PC 650 TABLE OF CONTENTS Plasmarc Cutting Console SAFETY INTRODUCTION SPECIFICATIONS MAIN SCHEMATIC MAINTENANCE REPLACEMENT PARTS Service Manual This manual provides service / troubleshooting instructions for PC650 consoles beginning with Serial Number P*J 623080 Manual # 0558006136 - Rev.
Be sure this information reaches the operator. You can get extra copies through your supplier. caution 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.
SECTIONS Safety Introduction Specifications Glossary Testing / Troubleshooting / Service 1 2 3 4 5 Schematic Section Map 5.0 Input Power Switch 5.1 Input Bridge Buss Supply 5.2 IGBT Block 5.4 Output Transformer Output Bridge 5.5 Control Transformer 5.7 PCB1 Control Board 5.8 Output Inductor 5.9 Startup Network 5.10 Fault Circuits 5.11 High Frequency 5.12 Shunt 5.13 Torch 5.14 Maintenance Replacement Parts General Information 5.3 5.
CONTENTS table of contents Section / Title 1.0 2.0 3.0 4.0 5.0 Page Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Power Specifications . . . . . . . . . . . . . .
CONTENTS table of contents Section / Title 6.0 7.0 Page 5.12.1 T3 High Frequency Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 5.12.2Spark Gap (0558001180) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 5.12.3Air Test Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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CONTENTS section 1 safety precautions 4&$5*0/ 4"'&5: 13&$"65*0/4 8"3/*/( 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/ .
CONTENTS section 1 safety precautions Full responsibility for the safety of personnel working on or near these systems rests on user of ESAB Welding Equipment. Incorrect operation can lead to an abnormal situation, injury to the operator and /or damage to the equipment.
CONTENTS section 1 safety precautions ELECTRIC SHOCK - Can kill - Install and ground welding equipment in accordance with obligatory standards. - Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothes. - Insulate yourself from ground and workpiece. - Ensure your work position is safe. FUMES AND GASES - Can be dangerous to your health - Do not breath the fumes. - Use ventilation and/or extraction to keep fumes and gases away from your breathing zone and surroundings.
CONTENTS section 2 INTRODUCTION 2.0 Introduction The PC650 is a compact Inverter Plasma unit designed to deliver up to 40 Amps of power at approximately 120 cutting volts. It has an adjustable output and a built in trigger “lock-in” circuit. This lightweight unit is supplied in versions that allow input voltages of 208/230/400/or 460 volts AC. The system comes equipped with a PT31XL “drag type” torch and a spare parts kit.
CONTENTS section 3 3.0 SPECIFICATIONS Power Specifications PC650 Power Specifications 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 208/230 vac 1 ph. 50/60 Hz., 35/32 amps Input @ 40A/120V 460 vac 3 ph. 50/60 Hz.
CONTENTS section 3 3.1 SPECIFICATIONS 208 / 230 Wiring PC650 CE Power Specifications 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 220/230 vac 1 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) Efficiency @ 40A Output 85% (Typical) Air requirements 118 l/m @ 5.
CONTENTS section 3 3.
CONTENTS section 3 SPECIFICATIONS 3.1 208 / 230 Wiring CONNECTIONS ELECTRIC SHOCK CAN KILL! Precautionary measures should be taken to provide maximum protection against electrical shock. Be sure that all power is off by opening the line (wall) disconnect switch and by unplugging the power cord to the unit when connections are made inside of the power source. PRIMARY ELECTRICAL INPUT CONNECTIONS FIGURE 3.
CONTENTS section 3 SPECIFICATIONS 3.1 208 / 230 Wiring Recommended Sizes for Input Conductors and Line Fuses Rated Input Volts Amp Phases 208 35 230 32 400 9 1 1 3 460 8 3 Input & GND Conductor CU/AWG* Fuse Size No. 10 No. 10 No. 12 No. 12 50 Amps 50 15 15 * 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.
CONTENTS section 3 3.2 SPECIFICATIONS Machine Operation Flowchart 3.3 PC650 Machine Section Index Section Index Sec. #5. Section Name Page Sec. #5.
CONTENTS section 3 3.
