ESAB Mechanized Conversion Kit Installation Instructions for PC-1300/1600 Installation manual

Mechanized Conversion Kit Installation Instructions
for PC-1300/1600

0558008079 03/2011

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. 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 be­fore installing or operating this equipment.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompa­nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc­tions 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 imme­diately. 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 ser­vice facility designated by the manufacturer.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

2

SAFETY PRECAUTIONS

Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that
anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions
must meet the requirements that apply to this type of welding or plasma cutting equipment. The following
recommendations should be observed in addition to the standard regulations that apply to the workplace.

All work must be carried out by trained personnel well acquainted with the operation of the welding or plasma
cutting equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in
injury to the operator and damage to the equipment.

1. Anyone who uses welding or plasma cutting equipment must be familiar with:

- its operation

- location of emergency stops

- its function

- relevant safety precautions

- welding and / or plasma cutting

2. The operator must ensure that:

- no unauthorized person stationed within the working area of the equipment when it is started up.

- no one is unprotected when the arc is struck.

3. The workplace must:

- be suitable for the purpose

- be free from drafts

4. Personal safety equipment:

- Always wear recommended personal safety equipment, such as safety glasses, ame proof
clothing, safety gloves.

- Do not wear loose tting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.

5. General precautions:

- Make sure the return cable is connected securely.

- Work on high voltage equipment may only be carried out by a qualied electrician.

- Appropriate re extinquishing equipment must be clearly marked and close at hand.

- Lubrication and maintenance must not be carried out on the equipment during operation.

3

SAFETY PRECAUTIONS

WELDING AND PLASMA CUTTING CAN BE INJURIOUS TO YOURSELF AND
OTHERS. TAKE PRECAUTIONS WHEN WELDING OR CUTTING. ASK FOR

WARNING

ELECTRIC SHOCK - Can kill.

- Install and earth (ground) the welding or plasma cutting unit in accordance with applicable standards.

- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

- Insulate yourself from earth and the workpiece.

- Ensure your working stance is safe.

FUMES AND GASES - Can be dangerous to health.

- Keep your head out of the fumes.

- Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone
and the general area.

YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE BASED ON
MANUFACTURERS’ HAZARD DATA.

ARC RAYS - Can injure eyes and burn skin.

- Protect your eyes and body. Use the correct welding / plasma cutting screen and lter lens and wear
protective clothing.

- Protect bystanders with suitable screens or curtains.

FIRE HAZARD

- Sparks (spatter) can cause re. Make sure therefore that there are no inammable materials nearby.

NOISE - Excessive noise can damage hearing.

- Protect your ears. Use earmus or other hearing protection.

- Warn bystanders of the risk.

MALFUNCTION - Call for expert assistance in the event of malfunction.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

4

MECHANIZED CONVERSION KIT INSTALLATION INSTRUCTIONS

2

4

5

10

11

12

1

8

3

6, 7

9

2

2 wire connector cable

Powercut-1300/1600

Mechanized Conversion Kit contents

p/n 0558007885

Item No. Part No. Qty Description

1 0558038337 1 PC BOARD - REMOTE

2 0558007890 1 RECEPTACLE / CABLE ASSY 14 PIN

3 * 1 TOROIDAL CORE

4 * 1 CONNECTOR COMBICON 10 PIN

5 * 1 CONNECTOR COMBICON 3 PIN

6 * 1 STRAIN RELIEF SEALED 1/2" ZINC

7 * 1 LOCKNUT CONDUIT 1/2"

8 * 0.75" HEATSHRINK 1" BLACK

9 * 1 CLAMP CABLE STEEL .375 DIA

10 * 2 SCREW HEX WSH TAP #8 x .438 RIBBED

11 * 9 TYWRAP SM 4"

12 0558008111 1 KIT JUMPER - MECHANIZED LOGIC

NOTE:

Requires software version 1.04 or higher. The software version is displayed during power-up of the con-

sole. Contact factory for any required software updates.

5

MECHANIZED CONVERSION KIT INSTALLATION INSTRUCTIONS

1. Access the inside of the PC-1300/1600 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 the top right side of the back of the unit.

6

MECHANIZED CONVERSION KIT INSTALLATION INSTRUCTIONS

Cut the tie wraps here

4. Cut the tie wraps, unplug control transform­er wires to allow for easier cable routing (on
a multi-voltage unit unplug voltage select
switch wires also).

5. Thread the cable through the hole as shown
and allow cable to hang loose. Add locknut
and partially tighten. Add heatshrink to ca­ble and leave loose, before applying clamp.

6. Assemble the cable clamp onto the exposed shield area and attach to the frame with the screw pro­vided. Orient clamp downward as shown.

