ESAB Jesse James SIGNATURE Series User manual

ESAB Console Item No. 0558005338
Portable Plasma Cutting System
POWERCUT 650
Signature Series
0558005347 12/2007
Instruction Manual
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This equipment will perform in conformity with the description thereof contained in this manual and accompa-
nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-
tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment
should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme-
diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone
or written request for service advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a ser-
vice facility designated by the manufacturer.
BE SURE THIS INFORMATION REACHES THE OPERATOR.
YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.
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,” 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 be-
fore installing or operating this equipment.
CAUTION
USER RESPONSIBILITY
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
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SECTION TITLE PAGE
SECTION 1 SAFETY........................................................................................................................5
SECTION 2 INTRODUCTION.....................................................................................................................................7
2.0 General.......................................................................................................................................................8
2.1 Scope ..........................................................................................................................................................8
SECTION 3 INSTALLATION........................................................................................................................................9
3.0 General.......................................................................................................................................................9
3.1 Equipment Required.............................................................................................................................9
3.2 Location .....................................................................................................................................................9
3.3 Inspection..................................................................................................................................................9
3.4 Connections .............................................................................................................................................10
3.4.1 Primary Electrical Input Connections..............................................................................................10
3.4.2 Connecting Powercut 650 for 208 Vac Input................................................................................11
3.5 Secondary Connections.......................................................................................................................12
3.6 Assembling PT-31XLPC Consumable Parts...................................................................................13
SECTION 4 OPERATION .............................................................................................................................................15
4.0 Powercut 650 Controls..........................................................................................................................15
4.1 Cutting with the PT-31XLPC ...............................................................................................................17
4.2 Operating Techniques...........................................................................................................................17
4.3 Common Cutting Problems................................................................................................................19
SECTION 5 MAINTENANCE ......................................................................................................................................21
5.0 Inspection and Cleaning......................................................................................................................21
5.1 Flow Switch...............................................................................................................................................21
5.2 Troubleshooting .....................................................................................................................................22
5.3 Troubleshooting Guide ........................................................................................................................23
5.4 Sequence of Operation ........................................................................................................................27
5.5 Re-tting the PT-31XLPC Torch..........................................................................................................29
SECTION 6 REPLACEMENT PARTS........................................................................................................................31
6.0 General.......................................................................................................................................................31
6.1 Ordering.....................................................................................................................................................31
TABLE OF CONTENTS
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4
TABLE OF CONTENTS
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5
SECTION 1 SAFETY PRECAUTIONS
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6
SECTION 1 SAFETY PRECAUTIONS
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7
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
Delivers big machine cutting power in a rugged,•
lightweight package.
Arrives ready to cut, with torch connected and front-end•
parts in place, for the ultimate in operator convenience.
High frequency starting - starts through paint•
Trigger lock-in for long-cut operator comfort.•
Adjustable output - tailor the current to the material•
being cut
Compact simple torch - easy access, little maintenance•
New quick - connect torch switch plug•
New durable torch cable prevents snagging on xtures•
and materials
Patented XT nozzles - extended shape gives good•
visibility as well as good consumable life
Drag or stando cutting - easy operation with little•
or no training
Template following feature - easily duplicates curves or•
straight lines
Tolerates poor power lines•
Three-year warranty on console•
One-year warranty on torch•
Specifications
Cuts 5/8 in.; severs 3/4 in.
Output: 40% duty cycle..........................................................40A/120V
60% duty cycle..........................................................30A/120V
100% duty cycle .......................................................22A/120V
Output Current Range............................................................... 10 to 40 Amperes
Open Circuit Voltage ..................................................................290 Vdc Nominal
Input @ 35A/120V ...................208/230 vac 1 ph. 50/60 Hz., 35/32 amps
Power factor @ 40A Output.............................................................76% (1 Phase)
Eciency @ 40A Output....................................................................85% (Typical)
Air requirements ................................................................ 250 cfh at 80 psig
Dimensions: Length..............................................................16.00" (406mm)
w/ handles.................................................25.70" (653mm)
Height...............................................................16.38" (416mm)
Width................................................................12.50" (318mm)
w/ Opt. torch wrap.................................15.50" (394mm)
Weight (less torch & work cable)....................................................53 lbs. (24 kg)
Torch
Uses PT-31XLPC
ThePowercut650 comesoutof the boxreadytogo!Thetorchis attached with
parts inplace,primary cord is attached andthe lter/regulator isinstalled. Just
hook up the air, plug it in and cut.
