ESAB PCM-875A Instruction manual

F15-335-E
July, 2007
INSTRUCTION MANUAL
PCM-875
PLASMA ARC CUTTING PACKAGE
This manual provides installation and operation instructions for the following PCM-875 cutting packages starting with Serial No.
PHJ205001:
P/N 36590 - 208/230 V, 1 & 3-Phase, 50/60 Hz
P/N 36592 - 460 V, 3-Phase, 50/60 Hz
P/N 36714 - 575 V, 3-Phase, 60 Hz
P/N 36725 - 400 V, 3-Phase, 50/60 Hz
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.
Be sure this information reaches the operator.
You can get extra copies through your supplier.
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 be­
fore installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompa­
nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc­
tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment
should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme­
diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone
or written request for service advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a ser­
vice facility designated by the manufacturer.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
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 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.
TABLE OF CONTENTS
SECTION
PARAGRAPH
TITLE
PAGE
SECTION 1
1.1
1.2
1.3
1.4
DESCRIPTION .................................................................................................
General .............................................................................................................
Scope ................................................................................................................
Packages Available ...........................................................................................
Specifications ....................................................................................................
7
7
7
7
8
SECTION 2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
INSTALLATION ................................................................................................
General .............................................................................................................
Equipment Required .........................................................................................
Location ............................................................................................................
Inspection ..........................................................................................................
Primary Electrical Input Connections ................................................................
Secondary Output Connections ........................................................................
Connecting PCM-875 for 200(208)Vac Input ....................................................
Mechanized Cutting Installation with the PT-20AM Torch .................................
10
10
10
10
10
10
11
13
14
SECTION 3
3.1
3.2
3.3
3.4
OPERATION.....................................................................................................
Operation ..........................................................................................................
PCM-875 Controls ............................................................................................
Cutting with the PT-27 .......................................................................................
Common Cutting Problems ...............................................................................
16
16
16
16
18
SECTION 4
4.1
4.2
4.3
4.4
4.5
MAINTENANCE ............................................................................................... 19
General ............................................................................................................. 19
Inspection and Cleaning .................................................................................... 19
PT-27 Torch Consumable Parts ........................................................................ 19
Flow Switch ....................................................................................................... 20
IGBT Handling and Replacement ...................................................................... 20
SECTION 5
5.1
5.2
5.3
5.4
TROUBLESHOOTING ..................................................................................... 21
Troubleshooting ................................................................................................ 21
Troubleshooting Guide ...................................................................................... 21
Reference Voltage Checks ............................................................................... 25
Sequence of Operation ..................................................................................... 26
SECTION 6
6.1
6.2
REPLACEMENT PARTS .................................................................................
General .............................................................................................................
Ordering ............................................................................................................
2
37
37
37
SAFETY PRECAUTIONS
WARNING: These Safety Precautions are for
your protection. They summarize precautionary information from the references listed in
Additional Safety Information section. Before
performing any installation or operating procedures, be
sure to read and follow the safety precautions listed below
as well as all other manuals, material safety data sheets,
labels, etc. Failure to observe Safety Precautions can result
in injury or death.
5. Do not use equipment beyond its ratings. For example,
overloaded welding cable can overheat and create a fire
hazard.
6. After completing operations, inspect the work area to
make certain there are no hot sparks or hot metal which
could cause a later fire. Use fire watchers when necessary.
7. For additional information, refer to NFPA Standard 51B,
"Fire Prevention in Use of Cutting and Welding Processes", available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
PROTECT YOURSELF AND OTHERS -Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation and
can injure skin and eyes. Hot metal can cause burns.
Training in the proper use of the processes and equipment is essential to prevent accidents. Therefore:
ELECTRICAL SHOCK -- Contact with live
electrical parts and ground can cause
severe injury or death. DO NOT use AC
welding current in damp areas, if movement is confined, or if there is danger of
falling.
1. Always wear safety glasses with side shields in any work
area, even if welding helmets, face shields, and goggles
are also required.
2. Use a face shield fitted with the correct filter and cover
plates to protect your eyes, face, neck, and ears from
sparks and rays of the arc when operating or observing
operations. Warn bystanders not to watch the arc and
not to expose themselves to the rays of the electric-arc
or hot metal.
3. Wear flameproof gauntlet type gloves, heavy long-sleeve
shirt, cuffless trousers, high-topped shoes, and a welding helmet or cap for hair protection, to protect against
arc rays and hot sparks or hot metal. A flameproof apron
may also be desirable as protection against radiated
heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cuffs, or pockets. Sleeves and collars should be
kept buttoned, and open pockets eliminated from the
front of clothing
5. Protect other personnel from arc rays and hot sparks
with a suitable non-flammable partition or curtains.
6. Use goggles over safety glasses when chipping slag or
grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety glasses.
1. Be sure the power source frame (chassis) is connected
to the ground system of the input power.
2. Connect the workpiece to a good electrical ground.
3. Connect the work cable to the workpiece. A poor or
missing connection can expose you or others to a fatal
shock.
4. Use well-maintained equipment. Replace worn or damaged cables.
5. Keep everything dry, including clothing, work area,
cables, torch/electrode holder, and power source.
6. Make sure that all parts of your body are insulated from
work and from ground.
7. Do not stand directly on metal or the earth while working
in tight quarters or a damp area; stand on dry boards or
an insulating platform and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)
for specific grounding recommendations. Do not mistake the work lead for a ground cable.
ELECTRIC AND MAGNETIC FIELDS —
May be dangerous. Electric current flowing through any conductor causes localized Electric and Magnetic Fields
(EMF). Welding and cutting current creates EMF around welding cables and
welding machines. Therefore:
FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot slag
or sparks can also cause fires and explosions. Therefore:
1. Remove all combustible materials well away from the
work area or cover the materials with a protective nonflammable covering. Combustible materials include wood,
cloth, sawdust, liquid and gas fuels, solvents, paints and
coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or
crevices in floors or wall openings and cause a hidden
smoldering fire or fires on the floor below. Make certain
that such openings are protected from hot sparks and
metal.“
3. Do not weld, cut or perform other hot work until the
workpiece has been completely cleaned so that there
are no substances on the workpiece which might produce flammable or toxic vapors. Do not do hot work on
closed containers. They may explode.
4. Have fire extinguishing equipment handy for instant use,
such as a garden hose, water pail, sand bucket, or
portable fire extinguisher. Be sure you are trained in its
use.
1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.
2. Exposure to EMF may have other health effects which are
unknown.
3. Welders should use the following procedures to minimize
exposure to EMF:
A. Route the electrode and work cables together. Secure
them with tape when possible.
B. Never coil the torch or work cable around your body.
C. Do not place your body between the torch and work
cables. Route cables on the same side of your body.
D. Connect the work cable to the workpiece as close as
possible to the area being welded.
E. Keep welding power source and cables as far away
from your body as possible.
3
11/95
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shielding gases can cause asphyxiation.
Therefore:
2.
3.
1. Always provide adequate ventilation in the work area by
natural or mechanical means. Do not weld, cut, or gouge
on materials such as galvanized steel, stainless steel,
copper, zinc, lead, beryllium, or cadmium unless positive mechanical ventilation is provided. Do not breathe
fumes from these materials.
2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly toxic
gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat irritation
while operating, this is an indication that ventilation is not
adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not continue to
operate if physical discomfort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specific ventilation recommendations.
4.
5.
6.
perform any electrical work unless you are qualified to
perform such work.
Before performing any maintenance work inside a power
source, disconnect the power source from the incoming
electrical power.
