PCM-875A Plasmarc Mechanized Cutting System - esabna.com equipment/cutting packages...F-15-753 November, 2002 Installation, Operation and Maintenance Manual for the PCM-875A Plasmarc

F-15-753 November, 2002

Installation, Operation and Maintenance Manual for the

PCM-875A Plasmarc Mechanized Cutting System

Cutting Systems 411 South Ebenezer Road Florence, South Carolina, U.S.A.

The equipment described in this manual is potentially hazardous. Use caution when installing, operating and maintaining this equipment.

Purchaser is solely responsible for the safe operation and use of all products purchased, including compliance with OSHA and other government standards. ESAB Cutting Systems has no liability for personal injury or other damage arising out of the use of any product manufactured or sold be ESAB. See standard ESAB terms and conditions of sale for a specific statement of ESAB’s responsibilities and limitations on its liability.

ESAB Cutting Systems first priority is total customer satisfaction. We constantly look for ways to improve our products, service and documentation. As a result, we make enhancements and/or design changes as required. ESAB makes every possible effort to ensure our documentation is current. We cannot guarantee that each piece of documentation received by our customers reflects the latest design enhancements. Therefore, the information contained in this document is subject to change without notice.

This manual is ESAB Part Number F15753

This manual is for the convenience and use of the cutting machine purchaser. It is not a contract or other obligation on the part of ESAB Cutting Systems.

© ESAB Cutting Systems, 2002

Printed in U.S.A.

PCM-875A System Table of Contents

i

Section 1 Safety Page 1-(_) 1.1 Introduction ................................................................................................... 1

1.2 Safety Notations And Symbols ....................................................................... 2

1.3 General Safety Information ............................................................................. 3-4

1.4 Installation Precautions................................................................................... 4

1.5 Electrical Grounding ....................................................................................... 5

1.6 Operating A Plasma Cutting Machine ............................................................. 5-8

1.7 Service Precautions........................................................................................ 9-10

1.8 Safety References .......................................................................................... 11-16

1.8.1 National Standards................................................................................. 11

1.8.2 International Standards........................................................................... 12-16

Section 2 Description Page 2-(_) 2.1 General........................................................................................................... 1

2.2 PCM-875A Power Console ............................................................................ 1

2.2.1 Technical Specifications – PCM-875A..................................................... 1

2.2.2 Dimensions and Weight.......................................................................... 2

2.3 Remote Arc Starter (RAS2)............................................................................. 3

2.3.1 Technical Specifications ......................................................................... 3


2.4 PT-20AMX Torch ........................................................................................... 4

2.4.1 Technical Specifications ......................................................................... 4


2.4.3 Torch Spare Parts Kit ............................................................................. 6


ii

Section 3 Installation Page 3-(_) 3.1 General .......................................................................................................... 1

3.2 Installation of power console ........................................................................... 1

3.2.1 Requirements ......................................................................................... 1

3.2.2 Location ................................................................................................. 2

3.2.3 Inspection before installation ................................................................... 2

3.2.4 Primary Electrical Input Connections........................................................ 3

3.2.5 Connection of Plasma Console to CNC Interface..................................... 4

3.2.6 Secondary (Output) Connection .............................................................. 5-8

3.3 Connection of Remote Arc Starter (RAS2) ....................................................... 9

3.3.1 Mounting ............................................................................................... 9

3.3.2 Connecting Service Lines (Input).............................................................. 10

3.3.3 Setting Spark Gap .................................................................................. 11

3.3.4 RAS2 Output Connections...................................................................... 12

3.3.5 Termination of Torch Shield Braid............................................................ 13-14

3.4 Installing Front-end torch Parts ........................................................................ 15-17

3.5 Interconnecting Diagram................................................................................. 18-19

Section 4 Operation Page 4-(_) 4.1 PCM-875A Console Operation -- General ....................................................... 1