CONTENTS section 3 3.3 SPECIFICATIONS Sequence of Operations 1. The operator engages the torch switch on the torch, requesting a cutting operation. This closes the torch switch connection at the control PCB (P5-1, P5-2). This enables the torch switch circuit, which, ultimately, sends two logic signals out of that circuit. One signal leaves IC1-4 to enable the control chip IC2 on PCB-1. The other signal leaves IC9-5 destined for the current control logic chip IC10 –1 via D22.
CONTENTS SECTION 4 GLOSSARY 4.0 Glossary (General Definitions and Symbols) SYMBOL NOTATION NAME VALUES A Amperage n Current: effectively the "amount of flow" of electricity. V Volts n Electromotive force: effectively the "pressure" of electron movement. R Resistance n Opposition to electron transfer: expressed in OHMS. W Watt n A measure of Power. Watts = V*A F Farad n Amount of electrical storage in a capacitor. A voltage used to control or stabilize an electronic circuit.
CONTENTS SECTION 4 GLOSSARY 4.0 Glossary (General Definitions and Symbols) SYMBOL NOTATION VALUES DESCRIPTION NEUTRAL Electronic neutral or common. PLUG CONNECTION Variously configured male/female separable connectors. SOL n SOLENOID Electro-magnetically operated valve. Mn MOTOR ltr Mn NAME n Ø,HP,V A device which converts electrical energy to mechanical energy (motion). A resistor whose resistance changes with temperature.
CONTENTS SECTION 4 4.0 GLOSSARY Glossary (General Definitions and Symbolsl) LOGIC SYMBOLS NAME SYMBOL DESCRIPTION An AND gate can have two or more inputs. The output of an AND gate is true when all its inputs are true. AND INPUT A B X A 0 0 1 1 AND GATE OUTPUT B 0 1 0 1 X = AB 0 0 0 1 An OR gate can have two or more inputs. The output of an OR gate is true when at least one of its inputs is true.
CONTENTS section 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.
CONTENTS section 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.
CONTENTS section 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.1 Input Power Switch (0558004125) The power input switch S3, when in the “ON” position, passes the input voltage, either 208 or 230 VAC, to the input bridge IBR. Across the switch is a 275V, Metal Oxide Varistor (MOV1) for surge protection. Also connected across S3 is a .047µF, 300V capacitor (C20) for filtering of the input power.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.2 Input Bridge Single-phase 208 or 230 VAC power enters the rectifier block where it is rectified by the IBR and gated on and off by an SCR. The rectified 325 VDC output (230VAC input) is coupled to the Bus Supply via L2 on the negative side of the bridge, and is directly coupled to the IGBTs on the positive side. L2 is an inductor that has 2 purposes.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.
CONTENTS SECTION 5 5.3 MACHINE TESTING / TROUBLESHOOTING / SERVICE Buss Supply Capacitor Information caution Serious Shock Possible! Buss cap warning Serious Shock Possible The “buss capacitors” in the PC650 will maintain a voltage charge for approximately 2 minutes after power is removed from the input of the machine.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.3.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.3.2 Buss Supply Values Buss Supply Values & Testing 208 / 230 Volt Model The buss supply for the 208/230 Volt model of the PC650 consists of 3 capacitors and 4 resistors. R2, R15, R16 & R17 are all 50kΩ12Wresistors. The resistors are used for providing a discharge path for the buss supply. C3, a 1μF / 630Vdc capacitor, is used primarily for filtering. The key components in the buss are the polarized capacitors, C1 & C2.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.4 IGBT Block The Inverter block consists of the IGBT driver board and the IGBT block. 5.4.1 IGBT Driver Board The IGBT driver board conditions the 13 VAC gating signals coming from PCB1. This is done to reduce noise on these signals and also to protect the IGBTs. Signals are passed from the secondary of the PCB1 pulse transformer (T1) to the IGBT driver boards. These signals feed through the driver board and connect to the IGBT module.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.4.1 IGBT Driver Board IGBT DRIVER BOARDS REPLACEMENT PARTS ITEM QTY DESCRIPTION 2 4 6 7 8 2 4 2 2 2 CAPACITOR, .047UF @ 63V DIODE, ZENER 18V, 2W 5% (1N4746A) RESISTOR, 47.5 OHM 1/2W 1% RESISTOR, 1K 1/2W 1% RESISTOR, 2.74 OHMS 1/2W 1% C1,2 ZD1-ZD4 R1,R2 R3,4 R5,6 10 11 16 4 AR 2 TERMINAL, FASTON .
