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ESAB Jesse James SIGNATURE Series Instruction Manual

Portable plasma cutting system
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POWERCUT 650
Portable Plasma Cutting System
Instruction Manual
ESAB Console Item No. 0558005338
0558005347
12/2007

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Summary of Contents for ESAB Jesse James SIGNATURE Series

  • Page 1 All manuals and user guides at all-guides.com POWERCUT 650 Portable Plasma Cutting System Instruction Manual ESAB Console Item No. 0558005338 0558005347 12/2007...
  • Page 2 All manuals and user guides at all-guides.com 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,”...

  • Page 3: Table Of Contents

    All manuals and user guides at all-guides.com taBle of contents section title page section 1 safetY ........................5 section 2 introDuction .............................7 General ...............................8 Scope ................................8 section 3 installation............................9 General ...............................9 Equipment Required ..........................9 Location ..............................9 Inspection ..............................9 Connections .............................10 3.4.1 Primary Electrical Input Connections ....................10 3.4.2 Connecting Powercut 650 for 208 Vac Input ................11...
  • Page 4 All manuals and user guides at all-guides.com taBle of contents...

  • Page 5: Safety

    All manuals and user guides at all-guides.com section 1 safetY precautions...
  • Page 6 All manuals and user guides at all-guides.com section 1 safetY precautions...

  • Page 7: Introduction

    All manuals and user guides at all-guides.com section 2 introDuction Powercut ® 650 Cutting Package • Manually cuts 5/8 inch and severs 3/4 inch - powerful cutting performance • Economical price - tremendous cutting value for the money • Compact portable design - goes to the job, easily moved about •...

  • Page 8: General

    Includes the following items: Seat - 0558000510 (19679) O-ring - 0558000514 (950790) Do not use any torch with this power source other than the esaB brand pt-31xlpc torch. serious injury may occur if used with any other torch. Wheel Kit For easy transport of system ............

  • Page 9: Installation

    All manuals and user guides at all-guides.com section 3 installation general Proper installation can contribute materially to the satisfactory and trouble-free operation of the Powercut 650 cutting package. It is suggested that each step in this section be studied carefully and followed as closely as possible.

  • Page 10: Connections

    All manuals and user guides at all-guides.com section 3 installation connections electric shocK can Kill! precaution- 3.4.1 primarY electrical input connections (figure 3.1) ary measures should be taken to provide maximum protection against electrical A line (wall) disconnect switch with fuses or circuit breakers should be provided at shock.

  • Page 11: Connecting Powercut 650 For 208 Vac Input

    All manuals and user guides at all-guides.com section 3 installation 3.4.2 connecting poWercut 650 for 208 vac input The Powercut 650 power source with 208/230 vac, single-phase input capability is factory set for 230 vac input. If using 208 vac input, the Powercut 650 must be reconnected as follows before connecting to 208 vac input power.

  • Page 12: Secondary Connections

    All manuals and user guides at all-guides.com section 3 installation 3.5 seconDarY connections (refer to fig. 3.3) The Powercut 650 is supplied from the factory with the complete PT-31XLPC torch and the work cable with clamp assembly pre-installed. No further installation is required.

  • Page 13: Assembling Pt-31Xlpc Consumable Parts

    TION OF HEAT SHIELD. closed when the shield is removed. al- WaYs replace torch With the proper torch manufactureD BY esaB since it alone contains esaB’s patenteD safetY interlocK. figure 3.4 assembly of “xt” consumable parts...
  • Page 14 All manuals and user guides at all-guides.com section 3 installation...

  • Page 15: Operation

    All manuals and user guides at all-guides.com section 4 operation B. POWER LIGHT H. FAULT LIGHT (WHITE) (AMBER) F. AIR PRESSURE CONTROL KNOB rear VieW E. AIR PRESSURE GAUGE C. CURRENT CONTROL KNOB D. AIR G. TRIGGER LOCK TEST SWITCH SWITCH front VieW A.
  • Page 16 All manuals and user guides at all-guides.com section 4 operation flow fault: The fault light will be mostly on but will flick off for approx.1/10th of a second every second. This indicates that the air flow supply is low. Seconds over temperature: The fault light will be mostly off but will flick on for approx.

  • Page 17: Cutting With The Pt-31Xlpc

    All manuals and user guides at all-guides.com section 4 operation TOO FAST TOO SLOW CORRECT fig. 4.2 - effect of cutting speed 4.1 cutting With the pt-31xlpc After placing the primary (wall) switch to the ON position and making control and Wear the usual protective gloves, cloth- air pressure adjustments as described above, proceed as follows: ing, and helmet.
  • Page 18 All manuals and user guides at all-guides.com section 4 operation WHEN THE ARC BREAKS THROUGH THE WORK, BRING THE TORCH TO AN UPRIGHT POSI- TION AND PROCEED TO CUT. TO START A PIERCE, TILT THE TORCH TO PREVENT MOLTEN MATERIAL FROM COMING BACK AGAINST AND DAMAG- ING THE TORCH.