4.2 Console Controls............................................................................................ 2-3

4.3 RAS2 ............................................................................................................. 3

4.4 PT-20AMX Plasma Torch................................................................................ 4

4.5 Cut Quality ..................................................................................................... 5

4.5.1 Introduction ............................................................................................ 5

4.5.2 Cut Angle ............................................................................................... 6

4.5.3 Cut Flatness ........................................................................................... 7

4.5.4 Surface Finish (Roughness) ..................................................................... 8

4.5.5 Dross ..................................................................................................... 9-10

4.5.6 Dimensional Accuracy............................................................................. 10-11

4.6 Process Data................................................................................................... 11-23


iii

Section 5 Maintenance Page 5-(_) 5.1 PCM-875A Console ....................................................................................... 1

5.1.1 General .................................................................................................. 1

5.1.2 Inspection and Cleaning ......................................................................... 2-3

5.1.3 Flow Switch 4

5.2 RAS2 (Remote Arc Starter) ............................................................................. 5

5.2.1 General .................................................................................................. 5

5.2.2 Spark Gap Procedure............................................................................. 5

5.3 PT-20AMX Plasmarc Torch ............................................................................ 6

5.3.1 General .................................................................................................. 6

5.3.2 Dirt or Contamination ............................................................................. 7

5.3.3 Loose Consumables............................................................................... 7

5.3.4 Damage Caused by Loose Parts or Overheating ..................................... 8

5.3.5 Consumables- Remove and Replace ..................................................... 8-10

5.3.6 Measuring Torch Gas Flows ................................................................... 10

5.3.7 Removal and Replacement of the Torch Body......................................... 11


iv

Section 6 Troubleshooting Page 6-(_) 6.1 Troubleshooting PCM-875A Plasmarc System ................................................ 1

6.2 Console ......................................................................................................... 2-8

6.2.1 Power Light (PL1) does not come on....................................................... 2

6.2.2 No Air Flow............................................................................................. 2 6.2.3 Power Light is on but nothing happens when signal is given to fire with

no fault light ......................................................................................... 3

6.2.4 Fault light activates when torch fire signal is given.................................... 4-5

6.2.5 Air is on but nothing happens when torch fire signal is given .................... 6

6.2.6 High Frequency and Pilot Arc are on but no main arc transfer .................. 7

6.2.7 Poor Cutting Performance....................................................................... 7

6.2.8 Air does not shut off................................................................................ 7

6.2.9 Main arc difficult to start .......................................................................... 8

6.3 Reference Voltage Checks.............................................................................. 9

6.4 PT-20AMX Torch Troubleshooting10 .............................................................. 10-11

6.4.1 Insufficient Penetration ............................................................................ 10

6.4.2 Main Arc Extinguishes............................................................................. 10

6.4.3 Dross Formation ..................................................................................... 10

6.4.4 Double Arcing......................................................................................... 11

6.4.5 Uneven Arc............................................................................................. 11

6.4.6 Unstable Cutting Conditions.................................................................... 11

6.4.7 Main Arc Does Not Strike........................................................................ 11

6.4.8 Poor Consumable Life............................................................................. 11

6.5 230V Power Console Electrical Drawings ........................................................ 12-17

6.5.1 Schematic .............................................................................................. 12-13

6.5.2 Wiring Diagrams ..................................................................................... 14-17

6.6 400V Power Console Electrical Drawings ........................................................ 18-23

6.6.1 Schematic .............................................................................................. 18-19

6.6.2 Wiring Diagrams ..................................................................................... 20-23

6.7 Remote Arc Starter Schematic........................................................................ 24

Section 7 Replacement Parts Page 7-(_) 7.1 General .......................................................................................................... 1

7.2 Ordering......................................................................................................... 1

7.3 PCM875A Power Console – 230V .................................................................. 2-9

7.4 PCM-875A Power Console – 400V ................................................................. 10-18

7.5 Remote Arc Starter......................................................................................... 19-21

7.6 PT-20AMX Plasmarc Cutting Torch................................................................. 22-25

Customer/Technical Information Back Manual Cover

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY

1-1

1.1 Introduction

The process of cutting metals with plasma equipment provides industry with a valuable and versatile tool. ESAB cutting machines are designed to provide both operation safety and efficiency. However, as with any machine tool, sensible attention to operating procedures, precautions, and safe practices is necessary to achieve a full measure of usefulness. Whether an individual is involved with operation, servicing, or as an observer, compliance with established precautions and safe practices must be accomplished. Failure to observe certain precautions could result in serious personnel injury or severe equipment damage. The following precautions are general guidelines applicable when working with cutting machines. More explicit precautions pertaining to the basic machine and accessories are found in the instruction literature. For a wide scope of safety information on the field of cutting and welding apparatus, obtain and read the publications listed in the Recommended References.


