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ESAB PowerCut 1600, Service Manual

The ESAB PowerCut 1600 is a high-performance plasma cutting system designed for industrial use. Easily service and maintain your machine with the free downloadable Service Manual available at 88.208.23.73:8080. Get step-by-step instructions and troubleshooting tips to keep your PowerCut 1600 running at its best.

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181

BR1 

  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29, 61, 79, 80, 86, 128, 144

buss 

  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

C1 

  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

D1 

  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53, 92

D4 

  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53, 92

D101 

  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28, 36, 136

D102 

  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28, 36

IGBT 

  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64, 77, 78, 82, 172, 173, 174, 175, 176, 177

K1 

  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

L1 

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L2 

  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

M1 

  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28, 132

PCB1    . . . . . . . . . . 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 73, 82, 93
PCB2   47, 61, 62, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 78, 81, 82, 83, 84, 85, 86, 87, 88, 89, 93
PCB3    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90, 92, 96
PCB4    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84, 90, 92, 127
PCB5    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 96, 128
PCB6    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 102, 103, 104, 144, 178
PCB7    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Q101 

  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63, 78, 128, 144, 178

Q102 

  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63, 78, 128

Q103 

  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 128, 135

SOL1    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101, 127, 133, 137
SW1 

  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

SW2 

  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32, 54

T1 

  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33, 34, 92

T2 

  . . . . . . . . . . . . . . . . . . . . . . . . . . 25, 26, 27, 92, 112, 114, 116, 118, 119, 120, 121, 122, 123

torque    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
TS1 

  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93, 94

Index

Summary of Contents for PowerCut 1600

Page 1: ...Serial Number PORJ815099 ending with Serial Number PORJ852108 Powercut 1600 Plasmarc Cutting Package PART NO DESCRIPTION 0558007230 PC1600 230 460V Console 0558007230F PC1600 230 460V BL Console 0558...

Page 2: ...urer 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...

Page 3: ...GE SELECTOR SWITCH SW2 EMC FILTER CE Units PCB7 PRESSURE TRANSDUCER PT1 HELP CODES PILOT ARC CIRCUIT torch pt38 Plasma control DISPLAY board pcb1 POWER BOARD PCB2 THERMAL SWITCH TS1 POWER DRIVER PCB3...

Page 4: ...8317 43 4 8 5 PCB1_Protection Circuit 0558038317 44 4 8 6 PCB1_Gas Test Operate Switch 0558038317 45 4 8 7 PCB1_PWM Circuit 0558038317 46 4 8 8 PCB1_RS232 Input 0558038317 47 4 8 9 PCB1_Current Refere...

Page 5: ...2 Thermal Switch TS1 951085 93 4 13 Pilot Arc Driver Board PCB5 05580038344 95 4 14 Help Codes 97 4 15 Pressure Transducer 0558006148 98 4 16 EMC Filter 50A _ PCB7 CE Units _ 0455803881 100 4 17 Solen...

Page 6: ...t other personnel from arc rays and hot sparks with a suitable non ammable partition or curtains 6 Use goggles over safety glasses when chipping slag or grinding Chipped slag may be hot and can y far...

Page 7: ...round welding cables and welding machines Therefore 1 Welders having pacemakers should consult their physician before welding EMF may interfere with some pacemakers 2 Exposure to EMF may have other he...

Page 8: ...ation in the work area Do not continue to operate if physical dis comfort persists 4 Refer to ANSI ASC Standard Z49 1 see listing below for speci c ventilation recommenda tions 5 WARNING This product...

Page 9: ...AWS C5 3 Recommended Practices for Air Carbon Arc Gouging and Cutting 5 AWS C5 5 Recommended Practices for Gas Tungsten Arc Welding 6 AWS C5 6 Recommended Practices for Gas Metal Arc Welding 7 AWS SP...

Page 10: ...equire the assistance of an occupational health professional to reach full compliance For additional information about Hexavalent Chromium contact your occupational health professional and read the OS...

Page 11: ...hexavalent chromium Cr VI must be below the Permissible Exposure Limit PEL of 5 g m3 for an eight hour time weighted average Workplace or job speci c monitoring must be done to establish areas of pote...

Page 12: ...rmation which will as sist in troubleshooting and repairing malfunctions 2 3 Service Manual Format The machine operation flow diagram starts the breakdown of the functionally of the PC 1600 Each of th...

Page 13: ...60 Hz 82 74 A 1 ph Output 90 amps 40 duty cycle 3 ph Input 208 230 vac 3 ph 50 60 Hz 44 40 A 230 460 vac 3 ph 50 60 Hz 40 27 A 400 vac 3ph 50 60 Hz 26 A 575 vac 3ph 50 60 Hz 18 A 3 ph Output 90 amps 6...

Page 14: ...s this on the front panel display See PIP test below If the PIP test passes the machine is ready for operation 3 2 Parts In Place Check Parts In Place The PC1600 performs a Parts In Place PIP check du...

Page 15: ...loses Power board Relay RL1 the gas solenoid relay closes The gas valve opens Full buss voltage is available 2 seconds of preflow The piston in the torch cycles The Control Board PCB 1 turns on the ga...

