Instruction manual

ManualsBrandsESAB ManualsDo-It-Yourself toolsPCM-875A

INSTRUCTION MANUAL

PCM-875

PLASMA ARC CUTTING PACKAGE

F15-335-E

July, 2007

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.

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

Summary of content (48 pages)

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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.
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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.
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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.
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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.
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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.
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PRÉCAUTIONS DE SÉCURITÉ a. Éloigner suffisamment tous les matériaux combustibles du secteur où lon exécute des soudures ou des coupes à larc, à moins de les recouvrir complètement dune bâche non-inflammable. Ce type de matériaux comprend notamment le bois, les vêtements, la sciure, lessence, le kérosène, les peintures, les solvants, le gaz naturel, lacétylène, le propane et autres substances combustibles semblables. b.
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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 linstallation, le dépannage et lentretien du poste de soudage et de coupage. Neffectuez aucune réparation électrique sur léquipement à moins dêtre qua-lifié à cet effet. b.
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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).
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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SECTION 5 TROUBLESHOOTING 5.3REFERENCE VOLTAGE CHECKS A. Control Board Assembly (PCB1) 1. LEDs 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.
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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.
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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.
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D-36587 28 Figure 5-1.
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D-36595 29 Figure 5-2.
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D-36595 30 Figure 5-3.
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31 D-36597-B Figure 5-4.
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D-36598 32 Figure 5-5.
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D-36598 33 Figure 5-6.
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D-36715-A 34 Figure 5-7.
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D-36716 35 Figure 5-8.
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D-36716 36 Figure 5-9.
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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 ..........................
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.