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INSTRUCTION MANUAL

PCM-875

PLASMA ARC CUTTING PACKAGE

F15-335-

E

July

, 200

7

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.
P

HJ2

0

5

001:

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

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Summary of Contents for PCM-875

Page 1: ...pt 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 insta...

Page 2: ...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 principles of operation and safe practices for arc we...

Page 3: ...faulty maintenance damage improper 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 Prima...

Page 4: ... 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 11 95 5 Do not use equipment beyond its ratings For example overloaded welding cable can overh...

Page 5: ...Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 EQUIPMENT MAINTENANCE Faulty or im properly maintained equipment can cause injury or death Therefore 1 Always have qualified personnel perform the installa tion troubleshooting and maintenance work Do not perform any electrical work unless you are qualified to perform such work 2 Before performing any maintenance work insid...

Page 6: ...oigné 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 entr...

Page 7: ...iculières 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 8: ...3 PCM 875 Console Power Source See below Depending on the choice of input power each package includes the following appropriate PCM 875 Console Power Source 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 P N 36724 1 3 2 Mechanized Cutting Packages Also available are mechanized packages using the PT 20AM Mechanized Pla...

Page 9: ...nput 7 2 kW Max Output Power 60 A 120 Vdc 208 230 V ac 50 60 Hz 3 phase 26 24 A phase 208 230 V ac 50 60 Hz 1 phase 55 49 A 400 V ac 50 60 Hz 3 phase 13 A phase 460 V ac 50 60 Hz 3 phase 11 A phase 575 V ac 50 60 Hz 9 A phase Power Factor 60 Amperes Output 74 208 230 V 1 phase 90 208 230 V 3 phase 92 400 460 575 V 3 phase Efficiency 60 Amperes Output 90 Typical Current Capacity PT 27 80 A DCSP Air...

Page 10: ...s 5 7 8 high cart has front swivel casters and rear casters to make it easier to roll the PCM 875 around the job site 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 0 0625 0 125 0 1875 0 25 0 3125 0 375 Stand Off Distance in Watts A x V W 0 20 40 60 80 100 120 140 160 Arc Voltage 3 16 to 1 4 Maintain Proper Stand off Distance IMPORTANT 1 16 1 8 3 16 1 4 5 16 3 8 Maximum Output Power output increas...

Page 11: ...ed 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 your ...

Page 12: ...d 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 workpiece is connected to an approved earth ground with a properly sized ground cable Table 2 1 Recommended Sizes For Input Conductors and Line Fuses Input Requirements Input Gnd Fuse Volts Phase Amps Conductor Size...

Page 13: ...See Table 2 1 and WARNING in 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 875 Interconnection Diagram NOTE The 208 230 V models are equipped with a plug for single phase connection only The plug is mounted to a 4 conductor cable If 3 phase connection is desired remove and discard the plug and refer t...

Page 14: ...75to208vac input power X3 TB3 X2 X1 FROM MAIN TRANSFORMER OUTPUT BRIDGE D1 Fig 2 2 7CONNECTING PCM 875 FOR 200 208 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 200 208 VAC Inp...

Page 15: ...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 NOTE Use Cable P N 2239902 UL CSA approved cable Flex 20 guage 12 conductor with copper braided shield Installation for mechanized cutting should be performed by an experienced service technician Do NOT permit untrained persons to insta...

Page 16: ...BLK 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 875 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 sh...

Page 17: ... 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 befor...

Page 18: ...ITCH CURRENT CONTROL KNOB FUSE 15A 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 electrodeforwear Iflessthan19 32 ofelectrode shaft is remaining replace the electrode If the electrodeisusedbeyondthisrecommendedwear limit damagetothetorchandpowersourcemay occur Nozzle life is also greatly reduced when ...

Page 19: ...utting nozzle 4 Improper air pressure 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 Low air pr...

Page 20: ...ings and ground connec tions are tight G With all input power disconnected and wearing propereyeandfaceprotection blowouttheinside of the PCM 875 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 875 H Occasionally bleed all water from the filter be neath the air...

Page 21: ...n torque 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 co...

Page 22: ...onnections 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 to the input power receptacle b Measure the input power a...

Page 23: ...te 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 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...

Page 24: ...is set to 040 Disconnect HI FREQUENCY leads Check for 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...

Page 25: ... 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 26: ...gh 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 20 KHz TP 10 IGBT s driving signal switching frequency 20 KHz 0 13vdc 13vdc 40usec LPG50 50usec LPG80 6usec LPG50 9usec LPG80 For 208 230 VAC input the IGBT off time is 3µsec For 400 460 575 VAC input the IGBT off time is 6µsec Figure 5...

Page 27: ...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 28: ...n 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 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 PREF...