Maintain cables, grounding wire, connections, power cord,
and power supply in safe working order. Do not operate
any equipment in faulty condition.
Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces, wet
conditions such as water puddles, oil or grease, corrosive
atmospheres and inclement weather.
Keep all safety devices and cabinet covers in position and
in good repair.
Use equipment only for its intended purpose. Do not
modify it in any manner.
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for electric arc welding and cutting equipment, ask
your supplier for a copy of "Precautions and
Safe Practices for Arc Welding, Cutting and
Gouging", Form 52-529.
The following publications, which are available from the
American Welding Society, 550 N.W. LeJuene Road, Miami,
FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. 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 - "Safe Practices" - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, "Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous
Substances."
CYLINDER HANDLING -- Cylinders, if
mishandled, can rupture and violently
release gas. Sudden rupture of cylinder, valve, or relief device can injure or
kill. Therefore:
1. Use the proper gas for the process and use the proper
pressure reducing regulator designed to operate from
the compressed gas cylinder. Do not use adaptors.
Maintain hoses and fittings in good condition. Follow
manufacturer's operating instructions for mounting regulator to a compressed gas cylinder.
2. Always secure cylinders in an upright position by chain
or strap to suitable hand trucks, undercarriages, benches,
walls, post, or racks. Never secure cylinders to work
tables or fixtures where they may become part of an
electrical circuit.
3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases in
Cylinders", which is available from Compressed Gas
Association, 1235 Jefferson Davis Highway, Arlington,
VA 22202.
This symbol appearing throughout this manual
means Attention! Be Alert! Your safety is
involved.
The following definitions apply to DANGER, WARNING,
CAUTION found throughout this manual:
Used to call attention to immediate hazards which, if not avoided, will result in
immediate, serious personal injury or
loss of life.
EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause
injury or death. Therefore:
Used to call attention to potential hazards which could result in personal injury
or loss of life.
1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do not
Used to call attention to hazards which
could result in minor personal injury.
4
PRÉCAUTIONS DE SÉCURITÉ
a. Éloigner suffisamment tous les matériaux combustibles du secteur où l’on exécute des soudures ou des
coupes à l’arc, à moins de les recouvrir complètement
d’une bâche non-inflammable. Ce type de matériaux
comprend notamment le bois, les vêtements, la sciure,
l’essence, le kérosène, les peintures, les solvants, le
gaz naturel, l’acétylène, le propane et autres substances combustibles semblables.
b. Les étincelles ou les projections de métal incandescent peuvent tomber dans des fissures du plancher ou
dans des ouvertures des murs et y déclencher une
ignition lente cachée. Veiller à protéger ces ouvertures
des étincelles et des projections de métal.
c. N’exécutez pas de soudures, de coupes, d’opérations
de gougeage ou autres travaux à chaud à la surface
de barils, bidons, réservoirs ou autres contenants
usagés, avant de les avoir nettoyés de toute trace de
substance susceptible de produire des vapeurs
inflammables ou toxiques.
d. En vue d’assurer la prévention des incendies, il
convient de disposer d’un matériel d’extinction prêt à
servir immédiatement, tel qu’un tuyau d’arrosage, un
seau à eau, un seau de sable ou un extincteur portatif.
e. Une fois le travail à l’arc terminé, inspectez le secteur
de façon à vous assurer qu’aucune étincelle ou projection de métal incandescent ne risque de provoquer
ultérieurement un feu.
3. CHOC ÉLECTRIQUE-- Le gougeage à l’arc et à l’arc
au plasma exige l’emploi de tensions à vide
relativement importantes; or, celles-ci risquent de
causer des dommages corporels graves et même
mortels en cas d’utilisation inadéquate. La gravité du
choc électrique reçu dépend du chemin suivi par le
courant à travers le corps humain et de son intensité.
a. Ne laissez jamais de surfaces métalliques sous tension venir au contact direct de la peau ou de
vêtements humides. Veillez à porter des gants bien
secs.
b. Si vous devez effectuer un travail sur une surface
métallique ou dans un secteur humide, veillez à assurer votre isolation corporelle en portant des gants secs
et des chaussures à semelles de caoutchouc et en
vous tenant sur une planche ou une plate-forme
sèche.
c. Mettez toujours à la terre le poste de soudage/coupage
en le reliant par un câble à une bonne prise de terre.
d. N’utilisez jamais de câbles usés ou endommagés. Ne
surchargez jamais le câble. Utilisez toujours un
équipement correctement entretenu.
e. Mettez l’équipement hors tension lorsqu’il n’est pas en
service. une mise à la masse accidentelle peut en
effet provoquer une surchauffe de l’équipement et un
danger d’incendie. Ne pas enrouler ou passer le câble
autour d’une partie quelconque du corps.
f. Vérifiez si le câble de masse est bien relié à la pièce en
un point aussi proche que possible de la zone de
travail. Le branchement des câbles de masse à
l’ossature du bâtiment ou en un point éloigné de la
zone de travail augmente en effet le risque de passage d’un courant de sortie par des chaînes delevage
AVERTISSEMENT: Ces règles de sécurité ont pour objet
d’ assurer votre protection. Veillez à lire et à observer les
précautions énoncées ci-dessous avant de monter l’
équipement ou de commercer à l’utiliser. Tout défaut
d’observation de ces précautions risque d’entraîner des
blessures graves ou mortelles.
1. PROTECTION INDIVIDUELLE-- Les brûlures de la
peau et des yeux dues au rayonnement de l’arc
électrique ou du métal incandescent, lors du soudage
au plasma ou à l’électrode ou lors du gougeage à
l’arc, peuvent s’avérer plus graves que celles
résultant d’une exposition prolongée au soleil. Aussi
convient-il d’observer les précautions suivantes:
a. Portez un écran facial adéquat muni des plaques
protectrices et des verres filtrants appropriés afin de
vous protéger les yeux, le visage, le cou et les oreilles
des étincelles et du rayonnement de l’arc électrique
lorsque vous effectuez des soudures ou des coupes
ou lorsque vous en observez l’exécution.
AVERTISSEZ les personnes se trouvant à proximité
de façon à ce qu’elles ne regardent pas l’arc et à ce
qu’elles ne s’exposent pas à son rayonnement, ni à
celui du métal incandescent.
b. Portez des gants ignifugés à crispins, une tunique
épaisse à manches longues, des pantalons sans
rebord, des chaussures à embout d’acier et un
casque de soudage ou une calotte de protection, afin
d’éviter d’exposer la peau au rayonnement de l’arc
électrique ou du métal incandescent. ll est également
souhaitable d’utiliser un tablier ininflammable de
façon à se protéger des étincelles et du rayonnement
thermique.
c. Les étincelles ou les projections de métal incandescent risquent de se loger dans des manches
retroussées, des bords relevés de pantalons ou dans
des poches. Aussi convient-il de garder boutonnés le
col et les manches et de porter des vêtements sans
poches à l’avant.
d. Protégez des étincelles et du rayonnement de l’arc
électrique les autres personnes travaillant à proximité
à l’aide d’un écran ininflammable adéquat.
e. Ne jamais omettre de porter des lunettes de sécurité
lorsque vous vous trouvez dans un secteur où l’on
effectue des opérations de soudage ou de coupage à
l’arc. Utilisez des lunettes de sécurité à écrans ou
verres latéraux pour piquer ou meûler le laitier. Les
piquetures incandescentes de laitier peuvent être
projetées à des distances considérables. Les
personnes se trouvant à proximité doivent également
porter des lunettes de protection.
f. Le gougeage à l’arc et le soudage à l’arc au plasma
produisent un niveau de bruit extrêmement élevé (de
100 à 114 dB) et exigent par conséquent l’emploi de
dispositifs appropriés de protection auditive.
