ESAB PCM-1125 Instruction Manual
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ESAB PCM-1125 Instruction Manual

ESAB PCM-1125 Instruction Manual

Plasma arc cutting package
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This manual provides installation and operation instructions for the following PCM-1125 cutting packages starting with
Serial No. PHJ205001 :
P/N 37496 - 208/230 V, 1 & 3-Phase, 50/60 Hz
P/N 37498 - 460 V, 3-Phase, 50/60 Hz
P/N 37500 - 575 V, 3-Phase, 60 Hz
P/N 0558002834 - 400 V, 3-Phase, 50/60 Hz
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.
PCM-1125 PLASMA ARC
CUTTING PACKAGE
F-15-482-B
February, 2002

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  • Page 1 February, 2002 PCM-1125 PLASMA ARC CUTTING PACKAGE This manual provides installation and operation instructions for the following PCM-1125 cutting packages starting with Serial No. PHJ205001 : P/N 37496 - 208/230 V, 1 & 3-Phase, 50/60 Hz P/N 37498 - 460 V, 3-Phase, 50/60 Hz...

  • Page 2: Table Of Contents

    Connecting PCM1125 for 200(208)Vac Input ............ 13 Mechanized Cutting Installation with the PT-20AM Torch ......... 14 SECTION 3 OPERATION ..................... 16 Operation ......................16 PCM-1125 Controls ................... 16 Cutting with the PT-27 ..................17 Common Cutting Problems ................18 SECTION 4 MAINTENANCE ....................19 General ......................
  • Page 3 SAFETY PRECAUTIONS WARNING: hese Safety Precautions are for 5. Do not use equipment beyond its ratings. For example, your protection. They summarize precaution- overloaded welding cable can overheat and create a fire ary information from the references listed in hazard. Additional Safety Information section.
  • Page 4 EQUIPMENT MAINTENANCE -- Faulty or FUMES AND GASES -- Fumes and improperly maintained equipment can gases, can cause discomfort or harm, cause injury or death. Therefore:\ particularly in confined spaces. Do not breathe fumes and gases. Shield- ing gases can cause asphyxiation. 1.
  • Page 5 PRÉCAUTIONS DE SÉCURITÉ a. Éloigner suffisamment tous les matériaux combus- AVERTISSEMENT: Ces règles de sécurité ont pour objet tibles du secteur où l’on exécute des soudures ou des d’ assurer votre protection. Veillez à lire et à observer les coupes à l’arc, à moins de les recouvrir complètement précautions énoncées ci-dessous avant de monter l’...
  • Page 6 à empêcher la forma- 52529 “Precautions and Safe Practices for Arc Weld- tion de poches d’hydrogène, lesquelles présentent un ing, Cutting and Gouging” publié par ESAB. Nous danger d’explosion; ce ventilateur ne fonctionne que conseillons également de consulter les publications si l’interrupteur correspondant du panneau avant se...

  • Page 7: Description

    (90-150 psi). The PCM-1125 package uses the heavy-duty PT-27 torch PCM-1125 listed on the front cover includes the following to deliver cutting power for severing materials up to 1-1/4 components: inch thick.

  • Page 8: Specifications

    (150 l/min @ 4.5 - 5.2 bars) Length 20.3" (516 mm) Height 16.1" (409 mm) w/handles 18.3" (465 mm) Dimensions Width w/o opt. storage 10.1" (275 mm) w/ opt. torch storage 13.1" (333 mm) Weight of PCM-1125 System Shipping Weight...
  • Page 9 2. Wheel Cart, P/N 34324. This 5 7/8" high cart has 1. Torch Wrap/Spare Parts Kit Holder, P/N 33952GY. front swivel casters and rear casters to make it Units have 4 mounting holes on left side for mounting easier to roll the PCM-1125 around the job site. this accessory holder.

  • Page 10: Installation

    208/230 V to a 460 V Adequate ventilation is necessary to provide proper input power supply. Damage to the machine may cooling of the PCM-1125. The amount of dirt, dust, and occur. excessive heat to which the equipment is exposed, should be minimized.

  • Page 11: Secondary Output Connections

    SECTION 2 INSTALLATION 1. For operator safety, the torch connections are lo- Table 2-1. Recommended Sizes For cated on the output terminal board behind the lower Input Conductors and Line Fuses portion of the front panel. Remove access door to output terminal board from right panel of power Input Requirements Input &...
  • Page 12 The plug is mounted to a 4- conductor cable. If 3-phase connection is desired, remove and discard the plug and refer to Sect. 2.5. CNC INTERFACE CONNECTION (INSIDE ON LEFT SIDE OF BASE.) Figure 2-1. PCM-1125 Interconnection Diagram DETAIL “A”...

