ESAB PCM-500i Instruction Manual
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ESAB PCM-500i Instruction Manual

Plasma arc cutting packages
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PLASMA ARC CUTTING PACKAGES
This manual provides complete instructions for the following PCM-500i cutting packages starting with Serial No. PORI612001:
ESAB P/N 36314 - 208/230 V, 1-Phase, 50/60 Hz
ESAB P/N 36316 - 400 V (380/415 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 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.
INSTRUCTION MANUAL
PCM-500i
F-15-296-E
Feb., 2004

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Summary of Contents for ESAB PCM-500i

  • Page 1 PCM-500i PLASMA ARC CUTTING PACKAGES This manual provides complete instructions for the following PCM-500i cutting packages starting with Serial No. PORI612001: ESAB P/N 36314 - 208/230 V, 1-Phase, 50/60 Hz ESAB P/N 36316 - 400 V (380/415 V), 3-Phase, 50/60 Hz These INSTRUCTIONS are for experienced operators.

  • Page 2: Table Of Contents

    Equipment Required ..................10 Location ......................10 Inspection ......................10 Primary Electrical Input Connections ..............10 Secondary (Output) Connections ..............11 Connecting PCM-500i for 200(208) Vac Input ........... 13 SECTION 3 OPERATION ..................... 15 Operation ......................15 PCM-500i Controls .................... 15 Assembling PT-31XL Consumable Parts ............
  • 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- 1. Always have qualified personnel perform the installa- ing gases can cause asphyxiation.
  • 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

    1.3 PACKAGES AVAILABLE Table 1-1 lists available PCM-500i packages. Table 1-1. PCM-500i Cutting Packages Each PCM-500i Plasma Arc Cutting Package includes a Power Source, PT-31XL Torch with 25-ft. (8m) service lines, and Torch Spare Parts Kit as listed. Contents of...

  • Page 8: Specifications

    NOTE: PT-31XL Torch Assembly P/N 21985 is supplied with the nozzle, electrode, swirl baffle, and heat shield assembled. 1.4 SPECIFICATIONS Refer to Tables 1-3, 1-4, and Figures 1-1 and 1-2 for PCM-500i technical specifications. Table 1-3. PCM-500i Specifications 40% Duty Cycle*...

  • Page 9: Optional Accessories

    Nozzle, P/N 19667; 4-Electrode, P/N 18205; 1-Swirl tober, 1996. Wheel Cart, P/N 34324. This 5 7/8" high cart has Baffle, P/N 18785; and 1 oz. Lubricant, P/N 17672. front swivel casters and rear casters to make it easier to roll the PCM-500i around the job site.

  • Page 10: Installation

    Damage to the machine may Adequate ventilation is necessary to provide proper occur. cooling of the PCM-500i and the amount of dirt, dust, and excessive heat to which the equipment is exposed, should be minimized. There should be at least one foot...

  • Page 11: Secondary (Output) Connections

    SECTION 2 INSTALLATION 2.6SECONDARY (OUTPUT) CONNECTIONS output terminal board from right panel of power source. (REFER TO FIG. 2-1) 2. Thread the power cable and switch lead of the PT- 31XL through the right open bushing of the front panel. Connect power cable to the torch fitting (left- hand threads) and plug in the switch lead to the torch switch receptable on the output terminal board.
  • Page 12 2.5.) NOTE: If using 208 V input, see Section 2.7 and Fig. 2-2. See Table 2.1 PLUG (Equipped only on RECEPTACLE (P/N 674540) 230 V, 1-phase units) (Optional for 208/230 V, 1-phase power sources) Figure 2-1. PCM-500i Interconnection Diagram...

  • Page 13: Connecting Pcm-500I For 200(208) Vac Input

    The PCM-500i power source with 208/230 vac, 1-phase 4. Leave all other wires the same. input capability is factory set for 230 vac input. If using 5. Reinstall cover and connect the PCM-500i to the 208 vac input, the PCM-500i must be reconnected as 208vac input power.
  • Page 14 SECTION 2 INSTALLATION EARTH GROUND DO NOT ATTACH WORK CABLE TO PIECE BEING CUT WORK CABLE FREE GROUNDED WORK TABLE BE SURE WORK IS IN GOOD CONTACT WITH TABLE. EARTH GROUND WORK CABLE Figure 2-3. Ground and Work Cable Connections...

  • Page 15: Operation

    When placed in OFF position, torch switch must be held closely by the Position the PCM-500i at least 10 feet (3 meters) from operator during the entire cutting operation and the cutting area. Sparks and hot slag from the cut- then released at the end of cut.

  • Page 16: Assembling Pt-31Xl Consumable Parts

    ALWAYS REPLACE TORCH WITH THE PROPER TORCH MANUFAC- TURED BY ESAB SINCE IT ALONE CONTAINS ESAB’S PATENTED SAFETY INTERLOCK. Make sure power switch on power source is in OFF position and primary input power is deenergized.
  • Page 17 AGAINST AND DAMAGING THE TORCH. Figure 3-4. Piercing Technique using the PT-31XL Cutting Speed Range — PCM-500i CAUTION: Do not depress the torch switch unless the (Using Air with XT Consumables @ 75 psi) torch nozzle is touching or within 0.020-in.