2. PRÉVENTION DES INCENDES-- Les projections de
laitier incandescent
ou d’étincelles peuvent
provoquer de graves incendies au contact de
matériaux combustibles solides, liquides ou gazeux.
Aussi faut-il observer les précautions suivantes:
5
9/97
des dommages corporels graves, voire mortels en
déclenchant des incendies ou des chocs électriques.
Observez par conséquent les précautions suivantes:
a. Efforcez-vous de toujours confier à un personnel qualifié l’installation, le dépannage et l’entretien du poste
de soudage et de coupage. N’effectuez aucune
réparation électrique sur l’équipement à moins d’être
qua-lifié à cet effet.
b. Ne procédez jamais à une tâche d’entretien
quelconque à l’intérieur du poste de soudage/
coupage, avant d’avoir débranché l’alimentation
électrique.
c. Maintenez en bon état de fonctionnement les câbles,
le câble de masse, les branchements, le cordon
d’alimentation et le poste de soudage/coupage.
N’utilisez jamais le poste ou l’équipement s’il présente
une défectuosité quelconque.
d. Prenez soin du poste de soudage et de coupage et
des équipements accessoires. Gardez-les à l’écart
des sources de charleur, notamment des fours, de
l’humidité, des flaques d’eau maintenez-les à l’abri des
traces d’huile ou de graisse, des atmosphères corrosives et des intempéries.
e. Laissez en place tous les dispositifs de sécurité et tous
les panneaux de l’armoire de commande en veillant à
les garder en bon état.
f. Utilisez le poste de soudage/coupage conformément à
son usage prévu et n’effectuez aucune modification.
6. INFORMATIONS COMPLÉMENTAIRES RELATIVES
À LA SÉCURITÉ-Pour obtenir des informations complémentaires sur les
règles de sécurité à observer pour le montage et
l’utilisation d’équipements de soudage et de coupage
électriques et sur les méthodes de travail
recommandées, demandez un exemplaire du livret N°
52529 “Precautions and Safe Practices for Arc Welding, Cutting and Gouging” publié par ESAB. Nous
conseillons également de consulter les publications
sui-vantes, tenues à votre disposition par l’American
Welding Society, 550 N.W. LeJuene Road, Miami, FL
32126:
a. “Safety in Welding and Cutting” AWS Z49.1
b. “Recommended Safe Practices for Gas-Shielded Arc
Welding “AWS A6. 1.
c. “Safe Practices for Welding and Cutting Containers
That Have Held Combustibles” AWS-A6.0.
d. “Recommended Safe Practices for Plasma Arc Cutting” AWS-A6. 3.
e. “Recommended Safe Practices for Plasma Arc Welding” AWS-C5. 1.
f. “Recommended Safe Practices for Air Carbon Arc
Gouging and Cutting” AWS-C5. 3.
g. “Code For Safety in Welding and Cutting”
CSA-Standard W117. 2.
des câbles de grue ou divers chemins électriques.
g. Empêchez l’apparition de toute humidité, notamment
sur vos vêtements, à la surface de l’emplacement de
travail, des câbles, du porte-électrode et du poste de
soudage/coupage. Réparez immédiatement toute
fuite d’eau.
4. VENTILATION-- La respiration prolongée des fumées
résultant des opérations de soudage/coupage, à
l’intérieur, d’un local clos, peut provoquer des malaises et des dommages corporels. Aussi convient-il
d’observer les précautions suivantes:
a. Assurez en permanence une aération adéquate de
l’emplacement de travail en maintenant une ventilation naturelle ou à l’aide de moyens mécaniques.
N’effectuez jamais de travaux de soudage ou de
coupage sur des matériaux de zinc, de plomb, de
beryllium ou de cadmium en l’absence de moyens
mécaniques de ventilation capables d’empêcher
l’inhalation des fumées dégagées par ces matériaux.
b. N’effectuez jamais de travaux de soudage ou de
coupage à proximité de vapeurs d’hydrocarbure
chloré résultant d’opérations voisines de dégraissage
ou de pulvérisation. La chaleur dégagée ou le
rayonnement de l’arc peut déclencher la formation de
phosgène -- gaz particulièrement toxique -- et d’autres
gaz irritants, à partir des vapeurs de solvant.
c. Une irritation momentanée des yeux, du nez ou de la
gorge constatée au cours de l’utilisation de
l’équipement dénote un défaut de ventilation. Arrêtezvous de travailler afin de prendre les mesures nécessaires à l’amélioration de la ventilation. Ne poursuivez
pas l’opération entreprise si le malaise persiste.
d. Certaines commandes comportent des canalisations
où circule de l’hydrogène. L’armoire de commande
est munie d’un ventilateur destiné à empêcher la
formation de poches d’hydrogène, lesquelles
présentent un danger d’explosion; ce ventilateur ne
fonctionne que si l’interrupteur correspondant du
panneau avant se trouve placé en position ON
(Marche). Veillez à manœuvrer cette commande en
vérifiant si le couvercle est bien en place, de façon à
assurer l’efficacité de la ventilation ainsi réalisée. Ne
jamais débrancher le ventilateur.
e. Les fumées produites par l’opération de soudage ou
de coupage peuvent s’avérer toxiques. Aussi est-il
nécessaire de disposer en permanence d’un dispositif
adéquat de ventilation de type aspirant, afin d’éliminer du voisinage de l’opérateur tout dégagement de
fumée visible.
f. Consultez les recommandations particulières en
matière de ventilation indiquées à l’alinéa 6 de la
norme Z49.1 de l’AWS.
5. ENTRETIEN DE L’ÉQUIPEMENT-- Un équipement
entretenu de façon défectueuse ou inadéquate risque
non seulement de réaliser un travail de mauvaise
qualité mais, chose plus grave encore, d’entraîner
9/97
6
SECTION 1
DESCRIPTION
1.1 GENERAL
PT-27 Torch, 75° head, 25-ft. .......................... P/N 21661
PT-27 Spare Parts Kit (see Table 1-1) ............ P/N 21623
PCM-875 Console/Power Source .................... See below
The PCM-875 is a compact, completely self-contained
plasma cutting system. As shipped, the system is fully
assembled and ready to cut after being connected to
input power and a source of compressed air (90-150
psi). The PCM-875 package uses the heavy-duty PT-27
torch to deliver cutting power for severing materials up to
1-1/4 inch thick. Refer to the following paragraphs for
descriptions of the PCM-875 packages available as well
as performance specifications.
Depending on the choice of input power, each package
includes the following appropriate PCM-875 Console/
Power Source:
208/230 V, 50/60 Hz, 1 or 3-phase .................
460 V, 50/60 Hz, 3-phase ...............................
575 V, 60 Hz, 3-phase ....................................
400 V, 50/60 Hz, 3-phase ...............................
P/N 36580
P/N 36584
P/N 36713
P/N 36724
1.3.2 Mechanized Cutting Packages
Also available are mechanized packages using the
PT-20AM Mechanized Plasma Torch with the PCM-875
Console/Power Source. A typical package includes:
PCM-875 Console/Power Source, PT-20AM Torch (4.5
or 17 ft.), Remote Arc Starter, Torch Spare Parts Kit,
Pilot Arc Cable (50 or 100 ft.), Power Cable (50 or 100 ft.),
Gas Hose (50 or 100 ft.), Arc Starter AC Power Cable (50
or 100 ft.) and a hose adaptor. See Section 2.8 for
installation details and part numbers of components.
