ESAB Powercut 650 User manual

POWERCUT 650
0558005362
Instruction Manual (EN)
Portable Plasma Cutting System
ESAB Consoles:
ESAB P/N 0558005151 - 230V, 1/3-Phase, 50/60 Hz - "CE"
ESAB P/N 0558005152 - 400V, 3-Phase, 50/60 Hz - "CE"
ESAB P/N 0558007820 - 400V, 3-Phase, 50/60 Hz
ESAB AB
SE--695 81 LAXÅ
SWEDEN
Phone [phone]
Fax [phone]
www.esab.com
030210
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna--Liesing
Tel: [phone]
Fax: [phone]
BELGIUM
S.A. ESAB N.V.
Brussels
Tel: [phone]
Fax: [phone]
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Prague
Tel: [phone]
Fax: [phone]
DENMARK
Aktieselskabet ESAB
Copenhagen--Valby
Tel: [phone]
Fax: [phone]
FINLAND
ESAB Oy
Helsinki
Tel: [phone]
Fax: [phone]
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: [phone]
Fax: [phone]
GERMANY
ESAB GmbH
Solingen
Tel: [phone]
Fax: [phone]
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: [phone]
Fax: [phone]
ESAB Automation Ltd
Andover
Tel: [phone]
Fax: [phone]
HUNGARY
ESAB Kft
Budapest
Tel: [phone]
Fax: [phone]
ITALY
ESAB Saldatura S.p.A.
Mesero (Mi)
Tel: [phone]
Fax: [phone]
THE NETHERLANDS
ESAB Nederland B.V.
Utrecht
Tel: [phone]
Fax: [phone]
NORWAY
AS ESAB
Larvik
Tel: [phone]
Fax: [phone]
POLAND
ESAB Sp.z.o.o
Warszaw
Tel: [phone]
Fax: [phone]
PORTUGAL
ESAB Lda
Lisbon
Tel: [phone]
Fax: [phone]
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: [phone]
Fax: [phone]
SPAIN
ESAB Ibérica S.A.
Alcobendas (Madrid)
Tel: [phone]
Fax: [phone]
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: [phone]
Fax: [phone]
ESAB International AB
Gothenburg
Tel: [phone]
Fax: [phone]
SWITZERLAND
ESAB AG
Dietikon
Tel: [phone]
Fax: [phone]
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: [phone]
Fax: [phone]
BRAZIL
ESAB S.A.
Contagem--MG
Tel: [phone]
Fax: [phone]
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: [phone]
Fax: [phone]
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: [phone]
Fax: [phone]
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: [phone]
Fax: [phone]
Asia/Pacific
CHINA
Shanghai ESAB A/P
Shanghai
Tel: [phone]
Fax: [phone]
INDIA
ESAB India Ltd
Calcutta
Tel: [phone]
Fax: [phone]
INDONESIA
P.T. Esabindo Pratama
Jakarta
Tel: [phone]
Fax: [phone]
MALAYSIA
ESAB (Malaysia) Snd Bhd
Selangor
Tel: [phone]
Fax: [phone]
SINGAPORE
ESAB Singapore Pte Ltd
Singapore
Tel: [phone]
Fax: [phone]
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: [phone]
Fax: [phone]
SOUTH KOREA
ESAB SeAH Corporation
Kyung--Nam
Tel: [phone]
Fax: [phone]
UNITED ARAB EMIRATES
ESAB Middle East
Dubai
Tel: [phone]
Fax: [phone]
Representative offices
BULGARIA
ESAB Representative Office
Sofia
Tel/Fax: [phone]
EGYPT
ESAB Egypt
Dokki--Cairo
Tel: [phone]
Fax: [phone]
ROMANIA
ESAB Representative Office
Bucharest
Tel/Fax: [phone]
RUSSIA--CIS
ESAB Representative Office
Moscow
Tel: [phone]
Fax: [phone]
ESAB Representative Office
St Petersburg
Tel: [phone]
Fax: [phone]
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com

96
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!

