ESAB PCM-875A Service manual

PCM-875
PLASMA CUTTING
CONSOLE/POWER SOURCES
with CE Compliances
230 V, 50 Hz, 3-Phase
400 V, 50 Hz, 3-Phase
Service Manual
558000-892
0202
WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD
BE BASED ON MANUFACTURERS’ HAZARD DATA.
ELECTRIC SHOCK - Can kill
l
Install and earth the welding unit in accordance with applicable standards.
l
Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
l
Insulate yourself from earth and the workpiece.
l
Ensure your working stance is safe.
FUMES AND GASES - Can be dangerous to health
l
Keep your head out of the fumes
l
Use ventilation, extraction at the arc, or both, to keep fumes and gases from your breathing zone
and the general area.
ARC RAYS - Can injure eyes and burn skin.
l
Protect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
l
Protect bystanders with suitable screens or curtains.
FIRE HAZARD
l
Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE - Excessive noise can damage hearing
l
Protect your ears. Use ear defenders or other hearing protection
l
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!
TABLE OF CONTENTS
SECTION 1
SECTION 2
SECTION 3
SECTION 4
SPECIFICATIONS ............................................................................................................ 3
MAINTENANCE ................................................................................................................ 4
General, Inspection and Cleaning, PT-27 Torch
Consumable Parts, Flow Switch, IGBT
Handling & Replacement
TROUBLESHOOTING ...................................................................................................... 6
Troubleshooting, Troubleshooting Guide,
Reference Voltage Checks, Sequence of
Operation, Schematic and Wiring Diagrams
REPLACEMENT PARTS ................................................................................................ 19
Maintenance and Repair work should be performed by an experienced person, and
electrical work only by a trained electrician. Do not permit untrained persons to
inspect, clean, or repair equipment. Use only recommended replacement parts.
For installation and operation instructions, see 558000-880 (F-15-418).
2
SECTION 1
SPECIFICATIONS
PCM-875 Specifications
Rated
60% Duty Cycle*
60 A @ 120 V dc
Output
100% Duty Cycle*
50 A @ 120 V dc
Output Current Range
10 to 60 Amperes
Open Circuit Voltage
275 V dc
Rated Primary Input
220 V ac, 50/60 Hz, 3-phase
24 A/phase
@ 7.2 kW Max. Output Power
400 V ac, 50/60 Hz, 3-phase
13 A/phase
60 A @ 120 Vdc
Power Factor @ 60 Amperes Output
90% (220 V, 3-phase)
92% (400 V, 3-phase)
Efficiency @ 60 Amperes Output
90% Typical
Current Capacity
PT-27
80 A DCSP
Air Requirements
PT-27
150 l/min @ 4.5 - 5.2 bar
Dimensions
Length
516 mm
Height
409 mm
w/handles
465 mm
Width
w/o opt. storage
275 mm
w/opt. torch storage
333 mm
Weight of PCM-875 System
39.5 kg
Shipping Weight
45.4 kg
* Duty cycle is based on a 10-minute period; therefore, a 60-percent duty cycle means the power source may operate for 6 minutes with a cool
down period of 4 minutes and a 100-percent duty cycle means the power source may operate continuously.
3
SECTION 2
MAINTENANCE
2.1 GENERAL
If this equipment does not operate properly, stop work
immediately and investigate the cause of the malfunction. Maintenance work must be performed by an experienced person, and electrical work by a trained electrician. Do not permit untrained persons to inspect,
clean, or repair this equipment. Use only recommended
replacement parts.
The PT-27 torch head contains a gas flow check
valve that acts in conjunction with the flow switch
and circuitry within the power source. This system prevents the torch from being energized with
high voltage if the torch switch is accidentally
closed when the shield is removed. Always replace
torch with the proper torch manufactured by ESAB
since it alone contains ESAB¹s patented safety interlock.
Be sure that the wall disconnect switch or wall circuit breaker is open before attempting any inspection or work inside of the PCM-875.
To assemble the consumable parts, refer to Figure 2-1.
A. Place nozzle, swirl baffle and electrode into the
shield as shown.
B. Thread assembly to the torch body and hand tighten.
Always make sure the shield is very tight before
cutting.
