.

3. CHOC ÉLECTRIQUE-- Le gougeage à l’arc et à l’arc
au plasma exige l’emploi de tensions à vide
relativement importantes; or, celles-ci risquent de
causer des dommages corporels graves et même
mortels en cas d’utilisation inadéquate. La gravité du
choc électrique reçu dépend du chemin suivi par le
courant à travers le corps humain et de son intensité.

a. Ne laissez jamais de surfaces métalliques sous ten-

sion venir au contact direct de la peau ou de
vêtements humides. Veillez à porter des gants bien
secs.

b. Si vous devez effectuer un travail sur une surface

métallique ou dans un secteur humide, veillez à assu­rer votre isolation corporelle en portant des gants secs
et des chaussures à semelles de caoutchouc et en
vous tenant sur une planche ou une plate-forme
sèche.

c. Mettez toujours à la terre le poste de soudage/coupage

en le reliant par un câble à une bonne prise de terre.

d. N’utilisez jamais de câbles usés ou endommagés. Ne

surchargez jamais le câble. Utilisez toujours un
équipement correctement entretenu.

e. Mettez l’équipement hors tension lorsqu’il n’est pas en

service. une mise à la masse accidentelle peut en effet
provoquer une surchauffe de l’équipement et un dan­ger d’incendie. Ne pas enrouler ou passer le câble
autour d’une partie quelconque du corps.

f. Vérifiez si le câble de masse est bien relié à la pièce en

un point aussi proche que possible de la zone de
travail. Le branchement des câbles de masse à
l’ossature du bâtiment ou en un point éloigné de la
zone de travail augmente en effet le risque de pas­sage d’un courant de sortie par des chaînes delevage

9/97

8

SECTION 1 PRÉCAUTIONS DE SÉCURITÉ

des câbles de grue ou divers chemins électriques.

g. Empêchez l’apparition de toute humidité, notamment

sur vos vêtements, à la surface de l’emplacement de
travail, des câbles, du porte-électrode et du poste de
soudage/coupage. Réparez immédiatement toute
fuite d’eau.

4. VENTILATION-- La respiration prolongée des fumées
résultant des opérations de soudage/coupage, à
l’intérieur, d’un local clos, peut provoquer des mal­aises et des dommages corporels. Aussi convient-il
d’observer les précautions suivantes:

a. Assurez en permanence une aération adéquate de

l’emplacement de travail en maintenant une ventila­tion naturelle ou à l’aide de moyens mécaniques.
N’effectuez jamais de travaux de soudage ou de
coupage sur des matériaux de zinc, de plomb, de
beryllium ou de cadmium en l’absence de moyens
mécaniques de ventilation capables d’empêcher
l’inhalation des fumées dégagées par ces matériaux.

b. N’effectuez jamais de travaux de soudage ou de

coupage à proximité de vapeurs d’hydrocarbure
chloré résultant d’opérations voisines de dégraissage
ou de pulvérisation. La chaleur dégagée ou le
rayonnement de l’arc peut déclencher la formation de
phosgène -- gaz particulièrement toxique -- et d’autres
gaz irritants, à partir des vapeurs de solvant.

c. Une irritation momentanée des yeux, du nez ou de la

gorge constatée au cours de l’utilisation de
l’équipement dénote un défaut de ventilation. Arrêtez­vous de travailler afin de prendre les mesures néces­saires à l’amélioration de la ventilation. Ne poursuivez
pas l’opération entreprise si le malaise persiste.

d. Certaines commandes comportent des canalisations

où circule de l’hydrogène. L’armoire de commande est
munie d’un ventilateur destiné à empêcher la forma­tion de poches d’hydrogène, lesquelles présentent un
danger d’explosion; ce ventilateur ne fonctionne que
si l’interrupteur correspondant du panneau avant se
trouve placé en position ON (Marche). Veillez à
manœuvrer cette commande en vérifiant si le
couvercle est bien en place, de façon à assurer
l’efficacité de la ventilation ainsi réalisée. Ne jamais
débrancher le ventilateur.

e. Les fumées produites par l’opération de soudage ou

de coupage peuvent s’avérer toxiques. Aussi est-il
nécessaire de disposer en permanence d’un dispositif
adéquat de ventilation de type aspirant, afin d’élimi­ner du voisinage de l’opérateur tout dégagement de
fumée visible.

f. Consultez les recommandations particulières en

matière de ventilation indiquées à l’alinéa 6 de la
norme Z49.1 de l’AWS.

5. ENTRETIEN DE L’ÉQUIPEMENT-- Un équipement
entretenu de façon défectueuse ou inadéquate risque
non seulement de réaliser un travail de mauvaise
qualité mais, chose plus grave encore, d’entraîner des

dommages corporels graves, voire mortels en
déclenchant des incendies ou des chocs électriques.
Observez par conséquent les précautions suivantes:

a. Efforcez-vous de toujours confier à un personnel qua-

lifié l’installation, le dépannage et l’entretien du poste
de soudage et de coupage. N’effectuez aucune
réparation électrique sur l’équipement à moins d’être
qua-lifié à cet effet.

b. Ne procédez jamais à une tâche d’entretien

quelconque à l’intérieur du poste de soudage/
coupage, avant d’avoir débranché l’alimentation
électrique.

c. Maintenez en bon état de fonctionnement les câbles,

le câble de masse, les branchements, le cordon
d’alimentation et le poste de soudage/coupage.
N’utilisez jamais le poste ou l’équipement s’il présente
une défectuosité quelconque.

d. Prenez soin du poste de soudage et de coupage et des

équipements accessoires. Gardez-les à l’écart des
sources de charleur, notamment des fours, de
l’humidité, des flaques d’eau maintenez-les à l’abri des
traces d’huile ou de graisse, des atmosphères corro­sives et des intempéries.

e. Laissez en place tous les dispositifs de sécurité et tous

les panneaux de l’armoire de commande en veillant à
les garder en bon état.

f. Utilisez le poste de soudage/coupage conformément à

son usage prévu et n’effectuez aucune modification.

