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ESAB PCM-1125, Instruction Manual

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ESAB PCM-1125 Instruction Manual Download Page 33

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. 

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.

PISTON PLUG

PISTON

SPRING

FLOW SWITCH

Figure 5-2. Disassembly / Assembly of Flow Switch

SeCTION 5 

MAINTeNANCe

Summary of Contents for PCM-1125

Page 1: ...instructions for the following PCM 1125 cutting packages starting with Serial No PORJ138001 P N 0558001248 208 230 V 1 3 Phase 50 60 Hz P N 0558001249 460 V 3 Phase 50 60 Hz P N 0558002989 400 V 3 Phase 50 60 Hz P N 0558001250 575 V 3 Phase 50 60 Hz Instruction Manual F15 707 A 12 2005 ...

Page 2: ...le responsibility for any malfunction which results from improper use faulty maintenance damage improper repair or alteration by anyone other than the manufacturer or a ser vice facility designated by the manufacturer Be sure this information reaches the operator You can get extra copies through your supplier These INSTRUCTIONS are for experienced operators If you are not fully familiar with the p...

Page 3: ...ections 22 3 6 Secondary Output Connections 23 3 7 Connecting PCM1125 for 200 208 Vac Input 25 4 0 Operation 27 4 1 Operation 27 4 2 PCM 1125 Controls 27 4 3 Cutting with the PT 27 28 5 0 Maintenance 31 5 1 General 31 5 2 Inspection and Cleaning 31 5 3 PT 27 Torch Consumable Parts 32 5 4 Flow Switch 33 5 5 1GBT Handling and Replacement 34 5 6 Troubleshooting 35 5 7 Troubleshooting Guide 36 5 8 Com...

Page 4: ... table of contents ...

Page 5: ...clothing 5 Protect other personnel from arc rays and hot sparks with a suitable non flammable partition or curtains 6 Usegogglesoversafetyglasseswhenchippingslag orgrinding Chippedslagmaybehotandcanflyfar Bystanders should also wear goggles over safety glasses FIRES AND EXPLOSIONS Heat from flames and arcs can start fires Hot slagorsparkscanalsocausefiresand explosions Therefore 1 Remove all combu...

Page 6: ...2 ExposuretoEMFmayhaveotherhealtheffectswhich are unknown 3 Welders should use the following procedures to minimize exposure to EMF A Route the electrode and work cables together Secure them with tape when possible B Never coil the torch or work cable around your body C Do not place your body between the torch and work cables Route cables on the same side of your body D Connecttheworkcabletothewor...

Page 7: ... 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 Alwayshavequalifiedpersonnelperformtheinstal lation troubleshooting and maintenance work Do not perform any electrical work unless you are qualified to perform such work 2 Before performing any maintenance w...

Page 8: ... Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances Meaning of symbols As used throughout this manual Means Atten tion Be Alert Your safety is involved Meansimmediatehazardswhich if not avoided will result in im mediate serious personal injury or loss of life Means potential hazards which could result in personal injury or loss of life Meanshazardswhichcouldre...

Page 9: ...os del arco y chis pascalientesconunacortina adecuadano flamable como división 6 Usecaretaprotectoraademásdesusgafasdesegu ridad cuando esté removiendo escoria o puliendo La escoria puede estar caliente y desprenderse con velocidad Personas cercanas deberán usar gafas de seguridad y careta protectora FUEGO Y EXPLOSIONES El calor de lasflamasyelarco puedenocacionar fuegos Escoria caliente y las chi...

Page 10: ... 2 Exponerseacamposelectromagnéticos EMF puede causar otros efectos de salud aún desconocidos 3 Los soldadores deberán usar los siguientes proced imientos para minimizar exponerse al EMF A Mantenga el electrodo y el cable a la pieza de trabajo juntos hasta llegar a la pieza que usted quiere soldar Asegúrelos uno junto al otro con cinta adhesiva cuando sea posible B Nunca envuelva los cables de sol...

Page 11: ...ENIMIENTO DEL EQUIPO Equipo defectuoso o mal mantenido puede cau sar daño o muerte Por lo tanto 1 Siempre tenga personal cualificado para efec tuar l a instalación diagnóstico y mantenimiento del equipo No ejecute ningún trabajo eléctrico a menos que usted esté cualificado para hacer el trabajo 2 Antes de dar mantenimiento en el interior de la fuente de poder desconecte la fuente de poder del sumi...

Page 12: ...ón 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 ...

Page 13: ...ection Ils récapitulent les informations de précaution provenant des références dans la section desInformationsdesécuritésupplémentaires Avantde procéderàl installationoud utiliserl unité assurez vous de lire et de suivre les précautions de sécurité ci des sous dans les manuels les fiches d information sur la sécuritédumatérieletsurlesétiquettes etc Toutdéfaut d observer ces précautions de sécurit...