2.2 INSPECTION AND CLEANING
Frequent inspection and cleaning of the PCM-875 is
recommended for safety and proper operation. Some
suggestions for inspecting and cleaning are as follows:
A. Check work cable for secured connection to
workpiece.
B. Check safety earth ground at workpiece and at
power source chassis.
C. Check heat shield on torch. It should be replaced
if damaged.
D. Check the torch electrode and cutting nozzle for
wear on a daily basis. Remove spatter or replace
if necessary.
E. Make sure cable and hoses are not damaged or
kinked.
F. Make sure all plugs, fittings, and ground connections are tight.
G. With all input power disconnected, and wearing
proper eye and face protection, blow out the inside of the PCM-875 using low-pressure dry compressed air.
ELECTRODE
SWIRL BAFFLE
NOZZLE
SHIELD
Water or oil occasionally accumulates in compressed air lines. Be sure to direct the first blast
of air away from the equipment to avoid damage
to the PCM-875.
H. Occasionally, bleed all water from the filter beneath
the air filter-regulator.
IMPORTANT!
MAKE SHIELD VERY TIGHT!
2.3 PT-27 TORCH CONSUMABLE PARTS
Figure 2-1. Assembly of PT-27 Torch Front End Parts
Make sure power switch on PCM-875 is in OFF position before working on the torch.
4
SECTION 2
MAINTENANCE
2.4 FLOW SWITCH (FIGURE 2-2)
•
When excessive contamination is found in the air, the
flow switch (FS-4) should be disassembled and cleaned
as follows:
•
A. Ensure the system is shut down and there is no
trapped air under pressure in the piping.
B. Remove the piston plug.
C. Remove the spring. Use care when handling spring
to prevent distortion.
D. Remove the piston.
E. Clean all parts with cleaning agent.
•
•
Use grounded work station with grounded floors
and grounded wrist straps when handling devices.
Use a 100W resistor in series with the gate when
performing curve tracer tests.
Never install devices into systems with power connected to the system.
Use soldering irons with grounded tips when soldering to gate terminals.
When mounting IGBT modules on a heatsink, certain
precautions should be taken to prevent any damage
against a sudden torque. If a sudden torque (“one-sided
tightening”) is applied at only one mounting terminal
the ceramic insulation plate or silicon chip inside the
module may get damaged.
NOTE
Ensure cleaning agent does not contain solvents
which can degrade polysulfone. Warm water and
detergent is recommended for cleaning. Allow all
parts to dry thoroughly before reassembly.
The mounting screws are to be fastened in the order
shown in Figure 2-3. Also, care must be taken to
achieve maximum contact (i.e. minimum contact thermal resistance) for the best heat dissipation.
Reassemble the flow switch in reverse order.
Application of a thermal pad on the contact surface
improves its thermal conductivity. See Replacement
Parts section for the required pad.
PISTON PLUG
A torque wrench should be used. Tighten mounting
screws to 32 kg-cm; wire connecting screws to 22 kgcm. If torque is too heavy, the device can damage like
the above “one-sided tightening”.
SPRING
PISTON
FLOW SWITCH
Two-Point Mounting Type
Temporary tightening  è‚
Final tightening  ‚è

‚
Figure 2-2. Disassembly / Assembly of Flow Switch
2.5 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 emmiter sense
pins.

Four-Point Mounting Type
Temporary tightening  è‚èƒè„
Final tightening  „èƒè‚è
ƒ
„
‚
Always ground parts touching gate pins during installation. In general, standard ESD precautlions application to FETs should be followed.
Other handling precautions that should also be observed are as follows:
Figure 2-3. Screw Fastening Order
5
SECTION 3
TROUBLESHOOTING
3.1Troubleshooting
The cause of control malfunctions can be found by
referring to the sequence of operations and electrical
schematic diagram (Figure 3-1 or 3-3) and checking
the various components. A volt-ohmmeter will be necessary for some of these checks.
ELECTRIC SHOCK CAN KILL! Be sure that all
primary power to the machine has been externally
disconnected. Open the line (wall) disconnect switch
or circuit breaker before attempting inspection or
work inside of the power source.
Voltages in plasma cutting equipment are high
enough to cause serious injury or possibly death.
Be particularly careful around equipment when the
covers are removed.
