ESAB PCM-875A Installation, Operation And Maintenance Manual Download

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SECTION 6

PCM-875A Plasmarc System

Troubleshooting

6-1

6.1 Troubleshooting PCM-875A Plasmarc System

WARNING

Electric Shock Can Kill!

Ensure that all primary power to the
machine has been externally
disconnected.

Open the line disconnect switch or circuit
breaker before inspection, maintenance or
repair inside power console.

Match the problem with the conditions below.

If problem is not listed,

shut off input power,

open unit by removing cover

Visual inspection of all components and wiring

Check for loose terminal connections

Burned wiring or other components

Bulged or leaking capacitors

Any other signs of damage or discoloration.

Summary of Contents for PCM-875A

Page 1: ...F 15 753 November 2002 Installation Operation and Maintenance Manual for the PCM 875A Plasmarc Mechanized Cutting System Cutting Systems 411 South Ebenezer Road Florence South Carolina U S A ...

Page 2: ...n its liability ESAB Cutting Systems first priority is total customer satisfaction We constantly look for ways to improve our products service and documentation As a result we make enhancements and or design changes as required ESAB makes every possible effort to ensure our documentation is current We cannot guarantee that each piece of documentation received by our customers reflects the latest d...

Page 3: ...e Precautions 9 10 1 8 Safety References 11 16 1 8 1 National Standards 11 1 8 2 International Standards 12 16 Section 2 Description Page 2 _ 2 1 General 1 2 2 PCM 875A Power Console 1 2 2 1 Technical Specifications PCM 875A 1 2 2 2 Dimensions and Weight 2 2 3 Remote Arc Starter RAS2 3 2 3 1 Technical Specifications 3 2 3 2 Dimensions and Weight 3 2 4 PT 20AMX Torch 4 2 4 1 Technical Specification...

Page 4: ...ter RAS2 9 3 3 1 Mounting 9 3 3 2 Connecting Service Lines Input 10 3 3 3 Setting Spark Gap 11 3 3 4 RAS2 Output Connections 12 3 3 5 Termination of Torch Shield Braid 13 14 3 4 Installing Front end torch Parts 15 17 3 5 Interconnecting Diagram 18 19 Section 4 Operation Page 4 _ 4 1 PCM 875A Console Operation General 1 4 2 Console Controls 2 3 4 3 RAS2 3 4 4 PT 20AMX Plasma Torch 4 4 5 Cut Quality...

Page 5: ...h 4 5 2 RAS2 Remote Arc Starter 5 5 2 1 General 5 5 2 2 Spark Gap Procedure 5 5 3 PT 20AMX Plasmarc Torch 6 5 3 1 General 6 5 3 2 Dirt or Contamination 7 5 3 3 Loose Consumables 7 5 3 4 Damage Caused by Loose Parts or Overheating 8 5 3 5 Consumables Remove and Replace 8 10 5 3 6 Measuring Torch Gas Flows 10 5 3 7 Removal and Replacement of the Torch Body 11 ...

Page 6: ... Reference Voltage Checks 9 6 4 PT 20AMX Torch Troubleshooting10 10 11 6 4 1 Insufficient Penetration 10 6 4 2 Main Arc Extinguishes 10 6 4 3 Dross Formation 10 6 4 4 Double Arcing 11 6 4 5 Uneven Arc 11 6 4 6 Unstable Cutting Conditions 11 6 4 7 Main Arc Does Not Strike 11 6 4 8 Poor Consumable Life 11 6 5 230V Power Console Electrical Drawings 12 17 6 5 1 Schematic 12 13 6 5 2 Wiring Diagrams 14...

Page 7: ... Whether an individual is involved with operation servicing or as an observer compliance with established precautions and safe practices must be accomplished Failure to observe certain precautions could result in serious personnel injury or severe equipment damage The following precautions are general guidelines applicable when working with cutting machines More explicit precautions pertaining to ...

Page 8: ...rmation DANGER Used to call attention to immediate hazards which if not avoided will result in serious personal injury or loss of life WARNING Used to call attention to potential hazards that could result in personal injury or loss of life CAUTION Used to call attention to hazards that could result in minor personal injury or equipment damage CAUTION Used to call attention to minor hazards to equi...

Page 9: ...als and equipment not involved in production process clear of entire system area Fence off entire work cell to prevent personnel from passing through area or standing in the working envelope of the equipment Post appropriate WARNING signs at every work cell entrance Follow lockout procedure before servicing any equipment WARNING Failure to follow operating instructions could result in death or ser...

Page 10: ...elines while installing machine Contact your ESAB representative before installation He can suggest certain precautions regarding piping installation and machine lifting etc to ensure maximum security Never attempt any machine modifications or apparatus additions without first consulting a qualified ESAB representative Observe machine clearance requirements for proper operation and personnel safet...

Page 11: ... A Plasma Cutting Machine WARNING Flying debris and loud noise hazards Hot spatter can burn and injure eyes Wear goggles to protect eyes from burns and flying debris generated during operation Chipped slag may be hot and fly far Bystanders should also wear goggles and safety glasses Noise from plasma arc can damage hearing Wear correct ear protection when cutting above water WARNING Burn hazard Ho...

Page 12: ...m workpiece and electrical ground Keep gloves shoes clothing work area and equipment dry Replace worn or damaged cables WARNING Fume hazard Fumes and gases generated by the plasma cutting process can be hazardous to your health Do NOT breathe fumes Do not operate plasma torch without fume removal system operating properly Use additional ventilation to remove fumes if necessary Use approved respira...

Page 13: ... the arc unless wearing appropriate safety glasses Prepare cutting area to reduce reflection and transmission of ultraviolet light Use special paint on walls to absorb UV light Install protective screens or curtains to reduce ultraviolet transmission CAUTION Do Not Use this Torch Under Water The PT 20AMX is designed to be a dry cutting process Cutting under water may result in reduced consumable l...

Page 14: ...nt clothing covering all exposed areas Wear cuffless trousers to prevent entry of sparks and slag Have fire extinguishing equipment available for use WARNING Explosion hazard Certain molten aluminum lithium Al Li alloys can cause explosions when plasma cut OVER water These alloys should only be dry cut on a dry table DO NOT dry cut over water Contact your aluminum supplier for additional safety in...

Page 15: ...ays turn power off to plasma power supplies before removing covers or panels to service any system component Do not touch live electrical parts Keep all panels and covers in place when machine is connected to power source Keep gloves shoes clothing work area and equipment dry Inspect power and ground leads cables for wear or cracking Replace worn or damaged cables Do not use if damaged Never bypas...

Page 16: ...ng test equipment or hand tools on machine Severe electrical or mechanical damage could occur to equipment or machine CAUTION Extreme caution should be used when probing circuitry with an oscilloscope or voltmeter Integrated circuits are susceptible to over voltage damage Power off before using test probes to prevent accidental shorting of components All circuit boards securely seated in sockets a...

Page 17: ... and Plasma Arc Cutting AWS C5 10 94 American Welding Society Recommended Practices for Plasma Arc Welding AWS C5 1 American Welding Society Recommended Practices for Arc Cutting AWS C5 2 American Welding Society Safe Practices AWS SP American Welding Society Standard for Fire Protection in Use of Cutting and Welding Procedures NFPA 51B National Fire Protection Association 60 Batterymarch Street B...