97
SECTION TITLE PAGE
PARAGRAPH
SECTION 1 SAFETY........................................................................................................................99
SECTION 2 INTRODUCTION.....................................................................................................................................101
2.0 General.......................................................................................................................................................102
2.1 Scope ..........................................................................................................................................................102
SECTION 3 INSTALLATION........................................................................................................................................103
3.0 General.......................................................................................................................................................103
3.1 Equipment Required.............................................................................................................................103
3.2 Location .....................................................................................................................................................103
3.3 Inspection..................................................................................................................................................103
3.4 Connections .............................................................................................................................................104
3.4.1 Primary Electrical Input Connections..............................................................................................104
3.5 Secondary Connections.......................................................................................................................107
3.6 Assembling PT-31XLPC Consumable Parts ...................................................................................108
SECTION 4 OPERATION .............................................................................................................................................109
4.0 POWERCUT 650 Controls.....................................................................................................................109
4.1 Cutting with the PT-31XLPC ...............................................................................................................111
4.2 Operating Techniques...........................................................................................................................111
4.3 Common Cutting Problems................................................................................................................113
SECTION 5 MAINTENANCE ......................................................................................................................................115
5.0 Inspection and Cleaning......................................................................................................................115
5.1 Flow Switch...............................................................................................................................................115
5.2 Troubleshooting .....................................................................................................................................116
5.3 Troubleshooting Guide ........................................................................................................................117
5.4 Sequence of Operation ........................................................................................................................121
5.5 Re-tting the PT-31XLPC Torch..........................................................................................................123
SECTION 6 REPLACEMENT PARTS........................................................................................................................305
6.0 General.......................................................................................................................................................305
6.1 Ordering.....................................................................................................................................................305
TABLE OF CONTENTS