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.4.
CONTENTS SECTION 5 5.5 MACHINE TESTING / TROUBLESHOOTING / SERVICE Main Transformer T1 The Main Transformer T1 takes the 325 VAC received from the IGBT block, and steps it down to 290 VAC.
CONTENTS SECTION 5 5.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.5.1 Coupling Circuit The coupling circuit consists of resistor R9 (39kΩ, 2W) and capacitor C4 (20μF, 400Vdc). The purpose of this network is to prevent DC power from flowing into the primary of the main transformer (T1). C4 acts as a short to the 20 KHz AC power and acts as an open circuit to DC.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.5.2 Current Transformer T4 (32958) Current transformer (T4) measures the current flowing through the primary of the main transformer (T1). If this current is too high (100 amps), a signal (1 volt) is sent to the control board via P1-7 and P1-8 to the over current circuitry (IC2, pin 3) that will indicate an over current fault on the PC650.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.6 Output Rectifier 1 (952150) The Bridge diode D1 is a full wave bridge rectifier, which converts the IGBT’s 290 VAC output to dc volts which is supplied to the shunt and output inductor (L1). Due to the tolerance of the inputs, the range of values for this dc voltage is from 260Vdc to 290Vdc. The resistors in the circuit, R3 through R6, as well as capacitors C5 through C8 are used for electrical noise suppression.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.
CONTENTS SECTION 5 5.7 MACHINE TESTING / TROUBLESHOOTING / SERVICE Control Transformer T2 (35940) This transformer supplies reduced AC voltages to the PCB1 control board. It receives 230 volts on the H1 (red) and H3 (gray) leads on the primary, which is stepped down to multiple secondary voltages (See the accompanying chart). For the PC 650, the X1- X2 winding feeds 12VAC to the torch switch circuit. The X3-X4 18VAC winding is not connected. The X5-X6 winding sends 12VAC to the –12VDC bias supply.
CONTENTS SECTION 5 5.
CONTENTS SECTION 5 5.7 MACHINE TESTING / TROUBLESHOOTING / SERVICE Control Transformer T2 - 230/400/460/575V (332914) TERMINAL VOLTAGE TURNS AWG H1 - H2 * H1 - H3 H1 - H4 H1 - H5 X2 - X2 X3 - X4 X5 - X6 X7 - X8 X9 - X10 X11 - X12 230.0 402.5 ± 0.4 460.0 ± 0.4 575.0 ± 0.4 24.8 ± 0.5 20.2 ± 0.4 12.4 ± 0.4 18.4± 0.4 12.4 ± 0.4 125 ± 0.
CONTENTS SECTION 5 5.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.7.1 Axial Fan (951182) Active 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 while the PC650 is in operation. Open circuit resistance is 150 Ohms. Specifications: 5.9 DIA. x 2.16 In., 247.2 CFM 230V 60Hz/ 55dB(A)/ -40 ~ +55°C Metal housing and impeller Shaded pole motor, air output over struts Elec. connection via 2 leads AWG 18, 14 in.
CONTENTS SECTION 5 5.8 MACHINE TESTING / TROUBLESHOOTING / SERVICE Plasma Control Board (38214) PCB 1 is the control module for the PC 650. The module develops bias voltages for the onboard circuitry, and has on it the control functions, PWM functions, error functions (current limit, over current detection) and Arc on circuitry.