Use only ESAB Plasmarc torches that are designed
for use with this console. Use of torches not designed for use with this console could create an
ELECTRIC SHOCK HAZARD. Do NOT use or modify
the PT-23, PCT-80 or any other torch for use on this
console.
1.2 SCOPE
The following PCM-875 Mechanized Packages are available:
The purpose of this manual is to provide the operator
with all the information required to install and operate the
PCM-875 plasma arc cutting package. Technical reference material is also provided to assist in troubleshooting the cutting package.
875M, 230V/PT-20AM, 4.5'/50’System ...........
875M, 230V/PT-20AM, 4.5'/100' System ........
875M, 230V/PT-20AM, 17'/50' System ...........
875M, 230V/PT-20AM, 17'/100' System .........
875M, 460V/PT-20AM, 4.5'/50’System ...........
875M, 460V/PT-20AM, 4.5'/100' System ........
875M, 460V/PT-20AM, 17'/50' System ...........
875M, 460V/PT-20AM, 17'/100' System .........
1.3 PACKAGES AVAILABLE
1.3.1 Manual Cutting Packages
PCM-875 packages listed on the front cover includes the
following components:
Table 1-1. PT-27 Spare Parts Kit, P/N 21623, Contents
Description
50 - 60 A Nozzle
Electrode
Swirl Baffle
Heat Shield
Standoff Guide
Valve Pin
Fuse, 15 A, 600 VDC, Fast Acting
7
Part Number
Quantity
33369
33366
33367
21616
21420
21619
952137
4
3
1
2
1
1
1
P/N
P/N
P/N
P/N
P/N
P/N
P/N
P/N
37617
37618
37619
37620
37621
37622
37623
37624
SECTION 1
DESCRIPTION
1.4 SPECIFICATIONS
Table 1-2. PCM-875 Specifications
Rated
Output
60% Duty Cycle*
60 A @ 120 V dc
100% Duty Cycle*
50 A @ 120 V dc
Output Current Range
10 to 60 Amperes
Open Circuit Voltage
275 V dc
Rated Primary Input
@
7.2 kW Max. Output Power
60 A @ 120 Vdc
208/230 V ac, 50/60
Hz, 3-phase
26/24 A/phase
208/230 V ac, 50/60
Hz, 1-phase
55/49 A
400 V ac, 50/60 Hz, 3phase
13 A/phase
460 V ac, 50/60 Hz, 3phase
11 A/phase
575 V ac, 50/60 Hz,
9 A/phase
74% (208/230 V, 1-phase)
90% (208/230 V, 3-phase)
92% (400/460 & 575 V, 3-phase)
Power Factor @ 60 Amperes Output
Efficiency @ 60 Amperes Output
90% Typical
Current Capacity
PT-27
80 A DCSP
Air Requirements
PT-27
320 cfh @ 65 - 75 psig
(150 l/min @ 4.5 - 5.2 bars)
Length
Height
Dimensions
w/handles
Width
w/o opt. storage
w/ opt. torch storage
Weight of PCM-875 System
Shipping Weight
20.3" (516 mm)
16.1" (409 mm)
18.3" (465 mm)
10.1" (275 mm)
13.1" (333 mm)
87 lbs (39.5 kg)
100 lbs (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.
8
SECTION 1
DESCRIPTION
Table 1-3. PT-27 Torch Specifications
7.3" (185 mm)
Current Capacity (100% duty)
Length of Service Lines
Weight
25 ft
50 ft
80 A DCSP
25 ft or 50 ft
3" (76 mm)
5.2 lbs (2.4 kg)
9.6 lbs (4.4 kg)
75°
1" (25.4 mm)
1"
(25.4 mm)
Figure 1-1. PT-27 Dimensions
CUTTING SPEED (IN. PER MIN.)
120
Steel
100
PT-27 Torch
Air @75psi
3/16" - 1/4" Stand-off
Maximum Current
80
60
Aluminum
40
Stainless
20
0
1/16
1/8
3/16
1/4
5/16
3/8
7/16
1/2
9/16
5/8
11/16
3/4 13/16 7/8
MATERIAL THICKNESS (IN.)
Figure 1-2. PT-27/PCM 875 Cutting Performance
9000
160
Maximum Output
140
7000
6000
5000
4000
120
IMPORTANT
Maintain Proper
IMPORTANT!!!
Stand-off
Distance
Maintain Proper
Power output
increases with
stand-off distance
Stand-off Distance
3/16 to 1/4“
3000
Best
Range
2000
80
60
40
20
1000
0
1/16
0.0625
100
Arc Voltage
Watts (A x V=W)
8000
0
3/16
1/4
1/8
5/16
0.125
0.1875
0.25
0.3125
Stand-Off Distance (in.)
3/8
0.375
Figure 1-3. Standoff vs. Power Output
1.5 OPTIONAL ACCESSORIES
2. Wheel Cart, P/N 34324. This 5 7/8" high cart has
front swivel casters and rear casters to make it
easier to roll the PCM-875 around the job site.
1. Torch Wrap/Spare Parts Kit Holder, P/N 33952GY.
Units have 4 mounting holes on left side for mounting
this accessory holder.
9
SECTION 2
INSTALLATION
2.1 GENERAL
2.5 PRIMARY ELECTRICAL INPUT
CONNECTIONS (FIGURE 2-1)
Proper installation is important for satisfactory and troublefree operation of the PCM-875 cutting package. It is
suggested that each step in this section be studied
carefully and followed closely.
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.
2.2 EQUIPMENT REQUIRED
A source of clean, dry air that supplies 320 cfh at 65-75
psig is required for the cutting operation. The air supply
should not exceed 150 psig (the maximum inlet pressure
rating of the air filter-regulator supplied with the package).
Be sure that the power source is properly configured
for your input power supply. DO NOT connect a
power source configured for 208/230 V to a 460 V
input power supply. Damage to the machine may
occur.
2.3 LOCATION
Adequate ventilation is necessary to provide proper
cooling of the PCM-875. The amount of dirt, dust, and
excessive heat to which the equipment is exposed,
should be minimized. There should be at least one foot
of clearance between the PCM-875 power source and
wall or any other obstruction to allow freedom of air
movement through the power source.
NOTE: If using 200(208) V input power, the PCM-875
must be reconnected for 200 V use as directed
in Section 2.7 and Fig. 2-2.
The PCM-875 consoles are equipped with a 10-ft,
4-conductor input power cable for 3-phase connection.
If single-phase connection is desired, tape back the red
wire on the input power cable.
Installing or placing any type of filtering device will
restrict the volume of intake air, thereby subjecting
the power source internal components to overheating. The warranty is void if any type of filter device
is used.
NOTE: The 208/230 V models are equipped with a plug
for single-phase connection only. The plug is
mounted to a 4-conductor cable. If 3-phase
connection is desired, remove and discard the
plug and proceed as described above.
2.4 INSPECTION
A.
Remove the shipping container and all packing
material and inspect for evidence of concealed
damage which may not have been apparent upon
receipt of the PCM-875. Notify the carrier of any
defects or damage at once.
B.
Check container for any loose parts prior to disposing of shipping materials.
C.
Check air louvers and any other openings to ensure
that any obstruction is removed.
