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

ESAB PCM-1125 Instruction Manual

Esab plasma arc cutting package
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PCM-1125
PLASMA ARC CUTTING PACKAGE
Instruction Manual
This manual provides installation and operation 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
F15-707-A
12/2005

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Summary of Contents for ESAB PCM-1125

  • Page 1 PCM-1125 PLASMA ARC CUTTING PACKAGE Instruction Manual This manual provides installation and operation 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...

  • Page 2: User Responsibility

    Be SuRe THIS INFORMATION ReACHeS THe OPeRATOR. YOu CAN geT exTRA COPIeS THROugH YOuR SuPPlIeR. CAuTION 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,”...

  • Page 3: Table Of Contents

    TABle OF CONTeNTS Section / Title Page Safety Precautions ..................................5 Safety - English ..................................5 Safety - Spanish ..................................9 Safety - French ..................................1 Description .....................................17 General ....................................17 . Scope .....................................17 . Packages Available ................................17 .4 Specifications ..................................18 .5 Optional Accessories ................................19 Installation......................................
  • Page 4 TABle OF CONTeNTS...

  • Page 5: Safety Precautions

    SeCTION 1 SAFeTY PReCAuTIONS Safety Precautions Safety - english WARNINg: These Safety Precautions are FIReS AND exPlOSIONS -- Heat from for your protection. They summarize pre- flames and arcs can start fires. Hot cautionary information from the references slag or sparks can also cause fires and listed in Additional Safety Information sec- explosions.
  • Page 6 SeCTION 1 SAFeTY PReCAuTIONS 1. Be sure the power source frame (chassis) is con- . Welders should use the following procedures to nected to the ground system of the input power. minimize exposure to EMF: . Connect the workpiece to a good electrical A.
  • Page 7 SeCTION 1 SAFeTY PReCAuTIONS 5. WARNINg: This product, when used for welding 1. Always have qualified personnel perform the instal- or cutting, produces fumes or gases lation, troubleshooting, and maintenance work. which contain chemicals known to Do not perform any electrical work unless you are the State of California to cause birth qualified to perform such work.
  • Page 8 SeCTION 1 SAFeTY PReCAuTIONS 5. AWS C5.5 - "Recommended Practices for Gas Tung- sten Arc Welding“ 6. AWS C5.6 - "Recommended Practices for Gas Metal Arc Welding"“ 7. AWS SP - "Safe Practices" - Reprint, Welding Hand- book. 8. ANSI/AWS F4.1, "Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances."...

  • Page 9: Safety - Spanish

    SeCTION 1 SeguRIDAD Safety - Spanish La escoria puede estar caliente y desprenderse con velocidad. Personas cercanas deberán usar gafas ADVeRTeNCIA: Estas Precauciones de Se- de seguridad y careta protectora. guridad son para su protección. Ellas hacen resumen de información proveniente de las FuegO Y exPlOSIONeS -- el calor de referencias listadas en la sección "Información Adi- las flamas y el arco pueden ocacionar...
  • Page 10 SeCTION 1 SeguRIDAD 1. Asegúrese de que el chasis de la fuente de poder . Los soldadores deberán usar los siguientes proced- esté conectado a tierra através del sistema de imientos para minimizar exponerse al EMF: electricidad primario. . Conecte la pieza de trabajo a un buen sistema de A.
  • Page 11 SeCTION 1 SeguRIDAD 5. ADVeRTeNCIA-- este producto cuando se uti- 1. Siempre tenga personal cualificado para efec- liza para soldaduras o cortes, tuar l a instalación, diagnóstico, y mantenimiento produce humos o gases, los del equipo. No ejecute ningún trabajo eléctrico a cuales contienen químicos menos que usted esté...
  • Page 12 SeCTION 1 SeguRIDAD SIgNIFICADO De lOS SIMBOlOS -- Según usted avanza en la lectura de este folleto: los Símbolos Sig- nifican ¡Atención! ¡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.