Check the problem against the symptoms in the
following troubleshooting guide. The remedy may be
quite simple. If the cause cannot be quickly located,
shut off the input power, open up the unit, and perform a
simple visual inspection of all the components and wiring. Check for secure terminal connections, loose or
burned wiring or components, bulged or leaking capacitors, or any other sign of damage or discoloration.
NOTE
Before checking voltages in the circuit, disconnect the
power from the high frequency generator to avoid damaging your voltmeter.
3.2TROUBLESHOOTING GUIDE
A. Power Light (PL1) does not come on.
1. Visually inspect the machine for any damage.
2. Check if the cooling fan is running. If not, then check the following :
a. Check if the machine power cord is plugged to the input power receptacle.
b. Measure the input power at the receptacle. If not present, then check the wall
disconnect switch and it’s fuses.
c.
Check Fuse (F1). If fuse is ok, then check the input circuit breaker (CB1) for proper operation. Replace
if defective.
3. If above items check OK , the problem is internal. Send unit to an Authorized Repair Station for repair.
a. If the cooling fan is running, then measure voltage between pins P2-11 and P2-14 of the control
board (should be 115 VAC). If there is no voltage, then replace transformer T2.
b. If the voltage is present, then the pilot light may be defective.
B. No Air Flow
A. Check air inlet supply. Unit requires 150 l/min at 4.5 bars.
B. Check air hose and connections. Tighten if leaking.
C. Does air flow when “air test” switch is in test position?
a. If not, check torch consumables, replace if necessary.
b. If above items check OK , the problem is internal. Take unit to an Authorized Repair Station for repair.
6
SECTION 3
TROUBLESHOOTING
C. The Power light is on, but nothing happens when the torch switch is depressed. Fault light
does not activate.
NOTE: Unplug high frequency connection before attempting to work on this problem.
1. Check the Pilot Arc fuse (F2) located on the rear panel. An open fuse will indicate a short in the torch. If the fuse
is all right, then check the following:
a. With the machine power on, depress the torch switch. On the control board the LED 1 should be lit as long as
the switch is depressed. If not then check:
i.
Turn power off to the machine. Unplug Control board. Put an ohmmeter across P5-1 and P5-2 to take
resistance reading. Depress torch switch. Meter should read a short. If not, then one of the following is
not working properly:
ii.
Torch switch or the leads. Unplug the torch switch leads at the machine. Put a meter across the two plug
pins. Should read a short when the torch switch is depressed. If not, then either broken switch leads or
defective switch.
b. Check T2 transformer secondary voltages at the plugs P1 and P2. Refer to system schematic. Replace the
transformer if the correct secondary voltages are not present.
c.
If everything above checks out all right, then the PCB1 Control Board should be replaced.
D. Fault light activates when torch switch is closed.
The Fault circuit is used to monitor conditions necessary for the safe operation of the PCM-875. The fault light
will glow amber under the following conditions and operations will come to a complete stop:
1. High/Low line voltage. The Fault Light will rapidly blink on and off (5 times per second). This indicates that
the input voltage is outside the “+” or “-” 15% safe operating range rating.
2. Flow fault - The fault light will be mostly on but will blink off for 1/10th of a second every second. This indicates
that the air flow is low.
a. Check the air pressure at the machine regulator. It should be adjusted to 65 psig. If no air pressure, check the
air at the supply point. Also, check for any obstructions in the air hose.
b. Air flow may be blocked at the torch tip. Check the torch consumables. Also check for any obstructions in the
torch leads.
NOTE: If above items check OK , the problem is internal. send unit to an Authorized Repair Station for repair.
c.. Put the ‘Air Check’ switch to On position. Air should flow through torch. If not, then the flow switch may be
stuck due to oil in the air. Clean air flow switch per supplier’s instructions or replace switch. To check if the
flow switch is open, put voltmeter leads between P1-12 and P1-1. It should read about 12 VDC. When the
flow switch closes, the voltage will drop to zero volts.
d. Air Check switch may also be defective if the air is flowing continuously or putting in the On position does
not turn air on.
3. Over Temperature. The fault light will be mostly off but will blink on for 1/10 of a second, every second. This
generally indicates that the duty cycle has been exceeded. Allow the power source to cool before returning to
operate.
a. Thermal switch may be open. It will open if the temperature at the IGBT base reaches 94oC. With the
machine power off, check the continuity between P1-1 and P1-2 of the control board. If the switch is OK, then
7
SECTION 3
TROUBLESHOOTING
the ohmmeter should read a direct short. If not then it should read open.
b. If the switch is defective, replace it. Clean the surface of the heat sink before installing the switch.