Instruction Literature, order number............................................0558005347
Powercut®650 CuttingPackage
Powercut650 / PT-31XLPC CuttingPerformance
For a complete list of torch parts, refer to Optional Accessories .
HowTo Order
The Powercut®650 comes complete with everything you need:
console, 25 ft. PT-31XLPC torch, torch spare parts kit, air lter/
regulator,inputpowercordwithplug,25ft.workcablewithclamp.
System arrives fully assembled and ready to cut.
OrderingInformation
Powercut ®650 / 25 ft. PT-31XLPC package
Powercut®650,
208/230 vac 1 ph. 25 ft. PT-31XLPC.........................................0558003386
SECTION 2 INTRODUCTION
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8
OptionalAccessories
Torch Guide Kits
The Deluxe kit, in a rugged plastic carrying case, includes
attachments for circle and straight line cutting on ferrous and
non-ferrous metals
Deluxe: 1 3/4" - 42" Radius..........................................................0558003258
Basic: 1 3/4" - 28" Radius..............................................................0558002675
Plasma Flow Measuring Kit
This valuable troubleshooting tool allows measurement of
the actual plasma gas ow through the torch................................ 19765
Input Receptacle
230Vac/50Amp, 3 Prong........................................................................674540
Torch Wrap and Spare Parts Kit Holder
This enables operator to store S/P Kit, wrap torch and
work cable for easy transport and storage...........................0558003398
Wheel Kit
For easy transport of system......................................................0558003399
Electrode
20862
Swirl Bae
20463
Seat
19679
Plunger
20324
Heat Shield
20282
Nozzle
20860
PT-31XLPC Spare Parts Kit (P/N 0558003301) includes:
Heat Shield (1) .................................................................................................. 20282
Nozzles (3).......................................................................................................... 20860
Swirl Bae (1)................................................................................................... 20463
Electrodes (2) .................................................................................................... 20862
PT-31XLPC Replacement Torch.........................................0558003183
Torch comes assembled with Heat Shield, Nozzle, Electrode, and Swirl
Bae.
Powercut shown with OptionalTorch Wrap
and Spare Parts Kit Holder installed.
2.0 GENERAL
The Powercut 650 is a compact, completely self-contained
plasma cutting system. As shipped, the system is fully as-
sembled and ready to cut after being connected to input
power and a source of preltered compressed air (90-150
psi). The Powercut 650 package uses the PT-31XLPC torch
to deliver cutting power for materials up to 5/8-in. thick or
for severing up to 3/4-in. thick.
2.1 SCOPE
The purpose of this manual is to provide the operator with
all the information required to install and operate the Pow-
ercut 650 plasma arc cutting package. Technical reference
material is also provided to assist in troubleshooting the
cutting package.
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.
Torch Body
*0558000790
(20072)
*Includes the following items:
Seat - 0558000510 (19679)
O-ring - 0558000514 (950790)
SECTION 2 INTRODUCTION
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9
3.0 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.
3.1 EQUIPMENT REQUIRED
Asourceofclean,preltereddryair thatsupplies250cfhat 80psigisrequiredforthecutting operation.
The air supply should not exceed 150 psig (the maximum inlet pressure rating of the air lter-regulator
supplied with the package).
3.2 LOCATION
Adequate ventilation is necessary to provide proper cooling of the Powercut 650 and the amount of
dirt, dust, and excessive heat to which the equipment is exposed, should be minimized. There should
be at least one foot of clearance between the Powercut 650 power source and wall or any other ob-
struction to allow freedom of air movement through the power source.
Installing or placing any type of ltering device will restrict the volume of intake air, thereby subject-
ing the power source internal components to overheating. The warranty is void if any type of lter
device is used.
3.3 INSPECTION
A. Remove the shipping container and all packing material and inspect for evidence of concealed
damage which may not have been apparent upon receipt of the Powercut 650. Notify the carrier
of any defects or damage at once.
B. Check container for any loose parts prior to disposing of shipping materials.
C. Check air louvers and any other openings to ensure that any obstruction is removed.
SECTION 3 INSTALLATION
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10
3.4 CONNECTIONS
3.4.1 PRIMARY ELECTRICAL INPUT CONNECTIONS FIGURE 3.1
A line (wall) disconnect switch with fuses or circuit breakers should be provided at
the main power panel (see Fig. 3-1 and Table 3-1 for fuse sizes). The input power
cable of the console may be connected directly to the disconnect switch or you
may purchase a proper plug and receptacle from a local electrical supplier. If using
plug/receptacle combination, see Table 3-1 for recommended input conductors for
connecting receptacle to line disconnect switch.