A line (wall) disconnect switch with fuses or circuit
breakers should be provided at the main power panel
(see Fig. 2-1 and Table 2-1 for fuse sizes). The input
power cable of the console may be connected directly to
the disconnect switch or you may purchase a proper plug
and receptacle from a local electrical supplier. If using
plug/receptacle combination, see Table 2-1 for recommended input conductors for connecting receptacle to
line disconnect switch.
The chassis must be connected to an approved
electrical ground. Failure to do so may result in
electrical shock, severe burns or death.
10
SECTION 2
INSTALLATION
Table 2-1. Recommended Sizes For
Input Conductors and Line Fuses
Input Requirements
Volts
Phase
208
208
230
230
400
460
575
1
3
1
3
3
3
3
Amps
55A
26A/Ph.
49A
24A/Ph.
13
11
9
Input & Gnd
1. For operator safety, the torch connections are located
on the output terminal board behind the lower portion
of the front panel. Remove access door to output
terminal board from right panel of power source.
2. Thread the power cable, pilot arc cable and switch
lead of the PT-27 through the right open bushing of
the front panel. Connect power cable to the torch
fitting (left-hand threads); bolt the pilot arc cable ring
connection to the copper terminal; and plug in the
switch lead to the torch switch receptable on the
output terminal board. Make sure the power and
pilot arc cable connections are wrench-tight. Make
sure plug of switch lead is firmly locked in place.
3. Reassemble the access door to the power source.
4. Connect your air supply to the inlet connection of
the filter-regulator.
5. Clamp the work cable to the workpiece. Be sure
the workpiece is connected to an approved earth
ground with a properly sized ground cable.
Fuse
Conductor
Size
CU/AWG
Amps
6
6
6
6
10
10
10
80
50
80
50
25
25
20
2.6 SECONDARY (OUTPUT) CONNECTIONS
(REFER TO FIG. 2-1)
Before making any connections to the power source
output terminals, make sure that all primary input
power to the power source is deenergized (off) at
the main disconnect switch and that the input power
cable is unplugged.
Red - NOT USED ON SINGLE PHASE
White
Black
Green
PRIMARY INPUT
POWER CABLE
11
SECTION 2
INSTALLATION
TORCH
PILOT
ARC
CONNECTION
Allow at least 10 ft. (3m)
between work and power source
TORCH
POWER
CABLE
CONNECTION
WORK
TORCH
SWITCH
RECEPTACLE
SAFETY
GROUND
ACCESS DOOR FOR
TORCH CONNECTION
PT-27
ACCESS FOR CNC
INTERFACE CONNECTIONS.
(See Detail “A”)
Prefiltered AIR SUPPLY
(Customer Supplied)
(90 to 150 psig max)
CUSTOMER FUSED LINE
DISCONNECT SWITCH(See
Table 2.1 and WARNING in
regards to chassis ground in
Section 2.5.)
INPUT POWER CABLE
(See Table 2.1)
NOTE: The 208/230 V models are equipped with a plug for
single-phase connection only. The plug is mounted to a
4-conductor cable. If 3-phase connection is desired,
remove and discard the plug and refer to Sect. 2.5.
Figure 2-1. PCM-875 Interconnection Diagram
12
SECTION 2
INSTALLATION
2.7CONNECTING PCM-875 FOR 200(208)
VAC INPUT
1. Remove cover from the PCM-875 power source.
2. Locate the Input Bridge (IBR) and TB5 terminal
block (see Fig. 1) on the left side towards the rear
panel. Disconnect the gray lead from TB5-2 and
then connect it to TB5-1.
3. Locate the output bridge (D1) on left side towards
the front panel (see Fig. 2). Disconnect and swap
leads X2 and X3 from the main transformer. For
200(208) vac input, X2 is connected to TB3 and X3
is connected to terminal 3 of D1. Make sure the
connections are firmly tightened.
4. Leave all other wires the same.
5. Reinstall cover and connect the PCM-875 to 208 vac
input power.
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
reconnecting for 200(208) VAC Input.
The PCM-875 power source with 200/230 vac, 1-phase
input capability is factory set for 230 vac input. If using
200(208) vac input, the PCM-875 must be reconnected
as follows before connecting to your input power:
Fig. 1
Fig. 2
GRY
TB5
FROM MAIN
TRANSFORMER
(IBR)
INPUT
BRIDGE
R
R2
X3
BLK
BLK
GRY
S G
+
T +
OUTPUT
BRIDGE (D1)
~
1
~
2
~
3
X1
TB3
X2
Figure 2-2. Original Factory Setup for 230 Vac Input on
Power Source with 200/230 Vac Input Power Capability
13
SECTION 2
INSTALLATION
2.8 MECHANIZED CUTTING INSTALLATION WITH THE PT-20AM TORCH
Installation for mechanized cutting should be performed by an experienced service technician. Do NOT permit
untrained persons to install, operate, or maintain this equipment. Be sure to read all Safety Precautions
before installing or servicing this equipment.
ARC STARTER CABLE - 37410 (50’)
37411 (100’)
POWER CABLE - 37341 (50’)
37342 (100’)
ARC STARTER
37338
PT-20AM - 21785 (4.5’)
WORK
CABLE(25’)
(Supplied with
PCM-875)
AIR HOSE - 37343 (50’)
37344 (100’)
21786 (17’)
PILOT ARC CABLE - 37339 (50’)
37340 (100’)
SCHEMATIC - MECHANICAL SYSTEM SETUP (See Figure 2-4 for detailed connections)
NOTE:
Use Cable P/N 2239902
(UL / CSA approved cable
Flex, 20 guage, 12 conductor
with copper braided shield)
CNC Interface Connection (Located inside console, left side of base.)
Figure 2.3 - MECHANICAL CUTTING INTERFACE DIAGRAM
14
SECTION 2
INSTALLATION
View A-A
Disconnect These
Two Black Leads
Connect Arc Start Cable As Shown. (See step 5 below).
WHT Arc Start
“A”
“B”
“C”
“D”
Arc Starter
Cable (Ref.)
BLK Arc Start
ADAPTOR - 999278
“A”
“D”
“C” “B”
PILOT ARC CABLE - 37339 (50’)
37340 (100’)
SPLICE CONNECTOR*
(Supplied with 37338)
25mm min.
Make sure all power is off before making following
connections.
1.
2.
AIR HOSE - 37343 (50’)
37344 (100’)
3.
POWER CABLE - 37341 (50’)
37342 (100’)
4.
ARC STARTER CABLE - 37410 (50’)
37411 (100’)
5.
6.
Arc Starter
37338
Remove cover from PCM-875.
Insert the 4 service lines from Arc Starter through the
torch opening of front panel.
Connect large hole terminal end of Pilot Arc Cable
("A") to connection where shown. Tighten screw
firmly.
Connect adaptor 999278 to fitting where shown.
Connect Air Hose ("C") to adaptor. Connect power
cable ("B") to one of the threaded holes of adaptor.
Tighten all connections firmly.
Locate TB1 Terminal Block. Referring to view D-D
above, disconnect the two black wires from TB1.
Connect the black lead of Arc Starter Cable ("D") to
TB1-1 and the white lead to TB1-2.
Reassemble cover. Proceed to connect the 4 service lines to the Arc Starter. Then connect PT-20AM
torch to Arc Starter.
(4) .250” (6 mm)
2.125”
(54mm)
.035” (0.9mm)
7”
(178mm)
25mm min.
PT-20AM
TORCH
SPLICE CONNECTOR*
(Supplied with 37338)
*Insulate splice connectors with vinyl tubing
and secure with electrical
tape.