1-2

1.2 Safety Notations And Symbols The following words and symbols are used

throughout this manual. They indicate different levels of required safety involvement.

!

ALERT or ATTENTION. Your safety is involved or potential equipment failure exists. Used with other symbols and information.

DANGER!Used to call attention to immediate hazards which, if not avoided, will result in serious personal injury or loss of life.

WARNING! Used to call attention to potential hazards that could result in personal injury or loss of life.

CAUTION!Used to call attention to hazards that could result in minor personal injury or equipment damage.

CAUTION Used to call attention to minor hazards to equipment.

NOTICE

Used to call attention to important installation, operation or maintenance information not directly related to safety hazards.


1-3

1.3 General Safety Information

NOTICE

Some subjects listed are not related specifically to the type of equipment covered in this manual. However, the safety principles still apply. They are offered as a reminder that this equipment or related apparatus should be operated with alertness and understanding. Safety of operators, technicians, maintenance workers and observers should not be taken for granted.

WARNING!

Machinery may start automatically. Equipment positioning mechanized plasma torch moves in various directions and speeds.

�� Moving machinery can crush.

�� Only qualified personnel should operate or service this power source.

�� Keep all personnel, materials, and equipment not involved in production process clear of entire system area.

�� Fence off entire work cell to prevent personnel from passing through area or standing in the working envelope of the equipment.

�� Post appropriate WARNING signs at every work cell entrance.

�� Follow lockout procedure before servicing any equipment.

WARNING!

Failure to follow operating instructions could result in death or serious injury. Read and understand this operator’s manual before using machine.

�� Read entire procedure before operating or performing any system maintenance.

�� Special attention must be given to all hazard warnings that provide essential information regarding personnel safety and/or possible equipment damage.

�� All safety precautions relevant to electrical equipment and process operations must be strictly observed by all having system responsibility or access.

�� Read all safety publications made available by your company.


1-4

WARNING!

Failure to follow safety warning label instructions could result in death or serious injury. Read and understand all safety warning labels on machine.

Refer to operator’s manual for additional safety information.

1.4 Installation Precautions

WARNING!Improperly Installed Equipment Can Cause Injury Or Death. Follow these guidelines while installing machine:

�� Contact your ESAB representative before installation. He can suggest certain precautions regarding piping installation and machine lifting, etc. to ensure maximum security.

�� Never attempt any machine modifications or apparatus additions without first consulting a qualified ESAB representative.

�� Observe machine clearance requirements for proper operation and personnel safety.

�� Always have qualified personnel perform installation, troubleshooting and maintenance of this equipment.

�� Provide a wall mounted disconnect switch with proper fuse sizes close to the power supply.


1-5

1.5 Electrical Grounding

Electrical grounding is imperative for proper machine operation and SAFETY. Refer to this manual’s Installation section for detailed grounding instructions.

WARNING!

Electric shock hazard.

Improper grounding can cause severe injury or death.

Machine must be properly grounded before put into service.

1.6 Operating A Plasma Cutting Machine

WARNING!

Flying debris and loud noise hazards. �� Hot spatter can burn and injure eyes. Wear

goggles to protect eyes from burns and flying debris generated during operation.

�� Chipped slag may be hot and fly far. Bystanders should also wear goggles and safety glasses.

�� Noise from plasma arc can damage hearing. Wear correct ear protection when cutting above water.

WARNING!Burn hazard. Hot metal can burn.

�� Do not touch metal plate or parts immediately after cutting. Allow metal time to cool, or douse with water.

�� Do not touch plasma torch immediately after cutting. Allow torch time to cool.


1-6

WARNING!Hazardous voltages. Electric shock can kill. �� Do NOT touch plasma torch, cutting table or cable connections during plasma cutting process.

�� Always turn power off to plasma power supplies before touching or servicing plasma torch.

�� Always turn power off to plasma power supplies before servicing any system component.