Page 16: ...3 0 16 section 3 SPECIFICATIONS 3 4 Machine Operation Flowchart...

Page 17: ...1600V 3 Q101 102 IGBT DUAL 150A 600V 5 Q103 IGBT 50A 1200V D101 102 DIODE MODULE 100A 600V 7 PCB1 PC BOARD CONTROL DISPLAY 8 PCB2 PC BOARD POWER 10 PCB3 4 PC BOARD DRIVER BOARD 11 PCB5 PC BOARD PILOT...

Page 18: ...4 0 18 4 0 Machine Testing Troubleshooting Service SECTION 4 DESCRIPTION OF OPERATION 1 2 4 8 3 11 9 10 5 12 4 0 Schematic Section Map 230 460V 0558007542...

Page 19: ...4 0 19 4 0 Schematic Section Map 0558007542 SECTION 4 DESCRIPTION OF OPERATION 6 9 7 13 15 18 10 12 17...

Page 20: ...4 0 20 4 0 Schematic Section Map 400V 400V CE 0558007546 SECTION 4 DESCRIPTION OF OPERATION 1 2 4 8 3 11 10 16 16 7...

Page 21: ...4 0 21 4 0 Schematic Section Map 0558007546 400V 400V CE SECTION 4 DESCRIPTION OF OPERATION 6 9 7 13 15 18 17 12 10...

Page 22: ...4 0 22 4 0 Schematic Section Map 575V 0558007544 SECTION 4 DESCRIPTION OF OPERATION 1 2 4 8 3 11 16 10...

Page 23: ...4 0 23 4 0 Schematic Section Map 0558007544 SECTION 4 DESCRIPTION OF OPERATION 6 9 7 13 15 17 12 10 18...

Page 24: ...10 6 for more information Switch testing With power disconnected from the unit Switch open From pole L1 of the switch to T1 of the switch open Or High resistance From pole L2 of the switch to T2 of t...

Page 25: ...in the PC1600 Since the PowerCut 1600 is available in with different input voltage configurations the control transformer has a multiple tap primary to allow it to be used in all ver sions T2 supplies...

Page 26: ...1 ohm H5 ORANGE 575 H1 H5 1 ohm Output Voltage X1 X2 RED YELLOW 24 VAC X1 X2 1 ohm X3 BROWN 18 VAC X3 X4 1 ohm X4 BLACK CT 0 V X5 YELLOW 18VAC X4 X5 1 ohm X6 X7 VIOLET 24 VAC X6 X7 1 ohm H1 H2 is exc...

Page 27: ...4 2 27 4 2 Control Transformer T2 0558007188 SECTION 4 DESCRIPTION OF OPERATION...

Page 28: ...circuit will keep the fan running for the same amount of time the torch was cutting In other words if the torch was turned on for two minutes the fan will continue to run for two minutes after the to...

Page 29: ...led to the buss supply capacitors and the L1 input inductor A precharge Inrush circuit is mounted to the output of L1 and is in parallel with the Main Contactor This circuit allows the Buss supply to...

Page 30: ...4 3 30 4 3 Input Bridge 0558007068 0558007077 SECTION 4 DESCRIPTION OF OPERATION...

Page 31: ...This allows the relay to energize which allows full power to be applied to the filter buss 230 460 VAC UNITS 400 575 VAC UNITS DESCRIPTION AMPS 40 INDUCTIVE NO OF POLES 3 COIL VOLTAGE 24 MAIN TERMINAL...

Page 32: ...dependant upon the input voltage The power selector switch SW2 will place the four filter capacitors in either a series configu ration or in a parallel pair configuration The Voltage Selector switch...

Page 33: ...pts the 18 5 KHz AC power from the IGBTs and steps the voltage down be fore sending it to the output diodes where it is rectified to DC before being sent out to the torch SECTION 4 DESCRIPTION OF OPER...

Page 34: ...4 6 34 SECTION 4 DESCRIPTION OF OPERATION 4 6 Main Transformer T1 0558007189 0558007190 4 6 Main Transformer T1...

Page 35: ...4 6 35 blank...

Page 36: ...nnected to make a full wave bridge These modules are each rated at 100 Amps of forward current at 600 VDC D101 D102 DIODE RED LEAD BLACK LEAD RESISTANCE OHMS OUT OF CIRCUIT IN CIRCUIT 1 2 OPEN 20K 1 3...

Page 37: ...h Modulator CNC interface power up sequence gas pressure control error signals and the display The board receives its power from the power board bias supplies to operate and also creates a 5VDC bias s...

Page 38: ...4 8 38 4 8 PCB1 Control Board 0558038317 SECTION 4 DESCRIPTION OF OPERATION 4 10 6 8 5 3 11 7...

Page 39: ...4 8 39 4 8 PCB1 Control Board 0558038317 SECTION 4 DESCRIPTION OF OPERATION 13 PCB1 1 9 2 12 12...

Page 40: ...mong the 4 conductors and passed to the 5VDC sup ply circuit and also distributed to the different circuits on the board The negative 15 VDC is brought in on the J1 connection at pins 5 and 6 and then...

