ESAB PowerCut-550 Instruction Manual
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ESAB PowerCut-550 Instruction Manual

ESAB PowerCut-550 Instruction Manual

Plasma arc cutting packages
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PLASMA ARC CUTTING PACKAGES
This manual provides complete instructions for the following PowerCut-550 cutting packages starting with Serial No. PPOR113001:
ESAB P/N 0558002612 - 208 and 230 V, 1-Phase, 50/60 Hz
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of
operation and safe practices for arc welding 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.
Be sure this information reaches the operator.
You can get extra copies through your supplier.
INSTRUCTION MANUAL
PowerCut-550
F-15-654
May, 2001

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Summary of Contents for ESAB PowerCut-550

  • Page 1 PowerCut-550 PLASMA ARC CUTTING PACKAGES This manual provides complete instructions for the following PowerCut-550 cutting packages starting with Serial No. PPOR113001: ESAB P/N 0558002612 - 208 and 230 V, 1-Phase, 50/60 Hz These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding equipment, we urge you to read our booklet, "Precautions...

  • Page 2: Table Of Contents

    Equipment Required ..............10 Location ..................10 Inspection ..................10 Primary Electrical Input Connections ..........10 Secondary (Output) Connections ..........11 Connecting PowerCut-550 for 200(208) Vac Input ....... 12, 13 SECTION 3 OPERATION ................14 Operation ..................14 PowerCut-550 Controls ..............14 Assembling PT-31XL Consumable Parts ........
  • Page 3 SAFETY PRECAUTIONS 5. Do not use equipment beyond its ratings. For example, WARNING: hese Safety Precautions are overloaded welding cable can overheat and create a for your protection. They summarize precau- fire hazard. tionary information from the references listed 6. After completing operations, inspect the work area to in Additional Safety Information section.
  • Page 4 FUMES AND GASES -- Fumes and EQUIPMENT MAINTENANCE -- Faulty or gases, can cause discomfort or harm, improperly maintained equipment can particularly in confined spaces. Do cause injury or death. Therefore: not breathe fumes and gases. Shield- ing gases can cause asphyxiation. 1.
  • Page 5 PRÉCAUTIONS DE SÉCURITÉ 2. PRÉVENTION DES INCENDES-- Les projections AVERTISSEMENT: Ces règles de sécurité ont pour de laitier incandescent ou d’étincelles peuvent objet d’ assurer votre protection. Veillez à lire et à provoquer de graves incendies au contact de observer les précautions énoncées ci-dessous matériaux combustibles solides, liquides ou avant de monter l’...
  • Page 6 Arc Welding, Cutting and Gouging” publié par ventilateur ne fonctionne que si l’interrupteur ESAB. Nous conseillons également de consulter correspondant du panneau avant se trouve placé en position ON (Marche). Veillez à manœuvrer les publications sui-vantes, tenues à...

  • Page 7: Description

    SECTION 1 DESCRIPTION 1.1 GENERAL The PowerCut-550 is a compact, completely self- contained plasma cutting system. As shipped, the Do not use any torch with this power source system is fully assembled and ready to cut after other than the ESAB brand PT-31XL torch.

  • Page 8: Specifications

    NOTE: PT-31XL Torch Assembly P/N 21985 is supplied with the nozzle, electrode, swirl baffle, and heat shield assembled. 1.4 SPECIFICATIONS Refer to Tables 1-3, 1-4, and Figures 1-1 and 1-2 for PowerCut-550 technical specifications. Table 1-3. PowerCut-550 Specifications 40% Duty Cycle*...

  • Page 9: Specifications ............................................................................... 8

    SECTION 1 DESCRIPTION Table 1-4. PT-31XL Torch Specifications PT-31XL Torch 75° Torch Current Capacity ........50A DCSP Shipping Wgt........... 2 lbs (1 kg) 5 1/4" Length of Service Lines ......25-ft. (7.6 m) (133mm) Figure 1-1. PT-31XL Dimensions Figure 1-2. PT-31XL Cutting Performance...

  • Page 10: Installation

    208/230 V to Adequate ventilation is necessary to provide proper a 460 V input power supply. Damage to the cooling of the PowerCut-550 and the amount of dirt, machine may occur. dust, and excessive heat to which the equipment is exposed, should be minimized.

  • Page 11: Secondary (Output) Connections

    SECTION 2 INSTALLATION 2.6 SECONDARY (OUTPUT) 1. The torch connections are located at the CONNECTIONS (REFER TO flowswitch on upper left side of machine. FIG. 2-1) 2. Thread the power cable and switch lead of the PT-31XL through the right side (above pressure Torch comes factory installed.

  • Page 12: Connecting Powercut-550 For 200(208) Vac Input

    (90 to 150 psig max) CUSTOMER FUSED LINE DISCONNECT SWITCH See Table 2.1 RECEPTACLE (P/N 674540) (Optional for 208/230 V, 1-phase power sources) PLUG (See Table 2.1 and WARNING in regards to chassis ground in Section 2.5.) Figure 2-1. PowerCut-550 Interconnection Diagram...
  • Page 13 SECTION 2 INSTALLATION EARTH GROUND DO NOT ATTACH WORK CABLE TO PIECE BEING WORK CABLE CUT FREE GROUNDED WORK TABLE BE SURE WORK IS IN GOOD CONTACT WITH TABLE. EARTH GROUND WORK CABLE...

