ESAB Powercut 650 Specifications

Manual # 0558006136 - Rev. 0 9/2006PC 650Plasmarc Cutting ConsoleService ManualThis manual provides service / troubleshooting instr

10SECTION 2 INTRODUCTION2.0 Introduction2.1 ScopeThe purpose of this manual is to provide qualied repair personnel with technical information, whic

1007.13 PC650 Replacement Parts OutsideSECTION 7 REPLACEMENT PARTS7.13 PC650 Replacement Parts Outside BOMPC650 REPLACEMENT PARTSITEM QTY P/N DESCR

1017.14 PC650 Replacement Parts SpreadsheetSECTION 7 REPLACEMENT PARTSPC650 REPLACEMENT PARTSQTY ITEM P/N DESCRIPTION SYMBOL0558005152-400 V CE05580

1021 1 1 1 105 0558001180 SPARK GAP ASSEMBLY1 106 0558004125 SWITCH POWER DISCONN PC650 S31 1 1 106 36107 SWITCH POWER DISCONN PC650 600V 63A1 1 108 0

103KIT COMPONENTS WIRE MAIN PC-650 400/460V & CE1 1 120 0558005316KIT WIRE MAIN PC-650 400/460V (SEE COMPONENTS BELOW)1 1 951179 TRANSFORMER HIGH

1047.14 PC650 Replacement Parts SpreadsheetSECTION 7 REPLACEMENT PARTSKIT COMPONENTS_230 V 1 Phase CE (PN: 0558005345)1 122 0558005345KIT WIRE POWER

1057.14 PC650 Replacement Parts SpreadsheetSECTION 7 REPLACEMENT PARTS1 151 954700 LABEL INPUT 200VAC PCM-1251 1 153 954746 LABEL FAULT INDICATOR1 1

106Yellow LEDDocumentsPDFCompleteClick Here & UpgradeExpanded FeaturesUnlimited Pages6156 SolenoidR1SECTION 8 GENERAL INFORMATION8.0 Solenoid -

107SECTION 8 GENERAL INFORMATION8.1 Trouble Shooting Flow ChartCONTENTS

1088.2 Low Voltage Check***Before performing Low Voltage Check be sure that PC650 is powered down***Connect the Variac across the AC2 ( R) and AC1 (T

1098.3 PT31 TorchTest Procedure for PT31XLPC torchEquipment Required: A. Supply of 100 PSI Air or Nitrogen gas with regulator. B. Test xture

11The Powercut 650 is available as 208/230 VAC single-phase power, or as 460 VAC 3 phase. The 208/230 volt model comes congured from the factory for

110bias supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

111REVISION HISTORYOriginal release - 9/ 20061.CONTENTS

112Manual #0558006136 - Rev. 0 9/2006A. CUSTOMER SERVICE QUESTIONS: Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM E

12SECTION 3 SPECIFICATIONS3.1 208 / 230 WiringThe Powercut 650 “CE model” is available as 230 VAC single-phase power, or as 400 VAC 3 phase. Note:

13SECTION 3 SPECIFICATIONS3.1 208 / 230 WiringCONTENTS

14NOTE: PC650 input cable dierencesThe colors of input phases of the CE models dier from those of the “non CE” models. Below is a table comparing t

15SECTION 3 SPECIFICATIONS3.1 208 / 230 WiringFigure 3.1 Customer Fused Line Disconnect and ReceptacleFactory supplied primary power cable with plug

16SECTION 3 SPECIFICATIONS3.2 Machine Operation Flowchart3.3 PC650 Machine Section IndexSection IndexSec. #5. Section Name Page Sec. #5. Section Na

173.3 Sequence of OperationsSECTION 3 SPECIFICATIONSCONTENTS

181. The operator engages the torch switch on the torch, requesting a cutting operation. This closes the torch switch connection at the control PCB (

194.0 Glossary (General Denitions and Symbols)SECTION 4 GLOSSARYGROUNDT nL nL nSILICOND nD nD nSW nF nELECTROLITICRESISTORDESCRIPTIONWound wire de

