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 PRECAU-

TIONS 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 l

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

Insulate yourself from earth and the workpiece.

l

Ensure your working stance is safe.

FUMES AND GASES - Can be dangerous to health l l

Keep your head out of the fumes

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 l

Protect your ears. Use ear defenders or other hearing protection

Warn bystanders of the risk.

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

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

TABLE OF CONTENTS

SECTION 1 SPECIFICATIONS ............................................................................................................ 3

SECTION 2 MAINTENANCE................................................................................................................ 4

General, Inspection and Cleaning, PT-27 Torch

Consumable Parts, Flow Switch, IGBT

Handling & Replacement

SECTION 3 TROUBLESHOOTING...................................................................................................... 6

Troubleshooting, Troubleshooting Guide,

Reference Voltage Checks, Sequence of

Operation, Schematic and Wiring Diagrams

SECTION 4 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

PCM-875 Specifications

Rated

Output

Output Current Range

60% Duty Cycle*

100% Duty Cycle*

Open Circuit Voltage

Rated Primary Input

@ 7.2 kW Max. Output Power

60 A @ 120 Vdc

Power Factor @ 60 Amperes Output

220 V ac, 50/60 Hz, 3-phase

400 V ac, 50/60 Hz, 3-phase

Efficiency @ 60 Amperes Output

Current Capacity

Air Requirements

Dimensions

PT-27

PT-27

Length

Height w/handles

Width w/o opt. storage w/opt. torch storage

Weight of PCM-875 System

Shipping Weight

SPECIFICATIONS

60 A @ 120 V dc

50 A @ 120 V dc

10 to 60 Amperes

275 V dc

24 A/phase

13 A/phase

90% (220 V, 3-phase)

92% (400 V, 3-phase)

90% Typical

80 A DCSP

150 l/min @ 4.5 - 5.2 bar

516 mm

409 mm

465 mm

275 mm

333 mm

39.5 kg

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

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.

Be sure that the wall disconnect switch or wall circuit breaker is open before attempting any inspection or work inside of the PCM-875.

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.

MAINTENANCE

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.

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.

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.

2.3 PT-27 TORCH CONSUMABLE PARTS

IMPORTANT!

MAKE SHIELD VERY TIGHT!

Make sure power switch on PCM-875 is in OFF position before working on the torch.

4

Figure 2-1. Assembly of PT-27 Torch Front End Parts

SECTION 2

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.

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.

Reassemble the flow switch in reverse order.

SPRING

FLOW SWITCH

PISTON PLUG

PISTON

MAINTENANCE

• 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.

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.

Application of a thermal pad on the contact surface improves its thermal conductivity. See Replacement

Parts section for the required pad.

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”.



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.

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:

„



Four-Point Mounting Type

Temporary tightening   è ‚ è ƒ è „

Final tightening  „

è

ƒ

è

‚

è



ƒ

‚

Figure 2-3. Screw Fastening Order

5

SECTION 3

3.1Troubleshooting

TROUBLESHOOTING

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.

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.

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.

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 & 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 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 FRE-

QUENCY 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. The most common reason is worn or missing consumables. Check and replace if necessary.

2. Input air must be clean and dry.

3. Input air pressure must be between 4.5 and 5.2 bar.

4. Torch connections must be tight.

5. 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

3.3REFERENCE VOLTAGE CHECKS

A. Control Board Assembly (PCB1)

1. LED’s

LED-1 Torch Switch

LED-2 High Frequency

LED-3 Gas Solenoid Valve

2. 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

TROUBLESHOOTING

50 µ sec

13 vdc

0

13 vdc

For 220 VAC input, the IGBT off time is 3 µ sec.

For 400 VAC input, the IGBT off time is 6 µ sec.