�� Do not touch live electrical parts.

�� Keep all panels and covers in place when machine is connected to power source.

�� Wear insulating gloves, shoes and clothing to insulate yourself from workpiece and electrical ground.

�� Keep gloves, shoes, clothing, work area, and equipment dry.

�� Replace worn or damaged cables.

WARNING!

Fume hazard. Fumes and gases generated by the plasma cutting process can be hazardous to your health.

�� Do NOT breathe fumes.

�� Do not operate plasma torch without fume removal system operating properly.

�� Use additional ventilation to remove fumes if necessary.

�� Use approved respirator if ventilation is not adequate.

�� Provide positive mechanical ventilation when cutting galvanized steel, stainless steel, copper, zinc, beryllium, or cadmium. Do not breathe these fumes.

�� Do not operate near degreasing and spraying operations. Heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas and other irritant gases.


1-7

WARNING!Radiation hazard. Arc rays can injure eyes and burn skin.

�� Wear correct eye and body protection.

�� Wear dark safety glasses or goggles with side shields. Refer to following chart for recommended lens shades for plasma cutting:

Arc Current Lens Shade

Up to 100 Amps Shade No. 8

100-200 Amps Shade No. 10

200-400 Amps Shade No. 12

Over 400 Amps Shade No. 14

�� Replace glasses/goggles when lenses are pitted or broken

�� Warn others in area not to look directly at the arc unless wearing appropriate safety glasses.

�� Prepare cutting area to reduce reflection and transmission of ultraviolet light.

��Use special paint on walls to absorb UV light.

��Install protective screens or curtains to reduce ultraviolet transmission.

CAUTION

Do Not Use this Torch Under Water.

The PT-20AMX is designed to be a dry cutting process.

Cutting under water may result in:

�� reduced consumable life

�� degradation of cut quality

�� possible damaged torch

Cutting under water may result in poor cutting performance. Water vapor created when hot material or sparks contact liquid may cause arcing inside torch.

When cutting on a water table, reduce the water level to provide maximum clearance between water and material.


1-8

WARNING!

Burn Hazard. Heat, spatter, and sparks cause fire and burns.

�� Do not cut near combustible material.

�� Do not have on your person any combustibles (e.g. butane lighter).

�� Pilot arc can cause burns. Keep torch nozzle away from yourself and others when activating plasma process.

�� Wear correct eye and body protection.

�� Wear gauntlet gloves, safety shoes and hat.

�� Wear flame-retardant clothing covering all exposed areas.

�� Wear cuffless trousers to prevent entry of sparks and slag.

�� Have fire extinguishing equipment available for use.

WARNING! Explosion hazard.

�� Certain molten aluminum-lithium (Al-Li) alloys can cause explosions when plasma cut OVER water.

�� These alloys should only be dry cut on a dry table.

��DO NOT dry cut over water.

��Contact your aluminum supplier for additional safety information regarding hazards associated with these alloys.

�� Do not cut in atmospheres containing explosive dust or vapors.

�� Do not carry any combustibles on your person (e.g. butane lighter)

�� Do not cut containers that have held combustibles.


1-9

1.7 Service Precautions

WARNING!

Hazardous voltages. Electric shock can kill. �� Do NOT touch plasma torch, cutting table or cable connections during plasma cutting process.

�� Always turn power off to plasma power supplies before touching or servicing plasma torch.

�� Always turn power off to plasma power supplies before removing covers or panels to service any system component.

�� Do not touch live electrical parts.

�� Keep all panels and covers in place when machine is connected to power source.

�� Keep gloves, shoes, clothing, work area, and equipment dry.

�� Inspect power and ground leads cables for wear or cracking. Replace worn or damaged cables. Do not use if damaged.

�� Never bypass safety interlocks.

�� Follow lock-out procedures.

WARNING!

Hot Torch can cause skin burns. Allow torch to cool before servicing.


1-10

DANGER!

Danger of Electric Shock. Torch may be electrically active. Turn off Plasma Power Console before servicing torch.

CAUTIONEstablish and adhere to preventive maintenance. A composite program can be established from recommended schedules.

Avoid leaving test equipment or hand tools on machine. Severe electrical or mechanical damage could occur to equipment or machine.