Page 41: ...1_Display 0558038317 The Main control board microcontroller outputs the digital signals to the display driver chips These chips then drive the displays mounted on the control board SECTION 4 DESCRIPTI...

Page 42: ...ensors mount ed on the power board The control board micro controller receives the current reference input current reference circuit and then outputs that on U5 pin 47 as the SDO signal This combined...

Page 43: ...o flow through the torch for setting inlet pres sures In the center position Normal Mode the unit is in Operate Mode In the down position Trigger Lock the torch trigger can be released after an arc is...

Page 44: ...trigger signal present The comparator circuit senses if output current is above zero when the pwm_engage signal is not present It automatically shuts down the pwm circuit if that condition exists Thi...

Page 45: ...the Gas in Pounds per Squire Inch PSIG or in Bars to be displayed on the front panel LED display SW1 2 has no function SW1 is hard mounted to the Main Control board With SW1 1 in the OFF position the...

Page 46: ...r current condition the PWM chip can be shut down from either the microcontroller or from the Protection circuit see Protection Circuit section XX The PWM circuit receives an enable signal from the mi...

Page 47: ...RIPTION OF OPERATION Serial Input Circuit The Serial Input circuit is used for the Power Board PCB2 to communicate to the Main Control Board This is an RS232 interface and is used primarily for the Po...

Page 48: ...through the front panel of the console The wiper of this pot is connected to the microcontroller through resistor R468 The pot is connected across 5 volts and ground The resulting voltage divider fro...

Page 49: ...has a temperature sensing circuit built into it for circuit protection If the tempera ture in the case exceeds 40 degrees centigrade 104 deg F the microcontroller will shut down the unit The precisio...

Page 50: ...the two ribbon cables connecting the Main Control board to the Power Board These two ribbon cables connected to the Main Control Board at J1 and J2 are the I O bus of the unit Control board J1 connec...

Page 51: ...as Valve Relay RL1 on the Power Board PCB2 SECTION 4 DESCRIPTION OF OPERATION he Microcontroller on the Main Control Board contains the programming necessary to run the PC1600 Here the unit receives s...

Page 52: ...4 8 52 4 8 14 PCB1 Layout 0558038317 SECTION 4 DESCRIPTION OF OPERATION...

Page 53: ...uF 35VDC ELECT C37 13 3 CAP 27pF 300VDC MICA C38 C47 C49 14 2 DIODE ZENER 5 6V 1N4734A D1 D15 15 1 DIODE SCHOTTKY 31DQ05 D2 16 11 DIODE SCHOTTKY 11DQ05 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 17 1 DIODE...

Page 54: ...41 1 RES 499K 25W 1 R33 42 1 RES 158 25W 1 R34 43 1 RES 9 53K 25W 1 R42 44 1 RES TRIMPOT 10K R43 45 1 RES 6 19K 25W 1 R44 46 5 RES 20K 25W 1 R54 R65 R80 R81 R82 47 3 RES 49 9K 25W 1 R60 R61 R66 48 1 R...

Page 55: ...and 575 VAC units This is a three gang unit of three 170 micro Henrys capable of passing 22 amps of current 0558007151 Input Inductor The Input Inductor L1 is a line reactor inductor used to filter o...

Page 56: ...Inductor 0558007152 The output inductor L2 is used to filter the DC output of the PC1600 The inductor is a 600 micro Henry unit designed to resist changes in the output of the PC1600 SECTION 4 DESCRI...

Page 57: ...TION 4 DESCRIPTION OF OPERATION The power board in the PC1600 allows the power connections to be made in a solid central way that makes short power runs with hi power carrying capacity All of the powe...

Page 58: ...4 10 58 4 10 1 Power PC Board Schematic 0558038315 SECTION 4 DESCRIPTION OF OPERATION 17 4 16 7 9 6 8 12 18 15 7...

Page 59: ...4 10 59 4 10 1 Power PC Board Schematic 0558038315 SECTION 4 DESCRIPTION OF OPERATION 17 19 13 5 11 20 17 10 11...

Page 60: ...4 10 60 4 10 2 Power PC Board Schematic 2 0558038315 SECTION 4 DESCRIPTION OF OPERATION 3 14 8...

Page 61: ...by turning on the mosfet Q4 When Q4 is forward biased the Mosfet conducts and places a low on pin 5 of the regulator U13 The Q4 MOSFET is turned on by the microcontroller on the Power Board PCB2 Power...

Page 62: ...ly Circuit 0558038315 SECTION 4 DESCRIPTION OF OPERATION PCB2 BIAS SUPPLY TEST POINTS Test point Reference Point Value TP2 TP1 15VDC TP3 TP1 5VDC TP4 TP1 15VDC J20 pin 4 J20 Pin 5 18 VAC J20 pin 6 J20...

Page 63: ...U10A on pin 3 for buffering The output of U10A on pin 1 passes through D10 and is sent to the main control board PCB1 as signal bridge_peak When this voltage exceeds 2 75 VDC the main control board P...