98
TABLE OF CONTENTS

99

4&$5*0/ 4"'&5:13&$"65*0/4
 4BGFUZ1SFDBVUJPOT
6TFSTPG&4"#XFMEJOHBOEQMBTNBDVUUJOHFRVJQNFOUIBWFUIFVMUJNBUFSFTQPOTJCJMJUZGPSFOTVSJOHUIBUBOZPOF
XIPXPSLTPOPSOFBSUIFFRVJQNFOUPCTFSWFTBMMUIFSFMFWBOUTBGFUZQSFDBVUJPOT4BGFUZQSFDBVUJPOTNVTUNFFU
UIFSFRVJSFNFOUTUIBUBQQMZUPUIJTUZQFPGXFMEJOHPSQMBTNBDVUUJOHFRVJQNFOU5IFGPMMPXJOHSFDPNNFOEBUJPOT
TIPVMECFPCTFSWFEJOBEEJUJPOUPUIFTUBOEBSESFHVMBUJPOTUIBUBQQMZUPUIFXPSLQMBDF
"MMXPSLNVTUCFDBSSJFEPVUCZUSBJOFEQFSTPOOFMXFMMBDRVBJOUFEXJUIUIFPQFSBUJPOPGUIFXFMEJOHPSQMBTNB
DVUUJOHFRVJQNFOU*ODPSSFDUPQFSBUJPOPGUIFFRVJQNFOUNBZMFBEUPIB[BSEPVTTJUVBUJPOTXIJDIDBOSFTVMUJO
JOKVSZUPUIFPQFSBUPSBOEEBNBHFUPUIFFRVJQNFOU
 "OZPOFXIPVTFTXFMEJOHPSQMBTNBDVUUJOHFRVJQNFOUNVTUCFGBNJMJBSXJUI
 JUTPQFSBUJPO
 MPDBUJPOPGFNFSHFODZTUPQT
 JUTGVODUJPO
 SFMFWBOUTBGFUZQSFDBVUJPOT
 XFMEJOHBOEPSQMBTNBDVUUJOH
 5IFPQFSBUPSNVTUFOTVSFUIBU
 OPVOBVUIPSJ[FEQFSTPOTUBUJPOFEXJUIJOUIFXPSLJOHBSFBPGUIFFRVJQNFOUXIFOJUJTTUBSUFEVQ
 OPPOFJTVOQSPUFDUFEXIFOUIFBSDJTTUSVDL
 5IFXPSLQMBDFNVTU
 CFTVJUBCMFGPSUIFQVSQPTF
 CFGSFFGSPNESBGUT
 1FSTPOBMTBGFUZFRVJQNFOU
 "MXBZTXFBSSFDPNNFOEFEQFSTPOBMTBGFUZFRVJQNFOUTVDIBTTBGFUZHMBTTFTnBNFQSPPG
 DMPUIJOHTBGFUZHMPWFT
 %POPUXFBSMPPTFmUUJOHJUFNTTVDIBTTDBSWFTCSBDFMFUTSJOHTFUDXIJDIDPVMECFDPNF
 USBQQFEPSDBVTFCVSOT
 (FOFSBMQSFDBVUJPOT
 .BLFTVSFUIFSFUVSODBCMFJTDPOOFDUFETFDVSFMZ
 8PSLPOIJHIWPMUBHFFRVJQNFOUNBZPOMZCFDBSSJFEPVUCZBRVBMJmFEFMFDUSJDJBO
 "QQSPQSJBUFmSFFYUJORVJTIJOHFRVJQNFOUNVTUCFDMFBSMZNBSLFEBOEDMPTFBUIBOE
 -VCSJDBUJPOBOENBJOUFOBODFNVTUOPUCFDBSSJFEPVUPOUIFFRVJQNFOUEVSJOHPQFSBUJPO
SECTION 1 SAFETY PRECAUTIONS
-- 4 --
EMCea
WARNING
Read and understand the instruction manual before installing or operating.
Arc welding and cutting can be injurious to yourself and others. Take precausions when welding.
Ask for your employer’s safety practices which should be based on manufacturers’ hazard data.
ELECTRIC SHOCK - Can kill
SInstall and earth the welding unit in accordance with applicable standards.
SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
SInsulate yourself from earth and the workpiece.
SEnsure your working stance is safe.
FUMES AND GASES - Can be dangerous to health
SKeep your head out of the fumes.
SUse ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone
and the general area.
ARC RAYS - Can injure eyes and burn skin.
SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
SProtect bystanders with suitable screens or curtains.
FIRE HAZARD
SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE - Excessive noise can damage hearing
SProtect your ears. Use earmuffs or other hearing protection.
SWarn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
WARNING!
Read and understand the instruction manual before installing
or operating.
CAUTION!
Class A equipment is not intended for use in residential locations where
the electrical power is provided by the public low--voltage supply
system. There may be potential difficulties in ensuring electromagnic
compatibility of class A equipment in those locations, due to conducted
as well as radiated disturbances.
Do not dispose of electrical equipment together with normal waste!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation in accordance with national law, electrical equipment
that has reached the end of its life must be collected separately and returned to an
environmentally compatible recycling facility. As the owner of the equipment, you should
get information on approved collection systems from our local representative.
By applying this European Directive you will improve the environment and human
health!
GB
Class A (400V CE) equipment is not intended for use in resi-
dential locations where the electrical power is provided by the
public low-voltage supply system. There may be potential dif-
culties in ensuring electromagnetic compatibility of Class A
equipment in those locations due to conducted as well as radi-
ated disturbances.
-- 4 --
EMCea
WARNING
Read and understand the instruction manual before installing or operating.
Arc welding and cutting can be injurious to yourself and others. Take precausions when welding.
Ask for your employer’s safety practices which should be based on manufacturers’ hazard data.
ELECTRIC SHOCK - Can kill
SInstall and earth the welding unit in accordance with applicable standards.
SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
SInsulate yourself from earth and the workpiece.
SEnsure your working stance is safe.
FUMES AND GASES - Can be dangerous to health
SKeep your head out of the fumes.
SUse ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone
and the general area.
ARC RAYS - Can injure eyes and burn skin.
SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
SProtect bystanders with suitable screens or curtains.
FIRE HAZARD
SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE - Excessive noise can damage hearing
SProtect your ears. Use earmuffs or other hearing protection.
SWarn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
WARNING!
Read and understand the instruction manual before installing
or operating.
CAUTION!
Class A equipment is not intended for use in residential locations where
the electrical power is provided by the public low--voltage supply
system. There may be potential difficulties in ensuring electromagnic
compatibility of class A equipment in those locations, due to conducted
as well as radiated disturbances.
Do not dispose of electrical equipment together with normal waste!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation in accordance with national law, electrical equipment
that has reached the end of its life must be collected separately and returned to an
environmentally compatible recycling facility. As the owner of the equipment, you should
get information on approved collection systems from our local representative.
By applying this European Directive you will improve the environment and human
health!
GB
CAUTION