Page 18: ...VBG 4 Elektrische Anlagen Welding Cutting and related working methods VBG 15 Schweißen un Schneiden un verwandte Verfahren Shot Blasting Works VBG 48 Strahlarbeiten Gases VBG 61 Gase Oxygen VBG 62 Sauerstoff Operating liquid jet cutting machines VBG 87 Arbeiten mit Flüssigkeitsstrahlem Laser beams accident prevention and Electro technology VBG 93 Laserstrahlung Unfallverhütungs vorschriften für Fe...

Page 19: ...ication for laser guards VDE 0837 50 Anforderung an Lasershcutzwänden TRAC Technical Rules for Acetylene and Carbide Stores TRAC Techische Regein für Azetylenanlagen und Calciumcargidlager Acetylene lines TRAC 204 Azetylenleitungen Acetylene cylinder battery systems TRAC 206 Azetylenflaschenbatterieanlagen Safety devices TRAC 207 Sicherheitseinrichtungen TRG Technical Rules for Pressure gases TRG ...

Page 20: ...e und Bennungen DIN 2310 Part 2 Thermal cutting determination of quality of cut faces Teil 2 Thermsiches Schneiden Ermittein der Güte von Schnittflächen DIN 2310 Part 4 Thermal cutting arc plasma cutting process principles quality dimensional tolerances Teil 4 Thermsiches Schneiden Plasmaschneiden Verfahrensgrundlagen Güte Maßtoleranzen DIN 2310 Part 5 Thermal cutting laser beam cutting of metalli...

Page 21: ...s reduction of risks to health DIN EN 626 1 Sichereit von Maschinen Reduzierung des Gesundheitsrisikos Single spindle vertical milling machines DIN EN 848 1 Fräsmaschine für einseitige Bearbeitung mit drehendem Werkzeug High pressure water jet machines DIN EN 1829 Hochdruckwasserstrahlschneidmaschine Thermal cutting oxygen cutting process principles dimensional tolerances DIN EN 9013 Thermisches S...

Page 22: ...0825 Strahlensicherheit von Laseranlagen Arrangement of protection devices DIN EN 999 Anordnung von Schutzeinrichtungen VDI Guidelines Quality of cut faces on metallic workpieces abrasive water jet cutting and arc plasma cutting VDI 2906 Schnittflächenqualität beim Schneiden von Werkstücken aus Metall Abrasiv Wasserstrahischneiden und Plasmastrahischneiden Room air Technical systems for welding wo...

Page 23: ...50 Hz 1 or 3 phase P N 0558003356 400 V 50 Hz 3 phase P N 0558003357 2 2 1 Technical Specifications PCM 875A 230V 50Hz 3 Phase P N 0558003356 Options 1 phase 3 phase 400V 50Hz 3 phase P N 0558003357 60 Duty Cycle 60 A at 120 VDC Rated Output 100 Duty Cycle 50 A at 120 VDC Output Current Range 10 to 60 A phase Open Circuit Voltage 275 VDC Rated Primary Input at 7 2 kW Maximum Output Power 60 A at 1...

Page 24: ...SECTION 2 PCM 875A Mechanized Plasma Cutting System Description 2 2 2 2 2 Dimensions and Weight PCM 875A Power Console 516 mm 275 mm 465 mm Weight 39 5 kg ...

Page 25: ... power console and torch The RAS is the source of high frequency energy used to start the plasma cutting process RAS 2 with 15 2 m leads RAS 2 with 30 4 m leads P N 0558003601 P N 0558003602 Technical Specifications Input 110 VAC 50 60 Hz Control power provided by PCM 875A console Spark Gap 1mm Dimensions and Weight 123 8mm 374mm 184 2mm Weight 3 4kg ...

Page 26: ...n steel aluminum or stainless steel PT 20AMX Torch with 1 2 m lead P N 0558002632 PT 20AMX Torch with 5 7 m lead P N 0558002633 PT 20AMX Torch with 7 6 m lead P N 0558003381 WARNING DO NOT use oxygen with this torch A hazardous fire may result 2 4 1 Technical Specifications Type Air Cooled single gas at 9 9 kl hr Rating 100 Amperes at 100 Duty Cycle Gas Purity Air Needs to be clean dry and free of...

Page 27: ...SECTION 2 PCM 875A Mechanized Plasma Cutting System Description 2 5 2 4 2 Dimensions 435 mm 34 9 mm ...

Page 28: ...trode 50Hz 0558001617 5 Electrode Insulator 21373 1 Electrode Holder Assembly 21332 1 Baffle Tube 21374 1 Pilot Arc Adaptor 19497 1 O ring 488157 5 Lubricant 1 oz 17672 1 Seat Baffle Wrench 21375 1 1 16 Hex Key Wrench 93750006 1 NOTICE The description of the heat shield P N 21326 listed above indicates a range of 70 to 100 amperes Testing has proven satisfactory results when used at 60 amps and lo...

Page 29: ...ARNING Failure to follow these directions carefully may lead to injury or death Read this entire manual before proceeding Damage to property or equipment may occur 3 2 Installation of the PCM 875A Power Console 3 2 1 Equipment Required A source of clean dry air at 153 4 liters minute at 5 2 to 5 9 bar The maximum inlet pressure of the air filter regulator is 10 4 bar and should not be exceeded ...

Page 30: ...ugh the louvers will cause overheating Do not install any type of air filtering device on to the power console cooling air passages Warranty will be voided if such a device is used 3 2 3 Inspection of Power Console Before installation A Remove equipment from the shipping containers B Remove all packing material and inspect for evidence of concealed damage which may not have been initially apparent...

Page 31: ...properly configured for your input power supply DO NOT connect a power console configured for 230V to a 460V input power Damage to machine will occur The PCM 875A Power Console is equipped with a 3 m 4 conductor power cable for 3 phase connection If single phase 230V is required tape back red wire on the input power cable A line wall disconnect switch with fuses or circuit breakers should be provi...

Page 32: ...ted on the front left corner of the console base Arc On Signal This signal originates in the plasma console It is a normally open contact which closes on main arc transfer Used to activate machine motion and arc voltage control Start Signal Signal is derived from CNC machine It is a normally open contact which closes starting the plasma sequence The system is off when this contact closure is remov...

Page 33: ...nsole WARNING Electric Shock Can Kill Ensure all power is off by opening the line wall disconnect switch and power cord is disconnected before attempting to make any connections inside the power console Remove outside cover Insert power cable pilot arc and air hose through power cable bushing Power Cable Bushing TB1 ...

Page 34: ...rc cable ring connection to the copper terminal 2 Connect air hose to air power connector left hand threads 3 Connect power cable to air power connector using 10 screw NOTICE The console cover does not have to be removed to make the three connections above Remove access panel if replacing cables or checking connections ...

Page 35: ...1 Insert115VAC Pilot Arc Cable Insert 115VAC RAS cable through strain relief located in the lower right corner of the front panel 115VAC RAS Cable Rout 115VAC RAS cable along inside edge in notches in insulating material to TB1 2 conductor 115VAC cable routed through notch ...