Cable clamp

Cable clamp in postion

Heatshrink (leave loose)

7

MECHANIZED CONVERSION KIT INSTALLATION INSTRUCTIONS

7. Tighten the strain relief nut from the inside
rst and then tighten the outside strain re­lief nut. Position heatshrink over threads to
prevent power leads from contacting sharp
edges. Electrical or other suitable tape may be
used if heatshrink gun is not available.

Heatshrink or suitable tape

each wire is numbered

8. Add toroidal core to cable and leave loose, be­fore installing connector. Align the 10-pin con­nector with the pc board header to identify which
end of the connector is pin 1 and therefore en­sure proper connections of the 10 cables wires.

1

2

3

4

5

6

7

8

9

10

9. Install each wire and tighten. Cable wires are numbered 1 through 10 and must be connected in nu­merical sequence starting with number 1. The pc board has been stamped with numbers 1 and 10 to
show the direction of sequence for the wires.

8

MECHANIZED CONVERSION KIT INSTALLATION INSTRUCTIONS

10. Connect the pc board to the main power control board as shown below. Connect the ring terminal
from the 14 pin cable and secure the pc board to the frame with the screw provided.

11. Connect the fast-on connectors of the
"2-wire cable" to the 14 pin cable. Posi­tion and tie wrap toroidal core.

Toroidal Core

Fast-on connectors

12. Route the "2-wire cable" under the pc
board and tie wrap to the frame using
the provided holes in the areas shown.

Install tie wraps as shown by arrows

13. Re-install the plugs and tie wraps on the
previously unplugged wires.

9

MECHANIZED CONVERSION KIT INSTALLATION INSTRUCTIONS

14. Route the "2-wire cable" downward behind the shelf brace.

15. Locate the 3-pin connector on the existing main 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 wire to the "+" and black wire to the "-"
from the "2-wire cable" as shown and tighten.

red wire "+"

black wire "-"

10

17. Plug in the 3-pin connector on the pc board.

MECHANIZED CONVERSION KIT INSTALLATION INSTRUCTIONS

18. Secure the cable with tie wraps as shown
by arrows. DO NOT tie any wires with the
nearby twisted pair.

19. Plug 5-pin jumper into J11 header. This
can be done by either inserting the jump­er from above or by removing the driver
pc board. Removing 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. Install­ing this plug will change the Trigger Lock
switch on the front panel for mechanized
logic. Refer to the mechanized section of
the machine instruction manual.

5-pin jumper

J11 header

three long header pins

5-pin jumper

driver pc board

J11 header

mounting pillars

driver pc board

11

MECHANIZED CONVERSION KIT INSTALLATION INSTRUCTIONS

20. Voltage Divider Adjustment: The Voltage Divider or VDR can be adjusted to provide optimum cut
capability. More precise cuts can be tuned in by adjusting the potentiometer and making test cuts to
gauge accuracy.

• Place ohm meter leads between P44-1 & P44-3. Set R90 to 750 ohms. (This nominal setting usu­ally performed at pc board calibration).

• Additional minor adjustments of the potentiometer may be performed to achieve desired cut
quality.

Potentiometer

21. Trim all tie wraps and replace the unit's
cover.

12

MECHANIZED CONVERSION KIT INSTALLATION INSTRUCTIONS

Mechanized Conversion Kit Schematic

PC-1300/1600

13

NOTES

14

REVISION HISTORY

1. Ocial release 06/2008.

2. 10/2008 - Minor changes.

3. 11/2008 - Added toroidal core.

4. 12/2008 - minor change.

5. 04/2009 - Updated pictures and schematic.

6. 03/2011 - Updated mechanized conversion kit contents per J. Magee.

15

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS:
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C. TECHNICAL SERVICE:
Telephone: (800) ESAB-123/ Fax: [phone] Hours: 8:00 AM to 5:00 PM EST
Part Numbers Technical Applications Specications Equipment Recommendations

D. LITERATURE REQUESTS:
Telephone: [phone] / Fax: [phone] Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS:
Telephone: [phone] / Fax: [phone] Hours: 7:30 AM to 3:30 PM EST
Repair Estimates Repair Status

F. WELDING EQUIPMENT TRAINING
Telephone: [phone] / Fax: [phone] Hours: 7:30 AM to 4:00 PM EST
Training School Information and Registrations

G. WELDING PROCESS ASSISTANCE:
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H. TECHNICAL ASST. CONSUMABLES:

Telephone : [phone] Hours: 7:30 AM to 5:00 PM EST

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123

Fax: [phone]

Hours: 7:30 AM to 5:00 PM EST

or

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