ESAB Powercut 650 Spezifikationen

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Manual # 0558006136 - Rev. 0 9/2006
PC 650
Plasmarc Cutting Console
Service Manual
This manual provides service / troubleshooting
instructions for PC650 consoles beginning with
Serial Number P*J 623080
208/230 Volt PN: 0558003179
460 Volt PN: 0558005328
220/230 Volt CE PN: 0558005151
400 Volt CE PN: 0558005152
TABLE OF CONTENTS
SAFETY
INTRODUCTION
SPECIFICATIONS
MAIN SCHEMATIC
MAINTENANCE
REPLACEMENT PARTS
Seitenansicht 0
1 2 3 4 5 6 ... 111 112

Inhaltsverzeichnis

Seite 1 - Plasmarc Cutting Console

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

Seite 2 - USER RESPONSIBILITY

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

Seite 3

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

Seite 4

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

Seite 5

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

Seite 6

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

Seite 7 - 8"3/*/(

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

Seite 8

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

Seite 9

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

Seite 10 - CONTENTS

107SECTION 8 GENERAL INFORMATION8.1 Trouble Shooting Flow ChartCONTENTS

Seite 11

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

Seite 12

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

Seite 13

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

Seite 14

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

Seite 15

111REVISION HISTORYOriginal release - 9/ 20061.CONTENTS

Seite 16

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

Seite 17

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:

Seite 18

13SECTION 3 SPECIFICATIONS3.1 208 / 230 WiringCONTENTS

Seite 19

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

Seite 20

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

Seite 21

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

Seite 22

173.3 Sequence of OperationsSECTION 3 SPECIFICATIONSCONTENTS

Seite 23

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

Seite 24

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

Seite 25

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

Seite 26

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

Seite 27

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

Seite 28

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

Seite 29

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

Seite 30

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

Seite 31

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

Seite 32

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

Seite 33

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

Seite 34

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

Seite 35

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

Seite 36

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

Seite 37

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

Seite 38

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

Seite 39

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

Seite 40

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

Seite 41

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

Seite 42

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

Seite 43

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

Seite 44

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

Seite 45

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

Seite 46

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

Seite 47

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

Seite 48

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

Seite 49

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

Seite 50

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

Seite 51

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

Seite 52

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

Seite 53

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

Seite 54

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

Seite 55

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

Seite 56

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

Seite 57

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

Seite 58

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

Seite 59

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

Seite 60

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

Seite 61

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

Seite 62

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

Seite 63

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

Seite 64

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

Seite 65

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

Seite 66

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

Seite 67

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

Seite 68

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

Seite 69

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

Seite 70

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

Seite 71

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

Seite 72

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

Seite 73 - SECTION 5.5 _ TEST IGBT _ 1

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

Seite 74

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

Seite 75

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

Seite 76

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

Seite 77

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

Seite 78

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

Seite 79

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

Seite 80

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

Seite 81

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

Seite 82

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

Seite 83

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

Seite 84

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

Seite 85

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

Seite 86

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

Seite 87

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

Seite 88

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

Seite 89

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

Seite 90

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

Seite 91

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

Seite 92

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

Seite 93

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

Seite 94

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

Seite 95

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

Seite 96

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

Seite 97

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

Seite 98

86SECTION 7 REPLACEMENT PARTS7.3 PC650 Replacement Parts FrontCONTENTS

Seite 99

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

Seite 100

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

Seite 101 - SECTION 7 REPLACEMENT PARTS

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

Seite 102

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

Seite 103

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

Seite 104

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

Seite 105

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

Seite 106 - Documents

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

Seite 107

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

Seite 108

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

Seite 109

967.10 PC650 Replacement Parts Right Inside 230SECTION 7 REPLACEMENT PARTSCONTENTS

Seite 110

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

Seite 111

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

Seite 112

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

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