Page 36: ...m TB1 TB1 Plug terminal connectors into 2 available lugs on TB1 CAUTION Cable Terminals to TB1 should be insulated to prevent possible damage due to internal arcing in the power console The above illustration shows the terminals un insulated for clarity of wire positions Replace cover if next step is not required ...

Page 37: ...sma Cutting System Installation 3 9 3 3 Connecting the Remote Arc Starter 3 3 1 Mounting RAS2 Mounting location of RAS unit is restricted by the length of torch leads 1 2 m 5 4 m or 7 6 m 13 5mm 203 2mm 55 9mm 12 7mm 228 6mm 82 6mm 8mm ...

Page 38: ... Air Connection Power Cable Lug Connect arc start cable to RAS2 box Connect pilot arc cable to pilot arc lug using 10 screw and nut with lock washers Connect power cable to power cable lug using screw with washers and nut Connect air hose fitting left hand threads Note that this hose has the same fittings on both ends and orientation does not matter Arc Start Cable Pilot Arc Cable Power Cable Air ...

Page 39: ... Spark Gap in the RAS2 1 mm a Factory set to 1mm Adjustment procedure 1 Loosen screw a using a 1 8 0 125 internal hex wrench 2 Insert 1mm feeler gage between the tungsten electrodes 3 Slide electrodes till slight pressure is felt on the gage 4 Tighten locking screws on spark gap assembly ...

Page 40: ...Torch Pilot Arc Connect pilot arc cable in torch bundle to pilot arc output lug using 10 screw lock washers and nut Torch left hand threads connect the torch gas air and plasma arc current Cable inside gas hose conducts the plasma cutting current Torch Lead Pilot Arc Connector Torch Lead Voltage Gas Hose ...

Page 41: ... Plasma Cutting System Installation 3 13 3 3 5 Terminating Shield Braid at RAS2 1 Insert Braid and hose bundle through RAS cover hole Insert bundle 2 Flare braid by bending it back at 90 degrees about 25 mm from the end Flair Braid ...

Page 42: ...Mechanized Plasma Cutting System Installation 3 14 3 Insert ground plate over torch leads Insert Ground Plate 4 Fasten ground plate with 4 screws inserted from the outside Trim braid strands if desired Fasten Ground Plate ...

Page 43: ...d to the front end of the torch IF the seat becomes damaged the torch body must be replaced DO NOT attempt to remove the seat from torch body Electrode Holder Assembly Baffle Tube 2 Electrode holder assembly 21332 includes the baffle tube 21374 If baffle tube becomes damaged it can be replaced by un threading the damaged tube out of the holder Use small hex end of the wrench 21375 in hex broach on...

Page 44: ...electrode assembly 4 Install nozzle onto the electrode assembly by inserting small shoulder on electrode insulator into nozzle s rear opening Place nozzle and electrode assembly into the heat shield as shown in page 6 If front end of the torch is facing down as normal in a setup the nozzle and electrode assembly can be stacked in the heat shield and then assembled to the torch Be sure to use prope...

Page 45: ... holder 7 After retainer heat shield is tightened try to rotate the nozzle with your finger tips If it rotates the sealing of components is not tight enough and will likely leak gas NOTICE See Section 6 Maintenance for torch lead installation or replacement CAUTION IMPORTANT See Maintenance section Follow all instructions in the booklet packed with your unit DO NOT install or attempt to operate th...

Page 46: ...SECTION 3 PCM 875A Mechanized Plasma Cutting System Installation 3 18 3 5 Interconnecting Diagram 4 6 14 15 17 16 18 8 5 13 12 7 9 6 5 10 7 19 20 21 22 1 2 3 11 ...

Page 47: ... Connection 7 Power Supply Cable 8 115 V High Frequency Start Cable 9 RAS Input Bulkhead 10 Remote Arc Starter 11 RAS Output Bulkhead 12 Pilot Arc Cable 13 Power Gas Hose 14 Torch Lead Bundle Shield Ground 15 PT 20 AMX Plasmarc Torch 16 Work Cable Clamp 17 Work Piece 18 Earth Ground 19 ATAS Start Stop CSR 20 CSR Cable 21 Height Control Cable Voltage Divider 22 Voltage Divider Height Control ...

Page 48: ...SECTION 3 PCM 875A Mechanized Plasma Cutting System Installation 3 20 This page intentionally left blank ...

Page 49: ...Plasma Arc Emits Hazardous UV and Visible Radiation Damage to skin and eyes is possible Do not ever look directly at a plasma arc Blindness could result Wear Safety Approved eye protection Comply to all local and national regulations for safety equipment WARNING Noise Levels May Exceed Safe Limits Sparks and Slag May Be Hazardous Wear Safety Approved Hearing Protection Wear Safety Approved Eye Pro...

Page 50: ...n Off Position No Power to the control circuit Power Switch White Pilot Light Output Current Control Front Panel Adjustable from 10 to 60 Amperes Current Output Control Air Test Switch Front Panel Test Position Air filter regulator can be adjusted to desired pressure 4 6 to 5 3 kgf cm 2 65 to 75 PSI Allow a few minutes for air to flow to remove an accumulated condensation Operate Position Place th...

Page 51: ...console to cool before returning to operation Light will blink off and on 5 times a second Indicates the input voltage is outside the plus or minus 15 range of input rating Light will be on continuously Indicates input current has been exceeded Over Current Fault Light NOTICE All fault lights will remain on for a minimum of 10 seconds If fault is resolved all will reset automatically except for ov...

Page 52: ...oltages at dangerous amperage Do not touch the Plasma torch Torch lead RAS RAS supply lines Console while power is applied to console WARNING Electric shock Can Kill Do not service torch or otherwise touch the plasma torch unless the power source has been disconnected or turned off CAUTION Hot Torch May Burn Skin Allow torch to cool before servicing ...

Page 53: ... not flat rounded or undercut 4 5 4 Surface roughness 4 5 5 Dross 4 5 6 Dimensional Accuracy Process Data Usually the recommended cutting parameters will give optimal cut quality Occasionally conditions may vary and slight adjustments will be required If so Make small incremental adjustments when making corrections Adjust arc voltage in one volt increments up or down as required Adjust cutting spe...

Page 54: ...n or damaged consumables Standoff low arc voltage Cutting speed slow machine travel rate Part Drop Part Positive Cut Angle Top dimension is less than the bottom dimension Misaligned torch Bent or warped material Worn or damaged consumables High standoff high arc voltage Cutting speed fast Current high or low See process data for recommended current level for specific nozzles Wrong secondary gas fl...

Page 55: ...tion 4 7 4 5 3 Cut Flatness Drop Part Top And Bottom Rounded Condition usually occurs when material is 0 25 thick 6 4mm or less High current for given material thickness See process data for proper settings Drop Part Top Edge Undercut Standoff low arc voltage ...

