ESAB PCM-875 Instruction Manual
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ESAB PCM-875 Instruction Manual

Plasma arc cutting package
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PLASMA ARC CUTTING PACKAGE
This manual provides installation and operation instructions for the following PCM-875 cutting packages starting with Serial No.
PHJ205001:
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
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.
INSTRUCTION MANUAL
PCM-875
F15-335-E
July, 2007

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Summary of Contents for ESAB PCM-875

  • Page 1 INSTRUCTION MANUAL PCM-875 PLASMA ARC CUTTING PACKAGE This manual provides installation and operation instructions for the following PCM-875 cutting packages starting with Serial No. PHJ205001: P/N 36590 - 208/230 V, 1 & 3-Phase, 50/60 Hz P/N 36592 - 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 USER RESPONSIBILITY TABLE OF CONTENTS...
  • Page 4 SAFETY PRECAUTIONS WARNING: PROTECT YOURSELF AND OTHERS Some welding, cutting, and gouging processes are noisy and require ear ELECTRICAL SHOCK -- Contact with live protection. The arc, like the sun, emits electrical parts and ground can cause ultraviolet (UV) and other radiation and severe injury or death.
  • Page 5 FUMES AND GASES -- Fumes and gases, can cause discomfort or harm, particularly in confined spaces. Do not breathe fumes and gases. Shield- ing gases can cause asphyxiation. Therefore: ADDITIONAL SAFETY INFORMATION -- For more information on safe practices for elec- tric arc welding and cutting equipment, ask your supplier for a copy of "Precautions and Safe Practices for Arc Welding, Cutting and...
  • Page 6 PRÉCAUTIONS DE SÉCURITÉ 9/97...
  • Page 7 9/97...

  • Page 8: Packages Available

    SECTION 1 DESCRIPTION 1.1 GENERAL 1.2 SCOPE 1.3 PACKAGES AVAILABLE Description Part Number Quantity 50 - 60 A Nozzle 33369 Electrode 33366 Swirl Baffle 33367 Heat Shield 21616 Standoff Guide 21420 Valve Pin 21619 Fuse, 15 A, 600 VDC, Fast Acting 952137...

  • Page 9: Specifications

    10.1" (275 mm) w/ opt. torch storage 13.1" (333 mm) Weight of PCM-875 System 87 lbs (39.5 kg) Shipping Weight 100 lbs (45.4 kg) *Duty cycle is based on a 10-minute period; therefore, a 60-percent duty cycle means the power source may operate for 6...

  • Page 10: Optional Accessories

    SECTION 1 DESCRIPTION Table 1-3. PT-27 Torch Specifications 7.3" (185 mm) Current Capacity (100% duty) 80 A DCSP Length of Service Lines 25 ft or 50 ft 3" (76 mm) Weight 25 ft 5.2 lbs (2.4 kg) 50 ft 9.6 lbs (4.4 kg) 75°...
  • Page 11 CONNECTIONS (FIGURE 2-1) 2.2 EQUIPMENT REQUIRED 2.3 LOCATION NOTE: If using 200(208) V input power, the PCM-875 must be reconnected for 200 V use as directed in Section 2.7 and Fig. 2-2. NOTE: The 208/230 V models are equipped with a plug for single-phase connection only.
  • Page 12 SECTION 2 INSTALLATION Table 2-1. Recommended Sizes For 1. For operator safety, the torch connections are located Input Conductors and Line Fuses on the output terminal board behind the lower portion of the front panel. Remove access door to output Input Requirements Input &...
  • Page 13 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 to Sect. 2.5. Figure 2-1. PCM-875 Interconnection Diagram...
  • Page 14 4. Leave all other wires the same. The PCM-875 power source with 200/230 vac, 1-phase 5. Reinstall cover and connect the PCM-875 to 208 vac input capability is factory set for 230 vac input. If using input power.
  • Page 15 AIR HOSE - 37343 (50’) WORK 37344 (100’) CABLE(25’) (Supplied with PILOT ARC CABLE - 37339 (50’) PCM-875) 37340 (100’) SCHEMATIC - MECHANICAL SYSTEM SETUP (See Figure 2-4 for detailed connections) NOTE: Use Cable P/N 2239902 (UL / CSA approved cable...
  • Page 16 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-875/PT-20AM with Arc Starter...
  • Page 17 SECTION 3 OPERATION 3.1 OPERATION 3.2 PCM-875 CONTROLS (FIGURE 3-1) 3.3 CUTTING WITH THE PT-27...
  • Page 18 THAN 19/32 INCH (15.1 MM) ELECTRODE Figure 3-3. Electrode Wear Limit 3.3.1. Drag Cutting with the PT-27/PCM-875 System Figure 3-2. Recommended Torch Angle of 5° to 15° If drag cutting is desired, the 15 amp pilot arc fuse located on the rear panel must be removed. This converts pilot arc...

