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ESAB 0558002834, Instruction Manual

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ESAB 0558002834 Instruction Manual Download Page 25

SECTION  5

         TROUBLESHOOTING

25

5.3REFERENCE 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

-

Ground

TP-1

-

+15 vdc

TP-2

-

+12 vdc

TP-3

-

-12 vdc

TP-4

-

+5 vdc

TP-9

-

IGBT’s driving signal - switching frequency = 16 KHz

TP-10 -

IGBT’s driving signal - switching frequency = 16 KHz

Frequency - 16.0 KHz

0

-13 vdc

13 vdc

40 usec - LPG50
50 usec - LPG80

6 usec - LPG50
9 usec - LPG80

Figure 5.1 IGBT Gating Signal

Off Time

5 

µ

s

62.5 

µ

s

Summary of Contents for 0558002834

Page 1: ...all 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 an...

Page 2: ...roper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer TABLE OF CONTENTS SECTION TITLE PAGE PARAGRAPH SECTION 1 DESCRIPTION 7 1 1 General 7 1 2 Scope 7 1 3 Packages Available 7 1 4 Specifications 8 SECTION 2 INSTALLATION 10 2 1 General 10 2 2 Equipment Required 10 2 3 Location 10 2 4 Inspection 10 2 5 Primary Electrical Input Connectio...

Page 3: ...es on the workpiece which might pro duce 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 SAFETY PRECAUTIONS 10 98 5 Do not use equipment beyond its ratings For example overloaded welding cable can ...

Page 4: ...s 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 EQUIPMENT MAINTENANCE Faulty or improperly maintained equipment can cause injury or death Therefore 1 Always have qualified personnel perform the i...

Page 5: ...loigné de la zone de travail augmente en effet le risque de pas sage d un courant de sortie par des chaînes delevage PRÉCAUTIONS DE SÉCURITÉ 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 ent...

Page 6: ...ticulières 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 des dommages corporels graves voire mortels en déclenchant des incendies ou des chocs électriques Observez par conséquent...

Page 7: ...ch for use on this console 1 2 SCOPE Thepurposeofthismanualistoprovidetheoperatorwith all the information required to install and operate the PCM 1125plasmaarccuttingpackage Technicalrefer ence material is also provided to assist in troubleshoot ing the cutting package 1 3 PACKAGES AVAILABLE PCM 1125listedonthefrontcoverincludesthefollowing components PT 27 Torch 75 head 25 ft P N 21661 PT 27 Spar...

Page 8: ...70A output change the input cable to 4 AWG 3 conductor or 4 AWG 2 conductor with ground Duty cycle is based on a 10 minute period therefore a 70 duty cycle means the power source may operate for 7 minutes with a cool down period of 3 minutes 100 duty cycle means the power source may operate continuously PCM 1125 Specifications for Literature Rated Inputs Rated Outputs Output Open Power Duty Amps C...

Page 9: ...CESSORIES 1 TorchWrap SparePartsKitHolder P N33952GY Unitshave4mountingholesonleftsideformounting this accessory holder 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 1125 around the job site Figure 1 2 PT 27 PCM 1125 Cutting Performance PT 27 PCM 1125 70A air Carbon Steel 0 10 20 30 40 50 60 70 80 90 0 0 5 1 1 5 Plate Thickn...

Page 10: ...moved 2 5 PRIMARY ELECTRICAL INPUT CONNECTIONS FIGURE 2 1 ELECTRIC SHOCK CAN KILL Precautionary mea sures should be taken to provide maximum protec tion 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 Besurethatthepowersourceisproperlyconfigured for yo...

Page 11: ...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 workpieceisconnectedtoanapprovedearthground with a properly sized ground cable Table 2 1 Recommended Sizes For Input Conductors and Line Fuses Input Req...