6. INFORMATIONS COMPLÉMENTAIRES RELATIVES
À LA SÉCURITÉ--

Pour obtenir des informations complémentaires sur les

règles de sécurité à observer pour le montage et
l’utilisation d’équipements de soudage et de coupage
électriques et sur les méthodes de travail
recommandées, demandez un exemplaire du livret N°
52529 “Precautions and Safe Practices for Arc Weld­ing, Cutting and Gouging” publié par ESAB. Nous
conseillons également de consulter les publications
sui-vantes, tenues à votre disposition par l’American
Welding Society, 550 N.W. LeJuene Road, Miami, FL
32126:

a. “Safety in Welding and Cutting” AWS Z49.1
b. “Recommended Safe Practices for Gas-Shielded Arc

Welding “AWS A6. 1.

c. “Safe Practices for Welding and Cutting Containers

That Have Held Combustibles” AWS-A6.0.

d. “Recommended Safe Practices for Plasma Arc Cutting”

AWS-A6. 3.

e. “Recommended Safe Practices for Plasma Arc Weld-

ing” AWS-C5. 1.

f. “Recommended Safe Practices for Air Carbon Arc

Gouging and Cutting” AWS-C5. 3.

g. “Code For Safety in Welding and Cutting”

CSA-Standard W117. 2.

9/97

9

SECTION 1 DESCRIPTION

The PowerCut 1250 plasma cutting package combines
the proven reliability of the PowerCut-1500 with the
newly designed PT-32EH torch. The very strong
composite case material makes the PowerCut-1250 an
excellent addition to any equipment rental fleet. The
PT-32EH plasma cutting torch is designed to provide
increased performance and longer consumable life
resulting in higher production rates at lower costs.

n

Multi input voltage (208)230/460V, easily changed on
back of machine.

n

Cuts 1-1/4 inch

n

Designed for rugged treatment and outdoor use
makes the PowerCut an excellent choice for rental
fleet and construction site uses.

n

More performance features than any machines in its
class.

n

Delivers big machine cutting power in a rugged,
lightweight package.

n

Pilot arc start facilitates starting on painted and coated
metals.

n

Long-life consumables and repairable torch minimize
operating costs.

n

Arrives ready to cut, with torch connected and front­end parts in place, for the ultimate in operator
convenience.

n

Trigger lock-in for long-cut operator comfort.

n

Built in line conditioner – handles poor power lines.

n

Auto Drag feature allows torch to drag on workpiece
without damage to the nozzle for easy template
following.

n

For longer nozzle life while drag cutting, a 40 amp
nozzle is available (P/N 0558002908)

n

Self protectant against improper input voltage

n

Multiple troubleshooting lights on front panel

n

Excellent gouging performance

n

Three year warranty on console.

n

One year warranty on torch.

Specifications: PowerCut-1250

Cuts 1-1/4 in. (32mm); severs 1-1/2 in. (38mm)

1 ph. Input ............................. 208/230 vac, 1 ph, 50/60 Hz, 67/61 A

1 ph. Output ............................ 70 amps/135vdc @ 60% duty cycle

3 ph. Input ............................ 208/230 vac, 3 ph, 50/60 Hz, 34/30 A

......................................... 230/460 vac, 3 ph, 50/60 Hz, 30/20 A

....................................................... 575 vac, 3ph, 50/60 Hz, 12 A

3 ph. Output .......................... 70 amps/135vdc @ 100% duty cycle

Dimensions ........................................................W = 12.5” (318mm)

........................................................................ H = 16.5” (419mm)

........................................................................... D = 32” (813mm)

Weight ........................................................................ 86 lbs. (39kg)

Shipping Weight ........................................................ 103 lbs. (47kg)

Air Requirements .... 350 cfh @ 80 psig (165 l/min @ 4.8-5.2 bars)

Torch

PowerCut-1250 uses the PT-32EH torch. For complete list

and breakdown of parts, refer to PT-32EH data page.

Ordering Information:

PowerCut-1250, 208/230/460 V, 25’ PT-32EH .............0558001933

PowerCut-1250, 208/230/460 V, 50’ PT-32EH .............0558001934

PowerCut-1250, 575 V, 25’ PT-32EH ..........................0558001939

PowerCut-1250, 575 V, 50’ PT- 32EH ..........................0558001940

The components that are included in the Powercut-1250 packages
may be purchased separately by using the appropriate P/N when
placing orders. Individual part numbers are listed below:

Consoles:

PowerCut-1250 (208)230/460 V,

50/60 Hz, 1/3-ph ..................................................... 0558001935

PowerCut-1250 575 V, 50/60 Hz, 3-ph ...................... 0558001941

PT-32EH Torches:

PT-32EH Torch, 90o head, 25-ft. ................................ 0558003548

PT-32EH Torch, 90o head, 50-ft. ................................ 0558003549

PT-32EH Spare Parts Kit (see Table 1-1) ................. 0558003508

10

SECTION 1 DESCRIPTION

Optional Accessories:

70 amp Spare Parts Kit ..............................................0558003508

Plasma Flow Measuring Kit:

This valuable troubleshooting tool allows measurement of

the actual plasma gas flow through the torch ................... 19765

Torch Guide Kit:

This complete kit, in a rugged plastic carrying case, includes
attachments for circle and straight line cutting on ferrous and

non-ferrous metals, 1 3/4" - 42" Radius, Deluxe ......0558003258

Basic, 1/34” - 28” Radius ......................................... 0558002675

Stand-off Guide

For proper stand-off distance when drag cutting ......0558002393

40 amp Drag Nozzle ................................................. 0558002908

Gouging Nozzle .......................................................... 0558003089

Heat Shield Gouging ................................................ 0558003090

Drag Heat Shield ........................................................ 0558003374

Wheel Kit

For easy transport of system ................................... 0558003060

Torch Wrap

This enables operator to store spare parts kit, wrap torch

and work cable for easy transport and storage ......... 0558003059

Valve Pin

0558001959

Electrode

0558001969

Contents of PT-32EH Spare Parts Kit, P/N 0558003508

Description P/N Quantity

Heat Shield 0558001957 2
70 amp Nozzle 0558002618 4
40 amp drag Nozzle 0558002908 1
Electrode 0558001969 3
Valve Pin 0558001959 1
Fuse 2amp, 600vdc 0558001379 1
Stand-off Guide 0558002393 1
Wrench 19129 1
Lubricant 17672 1

The PowerCut-1250 comes out of the box ready to go. The torch
is attached with parts in place, primary cord is attached (including
plug on 230 model), and the filter/regulator is installed. Just hook up
the air, plug it in and cut.

O-Ring - 85W51

(Supplied with head)

PT-32 Torch Head - 0558001965

PT-32EH Torch Head - 0558003412

Heat Shield

0558001957

PT-32EH DRAG MODE CUTTING SPEEDS

AIR @ 80PSI and OUTPUT CURRENT 40AMPS

Thickness Cutting

Material (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

Aluminum 1/16 200

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

Nozzle
40 AMP - 0558002908 (Drag Cutting)
50/70 AMP - 0558002618

PT-32 Cut Data-70 AMPS

Powercut 1250, PT-32, 70A Nozzle P/N 0558002618
Air Pressure - 80 psi, 5/32” Standoff

Max Speeds

Carbon Steel

Plate Drop Cut Sever

(Inches) (IPM) (IPM)

0.250 131 135

0.500 50 53

0.750 21 23

1.000 10 12

1.250 6 7

1.500 ---- 3

11

SECTION 1 DESCRIPTION

1.1 GENERAL

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.

The Powercut-1250 is a compact, completely self-contained plasma cutting
system. As shipped, the system is fully assembled and ready to cut after
being connected to input power and a source of compressed air (90-150 psi).
The Powercut-1250 package uses the heavy-duty PT-32EH torch to deliver
cutting power for severing materials up to 1-1/2 inch thick. Refer to the following
paragraphs for descriptions of the Powercut-1250 packages available as well
as performance specifications.

1.2 SCOPE

The purpose of this manual is to provide the operator with all the information
required to install and operate the Powercut-1250 plasma arc cutting
package. Technical reference material is also provided to assist in trouble­shooting the cutting package.

12

SECTION 2 INSTALLATION

2.1 GENERAL

Proper installation is important for satisfactory and trouble-free operation of
the PowerCut 1250 cutting package. It is suggested that each step in this
section be studied carefully and followed closely.

2.2 EQUIPMENT REQUIRED

A source of clean, dry air that supplies 350 cfh at 80 psig is required for the
cutting operation. The air supply should not exceed 150 psig (the maximum
inlet pressure rating of the air filter-regulator supplied with the package).

2.3 LOCATION

Adequate ventilation is necessary to provide proper cooling of the PowerCut

1250. 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 1250 power source and wall or any other
obstruction to allow freedom of air movement through the power source.

2.4 INSPECTION

Installing or placing any type of filter­ing 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 filter device is used.

ELECTRIC SHOCK CAN KILL! Precau­tionary measures should be taken to
provide maximum protection against
electrical shock. Be sure that all power
is off 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.

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 1250. 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.

2.5 PRIMARY ELECTRICAL INPUT
CONNECTIONS (FIGURE 2-1)

The PowerCut 1250 consoles are equipped with approximately 10-ft. of 4­conductor input power cable for 3-phase connection. If single-phase connec­tion is desired, tape back the red wire on the input power cable. Connect the
single phase input to the white and black wires only. When operating this
machine from a single-phase source, it must be connected to a dedicated
100 Amp feed. Due to the higher input current requirements, the duty cycle
of the machine is lower than in three-phase operation.

CUSTOMER FUSED LINE DISCONNECT SWITCH

(See Table 2.1 and WARNING in regards to chassis ground in Section 2.5.)

13

SECTION 2 INSTALLATION

Before connecting to input power, make sure there is a line (wall) disconnect
switch with fuses or circuit breakers at the main power panel. You may either

ELECTRIC SHOCK CAN KILL! Before
making electrical input connections to
the power source, "Machinery Lockout
Procedures" should be employed. If
the connections are to be made from a
line disconnect switch, place the switch
in the off position and padlock it to
prevent inadvertent tripping . If the
connection is made from a fusebox,
remove the corresponding fuses and
padlock the box cover. If it is not pos­sible to use padlocks, attach a red tag
to the line disconnect switch (or fuse
box) warning others that the circuit is
being worked on.