100

4&$5*0/ 4"'&5:13&$"65*0/4
8&-%*/("/%1-"4."$655*/($"/#&*/+63*06450:0634&-'"/%
05)&34  5",& 13&$"65*0/4 8)&/ 8&-%*/( 03 $655*/(  "4, '03
:063 &.1-0:&34 4"'&5: 13"$5*$&4 8)*$) 4)06-% #& #"4&% 0/
."/6'"$563&34)";"3%%"5"
&-&$53*$4)0$,$BOLJMM
 *OTUBMMBOEFBSUIHSPVOEUIFXFMEJOHPSQMBTNBDVUUJOHVOJUJOBDDPSEBODFXJUIBQQMJDBCMFTUBOEBSET
 %POPUUPVDIMJWFFMFDUSJDBMQBSUTPSFMFDUSPEFTXJUICBSFTLJOXFUHMPWFTPSXFUDMPUIJOH
 *OTVMBUFZPVSTFMGGSPNFBSUIBOEUIFXPSLQJFDF
 &OTVSFZPVSXPSLJOHTUBODFJTTBGF
'6.&4"/%("4&4$BOCFEBOHFSPVTUPIFBMUI
 ,FFQZPVSIFBEPVUPGUIFGVNFT
 6TFWFOUJMBUJPOFYUSBDUJPOBUUIFBSDPSCPUIUPUBLFGVNFTBOEHBTFTBXBZGSPNZPVSCSFBUIJOH[POF
 BOEUIFHFOFSBMBSFB
"3$3":4$BOJOKVSFFZFTBOECVSOTLJO
 1SPUFDUZPVSFZFTBOECPEZ6TFUIFDPSSFDUXFMEJOHQMBTNBDVUUJOHTDSFFOBOEmMUFSMFOTBOEXFBS
 QSPUFDUJWFDMPUIJOH
 1SPUFDUCZTUBOEFSTXJUITVJUBCMFTDSFFOTPSDVSUBJOT
'*3&)";"3%
 4QBSLTTQBUUFSDBODBVTFmSF.BLFTVSFUIFSFGPSFUIBUUIFSFBSFOPJOnBNNBCMFNBUFSJBMTOFBSCZ
/0*4&&YDFTTJWFOPJTFDBOEBNBHFIFBSJOH
 1SPUFDUZPVSFBST6TFFBSNVõTPSPUIFSIFBSJOHQSPUFDUJPO
 8BSOCZTUBOEFSTPGUIFSJTL
."-'6/$5*0/$BMMGPSFYQFSUBTTJTUBODFJOUIFFWFOUPGNBMGVODUJPO
3&"%"/%6/%&345"/%5)&*/4536$5*0/."/6"-#&'03&*/45"--*/(0301&3"5*/(
1305&$5:0634&-'"/%05)&34
8"3/*/(
SECTION 1 SAFETY PRECAUTIONS

101
•Manuallycuts15.9mm (5/8inch) andsevers19.1mm (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.
•Adjustableoutput-tailorthecurrenttothematerialbeing
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
Specications
Cuts 15.9mm (5/8 in.); severs 19.1mm (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 @ 40A/120V ........................230 vac 1/3 ph. 50/60 Hz., 37/20 amps
Input @ 40A/120V .....................................400 vac 3 ph. 50/60 Hz., 9 amps
Power factor @ 40A Output.............................................................76% (1 Phase)
Eciency @ 40A Output....................................................................85% (Typical)
Air requirements ..........................118 l/m @ 5.5 bar (250 cfh at 80 psig)
Dimensions: Length..............................................................406mm (16.00")
w/ handles.................................................653mm (25.70")
Height...............................................................416mm (16.38")
Width................................................................318mm (12.50")
w/ Opt. torch wrap.................................394mm (15.50")
Weight (less torch & work cable)....................................................24 kg (53 lbs.)
The POWERCUT® 650 comes out of the box ready to go! The torch is at-
tached with parts in place, primary cord is attached and the lter/regulator
is installed. Just hook up the air, plug it in and cut.
Instruction Literature P/N .................................................................0558005362
POWERCUT®650CuttingPackage
HowToOrder
The POWERCUT®650 comes complete with everything you need:
console, 7.6m (25 ft.) PT-31XLPC torch, torch spare parts kit, air
lter/regulator,input power cordwith plug,7.6m (25 ft.) work cable
with clamp. System arrives fully assembled and ready to cut.
OrderingInformation
POWERCUT ®650 / 7.6m (25 ft.) PT-31XLPC "CE" package
POWERCUT®650,
230 vac 1/3 ph. 7.6m (25 ft.) PT-31XLPC - "CE" ....................0558004800
400 vac 3 ph. 7.6m (25 ft.) PT-31XLPC - "CE".........................0558004801
400 vac 3 ph. 7.6m (25 ft.) PT-31XLPC.....................................0558007821
POWERCUT®650/ PT-31XLPC CuttingPerformance
SPEED/ Minutes
THICKNESS
40Amp
Mild Steel
CutSpeeds
SECTION 2 INTRODUCTION
400V CE Mains Supply .....................................................................Ssc min 1.3MVA
...................................................................................................................... Zmax 0.118Ω
400V CE Mains Supply, Ssc min
Minimum short circuit power on the network in accordance with
IEC61000-3-12.
400V CE Mains Supply, Zmax
Maximum permissible line on the network impedance in accordance
with IEC61000-3-11.

