PCM-875 PLASMA CUTTING CONSOLE/POWER SOURCES with CE Compliances 230 V, 50 Hz, 3-Phase 400 V, 50 Hz, 3-Phase Service Manual 558000-892 0202
WARNING ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANUFACTURERS’ HAZARD DATA. ELECTRIC SHOCK - Can kill l Install and earth the welding unit in accordance with applicable standards. l Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing. l Insulate yourself from earth and the workpiece. l Ensure your working stance is safe.
SECTION 1 SPECIFICATIONS PCM-875 Specifications Rated 60% Duty Cycle* 60 A @ 120 V dc Output 100% Duty Cycle* 50 A @ 120 V dc Output Current Range 10 to 60 Amperes Open Circuit Voltage 275 V dc Rated Primary Input 220 V ac, 50/60 Hz, 3-phase 24 A/phase @ 7.2 kW Max.
SECTION 2 MAINTENANCE 2.1 GENERAL If this equipment does not operate properly, stop work immediately and investigate the cause of the malfunction. Maintenance work must be performed by an experienced person, and electrical work by a trained electrician. Do not permit untrained persons to inspect, clean, or repair this equipment. Use only recommended replacement parts. The PT-27 torch head contains a gas flow check valve that acts in conjunction with the flow switch and circuitry within the power source.
SECTION 2 MAINTENANCE 2.4 FLOW SWITCH (FIGURE 2-2) • When excessive contamination is found in the air, the flow switch (FS-4) should be disassembled and cleaned as follows: • A. Ensure the system is shut down and there is no trapped air under pressure in the piping. B. Remove the piston plug. C. Remove the spring. Use care when handling spring to prevent distortion. D. Remove the piston. E. Clean all parts with cleaning agent.
SECTION 3 TROUBLESHOOTING 3.1Troubleshooting The cause of control malfunctions can be found by referring to the sequence of operations and electrical schematic diagram (Figure 3-1 or 3-3) and checking the various components. A volt-ohmmeter will be necessary for some of these checks. ELECTRIC SHOCK CAN KILL! Be sure that all primary power to the machine has been externally disconnected.
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.
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.
SECTION 3 TROUBLESHOOTING F. High Frequency and Pilot Arc are on but Main Arc does not transfer. 1. Make sure work clamp is connected to work material. 2. Check the torch. Replace consumables if necessary. 3. Make sure the current setting potentiometer is set above 10 amps. If it is, set below 10 amps, then HI FREQUENCY will go on and off at 5 sec intervals. G. Poor Cutting Performance. 1. Check air supply regulator . It should be adjusted to 4.5-5.2 bar. 2.
SECTION 3 TROUBLESHOOTING 3.3REFERENCE VOLTAGE CHECKS A. Control Board Assembly (PCB1) 1. LED’s LED-1 LED-2 LED-3 2. - Torch Switch High Frequency Gas Solenoid Valve Voltage Test Points Tests are made with power on - no arc.
SECTION 3 TROUBLESHOOTING 3.4 SEQUENCE OF OPERATION A. TRIGGER LOCK “UNLOCK” position TORCH SWITCH PUSH RELEASE OPEN CLOSE GAS SOLENOID VALVE 2 SEC. PREFLOW 10 SEC Postflow FLOW SWITCH CLOSE OPEN FAULT OVERLOAD LIGHT ENERGIZE HF CIRCUIT INVERTER CUTTING ARC (CURRENT) NOTES: 1. When the torch switch is pushed during postflow period, the postflow and preflow times are canceled, and the HF is energized immediately. 2. When the amber fault light comes on, cutting operation should be stopped.
SECTION 3 TROUBLESHOOTING B. TRIGGER LOCK "LOCK" position PUSH RELEASE PUSH RELEASE TORCH SWITCH OPEN CLOSE GAS SOLENOID VALVE 2 SEC. PREFLOW 10 SEC Postflow POSTFLOW CLOSE OPEN FLOW SWITCH FAULT LIGHT ENERGIZE HF CIRCUIT INVERTER CUTTING ARC (CURRENT) NOTES: 1. When the torch switch is pushed during postflow period, the postflow and preflow times are canceled, and the HF is energized immediately. 2. When the red fault light comes on, cutting operation should be stopped.
D-36918 Figure 3.
D-36917 Figure 3.
D-36917 Figure 3.
D-36604 Figure 3.
D-36605 Figure 3.
D-36605 Figure 3.
SECTION 4 REPLACEMENT PARTS 3, 4 5, 4 6 1, 2 7 8, 9 16 15 8 10, 11 14 12 13 Fig. 4-1. PCM-875 Power Source, Front View Item No. Qty. Req. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 1 1 2 1 1 1 2 1 1 1 4 1 1 1 2 558000373 558000372 558000698 558000596 558000385 558000383 558000384 558000593 558000594 558000178 558000608 558000552 558000630 558000631 558000599 558000598 Circuit Symbol Description KNOB POT. 10K 2W (NOMEX INSUL.
SECTION 4 REPLACEMENT PARTS 28 27 25, 26 25, 26 24 29, 30 31 23 32, 33, 34 22 21 35 36 37 38 46 39 40 41 42 43 44, 45 Fig. 4-2. PCM-875 Power Source, Left Side View (230 V) Item No. Qty. Req. Part No.
SECTION 4 REPLACEMENT PARTS 61 60 59 56, 57, 58 56, 57, 58 62 55 64, 65, 66 54 53 52 51 67 68 69 70 71 72 73 74 75, 76 Fig. 4-3. PCM-875 Power Source, Left Side View (400 V) Item No. Qty. Req. Part No.
SECTION 4 REPLACEMENT PARTS 90, 91 89 88 86 87 85 82, 83, 84 92 81 93 80 94 95 101, 102, 103 96 97 104 98, 99 100 Fig. 4-4. PCM-875 Power Source, Right Side View (230 V) Item No. Qty. Req. Part No.
SECTION 4 REPLACEMENT PARTS 119, 120 117 118 115 116 112, 113, 114 121 111 122 123 110 124 125 126 134 127, 128 129 133 130, 131, 132 Fig. 4-5. PCM-875 Power Source, Right Side View (400 V) Item No. Qty. Req. Part No.
SECTION 4 REPLACEMENT PARTS 142 143 141 144 145 140 Fig. 4-6. PCM-875 Power Source, Top View with PCB1 and Shelf Removed Item No. Qty. Req. Part No. 140 141 142 143 144 145 1 1 2 1 1 1 1 558000670 558000671 558000658 558000388 558000672 558000673 558000674 Circuit Symbol Description LABEL CNC INTERFACE TERM.
SECTION 4 REPLACEMENT PARTS 154, 155, 156 153 151, 152 157 158, 159 158, 163 160, 161 162 Fig. 6-7. PCM-875 Power Source, Rear View Item No. Qty. Req. Part No.
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.