Page 14: ...ste 4 Consultez ANSI ASC Standard Z49 1 à la page suivante pour des recommandations spécifiques concernant la ventilation 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 assurezunebonneconnexionafind é...

Page 15: ...s ou des gaz contenant des chimiques consi déresparl étatdelaCaliforniecomme étant une cause des malformations congénitales et dans certains cas du cancer California Health Safety Code 25249 5 et seq MANIPULATION DES CYLINDRES La manipulation d un cylindre sans observerlesprécautionsnécessaires peut produire des fissures et un échappement dangereux des gaz Unebrisuresoudaineducylindre delasoupapeo...

Page 16: ...n Soyez vigilant Votre sécurité est en jeu Signifie un danger immédiat La situation peut entraîner des blessures graves ou mortelles Signifieundangerpotentielquipeutentraînerdes blessures graves ou mortelles Signifieundangerquipeutentraînerdesblessures corporelles mineures DANGER AVERTISSEMENT ATTENTION ...

Page 17: ... listed on the front cover includes the following components PT 27 Torch 75 head 25 ft P N 21661 PT 27 Spare Parts Kit see Table 1 1 P N 21623 PCM 1125 Console Power Source See below Depending on the choice of input power each package includes the following appropriate PCM 1125 Console Power Source 208 230 V 50 60 Hz 1 or 3 phase P N 0558001248 460 V 50 60 Hz 3 phase P N 0558001249 575 V 60 Hz 3 p...

Page 18: ...ments PT 27 320 cfh 65 75 psig 150 l min 4 5 5 2 bars Dimensions Length 20 3 516 mm Height w handles 16 1 409 mm 18 3 465 mm Width w o opt storage w opt torch storage 10 1 275 mm 13 1 333 mm Weight of PowerCut 1125 System 87 lbs 39 5 kg Shipping Weight 102 lbs 46 4 kg 2 4 Specifications Table 2 2 PowerCut 1125 Specifications Rated Inputs Rated Outputs Phases Volts Amps Power Factor Duty Cycle Outp...

Page 19: ... job site Figure 2 2 PT 27 PCM 1125 Cutting Performance 9 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 Thickness in Cutting Speed in min 60 A Nozzle 90 in min max speed of side beam section 2 description Table 2 3 PT 27 Torch Specifications Current Capacity 100 duty 80 A DCSP Length of Service Lines 25 ft or 50 ft Weight 25 ft 5 2 lbs 2 4 kg 50 ft 9 6 lbs 4 4 ...

Page 20: ...20 section 2 description ...

Page 21: ...ould be minimized There should be at least one foot of clearance between the PCM 1125 power source and wall or any other obstruction to allow freedom of air movement through the power source 3 4 Inspection A Remove the shipping container and all packing material and inspect for evidence of concealed damage which may not have been apparent upon receipt of the PCM 1125 Notify the carrier of any defe...

Page 22: ...switch with fuses or circuit breakers should be provided at the main power panel see Fig 3 1 and Table 3 1 for fuse sizes The input power cable of the console may be connected directly to the disconnect switch or you may purchase a proper plug and receptacle from a local electrical supplier If using plug receptacle combination seeTable 3 1 for recommended input conductors for connecting receptacle...

Page 23: ...and plug in the switch lead to the torch switch receptable on the output terminal board Make sure the power and pilot arc cable connections 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 Clamptheworkcabletotheworkpiece Besuretheworkpieceisconnectedt...

Page 24: ... chassis ground in Section 3 5 TORCH POWER CABLE CONNECTION TORCH PILOT ARC CONNECTION INPUT POWER CABLE See Table 3 1 Figure 3 1 PCM 1125 Interconnection Diagram NOTE The 208 230V models are equipped with a plug for single phaseconnectiononly Theplugismountedtoa4 conductor cable If3 phaseconnectionisdesired removeanddiscard the plug and refer to Sect 3 5 ACCESS FOR CNC INTERFACE CONNECTIONS See D...

Page 25: ...from the main transformer For 208 vac input X2 is connected to TB3 and X3 is connected to terminal 3 of D2 Make sure the connections are firmly tightened 4 Leave all other wires the same 5 Reinstall cover and connect the PCM 1125 to 208 vac input power R R2 S G T IBR INPUT BRIDGE Fig 3 2a Figure 3 2 Original Factory Setup for 230 Vac Input on Power Source with 208 230 Vac Input Power Capability No...

Page 26: ...26 section 3 installation ...

Page 27: ...r about 1 10th of a second every second This indicates that the air flow supply is low OverTemperature 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 High Low Line Voltage The fault light will rapidly blink on and off five times per se...

Page 28: ...2 This angle is especially useful in helping to create a drop cut When not using the standoff guide the nozzle should be held approximately 1 4 inch from the work 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 This is to prevent the high frequency from reigniting after cutting arc exti...