CONTENTS section 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.8.1 PCB1 Control Board and Bias Supplies BIAS POWER SUPPLIES The PCB1Control Board creates 4 bias voltages for circuit function. These voltages are +/- 12 volts DC, +15 Volts DC and +5 volts DC. This provides operating voltages to the Pulse Width Modulator (PWM), the control circuit, the torch switch circuit, the over current protection circuit and the arc on circuit.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.8.1 PCB1 Control Board and Bias Supplies If the 20VAC signal is not there, check the PCB module transformer and associated cabling for output. If there is no 20VAC from the transformer, check for TEST POINT REFERENCE VALUE FUNCTION 230 VAC input to the transformer. If there TP0 GND Reference Ground is voltage there, deenergize the unit and test the windings with an Ohmmeter.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.8.2 PCB Torch Switch The switch on the torch closes the circuit requesting a cutting operation sending 12 VAC across rectifier bridge BR1 on the PCB control board. This 12 VAC signal originates from the PCB control transformer T2, but it is routed through the torch. The torch closes the circuit that completes the 12VAC circuit on the PCB module on Plug 5, pins 1 and 2 (P5-1 and P5-2).
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.8.3 Gas Circuit Once the torch switch circuit has been completed, the PC650 air will flow out of the torch. This is accomplished from the PCB1 control board. IC2 sends a high state signal out on pin 11. This places Q2 in conduction and allows relay K2 to energize. This closes K2 contacts 1 and 3. With these contacts closed, 24VAC is routed from the control transformer, through PCB relay K2, to the gas solenoid, SOL1, via P2-2 and P2-3.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.8.4 Pulse Width Modulator IC6 is the Pulse Width Modulator IC and it generates the drive signals, which drive the IGBT circuitry. This chip also provides the +5-volts for the board. Current control comes into the board on Plug 6 pin 14 (P6-14) and is routed through IC5 on pin 6, out through pin 7, through the 50-amp jumper J2, then input to IC6 on pin 2.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.8.5 Overcurrent Sense The current limit circuitry receives an input from the current sense transformer T4 and inputs that signal on pin 3 of IC3. This IC is a voltage comparator circuit and when its threshold is reached, 1V from the T4 transformer, sends an error signal to Pin 10 of IC6 and pin 3 of IC2. This has the effect of shutting down the pulses generated from IC6, and thereby shutting down the PC650.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.8.6 Arc On Circuit The Arc On circuit consists of IC4 and IC5 and their immediate supporting components. The input from the shunt is routed to the PCB control board module via Plug 6, pins 10 and 11 (P6-10, P6-11). The shunt circuit develops 75mV per amp, which it sends to the shunt amplifier. The shunt amplifier is set to fire the arc on circuit with as little as 5 amps of cutting torch draw (0.375 Volts from the shunt).
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.8.7 Lock In Switch Circuit The PCB module incorporates some safety interlocks into the system. There are 2 safety switch functions built into the board, a gas flow switch, and a thermal switch. The Thermal switch is a normally closed switch and is routed to IC2 via Plug 1 pins 1 and 2 (P1-1, P1-2).
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.8.8 Current Control Current control on the Powercut 650 is controlled from the front panel. The variable resistor R1 mounted on the front panel is connected to the positive 5-volt source of PCB1 on R1 pin 3 via P6-13 and to the 40A branch of the PCB1 voltage divider on R1 pin 2 via P6-6. R1 pin 1 is connected to ground through the P612 connection of the PCB1 control board.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.8.9 Over / Under Voltage Fault Circuit The PCB Control board has a voltage monitoring circuit and major fault logic built onto it. IC3 is a voltage comparator circuit, which monitors the unregulated voltage that feeds the positive 12 and 15 volt supplies. If the voltage dips below 11.8VDC IC3 sends an error signal to IC2 pin 4 and this signal sets the fault on IC2 pin 6 turning on Q5 and Q6.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.8.10 HF Activation When the operator requests a cutting operation to begin, after the start voltage is acquired, the control board will energize the onboard K1 relay. This occurs when IC2 pin 10 biases transistor Q1 into conduction. This allows the relay K1 to close, sending 120VAC out of the PCB1 control board on P2-12 and P2 -13. This voltage is routed to the spark gap unit for HF generation.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.8.11 Lock In Switch Circuit When the Trigger lock switch on the front panel is engaged, this closes the lock in switch circuit on the PCB control board. This engages the logic that allows the PC650 to continuously fire without depressing the torch trigger constantly. The trigger lock switch is connected to the PCB control board via P6-1 and P6-2.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.9 Output Inductor L1 - (952606) The Output Inductor L1 filters the ripple out of the output of the output rectifier D1 and couples the 300 VDC to the torch output on the PC650. Testing: With the device disconnected from the unit, the output inductor should read less than 1 Ohm of resistance. The Output Inductor L2 provides a final filter for any remaining AC ripple.