Page 29: ...28 D 36587 Figure 5 1 Schematic Diagram PCM 875 208 230 V 50 60 Hz 1 or 3 Phase ...

Page 30: ...29 D 36595 Figure 5 2 Wiring Diagram Sheet 1 of 2 PCM 875 208 230 V 50 60 Hz 1 or 3 Phase ...

Page 31: ...30 Figure 5 3 Wiring Diagram Sheet 2 of 2 PCM 875 208 230 V 50 60 Hz 1 or 3 Phase D 36595 ...

Page 32: ...31 D 36597 B Figure 5 4 Schematic Diagram PCM 875 400 460 V 50 60 Hz 3 Phase 1 2 3 4 5 6 ...

Page 33: ...32 D 36598 Figure 5 5 Wiring Diagram Sheet 1 of 2 PCM 875 400 460 V 50 60 Hz 3 Phase ...

Page 34: ...33 D 36598 Figure 5 6 Wiring Diagram Sheet 2 of 2 PCM 875 400 460 V 50 60 Hz 3 Phase ...

Page 35: ...34 D 36715 A Figure 5 7 Schematic Diagram PCM 875 575 V 60 Hz 3 Phase ...

Page 36: ...35 D 36716 Figure 5 8 Wiring Diagram Sheet 1 of 2 PCM 875 575 V 60 Hz 3 Phase ...

Page 37: ...36 D 36716 Figure 5 9 Wiring Diagram Sheet 2 of 2 PCM 875 575 V 60 Hz 3 Phase ...

Page 38: ...ion 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 dis tributor 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 replace...

Page 39: ...K 5 1 634518 SWITCH TOGGLE DPDT 2 POS 15 A 125 V S1 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 HEYCO 1214 11 1 680560 WORK CABLE 25 FT Not Shown 12 4 182W12 FOOT RUBBER 13 1 32237GY CHASSIS PCM 875 14 1 36330YL DOOR ACCESS YEL ESAB 15 1 954008 LABEL WARNING HI VOLTAGE 16 ...

Page 40: ...udes PAD 952280 IBR 33 1 2062282 CAPACITOR 22µf 1KV See wiring C19 34 3 951321 METAL OXIDE VARISTOR 275 V See wiring MOV1 2 3 35 2 951205 IGBT 600 V 100 A includes PAD 951190 Q1 2 36 2 17750010 RESISTOR 50 W 10 OHM PAD 951194 R7 10 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 ...

Page 41: ...R NEG 63 1 950487 TERM BLOCK 2 POS Not used on 400CE 575 V TB5 64 1 952235 MODULE INPUT BRIDGE SCR includes PAD 952280 IBR 65 1 2062282 CAPACITOR 22µf 1KV C19 66 3 950591 METAL OXIDE VARISTOR 510 V 400 400CE 460 V MOV1 2 3 3 951963 METAL OXIDE VARISTOR 625 V 575 V MOV1 2 3 67 2 17750010 RESISTOR 50W 10 OHM PAD 951194 R7 10 68 1 32958 CURRENT TRANSFORMER ASS Y T4 69 1 952255 CAPACITOR 40µf 400 VDC ...

Page 42: ...RMER ASS Y PCB4 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 C1...

Page 43: ...1488 SHUNT BOARD ASS Y PCB4 120 1 951515 CAPACITOR 047µf 660 VAC 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 1 950487 TERM...

Page 44: ...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 954700 LABEL INPUT 208 230 V 1 954681 LABEL INPUT 400 460 V Fig 6 6 PCM 875 Power Source Top View with PCB1 and Shelf Removed 143 142 141 140 145 144 ...

Page 45: ...9 LABEL RATING PCM 875 400CE 158 2 952136 FUSE HOLDER 159 1 952137 FUSE 15 A FAST ACTING F2 160 1 97W63 STRAIN RELIEF 161 1 36823 INPUT POWER CABLE 10 FT 4 COND 6AWG 208 230 V 1 35587 INPUT POWER CABLE 10 FT 4 COND 10AWG 400 460 575 V 1 35582 INPUT POWER CABLE 10 FT 4 COND 4 x 4 MM 400 V CE 162 1 951801 CIRCUIT BREAKER 3P 70 A 250 VAC 208 230 V CB1 1 951181 CIRCUIT BREAKER 3P 30 A 480 VAC 400 460 ...

Page 46: ...nd parts The C edition 2 02 of this manual covers the following changes 1 Revises Figure 3 3 to show the changes made to the electrode 2 Revises Figure 4 1 to show the removal of the Valve Pin which is no longer a part of the PT 27 Torch 3 The hi frequency gap is changed from between 027 and 033 to set to 040 See page 23 Section E Step 3 The D edition 10 2006 of this manual covers the following ch...

Page 47: ...46 ...

Page 48: ...thorized Repair 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 Repai...

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