Page 64: ...board PCB 2 via an IC on the power board The Pilot Arc IGBT is gated on from U9 Pin 7 This output is enabled when the microcontroller toggles on the PA relay signal to U9 pin 3 This places a high on U...

Page 65: ...n single phase operation Should the unit exceed the duty cycle the microcontroller will shut the machine down when the duty cycle limit is reached to prevent damage to the machine The single phase det...

Page 66: ...he control board RL2 is the fan relay The fan relay closes when the unit begins a cutting operation The fan will run as long as the unit is cutting and will continue to run for seven and a half minute...

Page 67: ...4 10 67 4 10 7 Power Board_PCB2 Control Relays 0558038315 SECTION 4 DESCRIPTION OF OPERATION...

Page 68: ...voltage be applied Two relays RL5 and RL6 provide the logic for the micro based on signals from the input It is the combination of these two signals and the V bias signal that tells the power board m...

Page 69: ...voltage be applied Two relays RL5 and RL6 provide the logic for the micro based on signals from the input It is the combination of these two signals and the V bias signal that tells the power board m...

Page 70: ...h will interface with a CNC via the J2 Amphenol plug The J8 connector passes all signals but one the external reference signal to the main control board PCB1 through the PCB2 J4 PCB1 J1 ribbon cable T...

Page 71: ...is connected to these two diodes at the negative terminals This 18 KHz output is rectified to DC and then passed through the Hall sensors and out to the Electrode Pilot Arc Lead and Work lead The Hal...

Page 72: ...cted to an electronic rectifier that outputs a DC reference voltage that is connected to the Microcontroller of PCB1 Voltage input on J14 and J15 from the tertiary windings of the main transformer are...

Page 73: ...e condition which could damage the unit When the on board relay K1 closes the filter capacitors charge through the thermistors R62 and R67 These two thermistors restrict the amount of current drawn by...

Page 74: ...al back from the device This signal is then passed to the Main Control board The pressure transducer receives 5 volts DC across J10 pin 3 5 VDC and pin 2 DC common The sig nal is returned from the tra...

Page 75: ...three phase input voltage is below 210 VAC in the 230 VAC mode In the event that the input power is low Q7 is turned on and conducts sending source voltage down to Q8 The microcontroller gates on Q8...

Page 76: ...l board as the START signal 24VAC is sent out on J12 pin 2 and routed to either the PT38 torch trigger or to a CNC Once the torch switch is closed the 24VAC is returned on J9 pin 2 and sent to D3 a fu...

Page 77: ...4 10 77 4 10 16 Buss Supply IGBT SECTION 4 DESCRIPTION OF OPERATION...

Page 78: ...of 325 VDC whether configured for 230 VAC input or 460 VAC input 4 10 16 Power Board_PCB2 Filter Buss IGBT Circuit 0558038315 Capacitor Information Serious Shock Possible SECTION 4 DESCRIPTION OF OPER...

Page 79: ...inverter block filter section known as the Buss Supply comprises C37 C40 C44 C47 R14 and R15 The purpose of this section is to transform the pulsating DC to a level DC operating voltage The drawing be...

Page 80: ...b and flow effect charging and discharging in contrast to the rise and fall of their input voltage A graphical representation of this is shown in the drawing below The resistors R14 R15 are in place t...

Page 81: ...discharge current reasonable The filter caps are configured in two different ways in the PC1600 230 460 model dependant upon the in put voltage The power selector switch S3 will place the four filter...

Page 82: ...to the main control board PCB1 across the serial interface Pulses for the Pilot Arc IGBT driver are developed here and sent to the driver circuit Also see Section 4 10 5 Pilot Arc Driver Section 4 10...

Page 83: ...rd where the voltage is passed to ground The output of this circuit is a logic low that is sent to the microcontroller on the Main Control Board PCB1 If the Thermal switch opens this will place a logi...

Page 84: ...pins 1 and 3 These are routed to U1 and U3 respec tively which buffers the signals and drives the power MOSFETs Q1 and Q2 used to supply pulses to the Power Driver boards PCB3 and PCB4 Testing TP1 is...

Page 85: ...eader J2 on the control card This is used for communication between the power board controller and the main controller This communication channel is also used for computer testing of the machine acces...

Page 86: ...1 BRIDGE 3A 400V GBPC 104 BR1 3 14 CAP 680pF 100VDC MET POLY C4 C3 C11 C13 C18 C21 C27 C33 C57 C58 C59 C62 C63 C70 4 16 CAP 0 22uF 100VDC CERAMIC C2 C6 C10 C12 C16 C23 C32 C36 C49 C60 C82 C85 C86 C90...

Page 87: ...1000uF 35VDC ELECT C71 C72 C73 C76 C77 C83 21 1 CAP 100uF 63VDC ELECT C79 22 4 DIODE P6KE33CA D1 D2 D7 D9 23 2 DIODE BRIDGE W10G D3 D13 24 1 DIODE LED RED D4 25 12 DIODE MUR160 D5 D6 D8 D10 D11 D15 D...