CONTENTS SECTION 5 5.10 MACHINE TESTING / TROUBLESHOOTING / SERVICE Startup Board PCB5 - (38131) The startup board assists with the arc creation process. This board provides a current boost during main arc creation. Arc starting consists of C1and R1 providing increased starting performance. The C1/R1 circuit provides additional current to overcome the inductance of the output inductor at the start of the main arc. Testing: Using a capacitance checker to measure, the value of C1, C1 is 56μF capacitor.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.11 Trigger Lock Switch S2 The Torch lock switch reduces operator fatigue by allowing the operator to start main arc by depressing the torch switch and then once the arc is created, allows the operator to release the trigger switch and continue cutting with the torch. To discontinue the arc the operator simply depresses the trigger switch and releases it. This is governed by logic on the IC2 chip.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.11.1 PC650 Fault Monitoring Over/Under voltage fault—Flashes 5 times per second. Over voltage--This condition is the only one that will activate before the torch switch is closed. The PCB1 Control board has a voltage monitoring circuit and major fault logic built onto it. IC3 is a voltage comparator circuit, which monitors the unregulated voltage that feeds the positive 12 and 15 volt supplies. If the voltage dips below 11.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.11.2 Fault Light On the front panel of the PC65 0 is the fault light. This is a visual indication of problems with the unit. The fault light will flash an error code for the user to translate. The fault codes are as follows: In the event that the PCB control board has a voltage problem on the board, this turns on the under voltage/over voltage fault on the front panel.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.12 High Frequency (951179) When the PCB control board enables the 120VAC for HF activation from relay K1, the 120VAC is routed to the high voltage transformer T5. This transformer steps up the 120VAC to 3500 VAC and passes it to the Spark gap generator. This feeds a continuous HF signal to the torch at roughly 1.5 MHz.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.12.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.12.2 Spark Gap (0558001180) The spark gap unit generates the HF necessary to create main arc in the PC650. The unit receives 115 VAC from PCB1 control board via relay K1. This voltage is stepped up to 3500 volts AC by transformer T5 in the spark gap unit. The interaction of components T5, C13 and C14 form a tuned circuit that creates a High Frequency of roughly 1.5 MHz.
CONTENTS SECTION 5 MACHINE TESTING / TROUBLESHOOTING / SERVICE 5.12.3 Air Test Switch The Air test switch (S1) bypasses the flow switch and opens the gas test solenoid to test integrity of the gas flow circuit. In the test position, the switch couples the 24VAC from transformer T2 to the gas solenoid, bypassing the PCB relay and the flow switch.
CONTENTS SECTION 5 5.13 MACHINE TESTING / TROUBLESHOOTING / SERVICE Shunt (31488) The Feedback shunt consists of a .001Ω resistor that feeds back a 0 – 100 mV signal to the PCB control module on P6-10 & P6-11. This voltage is input to the shunt amplifier on IC4 and a positive voltage is output to the error amp section of IC5 pin 9. This is compared to the reference signal entering the circuit on Pin 6 of IC5. The negative output of this op amp, on pin 7, is sent to Pin 9 of IC5 where they are summed.
CONTENTS SECTION 5 5.14 MACHINE TESTING / TROUBLESHOOTING / SERVICE PT31 Torch (0558003183) The PC650 uses the PT-31XLPC torch. It comes ready to use out of the box and can cut material 5/8” inch and server ¾” material. Constructed of glass-reinforced phenolic, it is a rugged lightweight torch for general-purpose cutting. The torch must come in contact with the material to draw an arc.
CONTENTS section 6 regular maintenance 6.0 6.0 Maintenance IGBT Testing IGBT Handling & Replacement Since IGBT gates are insulated from any other conducting region, care should be taken to prevent static build up, which could possibly damage gate oxides. All IGBT modules are shipped from the factory with conductive foam contacting the gate and emitter sense pins. Always ground parts touching gate pins during installation. In general, standard ESD precautions application to FETs should be followed.