Page 56: ...onfined to one axis Worn or damaged consumables Process Induced Roughness Or Machine Induced Roughness Machine Induced Roughness Can be difficult to distinguish from process induced roughness and is often confined to one axis Roughness is inconsistent Dirty rails wheels and or drive rack pinion Refer to maintenance section in machine owner s manual Carriage wheel adjustment ...

Page 57: ...minated with proper torch and cutting parameter setup Refer to Process Data Cut Face Lag Lines Roll Over Side View High Speed Dross Material weld or rollover on bottom surface along kerf Difficult to remove May require grinding or chipping S shaped lag lines Standoff high arc voltage Cutting speed fast Cut Face Lag Lines Globules Side View Slow Speed Dross Forms as globules on bottom along kerf Re...

Page 58: ...er on top of material Usually removes easily Cutting speed fast Standoff high arc voltage Intermittent Dross Appears on top or bottom along kerf Non continuous Can appear as any kind of dross Possible worn consumables Other Factors Affecting Dross Material temperature Heavy mill scale or rust High carbon alloys Gas Purity ...

Page 59: ...a NOTICE Recommended cutting speed and arc voltage will give optimal cutting performance Small incremental adjustments may be needed due to material quality material temperature and specific alloy The operator should remember that all cutting variables are interdependent Changing one setting affects all others and cut quality could deteriorate Always start at the recommended settings Before attemp...

Page 60: ...Plasmarc Torch Gas Air Lock Ring P N 57N70 Handle with Sleeve P N 05508003419 Torch Body P N 21359 Electrode Holder Assembly P N 21332 Electrode Insulator P N 21373 Electrode 50Hz P N 0558001617 Nozzle 50A P N 21330 Heat Shield Blue P N 21326 Note Heat shield rated at 70 to 100A is used for this application ...

Page 61: ...m Operation 4 13 40 Amperes PT 20AMX Process Data Mild Steel Material Thickness mm 2 0 3 0 Air Pressure Bar 5 5 Height Readings Initial Height mm 3 0 3 0 Arc Voltage Stand off 110 110 Travel Speed mm per minute 3810 2540 Kerf Width Millimeters 1 1 1 1 ...

Page 62: ...Plasmarc Torch Gas Air Lock Ring P N 57N70 Handle with Sleeve P N 05508003419 Torch Body P N 21359 Electrode Holder Assembly P N 21332 Electrode Insulator P N 21373 Electrode 50Hz P N 0558001617 Nozzle 50A P N 21330 Heat Shield Blue P N 21326 Note Heat shield rated at 70 to 100A is used for this application ...

Page 63: ... PT 20AMX Process Data Mild Steel Material Thickness mm 5 0 6 0 10 0 13 0 Air Pressure Bar 6 0 6 0 6 0 6 0 Height Readings Initial Height mm 3 0 5 0 6 0 8 0 Arc Voltage Stand off 110 120 130 150 Travel Speed mm per minute 2540 1651 1016 457 Kerf Width Millimeters 1 6 1 9 3 2 4 0 ...

Page 64: ...lasmarc Torch Gas Air Lock Ring P N 57N70 Handle with Sleeve P N 05508003419 Torch Body P N 21359 Electrode Holder Assembly P N 21332 Electrode Insulator P N 21373 Electrode 50Hz P N 0558001617 Nozzle 50A P N 21330 Heat Shield Blue P N 21326 Note Heat shield rated at 70 to 100A is used for this application ...

Page 65: ...m Operation 4 17 40 Amperes PT 20AMX Process Data Aluminum Material Thickness mm 2 0 3 0 Air Pressure Bar 5 5 Height Readings Initial Height mm 3 0 3 0 Arc Voltage Stand off 110 110 Travel Speed mm per minute 3810 2667 Kerf Width Millimeters 1 57 1 57 ...

Page 66: ...lasmarc Torch Gas Air Lock Ring P N 57N70 Handle with Sleeve P N 05508003419 Torch Body P N 21359 Electrode Holder Assembly P N 21332 Electrode Insulator P N 21373 Electrode 50Hz P N 0558001617 Nozzle 50A P N 21330 Heat Shield Blue P N 21326 Note Heat shield rated at 70 to 100A is used for this application ...

Page 67: ...20AMX Process Data Aluminum Material Thickness mm 5 0 6 0 10 0 13 0 Air Pressure Bar 6 0 6 0 6 0 6 0 Height Readings Initial Height mm 3 0 5 0 6 0 8 0 Arc Voltage Stand off 110 120 130 150 Travel Speed mm per minute 2286 1905 762 203 Kerf Width Millimeters Not Available 3 2 4 7 4 7 ...

Page 68: ...MX Plasmarc Torch Gas Air Lock Ring P N 57N70 Handle with Sleeve P N 05508003419 Torch Body P N 21359 Electrode Holder Assembly P N 21332 Electrode Insulator P N 21373 Electrode 50Hz P N 0558001617 Nozzle 50A P N 21330 Heat Shield Blue P N 21326 Note Heat shield rated at 70 to 100A is used for this application ...

Page 69: ...tion 4 21 40 Amperes PT 20AMX Process Data Stainless Steel Material Thickness mm 2 0 3 0 Air Pressure Bar 5 5 Height Readings Initial Height mm 3 0 3 0 Arc Voltage Stand off 110 110 Travel Speed mm per minute 3302 1905 Kerf Width Millimeters Not Available 1 6 ...

Page 70: ...MX Plasmarc Torch Gas Air Lock Ring P N 57N70 Handle with Sleeve P N 05508003419 Torch Body P N 21359 Electrode Holder Assembly P N 21332 Electrode Insulator P N 21373 Electrode 50Hz P N 0558001617 Nozzle 50A P N 21330 Heat Shield Blue P N 21326 Note Heat shield rated at 70 to 100A is used for this application ...

Page 71: ...MX Process Data Stainless Steel Material Thickness mm 5 0 6 0 10 0 13 0 Air Pressure Bar 6 0 6 0 6 0 6 0 Height Readings Initial Height mm 3 0 5 0 6 0 8 0 Arc Voltage Stand off 110 120 130 150 Travel Speed mm per minute 1270 762 203 152 Kerf Width Millimeters Not available 3 2 4 7 4 7 ...

Page 72: ...SECTION 4 PCM 875A Mechanized Plasma Cutting System Operation 4 24 This page intentionally left blank ...

Page 73: ...nt damage or personal injury may result CAUTION Do not permit untrained persons to inspect clean or repair this equipment Maintenance must be performed by specially trained personnel NOTICE Use of replacement parts other than ESAB replacement parts may void warranty WARNING Electric Shock Can Kill Disconnect wall switch before inspection and maintenance of the power console ...

Page 74: ...cure connection to workpiece B Check safety earth ground at workpiece and at power console chassis C Check heat torch heat shield Replace if damaged D Check torch electrode and cutting nozzle for wear at least once per 8 hours operation E Ensure cable and hoses are not damaged or kinked F Ensure all plugs fittings and ground connections are tight WARNING Wear safety eye protection when using compr...

Page 75: ...ed air lines Direct the first air blast away from equipment to avoid possible damage G With all input power disconnected wearing proper eye and face protection blow out the inside of the console using low pressure dry compressed air H Periodically drain water from the filter beneath the air filter regulator ...