This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed,

204.0 Glossary (General Denitions and Symbols)SECTION 4 GLOSSARYPLUGCONNECTIONVariously configured male/female separable connectors.DESCRIPTIONSYM

214.0 Glossary (General Denitions and Symbolsl)SECTION 4 GLOSSARYLOGIC SYMBOLSAND GATEOR GATENAND GATENOR GATENOTSYMBOLNAMEDESCRIPTION(INVERTER)AB

SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.0 Schematic Section Map 208/230 V 0558003302CONTENTS3211164511713101289

SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.0 Schematic Section Map 460 V 0558005314CONTENTS3211164511713101289

SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.0 Schematic Section Map 230 V CE 0558005343CONTENTS3211164511713101289

SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.0 Schematic Section Map 400 V CE 0558005314CONTENTS3211164511713101289

26SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICEThe power input switch S3, when in the “ON” position, passes the input voltage, either 208 or

27SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.1 Input Power SwitchPN: 36107 (400 / 460 V Units)PN: 0558004125 (208 / 230 V Units)CONTENT

28Single-phase 208 or 230 VAC power enters the rectier block where it is rectied by the IBR and gated on and o by an SCR. The rectied 325 VDC out

29SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.2 Input BridgeCONTENTS

SECTIONS1SafetyIntroduction2Testing / Troubleshooting / Service5Schematic Section Map5.0Specications3Glossary4Input Bridge5.2Buss Supply5.3Input Powe

30SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICEBuss cap warning Serious Shock PossibleThe “b

31SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.3.1 Buss Supply Schematic208 / 230 Volt460 VoltCONTENTS

325.3.2 Buss Supply Values5.3.3 Buss Supply TestingSECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICEBuss Supply Values & Testing208 / 230 V

33SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.4 IGBT BlockThe Inverter block consists of the IGBT driver board and the IGBT block.The IGB

34SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.4.1 IGBT Driver BoardIGBT DRIVER BOARDS REPLACEMENT PARTSITEM QTY DESCRIPTION SYMBOL2 2 CAP

35SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.4.2 IGBT Block208 / 230 Volt460 VoltCONTENTS

36SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.5 Main Transformer T1The Main Transformer T1 takes the 325 VAC received from the IGBT block

37SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.5 Main Transformer T1 (35941)CONTENTS

38SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.5.1 Coupling CircuitThe coupling circuit consists of resistor R9 (39kΩ, 2W) and capacitor C

39SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.5.2 Current Transformer T4 (32958)Current transformer (T4) measures the current owing thro

4TABLE OF CONTENTS1.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.6 Output Rectier 1 (952150)The Bridge diode D1 is a full wave bridge rectier, which conv

41SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.6 Output Rectier 1 (952150)CONTENTS

42SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.7 Control Transformer T2 (35940)This transformer supplies reduced AC voltages to the PCB1 c

43SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.7 Control Transformer T2 (35940)CONTENTS

44SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.7 Control Transformer T2 - 230/400/460/575V (332914)TERMINAL VOLTAGE TURNS AWGH1 - H2 * 23

455.7 Control Transformer T2 - 230/400/460/575V (32914)SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICECONTENTS

46Active device cooling (the IGBTs, IBR and D1) is performed by axial fan M1. This fan is connected across the 230-volt primary of the T2, and is on w

47SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.8 Plasma Control Board (38214)PCB 1 is the control module for the PC 650. The module develo

SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.8 Plasma Control Board Schematic (38214)CONTENTS

49SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.8.1 PCB1 Control Board and Bias SuppliesBIAS POWER SUPPLIES The PCB1Control Board creates 4

5TABLE OF CONTENTS5.12.1 T3 High Frequency Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICEIf the 20VAC signal is not there, check the PCB module transformer and associated cabling for

51SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.8.2 PCB Torch SwitchThe switch on the torch closes the circuit requesting a cutting operati

52SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.8.3 Gas CircuitOnce the torch switch circuit has been completed, the PC650 air will ow out

53SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.8.4 Pulse Width ModulatorIC6 is the Pulse Width Modulator IC and it generates the drive sig

54SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.8.5 Overcurrent SenseThe current limit circuitry receives an input from the current sense t

55SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.8.6 Arc On CircuitThe Arc On circuit consists of IC4 and IC5 and their immediate supporting

56SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.8.7 Lock In Switch CircuitThe PCB module incorporates some safety interlocks into the syste

575.8.8 Current ControlSECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICECurrent control on the Powercut 650 is controlled from the front panel.

58SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.8.9 Over / Under Voltage Fault CircuitThe PCB Control board has a voltage monitoring circui

59SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.8.10 HF ActivationWhen the operator requests a cutting operation to begin, after the start

6SECTION 1 SAFETY PRECAUTIONS1.0 Safety Precautions4&$5*0/ 4"'&5:13&$"65*0/4 4BGFUZ1SFDBVUJPOT6TFSTPG&4&qu

60SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.8.11 Lock In Switch CircuitWhen the Trigger lock switch on the front panel is engaged, this

61SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.9 Output Inductor L1 - (952606)The Output Inductor L1 lters the ripple out of the output o

62SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.10 Startup Board PCB5 - (38131)The startup board assists with the arc creation process. Thi

63SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.11 Trigger Lock Switch S2The Torch lock switch reduces operator fatigue by allowing the ope

64SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.11.1 PC650 Fault MonitoringOver/Under voltage fault—Flashes 5 times per second.Over voltage

65SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.11.2 Fault LightOn the front panel of the PC650 is the fault light. This is a visual indica

66SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.12 High Frequency (951179)When the PCB control board enables the 120VAC for HF activation f

67SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.12.1 T3 High Frequency TransformerCONTENTS

68SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.12.2 Spark Gap (0558001180)The spark gap unit generates the HF necessary to create main arc

69The Air test switch (S1) bypasses the ow switch and opens the gas test solenoid to test integrity of the gas ow circuit. In the test position, the

7SECTION 1 SAFETY PRECAUTIONS4&$5*0/ 4"'&5:13&$"65*0/48&-%*/("/%1-"4."$655*/($"/#&*/

70SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.13 Shunt (31488)The Feedback shunt consists of a .001Ω resistor that feeds back a 0 – 100 m

71SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE5.14 PT31 Torch (0558003183)The PC650 uses the PT-31XLPC torch. It comes ready to use out of

72Two-Point Mounting Type Temporary tightening = 1 then 2 Final tightening = 2 then 112IGBT Handling & ReplacementSince IGBT gates are insulated

73SECTION 6 REGULAR MAINTENANCE6.1 Buss Supply Power Control / IGBT Testing Procedure (1)38SECTION 5.5 _ TEST IGBT _ 1Take measurements on threaded

746.1 Buss Supply Power Control / IGBT Testing Procedure (2)39SECTION 5.5 _ TEST IGBT _ 2With meter on “OHMS (:)” setting, measure resistance by plac

75124563LED 133247.5 K9 V DC+ --+SW 1N.C.N.O.LARGE BLACKCLIPLARGE REDCLIP3 MSMALL YELLOWCLIPIGBT TESTERIGBT Tester Schematic6.2 Buss Supply Power Con

766.3 Buss Supply Power Control / IGBT / MOSFET Testing IGBTC2E1E2C1G1 E1E2 G2BLACK LEADRED LEADYELLOW OR SMALL CLIP1. CONNECT AS SHOWN2. LED ON= S