CONTENTS section 6 regular maintenance 6.1 Buss Supply Power Control / IGBT Testing Procedure (1) SECTION 5.5 _ TEST IGBT _ 1 IGBT Testing Take measurements on threaded partbelow below insulated chrome plated spacer.spacer.
CONTENTS section 6 regular maintenance 6.1 Buss Supply Power Control / IGBT Testing Procedure (2) SECTION 5.5 _ TEST IGBT _ 2 IGBT Testing Take measurements threaded part insulated chrome plated spacer. Take measurements ononthreaded partbelow below insulated chrome plated spacer.
CONTENTS section 6 regular maintenance 6.2 Buss Supply Power Control / IGBT Tester Schematic IGBT Tester Schematic IGBT TESTER LARGE BLACK CLIP LARGE RED CLIP SMALL YELLOW CLIP 1 + LED 1 2 332 N.O. 3 47.5 K 4 SW 1 5 N.C.
CONTENTS section 6 regular maintenance 6.3 Buss Supply Power Control / IGBT / MOSFET Testing IGBT Tester IGBT TEST IGBT C2 E1 BLACK LEAD ** Repeat steps for E2, C2 and G2 E2 RED LEAD C1 G1 E1 1. CONNECT AS SHOWN 2. LED ON= SHORTED JUNCTION, REPLACE PART 1. Connect as shown 3. PRESS PUSHBUTTON SWITCH: 2. Led On = Shorted Junction, Replace Part 3.
CONTENTS section 6 Wiring Diagrams 6.
CONTENTS section 6 Wiring Diagrams 6.
CONTENTS section 6 Wiring Diagrams 6.
CONTENTS section 6 Wiring Diagrams 6.
CONTENTS section 6 Wiring Diagrams 6.
CONTENTS section 6 Wiring Diagrams 6.
CONTENTS section 6 Wiring Diagrams 6.
CONTENTS section 6 Wiring Diagrams 6.
CONTENTS section 7 replacement parts 7.0 Replacement Parts 7.1 General Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on the unit nameplate. 7.2 Ordering To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this equipment. The use of non-ESAB parts may void your warranty. Replacement parts may be ordered from your ESAB Distributor.
CONTENTS section 7 replacement parts 7.
CONTENTS section 7 replacement parts 7.3 PC650 Replacement Parts Front BOM PC650 REPLACEMENT PARTS ITEM QTY P/N DESCRIPTION 10 1 21711 28 1 634518 SWITCH TOGGLE DPDT 2POS 15A 125V Q/D S1 29 1 673213 SWITCH TOGGLE SPST 2POS 15A 125V Q/D S2 40 2 951474 SWITCH SEAL BLACK 41 1 951526 LAMP NEON WHT 50 2 993426 GROMMET RUB 1.50ID 1.75GD X .06W 55 1 23602576 STRAIN RELIEF, (WORK CABLE) 61 AR 61325849 SCREW PHTF #6-32 X .25 62 AR 61325851 SCREW PHTF #6-32 X .
CONTENTS section 7 replacement parts 7.4 PC650 Replacement Parts Front Inside 7.4 PC650 Replacement Parts Front Inside BOM PC650 REPLACEMENT PARTS ITEM QTY P/N DESCRIPTION 57 AR 61341087 SCREW MACH. HEX HD .25-20 X 0.05 59 AR 61325826 SCREW PHTF #4-40 X .38 62 AR 61325851 SCREW PHTF #6-32 X .38 70 AR 63100100 NUT HEX BRASS 1/4-20 71 AR 63300100 NUT HEX STLZPC .
CONTENTS section 7 replacement parts 7.5 PC650 Replacement Parts Rear 7.5 PC650 Replacement Parts Rear BOM PC650 REPLACEMENT PARTS ITEM QTY P/N DESCRIPTION 61 AR 61325849 SCREW PHTF #6-32 X .25 62 AR 61325851 SCREW PHTF #6-32 X .38 67 AR 61325900 SCREW PHTF #10-24 X .38 77 AR 64302920 WASHER LOCK #10 98 1 0558005659 136 1 13730763 NAMEPLATE CODE SERIAL STOCK 138 AR 64307860 WSR LOCK #6 EXT TOOTH 144 AR 65509506 RIVET 1/8 GRIP .251-.