CAUTION!Extreme caution should be used when probing circuitry with an oscilloscope or voltmeter. Integrated circuits are susceptible to over voltage damage. Power off before using test probes to prevent accidental shorting of components.

All circuit boards securely seated in sockets, all cables properly connected, all cabinets closed and locked, all guards and covers replaced before power is turned on.


1-11

1.8 Safety References -- Regulations, Standards, Guidelines

The following recognized publications on safety in welding and cutting operations are recommended. These publications have been prepared to protect persons from injury or illness and to protect property from damage, which could result from unsafe practices. Although some of these publications are not related specifically to this type of industrial cutting apparatus, the principles of safety apply equally.

1.8.1 USA

�� “Precautions and Safe Practices in Welding and Cutting with

Oxygen-Fuel Gas Equipment,” Form 2035. ESAB Cutting Systems.

�� “Precautions and Safe Practices for Electric Welding and Cutting,” Form 52-529. ESAB Cutting Systems.

�� “Safety in Welding and Cutting” - ANSI Z 49.1, American Welding Society, 2501 NW 7th Street, Miami, Florida, 33125.

�� “Recommended Safe Practices for Shielded Gases for Welding and Plasma Arc Cutting” - AWS C5.10-94, American Welding Society.

�� “Recommended Practices for Plasma Arc Welding” - AWS C5.1, American Welding Society.

�� “Recommended Practices for Arc Cutting” - AWS C5.2, American Welding Society.

�� “Safe Practices” - AWS SP, American Welding Society.

�� “Standard for Fire Protection in Use of Cutting and Welding Procedures” - NFPA 51B, National Fire Protection Association, 60 Batterymarch Street, Boston, Massachusetts, 02110.

�� “Standard for Installation and Operation of Oxygen - Fuel Gas Systems for Welding and Cutting” - NFPA 51, National Fire Protection Association.

�� “Safety Precautions for Oxygen, Nitrogen, Argon, Helium, Carbon Dioxide, Hydrogen, and Acetylene,” Form 3499. ESAB Cutting Systems. Obtainable through your ESAB representative or local distributor.

�� "Design and Installation of Oxygen Piping Systems," Form 5110. ESAB Cutting Systems.

�� “Precautions for Safe Handling of Compressed Gases in Cylinders”, CGA Standard P-1, Compressed Gas Association.

Literature applicable to safe practices in welding and cutting with gaseous materials is also available from the Compressed Gas Association, Inc., 500 Fifth Ave., New York, NY 10036.


1-12

1.8.2 International

Accident Prevention

VBG- Unfallverhütungsvorshriften

General Provisions

VBG 1

Allgemeine Unfallverhütungsvorshriften

Electrical Equipment and operating Equipment

VBG 4

Elektrische Anlagen

Welding, Cutting and related working methods

VBG 15

Schweißen un Schneiden un verwandte Verfahren

Shot Blasting Works

VBG 48

Strahlarbeiten

Gases

VBG 61

Gase

Oxygen

VBG 62

Sauerstoff

Operating liquid jet cutting machines

VBG 87

Arbeiten mit Flüssigkeitsstrahlem

Laser beams, accident prevention and Electro-technology

VBG 93 Laserstrahlung, Unfallverhütungs-vorschriften für Feinmechnik und Elektrotechnik

Noise

VBG 121

Lärm


1-13

VDE Regulations

VDE - Vorschriften

Erection of power installations with normal voltages up to 1000 volts

VDE 0100

Bestimmungen für das Errichten von Stakstromanlagen mit Nennspannungen bis 1000 Volt

Electrical equipment of industrial machines

VDE0113

Elektrishe Ausrüstung von Industriemaschinen

Radiation safety of laser products; users guide (DIN EN 60825)

VDE 0837

Strahlungssicherheit von Lasereinrichtungen und Benutzungsrichtlinen (DIN EN 60825)

Specification for laser guards

VDE 0837-50 Anforderung an Lasershcutzwänden

TRAC Technical Rules for Acetylene and Carbide Stores TRAC- Techische Regein für Azetylenanlagen und Calciumcargidlager