Page 88: ...PIN DIP 100 OHM RN1 57 2 RES NET 10 PIN SIP 10K RN2 RN3 58 2 VARISTER 369VDC RV3 RV4 59 19 RES 1K 0 25W 1 R1 R5 R7 R8 R18 R25 R27 R28 R29R32 R35 R45 R49 R66 R77 R80 R93R111 R125 60 19 RES 100 0 25W 1...

Page 89: ...RES 49 9K 0 25W 1 R122 R123 90 1 SWITCH DIP 2 POSITION SW1 91 5 INSERT TB 1 TB 2 TB 3 TB 4 TB 7 92 7 TEST POINT TP1 TP2 TP3 TP4 TP5 TP6 TP7 93 2 TRANSFMR COMMON MODE FE2X03 3 2 T1 T3 94 1 TRANSFMR 1 1...

Page 90: ...for 180 degrees of pulse conduction During the negative half of the cycle each driver circuit drives the gate of the IGBT negative forcing the IGBT off During the positive half of the cycle the pulse...

Page 91: ...4 11 91 4 11 Power Driver 0558038335 SECTION 4 DESCRIPTION OF OPERATION...

Page 92: ...M FEED J1 9 2 TRANSISTOR PNP SILICON BC327 Q1 Q6 10 4 TRANSISTOR NPN SILICON MJE243 Q2 Q3 Q4 Q5 11 2 RES 27 0 5W 1 R1 R8 12 4 RES 470 1W 1 R2 R3 R9 R10 13 4 RES 470 0 5W 1 R4 R5 R11 R12 14 4 RES 4 7 0...

Page 93: ...en until the in ductor cools to 156 F The switch is physically attached to the heat sink and connected to the power board at J1 This switch is electrically connected to the Main Control Board Microcon...

Page 94: ...h is physically attached to the heat sink and connected to the power board at J16 This switch is electrically connected to the Main Control Board Microcontroller through the PCB2 J4 PCB1 J1 ribbon cab...

Page 95: ...r Circuit The Pilot Arc IGBT is gated on when power is needed for pilot arc The Main Power board PCB2 supplies a signal form J23 pin 1 and 3 to the IGBT driver board PCB5 A 12 VAC signal is received i...

Page 96: ...3 F1 1 FUSE 1 2 AMP 4 P1 1 PLUG COMBICON 3 POS VERTICAL 5 R1 1 RESISTOR 47 5 OHM 1 2W 1 6 R3 1 RESISTOR 1K 1 2W 1 7 R4 R5 2 RESISTOR 2 74 OHMS 1 2W 1 8 ZD1 ZD2 2 DIODE ZENER 18V 2W 5 1N4746A 9 AR EPOX...

Page 97: ...edback improper Primarily seen if current sensor is unplugged Check cable and connection between current sensor board and control board Send unit to an ARS for repair 11 Primary over current Converter...

Page 98: ...Pressure Transducer 0558006148 The Pressure Transducer is a 4 100 PSI unit designed to output 0 to 4 5 VDC to the control board as feedback for the pressure output to the torch SECTION 4 DESCRIPTION...

Page 99: ...45psi Pop 15 700 kPa SUPPLY VOLTAGE Vs 4 75 5 5 25 Vdc SUPPLY CURRENT Io 7 10 mAdc ZERO PRESSURE OFFSET Voff 0 184 0 409 Vdc FULL SCALE OUTPUT Vfso 4 587 4 7 4 813 Vdc FULL SCALE SPAN Vfss 4 5 Vdc ACC...

Page 100: ...rd is used on the 575VAC 460VAC and 400 VAC CE units to further reduce the electro magnetic interference of the unit NOTE This component is rated for handle 3 phase currents 50 amps Max Single phase u...

Page 101: ...used as a on off control for the gas flow through the PC1600 When the operator activates the torch trigger on the PC1600 the microcontroller on the main control board sends a gas valve command to the...

Page 102: ...put is a 0 10 VDC signal that is divided by two and sent to the Power Board PCB2 for routing to the Control board PCB1 Reference the schematic The start signal will start and stop the power supply on...

Page 103: ...DC 5 Start Signal 15 VDC active 6 Corner 15 VDC active 7 8 ARC ON Relay contacts for output to CNC 9 10 FAULT Relay contacts for output to CNC 0558038337 PCB6 Remote PC Board P1 1 Ground 2 4 Current r...

Page 104: ...DIODE 1A 600V MUR160 6 D3 D4 2 DIODE BI DIRECTIONAL P6KE43CA 7 D5 1 DIODE BRIDGE 1A 700V 8 J1 1 HEADER HORIZ PHOENIX 10 PIN 9 P1 1 HEADER CONNECTOR PHOENIX 10 POS 10 Q1 Q2 2 TRANSISTOR 2N2222 11 RL1 R...

Page 105: ...al components shown with PT 38 parts breakdown in section 2 3 Spare Parts Kits PT 38 Spare Parts Kits 0558007640 90 AMP PC1600 CE 0558007639 90 AMP PC1600 Part Number Description 3 3 0558005220 ELECTR...

Page 106: ...90A 0558004870 40 70A 0558005217 Retaining Cup 0558007549 Electrode 0558005220 Nozzle 90A 0558007680 70A 0558005219 40A 0558007682 Torch Trigger 0558006796 Trigger Spring 0558006799 Trigger Switch 05...