4. Over Current. The fault light will be on continuously. This indicates that the input current to the main transformer has exceeded preset limits.
a. To check if the output is shorted, measure the resistance by putting the ohmmeter leads (make sure to
disconnect HI Frequency leads):”+” of the meter to Torch “+” output terminal and Work “-” lead of the meter
to the “-” output terminal. Reading should be about 2 K Ohms. Reverse the voltmeter leads, the resistance
reading should be less than 1.5 K Ohms.
b. If the resistance reading is different than above, check the torch, the output bridge and Filter Board (PCB-5).
E. Air is On but nothing happens when torch switch is operated.
1. Check the pilot arc fuse located on the rear panel. If it is open, nothing will happen when the torch switch is
depressed.
2. Check the torch. Make sure the heat shield is tight. PT27 torch has a built in safety circuit in which the torch will
not fire if heat shield is tightly secured.
3. Check to assure high frequency is present at the torch. If not, then listen for high frequency at the high frequency
generator. It is located on the bottom/right side of the unit. The high frequency gap is set between 0.71 to 0.78mm
Disconnect HI FREQUENCY leads. Check for 115 volt supply to the high frequency unit between P2-12 & P213 of the control board with torch switch closed.
4. With HI FREQUENCY leads disconnected, measure open circuit voltage. It should be 275 VDC between “Work”
and “Torch” terminals. If it is not present then any one of the following may not be working properly:
a. Check the operation of the Thermal Switch. See D.3.a. above.
b. Check Air Check switch operation. It might be stuck in On position. Pilot arc will not initiate if this switch is on
the ON position. (safety reasons)
c.
Check air flow switch. There may be internal short. See D.2.c above.
d. Measure voltage across C1 or C2 capacitor. It should be as follows:
approx. 325 VDC for the 220 volt unit.
approx. 280 VDC to 325 VDC for the 400 volt unit
If not, one of following could be defective:
1). Check the capacitors C1 and C2 for any damage.
2.) Check input bridge/SCR Module (IBR) This can be checked without taking it out of the circuit using
an volt/ohmeter. Replace it if found defective. Follow bridge installation instructions.
3.) Check Inrush current resistor, R10 and SCR1. Both are located on the input bridge heat sink. Replace it if defective.
e. IGBTs (2 on 220 V, and 1 on the 400 V units) may be blown. See IGBT installation procedure. Before replacing IGBTs, make sure to check the zener diodes and pico fuses on the IGBT driver boards.
8
SECTION 3
TROUBLESHOOTING
F. High Frequency and Pilot Arc are on but Main Arc does not transfer.
1. Make sure work clamp is connected to work material.
2. Check the torch. Replace consumables if necessary.
3. Make sure the current setting potentiometer is set above 10 amps. If it is, set below 10 amps, then HI FREQUENCY will go on and off at 5 sec intervals.
G. Poor Cutting Performance.
1. Check air supply regulator . It should be adjusted to 4.5-5.2 bar.
2. The air supplied to the torch should be free of oil and water.
3. Make sure the consumables in the torch are acceptable.
4. Check open circuit voltage. See E.4 above.
5. Check the output. Use a calibrated current probe capable of measuring 100 amps in the presence of high
frequency.
H. Air does not shut off.
1. Check air test, the gas solenoid valve is energized when the switch is in the “on” position.
2. Does air flow stop when the torch switch is unplugged? If yes, check and repair the torch. If not, send unit to an
Authorized Repair Station for repair.
a. Check voltage to solenoid coil, if present when torch switch is unplugged, replace PCB1. If voltage is “0”,
replace solenoid valve.
I.
Main arc is difficult to start.
1.
2.
3.
4.
5.
The most common reason is worn or missing consumables. Check and replace if necessary.
Input air must be clean and dry.
Input air pressure must be between 4.5 and 5.2 bar.
Torch connections must be tight.
Work cable and clamp must be in good condition and must make a good electrical connection to the material to
be cut.