SPARK GAP ASSEMBLY
(Torch end of Arc Starter)
MOUNTING DIMENSIONS
Figure 2.4 Connection Diagram - PCM-875/PT-20AM with Arc Starter
15
SECTION 3
OPERATION
3.1 OPERATION
E.
Flow Fault: The fault light will be mostly on but
will flick off for about 1/10th of a second every
second. This indicates that the air flow supply is
low.
ELECTRIC SHOCK can kill.
• Do NOT operate the unit with the cover removed.
• Do NOT apply power to the unit while holding or
carrying the unit.
• Do NOT touch any torch parts forward of the torch
handle (nozzle, heat shield, electrode, etc.) with
power switch on.
Over Temperature: The fault light will be mostly
off but will flick on for about 1/10th of a second
every second. This indicates that the duty cycle
has been exceeded. Allow the power source to
cool down before returning to operate.
High/Low Line Voltage: The fault light will rapidly blink on and off (five times per second). This
indicates that the input voltage is outside the “+ or
-” 15% range of the input rating.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
• Wear welding helmet with No. 6 or 7 lens shade.
• Wear eye, ear, and body protection.
Over-Current: The fault light will be on continuously. This indicates that input current has been
exceeded.
Position the PCM-875 at least 10 feet (3 meters) from
the cutting area. Sparks and hot slag from the cutting operation can damage the unit.
All fault signals will remain on for a minimum
of 10 seconds. If fault clears, all will reset
automatically except for over-current. To clear
over-current, the power must be shut off for 5
seconds and then turned back on.
3.2 PCM-875 CONTROLS (FIGURE 3-1)
A.
Fault Light. Will glow amber under the following
conditions and operations will come to a complete
stop.
Power Switch (located on rear panel). When
placed in ON position, the green pilot light will glow
indicating control circuit is energized and the
cooling fan will run.
3.3 CUTTING WITH THE PT-27
Use the following procedures to cut with the PT-27 torch
(Figure 3-4).
B.
Output Current Control. Adjustable from 10 to
60 amperes.
A.
C.
Air Test Switch. When placed in Test position, air
filter-regulator can be adjusted to desired pressure (65-75 psig) before cutting operations. Allow
air to flow for a few minutes. This should remove
any condensation that may have accumulated
during shutdown period. Be sure to place switch
in OPERATE position before starting cutting operations.
Hold the torch nozzle approximately 1/8 to 3/16
inch above the work and tilted at about 15 - 30°.
This reduces the chance of spatter entering the
nozzle. If the PT-27's standoff tool is being used,
set the standoff between 3/16 and 1/4-inch.
B.
Depress the torch switch. Air should flow from the
torch nozzle.
C.
Trigger Lock Switch. When placed in LOCK
position, this permits releasing torch switch button
after cutting arc has been initiated. To extinguish
arc at end of cut, press and release torch switch
button again or pull torch away from work. When
placed in UNLOCK position, torch switch must be
held closed by the operator during the entire
cutting operation and then released at the end of
cut.
Two seconds after depressing the torch switch,
the pilot arc should start. The main arc should
immediately follow, allowing the cut to begin. (If
using the trigger LOCK mode, torch switch may be
released after establishing the cutting arc.)
D.
After starting the cut, the torch should be maintained at a 5-15° forward angle (Figure 3-2). This
angle is especially useful in helping to create a
"drop" cut. When not using the standoff guide, the
nozzle should be held approximately 1/4 inch from
the work.
D.
16
SECTION 3
OPERATION
AIR REGULATOR
CONTROL KNOB
POWER LIGHT
(WHITE)
FAULT LIGHT
(AMBER)
REAR VIEW
AIR
PRESSURE
GAUGE
FUSE (3A)
FUSE (15A)
AIR TEST
SWITCH
TRIGGER LOCK
SWITCH
POWER ON-OFF
(I-O) SWITCH &
CIRCUIT BREAKER
CURRENT
CONTROL
KNOB
Figure 3-1. PCM-875 Controls
E.
When ending a cut, the torch switch should be
released (press and release if using trigger LOCK
mode) and lifted off the workpiece just before the
end of the cut. This is to prevent the high frequency
from reigniting after cutting arc extinguishes and
causing damage to the nozzle (double arcing).
NOTE: When replacing the nozzle, always inspect the
electrode for wear. If less than 19/32" of electrode
shaft is remaining, replace the electrode. If the
electrode is used beyond this recommended wear
limit, damage to the torch and power source may
occur. Nozzle life is also greatly reduced when
using the electrode below the recommended
limit. Refer to Figure 3-3.
19/32"
(15.1 mm)
ELECTRODE
REPLACE ELECTRODE BEFORE
LENGTH BECOMES SHORTER
THAN 19/32 INCH (15.1 MM)
Figure 3-3. Electrode Wear Limit
3.3.1. Drag Cutting with the PT-27/PCM-875 System
If drag cutting is desired, the 15 amp pilot arc fuse located
on the rear panel must be removed. This converts pilot arc
starting to high frequency starting allowing you to cut by
dragging the torch nozzle on the workpiece. Cutting
thickness should not exceed 3/8" for drag cutting.
Figure 3-2. Recommended Torch Angle of 5° to 15°
F.
For rapid re-starts, such as grate or heavy mesh
cutting, do not release the torch switch. In the
postflow mode, the arc can be re-started immediately by depressing the torch switch. This avoids
the 2-second preflow portion of the cutting cycle.
17
SECTION 3
OPERATION
2
1
WHEN THE ARC BREAKS
THROUGH THE WORK,
BRING THE TORCH TO AN
UPRIGHT POSITION AND
PROCEED TO CUT.
TO START A PIERCE, TILT THE
TORCH TO PREVENT MOLTEN MATERIAL FROM COMING BACK
AGAINST AND DAMAGING THE
TORCH.
Figure 3-4. Piercing Technique using the PT-27
3.4 COMMON CUTTING PROBLEMS
D. Double Arcing. (Damaged Nozzle Orifice.)
1.
2.
3.
4.
Listed below are common cutting problems followed by
the probable cause of each. If problems are determined
to be caused by the PCM-875, refer to the maintenance
section of this manual. If the problem is not corrected
after referring to the maintenance section, contact your
ESAB distributor.
E. Uneven Arc.
1. Damaged cutting nozzle or worn electrode.
A. Insufficient Penetration.
1.
2.
3.
4.
5.
F. Unstable Cutting Conditions.
Current too low.
Cutting speed too fast.
Damaged cutting nozzle.
Improper air pressure.
Low air flow rate.
1. Incorrect cutting speed.
2. Loose cable or hose connections.
3. Electrode and/or cutting nozzle in poor condition.
B. Main Arc Extinguishes.
G. Main Arc Does Not Strike.
1. Cutting speed too slow.
2. Worn electrode.
1. Worn electrode.
2. Loose connections.
3. Worn cable not attached.
C. Dross Formation. (In some materials and thicknesses, it may be impossible to get dross-free cuts.)
1.
2.
3.
4.
5.
Low air pressure.
Damaged cutting nozzle.
Loose cutting nozzle.
Heavy spatter accumulation on nozzle.
H. Poor Consumable Life.
Current too low.
Cutting speed too fast or too slow.
Improper air pressure.
Faulty nozzle or electrode.
Low air flow rate.
1. Improper gas pressure.
2. Contaminated air supply.
3. Low air flow rate.
18
SECTION 4
MAINTENANCE
4.1 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 4-1.
A. Place nozzle, swirl baffle and electrode into the
shield as shown.