Page 107: ...107 4 19 PT38 Plasma Torch NOTE ORIENTATION OF THIS FEATURE WHEN REASSEMBLING Cap 0558006790 Screw 0 164x32x 12 61330890 SECTION 4 DESCRIPTION OF OPERATION NOTE DO NOT HEAT SHRINK SLEEVES WHEN REASSEM...

Page 108: ...4 19 108 Brazed Body 0558006789 Piston 0558006791 Cap 0558006790 O Ring 2223489 O Ring 5W51 SECTION 4 DESCRIPTION OF OPERATION 4 19 PT38 Plasma Torch...

Page 109: ...4 19 109 SECTION 4 DESCRIPTION OF OPERATION 4 19 PT38 Plasma Torch...

Page 110: ...4 19 110 SECTION 4 DESCRIPTION OF OPERATION 4 19 PT38 Plasma Torch...

Page 111: ...07878 SWITCH AY TRIGGER PT 38 10 1 0558006795 HANDLE SET PT 38 11 1 0558006796 TORCH TRIGGER PT 38 12 1 0558006799 SPRING TRIGGER PT 38 13 10 61950852 SCR BLK OX 6 X 500LG 14 1 61330890 SCR 13011 STLZ...

Page 112: ...5 0 112 section 5 WIring diagrams 5 1 Wiring Diagram 230 460 Volt 0558007543 5 0 Wiring Diagrams...

Page 113: ...5 0 113 5 1 Wiring Diagram 230 460 Volt 0558007543 section 5 WIring diagrams...

Page 114: ...5 0 114 5 1 Wiring Diagram 230 460 Volt 0558007543 section 5 WIring diagrams...

Page 115: ...5 0 115 5 1 Wiring Diagram 230 460 Volt 0558007543 section 5 WIring diagrams...

Page 116: ...5 0 116 section 5 WIring diagrams 5 1 Wiring Diagram 230 460 Volt 0558007543...

Page 117: ...5 0 117 section 5 WIring diagrams 5 1 Wiring Diagram 230 460 Volt 0558007543...

Page 118: ...5 0 118 5 2 Wiring Diagram 400 400V CE 0558007547 section 5 WIring diagrams...

Page 119: ...5 0 119 section 5 WIring diagrams 5 2 Wiring Diagram 400 400V CE 0558007547...

Page 120: ...5 0 120 5 2 Wiring Diagram 400 400V CE 0558007547 section 5 WIring diagrams...

Page 121: ...5 0 121 section 5 WIring diagrams 5 2 Wiring Diagram 400 400V CE 0558007547...

Page 122: ...5 0 122 5 2 Wiring Diagram 400 400V CE 0558007547 section 5 WIring diagrams...

Page 123: ...5 0 123 section 5 WIring diagrams 5 2 Wiring Diagram 400 400V CE 0558007547...

Page 124: ...124 5 3 Wiring Diagram 575V 0558007545 section 5 WIring diagrams...

Page 125: ...125 section 5 WIring diagrams 5 3 Wiring Diagram 575V 0558007545...

Page 126: ...126 5 3 Wiring Diagram 575V 0558007545 section 5 WIring diagrams...

Page 127: ...127 section 5 WIring diagrams 5 3 Wiring Diagram 575V 0558007545...

Page 128: ...128 5 3 Wiring Diagram 575V 0558007545 section 5 WIring diagrams...

Page 129: ...129 section 5 WIring diagrams 5 3 Wiring Diagram 575V 0558007545...

Page 130: ...130 blank...

Page 131: ...of non ESAB parts may void your warranty Replacement parts may be ordered from your ESAB Distributor Be sure to indicate any special shipping instructions when ordering replacement parts Refer to the...

Page 132: ...Replacement Parts _ Left Side C37 40 44 47 pn 0558007162 T2 pn 0558007188 L2 pn 0558007152 L1 230 460V pn 0558007151 400 575V pn 0558007149 T1 230 460V pn 0558007189 400V pn 0558007190 575V PN 055800...

Page 133: ...3 section 6 replacement parts 6 0 Replacement Parts _ Right Side SOL1 pn 0558007072 PRESSURE TRANSDUCER pn 0558006148 K1 pn 950247 PRESSURE REGULATOR pn 0558007071 PCB3 PCB4 pn 0558038335 PCB2 pn 0558...

Page 134: ...6 0 134 section 6 replacement parts 6 0 Replacement Parts _ Top PCB5 pn 0558038344 Q103 pn 0558007866 BR1 Q101 Q102 PCB2 pn 0558038315 PCB1 pn 0558038317 SW2 pn 0558007183...

Page 135: ...6 0 blank 135...

Page 136: ...6 0 136 section 6 replacement parts 6 3 Front 0558007540...

Page 137: ...3P 60A 600V SW1 69 1 0558007074 SOCKET PANEL MINI 250A WORK 93 1 0558007069 LATCH SLIDING 94 REF 0558007460 STRAIN RELIEF HALF Torch Cable 100 2 0558006911 END CAP HANDLE 146 AR 61328090 SCREW HEX WS...