The chassis must be connected to an
approved electrical ground. Failure to
do so may result in electrical shock,
severe burns or death.

use the factory-installed input power cable (No. 6 AWG, 4/c, type SO (90 °C),
12 ft (3.7 m) length) or provide your own input power leads. If you choose to
provide your own, make sure they are insulated copper conductors. You must
have two (single-phase) or three (three-phase) power leads and one ground
wire. The wires may be heavy rubber covered cable or may be run in a solid
or flexible conduit. Refer to Table 2-1 for recommended input conductors and
line fuse sizes.

Table 2-1. Recommended Sizes For

Input Conductors and Line Fuses

Input Requirements Input & Gnd Fuse

Volts Phase Amps Conductor Size

CU/AWG Amps

208 1 82A 6 100
208 3 44A/Ph. 6 80
230 1 74A 6 100
230 3 40A/Ph. 6 80
460 3 27 6 50

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

INPUT VOLTAGE SELECTOR

NOT POWER

ON - OFF SWITCH

USE POWER SWITCH ON FRONT

PANEL TO TURN

ON AND OFF

2.5.1 INPUT VOLTAGE CHANGEOVER

200 - 230 or 460 Mode

To simplify the use of the ESAB Powercut 1250 with different input volt­ages, it has been equipped with a convenient 230/460 selector switch lo­cated on the back panel of the unit. The Powercut 1250 is also equipped
with protective fuse that will prevent damage to the power source in the
event that the input voltage switch is not set correctly and the unit is pow­ered on.

Input Voltage
Selector Switch

Fuse*

A line (wall) disconnect switch with fuses or circuit breakers should be pro­vided at the main power panel (see Fig. 2-1 and Table 2-1 for fuse sizes).
The input power cable of the console may be connected directly to the
disconnect switch or you may purchase a proper plug and receptacle from
a local electrical supplier. If using plug/receptacle combination, see Table
2-1 for recommended input conductors for connecting receptacle to line
disconnect switch.

14

SECTION 2 INSTALLATION

2.6 SECONDARY (OUTPUT) CONNECTIONS (REFER TO
FIG. 2-1)

The Torch comes factory installed.

Figure 2-1. PowerCut 1250 Interconnection Diagram

Connect your air supply to the inlet connection of the filter-regulator.

Prefiltered DRY AIR
SUPPLY (Customer
Supplied)
(90 to 150 psig max)

FUSED

DISCONNECT

BOX

Clamp the work cable to the
workpiece. Be sure the
workpiece is connected to an
approved earth ground with a
properly sized ground cable.

SAFETY

GROUND

PRIMARY INPUT

POWER CABLE

WORK

15

PT-32EH

SECTION 3 OPERATION

A

B

Figure 3-1A. PowerCut 1250 Controls

C

D

3.1 OPERATION

3.2 PowerCut 1250 CONTROLS (FIGURE 3-1A)

A. Power Switch. When placed in ON position, the white pilot light will glow

indicating control circuit is energized.

B. Air Test Switch. When placed in Test position, air filter-regulator can

be adjusted to desired pressure (80 psig) before cutting operations.
Allow air to flow for a few minutes. This should remove any condensation
that may have accumulated during shutdown period. Be sure to place
switch in OPERATE position before starting cutting operations.

C. Trigger Lock Switch. When placed in LOCK position, this permits

releasing torch switch button after cutting arc has been initiated. To
extinguish arc at end of cut, press and release torch switch button again
or pull torch away from work. When placed in UNLOCK position, torch
switch must be held closed by the operator during the entire cutting
operation and then released at the end of cut.

D. Output Current Control. Adjustable from 20 to 70 amperes.

16

SECTION 3 OPERATION

G

F

E

Figure 3-1B. PowerCut 1250 Controls

H

I

3.2 PowerCut 1250 Indicator Lights (FIGURE 3-1B)

E. Power "ON" Indicator: Illuminates whenever the front panel power

switch is in the ON position.

F. AC Line Indicator or High/Low Line Voltage Indicator: This fault light

will blink to indicate that the input voltage is outside the “+ or -” 15% range
of the input rating.

G. Gas Flow Indicator: This fault light will blink to indicate that the air flow

supply is low or has no back pressure.

H. Fault Indicator: When this light blinks, either the system failed to initiate

a pilot arc after a number of attempts, or there has been an over-current
event within the system. If the light blinks for 10 seconds and then stops,
then the problem is pilot arc initiation. Check the consumables in the
torch.

If the light continues to blink, and the system does not reset, then the fault
is an over-current event. One likely source of an over-current fault is a
nozzle to electrode short. Turn off the machine and inspect the torch and
its consumables. Replace the consumables as needed. Turn the ma­chine back on. If the problem occurs again, the machine may require
service.

I. Over Temperature Indicator: This fault light will blink to indicate that the

duty cycle has been exceeded. Allow the power source to cool down
before returning to operation.

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 off for 5 seconds and then
turned back on.

17

SECTION 3 OPERATION

3.3 CUTTING WITH THE POWERCUT-1250

Use the following procedures to cut with the PT-32EH torch (Figure 3-4).

ELECTRIC SHOCK can kill.

• Do NOT operate the unit with the
cover removed.

• Do NOT apply power to the unit
while holding or carrying the unit.

• Do NOT touch any torch parts
forward of the torch handle (nozzle,
heat shield, electrode, etc.) with
power switch on.

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.