Figure 3.1 IGBT Gating Signal

10

SECTION 3

3.4SEQUENCE OF OPERATION

A. TRIGGER LOCK “UNLOCK” position

TROUBLESHOOTING

TORCH SWITCH

PUSH

GAS SOLENOID VALVE

OPEN

2 SEC.

PREFLOW

RELEASE

FLOW SWITCH CLOSE

CLOSE

10 SEC

Postflow

OPEN

FAULT OVERLOAD LIGHT

HF CIRCUIT

INVERTER

CUTTING ARC (CURRENT)

ENERGIZE

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

B. TRIGGER LOCK "LOCK" position

TROUBLESHOOTING

PUSH RELEASE PUSH RELEASE

TORCH SWITCH

OPEN

GAS SOLENOID VALVE

2 SEC.

CLOSE

CLOSE

PREFLOW

10 SEC

Postflow

POSTFLOW

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

14

15

16

17

18

SECTION 4

8, 9

7

6

5, 4

REPLACEMENT PARTS

3, 4

1, 2

16

10, 11

Item

No.

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

12 13

Fig. 4-1. PCM-875 Power Source, Front View

Qty.

Req.

1

2

1

1

1

4

1

1

1

2

1

1

1

2

1

1

Part

No.

558000373

558000372

558000698

558000596

558000385

558000383

558000384

558000593

558000594

558000178

558000608

558000552

558000630

558000631

558000599

558000598

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

15

8

14

Circuit

Symbol

R2

S2

S1

PL2

PL1

SECTION 4

28

27

REPLACEMENT PARTS

25, 26

25, 26

Item

No.

33

34

35

36

29

30

31

32

25

26

27

28

21

22

23

24

41

42

43

44

37

38

39

40

45

46

29, 30

31

24

23

Qty.

Req.

2

2

1

3

1

1

1

1

2

1

2

2

1

1

1

1

1

1

1

2

1

1

1

4

1

1

32, 33, 34

22

35 36 37 38 46 39 40 41 42 43

Fig. 4-2. PCM-875 Power Source, Left Side View (230 V)

21

44, 45

Part

No.

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

Description

BRIDGE 60ADC 100NS 600 V (PAD - 558000527)

CORE SATURABLE

STANDOFF INS.

BUSBAR NEG

CAPACITOR 1800 µ f 450VDC

GROMMET STRIP

PCB ASS'Y 1GBT DRIVER BOARD

HOSE AY B/A-2X 1/4NPT RUB 2 FT

BUSBAR POS

CAPACITOR 1 µ f 630VDC (Not shown - see wiring)

TERM BLOCK 2 POS

MODULE INPUT BRIDGE/SCR (PAD - 558000651)

CAPACITOR .22

µ f 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 µ f 400 VDC

THERMAL SWITCH 194°F

RESISTOR 24 W 20 OHMS (PAD 558000528)

FLOW SWITCH .25 GPM

CAPACITOR 1 µ f 630W VDC

HEATSINK

SOL. VALVE 1/4NPT 165 PSI 24 VAC

DIODE ZENER 60 V 75 MA (See Wiring)

FILTER EMI (230 V CE)

Circuit

Symbol

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

20

SECTION 4

61

60

59

REPLACEMENT PARTS

56, 57, 58

56, 57, 58

62

Item

No.

64

65

66

67

59

60

61

62

55

56

57

58

51

52

53

54

72

73

74

75

76

68

69

70

71

Qty.

Req.

3

2

1

1

1

1

1

1

2

2

1

2

1

1

1

1

1

1

4

1

1

1

1

1

1

64, 65, 66

55

54

53

52

51

75, 76

67 68 69 70 71 72 73 74

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

Fig. 4-3. PCM-875 Power Source, Left Side View (400 V)

Part

No.

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 1800 µ f 450 VDC

GROMMET STRIP

CAPACITOR 1 µ f 630 VDC (See wiring)

PCB ASS'Y IGBT DRIVER BOARD

CAPACITOR 2 µ f 800 VDC

HOSE ASS'Y B/A x 1/4 NPT RUB

BUSBAR NEG

MODULE INPUT BRIDGE/SCR (PAD - 558000651)

CAPACITOR .22

µ f 1KV

METAL OXIDE VARISTOR 510 V

RESISTOR 50W 10 OHM (PAD - 558000529)

CURRENT TRANSFORMER ASS'Y

CAPACITOR 40 µ f 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

IBR

C19

MOV1, 2, 3

R7, 10

T4

C4

FN1

TS1

R3, 4, 5, 6

FS

SOL1

ZD1

Circuit

Symbol

D1

L3

Q1

TB3

C1, 2

C3, 15

PCB2

C16

21

SECTION 4

90, 91

89 88 87

86

REPLACEMENT PARTS

85

82, 83, 84

92

81

93

Item

No.