CONTENTS section 7 replacement parts 7.
CONTENTS section 7 replacement parts 7.6 PC650 Replacement Parts Top Inside 2 BOM PC650 REPLACEMENT PARTS ITEM QTY P/N DESCRIPTION 3 1 0558002183 6 1 461107 TEE STREET 1/8-27 NPT 24 1 952086 ELBOW MALE SWIVEL 90 DEG 1/4NPTM 30 1 0558006156 38 1 951202 SW FLOW .25GPN SPST 63 AR 61325852 SCREW PHTF #6-32 X .50 64 AR 61325853 SCREW PHTF #6-32 X .63 65 AR 61325878 SCREW PHTF #8-32 X .38 66 AR 61325880 SCREW PHTF #8-32 X .50 67 AR 61325900 SCREW PHTF #10-24 X .
CONTENTS section 7 replacement parts 7.7 PC650 Replacement Parts Top Inside 7.7 PC650 Replacement Parts Top Inside BOM PC650 REPLACEMENT PARTS ITEM QTY P/N DESCRIPTION SYMBOL 4 1 38131 PCB START UP NETWORK PCB5 16 1 38214 PCB PLASMA CONTROL UNIVERSAL PCB1 18 AR 950908 CABLE TIE PUSH MOUNT 50 2 993426 GROMMET RUB 1.50ID 1.75GD X .06W 52 1 993837 GROMMET RUB 0.44ID 0.56GD X .06W 62 AR 61325851 SCREW PHTF #6-32 X .38 65 AR 61325878 SCREW PHTF #8-32 X .
CONTENTS section 7 replacement parts 7.8 PC650 Replacement Parts Top Inside 3 7.8 PC650 Replacement Parts Top Inside 3 BOM PC650 REPLACEMENT PARTS ITEM QTY P/N DESCRIPTION 5 1 13730222 BUSHING SNAP .
CONTENTS section 7 replacement parts 7.9 PC650 Replacement Parts Left Inside 7.9 PC650 Replacement Parts Left Inside 230 BOM PC650 REPLACEMENT PARTS ITEM QTY P/N 1 1 0558005394 DESCRIPTION SYMBOL FILTER REG AIR LINE B07-234-A1KA 9 1 673038 BUSHING SNAP 1.38 ID X 1.75 MH 2 10 1 21711 GAUGE 1.
CONTENTS section 7 replacement parts 7.9 PC650 Replacement Parts Left Inside 230 BOM PC650 REPLACEMENT PARTS ITEM QTY P/N DESCRIPTION 53 4 17721020 RESISTOR 20 OHM, 25 WATT 54 2 17750010 RESISTOR 50W 10 OHM 3% 56 2 60101025 PLUG HOLE HEX HD .25-20 X 0.50 58 AR 61308903 SCREW PHTF #10-24 X .62 59 AR 61325826 SCREW PHTF #4-40 X .38 62 AR 61325851 SCREW PHTF #6-32 X .38 63 AR 61325852 SCREW PHTF #6-32 X .50 64 AR 61325853 SCREW PHTF #6-32 X .
CONTENTS section 7 replacement parts 7.
CONTENTS section 7 replacement parts 7.10 PC650 Replacement Parts Right Inside 230 BOM PC650 REPLACEMENT PARTS ITEM QTY P/N DESCRIPTION SYMBOL 8 1 634220 TAB 12 1 32969 REACTOR ASSY HIGH FREQ T3 1 14 1 35941 XFMR ASSY MAIN 230V & 460V T1 18 AR 950908 CABLE TIE PUSH MOUNT 20 1 182W58 CABLE TIE SCREW MTG. 35 1 951182 FAN AC AXIAL M1 49 1 952606 INDUCTOR OUTPUT L1 61 AR 61325849 SCREW PHTF #6-32 X .25 64 AR 61325853 SCREW PHTF #6-32 X .
