PCM-875 Plasma Arc Cutting Package Instruction Manual This manual provides installation and operation instructions for the following PCM-875 cutting packages starting with Serial No.
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.
table of contents Section / Title Page 1.0 Safety Precautions............................................................................................................................................................................................. 5 1.1 Safety - English....................................................................................................................................................................................... 5 1.2 Safety - Spanish....................
table of contents
section 1 safety precautions 1.0 Safety Precautions 1.1 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.
section 1 safety precautions 1. Be sure the power source frame (chassis) is connected to the ground system of the input power. 3. Welders should use the following procedures to minimize exposure to EMF: 2. Connect the workpiece to a good electrical ground. A. Route the electrode and work cables together. Secure them with tape when possible. 3. Connect the work cable to the workpiece. A poor or missing connection can expose you or others to a fatal shock. B.
section 1 safety precautions 5. WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code §25249.5 et seq.) 1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do not perform any electrical work unless you are qualified to perform such work. 2.
section 1 safety precautions 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." Meaning of symbols - As used throughout this manual: Means Attention! Be Alert! Your safety is involved.
section 1 sEGURIDAD 1.2 Safety - Spanish La escoria puede estar caliente y desprenderse con velocidad. Personas cercanas deberán usar gafas de seguridad y careta protectora. ADVERTENCIA: Estas Precauciones de Seguridad son para su protección. Ellas hacen resumen de información proveniente de las referencias listadas en la sección "Información Adicional Sobre La Seguridad".
section 1 sEGURIDAD 1. Asegúrese de que el chasis de la fuente de poder esté conectado a tierra através del sistema de electricidad primario. 2. Conecte la pieza de trabajo a un buen sistema de tierra física. 3. Conecte el cable de retorno a la pieza de trabajo. Cables y conductores expuestos o con malas conexiones pueden exponer al operador u otras personas a un choque eléctrico fatal. 4. Use el equipo solamente si está en buenas condiciones. Reemplaze cables rotos, dañados o con conductores expuestos.
section 1 sEGURIDAD 5. ADVERTENCIA-- Este producto cuando se utiliza para soldaduras o cortes, produce humos o gases, los cuales contienen químicos conocidos por el Estado de California de causar defectos en el nacimiento, o en algunos casos, Cancer. (California Health & Safety Code §25249.5 et seq.) 1. Siempre tenga personal cualificado para efectuar l a instalación, diagnóstico, y mantenimiento del equipo. No ejecute ningún trabajo eléctrico a menos que usted esté cualificado para hacer el trabajo. 2.
section 1 sEGURIDAD SIGNIFICADO DE LOS sImbolOs -- Según usted avanza en la lectura de este folleto: Los Símbolos Significan ¡Atención! ¡Esté Alerta! Se trata de su seguridad. Significa riesgo inmediato que, de no ser evadido, puede resultar inmediatamente en serio daño personal o la muerte. Significa el riesgo de un peligro potencial que puede resultar en serio daño personal o la muerte. Significa el posible riesgo que puede resultar en menores daños a la persona.
section 1 sÉCURITÉ 1.3 Safety - French INCENDIES ET EXPLOSIONS -- La chaleur provenant des flammes ou de l'arc peut provoquer un incendie. Le laitier incandescent ou les étincelles peuvent également provoquer un incendie ou une explosion. Par conséquent : AVERTISSEMENT : Ces règles de sécurité ont pour but d'assurer votre protection. Ils récapitulent les informations de précaution provenant des références dans la section des Informations de sécurité supplémentaires.
section 1 sÉCURITÉ 1. Assurez-vous que le châssis de la source d'alimentation est branché au système de mise à la terre de l'alimentation d'entrée. 2. Branchez la pièce à traiter à une bonne mise de terre électrique. 3. Branchez le câble de masse à la pièce à traiter et assurez une bonne connexion afin d'éviter le risque de choc électrique mortel. 4. Utilisez toujours un équipement correctement entretenu. Remplacez les câbles usés ou endommagés. 5.
section 1 sÉCURITÉ 5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé dans une opération de soudage ou de coupage, dégage des vapeurs ou des gaz contenant des chimiques considéres par l'état de la Californie comme étant une cause des malformations congénitales et dans certains cas, du cancer. (California Health & Safety Code §25249.5 et seq.) ENTRETIEN DE L'ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou inadéquate peut causer des blessures graves ou mortelles. Par conséquent : 1.