102
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: 44.5mm - 1,066.8mm (1 3/4" - 42") Radius ..........0558003258
Basic: 44.5mm - 711.2mm (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....0558000739 (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
0558000507
(20862)
Swirl Bae
0558000506
(20463)
Seat
0558000510
(19679)
Plunger
0558000511
(20324)
Heat Shield
0558000509
(36284)
Torch Body
*0558000790
(20072)
Nozzle
0558000512
(20860)
PT-31XLPC Spare Parts Kit (P/N 0558005392) includes:
Heat Shield, Long (1)..........................................................0558000509 (36284)
Nozzles, High Performance (3) .......................................0558000512 (20860)
Swirl Bae (1).......................................................................0558000506 (20463)
Electrodes (2) ........................................................................0558000507 (20862)
PT-31XLPC Replacement Torch.........................................0558005393
Torch comes assembled with Long "CE" Heat Shield, Nozzle, Electrode,
and Swirl Bae.
POWERCUT shown with OptionalTorch Wrap
and Spare Parts Kit Holder installed.
2.0 GENERAL
ThePOWERCUT650isacompact,completelyself-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 (6.2-10.3
bar / 90-150 psig). The POWERCUT 650 package uses the
PT-31XLPC torch to deliver cutting power for materials up
to 15.9mm (5/8-in.) thick or for severing up to 19.1mm
(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
POWERCUT650plasmaarccuttingpackage.Technicalrefer-
ence material is also provided to assist in troubleshooting
the cutting package.
*Includes the following items:
Seat - 0558000510 (19679)
O-ring - 0558000514 (950790)
Donotuseanytorchwiththispowersource
other than the ESAB brand PT-31XLPC
torch.Seriousinjurymayoccurifusedwith
any other torch.
WARNING
SECTION 2 INTRODUCTION

103
3.0 GENERAL
Proper installationcan contributemateriallyto the satisfactoryand trouble-freeoperationof 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
A source of clean, preltered dry air that supplies 118 l/m @ 5.5 bar (250 cfh at 80 psig) is required for the
cutting operation. The air supply should not exceed 10.3 bar (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 obstruction 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 subjecting 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 dam-
age 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

104
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,seeTable3-1forrecommendedinputconductorsforconnectingreceptacle
to line disconnect switch.
The POWERCUT 650 power source with 230 vac, 1 / 3 -phase input capability is factory
set for 230 vac input.
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 connectionsare madeinside of
the power source.
Be sure that the power source is properly
congured for your input power supply.
DONOTconnectapowersourcecongured
for 230 V to a 460 V input power supply.
Damage to the machine may occur.
CAUTION
WARNING
SECTION 3 INSTALLATION
Input Standard
L1 Black
L2 Red
L3 White
GND Green
Input CE
L1 Brown
L2 Grey
L3 Black
GND Green/Yellow
NOTE: PC-650 input cable dierences
The colors of input phases of the CE models dier from those of the“non CE”models.
Below is a table comparing the two:
400 & 460-Volt CE
For the 400 and 460-Volt units, it isn’t important which leg is connected to L1, L2 and
L3, when 3-Phase input is used, however if inputting 1 phase power, L2 will be the un-
used leg. The T2 must have power to operate and it is connected across L1 and L3.
208/230-Volt models
**FOR SINGLE-PHASE CONNECTION OF 230-Volt CE MODELS:**
If single-phase connection is desired, connect the BLACK leg to “L3” and the
BROWN leg to “L1” with the GREY (L2) leg disconnected, lugged, and taped back.
, L2 will be the un-used leg. The T2 must have power to operate and it is connected
across L1 and L3.
NOTE !!!
400V CE Mains Supply Requirements:
High power equipment may, due to the primary current drawn from the mains supply, inuence the pow-
er quality of the grid. Therefore connection restrictions or requirements regarding the maximum permis-
sible mains impedance or the required minimum supply capacity at the interface point to the public grid
may apply for some types of equipment (see technical data). In this case it is the responsibility of the
installer or user of the equipment to ensure, by consultation with the distribution network operator if
necessary, that the equipment may be connected.