Page 12: ... regards to chassis ground in Section 2 5 TORCH POWER CABLE CONNECTION TORCH PILOT ARC CONNECTION INPUT POWER CABLE See Table 2 1 Figure 2 1 PCM 1125 Interconnection Diagram NOTE The 208 230 V model is equipped with a plug for single phase connection only The plug is mounted to a 4 conductorcable If3 phaseconnectionisdesired remove and discard the plug and refer to Sect 2 5 ACCESS FOR CNC INTERFAC...

Page 13: ... vac input power Fig 2 Connecting PCM 1125 for 208 Vac Input ELECTRIC SHOCK CAN KILL Precautionary mea sures should be taken to provide maximum protec tion 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 208 VAC Input ThePCM 1125powersourcewith208 230vac 1 phase input capability is ...

Page 14: ...1125 AIR HOSE 37343 50 37344 100 ARC STARTER CABLE 37410 50 37411 100 PT 20AM 21785 4 5 21786 17 SCHEMATIC MECHANICAL SYSTEM SETUP See Figure 2 4 for detailed connections Figure 2 3 MECHANICAL CUTTING INTERFACE DIAGRAM CNC Interface Connection Located inside console left side of base 2 8 MECHANIZED CUTTING INSTALLATION WITH THE PT 20AM TORCH ...

Page 15: ...Arc Start WHT Arc Start Arc Starter Cable Ref ADAPTOR 999278 2 125 54mm Make sure all power is off before making following connections 1 Remove cover from PCM 1125 2 Insert the 4 service lines from Arc Starter through the torch opening of front panel 3 Connect large hole terminal end of Pilot Arc Cable A to connection where shown Tighten screw firmly 4 Connect adaptor 999278 to fitting where shown...

Page 16: ...d operations will come to a complete stop 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 befo...

Page 17: ...ONTROL KNOB FAULT LIGHT AMBER POWER LIGHT WHITE AIR PRESSURE GAUGE AIR TEST SWITCH TRIGGER LOCK SWITCH CURRENT CONTROL KNOB POWER ON OFF I O SWITCH CIRCUIT BREAKER FUSE 3A Figure 3 2 Recommended Torch Angle of 5 to 15 NOTE When replacing the nozzle always inspect the electrode for wear If less than 19 32 of elec trode shaft is remaining replace the electrode If the electrode is used beyond this re...

Page 18: ...ssure 5 Low air flow rate B Main Arc Extinguishes 1 Cutting speed too slow 2 Worn electrode C Dross Formation In some materials and thick nesses it may be impossible to get dross free cuts 1 Current too low 2 Cutting speed too fast or too slow 3 Improper air pressure 4 Faulty nozzle or electrode 5 Low air flow rate D Double Arcing Damaged Nozzle Orifice 1 Nozzle contacting work when current is set...

Page 19: ...ings and ground connec tions are tight G With all input power disconnected and wearing propereyeandfaceprotection blowouttheinside of the PCM 1125 using low pressure dry com pressed air Wateroroiloccasionallyaccumulatesincompressed air lines Be sure to direct the first blast of air away from the equipment to avoid damage to the PCM 1125 H Occasionally bleed all water from the filter be neath the a...

Page 20: ...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 4 3 Also care must be taken to achieve maximum contact i e minimum contact thermal resis tance for the best heat dissipation Application of a thermal pad on the contact sur...

Page 21: ...nnections loose or burned wiring or components bulged or leaking capacitors or any other sign of damage or discoloration 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 into the input power receptacle b Measure the input power ...

Page 22: ...op 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 p...

Page 23: ... 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 oper...

Page 24: ... 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...

Page 25: ...ade with power on no arc Disable High Frequency by disconnecting blue wire with black sleeve TP 0 Ground TP 1 15 vdc TP 2 12 vdc TP 3 12 vdc TP 4 5 vdc TP 9 IGBT s driving signal switching frequency 16 KHz TP 10 IGBT s driving signal switching frequency 16 KHz Frequency 16 0 KHz 0 13vdc 13vdc 40usec LPG50 50usec LPG80 6usec LPG50 9usec LPG80 Figure 5 1 IGBT Gating Signal Off Time 5 µs 62 5 µs ...