section 1 sÉCURITÉ SIGNIFICATION DES SYMBOLES Ce symbole, utilisé partout dans ce manuel, signifie "Attention" ! Soyez vigilant ! Votre sécurité est en jeu. DANGER Signifie un danger immédiat. La situation peut entraîner des blessures graves ou mortelles. AVERTISSEMENT Signifie un danger potentiel qui peut entraîner des blessures graves ou mortelles. ATTENTION Signifie un danger qui peut entraîner des blessures corporelles mineures.
section 2 description 2.1 General Depending on the choice of input power, each package includes the following appropriate PCM-875 Console/Power Source: 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.
section 2 description 2.4 Specifications Table 2-2. 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.
section 2 description 7.3" (185 mm) Table 2-3. PT-27 Torch Specifications 3" (76 mm) Current Capacity (100% duty) 80 A DCSP Length of Service Lines 25 ft or 50 ft 75° Weight 25 ft 5.2 lbs (2.4 kg) 50 ft 9.6 lbs (4.4 kg) 1" (25.4 mm) 1" (25.4 mm) Figure 2-1. PT-27 Dimensions 120 CUTTING SPEED (IN. PER MIN.
section 2 description 20
section 3 installation 3.1 General 3.5 Primary Electrical Input Connections (Figure 3-1) 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.
section 3 installation Table 3-1. Recommended Sizes For Input Conductors and Line Fuses Input Requirements Volts Phase Amps 208 1 55A 208 3 26A/Ph. 230 1 49A 230 3 24A/Ph. 400 3 13 460 3 11 575 3 9 Input & Gnd Fuse Conductor Size 1. CU/AWG Amps 2. 6 80 6 50 6 80 6 50 10 25 10 25 10 20 3.6 SECONDARY (OUTPUT) CONNECTIONS (Refer to Fig. 3-1) 3. 4. 5.
section 3 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 3-1 and WARNING in regards to chassis ground in Section 3.5.
section 3 installation 3.7 Connecting PCM-875 for 200(208) Vac Input 1. 2. 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. 3. 4. 5. The PCM-875 power source with 200/230 vac, 1-phase input capability is factory set for 230 vac input.
section 3 installation 3.8 MECHANIZED CUTTING INSTALLATION WITH THE PT-20AM TORCH ARC STARTER CABLE - 37410 (50’) 37411 (100’) POWER CABLE - 37341 (50’) 37342 (100’) ARC STARTER 37338 WORK CABLE(25’) (Supplied with PCM-875) AIR HOSE - 37343 (50’) 37344 (100’) PT-20AM 21785 (4.5’) 21786 (17’) PILOT ARC CABLE - 37339 (50’) 37340 (100’) SCHEMATIC - MECHANICAL SYSTEM SETUP (See Figure 3-4 for detailed connections) CNC Interface Connection (Located inside console, left side of base.) Figure 3-3.
section 3 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” PILOT ARC CABLE - 37339 (50’) 37340 (100’) SPLICE CONNECTOR* (Supplied with 37338) “C” “B” Make sure all power is off before making following connections. 25mm min. 1. 2. AIR HOSE - 37343 (50’) 37344 (100’) 3. 4.
section 4 operation 4.1 Operation 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. 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. ELECTRIC SHOCK can kill. • Do NOT operate the unit with the cover removed.
section 4 operation AIR REGULATOR CONTROL KNOB POWER LIGHT (WHITE) FAULT LIGHT (AMBER) REAR VIEW AIR PRESSURE GAUGE AIR TEST SWITCH TRIGGER LOCK SWITCH CURRENT CONTROL KNOB POWER ON-OFF (I-O) SWITCH FUSE (3A) Figure 4-1. PCM-875 Controls NOTE: 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.
section 4 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 4-4. Piercing Technique using the PT-27 4.4 Common Cutting Problems D. Double Arcing. (Damaged Nozzle Orifice.) Listed below are common cutting problems followed by the probable cause of each.
section 4 operation 30
section 5 maintenance 5.1 General 5.3 PT-27 Torch Consumable Parts 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. Make sure power switch on PCM-875 is in OFF position before working on the torch.
section 5 maintenance Other handling precautions that should also be observed are as follows: 5.4 Flow Switch (Figure 5-2) 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.
section 5 maintenance 5.6 Troubleshooting 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.
section 5 maintenance 5.7 Troubleshooting GUIDE A. Power Light (PL1) does not come on. 1. 2. Visually inspect the machine for any damage. Check if the cooling fan is running. If not, then check the following : a. b. Check if the machine power cord is plugged to the input power receptacle. Measure the input power at the receptacle. If not present, then check the wall disconnect switch and it’s fuses. c. Check Fuse (F1).
section 5 maintenance 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.
section 5 maintenance 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.