Page 138: ...558007202 BRACKET FAN 4 1 0558007201 BRACKET XFMR 7 1 0558007204 BOX PCB BOX PCB 15 1 0558007152 INDUCTOR OUTPUT L2 17 1 0558007188 XFMR CONTROL T2 23 1 0558007154 HEATSINK HEATSINK 38 1 17300001 RESI...

Page 139: ...D 06W 108 6 92W57 GROMMET RUBBER 0 63ID 0 88GD 06W 113 1 13 90861726 TUBING PVC 300V 1 BLACK 136 AR 61325826 SCREW SQ PAN TRI 4 40 x 38 137 AR 61325849 SCREW SQ PAN TRI 6 32 x 25 139 AR 61325878 SCREW...

Page 140: ...6 0 140 6 3 Top 0558007540 section 6 replacement parts...

Page 141: ...0 44GD 06W 109 1 950167 GROMMET RUBBER 1 12ID 1 50GD 06W 113 1 13 90861726 TUBING PVC 300V 1 BLACK 131 AR 61387910 SCREW SQ PAN TRI 10 32 x 38 w LW 133 10 0558002087 SCREW PHL HEX w FLW M5 x 12 171 AR...

Page 142: ...8007154 HEATSINK HEATSINK 27 2 951185 DIODE MODULE 100A 600V D101 102 39 2 17750851 RESISTOR 10 OHM 50W 3 R14 15 40 4 17721820 RESISTOR 20 OHM 25W 1 R5 7 10 12 45 1 951085 SWITCH THERMAL N C 176 F TS1...

Page 143: ...W 108 6 92W57 GROMMET RUBBER 0 63ID 0 88GD 06W 113 1 13 90861726 TUBING PVC 300V 1 BLACK 136 AR 61325826 SCREW SQ PAN TRI 4 40 x 38 137 AR 61325849 SCREW SQ PAN TRI 6 32 x 25 139 AR 61325878 SCREW SQ...

Page 144: ...6 0 144 section 6 replacement parts 6 3 Left Inside2 0558007540...

Page 145: ...59 SPACER ALUM 1 4 ID 7 16 LG 87 6 0558007158 STANDOFF ALUM FEMALE 6 32 HEX 1 1 8 LG 88 6 0558007078 STANDOFF PLASTIC PCB 7 8 LG 115 38 2132496 TUBING PVC 600V 5 8 BLACK 127 2 647182 WASHER INSULATING...

Page 146: ...6 0 146 section 6 replacement parts 6 3 Rear View 0558007540...

Page 147: ...EET 90 1 4NPT 83 1 75 908597202 HOSE POLYURETHANE 3 16 ID 5 16 OD Red 96 2062151 LOCKNUT CONDUIT 1 2 97 1 0558002581 STRAIN RELIEF NYLON 1 Black 98 1 950435 LOCKNUT CONDUIT 1 101 2 0558007182 FOOT RUB...

Page 148: ...6 0 148 6 3 Front Rear Isometric Views 0558007540 section 6 replacement parts...

Page 149: ...5878 SCREW SQ PAN TRI 8 32 x 38 153 AR 61327747 SCREW SLT HEX TAP 8 x 38 Serrated 170 AR 64307860 WASHER LOCK EXT 6 187 1 13730763 LABEL NAMEPLATE Stock Serial No 189 1 2091514 LABEL WARNING GENERAL A...

Page 150: ...IGBT DUAL 200A 600V Q101 102 2 0558005462 IGBT DUAL 150A 1200V Q101 102 1 1 33 0558038337 PC BOARD REMOTE PCB6 1 1 34 0455803881 PC BOARD EMC FILTER 50A PCB7 4 4 4 4 36 0558007161 CAPACITOR ALUM 4100u...

Page 151: ...SLT PAN TAP 10 x 38 1 1 1 186 0558954073 LABEL RATING 208 230 460V PC 1600 1 0558954074 LABEL RATING 575V PC 1600 0558954078 LABEL RATING 400V PC 1300 1 1 1 0558954075 LABEL RATING 400V PC 1600 1 1 1...

Page 152: ...0 1 RECEPTACLE CABLE ASSY 14 PIN 3 951016 1 CONNECTOR COMBICON 10 PIN 4 951005 1 CONNECTOR COMBICON 3 PIN 5 526652 1 STRAIN RELIEF SEALED 1 2 ZINC 6 2062151 1 LOCKNUT CONDUIT 1 2 7 2235784 1 CLAMP CAB...

Page 153: ...1 Access the inside of the PC 1300 1 1600 by unscrewing the screws and removing the cover 2 Assemble the strain relief onto the 14 pin cable as shown and partially tighten 3 Remove the hole plug on th...

Page 154: ...it unplug voltage select switch wires also Cut the tie wraps here 5 Thread the cable through the hole as shown and allow cable to hang loose Add locknut and partially tighten 6 Assemble the cable clam...

Page 155: ...d therefore ensure proper connections of the 9 cables wires 9 Install each wire and tighten Cable wires are numbered 2 through 10 and must be connected in numerical sequence starting with number 2 The...