ELECTRIC SHOCK CAN KILL! Precaution-
ary measures should be taken to provide
maximum protection against electrical
shock. Be sure that all power is o by
opening the line (wall) disconnect switch
and by unplugging the power cord to the
unitwhen connections aremade insideof
the power source.
Be sure that the power source is properly
conguredforyourinputpowersupply.DO
NOTconnectapowersourceconguredfor
208/230 V to a 460 V input power supply.
Damage to the machine may occur.
Table 3.1. Recommended Sizes for Input Conductors
and Line Fuses
Rated Input Input & GND Fuse Size
Conductor Amps
Volts Amp Phases CU/AWG*
208 35 1 No. 10 50
230 32 1 No. 10 50
* Sized per National Code for 80°C rated copper conductors @ 30°C ambient. Not more than three
conductors in raceway or cable. Local codes should be followed if they specify sizes other than those
listed above.
Figure 3.1 Customer Fused Line Disconnect and Receptacle
Factory supplied primary
power cable with plug.
CUSTOMER FUSED LINE DISCONNECT SWITCH
(See Table 3.1 and WARNING in regards to chassis
ground in Section 3.4.)
SECTION 3 INSTALLATION
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11
Before making any connections to the
powersourceoutputterminals,makesure
that all primary input power to the power
source is deenergized (o) at the main
disconnectswitchandthattheinputpower
cable is unplugged.
ELECTRICSHOCKCANKILL!Precautionary
measuresshouldbetakentoprovidemaxi-
mum protection against electrical shock.
Be sure that all power is o by opening
the line (wall) disconnect switch and by
unplugging the power cord to the unit
when reconnecting for 208Vac 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.
1. Unplug the unit from the primary input power.
2. Remove the left side panel by removing the front handle and sliding the cover
forward from the aluminum frame rail.
3. Locate the input bridge (IBR) and the two-position terminal block on the left
side of the unit towards the rear panel (see Fig. 3.2). Locate the gray wire con-
nected toTB5-2 and to IBR terminal "R". For 208 vac input, disconnect the gray
wire from TB5-2 and then rmly connect it to TB5-1.
4. Locate the output bridge (D1) on the left side towards the front panel (see
g. 3.2). Disconnect and swap leads X2 and X3 from the main transformer. For
208 vac input, X2 is connected toTB3 and X3 is connected to terminal 3 of D1.
Make sure the connections are rmly tightened.
5. Leave all other wires the same.
6. Reinstall cover by sliding it back into the frame rail. Connect the front handle
and connect the Powercut 650 to the 208 vac input power.
Figure 3.2 Primary Voltage Connection Diagram
208 / 230 vac Input Power Connections
SECTION 3 INSTALLATION
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12
3.5 SECONDARY CONNECTIONS REFER TO FIG. 3.3
1. ThePowercut650issuppliedfromthefactorywiththecompletePT-31XLPCtorch
and the work cable with clamp assembly pre-installed. No further installation
is required. For information on torch connections or retting the torch (see Sec.
5.4).
2. Connect your air supply to the inlet connection of the lter-regulator.
3. Clamp the work cable to the workpiece. Be sure the workpiece is connected to
an approved earth ground with a properly sized ground cable.
Grounded Work
Table
Work Cable
Earth Ground
Be sure work is
in good contact
with the table
Figure 3.3 Secondary Connections Diagram
SECTION 3 INSTALLATION
Air Supply
250cfh @ 80 psig
Air Supply Connection
Air Pressure
Adjustment Knob
Moisture Bleed
Screw
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13
3.6 ASSEMBLING PT31XLPC CONSUMABLE PARTS
The PT-31XLPC Torch is supplied complete; ready to cut and needs no further
assembly. If it becomes necessary to inspect the front end wear parts, see Figure
3.4 for correct assembly order.
Install the electrode, bae, nozzle, and heat shield as shown in Fig. 3.4.Tighten heat
shield snugly but do not overtighten.
Figure 3.4 Assembly of“XT”Consumable Parts
For additional torch information, see booklet packed with the PT-31XLPC torch.
BE SURE to install the swirl bae in the
torch. Failure to do so would allow the
nozzle (tip) to contact the electrode.
This contact would permit high voltage
tobeappliedtothe nozzle.Yourcontact
withthenozzleorworkpiececouldthen
result in serious injury or death by
electric shock.