  • Page 13: Safety - French

    SeCTION 1 SÉCuRITÉ Safety - French INCeNDIeS eT exPlOSIONS -- la chaleur provenant des flammes ou de AVeRTISSeMeNT : Ces règles de sécurité l'arc peut provoquer un incendie. le ont pour but d'assurer votre protection. Ils laitier incandescent ou les étincelles récapitulent les informations de précaution provenant des références dans la section peuvent également provoquer un...
  • Page 14 SeCTION 1 SÉCuRITÉ 1. Assurez-vous que le châssis de la source . Les soudeurs doivent suivre les procédures suivantes d'alimentation est branché au système de mise à pour minimiser l'exposition aux champs électriques la terre de l'alimentation d'entrée. et magnétiques : .
  • Page 15 SeCTION 1 SÉCuRITÉ 5. AVeRTISSeMeNT : Ce produit, lorsqu'il est utilisé eNTReTIeN De l'ÉQuIPeMeNT -- un équipe- dans une opération de soudage ou de ment entretenu de façon défectueuse ou coupage, dégage des vapeurs ou des inadéquate peut causer des blessures gaz contenant des chimiques consi- graves ou mortelles.
  • Page 16 SeCTION 1 SÉCuRITÉ SIgNIFICATION DeS SYMBOleS Ce symbole, utilisé partout dans ce manuel, signifie "Attention" ! Soyez vigilant ! Votre sécurité est en jeu. DANgeR Signifie un danger immédiat. la situation peut entraîner des blessures graves ou mortelles. AVeRTISSeMeNT Signifie un danger potentiel qui peut entraîner des blessures graves ou mortelles.

  • Page 17: Description

    PT-7 torch to deliver cutting power for severing materials up to 1-1/4 inch thick. Refer to the following paragraphs for descriptions of the PCM-115 packages available as well as performance specifications. use only eSAB Plasmarc torches that are designed for use with this console. use WARNINg of torches not designed for use with this console could create an eleCTRIC SHOCK HAZARD.

  • Page 18: Specifications

    SeCTION 2 DeSCRIPTION 2.4 SPeCIFICATIONS Table 2-2. PowerCut-1125 Specifications Rated Inputs Rated Outputs Phases Volts Amps Power *Duty Output Open Efficiency Factor Cycle Amps @ Circuit 10V DC Voltage 80V DC 100% 80V DC 70V DC 100% 70V DC Three 100% 85V DC 100%...

  • Page 19: Optional Accessories

    5. lbs (.4 kg) 1" 50 ft 9.6 lbs (4.4 kg) (5.4 mm) Figure 2-1. PT-27 Dimensions PT-27, PCM-1125, 70A, air, Carbon Steel 90 in/min max speed of side beam 60 A Nozzle Plate Thickness (in) Figure 2-2. PT-27/PCM-1125 Cutting Performance 2.5 OPTIONAl ACCeSSORIeS...
  • Page 20 SeCTION 2 DeSCRIPTION...

  • Page 21: Installation

    SeCTION 3 INSTAllATION 3.1 geNeRAl Proper installation is important for satisfactory and trouble-free operation of the PCM-115 cutting package. It is suggested that each step in this section be studied carefully and followed closely. 3.2 eQuIPMeNT ReQuIReD A source of clean, dry air that supplies 0 cfh at 65-75 psig is required for the cutting operation. The air supply should not exceed 150 psig (the maximum inlet pressure rating of the air filter-regulator supplied with the package).

  • Page 22: Primary Electrical Input Connections

    DO NOT connect a power source configured for 208/230 V to a 460 V input power supply. Damage to the machine may occur. NOTE: If using 208 V input power, the PCM-1125 must be reconnected for 208 V use as directed in Section 3.7 and Fig. 3-2.
  • Page 23 SeCTION 3 INSTAllATION 3.6 SeCONDARY (OuTPuT) CONNeCTIONS (ReFeR TO FIg. 3-1) Before making any connections to the power source output terminals, make sure WARNINg that all primary input power to the power source is deenergized (off) at the main disconnect switch and that the input power cable is unplugged. For operator safety, the torch connections are located on the output terminal board behind the lower portion of the front panel.
  • Page 24 The plug is mounted to a 4-conductor cable. If 3-phase connection is desired, remove and discard the plug and refer to Sect. 3.5. CNC INTERFACE CONNECTION (INSIDE ON LEFT SIDE OF BASE.) Figure 3-1. PCM-1125 Interconnection Diagram DeTAIl “A”...
  • Page 25 SeCTION 3 INSTAllATION CONNeCTINg PCM-1125 FOR 208 VAC INPuT eleCTRIC SHOCK CAN KIll! Precautionary measures should be taken to provide WARNINg maximum protection against electrical shock. Be sure that all power is off by open- ing the line (wall) disconnect switch and by unplugging the power cord to the unit when reconnecting for 208 VAC Input.
  • Page 26 SeCTION 3 INSTAllATION...