Page 76: ...enoid Location Note The flow switch can be disassembled and cleaned without extraction from the power supply Piston Plug Spring Piston Flow Switch Body 1 Turn Off power supply 2 Remove piston plug 3 Remove the spring Use care when handling spring to prevent distortion 4 Remove the piston 5 Clean all parts with warm water and a mild detergent Allow parts to dry thoroughly before reassembly 6 Reasse...

Page 77: ...t bulkhead connections for tightness 5 2 2 Spark Gap 1 mm a Factory set to 1mm Adjustment procedure 1 Loosen screw a using a 1 8 0 125 internal hex wrench 2 Insert 1mm feeler gage between the tungsten electrodes 3 Slide electrodes till slight pressure is felt on the gage 4 Tighten locking screws on spark gap assembly ...

Page 78: ...RGIZED 5 3 1 General 1 Periodically check heat shield electrode holder assembly electrode nozzle seat and electrode insulator Replace if worn or damaged 2 Apply a thin film of lubricant 17672 supplied in spare parts kit to O ring Check O ring for damage whenever shield is removed Replace if necessary 3 Power and pilot arc cables should be inspected periodically If cuts through protective sheath or...

Page 79: ...other contamination is allowed to collect there 5 3 3 Loose Consumables Tests have shown that with proper use of the torch within rated operating conditions especially arc current and gas flow rate the torch consumable parts do not become loose if they are firmly installed in the first place 1 Tighten heat shield fully at each consumable change or inspection Fully means at least 5 mm of rotation a...

Page 80: ...ed by arcing will cause destruction of torch Parts damaged by arcing must be replaced Deformation at this edge indicates torch overheating Check gas pressure gas flow rate and current setting Deformation leads to loose parts and internal arcing Do not operate torch with a deformed insulator 5 3 5 Consumables Remove and Replace 1 Bring torch to a position where it is easily accessed by machine oper...

Page 81: ...hand and twist Inspect electrode insulator and electrode holder assembly for signs of damage such as arc tracking or cracking and replace them if any are found Insure that the baffle tube is securely threaded into the electrode holder but do not over tighten Use the small hex end of the plastic wrench in the spare parts kit After installing the electrode insulator onto the electrode holder assembl...

Page 82: ...ical contact for electrode and nozzle Fully means at least 3 16 inch of rotation after electrode seat contacts electrode holder 5 3 6 Measuring Torch Gas Flows Flow Measuring Kit P N 19765 Check gas flow if suspected of causing poor cutting performance Use Plasma Torch Flow Measuring Kit P N 19765 The kit includes a hand held rotameter flowmeter that indicates the gas flow rate exiting the torch T...

Page 83: ...nch supplied in the spare parts kit to loosen the pilot arc connector set screw closest to the torch body being careful not to totally remove the screw Slip the torch s pilot arc lead out of the connector 4 Unscrew the power cable fitting from the torch s power lead using a 7 16 open end wrench and remove the torch body 5 Connect the pilot arc cable and the power cable to the new torch body s pilo...

Page 84: ...SECTION 5 PCM 875A Plasmarc Cutting System Maintenance 5 12 This page intentionally left blank ...

Page 85: ... the line disconnect switch or circuit breaker before inspection maintenance or repair inside power console Match the problem with the conditions below If problem is not listed shut off input power open unit by removing cover Visual inspection of all components and wiring Check for loose terminal connections Burned wiring or other components Bulged or leaking capacitors Any other signs of damage o...

Page 86: ...Check input circuit breaker CB1 If cooling fan is running measure voltage between pins P2 11 and P2 14 of control board should be 115VAC If no voltage replace transformer T2 If voltage is present power light may be burned out The problem is internal if above items are ok Send unit to Authorized Repair Station 6 2 2 No air flow Check air inlet supply Unit requires 9 2 3 m h at 4 48 bar Check air ho...

Page 87: ...epressed If not then check Turn power off to the machine Unplug Control board Put an ohmmeter across P5 1 and P5 2 to take resistance reading Depress torch switch Meter should read a short If not then one of the following is not working properly Torch switch or the leads Unplug the torch switch leads at the machine Put a meter across the two plug pins Should read a short when the torch switch is d...

Page 88: ...regulator It should be adjusted to 65 psig If no air pressure check the air at the supply point Also check for any obstructions in the air hose Air flow may be blocked at the torch tip Check the torch consumables Also check for any obstructions in the torch leads NOTE If above items check OK the problem is internal send unit to an Authorized Repair Station for repair Put the Air Check switch to On...

Page 89: ...read a direct short If not then it should read open If the switch is malfunctioning replace it Clean the surface of the heat sink before installing the switch Over Current The fault light will be on continuously This indicates that the input current to the main transformer has exceeded preset limits To check if the output is shorted measure the resistance by putting the ohmmeter leads make sure to...

Page 90: ...rly Check the operation of the Thermal Switch See D 3 a above Check Air Check switch operation It might be stuck in On position Pilot arc will not initiate if this switch is in the ON position safety reasons Check air flow switch There may be internal short See D 2 c above Measure voltage across C1 or C2 capacitor It should be as follows approx 325 VDC for the 208 230 volt unit approx 280 VDC to 3...

Page 91: ...to 65 75 psig The air supplied to the torch should be free of oil and water Make sure the consumables in the torch are acceptable Check open circuit voltage Check the output Use a calibrated current probe capable of measuring 100 amps in the presence of high frequency 6 2 8 Air does not shut off Check air test the gas solenoid valve is energized when the switch is in the on position Does air flow ...

Page 92: ... must be tight Work cable and clamp must be in good condition and must make a good electrical connection to the material to be cut If above items check OK the problem is internal Send unit to an Authorized Repair Station for repair Missing or weak pilot arc Check pilot arc fuse open circuit voltage pilot arc resistors and pilot arc wiring Inoperative starter board PCB 5 Check Spark gap in RAS unit...

Page 93: ...e 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 13 vdc 13 vdc 5 msec 62 µsec 0 IGBT Gating Signal For 208 230 VAC input the IGBT off time is 3msec For 400 460 575 VAC input the IGBT of...

Page 94: ...lem is not corrected after referring to the maintenance section contact your ESAB distributor 6 4 1 Insufficient Penetration Current too low Cutting speed too fast Damaged cutting nozzle Improper air pressure Low air flow rate 6 4 2 Main Arc Extinguishes Cutting speed too slow Worn electrode 6 4 3 Dross Formation In some materials and thicknesses it may be impossible to get dross free cuts Current...

Page 95: ... on nozzle 6 4 5 Uneven Arc Damaged cutting nozzle or worn electrode 6 4 6 Unstable Cutting Conditions Incorrect cutting speed Loose cable or hose connections Electrode and or cutting nozzle in poor condition 6 4 7 Main Arc Does Not Strike Worn electrode Loose connections Worn cable not attached 6 4 8 Poor Consumable Life Improper gas pressure Contaminated air supply Low air flow rate ...