ThePT-31XLPCtorchheadcontainsagas
owcheckvalvethatactsinconjunction
withtheowswitchandcircuitry within
the power source.This system prevents
thetorchfrombeingenergizedwithhigh
voltageifthetorchswitchisaccidentally
closed when the shield is removed. AL-
WAYSREPLACETORCHWITHTHEPROPER
TORCHMANUFACTUREDBYESABSINCE
IT ALONE CONTAINS ESAB’S PATENTED
SAFETY INTERLOCK.
Makesurepowerswitchonpowersource
isinOFFpositionandprimaryinputpower
is deenergized.
NOZZLE, SWIRL BAFFLE AND ELEC-
TRODE IN PLACE READY FOR INSTALLA-
TION OF HEAT SHIELD.
Electrode
20862
Swirl Bae
20463
Heat Shield
20282
Nozzle
20860
Torch Body
*0558000790
(20072)
*Includes the following items:
Seat - 0558000510 (19679)
O-ring - 0558000514 (950790)
SECTION 3 INSTALLATION
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14
SECTION 3 INSTALLATION
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15
Figure 4.1. Powercut 650 Controls
4.0 POWERCUT 650 CONTROLS (FIGURE 4.1)
A. Power Switch (located on rear panel). When placed in ON position, the white
pilotlightwillglowindicatingcontrolcircuitisenergizedandthecoolingfanwill
run. The Powercut 650 is now in the "READY" mode given a suitable air supply
and a properly assembled torch.
B. Power Light. Indicates that the Power Switch is in the ON position.
C. Output Current Control. Adjustable from 10 to 40 amperes to suit cutting
conditions.
D. Air Check Switch. When placed in ON position, air lter-regulator can be
adjusted to desired pressure (80 psig) before cutting operations. Allow air to
ow for a few minutes. This should remove any condensation that may have
accumulated during shutdown period. Be sure to place switch in OFF position
before starting cutting operations.
E. Air Pressure Gauge. Indicates supply pressure to the unit.
F. Air Regulator Control Knob. Used to adjust the air pressure for the cutting
process. Proper operating range for the Powercut 650 is 80 psig.
G. Lock-In Switch. When placed in ON position, permits releasing torch switch
button after cutting arc has been initiated. To extinguish arc at end of cut, press
andreleasetorchswitchbuttonagainorpulltorchawayfromwork. Whenplaced
in OFF position, torch switch must be held closed by the operator during the
entire cutting operation and then released at the end of cut.
H. Fault Light. Will glow amber under the following conditions and operations
will come to a complete stop.
ELECTRIC SHOCK can kill.
• DoNOToperatetheunitwiththecover
removed.
• DoNOTapplypowertotheunitwhile
holding or carrying the unit.
• DoNOTtouchanytorchpartsforward
of the torch handle (nozzle, heat shield,
electrode, etc.) with power switch on.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
• WearweldinghelmetwithNo.6or7
lens shade.
• Weareye,ear,andbodyprotection.
D. AIR
TEST SWITCH G. TRIGGER LOCK
SWITCH
H. FAULT LIGHT
(AMBER)
B. POWER LIGHT
(WHITE)
E. AIR
PRESSURE
GAUGE C. CURRENT
CONTROL
KNOB
FRONT VIEW
SECTION 4 OPERATION
A. POWER ON-OFF
(I-O) SWITCH
REAR VIEW
F. AIR PRESSURE
CONTROL KNOB
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16
Flow Fault:The fault light will be mostly on but will ick o for approx.1/10th
of a second every second. This indicates that the air ow supply is low.
0123
Seconds
ON
OFF
OverTemperature:Thefaultlightwillbemostlyobutwillickonforapprox.
1/10th of a second every second. This indicates that the duty cycle has been
exceeded. Allow the power source to cool down before returning to opera-
tion.
0123
Seconds
ON
OFF
High/LowLineVoltage:Thefaultlightwillrapidlyblinkonando(vetimes
per second). This indicates that the input voltage is outside the “+ or -” 15%
range of the input rating.
0123
Seconds
ON
OFF
Over-Current:Thefault lightwillbeon continuously.Thisindicatesthatinput
current has been exceeded.
0123
Seconds
ON
OFF
Allfaultsignalswill remainon foraminimumof 10seconds.If faultclears,
all will reset automatically except for over-current.To clear over-current,
the power must be shut o for 5 seconds and then turned back on.
SECTION 4 OPERATION
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17
TOO FAST TOO SLOW CORRECT
Fig. 4.2 - Eect of Cutting Speed
4.1 CUTTING WITH THE PT-31XLPC
After placing the primary (wall) switch to the ON position and making control and
air pressure adjustments as described above, proceed as follows:
1. Touch the tip of the torch to the workpiece (or within 0.020-in. of the workpiece)
holding the torch at about 15- 30° angle to avoid damaging the tip.