A. Make sure that the wall disconnect switch is on. Turn on the Front Panel

Power Switch.
B. Set Pressure Regulator to 80 psig.
C. 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-32EH's standoff guide P/N 0558002393 is being used,

the distance between Electrode and Work Piece will be approx. 3/16-

inch.
D. Depress the torch switch. Air should flow from the torch nozzle.
E. Two seconds after depressing the torch switch, the pilot arc should

start. The main arc should immediately follow, allowing the cut to begin.

(If using the trigger LOCK mode, torch switch may be released after

establishing the cutting arc.)
F. After starting the cut, the torch should be maintained at a 5-15° forward

angle (Figure 3-2). This angle is especially useful in helping to create

a "drop" cut. When not using the standoff guide, the nozzle should be

held approximately 1/4 inch from the work.

Position the PowerCut 1250 at least 10
feet (3 meters) from the cutting area.
Sparks and hot slag from the cutting
operation can damage the unit.

CUT

DIRECTION

Figure 3-2. Recommended Torch Angle of 5° to 15°

IMPORTANT!!!

Maintain Proper

Stand-Off Distance

3/16 to 1/4 Inch

Power Output increases with Stand Off Distance!

Standoff vs. Power Output

18

SECTION 3 OPERATION

E. When ending a cut, the torch switch should be released (press and

release if using trigger LOCK mode) and the torch lifted off the workpiece
just before the end of the cut. This is to prevent the high frequency from
reigniting after cutting arc extinguishes and causing damage to the
nozzle (double arcing).

F. For rapid re-starts, such as grate or heavy mesh cutting, do not release

the torch switch. In the postflow mode, the arc can be re-started
immediately by depressing the torch switch. This avoids the 2-second
preflow portion of the cutting cycle.

PLACE THE VALVE PIN INTO THE
ELECTRODE AND SCREW THE
ELECTRODE INTO THE TORCH HEAD
AND TIGHTEN SECURELY WITH
WRENCH #19129.

1

*

VALVE PIN

ELECTRODE

NOZZLE

SHIELD

PLACE NOZZLE INTO
HEAT SHIELD AND
THREAD THIS ASSEM­BLY TO THE TORCH
BODY AND HAND
TIGHTEN.

IMPORTANT!

MAKE SHIELD VERY

TIGHT!

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

*

tion is to open the gas flow 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.

Fig 3.3. Exploded View of PT-32EH Torch

2

3

LOW CURRENT AUTO-DRAG FEATURE

If drag cutting is desired for thin material under 3/8" thick, remove the
standard 70 amp nozzle (P/N 0558002618) from the PT-32EH 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 (3.3). Also refer to PT­32EH Instruction Manual No. F-15-440.

19

SECTION 3 OPERATION

HIGH CURRENT CUTTING with STAND-OFF GUIDE

If drag cutting is desired on materials above 3/8” thick, be sure that the 70 amp
nozzle (P/N 0558002618) is installed in the PT-32EH torch. Attach ESAB's
stand-off guide (P/N 0558002393) and operate as shown in Figure 3.4.

Installation and Operation
of Steel Heat Shield Guards

Drag cutting, even with lower current levels may significantly reduce the life
of torch consumables. Attempting to Drag Cut with currents above 40 amps
may cause immediate catastrophic consumable damage.

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

STEEL GUARD
STAND OFF GUIDE
P/N 0558002393

GUIDE AGAINST
STRAIGHT EDGE
OR FREE-HAND
CUT

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

THIN GAUGE MATERIALS
CAN BE CUT WITH 1/16" (1.6 mm)
TORCH-TO-WORK DISTANCE
ADJUST TO 3/16" (4.8 mm) FOR
MATERIALS OVER 1/4" (6.4 mm) THICK

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

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

Figure 3-4. Installation and Operation of Steel Heat Shield Guards

20

SECTION 3 OPERATION

WHEN THE ARC BREAKS

2

THROUGH THE WORK,
BRING THE TORCH TO AN
UPRIGHT POSITION AND
PROCEED TO CUT.

TO START A PIERCE, TILT THE

1

TORCH TO PREVENT MOLTEN
MATERIAL FROM COMING BACK
AGAINST AND DAMAGING THE
TORCH.

Figure 3-5. Piercing Technique using the PT-32EH

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

Drag cutting, even with lower current
levels may significantly reduce the life
of torch consumables. Attempting to
Drag Cut with higher currents (40
amps) may cause immediate cata­strophic consumable damage.

3.4 POSSIBLE CUTTING ISSUES

NEW

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

Figure 3-6. Electrode Wear Limit

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 3-3.

3.3.1. Drag Cutting with the PT-32EH torch / PowerCut 1250 package.

LOW CURRENT AUTO-DRAG FEATURE
If drag cutting is desired for thin material under 3/8" thick, remove the standard
70 amp nozzle from the PT-32EH 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 (3.3). Also refer to PT-32EH Instruction Manual No.
F-15-440.

WORN

HIGH CURRENT DRAG CUTTING
If drag cutting is desired on materials above 3/8” thick, be sure that the 70 amp
nozzle (P/N 0558002618) is installed in the PT-32EH torch. Attach ESAB's
stand-off guide (P/N 0558002393) and operate as shown in Figure 3.4.

21

SECTION 3 OPERATION

Listed below are common cutting problems followed by the probable cause
of each. If problems are determined to be caused by the PowerCut 1250, refer
to the maintenance section of this manual. If the problem is not corrected after
referring to the maintenance section, contact your ESAB distributor.