  • Page 27: Operation

    • Wear welding helmet with No. 6 or 7 lens shade. • Wear eye, ear, and body protection. CAuTION Position the PCM-1125 at least 10 feet (3 meters) from the cutting area. Sparks and hot slag from the cutting operation can damage the unit. 4.2 PCM-1125 CONTROlS (FIguRe 4-1) Power Switch (located on rear panel).

  • Page 28: Cutting With The

    FUSE (A) CONTROL KNOB Figure 4-1. PCM-1125 Controls 4.3 CuTTINg WITH THe PT-27 Use the following procedures to cut with the PT-7 torch (Figure 4-4). Hold the torch nozzle approximately 1/8 to /16 inch above the work and tilted at about 15 - 0°. This reduces the chance of spatter entering the nozzle.
  • Page 29 Nozzle life is also greatly reduced when using the electrode below the recommended limit. Refer to Figure 4-3. 4.3.1. Drag Cutting with the PT-27/PCM-1125 System Reduce current to 40 Amperes. Then follow steps in Section 4..
  • Page 30 SeCTION 4 OPeRATION...

  • Page 31: Maintenance

    WARNINg Be sure that the wall disconnect switch or wall circuit breaker is open before at- tempting any inspection or work inside of the PCM-1125. 5.2 INSPeCTION AND CleANINg Frequent inspection and cleaning of the PCM-115 is recommended for safety and proper operation. Some suggestions for inspecting and cleaning are as follows: Check work cable for secured connection to workpiece.

  • Page 32: Pt-7 Torch Consumable Parts

    SeCTION 5 MAINTeNANCe 5.3 PT-27 TORCH CONSuMABle PARTS 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 WARNINg the flow switch and circuitry within the power source.

  • Page 33: Flow Switch

    SeCTION 5 MAINTeNANCe 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: Ensure the system is shut down and there is no trapped air under pressure in the piping. Remove the piston plug.
  • Page 34 SeCTION 5 MAINTeNANCe 5.5 IgBT Handling & Replacement Since IGBT gates are insulated from any other conducting region, care should be taken to prevent static build up, which could possibly damage gate oxides. All IGBT modules are shipped from the factory with conductive foam contacting the gate and emmiter sense pins.

  • Page 35: Troubleshooting

    SeCTION 5 MAINTeNANCe TROuBleSHOOTINg eleCTRIC SHOCK CAN KIll! Be sure that all primary power to the machine has WARNINg been externally disconnected. Open the line (wall) disconnect switch or circuit breaker before attempting inspection or work inside of the power source. Check the problem against the symptoms in the following troubleshooting guide.

  • Page 36: Troubleshooting Guide

    SeCTION 5 MAINTeNANCe TROuBleSHOOTINg guIDe A. Power light (Pl1) does not come on. Visually inspect the machine for any damage. Check if the cooling fan is running. If not, then check the following : Check if the machine power cord is plugged into the input power receptacle. b.
  • Page 37 SeCTION 5 MAINTeNANCe b. Check T transformer secondary voltages at the plugs P1 and P. Refer to system schematic. Replace the transformer if the correct secondary voltages are not present. If everything above checks out all right, then the PCB1 Control Board should be replaced. D.
  • Page 38 SeCTION 5 MAINTeNANCe Check to assure high frequency is present at the torch. If not, then listen for high frequency at the high frequency generator. It is located on the bottom/right side of the unit. The high frequency gap is set to 0.040”. Disconnect HI FReQueNCY leads.
  • Page 39 SeCTION 5 MAINTeNANCe g. Poor Cutting Performance. Check air supply regulator . It should be adjusted 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.

  • Page 40: Common Cutting Problems

    Listed below are common cutting problems followed by the probable cause of each. If problems are determined to be caused by the PCM-115, refer to the maintenance section of this manual. If the problem is not corrected after referring to the maintenance section, contact your ESAB distributor. A. Insufficient Penetration.