6. If above items check OK , the problem is internal. send unit to an Authorized Repair Station for repair.
a. Missing or weak pilot arc. Check pilot arc fuse, open circuit voltage, pilot arc resistors and pilot arc wiring.
b. Inoperative starter board (PCB-5).
9
SECTION 3
TROUBLESHOOTING
3.3REFERENCE VOLTAGE CHECKS
A. Control Board Assembly (PCB1)
1.
LED’s
LED-1
LED-2
LED-3
2.
-
Torch Switch
High Frequency
Gas Solenoid Valve
Voltage Test Points
Tests are made with power on - no arc.
Disable High Frequency by disconnecting blue wire with black sleeve
TP-0
TP-1
TP-2
TP-3
TP-4
TP-9
TP-10
-
Ground
+15 vdc
+12 vdc
-12 vdc
+5 vdc
IGBT’s driving signal - switching frequency = 20 KHz
IGBT’s driving signal - switching frequency = 20 KHz
50 µsec
13 vdc
0
13 vdc
For 220 VAC input, the IGBT off time is 3µsec.
For 400 VAC input, the IGBT off time is 6µsec.
Figure 3.1 IGBT Gating Signal
10
SECTION 3
TROUBLESHOOTING
3.4 SEQUENCE OF OPERATION
A. TRIGGER LOCK “UNLOCK” position
TORCH SWITCH
PUSH
RELEASE
OPEN
CLOSE
GAS SOLENOID VALVE
2 SEC.
PREFLOW
10 SEC
Postflow
FLOW SWITCH
CLOSE
OPEN
FAULT OVERLOAD LIGHT
ENERGIZE
HF CIRCUIT
INVERTER
CUTTING ARC (CURRENT)
NOTES:
1. When the torch switch is pushed during postflow period, the postflow and preflow times are
canceled, and the HF is energized immediately.
2. When the amber fault light comes on, cutting operation should be stopped. The postflow
time starts from the moment the torch switch is released.
11
SECTION 3
TROUBLESHOOTING
B. TRIGGER LOCK "LOCK" position
PUSH
RELEASE
PUSH
RELEASE
TORCH SWITCH
OPEN
CLOSE
GAS SOLENOID VALVE
2 SEC.
PREFLOW
10 SEC
Postflow
POSTFLOW
CLOSE
OPEN
FLOW SWITCH
FAULT LIGHT
ENERGIZE
HF CIRCUIT
INVERTER
CUTTING ARC (CURRENT)
NOTES:
1. When the torch switch is pushed during postflow period, the postflow and preflow times are
canceled, and the HF is energized immediately.
2. When the red fault light comes on, cutting operation should be stopped. The postflow time
starts from the moment the torch switch is released.
3. FAULT light is on during second "turn-off" trigger only. This does not affect performance in
any way.
12
13
D-36918
Figure 3.1 - Schematic Diagram, PCM-875, 230 V, 50/60 Hz, 3-Phase
14
D-36917
Figure 3.2 - Wiring Diagram (Sheet 1 of 2), PCM-875, 230 V, 50/60 Hz, 3-Phase
15
D-36917
Figure 3.2 Wiring Diagram (Sheet 2 of 2), PCM-875, 220 V, 50/60 Hz, 3-Phase
16
D-36604
Figure 3.3 - Schematic Diagram, PCM-875, 400 V, 50/60 Hz, 3-Phase
17
D-36605
Figure 3.4 Wiring Diagram (Sheet 1 of 2), PCM-875, 400 V, 50/60 Hz, 3-Phase
18
D-36605
Figure 3.4 - Wiring Diagram (Sheet 2 of 2), PCM-875, 400 V, 50/60 Hz, 3-Phase
SECTION 4
REPLACEMENT PARTS
3, 4
5, 4
6
1, 2
7
8, 9
16
15
8
10, 11
14
12
13
Fig. 4-1. PCM-875 Power Source, Front View
Item
No.
Qty.
Req.