Acetylene lines

TRAC-204

Azetylenleitungen

Acetylene cylinder battery systems

TRAC-206

Azetylenflaschenbatterieanlagen

Safety devices

TRAC-207

Sicherheitseinrichtungen

TRG Technical Rules for Pressure gases TRG – Technische Regein für Druckgase

General regulations for pressure gases

TRG 100

Allgemeine Bestimmungen für Druckgase

Pressure gases

TRG 101

Druckgase

Technical gas mixtures

TRG 102

Technishe Gasgemische

Pressure gases; alterative use of compressed gas tanks

TRG 104 Druckgase, wahlweise Verwendung von

Druckgasbehältem


1-14

TRGS – Technische Richtlinien für Gefahrstoffe

TRGS-102 Techn. Richtkonzentration (TRK) für gefährliche Stoffe

TRGS-402 Ermittlung u. Beurteilung der Konzentration gefährlicher Stoffe in der Luft im Arbeitsbereich

TRGS-900 Grenzwerte in der Luft am Arbeitsplatz (Luftgrenzwerte)

TA TA-Luft un TA-Lärm (BLm SchV)

DIN Standards

DIN-Normen

DIN 2310

Part 1 Thermal cutting; terminology and nomenclature

Teil 1 Thermsiches Schneiden, Allgemeine Begriffe und Bennungen

DIN 2310

Part 2 Thermal cutting; determination of quality of cut faces

Teil 2 Thermsiches Schneiden, Ermittein der Güte von Schnittflächen

DIN 2310

Part 4 Thermal cutting; arc plasma cutting; process principles, quality, dimensional tolerances

Teil 4 Thermsiches Schneiden, Plasmaschneiden, Verfahrensgrundlagen, Güte, Maßtoleranzen

DIN 2310

Part 5 Thermal cutting; laser beam cutting of metallic materials; process principles

Teil 5 Laserstrahlschneiden von metallischen Werkstoffen, Verfahrensgrundlagen, Güte, Maßtoleranzen

DIN 2310

Part 6 Thermal cutting; Classification, processes

Teil 6 Einführung, Verfahren

DIN 4844

Part 1 Safety markings (DIN EN 7287)

Teil 1 Sicherheitskennzeichen (Siehe EN 7287)


1-15

DIN EN ISO Harmonized Standards DIN EN ISO-Harmonisierte Normen

Safety of machinery

DIN EN 292/1 and 2 Sicherheit von Maschinen, Geräten und Anlagen

Hoses for welding, cutting and allied processes

DIN EN 559 Schläuche für Schweißen, Schneiden und verwandte

Verfahren

Hose connections and hose couplings for equipment for welding, cutting and allied processes

DIN EN 560 Schlauchanschlüsse und Schlauchverbindungen für

Geräte zum Schweißen, Schneiden und verwandte Verfahren

Gas welding equipment hose couplings

DIN EN 561

Gasschweißgeräte, Kupplungen

Safety of machines, reduction of risks to health

DIN EN 626-1 Sichereit von Maschinen, Reduzierung des

Gesundheitsrisikos

Single spindle vertical milling machines

DIN EN 848-1 Fräsmaschine für einseitige Bearbeitung mit drehendem

Werkzeug

High pressure water jet machines

DIN EN 1829 Hochdruckwasserstrahlschneidmaschine

Thermal cutting, oxygen cutting, process principles, dimensional tolerances

DIN EN 9013 Thermisches Schneiden, Autogenes Brennschneiden,

Verfahrensgrundlagen, Güte, Maßtoleranzen

Imperfections in oxy/fuel flame cuts, laser beam cuts and plasma

DIN EN 12584 Unregeimäßigkeiten an Brennschnitten, Laserstrahl- und

Plasmaschnitten

Laser processing machines

DIN EN 12626 Laserbearbeitungsmaschinen

Acceptance testing for oxygen cutting machines

DIN EN 28206 Abnahmeprüfung für Brennschneidmaschinen

Laser Equipment

DIN EN 31252 Lasergeräte


1-16

Laser and laser related equipment

DIN EN 31553 Laser und Laseranlagen

Electrical equipment of machines

DIN EN 60204-1 Elekrische Ausrüstung von Maschinen

Radiation safety of laser products

DIN EN 60825 Strahlensicherheit von Laseranlagen

Arrangement of protection devices

DIN EN 999

Anordnung von Schutzeinrichtungen

VDI Guidelines

Quality of cut faces on metallic workpieces; abrasive water jet cutting and arc plasma cutting