4.2 INSPECTION AND CLEANING
B. Thread assembly to the torch body and hand tighten.
Always make sure the shield is very tight before
cutting.
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.
B.
C.
D.
E.
F.
G.
Check work cable for secured connection to
workpiece.
Check safety earth ground at workpiece and at
power source chassis.
Check heat shield on torch. It should be replaced
if damaged.
Check the torch electrode and cutting nozzle for
wear on a daily basis. Remove spatter or replace
if necessary.
Make sure cable and hoses are not damaged or
kinked.
Make sure all plugs, fittings, and ground connections are tight.
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 PCM875.
H.
Occasionally, bleed all water from the filter beneath the air filter-regulator.
IMPORTANT!
MAKE SHIELD VERY TIGHT!
4.3 PT-27 TORCH CONSUMABLE PARTS
Make sure power switch on PCM-875 is in OFF
position before working on the torch.
Figure 4-1. Assembly of PT-27 Torch Front End Parts
19
SECTION 4
MAINTENANCE
4.4 FLOW SWITCH (FIGURE 4-2)
•
When excessive contamination is found in the air, the
flow switch (FS-4) should be disassembled and cleaned
as follows:
•
A.
•
B.
C.
D.
E.
•
Ensure the system is shut down and there is no
trapped air under pressure in the piping.
Remove the piston plug.
Remove the spring. Use care when handling spring
to prevent distortion.
Remove the piston.
Clean all parts with cleaning agent.
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 4-3. 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 it thermal conductivity. See Replacement Parts
section for the required pad.
PISTON PLUG
A torque wrench should be used. Tighten mounting
screws to 28 in-lbs; wire connecting screws to 19 in-lbs.
If torque is too heavy, the device can damage like the
above “one-sided tightening”.
SPRING
FLOW SWITCH
Use grounded work station with grounded floors and
grounded wrist straps when handling devices.
Use a 100Ω 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.
PISTON

Two-Point Mounting Type
Temporary tightening  è‚
Final tightening  ‚è
‚
Figure 4-2. Disassembly / Assembly of Flow Switch
4.5 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 4-3. Screw Fastening Order
20
SECTION 5
TROUBLESHOOTING
5.1 TROUBLESHOOTING
The cause of control malfunctions can be found by
referring to the sequence of operations and electrical
schematic diagram (Figure 5-1) 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.
5.2TROUBLESHOOTING 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 P2-14of 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 burnt out.
B. No Air Flow
A. Check air inlet supply. Unit requires 320 CFH at 65 psig.
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.
21
SECTION 5
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
malfunctioning 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 malfunctioning 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
22
SECTION 5
TROUBLESHOOTING
the ohmmeter should read a direct short. If not then it should read open.
b. If the switch is malfunctioning, 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 (PCB5).
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 very tight.
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 to .040". Disconnect HI
FREQUENCY leads. Check for 115 volt supply to the high frequency unit between P2-12 & P2-13 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 in
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 208/230 volt unit.
approx. 280 VDC to 325 VDC for the 400 or 460 volt unit
approx. 410 VDC for the 575 volt unit
If not, one of following could be malfunctioning:
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 malfunctioning. Follow bridge installation instructions.
3.) Check Inrush current resistor, R10 and SCR1. Both are located on the input bridge heat sink. Replace it if malfunctioning.
e. IGBTs (2 on 230 V, and 1 on the 400 V & 460 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.
23
SECTION 5
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 65-75 psig.
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 65 - 75 psig.
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).
24
SECTION 5
TROUBLESHOOTING
5.3REFERENCE 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
40 usec - LPG50
50 usec - LPG80
0
6 usec - LPG50
9 usec - LPG80
-13 vdc
For 208/230 VAC input, the IGBT off time is 3µsec.
For 400/460/575 VAC input, the IGBT off time is 6µsec.
Figure 5.1 IGBT Gating Signal
25
SECTION 5
TROUBLESHOOTING
5.4SEQUENCE OF OPERATION
A. TRIGGER LOCK “UNLOCK” position
PUSH
TORCH SWITCH
RELEASE
OPEN
CLOSE
GAS SOLENOID VALVE
PREFLOW
2 SEC.
10 SEC
Postflow
FLOW SWITCH
CLOSE
OPEN
FAULT OVERLOAD LIGHT
HF CIRCUIT
ENERGIZE
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.
26
SECTION 5
B.
TROUBLESHOOTING
TRIGGER LOCK "LOCK" position
PUSH
RELEASE
PUSH
RELEASE
TORCH SWITCH
OPEN
GAS SOLENOID VALVE
2 SEC.
CLOSE
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.
27
D-36587
28
Figure 5-1. Schematic Diagram, PCM-875, 208/230 V, 50/60 Hz, 1 or 3-Phase
D-36595
29
Figure 5-2. Wiring Diagram (Sheet 1 of 2), PCM-875, 208/230 V, 50/60 Hz, 1 or 3-Phase
D-36595
30
Figure 5-3. Wiring Diagram (Sheet 2 of 2), PCM-875, 208/230 V, 50/60 Hz, 1 or 3-Phase
31
D-36597-B
Figure 5-4. Schematic Diagram, PCM-875, 400/460 V, 50/60 Hz, 3-Phase
1 2 3 4 5 6
D-36598
32
Figure 5-5. Wiring Diagram (Sheet 1 of 2), PCM-875, 400/460 V, 50/60 Hz, 3-Phase
D-36598
33
Figure 5-6. Wiring Diagram (Sheet 2 of 2), PCM-875, 400/460 V, 50/60 Hz, 3-Phase
D-36715-A
34
Figure 5-7. Schematic Diagram, PCM-875, 575 V, 60 Hz, 3-Phase
D-36716
35
Figure 5-8. Wiring Diagram (Sheet 1 of 2), PCM-875, 575 V, 60 Hz, 3-Phase
D-36716
36
Figure 5-9. Wiring Diagram (Sheet 2 of 2), PCM-875, 575 V, 60 Hz, 3-Phase
SECTION 6
6.1 GENERAL
Replacement Parts are illustrated on the following figures. When ordering replacement parts, order by part
number and part name, as illustrated on the figure.
208/230 V, 50/60 Hz, 1 or 3-phase ............ P/N 36580
460 V, 50/60 Hz, 3-phase .......................... P/N 36584
575 V, 60 Hz, 3-phase ............................... P/N 36713
400 V, 50/60 Hz, 3-phase .......................... P/N 36724
Always provide the series or serial number of the unit
on which the parts will be used. The serial number is
stamped on the unit nameplate.
6.2 ORDERING
To assure 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
Replacement parts may be ordered from your ESAB distributor or from:
ESAB Welding & Cutting Products
Attn: Customer Service Dept.
P.O. Box 100545, 411 S. Ebenezer Road
Florence, SC 29501-0545
Be sure to indicate any special shipping instructions
when ordering replacement parts.
To order parts by phone, contact ESAB at 1-843-6645540. Orders may also be faxed to 1-800-634-7548. Be
sure to indicate any special shipping instructions when
ordering replacement parts.
Refer to the Communication Guide located on the last
page of this manual for a list of customer service phone
numbers.