105
208 V CONFIGURATION
GRAY
NOTE:
FOR 208 vac MOVE GREY WIRE FROM TB5-2 TO TB5-1, MOVE T1 LEAD X2 TO TB3 AND T1 LEAD X3 TO D1-3.
DO NOT CHANGE ANY OTHER WIRES.
X2 HERE FOR 208 vac INPUT
X3 HERE FOR 208 vac INPUT
208 vac
GRAY
BLACK
BLACK
INPUT BRIDGE (IBR)
SECTION 3 INSTALLATION
The Powercut 650“CE model”is available as 230 vac single-phase power, or as 400 vac 3 phase.
Note: The 400 vac 3 phase unit is designed to work best when 3 phase input power is used, however with a slight de-rating
of the machine output, the PC-650 can be used on single phase.
Reasons for de-rating:
Input diode stress. 1 phase uses 4 diodes at higher current levels
Buss capacitors will see higher ripple currents
Connecting PC-650 for 208 vac input:
Unplug the unit from the primary input power.1.
Remove the left side panel by removing the rear handle and sliding the cover forward from the aluminum frame2.
rail.
Locate the input bridge (IBR) and the two-position terminal block on the left side of the unit towards the rear3.
panel. Locate the gray wire connected to TB5-2 and to IBR terminal “R”. For 208 vac input, disconnect the gray wire
from TB5-2 and then rmly connect it to TB5-1.
Locate the output bridge (D1) on the left side towards the front panel. Disconnect and swap leads X2 and X3 from4.
the main transformer. For 208 vac input, X2 is connected to TB3 and X3 is connected to terminal 3 of D1. Make sure
the connections are rmly tightened.
Leave all other wires the same.5.
Reinstall cover by sliding it back into the frame rail. Connect the rear handle and connect the Powercut 650 to the6.
208 vac input power.

106
SECTION 3 INSTALLATION
* 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 DISCON-
NECT SWITCH (SeeTable 3.1 and
WARNING in regards to chassis
ground in Section 3.4)
Rated Input Input & GND
Conductor
CU/AWG*
Fuse Size
Amps
Volts Amp Phases
230 37/20 1/3 No. 6mm 50/40
400 9 3 No. 4mm 15
Table 3.1. Recommended Sizes for Input Conductors
and Line Fuses
FACTORY SET FOR 230 vac INPUT
GRAY
DO NOT CHANGE ANY OTHER WIRES.
X3 HERE FOR 230 vac INPUT
X2 HERE FOR 230 vac INPUT
230 vac
GRAY
BLACK
BLACK
INPUT BRIDGE (IBR)

107
SECTION 3 INSTALLATION
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 208 vac input.
3.5 SECONDARY CONNECTIONS REFER TO FIG. 3.3
1. ThePOWERCUT 650 is supplied from thefactory with the complete PT-31XLPC
torch and the work cable with clamp assembly pre-installed. No further instal-
lation 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.
WARNING
WARNING Grounded Work
Table
Work Cable
Earth Ground
Be sure work is
in good contact
with the table
Figure 3.3 Secondary Connections Diagram
Air Supply
250cfh @ 80 psig
Air Supply Connection
Air Pressure
Adjustment Knob
Moisture Bleed
Screw

108
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
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
tobeapplied tothenozzle.Yourcontact
withthenozzle orworkpiececouldthen
result in serious injury or death by
electric shock.
ThePT-31XLPCtorchheadcontainsagas
owcheckvalvethatactsinconjunction
withtheowswitchand circuitrywithin
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
0558000507
(20862)
Swirl Bae
0558000506
(20463)
Heat Shield
0558000509
(36284)
Nozzle
0558000512
(20860)
Torch Body
*0558000790
(20072)
*Includes the following items:
Seat - 0558000510 (19679)
O-ring - 0558000514 (950790)
WARNING
WARNING
WARNING
SECTION 3 INSTALLATION