Part
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
1
1
2
1
1
1
2
1
1
1
4
1
1
1
2
558000373
558000372
558000698
558000596
558000385
558000383
558000384
558000593
558000594
558000178
558000608
558000552
558000630
558000631
558000599
558000598
Circuit
Symbol
Description
KNOB
POT. 10K 2W (NOMEX INSUL. - 676876)
SWITCH TOGGLE SPST 2 POS 15 A 125 V
SWITCH SEAL BLACK
SWITCH TOGGLE DPDT 2 POS 15 A 125 V
LAMP LED YEL 12 V
LAMP NEON WHITE
GROMMET RUBBER 1.50 ID x 1.76 OD
GAUGE 1.50 160 PSI WHITE
STRAIN RELIEF HEYCO #1214
WORK CABLE 25 FT. (Not Shown)
FOOT RUBBER
CHASSIS PCM-875
DOOR ACCESS YEL (ESAB)
LABEL WARNING HI VOLTAGE
LABEL ESAB
19
R2
S2
S1
PL2
PL1
SECTION 4
REPLACEMENT PARTS
28
27
25, 26
25, 26
24
29, 30
31
23
32, 33, 34
22
21
35
36
37
38
46
39
40 41
42
43
44, 45
Fig. 4-2. PCM-875 Power Source, Left Side View (230 V)
Item
No.
Qty.
Req.
Part
No.
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
1
1
1
1
2
2
2
1
1
1
1
1
1
3
2
2
1
1
1
4
1
2
1
1
1
1
558000626
558000634
558000635
558000636
558000637
558000638
558000639
558000640
558000641
558000642
558000600
558000643
558000622
558000689
558000450
558000400
558000408
558000644
558000412
558000404
558000410
558000532
558000645
558000409
558000625
558000826
Circuit
Symbol
Description
BRIDGE 60ADC 100NS 600 V (PAD - 558000527)
CORE SATURABLE
STANDOFF INS.
BUSBAR NEG
CAPACITOR 1800 µf 450VDC
GROMMET STRIP
PCB ASS'Y 1GBT DRIVER BOARD
HOSE AY B/A-2X 1/4NPT RUB 2 FT
BUSBAR POS
CAPACITOR 1µf 630VDC (Not shown - see wiring)
TERM BLOCK 2 POS
MODULE INPUT BRIDGE/SCR (PAD - 558000651)
CAPACITOR .22µf 1KV (See wiring)
METAL OXIDE VARISTOR 275 V (See wiring)
IGBT 600 V 100 A (PAD - 558000539)
RESISTOR 50 W 10 OHM (PAD - 558000529)
CURRENT TRANSFORMER ASS'Y
CAPACITOR 40 µf 400 VDC
THERMAL SWITCH 194°F
RESISTOR 24 W 20 OHMS (PAD 558000528)
FLOW SWITCH .25 GPM
CAPACITOR 1µf 630W VDC
HEATSINK
SOL. VALVE 1/4NPT 165 PSI 24 VAC
DIODE ZENER 60 V 75 MA (See Wiring)
FILTER EMI (230 V CE)
20
D1
L3
TB3
C1, 2
PCB2, 3
C3
TB5
IBR
C19
MOV1, 2, 3
Q1, 2
R7, 10
T4
C4
TS1
R3, 4, 5, 6
FS
C15, 16
SOL1
ZD1
FN1
SECTION 4
REPLACEMENT PARTS
61
60
59
56, 57, 58
56, 57, 58
62
55
64, 65, 66
54
53
52
51
67
68
69
70
71
72
73
74
75, 76
Fig. 4-3. PCM-875 Power Source, Left Side View (400 V)
Item
No.
Qty.
Req.
Part
No.