VDI 2906 Schnittflächenqualität beim Schneiden von Werkstücken

aus Metall, Abrasiv- Wasserstrahischneiden und Plasmastrahischneiden

Room air; Technical systems for welding workshops

VDI 2084

Raumluft techn. Anlagen für Schweißwerkstätten

SECTION 2 PCM-875A Mechanized Plasma Cutting System Description

2-1

2.1 General

The PCM-875A Mechanized Plasma Cutting System is a compact 60 ampere package consisting of plasma power console, remote arc starter, and PT-20AMX plasma torch. Simple bulkhead connections allow easy system assembly. Connect to input power and a source of clean, dry, compressed air (5,18 to 5,87 bar) and you can begin cutting up to 13 mm thick material.

2.2 PCM-875A Power Console There are 2 power console options available:

230 V 50 Hz, 1 or 3 phase P/N 0558003356

400 V 50 Hz, 3 phase P/N 0558003357

2.2.1 Technical Specifications: PCM-875A

230V 50Hz, 3 Phase P/N 0558003356 Options

1 phase 3 phase

400V 50Hz, 3 phase P/N 0558003357

60% Duty Cycle 60 A at 120 VDC Rated Output

100 % Duty Cycle 50 A at 120 VDC

Output Current Range 10 to 60 A/phase

Open Circuit Voltage 275 VDC

Rated Primary Input at 7,2 kW Maximum Output Power, 60 A at 120 VDC

55/49 A (230V, 1 phase)

26/24 A per phase

(230V, 3 phase)

13 A/phase

Power Factor at 60 Amperes Output 74% (230 V,

1 phase) 90% (230 V, 3

phase) 92% (400 V, 3 phase)

Efficiency at 60 Amperes Output 90% typical

Current Capacity 60 A DCSP

Air Requirements 153,4 l/minute at 5,2 bars

Power Cord Length Provided 1,8m 3,1m


2-2

2.2.2 Dimensions and Weight: PCM-875A Power Console

516 mm

275 mm

465 mm

Weight = 39,5 kg


2-3

2.3 Remote Arc Starter (RAS-2)

The remote arc starter (RAS-2) is placed inline between power console and torch. The RAS is the source of high frequency energy used to start the plasma cutting process.

RAS-2 with 15,2 m leads

RAS-2 with 30,4 m leads

P/N 0558003601

P/N 0558003602

Technical Specifications

Input: 110 VAC, 50/60 Hz. Control power provided by PCM-875A console.

Spark Gap: 1mm

Dimensions and Weight

123,8mm

374mm

184,2mm

Weight = 3,4kg


2-4

2.4 PT-20AMX

The patented PT-20AMX is a 100 amp capacity, pilot-arc mechanized torch available in 3 different torch lead length packages.

The torch uses clean, dry air as the cut gas for cutting carbon steel, aluminum, or stainless steel.

PT-20AMX Torch with 1,2 m lead P/N 0558002632



WARNING!

DO NOT use oxygen with this torch! A hazardous fire may result.

2.4.1 Technical Specifications

Type: Air Cooled, single gas at 9,9 kl/hr

Rating: 100 Amperes at 100% Duty Cycle

Gas Purity: Air: Needs to be clean, dry and free of all particulate matter. Nitrogen: 99.995% clean

Gs Type: Air, nitrogen


2-5

2.4.2 Dimensions

435 mm

34,9 mm


2-6

2.4.3 Torch Spare Part Kit

PT-20AMX Torch Spare Parts Kit is available for maintaining the PT-20AMX torch with minimum downtime. P/N 0558002319

Description P/Number Quantity

Heat Shield (70/100 A) 21326 3

Cutting Nozzle (50 A) 21330 5 Cutting Nozzle (70 A) 23129 5

Electrode 50Hz 0558001617 5 Electrode Insulator 21373 1

Electrode Holder Assembly 21332 1 Baffle Tube 21374 1

Pilot Arc Adaptor 19497 1 O-ring 488157 5

Lubricant (1 oz.) 17672 1 Seat/Baffle Wrench 21375 1

1/16: Hex-Key Wrench 93750006 1

NOTICE

The description of the heat shield (P/N 21326) listed above indicates a range of 70 to 100 amperes. Testing has proven satisfactory results when used at 60 amps and lower.