Page 96: ...V V V V P1 7 P4 2 P4 4 P4 1 P4 5 V V V V P3 2 P3 4 P3 1 275V 4 5 C2E1 Q1 G1 C2 C1 R10 10 50W 3 2 1 R15 R2 C3 IBR G R2 D6 D5 D4 R S AC3 AC2 MOV3 275V 1 LOAD LINE 2 A A BLK T1 L1 MOV2 B B 275V MOV1 EMC FILTER FN1 L2 RED T2 50 60 HZ 3 PH CE 208 230 VAC 3A 600VAC TS1 1UF 600V 3 2 C1 E2 1800UF 450VDC 1800UF 450VDC 600V 2 C15 1UF 1 1 2 3 10K 2W R1 10K 25W 10K 25W C19 22UF 1KV D3 T D2 D1 AC1 L2 X1 X2 2 1...

Page 97: ...P2 13 P2 12 GND 2 TB1 2 GND 4 01UF 250 VAC H1 01UF 1KV C11 TB1 1 01UF C12 1KV H2 C9 115 VAC V V 250VAC K1 B A SHIELD P5 1 P5 2 V C18 V P5 6 V PL2 C17 250VAC 022UF 4T L3 TORCH SWITCH J1 V 2 V 1 SIGNAL TO CNC VOLTAGE DIVIDER SIGNAL TO CNC CONTROL BOARD PCB1 5 P6 2 P2 2 P2 3 SOL1 V V V P1 12 P1 11 P6 1 V 1 V V 1 NOT USED ON CONSOLES 2 1 2 75mA 60V ZD1 S3 FS 2 4 0558003357 0558003356 P2 3 P2 4 V V V V...

Page 98: ...U PCB1 P6 2 3 2 PCB1 P6 6 WHT R1 1 S3 2 1 PCB1 P6 13 RED PCB1 P6 12 BRN PCB1 P5 6 BLK PCB1 P6 1 BLU PCB1 P2 4 ORN 3 2 1 PCB1 P1 12 BLK 4 5 6 GRY PCB1 P2 3 S2 RED FS 2 T5 X1 RED TB1 2 BLK H1 TB2 SG 1 RED T5 X2 RED SG 1 2 C 14 T3 H2 RED C13 X1 SPLICE 2 FS RED 1 RED TB1 1 BLK PCB1 P1 11 RED S1 5 RED SG 2 RED X2 T5 H2 YEL PCB1 P2 14 YEL PCB1 P2 11 PCB1 P5 5 RED PL1 2 PL2 1 CE MARKED UNITS B LINE S1 T1...

Page 99: ...RY 8 7 K1 A BLU 12 K1 B TB1 2 PL1 2 13 14 13 BLU YEL BLU TB1 1 PL1 1 T2 X11 12 11 11 BLU YEL VIO 9 T2 X3 11 FS 1 12 S1 4 10 T2 X4 8 T4 2 7 T4 1 7 IBR G YEL WHT 8 IBR BRN 9 RED BLK 10 WHT ORN 6 ORN 5 13 R1 3 12 R1 1 11 PCB4 4 RED BRN RED TP PCB1 P6 5 WHT 8 TB4 2 9 10 PCB4 3 8 7 TB4 1 ORN BLK TP YEL DETAIL A PCB1 5 4 3 2 T2 X10 5 T2 X5 3 4 T2 X9 1 TS1 1 2 TS1 2 P1 T2 X8 SOL1 2 S1 3 BLU 4 BRN BRN 3 3...

Page 100: ...2 7 YEL 2 MOV MOV 3 C19 G S R2 R FN1 LOAD A IBR T2 H2 BLK T2 H3 GRY M1 1 BLK TB5 C3 C4 4 BLU R7 1 PCB1 P1 2 VIO PCB1 P1 1 VIO C4 2 RED TS1 Q2 Q1 C10 2 1 2 C2E1 C2E1 PCB2 C1 1 2 C16 C15 E2 C1 E2 C1 1 3 4 2 3 4 PCB3 TB4 4 BLK P A BUS SOL1 2 1 J1 1 PCB1 P2 2 WHT PCB1 P2 3 GRY ZD1 2 CLR BLK PCB1 P5 2 BLK TP PCB1 P5 1 CLR TP T1 X3 TB3 R15 1 BLK C2 L3 34 56 12 PCB1 P4 GRY L2 X1 5 1 4 2 3 IBR RED WHT RED...

Page 101: ...ED C2 BLK R15 2 1 D1 1 BLK C1 BLK Q2 C2E1 C4 4 2 R2 1 L2 IBR C1 X1 X2 SHUNT PCB4 B 1 R11 2 1 R12 2 BLU BLU VIEW F F PCB4 2 BLU K1 T3 YEL TOP AND BOTTOM VIEW C C X7 X12 PCB1 P1 3 BRN PCB1 P2 4 ORN PCB1 P2 1 ORN PCB1 P1 4 BRN PCB1 P2 11 VIO X8 X9 X10 X11 PCB1 P2 14 VIO TOP X6 X1 PCB1 P5 4 YEL PCB1 P1 5 BLU PCB1 P1 6 BLU PCB1 P1 9 WHT PCB1 P1 10 WHT X4 X5 X3 X2 T2 PCB1 P5 3 YEL TOP TB5 1 BLK TB5 2 GR...

Page 102: ... V V P4 5 P4 4 V V P3 5 P3 4 FN1 4 5 C2 1800uf 450VDC C15 R15 10K 25W 1 UF 630VDC 2 3 R10 R2 G 1 10 50W T R IBR S MOV 510V 2 510V 510V 2 1 MOV 3 MOV 1 F1 3A 600VAC TS1 1800uf C1 450VDC C3 R2 10K 25W 630VDC 1 UF 2 1 1 2 3 10K 2W R1 0 22UF 1KV C19 50 60 HZ 3 PH 400 VAC 2 P6 5 V V V P1 2 P1 1 MAX V V V P6 6 P6 12 P6 13 V V P2 7 P2 8 1 L2 LOAD LINE P N 952253 EMC FILTER A AH2 A B C BH2 B CH2 C AH1 6 C...

Page 103: ...VAC P2 13 P2 12 TB1 2 TB1 1 GND 4 C11 01UF 1KV C12 01UF 1KV C9 01UF 250 VAC V 115 VAC V K1 B GND 2 A V V V P5 2 P5 1 P5 6 C17 022UF C18 250VAC 022UF PL2 1 J1 2 V V L3 SHIELD 4T TORCH SWITCH START SIGNAL SIGNAL TO CNC SIGNAL TO CNC VOLTAGE DIVIDER CONTROL BOARD P N 38109 PCB1 CONSOLES 0558003356 4 P1 12 V V V V V V P2 3 P2 2 P6 1 P6 2 P1 11 SOL1 75mA 2 60V 1 ZD1 2 1 2 NOT USED ON 0558003357 FS 1 3 ...