92

93

94

95

88

89

90

91

84

85

86

87

80

81

82

83

100

101

102

103

104

96

97

98

99

80

94

95

Qty.

Req.

1

1

1

1

1

1

1

2

1

1

2

1

1

2

1

1

2

1

1

1

1

1

2

1

1

96 97 104 98, 99 100

Fig. 4-4. PCM-875 Power Source, Right Side View (230 V)

Part

No.

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

Description

CONTROL TRANSFORMER ASS'Y

RESISTOR ASS'Y PILOT ARC

RELAY 25 A 120 VAC

CAPACITOR .82

µ f 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 .022

µ f 250 VAC (See Wiring)

SHUNT BOARD ASS'Y

CAPACITOR .047

µ f 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 .01

µ f 1KV (See wiring)

CAPACITOR .01

µ f 250 VAC (See wiring)

BOX HI FREQ.

22

101, 102, 103

Circuit

Symbol

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

115

119, 120

118

117

116

121

122

112, 113, 114

111

Item

No.

118

119

120

121

122

123

124

125

110

111

112

113

114

115

116

117

126

127

128

129

130

131

132

133

134

123

Qty.

Req.

1

1

1

1

1

1

2

1

1

1

2

1

1

2

1

1

1

1

1

2

1

2

1

1

1

Description

CONTROL TRANSFORMER ASS'Y

RESISTOR ASS'Y PILOT ARC

RELAY 25 A 120 VAC

CAPACITOR .82

µ f 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 .022

µ f 250 VAC (See wiring)

SHUNT BOARD ASS'Y

CAPACITOR .047

µ f 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 .01

µ f 1KV (See wiring)

CAPACITOR .01

µ f 250 VAC (See wiring)

REACTOR 3PH LINE 12 A

BOX HI FREQ

110

124

125

126 134 127, 128

129

133

130, 131, 132

Fig. 4-5. PCM-875 Power Source, Right Side View (400 V)

Part

No.

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

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

23

SECTION 4

143 142

REPLACEMENT PARTS

141

144 145

140

Item

No.

140

141

142

143

144

145

Fig. 4-6. PCM-875 Power Source, Top View with PCB1 and Shelf Removed

Qty.

Req.

1

1

1

2

1

1

1

Part

No.

558000670

558000671

558000658

558000388

558000672

558000673

558000674

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)

Circuit

Symbol

TB4

R2, 15

M1

24

SECTION 4

157

158, 159

REPLACEMENT PARTS

154, 155, 156

153

151, 152

158, 163

160, 161

162

Fig. 6-7. PCM-875 Power Source, Rear View

158

159

160

161

162

163

Item Qty.

No.

Req.

151

152

153

154

155

156

157

Part

No.

Description

1 558000675 FILTER REGULATOR

1 558000534 ADAPTOR B/A-WM x 1/4 NPTM

2 558000592 HANDLE

1 558000676 TOP COVER

1 558000536 LABEL WARNING

1 558000562 LABEL WARNING

1 558000957 LABEL RATING PCM-875 220 3PH. V

1 558000681 LABEL RATING PCM-875 400 3PH. V

2 558000516 FUSE HOLDER

1 558000517 FUSE 15 A FAST ACTING

1 558000682 STRAIN RELIEF

1 558000458 INPUT POWER CABLE, 10 FT 4-COND. 6AWG (230 V)

1 558000459 INPUT POWER CABLE, 10 FT 4-COND. 4 x 4 MM (400 V CE)

1 558000474 CIRCUIT BREAKER 3P 30 A 480 VAC (400 V)

1 558000686 FUSE 3A FAST ACTING

Circuit

Symbol

F2

CB1

F1

25

26

27

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS:

Order Entry

Order Changes

Product Availability

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

H. TECHNICAL ASST. CONSUMABLES :

Telephone : (800) 933-7070

Hours: 7:30 AM to 4:00 PM EST

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.