  • Page 41: Reference Voltage Checks

    SeCTION 5 MAINTeNANCe 5.9 ReFeReNCe VOlTAge CHeCKS A. Control Board Assembly (PCB1) leD’s LED-1 Torch Switch LED- High Frequency LED- 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 42: Sequence Of Operation

    SeCTION 5 MAINTeNANCe 5.10 SeQueNCe OF OPeRATION A. TRIggeR lOCK “uNlOCK” position PUSH RELEASE TORCH SWITCH OPEN CLOSE GAS SOLENOID VALVE  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 43 SeCTION 5 MAINTeNANCe TRIggeR lOCK "lOCK" position PUSH RELEASE PUSH RELEASE TORCH SWITCH OPEN CLOSE GAS SOLENOID VALVE PREFLOW  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 44 SeCTION 5 MAINTeNANCe...

  • Page 45: Replacement Parts

    Ordering To ensure proper operation, 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 Distributor.
  • Page 46 LOCK CONTROL (70 PSIG) TEST LOCK Min. UNLOCK OPERATE 70 Max. 10, 11 TORCH WORK Fig. 6-1. PCM-1125 Power Source, Front View Item Part Circuit Req. Description Symbol 170611 KNOB 0558001176 POT. 10K W (NOMEX INSUL - 676876) 671 SWITCH TOGGLE SPST  POS 15 A 15 V...
  • Page 47 SeCTION 6 RePlACeMeNT PARTS 5, 6 5, 6 9, 0 , , 4 44, 45 6, 49 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 48 SeCTION 6 RePlACeMeNT PARTS 56, 57, 58 56, 57, 58 64, 65, 66 7, 78, 79 69, 70 67, 79A 75, 76 Fig. 6-3. PCM-1125 Power Source, left Side View (460/575)
  • Page 49 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,  9500 CORE SATURABLE 9587 MODULE DUAL IGBT 00A, 100 V (460 V)
  • Page 50 SeCTION 6 RePlACeMeNT PARTS 90, 91 94, 105 8, 8, 84 98, 99 101, 10, 10 Fig. 6-4. PCM-1125 Power Source, Right Side View (208/230)
  • Page 51 SeCTION 6 RePlACeMeNT PARTS Fig. 6-4. PCM-1125 Power Source, Right Side View (208/230) Item Qty. Part Circuit Req. Description Symbol 5940 CONTROL TRANSFORMER ASS'Y 170001 RESISTOR 00W 1 OHM R11, 1 67458 CONTACTOR  POLE 110 VAC 40 A 95557 CAPACITOR .8µf 60 VDC (See Wiring)
  • Page 52 SeCTION 6 RePlACeMeNT PARTS 119, 10 11, 11, 114 1, 15 10, 11, 1 17, 18 Fig. 6-5. PCM-1125 Power Source, Right Side View (460/575 V)
  • Page 53 SeCTION 6 RePlACeMeNT PARTS Fig. 6-5. PCM-1125 Power Source, Right Side View (460/575 V) Item Qty. Part Circuit Req. Description Symbol 914 CONTROL TRANSFORMER ASS'Y 170001 RESISTOR 00 W 1 OHM R11, 1 67458 CONTACTOR  POLE 110VAC 40 A 95557 CAPACITOR .8µf 60 VDC (See wiring)
  • Page 54 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 95467 LABEL CNC INTERFACE 9506 TERM. BLOCK 7 POS 5 A 174010 RESISTOR 10 K 5 W...
  • Page 55 SeCTION 6 RePlACeMeNT PARTS 154, 155, 156, 164 151, 15 158, 16 160, 161 Fig. 6-7. PCM-1125 Power Source, Rear View Item Qty. Part Circuit Req. Description Symbol 1710 FILTER, REGULATOR AIR LINE 10Z0 ADAPTOR B/A-WM x 1/4 NPTM 951575...
  • Page 56 NOTeS...
  • Page 57 NOTeS...
  • Page 58 NOTeS...

  • Page 59: Revision History

    ReVISION HISTORY Revision “A” Updated format. Made chgs per change notice # 0501. In replacement parts sec- tion added filter regulator, item 151, p/n 055800594 note. Moved schematics to 11 x 17 format. Revision "A" - 1/005 - Removed filter regulator, item 151, p/n 055800594 note, in replacement parts section.
  • Page 60 Welding & Cutting Products, Florence, SC Welding equipment COMMuNICATION guIDe - CuSTOMeR SeRVICeS CUSTOMER SERVICE QUESTIONS: Telephone: (800)6-7080 / Fax: (800) 64-7548 Hours: 8:00 AM to 7:00 PM EST Order Entry Product Availability Pricing Order Information Returns ENGINEERING SERVICE:...

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