Page 104: ...1 3 1 S2 2 1 PCB1 P6 13 RED PCB1 P6 12 BRN PCB1 P5 6 BLK 4 5 6 PCB1 P6 1 BLU PCB1 P2 4 ORN 3 2 1 PCB1 P1 12 BLK GRY PCB1 P2 3 S1 RED FS 2 T5 X1 RED X2 TB2 T5 X2 RED 2 1 SG C 14 T3 H2 RED C13 X1 SG 1 RED T5 TB1 1 BLK H1 H2 TB1 2 BLK H2 H1 A H2 SG 2 RED H1 B H2 H1 C IBR T IBR S IBR R S1 T3 S1 T2 S1 T1 L2 PCB1 P5 5 RED PL2 2 1 PL1 YEL PCB1 P2 14 YEL PCB1 P2 11 P4 P3 CE MARKED UNITS S1 T1 A ONLY S1 T2...

Page 105: ...2 13 13 12 BLU BLU BLU PL1 1 T2 X11 11 11 BLK 10 VIO YEL 8 T4 2 10 11 T2 X8 FS 1 9 T2 X7 6 T2 X6 7 T4 1 5 T2 X5 6 ORN IBR G IBR WHT RED 9 8 WHT 7 BRN YEL T2 X2 S1 2 BLU 4 ORN 5 BLU 4 ORN ORN 12 R1 1 R1 3 13 PCB4 4 11 PCB4 3 10 BRN RED RED TP BLK TP PCB1 P6 5 PCB1 P6 6 TB4 1 7 GRY R16 1 TB4 2 9 8 8 RED BLK PL2 PL2 6 R1 2 5 YEL ORN WHT WHT WHT DETAIL A PCB1 4 3 2 1 1 TS1 1 3 T2 X3 4 T2 X4 2 TS1 2 P1...

Page 106: ...LU B L K T1 H2 1 R7 C10 2 TS1 1 2 Q1 C1 C1 RED E2 C16 C1 1 PCB3 3 2 4 F2 2 ORN T1 X3 P A BUS J1 SOL1 1 2 PCB1 P2 2 WHT PCB1 P2 3 GRY ZD1 L1 H1 BLK 1 C6 C8 BLU R6 2 1 2 1 3 2 TB4 4 BLK BLK CLR L3 PCB1 P5 1 CLR TP PCB1 P5 2 BLK TP T1 X1 R5 1 2 2 C5 1 C7 2 1 D1 B L U PCB4 2 BLU T1 H1 T1 H1 R15 1 RED TB3 C2 C15 T1 X3 C4 2 YEL T2 H3 BLU P N A 950906 PINK FEMALE FASTON TERMINAL R2 1 RED WHT WHT WHT RED ...

Page 107: ... BLU P A BUS ORN C1 RED R2 2 1 K1 BLU C21 L1 A T1 B L3 L2 T2 T3 R11 2 YEL TOP X6 X4 BOTTOM TOP B SHUNT PCB4 TOP AND BOTTOM VIEW C C SPLICE M1 1 GRY F1 1 RED H1 PCB1 P2 14 VIO X11 X12 PCB1 P1 3 BRN PCB1 P1 4 BRN PCB1 P2 11 VIO PCB1 P1 5 BLU X5 PCB1 P1 9 WHT PCB1 P1 6 BLU VIEW F F C12 C11 NOT USED SPLICE IBR R BLU WHT ORN H5 H3 H2 H4 T2 X1 X2 X3 GND 4 C9 VIEW D D T5 H2 BLK PCB1 P2 13 BLU PCB1 P2 12 ...

Page 108: ...tem Troubleshooting 6 24 6 7 Remote Arc Starter RAS 2 Schematic REACTOR STEP UP C1 C2 2500 pF SPARK GAP C B A POWER SUPPLY TORCH FILTER TRANSFORMER 0 040 PILOT ARC IN PILOT ARC TO TORCH VAC 120 X1 X3 EMI FILTER L1 PCB1 P1 FN1 T1 SG1 ...

Page 109: ... Cutting Systems GmbH Robert Bosch Strasse 20 P O Box 1128 D 61184 Karben Phone 011 49 60 39 400 Fax 011 49 60 39 40301 02 http www esab de ESAB Welding and Cutting Products ATTN Customer Service Department PO Box 100545 Ebenezer Road Florence SC USA 29501 0545 Phone 843 664 4405 800 ESAB 123 372 3123 ESAB Cutting Systems Canada 6010 Tomken Road Mississauga Ontario Canada L5T 1X9 Phone 905 670 022...

Page 110: ...SECTION 7 Replacement Parts 7 2 7 3 PCM 875A Power Console 230V P N 0558003356 PCM 875A POWER FAULT AIR TEST TEST OPERATE CURRENT CONTROL AIR PRESSURE 0 20 30 40 50 60 TORCH WORK 1 2 3 4 5 6 7 8 9 10 ...

Page 111: ...K 30W R1 3 951526 1 Lamp Neon White PL1 4 21711 1 Gauge 1 5 160 PSI WHT CDM STL 5 634518 1 Toggle Switch 2 pos 15A 125V S2 6 Not Required when RAS 2 is used 1 Reactor Assembly Reference Only 7 182W12 4 Rubber Foot 8 Not Required when RAS 2 is used Spark Gap Assembly 9 0558003618 1 Wire Kit 10 673458 1 Contactor 3 pole 110VAC 40A K1 ...

Page 112: ...SECTION 7 Replacement Parts 7 4 PCM 875A Power Console 230V P N 0558003356 230V CE 1 2 3 4 5 6 7 8 9 10 11 12 ...

Page 113: ...15 3 952233 1 Output Inductor L1 4 2091558 1 Label 5 Label 6 952026 1 Term block 7 pos 25A 12 18AWG TB4 7 951202 1 Switch Flow 25 GPN SPST FS 8 952597 Filter EMC 250 440V 3ph FN1 9 950249 1 Valve Solenoid NPT 165 PSI 24VAC SOL1 10 Not used in conjunction with RAS 2 Spark Gap 11 0558003618 Wire Kit 12 673458 Contactor 3 pole 110VAC 40A ...

Page 114: ...eplacement Parts 7 6 PCM 875A Power Console 230V P N 0558003356 Top View and Right Side 1 2 3 4 5 6 Arc On Signal Relay Closing Start Signal Relay Closing 20 1 Voltage Divider Not Used 7 6 5 4 3 2 1 7 8 9 10 11 12 ...

Page 115: ... 38214 1 PCB Control PCB1 4 951339 1 Plug Female 12 pos PCB1 P1 5 951340 1 Plug Female 14 pos PCB1 P2 6 38131 1 PCB Startup PCB5 7 31488 1 PCB Ay Shunt Board PCB4 8 36586 1 XFMR Assy Main T1 9 17300012 2 Resistor 300W 12 ohm R11 12 10 952232 1 Inductor PFC used on 230V unit only L2 11 32914 1 XFMR Assy Control T2 12 950487 Terminal Block 2 pos 20A TB1 ...

Page 116: ...SECTION 7 Replacement Parts 7 8 PCM 875A Power Console 230V P N 0558003356 Left Side 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 230V CE Detail ...

Page 117: ...erminal Block 2 pos 20A TB5 6 952235 1 Module Input bridge scr IBR 7 951205 2 IGBT 600V 100A Ser H Q1 2 8 17250010 1 Resistor WW Fixed 50W 10 ohm R10 9 17750010 1 Resistor WW 50W 3 10 ohm R7 10 952255 1 Capacitor 40 uf 400VDC C4 11 950711 1 Thermal Switch 194 deg TS1 12 951940 2 Capacitor 1uf 630W VDC C15 16 13 17721020 4 Resistor WWFAHT 25W 1 20 ohm Nl R3 4 5 6 14 952150 1 Bridge 60ADC 100NS 600V...