  • Page 19: Common Cutting Problems

    SECTION 3 OPERATION WHEN THE ARC BREAKS THROUGH THE WORK, BRING THE TORCH TO AN UPRIGHT POSITION AND PROCEED TO CUT. TO START A PIERCE, TILT THE TORCH TO PREVENT MOLTEN MA- TERIAL FROM COMING BACK AGAINST AND DAMAGING THE TORCH.

  • Page 20: Inspection And Cleaning

    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-875 is in OFF Figure 4-1. Assembly of PT-27 Torch Front End Parts position before working on the torch.
  • Page 21 SECTION 4 MAINTENANCE 4.4 FLOW SWITCH (FIGURE 4-2) Ω PISTON PLUG SPRING PISTON FLOW SWITCH  Two-Point Mounting Type Temporary tightening   ‚ è Final tightening  ‚  è ‚ 4.5 IGBT Handling & Replacement Four-Point Mounting Type Temporary tightening ...

  • Page 22: Section 5 Troubleshooting

    SECTION 5 TROUBLESHOOTING 5.1 TROUBLESHOOTING 5.2TROUBLESHOOTING GUIDE A. Power Light (PL1) does not come on. B. No Air Flow...
  • Page 23 SECTION 5 TROUBLESHOOTING C. The Power light is on, but nothing happens when the torch switch is depressed. Fault light does not activate. NOTE: Unplug high frequency connection before attempting to work on this problem. D. Fault light activates when torch switch is closed. NOTE: If above items check OK , the problem is internal.
  • Page 24 SECTION 5 TROUBLESHOOTING the ohmmeter 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 25 SECTION 5 TROUBLESHOOTING F. High Frequency and Pilot Arc are on but Main Arc does not transfer. G. Poor Cutting Performance. H. Air does not shut off. Main arc is difficult to start.

  • Page 26: Troubleshooting

    SECTION 5 TROUBLESHOOTING 5.3REFERENCE VOLTAGE CHECKS A. Control Board Assembly (PCB1) 50 µsec 40 usec - LPG50 50 usec - LPG80 13 vdc 6 usec - LPG50 9 usec - LPG80 -13 vdc µ µ...
  • Page 27 SECTION 5 TROUBLESHOOTING 5.4SEQUENCE OF OPERATION 2 SEC. 10 SEC Postflow...
  • Page 28 SECTION 5 TROUBLESHOOTING 2 SEC. 10 SEC Postflow...
  • Page 38 SECTION 6 REPLACEMENT PARTS 6.1 GENERAL 6.2 ORDERING...
  • Page 39 SECTION 6 REPLACEMENT PARTS Fig. 6-1. PCM-875 Power Source, Front View...

  • Page 40: Section 6 Replacement Parts

    SECTION 6 REPLACEMENT PARTS Fig. 6-2. PCM-875 Power Source, Left Side View (208/230) µ µ µ µ µ...
  • Page 41 SECTION 6 REPLACEMENT PARTS Fig. 6-3. PCM-875 Power Source, Left Side View (400/400CE/460/575) µ µ µ µ µ µ µ µ...
  • Page 42 SECTION 6 REPLACEMENT PARTS Fig. 6-4. PCM-875 Power Source, Right Side View (208/230) µ µ µ µ µ...
  • Page 43 SECTION 6 REPLACEMENT PARTS Fig. 6-5. PCM-875 Power Source, Right Side View (400/400CE/460/575 V) µ µ µ µ µ...
  • Page 44 SECTION 6 REPLACEMENT PARTS Fig. 6-6. PCM-875 Power Source, Top View with PCB1 and Shelf Removed...
  • Page 45 SECTION 6 REPLACEMENT PARTS Fig. 6-7. PCM-875 Power Source, Rear View...
  • Page 46 1. Each replacement IGBT and bridge module now include the appropriate thermal pad. The "B" edition (9/98) of this manual covers the following changes: 1. Added mechanized cutting installation using PT-20AM torch with the PCM-875. 2. Deleted discontinued L-TEC packages and parts.
  • 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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