section 5 maintenance H. Air does not shut off. 1. 2. Check air test, the gas solenoid valve is energized when the switch is in the “on” position. 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. 6.
section 5 maintenance 5.8 Reference Voltage Checks A. Control Board Assembly (PCB1) 1. LED’s LED-1 LED-2 LED-3 - Torch Switch High Frequency Gas Solenoid Valve 2. Voltage Test Points Tests are made with power on - no arc.
section 5 maintenance 5.9 Sequence of Operation A. TRIGGER LOCK “UNLOCK” position TORCH SWITCH PUSH GAS SOLENOID VALVE RELEASE OPEN 2 SEC. PREFLOW CLOSE 10 SEC Postflow FLOW SWITCH FAULT OVERLOAD LIGHT OPEN CLOSE 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.
section 5 maintenance B. TRIGGER LOCK "LOCK" position TORCH SWITCH PUSH RELEASE GAS SOLENOID VALVE OPEN 2 SEC. PREFLOW PUSH RELEASE CLOSE 10 SEC Postflow CLOSE FLOW SWITCH POSTFLOW OPEN 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.
section 6 replacement parts 6.0 Replacement Parts 6.1 General Always provide the 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 ensure 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 may be ordered from your ESAB Distributor.
section 6 replacement parts 5, 4 3, 4 6 1, 2 7 8, 9 16 15 8 10, 11 14 13 12 Fig. 6-1. PCM-875 Power Source, Front View Item No. Qty. Req. Part No. Description 1 1 137630611 2 1 0558001176 3 1 673213 4 2 951474 5 1 634518 6 1 951754 7 1 951526 8 2 993426 9 1 21711 10 1 23606172 11 1 680560 12 4 182W12 13 1 0558001174 14 1 36330YL 15 1 954008 16 2 13734588 Circuit Symbol PCM-875, Series A KNOB POT. 10K 3W (NOMEX INSUL.
section 6 replacement parts 154, 155, 156 153 151, 152 157 158, 159 160, 161 162 Fig. 6-2. PCM-875 Power Source, Rear View Item No. Qty. Req. Part No.
section 6 replacement parts 28 29, 30 27 27 25, 26 43 42 25, 26 24 31 21 32, 33, 34 23 22 35 46,47 39 36 37 38 44, 45 41 40 Fig. 6-3.
section 6 replacement parts Fig. 6-3. PCM-875 Power Source, Left Side View (208/230) cont'd Item No. Qty. Req. Part No.
section 6 replacement parts 61 67 71 56, 57, 58 59 56, 57, 58 55 62 60 63 53 64, 65, 66 54 68 51 52 77, 78 74 70 69 75, 76 73 72 Fig. 6-4.
section 6 replacement parts Fig. 6-4. PCM-875 Power Source, Left Side View (400/400CE/460/575) Item Qty. Part No. Req. No.
section 6 replacement parts 90,91 89 88 87 81 86 92 93 80 94 95 82, 83, 84 96 97 104 98, 99 100 101,102,103 Fig. 6-5.
section 6 replacement parts Fig. 6-5. PCM-875 Power Source, Right Side View (208/230) cont'd Item No. Qty. Req. Part No.
section 6 replacement parts 119, 120 118 117 116 111 121 112, 113, 114 122 110 123, 135 126 124 125 134 127, 128 130, 131, 132 129 133 Fig. 6-6.
section 6 replacement parts Fig. 6-6. PCM-875 Power Source, Right Side View (400/400CE/460/575 V) cont'd Item No. Qty. Req. Part No.
section 6 replacement parts 142 143 144 145 140 141 Fig. 6-7. PCM-875 (208/230V) Power Source, Top View with PCB1 and Shelf Removed Item No. Qty. Req. Part No. Description 140 1 954673 141 1 952026 142 2 17240310 143 1 951182 144 1 2091558 145 1 954700 1 954681 Circuit Symbol LABEL CNC INTERFACE TERM.
section 6 replacement parts 53
notes 54
revision history 1. Revision “A” edition (1/2002) of the manual covers the following changes: Control Board Assembly, P/N 38175 was replaced with Control Board Assembly, P/N 38214. . Removes the Valve Pin, P/N 21619 from the PT-27 Spare Parts Kit and all other references to this part which is now obsolete for this package. . Revision B - updated replacement parts section. 4. Revision C - Changed 6 foot input power cable part number from 37573 to 0558004221.
ESAB Welding & Cutting Products, Florence, SC Welding Equipment COMMUNICATION GUIDE - CUSTOMER SERVICES A. CUSTOMER SERVICE QUESTIONS: Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST Order Entry Product Availability Pricing Order Information Returns B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting C.