  • Page 14: Operation

    • Wear welding helmet with No. 6 or 7 lens shade. • Wear eye, ear, and body protection. Position the PowerCut-550 at least 10 feet (3 meters) from the cutting area. Sparks and hot slag from the cutting operation can damage the unit.

  • Page 15: Assembling Pt-31Xl Consumable Parts

    Will switch off below 15psi (1 bar). ALWAYS REPLACE TORCH WITH THE PROPER TORCH MANUFACTURED BY ESAB SINCE IT On/Off Switch (White light) - will light when ALONE CONTAINS ESAB’S PATENTED SAFETY switched on, even if the machine stopped for INTERLOCK.

  • Page 16: Section 3 Operation

    TORCH. Figure 3-4. Piercing Technique using the PT-31XL CAUTION: Locate the console at least 10-ft. from Cutting Speed Range — PowerCut-550 the cutting work area. Chips and hot (Using Air with XT Consumables @ 75 psi) slag from the cutting operation can damage the console.

  • Page 17: Operating Techniques

    Loose cable or hose connections. problems are determined to be caused by the Electrode and/or cutting nozzle in poor PowerCut-550, refer to the maintenance section condition. of this manual. If the problem is not corrected after referring to the maintenance section, contact Main Arc Does Not Strike.

  • Page 18: Maintenance

    4.1 GENERAL With all input power disconnected, and wear- ing proper eye and face protection, blow out the inside of the PowerCut-550 using low- pressure dry compressed air. If this equipment does not operate properly, 4.3 FLOW SWITCH (FIGURE 4-1) stop work immediately and investigate the cause of the malfunction.

  • Page 19: Troubleshooting

    SECTION 5 TROUBLESHOOTING The cause of control malfunctions can be 5.1 TROUBLESHOOTING found by referring to the sequence of opera- tions and electrical schematic diagram (Figure 5-1) and checking the various components. A volt-ohmmeter will be necessary for some of these checks.
  • Page 20 SECTION 5 TROUBLESHOOTING No Air Is air hose connected? Connect Is air adjusted to 55 - 65psi (4 - 5 bar)? Adjust Does air come on with air check switch? • No electrode in torch • No valve pin in torch •...

  • Page 21: Section 5 Troubleshooting

    SECTION 5 TROUBLESHOOTING Air does not shut off Does arc start when nozzle contacts work without depressing torch switch?l; Check for short in torch switch Does air flow even when PowerCut 550 power switch is OFF? Replace Repair/replace control solenoid valve...
  • Page 22 SECTION 5 TROUBLESHOOTING On/Off switch light not energized. Is switch ON? Turn on switch Is plug in receptacle? Insert plug Is cooling fan turning? Replace On/Off switch Check voltage at receptacle and input power line Check main fuses Replace On/Off switch...
  • Page 23 SECTION 5 TROUBLESHOOTING Temperature LED light ON. Is the unit overheated? (LED turns off when unit cools down.) Is cooling air flowing? Duty cycle exceeded: 40% @ 35 A or 100% @ 22 A output Repair power source Repair fan No current output Is input voltage within -10% of units input rating? See (D.) sequence above...

  • Page 24: Sequence Of Operation

    SECTION 5 TROUBLESHOOTING PUSH RELEASE TORCH SWITCH OPEN CLOSE GAS SOLENOID VALVE 2 SEC. PREFLOW 10 SEC Postflow OPEN FLOW SWITCH CLOSE FAULT OVERLOAD LIGHT ENERGIZE HF CIRCUIT INVERTER CUTTING ARC (CURRENT) NOTES: When the torch switch is depressed during postflow period, the postflow and preflow times are canceled, and the HF is energized immediately.

  • Page 25: Replacement Parts

    SECTION 6 REPLACEMENT PARTS 6.2 ORDERING 6.1 GENERAL Replacement parts may be ordered from your ESAB Replacement Parts are illustrated on the following distributor or from: figures. When ordering replacement parts, order by part number and part name, as illustrated on the ESAB Welding &...
  • Page 26 SECTION 6 REPLACEMENT PARTS...

  • Page 27: Spare Parts List

    SECTION 6 REPLACEMENT PARTS Spare Parts List PowerCut-550 Item No. Part No. Description Cct. Ref. 0558002704 Lid with Handle/Strap (Not Shown) 0558002735 Knob 0558002754 Inverter/Main PCB 0558002755 Control PCB 0558002756 HF PCB 0558002757 HF Generator 0558002738 VR1 & 2 0558002739...
  • Page 28 ESAB Welding & Cutting Products, Florence, SC Welding Equipment COMMUNICATION GUIDE - CUSTOMER SERVICES A. CUSTOMER SERVICE QUESTIONS: Order Entry Product Availability Pricing Delivery Order Changes Saleable Goods Returns Shipping Information Eastern Distribution Center Telephone: (800)362-7080 / Fax: (800) 634-7548...

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