  • Page 13: Connecting Pcm1125 For 200(208)Vac Input

    4. Leave all other wires the same. The PCM-1125 power source with 208/230 vac, 1-phase 5. Reinstall cover and connect the PCM-1125 to 208 input capability is factory set for 230 vac input. If using vac input power.

  • Page 14: Mechanized Cutting Installation With The Pt-20Am Torch

    37344 (100’) CABLE(25’) (Supplied with PILOT ARC CABLE - 37339 (50’) PCM-1125) 37340 (100’) SCHEMATIC - MECHANICAL SYSTEM SETUP (See Figure 2-4 for detailed connections) CNC Interface Connection (Located inside console, left side of base.) Figure 2.3 - MECHANICAL CUTTING INTERFACE DIAGRAM...
  • Page 15 25mm min. SPLICE CONNECTOR* (Supplied with 37338) PT-20AM TORCH *Insulate splice connec- tors with vinyl tubing and secure with electrical SPARK GAP ASSEMBLY MOUNTING DIMENSIONS tape. (Torch end of Arc Starter) Figure 2.4 Connection Diagram - PCM-1125/PT-20AM with Arc Starter...

  • Page 16: Operation

    Over-Current: The fault light will be on continu- ously. This indicates that input current has been exceeded. Position the PCM-1125 at least 10 feet (3 meters) All fault signals will remain on for a minimum from the cutting area. Sparks and hot slag from the of 10 seconds.

  • Page 17: Cutting With The Pt-27

    ELECTRODE Figure 3-3. Electrode Wear Limit Figure 3-2. Recommended Torch Angle of 5° to 15° 3.3.1. Drag Cutting with the PT-27/PCM-1125 System Reduce current to 40 Amperes. Then follow steps in For rapid re-starts, such as grate or heavy mesh Section 3.3.

  • Page 18: Common Cutting Problems

    40 amps. the probable cause of each. If problems are determined 2. Low air pressure. to be caused by the PCM-1125, refer to the maintenance 3. Damaged cutting nozzle. section of this manual. If the problem is not corrected 4. Loose cutting nozzle.

  • Page 19: Maintenance

    Occasionally, bleed all water from the filter be- neath the air filter-regulator. IMPORTANT! MAKE SHIELD VERY TIGHT! 4.3 PT-27 TORCH CONSUMABLE PARTS Make sure power switch on PCM-1125 is in OFF Figure 4-1. Assembly of PT-27 Torch Front End Parts position before working on the torch.

  • Page 20: Flow Switch

    SECTION 4 MAINTENANCE 4.4 FLOW SWITCH (FIGURE 4-2) • Use grounded work station with grounded floors and grounded wrist straps when handling devices. • Use a 100Ω resistor in series with the gate when When excessive contamination is found in the air, the performing curve tracer tests.

  • Page 21: Troubleshooting

    SECTION 5 TROUBLESHOOTING 5.1 TROUBLESHOOTING The cause of control malfunctions can be found by referring to the sequence of operations and electrical schematic diagram (Figure 5-1) and checking the vari- ous components. A volt-ohmmeter will be necessary for some of these checks. ELECTRIC SHOCK CAN KILL! Be sure that all pri- mary power to the machine has been externally disconnected.

  • Page 22: Reference Voltage Checks

    D. Fault light activates when torch switch is closed. The Fault circuit is used to monitor conditions necessary for the safe operation of the PCM-1125. The fault light will glow amber under the following conditions and operations will come to a complete stop: 1.
  • Page 23 SECTION 5 TROUBLESHOOTING should read a direct short. If not then it should read open. b. If the switch is malfunctioning, replace it. Clean the surface of the heat sink before installing the switch. 4. Over Current. The fault light will be on continuously. This indicates that the input current to the main trans- former has exceeded preset limits.
  • Page 24 SECTION 5 TROUBLESHOOTING F. High Frequency and Pilot Arc are on but Main Arc does not transfer. 1. Make sure work clamp is connected to work material. 2. Check the torch. Replace consumables if necessary. 3. Make sure the current setting potentiometer is set above 10 amps. If it is, set below 10 amps, then HI FRE- QUENCY will go on and off at 5 sec intervals.
  • Page 25 SECTION 5 TROUBLESHOOTING 5.3REFERENCE VOLTAGE CHECKS A. Control Board Assembly (PCB1) LED’s LED-1 Torch Switch LED-2 High Frequency LED-3 Gas Solenoid Valve 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...