Page 29: ... 4 3 1 Drag Cutting with the PT 27 PCM 1125 System Reduce current to 40 Amperes Then follow steps in Section 4 3 section 4 operation WHEN THE ARC BREAKS THROUGH THE WORK BRING THE TORCH TO AN UPRIGHT PO SITION AND PROCEED TO CUT TO START A PIERCE TILT THE TORCH TO PREVENT MOLTEN MATERIAL FROM COM ING BACK AGAINST AND DAMAGING THE TORCH 1 2 Figure 4 4 Piercing Technique using the PT 27 Figure 4 2 R...

Page 30: ...30 section 4 operation ...

Page 31: ...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 ...

Page 32: ... ELECTRODE NOZZLE SHIELD IMPORTANT MAKE SHIELD VERY TIGHT WARNING WARNING Make sure power switch on PCM 1125 is in OFF position before working on the torch 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 c...

Page 33: ...emove 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 PISTON PLUG PISTON SPRING FLOW SWITCH Fig...

Page 34: ...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 p...

Page 35: ...re 5 4 and checking the various components A volt ohmmeter will be necessary for some of these checks NOTE Before checking voltages in the circuit disconnect the power from the high frequency generator to avoid damaging your voltmeter section 5 maintenance NOTE Schematics and Wiring Diagrams on 11 x 17 paper are included inside the back cover of this manual WARNING WARNING Voltages in plasma cutti...

Page 36: ... 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 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 ...

Page 37: ...een 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 malfunctioning if the air is flowing continuously or putting in the On position does not turn air on 3 OverTemperature The fault light will be mostly off but will blink on for 1 10 of a second every second This generally indicates that the air flow has been ...

Page 38: ...pprox 294 VDC with 208 V supplied to the 208 230 volt unit approx 280 VDC with 400 V supplied to the 400 volt unit approx 325 VDC with 460 V supplied to the 460 volt unit approx 400 VDC with 575 V supplied to the 575 volt unit If not one of following could be malfunctioning 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...

Page 39: ... to an Au thorized 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 65 75 psig 4 Torch connections must b...

Page 40: ... 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 over 40 amps 2 Low air pressure 3 Damaged cutting nozzle 4 Loose cutting nozzle 5 Heavy spatter accumulation on nozzle E Uneven Arc 1 Damaged c...

Page 41: ...sable 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 4 IGBT Gating Signal Off Time 5 µs 62 5 µs section 5 maintenance ...

Page 42: ...K 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 section 5 maintenance ...

Page 43: ...rch 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 way PREFLOW Postflow 2 SEC...

Page 44: ...44 section 5 maintenance ...

Page 45: ...f non ESAB parts may void your warranty Replacement parts may be ordered from your ESAB Distributor Be sure to indicate any special shipping instructions when ordering replacement parts Refer to the Communications Guide located on the back page of this manual for a list of customer service phone numbers 6 2 Ordering Bill of material items that have blank part numbers are provided for customer info...

Page 46: ... POS 15 A 125 V S3 4 2 951474 SWITCH SEAL BLACK 5 1 634518 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 0558001251GY CHASSIS PCM 1125 14 1 36330YL DOOR ACCES...

Page 47: ...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 1 952887 HEATSINK 44 1 950...

Page 48: ...48 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 section 6 replacement parts ...

Page 49: ... 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 TRANSFORMER ASS Y T4 69 1 95225...

Page 50: ...50 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 section 6 replacement parts ...

Page 51: ...SFORMER 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 32969 REACTOR ASS Y HI FREQ T3 98 1 36431 SPARK GAP ASS Y SG 99 2 951342 CAPACITOR 2500pf 15 K V C...

Page 52: ...52 119 120 118 117 116 115 111 112 113 114 110 133 130 131 132 129 127 128 134 126 125 124 123 135 122 121 Fig 6 5 PCM 1125 Power Source Right Side View 460 575 V section 6 replacement parts ...

Page 53: ...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 32969 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 TRANSFORMER HI VOLTAGE T5 130...

Page 54: ...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 section 6 replacement parts ...

Page 55: ...08 230 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 Source Rear View 160...

Page 56: ...56 notes ...

Page 57: ...57 notes ...

Page 58: ...58 notes ...

Page 59: ... chgs per change notice 053013 In replacement parts sec tion added filter regulator item 151 p n 0558005394 note Moved schematics to 11 x 17 format Revision A 12 2005 Removed filter regulator item 151 p n 0558005394 note in replacement parts section 1 ...

Page 60: ...ax 843 664 5557 Hours 7 30 AM to 3 30 PM EST Repair Estimates Repair Status F WELDING EQUIPMENT TRAINING Telephone 843 664 4428 Fax 843 679 5864 Hours 7 30 AM to 4 00 PM EST Training School Information and Registrations G WELDING PROCESS ASSISTANCE Telephone 800 ESAB 123 Hours 7 30 AM to 4 00 PM EST H TECHNICAL ASST CONSUMABLES Telephone 800 933 7070 Hours 7 30 AM to 5 00 PM EST IF YOU DO NOT KNOW...

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