109
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
pilot light will glow indicating control circuit is energized and the cooling fan
will 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 ad-
justedtodesiredpressure (5.5bar /80 psig)beforecuttingoperations. Allowair
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 5.5 bar (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.
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.
WARNING
WARNING
D. AIR
TEST SWITCH G. TRIGGER LOCK
SWITCH
A. POWER ON-OFF
(I-O) SWITCH
REAR VIEW
F. AIR PRESSURE
CONTROL KNOB
H. FAULT LIGHT
(AMBER)
B. POWER LIGHT
(WHITE)
E. AIR
PRESSURE
GAUGE
C. CURRENT
CONTROL
KNOB
FRONT VIEW
SECTION 4 OPERATION

110
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 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:Thefaultlight willbeon continuously.Thisindicatesthatinput
current has been exceeded.
0123
Seconds
ON
OFF
Allfaultsignalswill remainon fora minimumof10 seconds.Iffaultclears,
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

111
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 0.5mm / 0.02in. 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 6.4mm (1/4") thick material. When cutting material greater than 6.4mm (1/4"),
maintain a 3.2mm (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 3.2mm / 1/8in. thick) may be pierced with the torch
touching the work. When piercing thicker materials (up to 4.8mm / 3/16in. alu-
minum or 6.4mm / 1/4in. stainless or carbon steel) at an angle, position the torch
0.5mm (.02") above the workpiece. Start the cutting arc, then immediately raise
the torch to 1.6mm (1/16") stand-o and move the torch along the cut path.This
will reduce the chance of spatter from entering the torch and prevent the pos-
sibility 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.
Weartheusual protectivegloves,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.
WARNING
WARNING
WARNING
SECTION 4 OPERATION

112
WHEN THE ARC BREAKS
THROUGH THE WORK, BRING THE
TORCHTO AN UPRIGHT POSI-
TION AND PROCEED TO CUT.
TO START A PIERCE, TILT THETORCH
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 40A @ 5.2 bar / 75 psig)
Nozzle - P/N 0558000512 (20860 ), Electrode - P/N 0558000507 (20862)
With 1.6mm (1/16" ) Stando (Tip toWork Distance)
Cutting
Thickness Speed
Material (mm / in.) (mm/m / ipm)
Carbon 1.6 (1/16) 8,382 (330)
Steel 3.2 (1/8) 2,667 (105)
(AISI 1020) 6.4 (1/4) 1,346 (53)
9.5 (3/8) 559 (22)
12.7 (1/2) 305 (12)
15.9 (5/8) 203 (8)
19.1 (3/4) 102 (4)
Stainless 1.6 (1/16) 8,128 (320)
Steel 3.2 (1/8) 2,286 (90)
(AISI 304) 6.4 (1/4) 1,016 (40)
9.5 (3/8) 508 (20)
12.7 (1/2) 305 (12)
15.9 (5/8) 203 (8)
19.1 (3/4) 76 (3)
Aluminum 1.6 (1/16) 11,430 (450)
(6061) 3.2 (1/8) 5,080 (200)
6.4 (1/4) 1,778 (70)
9.5 (3/8) 762 (30)
12.7 (1/2) 356 (14)
15.9 (5/8) 279 (11)
19.1 (3/4) 203 (8)
NOTE: The speeds given here are typical for best
quality cuts. Your actual speeds may vary
dependingonmaterialcomposition,surface
condition, operator technique, etc. If cutting
speed is too fast, you may lose the cut. With
slower speeds excessive dross may accumu-
late. If speed is too slow, the arc may extin-
guish. Air cutting typically produces a rough
face on stainless steel and aluminum.
NOTE: Lower the air pressure to 5.2 bar (75 psig) on
materials < 1.6mm (1/16") or when inconsis-
tent arc starting is experienced at 5.5 bar (80
psig).
SECTION 4 OPERATION

113
4.3 COMMON CUTTING PROBLEMS
Listed below are common cutting problems followed by the probable cause of each. If problems 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

114
SECTION 4 OPERATION