Page 26: ...OPERATION A TRIGGER LOCK UNLOCK position PUSH RELEASE 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 10 SEC Postflow OPEN 2 SEC ...

Page 27: ...GIZE NOTES 1 When the torch switch is pushed during postflow period the postflow time is reset the preflow time is 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 wa...

Page 28: ...28 D 37567 Figure 5 1 Schematic Diagram PCM 1125 208 230V 50 60 Hz 1 and 3 Phase ...

Page 29: ...29 D 37568 Figure 5 2A Wiring Diagram Sheet 1 of 2 PCM 1125 208 230V 50 60 Hz 1 and 3 Phase ...

Page 30: ...30 D 37568 Figure 5 2 Wiring Diagram Sheet 2 of 2 PCM 1125 208 230V 50 60 Hz 1 and 3 Phase ...

Page 31: ...31 D 37569 Figure 5 3 Schematic Diagram PCM 1125 460V 50 60 Hz 3 Phase ...

Page 32: ...32 D 37570 Figure 5 4A Wiring Diagram Sheet 1 of 2 PCM 1125 460V 50 60 Hz 3 Phase ...

Page 33: ...33 D 37570 Figure 5 4B Wiring Diagram Sheet 2 of 2 PCM 1125 460V 50 60 Hz 3 Phase ...

Page 34: ...34 D 37571 Figure 5 5 Schematic Diagram PCM 1125 575V 60 Hz 3 Phase ...

Page 35: ...35 D 37572 Figure 5 6A Wiring Diagram Sheet 1 of 2 PCM 1125 575V 60 Hz 3 Phase ...

Page 36: ...36 D 37572 Figure 5 6B Wiring Diagram Sheet 2 of 2 PCM 1125 575V 60 Hz 3 Phase ...

Page 37: ...ay 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 Refer to the Communication Guide located on the last page of the manual for a list of customer service phone numbers 6 3 LITERATURE REVISIONS REVISION...

Page 38: ...18 SWITCH TOGGLE DPDT 2 POS 15 A 125 V S2 6 1 951754 LAMP LED YEL 12 V PL2 7 1 951526 LAMP NEON WHITE PL1 8 2 993426 GROMMET RUBBER 1 50 ID x 1 76 OD 9 1 21711 GAUGE 1 50 160 PSI WHITE 10 1 23602576 STRAIN RELIEF EYCO 1214 11 1 680560 WORK CABLE 25 FT Not Shown 12 4 182W12 FOOT RUBBER 13 1 37556GY CHASSIS PCM 1125 14 1 36330YL DOOR ACCESS YEL 15 1 954008 LABEL WARNING HI VOLTAGE 16 2 13734588 LABE...

Page 39: ...METAL OXIDE VARISTOR 275 V See wiring MOV1 2 3 35 2 952873 IGBT 600 V 200 A includes PAD 951191 Q1 1 36 2 17750010 RESISTOR 50 W 10 OHM PAD 951194 R7 37 1 32958 CURRENT TRANSFORMER ASS Y T4 38 1 952255 CAPACITOR 40 µf 400 VDC C4 39 1 950711 THERMAL SWITCH 194 F TS1 40 4 17721020 RESISTOR 24 W 20 OHMS PAD 951193 r3 4 5 6 41 1 951202 FLOW SWITCH 25 GPM FS 42 2 951940 CAPACITOR 1µf 630W VDC C15 16 43...

Page 40: ...SECTION 6 REPLACEMENT PARTS 40 59 60 61 56 57 58 62 63 64 65 66 77 67 79A 68 69 70 71 72 78 79 73 74 75 76 51 52 53 54 55 56 57 58 Fig 6 3 PCM 1125 Power Source Left Side View 460 575 ...