A. Insufficient Penetration.

1. Current too low.

2. Cutting speed too fast.

3. Damaged cutting nozzle.

4. Improper air pressure.

5. Low air flow 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 flow rate.

D. Double Arcing. (Damaged Nozzle Orifice.)

1. Low air pressure.

2. Damaged cutting nozzle.

3. Loose cutting nozzle.

4. Heavy spatter accumulation on nozzle.

E. Uneven Arc.

1. Damaged cutting nozzle or worn electrode.

F. Unstable Cutting 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 flow rate.

22

SECTION 4 MAINTENANCE

4.1 GENERAL

If this equipment does not operate properly, stop work immediately and
investigate the cause of the malfunction. Maintenance work must be
performed by an experienced person, and electrical work by a trained
electrician. Do not permit untrained persons to inspect, clean, or repair
this equipment. Use only recommended replacement parts.

Be sure that the wall disconnect switch or wall circuit breaker is
open before attempting any inspection or work inside of the Power­cut-1250.

4.2 INSPECTION AND CLEANING

Frequent inspection and cleaning of the Powercut-1250 is recommended
for safety and proper operation. Some suggestions for inspecting and
cleaning are as follows:

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.

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

protection, blow out the inside of the Powercut-1250 using low-pres-

sure dry compressed air.

Water or oil occasionally accumulates in compressed air lines. Be
sure to direct the first blast of air away from the equipment to avoid
damage to the Powercut-1250.

H. Occasionally, bleed all water from the filter beneath the air filter-

regulator.

4.3 PT-32EH TORCH CONSUMABLE PARTS

Make sure power switch on POWERCUT-1250 is in OFF position
before working on the torch.

The PT-32EH torch head contains a gas flow check valve that acts in
conjunction with the flow 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 manufactured by ESAB
since it alone contains ESAB¹s patented safety interlock.

To assemble the consumable parts, refer to Figure 3.3 .

23

SECTION 4 MAINTENANCE

4.4 IGBT Handling & Replacement

Since IGBT gates are insulated from any other conducting region, care should
be taken to prevent static build up, which could possibly damage gate oxides.
All IGBT modules are shipped from the factory with conductive foam contact­ing the gate and emitter sense pins.

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

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

• Use grounded work station with grounded floors and grounded wrist straps
when handling devices.

• Use a 100Ω 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 4-2. 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 its 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”.

c

f

Two-Point Mounting Type

d

c

e

d

Figure 4-2. Screw Fastening Order

Temporary tightening

cÎ d

Final tightening

dÎ c

Four-Point Mounting Type

Temporary tightening

cÎ dÎe Îf

Final tightening

fÎ eÎd Îc

24

SECTION 5 TROUBLESHOOTING

5.1TROUBLESHOOTING

ELECTRIC SHOCK CAN KILL! Be sure that all primary power to the
machine has been externally disconnected. Open the line (wall)
disconnect switch or circuit breaker before attempting inspection or
work inside of the power source.

Check the problem against the symptoms in the following troubleshooting
guide. The remedy may be quite simple. If the cause cannot be quickly
located, shut off 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 and electrical schematic diagram (Figure 5-1) and
checking the various components. A volt-ohmmeter will be necessary for
some of these checks.

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.

NOTE

Before checking voltages in the circuit, disconnect the power from the
high frequency PC Board (PCB-2, Connector J2) to avoid damaging your
voltmeter.

25

SECTION 5 TROUBLESHOOTING

5.2TROUBLESHOOTING GUIDE

A. Power Light does not come on.

1. Visually inspect the machine for any damage.

2. Check following:

a. Check if the machine power cord is plugged into the input

power receptacle.

b. Measure the input power at the receptacle. If not present,

then check the wall disconnect switch and it’s fuses.

c. Check Fuse (F1).

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

a. Ensure that ribbon cable is connected to main PCB-1 and

front panel PCB-3

b. Measure voltage between pins P7-5 and P7-6 of the

control board. If there is no voltage, then replace Control
Transformer (T6).

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

out.

B. No Air Flow

1. Check air inlet supply. Unit requires 350 cfh at 80psig.

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

3. Does air flow when “air test” switch is in test position?

a. If not, check torch consumables, replace if necessary.
b. If above items check OK , the problem is internal. Take unit

to an Authorized Repair Station for repair.

C. The Power light is on, but nothing happens when the torch

switch is depressed. Fault light does not activate.

NOTE: Unplug high frequency connection before attempting to work

on this problem.

1. 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:

a. Turn power off to the machine. Unplug Control board. Put an

ohmmeter across J3-3 and J3-4 to take resistance reading.
Depress torch switch. Meter should read a short. If not, then
one of the following is not working properly:

b. 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.

2. Check transformer secondary voltages at the output diode modules.

26

SECTION 5 TROUBLESHOOTING

Refer to system schematic. Replace the transformer module if the
correct secondary voltages are not present.

3. If everything above checks out all right, then the PCB1 Control Board
should be replaced.

D. Fault light activates when torch switch is closed.

The machine monitor conditions necessary for the safe operation of the
Powercut-1250. The fault lights will glow under the following conditions
and operations will come to a stop.

1. High/Low line voltage. The "AC LINE" light will blink to indicate that
the input voltage is outside the +/- 15% range of the nominal voltage.