Page 118: ...SECTION 7 Replacement Parts 7 10 7 4 PCM 875A Power Console 400V P N 0558003357 PCM 875A POWER FAULT AIR TEST TEST OPERATE CURRENT CONTROL AIR PRESSURE 0 20 30 40 50 60 TORCH WORK 1 2 3 4 5 6 7 8 9 10 ...

Page 119: ...76 1 POT 10K 30W R1 3 951526 1 Lamp Neon White PL1 4 21711 1 Gauge 1 5 160 PSI WHT CDM STL 5 634518 1 Toggle Switch 2 pos 15A 125V S2 6 Not Required when RAS 2 is used 1 Reactor Assembly Reference Only 7 182W12 4 Rubber Foot 8 Not Required when RAS 2 is used Spark Gap Assembly 9 0558003618 1 Wire Kit See next illustration ...

Page 120: ...SECTION 7 Replacement Parts 7 12 PCM 875A Power Console 400V P N 0558003357 400V CE 1 2 3 4 5 6 7 8 9 10 ...

Page 121: ... Resistor 10K 25W R2 15 3 952233 1 Output Inductor L1 4 952026 1 Term block 7 pos 25A 12 18AWG TB4 5 951202 1 Switch Flow 25 GPN SPST FS 6 952253 Filter EMC 400V FN1 7 950249 1 Valve Solenoid NPT 165 PSI 24VAC SOL1 8 Not used in conjunction with RAS 2 Spark Gap 9 0558003618 Wire Kit 10 0558001193 Wire Kit 400V CE L2 ...

Page 122: ...SECTION 7 Replacement Parts 7 14 PCM 875A Power Console 400V P N 0558003357 1 2 3 4 5 6 Arc On Signal Relay Closing Start Signal Relay Closing 20 1 Voltage Divider Not Used 7 6 5 4 3 2 1 7 8 9 10 11 12 ...

Page 123: ... P5 3 38214 1 PCB Control PCB1 4 951339 1 Plug Female 12 pos PCB1 P1 5 951340 1 Plug Female 14 pos PCB1 P2 6 38131 1 PCB Startup PCB5 7 31488 1 PCB Ay Shunt Board PCB4 8 36586 1 XFMR Assy Main T1 9 673458 1 Contactor 3 pole 110VAC 40A K1 10 17300012 2 Resistor 300W 12 ohm R11 12 11 32914 1 XFMR Assy Control T2 12 950487 Terminal Block 2 pos 20A TB1 ...

Page 124: ...SECTION 7 Replacement Parts 7 16 PCM 875A Power Console 400V P N 0558003357 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 400V CE 15 ...

Page 125: ...Terminal Block 2 pos 20A TB5 6 952235 1 Module Input bridge scr IBR 7 17750010 1 Resistor WW 50W 3 10 ohm R7 8 Not used with RAS 2 1 Spark Gap SG 9 951800 1 Module Dual IGBT 150V 1200A Q1 10 952255 1 Capacitor 40 uf 400VDC C4 11 950711 1 Thermal Switch 194 deg TS1 12 951964 1 Capacitor 2uf 800VDC C16 13 17721020 4 Resistor WWFAHT 25W 1 20 ohm Nl R3 4 5 6 14 952150 1 Bridge 60ADC 100NS 600V D1 15 9...

Page 126: ...SECTION 7 Replacement Parts 7 18 7 5 Remote Arc Starter RAS 2 P N 0558003670 A A B B View B B View A A 1 2 3 4 4 ...

Page 127: ...7 Replacement Parts 7 19 Ref Part Number Quantity Description Elect 1 674969 1 PC Board Filter PCB1 2 634090 1 Adapt NPTM C A W F Cable 3 0558003679 1 Reactor Assembly H F 4 Reference Screw PHTF 10 32 X 38 inch ...

Page 128: ...SECTION 7 Replacement Parts 7 20 Remote Arc Starter RAS 2 P N 0558003670 1 2 3 4 5 6 7 5 REF 8 9 10 11 12 12 ...

Page 129: ...58003686 Cable Pilot Arc RAS2 15 2m 3 0558003687 Cable Pilot Arc RAS2 30 4m 37341 Cable Power RAS 15 2m 4 37342 Cable Power RAS 30 4m 5 0558002818 Spark Gap Electrode Holder Assembly SG1 6 0558003675 2 Grounding Plate 7 0558003672 2 Cover Torch Connect RAS2 PT20AMX 8 0558003671 1 Cover Box Side 9 950853 2 Fitting 1 4 NPT to 3 8 id Hose 10 952860 2 Clamp 1 ear w insert 12 8 GER 11 4600030 30mil Nom...

Page 130: ...SECTION 7 Replacement Parts 7 22 7 6 PT 20AMX Plasmarc Cutting Torch 1 4 6 7 8 9 10 11 12 13 14 16 2 3 5 17 18 1 15 ...

Page 131: ...638 Torch Lead Assembly 17 ft 0558002639 Torch Lead Assembly 25 ft 0558003383 4 Lock Ring 57N70 5 Rubber Boot 0558001157 6 Wrap with electrical tape as shown Reference 7 H F Connector 17974 8 Set screw 6 32 X 3 16 Reference 9 Insulate with vinyl tubing and secure with electrical tape Reference 10 Handle and sleeve without rack 22329 11 Handle Reference 12 Basic Torch Body Assembly 21359 13 O ring ...

Page 132: ...SECTION 7 Replacement Parts 7 24 PT 20 AMX Front End and Spare Parts Kit 1 2 3 4 5 8 6 7 9 ...

Page 133: ...Shield 70 100 A 21326 3 Cutting Nozzle 50 A 21330 5 Cutting Nozzle 70 A 23129 5 Electrode 50Hz 0558001617 5 Electrode Insulator 21373 1 Electrode Holder Assembly 21332 1 Baffle Tube 21374 1 Pilot Arc Adaptor 19497 1 O ring 488157 5 Lubricant 1 oz 17672 1 Seat Baffle Wrench 21375 1 1 16 Hex Key Wrench 93750006 1 NOTICE The description of the heat shield P N 21326 listed above indicates a range of 7...

Page 134: ...SECTION 7 Replacement Parts 7 26 This page intentionally left blank ...

Page 135: ...See back of Title Page for revision list ...

Page 136: ...Road Florence SC 29501 0545 http www esab com ESAB Cutting Systems Canada 6010 Tomken Road Mississauga Ontario Canada L5T 1X9 Phone 905 670 0220 Fax 905 670 4879 ESAB Cutting Systems GMBH Robert Bosch Strasse 20 Postfach 1128 D 61184 Karben 1 Phone 011 49 6039 400 Fax 011 49 6039 403 02 http www esab de Printed in U S A ...

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ESAB PCM-875A, Installation, Operation And Maintenance Manual

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