Page 41: ... HOSE ASS Y B A x 1 4 NPT RUB 62 1 37561 BUSBAR NEG 63 1 950487 TERM BLOCK 2 POS Not used on 575 V TB5 64 1 952235 MODULE INPUT BRIDGE SCR includes PAD 952280 IBR 65 1 2062282 CAPACITOR 22µf 1KV See wiring C19 66 3 950591 METAL OXIDE VARISTOR 510 V See wiring MOV1 2 3 3 951963 METAL OXIDE VARISTOR 625 V 575 V See wiring MOV1 2 3 67 1 17750010 RESISTOR 50W 10 OHM PAD 951194 R7 68 1 32958 CURRENT TR...

Page 42: ...SECTION 6 REPLACEMENT PARTS 42 90 91 89 88 87 86 85 81 80 101 102 103 82 83 84 100 98 99 104 97 96 95 94 105 93 92 Fig 6 4 PCM 1125 Power Source Right Side View 208 230 ...

Page 43: ... Y PCB1 88 1 37603 MAIN TRANSFORMER ASS Y T1 89 2 951469 CAPACITOR 022µf 250 VAC See Wiring C17 18 90 1 31488 SHUNT BOARD ASS Y PCB4 91 1 951515 CAPACITOR 047µf 660 VAC C23 92 1 38039 START UP BOARD ASS Y PCB5 93 1 952233 INDUCTOR OUTPUT L1 94 1 36721 BUSBAR OUTPUT 95 1 182W64 LOCK TWIST MIDGET J1 96 1 36717 BRACKET OUTPUT 97 1 37669 REACTOR ASS Y HI FREQ T3 98 1 36431 SPARK GAP ASS Y SG 99 2 9513...

Page 44: ...SECTION 6 REPLACEMENT PARTS 44 119 120 118 117 116 115 111 112 113 114 110 133 130 131 132 129 127 128 134 126 125 124 123 135 122 121 Fig 6 5 PCM 1125 Power Source Right Side View 460 575 V ...

Page 45: ...0 VAC See wiring C17 18 119 1 31488 SHUNT BOARD ASS Y PCB4 120 1 951515 CAPACITOR 047µf 660 VAC See wiring C23 121 1 38039 START UP BOARD ASS Y PCB5 122 1 952233 INDUCTOR OUTPUT L1 123 1 36721 BUSBAR OUTPUT 124 1 182W64 LOCK TWIST MIDJET J1 125 1 36717 BRACKET OUTPUT KYDEX 126 1 37669 REACTOR ASS Y HI FREQ T3 127 1 36431 SPARK GAP ASS Y SG 128 2 951342 CAPACITOR 2500pf 15 K V C13 14 129 1 951179 T...

Page 46: ...INTERFACE 141 1 952026 TERM BLOCK 7 POS 25 A TB4 142 2 17240310 RESISTOR 10 K 25 W R2 15 143 1 951182 FAN AC AXIAL M1 144 1 2091558 LABEL GROUND BLACK 145 1 954787 LABEL INPUT 208 230 V 1 954681 LABEL INPUT 400 460 V Fig 6 6 PCM 1125 Power Source Top View with PCB1 and Shelf Removed 143 142 144 145 140 141 ...

Page 47: ...BEL RATING PCM 1125 208 230 1 954785 LABEL RATING PCM 1125 460 1 954786 LABEL RATING PCM 1125 575 158 2 952136 FUSE HOLDER 160 1 97W63 STRAIN RELIEF 161 1 37573 INPUT POWER CABLE 6 FT 4 COND 6AWG w PLUG 208 230 V 1 37574 INPUT POWER CABLE 10 FT 4 COND 10AWG 460 575 V 162 1 36107 SWITCH POWER 600 V 63 A S1 163 1 952559 FUSE 3A FAST ACTING F1 164 1 954746 LABEL FAULT INDICATOR Fig 6 7 PCM 1125 Power...

Page 48: ...epair Stations C TECHNICAL SERVICE Telephone 800 ESAB 123 Fax 843 664 4452 PartNumbers Technical Applications Hours 8 00 AM to 5 00 PM EST PerformanceFeatures Technical Specifications EquipmentRecommendations 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 H...

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