2. Gas Flow indicator - The fault light will blink to indicate that the air
flow is low or that the torch is not providing any back pressure.
a. Check the air pressure at the machine regulator. It should be

adjusted to 80 psig. If no air pressure, check the air at the supply
point. Also, check for any obstructions in the air hose.

b. Air flow may be blocked at the torch tip. Check the torch

consumables (see Figure 3.3). 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 flow through

torch. If not, and air pressure is set at required 80 PSIG, check
gas Solenoid (SOL1) for proper operation.

d. Air Check switch may also be malfunctioning if the air is flowing

continuously or putting in the On position does not turn air on.

3. Over Temperature indicator . The fault light will blink to indicate that
the machine is overheated. This generally indicates that the air flow
has been blocked. Clear blockage and allow the power source to cool
before operating.

a. Thermal Switch (TS1) may be open. It will open if the heat sink

temperature reaches 80°C. With the machine power off, check
the continuity between P6-7 and P6-8 of the control board. If
the switch is OK, then the ohmmeter should read a direct
short. If not then it should read open.

b. If the switch is malfunctioning, replace it. Clean the surface of the

heat sink before installing the switch.

4. Fault Indicator. When this light blinks, either the system failed to
initiate a pilot arc after a number of attempts, or there has been an
over-current event within the system.

a. If the light blinks for 10 seconds and then stops, then the problem

is pilot arc initiation. Check the consumables in the torch.

b. If the light continues to blink, and the system does not reset, then

the fault is an over-current event. One likely source of an over­current fault is a nozzle to electrode short. Turn off the machine
and inspect the torch and its consumables. Replace the
consumables as needed. Turn the machine back on. If the
problem occurs again, the machine may require service.

27

SECTION 5 TROUBLESHOOTING

c. To check if the output is shorted, measure the resistance by

putting the ohmmeter leads across the output. Put the black lead
to the "work" terminal and the red lead to the torch electrode
terminal. The reading should be about 2K OHMs.

b. If the resistance reading is different than above, check the torch,

the output bridge and Start-up Board (PCB-6).

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

1. Check the torch. Make sure that the valve pin is installed and the heat

shield is very tight.

2. Check to assure high frequency is present at the torch. Disconnect

HI FREQUENCY leads. Check for 575 volt supply to the high
frequency unit between P2A-1 & P2A-3 of the High Frequency Board
(PCB2) with torch switch closed.

3. With HI FREQUENCY leads disconnected, measure open circuit

voltage. It should be 320 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 (TS1). See D.3.a.

above.

b. Check Air Check switch operation. It might be stuck in On

position. Pilot arc will not initiate if this switch is in the ON
position. (safety reasons)

c. Check air flow switch. There may be internal short. See D.2.c

above.

d. Measure voltage across C5 or C6 capacitor. It should be as

follows:

approx. 325 VDC with 230 V supplied to the 230/460 volt unit.
approx. 294 VDC with 208 V supplied to the 230/460 volt unit
approx. 325 VDC with 460 V supplied to the 230/460 volt unit

approx. 400 VDC with 575 V supplied to the 575 volt unit

If not, one of following could be malfunctioning:

1). Check the capacitors C5 and C6 for any damage.

2.) Check input bridge/SCR Module (BR1) 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 (R1), located on the Input
Bridge Heatsink and SCR (Q1). Replace if
malfunctioning.

e. IGBTs may be damaged. See IGBT installation procedure. Before

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

28

SECTION 5 TROUBLESHOOTING

F. High Frequency and Pilot Arc are on but Main Arc does not

transfer.

1. Make sure work clamp is connected to work material.

2. Check the torch. Replace consumables if necessary.

G. Poor Cutting Performance.

1. Check air supply regulator . It should be adjusted to 80 psig.

2. The air supplied to the torch should be free of oil and water.

3. Make sure the consumables in the torch are acceptable.

4. Check open circuit voltage. See E.3 above.

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

H. Air does not shut off.

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

2. Does air flow 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 difficult 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 80 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 and pilot arc wiring.

b. Inoperative Start-up Board (PCB-6).

29

SECTION 5 TROUBLESHOOTING

5.3 REFERENCE VOLTAGE CHECKS

A. Control Board Assembly (PCB1)

1. LED’s

LED- (D9)- Torch Switch
LED- (D4)- Pilot Arc Relay
LED- (D1)- Gas Solenoid Valve

2. Voltage Test Points

Tests are made with power on - no arc.

Disable High Frequency by disconnecting blue wire with black
sleeve

TP-1 - Torch trigger signal
TP-4 - IGBT’s driving signal - switching frequency = 18.5 KHz
TP-5 - IGBT’s driving signal - switching frequency = 18.5 KHz
TP-7 - +5 vdc
TP-8 - +15 vdc
TP-9 - -15 vdc
TP-10- Ground

54 µs

13vdc

0

13vdc

Figure 5.1 IGBT Gating Signal

30

SECTION 5 TROUBLESHOOTING

5.4SEQUENCE OF OPERATION

A. TRIGGER LOCK “UNLOCK” position

PUSH RELEASE

TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

2 SEC.

PREFLOW

FLOW SWITCH CLOSE

FAULT OVERLOAD LIGHT

HF CIRCUIT

ENERGIZE

PILOT ARC

INVERTER

20 SEC

Postflow

OPEN

CUTTING ARC (CURRENT)

NOTES:

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

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

31

SECTION 5 TROUBLESHOOTING

B. TRIGGER LOCK "LOCK" position

PUSH RELEASE PUSH RELEASE

TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

2 SEC.

CLOSE OPEN

FLOW SWITCH

PREFLOW

20 SEC

Postflow

FAULT LIGHT

HF CIRCUIT

PILOT ARC

INVERTER

CUTTING ARC (CURRENT)

NOTES:

1. When the torch switch is pushed during postflow period, the postflow time

ENERGIZE

is reset, the preflow time is canceled, and the HF is energized immediately.

