PCM-500i PLASMA ARC CUTTING PACKAGES - equipment/cutting packages...INSTRUCTION MANUAL PCM-500i PLASMA ARC CUTTING PACKAGES These INSTRUCTIONS are for experienced operators. If you

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  • INSTRUCTION MANUAL

    PCM-500iPLASMA ARC CUTTING PACKAGES

    These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation andsafe practices for arc welding equipment, we urge you to read our booklet, "Precautions and Safe Practices for ArcWelding, Cutting, and Gouging," Form 52-529. Do NOT permit untrained persons to install, operate, or maintain thisequipment. Do NOT attempt to install or operate this equipment until you have read and fully understand theseinstructions. If you do not fully understand these instructions, contact your supplier for further information. Be sureto read the Safety Precautions before installing or operating this equipment.

    F-15-296-E Feb., 2004

    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 HzESAB P/N 36316 - 400 V (380/415 V), 3-Phase, 50/60 Hz

    Be sure this information reaches the operator.You can get extra copies through your supplier.

  • USER RESPONSIBILITY

    This equipment will perform in conformity with the description thereof contained in this manual and accompanyinglabels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions pro-vided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should notbe used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Shouldsuch repair or replacement become necessary, the manufacturer recommends that a telephone or written requestfor service advice be made to the Authorized Distributor from whom purchased.

    This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. Theuser of this equipment shall have the sole responsibility for any malfunction which results from improper use, faultymaintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facilitydesignated by the manufacturer.

    TABLE OF CONTENTS

    SECTION TITLE PAGEPARAGRAPH

    SECTION 1 DESCRIPTION ................................................................................................. 71.1 General ............................................................................................................. 71.2 Scope ................................................................................................................ 71.3 Packages Available ........................................................................................... 71.4 Specifications .................................................................................................... 8, 91.5 Optional Accessories ........................................................................................ 9

    SECTION 2 INSTALLATION ................................................................................................ 102.1 General ............................................................................................................. 102.2 Equipment Required ......................................................................................... 102.3 Location ............................................................................................................ 102.4 Inspection .......................................................................................................... 102.5 Primary Electrical Input Connections ................................................................. 102.6 Secondary (Output) Connections ...................................................................... 112.7 Connecting PCM-500i for 200(208) Vac Input ................................................... 13

    SECTION 3 OPERATION ..................................................................................................... 153.1 Operation .......................................................................................................... 153.2 PCM-500i Controls ............................................................................................ 153.3 Assembling PT-31XL Consumable Parts .......................................................... 163.4 Cutting with the PT-31XL .................................................................................. 163.5 Operating Techniques ....................................................................................... 173.6 Common Cutting Problems ............................................................................... 18

    SECTION 4 MAINTENANCE................................................................................................ 194.1 General ............................................................................................................. 194.2 Inspection and Cleaning .................................................................................... 194.3 Flow Switch ....................................................................................................... 19

    SECTION 5 TROUBLESHOOTING ..................................................................................... 205.1 Troubleshooting ................................................................................................ 205.2 Troubleshooting Guide ...................................................................................... 205.3 Sequence of Operation ..................................................................................... 25

    SECTION 6 REPLACEMENT PARTS .................................................................................. 336.1 General ............................................................................................................. 336.2 Ordering ............................................................................................................ 33

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    WARNING: These Safety Precautions are foryour protection. They summarize precaution-ary information from the references listed inAdditional Safety Information section. Before

    performing any installation or operating procedures, besure to read and follow the safety precautions listed belowas well as all other manuals, material safety data sheets,labels, etc. Failure to observe Safety Precautions can resultin injury or death.

    PROTECT YOURSELF AND OTHERS --Some welding, cutting, and gougingprocesses are noisy and require earprotection. The arc, like the sun, emitsultraviolet (UV) and other radiation and

    can injure skin and eyes. Hot metal can cause burns.Training in the proper use of the processes and equip-ment is essential to prevent accidents. Therefore:

    1. Always wear safety glasses with side shields in any workarea, even if welding helmets, face shields, and gogglesare also required.

    2. Use a face shield fitted with the correct filter and coverplates to protect your eyes, face, neck, and ears fromsparks and rays of the arc when operating or observingoperations. Warn bystanders not to watch the arc andnot to expose themselves to the rays of the electric-arcor hot metal.

    3. Wear flameproof gauntlet type gloves, heavy long-sleeveshirt, cuffless trousers, high-topped shoes, and a weld-ing helmet or cap for hair protection, to protect againstarc rays and hot sparks or hot metal. A flameproof apronmay also be desirable as protection against radiatedheat and sparks.

    4. Hot sparks or metal can lodge in rolled up sleeves,trouser cuffs, or pockets. Sleeves and collars should bekept buttoned, and open pockets eliminated from thefront of clothing

    5. Protect other personnel from arc rays and hot sparkswith a suitable non-flammable partition or curtains.

    6. Use goggles over safety glasses when chipping slag orgrinding. Chipped slag may be hot and can fly far.Bystanders should also wear goggles over safety glasses.

    FIRES AND EXPLOSIONS -- Heat fromflames and arcs can start fires. Hot slagor sparks can also cause fires and ex-plosions. Therefore:

    1. Remove all combustible materials well away from thework area or cover the materials with a protective non-flammable covering. Combustible materials include wood,cloth, sawdust, liquid and gas fuels, solvents, paints andcoatings, paper, etc.

    2. Hot sparks or hot metal can fall through cracks orcrevices in floors or wall openings and cause a hiddensmoldering fire or fires on the floor below. Make certainthat such openings are protected from hot sparks andmetal.

    3. Do not weld, cut or perform other hot work until theworkpiece has been completely cleaned so that thereare no substances on the workpiece which might pro-duce flammable or toxic vapors. Do not do hot work onclosed containers. They may explode.

    4. Have fire extinguishing equipment handy for instant use,such as a garden hose, water pail, sand bucket, orportable fire extinguisher. Be sure you are trained in itsuse.

    SAFETY PRECAUTIONS

    10/98

    5. Do not use equipment beyond its ratings. For example,overloaded welding cable can overheat and create a firehazard.

    6. After completing operations, inspect the work area tomake certain there are no hot sparks or hot metal whichcould cause a later fire. Use fire watchers when neces-sary.

    7. For additional information, refer to NFPA Standard 51B,"Fire Prevention in Use of Cutting and Welding Pro-cesses", available from the National Fire Protection Asso-ciation, Batterymarch Park, Quincy, MA 02269.

    ELECTRICAL SHOCK -- Contact with liveelectrical parts and ground can causesevere injury or death. DO NOT use ACwelding current in damp areas, if move-ment is confined, or if there is danger offalling.

    1. Be sure the power source frame (chassis) is connectedto the ground system of the input power.

    2. Connect the workpiece to a good electri

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