ESAB Powercut 650 Instruction Manual

ESAB Powercut 650 Instruction Manual

Portable plasma cutting system
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Powercut 650
Portable Plasma Cutting System
Instruction Manual
ESAB Console Item No. 0558003179, PC-650 208/230V 1 PH CONSOLE
ESAB Console Item No. 0558003515, PC-650 208/230V 1 PH CONSOLE (BL)
ESAB Console Item No. 0558005328, PC-650 460V CONSOLE
F15-696-D
12 / 2007

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Summary of Contents for ESAB Powercut 650

  • Page 1 Powercut 650 Portable Plasma Cutting System Instruction Manual ESAB Console Item No. 0558003179, PC-650 208/230V 1 PH CONSOLE ESAB Console Item No. 0558003515, PC-650 208/230V 1 PH CONSOLE (BL) ESAB Console Item No. 0558005328, PC-650 460V CONSOLE F15-696-D 12 / 2007...
  • Page 2: User Responsibility

    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

    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 Secondary Connections ...............................12 Assembling PT-31XLPC Consumable Parts......................13 SECtION 4 OPErAtION ..................................15 Powercut 650 Controls ..............................15 Cutting with the PT-31XLPC ............................17 Operating Techniques ..............................17...
  • Page 4 tABLE OF CONtENtS...
  • Page 5: Safety

    SECtION 1 SAFEtY PrECAutIONS...
  • Page 6 SECtION 1 SAFEtY PrECAutIONS...
  • Page 7: Introduction

    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

    20282 Includes the following items: Seat - 19679 O-ring - 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 ............0558003399 2.0 gENErAL...
  • Page 9: Installation

    There should be at least one foot of clearance between the Powercut 650 power source and wall or any other obstruction to allow freedom of air movement through the power source.
  • Page 10: Connections

    SECtION 3 INStALLAtION CONNECtIONS 3.4.1 PrIMArY ELECtrICAL INPut CONNECtIONS ELECtrIC SHOCK CAN KILL! Precaution- ary measures should be taken to provide (FIgurE 3.1) 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

    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

    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. For information on torch connections or refitting the torch (see Sec.
  • 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 SECtION 3 INStALLAtION...
  • Page 15: Operation

    ELECtrIC SHOCK can kill. run. The Powercut 650 is now in the "READY" mode given a suitable air supply • Do NOT operate the unit with the cover and a properly assembled torch.
  • Page 16: Section 4 Operation

    SECtION 4 OPErAtION H. Fault Light. Will glow amber under the following conditions and operations will come to a complete stop. Flow Fault: The fault light will be mostly on but will 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

    6. In the postflow mode, the arc can be restarted immediately by depressing the Position the Powercut 650 at least 10 torch switch. The two second preflow will automatically cancel. feet (3 meters) from the cutting area to protect the unit from sparks and hot slag 4.2 OPErAtINg tECHNIquES...
  • Page 18 COMING BACK AGAINST AND DAMAG- ING THE TORCH. Figure 4.3. Piercing technique using the Pt-31xLPC Cutting Speed range — Powercut 650 (using Air with xt Consumables 40 A @ 75 psi) Nozzle - P/N 20860, Electrode - P/N 20862 With 1/16" Standoff (tip to Work Distance)
  • Page 19: Common Cutting Problems

    Listed below are common cutting problems followed by the probable cause of each. If prob- lems are determined to be caused by the 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.
  • Page 20 SECtION 4 OPErAtION...
  • Page 21: Maintenance

    SECtION 5 MAINtENANCE 5.0 INSPECtION AND CLEANINg Frequent inspection and cleaning of the Powercut 650 is recommended for safety and proper operation. Some suggestions for inspecting and cleaning are as follows: If this equipment does not operate properly, stop work immediately and Check work cable to workpiece connection.
  • Page 22: Troubleshooting

    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

    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? Connect Is air adjusted to 65 - 75 psig? Adjust...
  • Page 24: Section 5 Maintenance

    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 solenoid valve source Figure 5-3.
  • Page 25 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 switch on Powercut 650 Figure 5-4. Sequence of Operations...
  • Page 26 • input rating. The light will not turn OFF even when correct voltage is restored. Reset by placing Powercut 650 power switch OFF and then ON again. NOtE: When in LOCK-IN mode, the FAULT light will turn on during second...
  • Page 27: Sequence Of Operation

    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) NOtES: When the torch switch is pushed during postflow period, the postflow and preflow times are canceled, and the HF is energized immediately.
  • Page 28 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: When the torch switch is pushed during postflow period, the postflow and preflow times are canceled, and the HF is energized immediately.
  • Page 29: Re-Fitting The Pt-31Xlpc Torch

    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 compartment from the front panel of power source. Thread the power cable and switch lead of the PT-31XLPC through the Strain Relief on the Access Cover.
  • Page 30 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: General

    Ordering To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this equipment. The use of non-ESAB parts may void your warranty. Replacement parts may be ordered from your ESAB Distributor.
  • Page 32 SECtION 6 rEPLACEMENt PArtS...
  • Page 33: Replacement Parts

    SECtION 6 rEPLACEMENt PArtS...
  • Page 34 SECtION 6 rEPLACEMENt PArtS...
  • Page 35 SECtION 6 rEPLACEMENt PArtS...
  • Page 36 section 6 replacement parts...
  • Page 37 SECtION 6 rEPLACEMENt PArtS...
  • Page 38 SECtION 6 rEPLACEMENt PArtS...
  • Page 39 SECtION 6 rEPLACEMENt PArtS...
  • Page 40 SECtION 6 rEPLACEMENt PArtS...
  • Page 41 SECtION 6 rEPLACEMENt PArtS...
  • Page 42 SECtION 6 rEPLACEMENt PArtS...
  • Page 43: Revision History

    6. Revision "B" - 05/2005 - added Air Line Filter Regulator p/n 0558005394 note in Replacement Parts section per CN #053013. Updated format. 7. Revision "B" - 06/2005 - added ESAB Console item no. 0558003515. In replacement parts section - Added item 1 page 32 p/n 0558005498M.
  • Page 44 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 Pricing Order Information Returns ENGINEERING SERVICE:...

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