CONTENTS section 7 replacement parts 7.11 PC650 Replacement Parts Left Inside Detail 460 7.11 PC650 Replacement Parts Left Inside Detail 460 BOM PC650 REPLACEMENT PARTS ITEM QTY P/N DESCRIPTION 58 AR 61308903 SCREW PHTF #10-24 X .62 77 AR 64302920 WASHER LOCK #10 78 AR 64304050 WASHER FLAT #10 114 4 92W57 GROMMET RUB .63 ID X .88 GD X .
CONTENTS section 7 replacement parts 7.12 PC650 Replacement Parts Right Inside Detail 460 7.12 PC650 Replacement Parts Right Inside Detail 460 BOM PC650 REPLACEMENT PARTS ITEM QTY P/N DESCRIPTION 65 AR 61325878 SCREW PHTF #8-32 X .
CONTENTS section 7 replacement parts 7.13 PC650 Replacement Parts Outside 7.
CONTENTS section 7 replacement parts 7.
CONTENTS section 7 replacement parts 7.
CONTENTS section 7 replacement parts 7.14 PC650 Replacement Parts Spreadsheet PC650 REPLACEMENT PARTS P/N DESCRIPTION SYMBOL 0558003179 - 208/230 V ITEM 0558005328 - 460 V 0558005151 - 230 V CE 0558005152400 V CE QTY KIT COMPONENTS WIRE MAIN PC-650 400/460V & CE 120 0558005316 KIT WIRE MAIN PC-650 400/460V (SEE COMPONENTS BELOW) 1 1 1 1 951179 1 1 17145339 1 1 951471 DIODE ZENER 60V 75mA 2 2 672348 CAPACITOR .01uf 1KV C11,C12 5 5 951313 CAPACITOR .
CONTENTS section 7 replacement parts 7.14 PC650 Replacement Parts Spreadsheet PC650 REPLACEMENT PARTS P/N DESCRIPTION SYMBOL 0558003179 - 208/230 V ITEM 0558005328 - 460 V 0558005151 - 230 V CE 0558005152400 V CE QTY KIT COMPONENTS_230 V 1 Phase CE (PN: 0558005345) 1 122 0558005345 KIT WIRE POWERCUT 230V 1PH CE (SEE COMPONENTS BELOW) 1 951028 CAPACITOR 1uf 630VDC 3 951321 VARISTOR METAL OXIDE, 275V 1 951515 CAPACITOR .
CONTENTS section 7 replacement parts 7.14 PC650 Replacement Parts Spreadsheet PC650 REPLACEMENT PARTS 1 P/N 1 151 954700 LABEL INPUT 200VAC PCM-125 1 1 153 954746 LABEL FAULT INDICATOR 1 1 154 954506 LABEL ISO 9002 1 1 155 954981 DECAL PC-650 6.25 X 1.75 1 155 1 1 1 1 0558954003 DECAL PC-650 CE 6.25 X 1.
PDF Complete Documents CONTENTS SECTION 8 GENERAL INFORMATION 8.
CONTENTS SECTION 8 GENERAL INFORMATION 8.
CONTENTS SECTION 8 GENERAL INFORMATION 8.2 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) terminals of the IBR Place a DC voltmeter across the IBR DC outputs, + and -. (Refer to IBR dwg) Place an AC meter across the Variac outputs Slowly increase the Variac voltage until the AC meter reads 50 VAC Check the DC meter.
CONTENTS SECTION 8 GENERAL INFORMATION 8.3 PT31 Torch Test Procedure for PT31XLPC torch Equipment Required: A. B. C. Supply of 100 PSI Air or Nitrogen gas with regulator. Test fixture P/N PG-071-16. Reference documents: Description PT-31 Assembly drawings 20072 Instruction Manual F-14-246-J Visual Inspection: Determine that all components are properly located and securely mounted. Check copper tube for proper angle and tightness; watch for interference with other connections and shorts.
CONTENTS Index bias supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73, 76 D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTENTS revision history 1.
CONTENTS ESAB Welding & Cutting Products, Florence, SC Welding Equipment COMMUNICATION GUIDE - CUSTOMER SERVICES A. CUSTOMER SERVICE QUESTIONS: Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST Order Entry Product Availability Pricing Order Information Returns B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting C.