  • Page 26: Sequence Of Operation

    SECTION 5 TROUBLESHOOTING 5.4SEQUENCE OF OPERATION A. TRIGGER LOCK “UNLOCK” position PUSH RELEASE TORCH SWITCH OPEN CLOSE GAS SOLENOID VALVE 2 SEC. PREFLOW 10 SEC Postflow OPEN FLOW SWITCH CLOSE FAULT OVERLOAD LIGHT ENERGIZE HF CIRCUIT INVERTER CUTTING ARC (CURRENT) NOTES: When the torch switch is pushed during postflow period, the postflow and preflow times are canceled, and the HF is energized immediately.
  • Page 27 SECTION 5 TROUBLESHOOTING TRIGGER LOCK "LOCK" position PUSH RELEASE PUSH RELEASE TORCH SWITCH OPEN CLOSE GAS SOLENOID VALVE PREFLOW 2 SEC. 10 SEC Postflow POSTFLOW CLOSE OPEN FLOW SWITCH FAULT LIGHT ENERGIZE HF CIRCUIT INVERTER CUTTING ARC (CURRENT) NOTES: 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.

  • Page 37: Replacement Parts

    6.3 LITERATURE REVISIONS To assure proper operation, it is recommended that only REVISIONS to prior issue dated November, 1998 genuine ESAB parts and products be used with this incorporated into this issue: equipment. The use of non-ESAB parts may void your warranty.

  • Page 38: Parts Diagrams & Lists

    SECTION 6 REPLACEMENT PARTS 6.4 PARTS DIAGRAMS & LISTS 5, 4 3, 4 1, 2 8, 9 10, 11 Fig. 6-1. PCM-1125 Power Source, Front View Item Part Circuit Req. Description Symbol 13730611 KNOB 2062018 POT. 10K 2W (NOMEX INSUL - 676876...
  • Page 39 SECTION 6 REPLACEMENT PARTS 25, 26 25, 26 29, 30 32, 33, 34 36, 49 44, 45 Fig. 6-2. PCM-1125 Power Source, Left Side View (208/230) Item Part Circuit Req. Description Symbol 951185 BRIDGE 100ADC 100NS 600 V (includes PAD - 951518)
  • Page 40 SECTION 6 REPLACEMENT PARTS 56, 57, 58 56, 57, 58 64, 65, 66 67, 79A 69, 70 72, 78, 79 75, 76 Fig. 6-3. PCM-1125 Power Source, Left Side View (460/575)
  • Page 41 SECTION 6 REPLACEMENT PARTS Fig. 6-3. PCM-1125 Power Source, Left Side View (460/575) Item Part Circuit Req. Description Symbol 951185 BRIDGE 100ADC 100NS 600 V (includes PAD - 951518) D1, 2 952002 CORE SATURABLE 952872 MODULE DUAL IGBT 200A, 1200 V (460 V)
  • Page 42 SECTION 6 REPLACEMENT PARTS 90, 91 94, 105 101, 102, 103 82, 83, 84 98, 99 Fig. 6-4. PCM-1125 Power Source, Right Side View (208/230)
  • Page 43 SECTION 6 REPLACEMENT PARTS Fig. 6-4. PCM-1125 Power Source, Right Side View (208/230) Item Qty. Part Circuit Req. Description Symbol 35940 CONTROL TRANSFORMER ASS'Y 17300012 RESISTOR 300W 12 OHM R11, 12 673458 CONTACTOR 3 POLE 110 VAC 40 A 952557 CAPACITOR .82µf 630 VDC (See Wiring)
  • Page 44 SECTION 6 REPLACEMENT PARTS 119, 120 112, 113, 114 123, 135 127, 128 130, 131, 132 Fig. 6-5. PCM-1125 Power Source, Right Side View (460/575 V)
  • Page 45 SECTION 6 REPLACEMENT PARTS Fig. 6-5. PCM-1125 Power Source, Right Side View (460/575 V) Item Qty. Part Circuit Req. Description Symbol 32914 CONTROL TRANSFORMER ASS'Y 17300012 RESISTOR 300 W 12 OHM R11, 12 673458 CONTACTOR 3 POLE 110VAC 40 A 952557 CAPACITOR .82µf 630 VDC (See wiring)
  • Page 46 SECTION 6 REPLACEMENT PARTS Fig. 6-6. PCM-1125 Power Source, Top View with PCB1 and Shelf Removed Item Qty. Part Circuit Req. Description Symbol 954673 LABEL CNC INTERFACE 952026 TERM. BLOCK 7 POS 25 A 17240310 RESISTOR 10 K 25 W...
  • Page 47 SECTION 6 REPLACEMENT PARTS 154, 155, 156, 164 151, 152 158, 163 160, 161 Fig. 6-7. PCM-1125 Power Source, Rear View Item Qty. Part Circuit Req. Description Symbol 21710 FILTER REGULATOR 10Z30 ADAPTOR B/A-WM x 1/4 NPTM 951575 HANDLE 36719YL...
  • Page 48 ESAB Welding & Cutting Products, Florence, SC Welding Equipment COMMUNICATION GUIDE - CUSTOMER SERVICES A. CUSTOMER SERVICE QUESTIONS: Order Entry Product Availability Pricing Delivery Order Changes Saleable Goods Returns Shipping Information Eastern Distribution Center Telephone: (800)362-7080 / Fax: (800) 634-7548...

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