51
52
53
54
55
56
57
58
59
60
61
62
64
65
66
67
68
69
70
71
72
73
74
75
76
1
1
1
1
1
2
2
2
1
1
1
1
1
1
3
2
1
1
1
1
4
1
1
1
1
558000626
558000634
558000646
558000635
558000647
558000637
558000638
558000642
558000619
558000649
558000640
558000650
558000643
558000622
558000629
558000400
558000408
558000644
558000654
558000412
558000404
558000410
558000645
558000409
558000625
Circuit
Symbol
Description
BRIDGE 60 ADC 100NS 600 V (PAD - 558000527)
CORE SATURABLE
MODULE DUAL IGBT 150 A, 1200 V (PAD - 558000526)
STANDOFF INS
BUSBAR POS
CAPACITOR 1800µf 450 VDC
GROMMET STRIP
CAPACITOR 1µf 630 VDC (See wiring)
PCB ASS'Y IGBT DRIVER BOARD
CAPACITOR 2µf 800 VDC
HOSE ASS'Y B/A x 1/4 NPT RUB
BUSBAR NEG
MODULE INPUT BRIDGE/SCR (PAD - 558000651)
CAPACITOR .22µf 1KV
METAL OXIDE VARISTOR 510 V
RESISTOR 50W 10 OHM (PAD - 558000529)
CURRENT TRANSFORMER ASS'Y
CAPACITOR 40µf 400 VDC
FILTER EMI (400 V CE)
THERMAL SWITCH 194°F
RESISTOR 25W 20 OHMS (PAD - 558000528)
FLOWSWITCH .25 GPM
HEATSINK
SOL, VALVE 1/4 NPT 165 PSI 24 VAC
DIODE ZENER 60 V 75m A
21
D1
L3
Q1
TB3
C1, 2
C3, 15
PCB2
C16
IBR
C19
MOV1, 2, 3
R7, 10
T4
C4
FN1
TS1
R3, 4, 5, 6
FS
SOL1
ZD1
SECTION 4
REPLACEMENT PARTS
90, 91
89
88
86
87
85
82, 83, 84
92
81
93
80
94
95
101, 102, 103
96
97
104
98, 99
100
Fig. 4-4. PCM-875 Power Source, Right Side View (230 V)
Item
No.
Qty.
Req.
Part
No.
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
1
1
1
2
2
1
1
1
1
2
1
1
1
1
1
1
1
1
1
2
1
1
2
1
1
558000604
558000655
558000656
558000657
558000658
558000563
558000659
558000660
558000661
558000585
558000396
558000521
558000498
558000662
558000663
558000380
558000664
558000403
558000610
558000611
558000467
558000600
558000602
558000665
558000666
Circuit
Symbol
Description
CONTROL TRANSFORMER ASS'Y
RESISTOR ASS'Y PILOT ARC
RELAY 25 A 120 VAC
CAPACITOR .82µf 630 VDC (See Wiring)
RESISTOR, 10K OHM 1W (See Wiring)
LABEL WARNING HI VOLTAGE RED
INDUCTOR PFC
CONTROL BOARD ASS'Y
MAIN TRANSFORMER ASS'Y
CAPACITOR .022µf 250 VAC (See Wiring)
SHUNT BOARD ASS'Y
CAPACITOR .047µf 660 VAC
START UP BOARD ASS'Y
INDUCTOR OUTPUT
BUSBAR OUTPUT
LOCK TWIST MIDGET
BRACKET OUTPUT
REACTOR ASS'Y HI FREQ.
SPARK GAP ASS'Y
CAPACITOR 2500pf 15 K V
TRANSFORMER HI VOLTAGE
TERM. BLOCK 2 POS 20 A
CAPACITOR .01µf 1KV (See wiring)
CAPACITOR .01µf 250 VAC (See wiring)
BOX HI FREQ.
22
T2
R11
K1
C21, 22
R12, 13
L2
PCB1
PCB4
C17, 18
PCB4
C23
PCB5
L1
J1
T3
SG
C13, 14
T5
TB1
C11, 12
C9
SECTION 4
REPLACEMENT PARTS
119, 120
117
118
115
116
112, 113, 114
121
111
122
123
110
124
125
126
134
127, 128
129
133
130, 131, 132
Fig. 4-5. PCM-875 Power Source, Right Side View (400 V)
Item
No.
Qty.
Req.
Part
No.
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
1
1
1
2
2
1
1
1
2
1
1
1
1
1
1
1
1
1
2
1
1
2
1
1
1
558000391
558000655
558000656
558000657
558000658
558000563
558000667
558000661
558000585
558000396
558000521
558000498
558000662
558000663
558000380
558000664
558000403
558000610
558000611
558000467
558000600
558000602
558000665
558000669
558000666
Circuit
Symbol
Description
CONTROL TRANSFORMER ASS'Y
RESISTOR ASS'Y PILOT ARC
RELAY 25 A 120 VAC
CAPACITOR .82µf 630 VDC (See wiring)
RESISTOR 10 K OHM 1 W (See wiring)
LABEL WARNING HI VOLTAGE RED
CONTROL BOARD ASS'Y
MAIN TRANSFORMER ASS'Y
CAPACITOR .022µf 250 VAC (See wiring)
SHUNT BOARD ASS'Y
CAPACITOR .047µf 660 VAC
START UP BOARD ASS'Y
INDUCTOR OUTPUT
BUSBAR OUTPUT
LOCK TWIST MIDJET
BRACKET OUTPUT KYDEX
REACTOR ASS'Y HI FREQ.