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

3. FAULT light is on during second "turn-off" trigger only. This does not affect
performance in any way.

32

Powercut-1250 Schematic Diagram

D-0558003510

33

SECTION 6 REPLACEMENT PARTS

A. REPLACEMENT PARTS

Replacement Parts are illustrated on the following figures. When ordering
replacement parts, order by part number and part name, as illustrated on the
figure. Always provide the series or serial number of the unit on which the
parts will be used. The serial number is stamped on the unit nameplate.

B. ORDERING

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

Replacement parts may be ordered from your ESAB distributor or from:

ESAB Welding & Cutting Products
Attn: Customer Service Dept.
P.O. Box 100545, 411 S. Ebenezer Road
Florence, SC 29501-0545

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

To order parts by phone, contact ESAB at 1-843-664-5540. Orders may also
be faxed to 1-800-634-7548. Be sure to indicate any special shipping in­structions when ordering replacement parts.

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

34

SECTION 6 REPLACEMENT PARTS

2

1

9

8

3

3

4

7

5

6

Front View - Powercut-1250

Item Part

No. Qty. No. Description Symbol

1 1 36107 SW Pwr Disc 600V S1
2 2 951474 Switch Seal Black
3 1 0558001818 Knob 1.37 Diam
4 1 0558003390M Panel Front Silkscreen
5 1 0558003001 Work Cable #6 AWG
6 1 13733935 Panel Receptacle
7 2 0558002780 Foot Plasma Tube
8 1 0558002581 Strain Relief Input NPT
9 1 0558002464M Cover Torch Connection

35

SECTION 6 REPLACEMENT PARTS

3

2

1

4

5

6

7

8

Rear View - Powercut-1250

Item Part

No. Qty. No. Description Symbol

1 1 21710 Regulator Air Line *808-02
2 1 21711 Gauge 1.50 *160 PSI WHT CB
3 1 0558002446 Switch 40A S2
4 1 0558003075 Fuse 2A 600VAC F1
5 1 97W63 Connector Cable Grip
6 1 0558003002 Cable Input Power, 10Ft.
7 1 951182 Fan 230V 50/60 Hz 233CFM M1
8 1 0558002994 Finger Guard 1.5MM (.06 IN.)

36

SECTION 6 REPLACEMENT PARTS

2

9

Resistors Hidden by Bar

3

4

5

1

8

7

6

Internal View - Powercut-1250

Lower Left Side

Item Part

No. Qty. No. Description Symbol

1 1 0558003377 Transformer Main, Module T2, T4
2 4 17721020 RES WWFAHT 25W 1% 20 OHMS R12-15
3 2 951185 Diode Module FDS 100A 600V D7, D8
4 2 0558003367 Transducer Current 100A T5, T7
5 1 0558002576 Relay SPST 24V w/MAG K2
6 1 952233 Inductor Output L2
7 1 0558002189 Switch Pressure .25 GPN FS1
8 1 0558002482 SOL AY 1/8 NPTF Port 3/16 BARB SOL1
9 1 0558003105 Switch Pressure High PS1

37

SECTION 6 REPLACEMENT PARTS

1

2

3 (Behind Bar)

6

5

4

Internal View - Powercut-1250

Right Side

Item Part

No. Qty. No. Description Symbol

1 1 952871 3PH BR Rect. w/out Thyristor BR1
2 2 0558003379 Module Dual IGBT 150A 600V Q2, Q3
3 2 17750010 RES WW AHNI 50W 3%K 10 OHM R6, R7
4 4 951161 CAPC Metpoly *20.0***UF 400VDC C11-C14
5 1 38240 PCB Power PCB5
6 1 38229 PCB HI Freq PCB2

38

SECTION 6 REPLACEMENT PARTS

3

1

6

5

2

4

Upper Left Side Internal View - Powercut-1250

Item Part

No. Qty. No. Description Symbol

1 1 38131 PCB Start-up Network PCB6
2 1 38238 PCB Display PCB3
3 1 38237 PCB Control PCB1

4 1 38242 PCB In Rush Control PCB4
5 1 950710 Switch Thermal 131°F TS2
6 1 951818 Relay SS 3—32VDC/24—28VAC 25A Q4

39

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS: Telephone: [phone] / Fax: [phone]

Order Entry Product Availability Pricing Delivery
Order Changes Saleable Goods Returns Shipping Information

B. ENGINEERING SERVICE: Telephone: [phone] / Fax : [phone]

Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations

C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: [phone]

Part Numbers Technical Applications Hours: 8:00 AM to 5:00 PM EST
Performance Features Technical Specifications Equipment Recommendations

D. LITERATURE REQUESTS: Telephone: [phone] / Fax: [phone]

E. WELDING EQUIPMENT REPAIRS: Telephone: [phone] / Fax: [phone]

Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST

F. WELDING EQUIPMENT TRAINING:

Telephone: [phone] / Fax: [phone]
Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST

G. WELDING PROCESS ASSISTANCE:

Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES:

Telephone : [phone] Hours: 7:30 AM to 5:00 PM EST

Hours: 8:00 AM to 7:00 PM EST

Hours: 7:30 AM to 4:00 PM EST

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123/ Fax: [phone]/ Web:http://www.esab.com

Hours: 7:30 AM to 5:00 PM EST

F-15-737 8/02