6.4 208/230 V Wiring Diagram ( 0558003179 )SECTION 6 WIRING DIAGRAMSCONTENTS

SECTION 6 WIRING DIAGRAMS6.4 208/230 V Wiring Diagram ( 0558003179 )CONTENTS

6.5 460 V Wiring Diagram (0558005328)SECTION 6 WIRING DIAGRAMSCONTENTS

8SECTION 1 SAFETY PRECAUTIONSWARNINGARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING OR CUTTING. ASK YO

SECTION 6 WIRING DIAGRAMS6.5 460 V Wiring Diagram (0558005328)CONTENTS

SECTION 6 WIRING DIAGRAMS6.6 230 V CE Wiring Diagram (0558005151)CONTENTS

SECTION 6 WIRING DIAGRAMS6.6 230 V CE Wiring Diagram (0558005151)CONTENTS

SECTION 6 WIRING DIAGRAMS6.7 400 V CE Wiring Diagram (0558005152)CONTENTS

SECTION 6 WIRING DIAGRAMS6.7 400 V CE Wiring Diagram (0558005152)CONTENTS

85SECTION 7 REPLACEMENT PARTS7.1 GeneralAlways provide the serial number of the unit on which the parts will be used. The serial number is stamped o

86SECTION 7 REPLACEMENT PARTS7.3 PC650 Replacement Parts FrontCONTENTS

877.3 PC650 Replacement Parts Front BOMSECTION 7 REPLACEMENT PARTSPC650 REPLACEMENT PARTSITEM QTY P/N DESCRIPTION SYMBOL10 1 21711 GAUGE 1.50 160PS

88SECTION 7 REPLACEMENT PARTS7.4 PC650 Replacement Parts Front Inside7.4 PC650 Replacement Parts Front Inside BOMPC650 REPLACEMENT PARTSITEM QTY P

89SECTION 7 REPLACEMENT PARTS7.5 PC650 Replacement Parts Rear7.5 PC650 Replacement Parts Rear BOMPC650 REPLACEMENT PARTSITEM QTY P/N DESCRIPTION SY

9SECTION 1 SAFETY PRECAUTIONSELECTRIC SHOCK - Can kill- Install and ground welding equipment in accordance with obligatory standards.- Do not touch l

90SECTION 7 REPLACEMENT PARTS7.6 PC650 Replacement Parts Top Inside 2CONTENTS

91SECTION 7 REPLACEMENT PARTS7.6 PC650 Replacement Parts Top Inside 2 BOMPC650 REPLACEMENT PARTSITEM QTY P/N DESCRIPTION SYMBOL3 1 0558002183 COVER

92SECTION 7 REPLACEMENT PARTS7.7 PC650 Replacement Parts Top Inside7.7 PC650 Replacement Parts Top Inside BOMPC650 REPLACEMENT PARTSITEM QTY P/N DE

93SECTION 7 REPLACEMENT PARTS7.8 PC650 Replacement Parts Top Inside 37.8 PC650 Replacement Parts Top Inside 3 BOMPC650 REPLACEMENT PARTSITEM QTY P/

947.9 PC650 Replacement Parts Left InsideSECTION 7 REPLACEMENT PARTS7.9 PC650 Replacement Parts Left Inside 230 BOMPC650 REPLACEMENT PARTSITEM QTY

95SECTION 7 REPLACEMENT PARTS7.9 PC650 Replacement Parts Left Inside 230 BOM53 4 17721020 RESISTOR 20 OHM, 25 WATT R3,4,5,654 2 17750010 RESISTOR 50

967.10 PC650 Replacement Parts Right Inside 230SECTION 7 REPLACEMENT PARTSCONTENTS

97SECTION 7 REPLACEMENT PARTS7.10 PC650 Replacement Parts Right Inside 230 BOMPC650 REPLACEMENT PARTSITEM QTY P/N DESCRIPTION SYMBOL8 1 634220 TAB 1

987.11 PC650 Replacement Parts Left Inside Detail 460SECTION 7 REPLACEMENT PARTS7.11 PC650 Replacement Parts Left Inside Detail 460 BOMPC650 REPLAC

99SECTION 7 REPLACEMENT PARTS7.12 PC650 Replacement Parts Right Inside Detail 4607.12 PC650 Replacement Parts Right Inside Detail 460 BOMPC650 REPL