Page 156: ...with the screw provided 11 Connect the fast on connectors of the 2 wire cable to the 14 pin cable 12 Route the 2 wire cable under the pc board and tie wrap to the frame using the provided holes in the...

Page 157: ...in power control board 3 pin connector 16 Align the 3 pin connector with the pc board header to identify which end of the connector aligns with the and on the pc board On the connector insert the red...

Page 158: ...pc board Remov ing the driver pc board will allow easier access Ensure board is reinstalled properly by aligning three long header pins and fully snapping board into place on mounting pillars Install...

Page 159: ...159 section 7 mechanized conversion 20 Trim all tie wraps and replace the unit s cover...

Page 160: ...e machine failed the PIP test because no current was detected Check the following Consumables anything that would prevent the electrode from touching the nozzle 1 Open torch leads check power cable an...

Page 161: ...n 8 errorS Toggle SW1 to opposite state 4 SW1 opposite state Turn on power LED Display will read RST Reset 5 Turn off power 6 Toggle SW1 to default state replace cover and 7 resume operations Reset 8...

Page 162: ...r 1 Check input bridge output 2 Check pre charge circuit on power board If the power board has just been replaced check posi 3 tion of J15 try position 1 and2 first if error 15 Err 15 must be rest int...

Page 163: ...via the power pcb at machine factory final test 1 02 B 18 Aug 08 Corrected Machine randomly fails to error condition 13 if power is applied to machine prior to shop air being supplied to machine 1 03...

Page 164: ...ground at work piece and at power source Check torch cables for worn insulation and confirm tight electrical connections Drain any moisture from the bowl of the input filter regulator Internal Check f...

Page 165: ...r on anything at your work station then there cannot be any static discharges Nonconductive materials e g fabrics or insulators e g plastics generate and hold staticcharge so you should not bring unne...

Page 166: ...10 166 SECTION 9 General information 10 3 Ohm s and Watt s Laws...

Page 167: ...ulate voltage Device in series with a load which opens the circuit if its current rating A is exceeded Component that opposes current flow proportionately to its Ohm rating Power dissapation is expres...

Page 168: ...physical crystal of piezo electric material to create an electrical signal with a very precise frequency A device which converts electrical energy to mechanical energy motion n A n V LAMP NEUTRAL Elec...

Page 169: ...ng that it is a Not AND gate The output of a NAND gate is A NAND gate can have two or more inputs The o on the output means true when at least one of its inputs is true An OR gate can have two or more...

Page 170: ...er the voltage drop An open contact in a branch circuit with a load will show a high voltage drop because the meter and the open switch have a very high resistance when compared to the load While a cl...

Page 171: ...10 171 10 6 Ohm Testing SECTION 9 General information...

Page 172: ...10 172 10 7 Diode Testing SECTION 9 General information...

Page 173: ...10 173 10 8 Ripple SECTION 9 General information...

Page 174: ...10 174 10 9 Voltage Measurement SECTION 9 General information...

Page 175: ...f a sudden torque one sided tightening is applied at only one mounting termi nal the ceramic insulation plate or silicon chip inside the module may get damaged The mounting screws are to be fastened i...

Page 176: ...he Collector C1 and the black lead on the Emitter C2E1 of the IGBT Connect a 9 VDC battery with the negative on the Emitter E1 and the positive on the Gate G1 The meter should register a low reading T...

Page 177: ...ct a 9 VDC battery with the negative on the Emitter E2 and the positive on the Gate G2 The meter should register a low reading Short the Emitter Gate G2 E2 leads to turn the IGBT off Take measurements...

Page 178: ...10 178 IGBT Tester Schematic 10 10 1 IGBT Testing SECTION 8 General information...

Page 179: ...ucting paste tape NOTE Small amounts of dirt between mating surfaces can cause com ponent failure or degraded performance DO NOT use silicon seal or other adhesives in place of thermal paste With a to...

Page 180: ...place Part Repeat steps for E2 C2 and G2 NOTE Black lead always on emitter Red lead always on collector Yellow on gate connections G1 GATE 1 G2 GATE 2 E1 EMITTER 1 E2 EMITTER 2 C1 COLLECTOR 1 C2 COLLE...

Page 181: ...44 45 46 47 48 49 50 51 52 53 54 73 82 93 PCB2 47 61 62 66 67 68 69 70 71 72 73 74 75 76 78 81 82 83 84 85 86 87 88 89 93 PCB3 90 92 96 PCB4 84 90 92 127 PCB5 95 96 128 PCB6 70 102 103 104 144 178 PC...

Page 182: ...182 revision history Original release 11 2008 1...

Page 183: ...rth America home page will appear Move your cursor to the naviga tion bar at the top of the page and click on the Find a Distributor area The Distributor Locator page will appear Select Repair Station...

Page 184: ...URE REQUESTS Telephone 843 664 5562 Fax 843 664 5548 Hours 7 30 AM to 4 00 PM EST E WELDING EQUIPMENT REPAIRS Telephone 843 664 4487 Fax 843 664 5557 Hours 7 30 AM to 3 30 PM EST Repair Estimates Repa...

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