2. Depress the torch switch. (Air and high frequency should energize.)
3. Two seconds after depressing torch switch, the plasma arc will start cutting. (If
using the LOCK-IN mode, torch switch can be released after establishing the cut-
ting arc.)
4. After starting the cut, the tip can be dragged along the workpiece if cutting up
to 1/4'’thick material. When cutting material greater than 1/4'’, maintain a
1/8'’tip-to-work (stando) distance.
5. When ending a cut, the torch switch should be released (press and release if
using LOCK-IN mode) and lifted o the workpiece just before the end of the cut
to minimize double-arcing which can damage the tip. This is to prevent high
frequency from reigniting after cutting arc extinguishes.
6. In the postow mode, the arc can be restarted immediately by depressing the
torch switch.The two second preow will automatically cancel.
4.2 OPERATING TECHNIQUES
1. Piercing - Materials (up to 1/8-in. thick) may be pierced with the torch touching
the work. When piercing thicker materials (up to 3/16-in. aluminum or 1/4-in.
stainlessorcarbonsteel)atanangle,positionthetorch.020"abovetheworkpiece.
Start the cutting arc, then immediately raise the torch to
1/16"stand-oandmovethetorchalongthecutpath.Thiswillreducethechance
of spatter from entering the torch and prevent the possibility of welding the tip
to the plate. The torch should be angled at about 30° when starting to pierce,
and then straightened after accomplishing the pierce.
2. Grate Cutting - For rapid restarts, such as grate or heavy mesh cutting, do not
release the torch switch. This avoids the 2 second preow portion of the cutting
cycle.
Wearthe usualprotectivegloves,cloth-
ing, and helmet. Helmet with lter lens
shadeNo.6or7shouldprovideadequate
protection for your eyes.
Never touch any parts forward of the
torchhandle(tip,heatshield,electrode,
etc.) unless the power switch is in the
OFF position.
Position the Powercut 650 at least 10
feet (3 meters) from the cutting area to
protecttheunitfromsparksandhotslag
from the cutting operation.
SECTION 4 OPERATION
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18
WHEN THE ARC BREAKS
THROUGH THE WORK, BRING THE
TORCHTO 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.
1
2
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" Stando (Tip to Work Distance)
Cutting
Thickness Speed
Material (In.) (ipm)
Carbon 1/16 330
Steel 1/8 105
(AISI 1020) 1/4 53
3/8 22
1/2 12
5/8 8
3/4 4
Stainless 1/16 320
Steel 1/8 90
(AISI 304) 1/4 40
3/8 20
1/2 12
5/8 8
3/4 3
Aluminum 1/16 450
(6061) 1/8 200
1/4 70
3/8 30
1/2 14
5/8 11
3/4 8
NOTE: Thespeedsgivenherearetypicalforbestquality
cuts. Your actual speeds may vary depending
on material composition, surface condition,
operator technique, etc. If cutting speed is too
fast, you may lose the cut. With slower speeds
excessive dross may accumulate. If speed is too
slow,thearcmayextinguish.Aircuttingtypically
produces a rough face on stainless steel and
aluminum.
NOTE: Lower the air pressure to 75 psig on materials
< 1/16" or when inconsistent arc starting is
experienced at 80 psig.
SECTION 4 OPERATION
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19
4.3 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.
A. Insucient Penetration.
1. Cutting speed too fast.
2. Damaged cutting nozzle.
3. Improper air pressure.
B. Main Arc Extinguishes.
1. Cutting speed too slow.
C. Dross Formation. (In some materials and thicknesses, it may be impossible to get dross-free
cuts.)
1. Cutting speed too fast or too slow.
2. Improper air pressure.
3. Faulty nozzle or electrode.
D. Double Arcing. (Damaged Nozzle Orice.)
1. Low air pressure.
2. Damaged cutting nozzle.
3. Loose cutting nozzle.
4. Heavy spatter.
E. Uneven Arc.
1. Damaged cutting nozzle or worn electrode.
F. Unstable Cutting Conditions.
1. Incorrect cutting speed.
2. Loose cable or hose connections.
3. Electrode and/or cutting nozzle in poor condition.
G. Main Arc Does Not Strike.
1. Loose connections.
H. Poor Consumable Life.
1. Improper gas pressure.
2. Contaminated air supply.
SECTION 4 OPERATION
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20
SECTION 4 OPERATION
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