SPARK GAP ASS'Y
CAPACITOR 2500pf 15 K V
TRANSFORMER HI VOLTAGE
TERM. BLOCK 2 POS 20 A
CAPACITOR .01µf 1KV (See wiring)
CAPACITOR .01µf 250 VAC (See wiring)
REACTOR 3PH LINE 12 A
BOX HI FREQ
23
T2
R11
K1
C21, 22
R12, 13
PCB1
T1
C17, 18
PCB4
C23
PCB5
L1
J1
T3
SG
C13, 14
T5
TB1
C11, 12
C9
L2
SECTION 4
REPLACEMENT PARTS
142
143
141
144
145
140
Fig. 4-6. PCM-875 Power Source, Top View with PCB1 and Shelf Removed
Item
No.
Qty.
Req.
Part
No.
140
141
142
143
144
145
1
1
2
1
1
1
1
558000670
558000671
558000658
558000388
558000672
558000673
558000674
Circuit
Symbol
Description
LABEL CNC INTERFACE
TERM. BLOCK 7 POS 25 A
RESISTOR 10 K 25 W
FAN AC AXIAL
LABEL GROUND BLACK
LABEL INPUT (208/230 V)
LABEL INPUT (400 V)
24
TB4
R2, 15
M1
SECTION 4
REPLACEMENT PARTS
154, 155, 156
153
151, 152
157
158, 159
158, 163
160, 161
162
Fig. 6-7. PCM-875 Power Source, Rear View
Item
No.
Qty.
Req.
Part
No.
151
152
153
154
155
156
157
1
1
2
1
1
1
1
1
2
1
1
1
1
1
1
558000675
558000534
558000592
558000676
558000536
558000562
558000957
558000681
558000516
558000517
558000682
558000458
558000459
558000474
558000686
158
159
160
161
162
163
Circuit
Symbol
Description
FILTER REGULATOR
ADAPTOR B/A-WM x 1/4 NPTM
HANDLE
TOP COVER
LABEL WARNING
LABEL WARNING
LABEL RATING PCM-875 220 3PH. V
LABEL RATING PCM-875 400 3PH. V
FUSE HOLDER
FUSE 15 A FAST ACTING
STRAIN RELIEF
INPUT POWER CABLE, 10 FT 4-COND. 6AWG (230 V)
INPUT POWER CABLE, 10 FT 4-COND. 4 x 4 MM (400 V CE)
CIRCUIT BREAKER 3P 30 A 480 VAC (400 V)
FUSE 3A FAST ACTING
25
F2
CB1
F1
26
27
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES
A. CUSTOMER SERVICE QUESTIONS:
Order Entry
Product Availability
Order Changes
Saleable Goods Returns
Pricing
Delivery
Shipping Information
Eastern Distribution Center
Telephone: (800)362-7080 / Fax: (800) 634-7548
Central Distribution Center
Telephone: (800)783-5360 / Fax: (800) 783-5362
Western Distribution Center
Telephone: (800) 235-4012/ Fax: (888) 586-4670
B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693
Welding Equipment Troubleshooting
Hours: 7:30 AM to 5:00 PM EST
Warranty Returns
Authorized Repair Stations
C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452
Part Numbers
Technical Applications
Hours: 8:00 AM to 5:00 PM EST
Performance Features Technical Specifications
Equipment Recommendations
D. LITERATURE 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
Repair Estimates
Repair Status
Hours: 7:30 AM to 3:30 PM EST
F. WELDING EQUIPMENT TRAINING:
Telephone: (843)664-4428 / Fax: (843) 679-5864
Training School Information and Registrations
Hours: 7:30 AM to 4:00 PM EST
G. WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-123
Hours: 7:30 AM to 4:00 PM EST
H. TECHNICAL ASST. CONSUMABLES:
Telephone : (800) 933-7070
Hours: 7:30 AM to 5:00 PM EST
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123/ Fax: (843) 664-4452/ Web:http://www.esab.com
Hours: 7:30 AM to 5:00 PM EST
F-15-424-A
2/02
Printed in U.S.A.