37
SECTION 6
REPLACEMENT PARTS
3, 4
5, 4
6
1, 2
7
8, 9
16
15
8
10, 11
14
12
13
Fig. 6-1. 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
137630611
2062018
673213
951474
634518
951754
951526
993426
21711
23602576
680560
182W12
32237GY
36330YL
954008
13734588
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
38
R2
S2
S1
PL2
PL1
SECTION 6
REPLACEMENT PARTS
28
27
25, 26
25, 26
24
29, 30
31
23
32, 33, 34
22
21
35
36
37
38
39
40 41
42
43
44, 45
Fig. 6-2. PCM-875 Power Source, Left Side View (208/230)
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
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
952150
952002
952208
36731
952237
994674
38052
36822
36730
951028
950487
952235
2062282
951321
951205
17750010
32958
952255
950711
17721020
951202
951940
952558
950249
951471
Circuit
Symbol
Description
BRIDGE 60ADC 100NS 600 V (includes PAD - 951192)
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 (includes PAD - 952280)
CAPACITOR .22µf 1KV (See wiring)
METAL OXIDE VARISTOR 275 V (See wiring)
IGBT 600 V 100 A (includes PAD - 951190)
RESISTOR 50 W 10 OHM (PAD - 951194)
CURRENT TRANSFORMER ASS'Y
CAPACITOR 40 µf 400 VDC
THERMAL SWITCH 194°F
RESISTOR 24 W 20 OHMS (PAD 951193)
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)
39
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
SECTION 6
REPLACEMENT PARTS
61
60
59
56, 57, 58
56, 57, 58
62
63
55
64, 65, 66
54
53
52
51
67
68
69
70
71
72
73
74
75, 76
Fig. 6-3. PCM-875 Power Source, Left Side View (400/400CE/460/575)
Item
No.
51
52
53
Qty.
Req.
1
1
1
Part
No.
952150
952002
951800
54
55
56
1
1
2
2
2
2
1
1
1
1
1
1
1
952208
36732
952237
952562
994674
951028
38099
951964
951892
36822
36733
950487
952235
1
3
3
2
1
1
1
1
1
4
1
1
1
1
2062282
950591
951963
17750010
32958
952255
952585
952253
950711
17721020
951202
952558
950249
951471
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
Description
BRIDGE 60 ADC 100NS 600 V (includes PAD - 951192)
CORE SATURABLE
MODULE DUAL IGBT 150 A, 1200 V
(includes PAD - 951191)
STANDOFF INS (Not used on 575 V)
BUSBAR POS
CAPACITOR 1800µf 450 VDC (400/400CE/460 V)
CAPACITOR 1800µf 500 VDC (575 V)
GROMMET STRIP
CAPACITOR 1µf 630 VDC (See wiring)
PCB ASS'Y IGBT DRIVER BOARD
CAPACITOR 2µf 800 VDC (400/400CE/460V)
CAPACITOR 0.68µf 1200 VDC (575 V)
HOSE ASS'Y B/A x 1/4 NPT RUB
BUSBAR NEG
TERM BLOCK 2 POS (Not used on 400CE/575 V)
MODULE INPUT BRIDGE/SCR
(includes PAD - 952280)
CAPACITOR .22µf 1KV
METAL OXIDE VARISTOR 510 V (400/400CE/460 V)
METAL OXIDE VARISTOR 625 V (575 V)
RESISTOR 50W 10 OHM (PAD - 951194)
CURRENT TRANSFORMER ASS'Y
CAPACITOR 40µf 400 VDC (400/400CE/460 V)
CAPACITOR 20µf 600 VDC (575 V)
FILTER EMI (400 V CE only)
THERMAL SWITCH 194°F
RESISTOR 25W 20 OHMS (PAD - 951193)
FLOWSWITCH .25 GPM
HEATSINK
SOL, VALVE 1/4 NPT 165 PSI 24 VAC
DIODE ZENER 60 V 75m A
40
Circuit
Symbol
D1
L3
Q1
TB3
C1, 2
C2
C3, 15
PCB2
C16
C16
TB5
IBR
C19
MOV1, 2, 3
MOV1, 2, 3
R7, 10
T4
C4
C4
FN1
TS1
R3, 4, 5, 6
FS
SOL1
ZD1
SECTION 6
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. 6-4. PCM-875 Power Source, Right Side View (208/230)
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
35940
951962
952577
952557
17130310
23604891
952232
38108
36586
951469
31488
951515
38039
952233
36721
182W64
36717
32969
36431
951342
951179
950487
672348
952204
36718
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.
41
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 6
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. 6-5. PCM-875 Power Source, Right Side View (400/400CE/460/575 V)
Item
No.
Qty.
Req.
Part
No.
110
111
112
113
114
115
116
117
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
1
32914
951962
952577
952557
17130310
23604891
38109
36586
36599
951469
31488
951515
38039
952233
36721
182W64
36717
32969
36431
951342
951179
950487
672348
952204
952213
36718
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
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 (400/400CE/460 V)
MAIN TRANSFORMER ASS'Y (575 V)
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
42
T2
R11
K1
C21, 22
R12, 13
PCB1
T1
T1
C17, 18
PCB4
C23
PCB5
L1
J1
T3
SG
C13, 14
T5
TB1
C11, 12
C9
L2
SECTION 6
REPLACEMENT PARTS
142
143
141
144
145
140
Fig. 6-6. 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
954673
952026
17240310
951182
2091558
954700
954681
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 (400/460 V)
43
TB4
R2, 15
M1
SECTION 6
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
1
1
2
1
1
1
1
1
1
1
1
1
21710
10Z30
951575
36719YL
2091514
954290
954666
954667
954668
954669
952136
952137
97W63
36823
35587
35582
951801
951181
952046
952559
158
159
160
161
162
163
Circuit
Symbol
Description
FILTER REGULATOR
ADAPTOR B/A-WM x 1/4 NPTM
HANDLE
TOP COVER YEL (ESAB)
LABEL WARNING
LABEL WARNING
LABEL RATING PCM-875 208/230
LABEL RATING PCM-875 400/460
LABEL RATING PCM-875 575
LABEL RATING PCM-875 400CE
FUSE HOLDER
FUSE 15 A FAST ACTING
STRAIN RELIEF
INPUT POWER CABLE, 10 FT 4-COND. 6AWG (208/230 V)
INPUT POWER CABLE, 10 FT 4-COND. 10AWG (400/460/575 V)
INPUT POWER CABLE, 10 FT 4-COND. 4 x 4 MM (400 V CE)
CIRCUIT BREAKER 3P 70 A 250 VAC (208/230 V)
CIRCUIT BREAKER 3P 30 A 480 VAC (400/460 V)
SWITCH POWER TOGGLE 3PST (575 V)
FUSE 3A FAST ACTING
44
F2
CB1
CB1
S3
F1
SECTION 6
REPLACEMENT PARTS
INSTRUCTION MANUAL CHANGES
The "A" edition (2/98) of this manual covers the following changes:
1. Each replacement IGBT and bridge module now include the appropriate thermal pad.
The "B" edition (9/98) of this manual covers the following changes:
1. Added mechanized cutting installation using PT-20AM torch with the PCM-875.
2. Deleted discontinued L-TEC packages and parts.
The "C" edition (2/02) of this manual covers the following changes:
1. Revises Figure 3-3 to show the changes made to the electrode.
2. Revises Figure 4-1 to show the removal of the Valve Pin which is no longer a part of the PT-27 Torch.
3. The hi frequency gap is changed from "between .027 and .033" to "set to .040". (See page 23, Section E, Step
3).
The "D" edition (10/2006) of this manual covers the following changes:
1. Incorporated inputs from Charles Aimar on Pages 12, 14 and 31.
The "E" edition (07/2007) of this manual covers the following changes:
1. Added updated Disclaimer page after front cover.
45
46
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
F15-335-E
07/2007
Printed in U.S.A.