  • Page 18: Operating Techniques

    Listed below are common cutting problems followed by Poor Consumable Life. the probable cause of each. If problems are determined to be caused by the PCM-500i, refer to the maintenance Improper gas pressure. section of this manual. If the problem is not corrected Contaminated air supply.

  • Page 19: Maintenance

    PCM-500i. Remove the piston. 4.2 INSPECTION AND CLEANING Clean all parts with cleaning agent. Frequent inspection and cleaning of the PCM-500i is NOTE recommended for safety and proper operation. Some Ensure cleaning agent does not contain solvents suggestions for inspecting and cleaning are as follows: which can degrade polysulfone.

  • Page 20: 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 21 SECTION 5 TROUBLESHOOTING No Air Is air hose connected? Connect Is air adjusted to 65 - 75 psig? Adjust Does air come on with air check switch? • No electrode in torch • No valve pin in torch • Replace electrode Check continuity of torch switch •...
  • Page 22 Is air check switch OFF? Turn switch OFF Does arc start when nozzle contacts work without depressing torch switch? Check for short in torch switch Does air flow even when PCM-500i power switch is OFF? Replace Repair power solenoid valve...
  • Page 23 Is main 230 volt switch ON? Turn on main disconnect Is plug in receptacle? Insert plug in receptacle Is cooling fan turning? Replace pilot light Check voltage at receptacle and input power line Check main fuses Faulty power switch on PCM-500i...
  • Page 24 • Fault light will energize if input voltage goes below or above ±15% of units input rating. The light will not turn OFF even when correct voltage is restored. Reset by placing PCM-500i power switch OFF and then ON again.

  • Page 25: Sequence Of Operation

    SECTION 5 TROUBLESHOOTING 5.3 SEQUENCE OF OPERATION LOCK-IN "OFF" position PUSH RELEASE TORCH SWITCH OPEN CLOSE GAS SOLENOID VALVE 2 SEC. 10 SEC PREFLOW 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 26 SECTION 5 TROUBLESHOOTING LOCK-IN "ON" position PUSH RELEASE PUSH RELEASE TORCH SWITCH OPEN CLOSE GAS SOLENOID VALVE PREFLOW 2 SEC. 10 SEC Postflow POSTFLOW CLOSE OPEN FLOW SWITCH FAULT PILOT 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 33: Replacement Parts

    Replacement Parts are illustrated on the following fig- ures. When ordering replacement parts, order by part genuine ESAB parts and products be used with this number and part name, as illustrated on the figure. equipment. The use of non-ESAB parts may void your warranty.
  • Page 34 SECTION 6 REPLACEMENT PARTS 7, 14 2, 3 12, 14 Figure 6-1. Front View, PCM-500i ITEM QTY. PART CIRCUIT REQ. DESCRIPTION SYMBOL 35946 CHASSIS 2062018 POTENTIOMETER 10K 2W 13730611 KNOB 35947YL COVER TOP 954707 WARNING LABEL 951575 HANDLE (Screws and Lockwashers included)
  • Page 35 SECTION 6 REPLACEMENT PARTS 32, 33, 34 49, 50 45, 46 Figure 6-2. Right Side View, PCM-500i ITEM QTY. PART CIRCUIT REQ. DESCRIPTION SYMBOL 951179 HI VOLTAGE TRANSFORMER 950487 TERMINAL BLOCK 2 POS 950204 CAPACITOR 0.1µf 250 VAC 672348 CAPACITOR 0.01µf 1 KV...
  • Page 36 SECTION 6 REPLACEMENT PARTS 68, 69 65, 66 65, 66 82, 83 75, 88 200/230 V, 1 Phase Power Source illustrated.
  • Page 37 SECTION 6 REPLACEMENT PARTS Figure 6-3. Left Side View, PCM-500i ITEM QTY. PART CIRCUIT REQ. DESCRIPTION SYMBOL 951313 CAPACITOR 0.01µF 1KV C5, 6, 7, 8, 10 952208 STANDOFF (230, 1-PHASE) 673038 SNAP BUSHING 952147 HEATSINK 950518 GROMMET 2.12" ID 952185 CAPACITOR 1000µf 400 VDC (230V)
  • Page 38 SECTION 6 REPLACEMENT PARTS Rear View Top View 104, 105, 106 113, 117 110, 111, 112 Figure 6-4. Top and Rear View, PCM-500i ITEM QTY. PART CIRCUIT REQ. DESCRIPTION SYMBOL 92W57 GROMMET 0.63 ID 951469 CAPACITOR 0.22µf 250 VAC C17, C18...
  • Page 39 The "B" edition of (10/98) of this manual covers the following changes that have occurred between May, 1997 (Serial No. PX-I618001) and September, 1998: 1. Removed the L-TEC and the European CE labeled packages. L-TEC units were discontinued. CE units are now covered in F-15-417 and F-15-424.
  • Page 40 ESAB Welding & Cutting Products, Florence, SC Welding Equipment COMMUNICATIONS GUIDE - CUSTOMER SERVICES A. CUSTOMER SERVICE QUESTIONS: Telephone (843) 664-5540/Fax: (800) 634-7548 Order Entry Product Availability Pricing Hours: 8:30 AM to 5:00 PM EST Order Changes Saleable Goods Returns...

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