  • Page 19: Common Cutting Problems

    Powercut 650, refer to the maintenance section of this manual. If the problem is not corrected after referring to the maintenance section, contact your ESAB representative. insufficient penetration. Cutting speed too fast.
  • Page 20 All manuals and user guides at all-guides.com section 4 operation...

  • Page 21: Maintenance

    All manuals and user guides at all-guides.com section 5 maintenance 5.0 inspection anD cleaning Frequent inspection and cleaning of the Powercut 650 is recommended for safety and if this equipment does not operate proper operation. Some suggestions for inspecting and cleaning are as follows: properly, stop work immediately and investigate the cause of the malfunction.

  • Page 22: Troubleshooting

    All manuals and user guides at all-guides.com section 5 maintenance 5.2 trouBleshooting 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 electric shocK can Kill! Be sure that all the input power, open up the unit, and perform a simple visual inspection of all the primary power to the machine has been components and wiring.

  • Page 23: Troubleshooting Guide

    All manuals and user guides at all-guides.com section 5 maintenance 5.3 trouBleshooting guiDe Difficult starting. • Change electrode • Change nozzle • Check for good, clean connection of work lead to workpiece • Check air pressure (65 - 75 psig) • Check torch power cable for continuity Depress torch switch. After 2 seconds, is high frequency present? Repair power Repair/replace source high frequency unit no air Is air hose connected?
  • Page 24 All manuals and user guides at all-guides.com section 5 maintenance air does not shut off Is air check switch OFF? Turn switch OFF Does arc start when nozzle contacts work without depressing torch switch? Check for short in torch switch Does air flow even when Powercut 650 power switch is OFF? Replace Repair power...
  • Page 25 All manuals and user guides at all-guides.com section 5 maintenance White "power" light not energized. Is main 230 volt switch ON? Turn on main disconnect Is plug in receptacle? Insert plug in receptacle Is cooling fan turning? Replace pilot light Check voltage at receptacle and input power line Check main fuses Faulty power...
  • Page 26 All manuals and user guides at all-guides.com section 5 maintenance e. amber "fault" light on. Is the unit overheated? ("Fault" lights turns off when Unit cools down.) Is air flowing? Duty cycle exceeded: 40% @ 40 A, 60% @ 30 A, or 100% @ 22 A output See Sect 5.1 Is input voltage within ±15% of units input rating?

  • Page 27: Sequence Of Operation

    All manuals and user guides at all-guides.com section 5 maintenance 5.4 sequence of operation locK-in "off" position PUSH RELEASE TORCH SWITCH GAS SOLENOID VALVE OPEN CLOSE 2 SEC. 10 SEC PREFLOW Postflow FLOW SWITCH CLOSE OPEN FAULT OVERLOAD LIGHT ENERGIZE HF CIRCUIT INVERTER CUTTING ARC (CURRENT)
  • Page 28 All manuals and user guides at all-guides.com section 5 maintenance locK-in "on" position PUSH RELEASE PUSH RELEASE TORCH SWITCH OPEN CLOSE GAS SOLENOID VALVE PREFLOW 2 SEC. 10 SEC Postflow CLOSE OPEN FLOW SWITCH FAULT PILOT LIGHT ENERGIZE HF CIRCUIT INVERTER CUTTING ARC (CURRENT) notes:...

  • Page 29: Re-Fitting The Pt-31Xlpc Torch

    All manuals and user guides at all-guides.com section 5 maintenance re-fitting the pt-31xlpc torch 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 torch connection compart- ment from the front panel of power source.
  • Page 30 All manuals and user guides at all-guides.com section 5 maintenance note: Schematics and Wiring Diagrams on 279.4mm x 431.8mm (11” x 17”) paper are included inside the back cover of this manual.

  • Page 31: Replacement Parts

    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.
  • Page 32 All manuals and user guides at all-guides.com section 6 replacement parts...
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  • Page 41 All manuals and user guides at all-guides.com section 6 replacement parts...
  • Page 42 All manuals and user guides at all-guides.com notes...
  • Page 43 All manuals and user guides at all-guides.com reVision historY Original release April, 2005 Revision 08/2005 - Made various updates per D. Smith and in replacement parts section, updated finger guard from: p/n 0558002994 to: p/n 0558005659 per CN-053103. Revision 12/2005 - Updated all rear view pics per D. Smith. Revision 12/2007 - Updated Replacement Parts to revision "0558004210-R"...
  • Page 44 All manuals and user guides at all-guides.com esaB Welding & cutting products, florence, sc Welding equipment communication guiDe - customer serVices CUSTOMER SERVICE QUESTIONS: Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST Order Entry Product Availability...
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This manual is also suitable for:

Powercut 650

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