NOTICE

The 50A cutting nozzle can be used at 50 amperes and lower. The 70A cutting nozzle can be used at 50 to 70 cutting amperes.

SECTION 3 PCM-875A Mechanized Plasma Cutting System Installation

3-1

3.1 General

Proper installation is important for satisfactory and trouble free operation. Follow these instructions carefully.

WARNING!

Failure to follow these directions carefully may lead to injury or death.Read this entire manual before proceeding. Damage to property or equipment may occur.

3.2 Installation of the PCM-875A Power Console

3.2.1 Equipment Required

A source of clean dry air at 153,4 liters/minute at 5,2 to 5,9 bar. The maximum inlet pressure of the air filter-regulator is 10,4 bar and should not be exceeded.


3-2

3.2.2 Location

Console

Adequate ventilation is necessary to provide proper cooling of the PCM-875A.

Exposure to dirt, dust and excessive heat should be minimized.

There should be a minimum of 305 mm clearance between the power console and any wall or other obstruction for free air movement.

CAUTIONRestricting airflow into the power console through the louvers will cause overheating. Do not install any type of air filtering device on to the power console cooling air passages. Warranty will be voided if such a device is used.

3.2.3 Inspection of Power Console Before installation

A. Remove equipment from the shipping containers.

B. Remove all packing material and inspect for evidence of concealed damage, which may not have been initially apparent. Notify the shipping carrier of any damage at once.

C. Check container for any loose parts prior to disposing of shipping materials.

D. Check air louvers and all other openings to ensure that any obstruction is removed.


3-3

3.2.4 Primary electrical Input Connections

WARNING!

Electric Shock Can Kill! Ensure all power is off by opening the line (wall) disconnect switch and power cord is disconnected before attempting to make any connections inside the power console.

CAUTION!Ensure that the power source is properly configured for your input power supply. DO NOT connect a power console configured for 230V to a 460V input power. Damage to machine will occur.

The PCM-875A Power Console is equipped with a 3 m 4 conductor power cable for 3- phase connection. If single-phase 230V is required, tape back red wire on the input power cable. A line (wall) disconnect switch with fuses or circuit breakers should be provided at the main power panel.

Input Requirements

Volts Phase Amps

Input and Ground

Conductor (mm2)

Fuse Size (A)

230 1 49 16 80 230 3 24 16 50 400 3 13 6 25


3-4

WARNING!

Failure to connect chassis to an approved electrical ground may result in electrical shock, severe burns or death. The chassis must be connected to an approved electrical ground.

Console Power Lead

The PCM-875A power console is internally wired for connecting to an external power source.

3.2.5 Connection of Plasma Console To CNC Interface

Arc

On

Sig

nal

Rel

ayC

losi

ng

Sta

rtS

ign

al

Rel

ayC

losi

ng

20:1

(+)

Vo

ltag

eD

ivid

er

No

t U

sed

1 2 3 4 5 6 7

The CNC interface (TB4) is mounted on the front left corner of the console base. �� Arc On Signal – This signal originates in the plasma console. It is a normally open contact, which closes on main arc transfer. Used to activate machine motion and arc voltage control.

�� Start Signal – Signal is derived from CNC machine. It is a normally open contact, which closes starting the plasma sequence. The system is off when this contact closure is removed.

�� 20:1 (+) Voltage Divider – The voltage divider provides a signal ouput, which is proportional to the cutting voltage. Signal reduction is 20 to 1 and controls whether the torch is raised or lowered in reference to the work piece. This is referred to torch to work distance. This distance is adjustable by varying arc voltage reference voltage.

�� Not Used


3-5

3.2.6 Secondary (Output) Connections to Power Console

WARNING!

Electric Shock Can Kill! Ensure all power is off by opening the line (wall) disconnect switch and power cord is disconnected before attempting to make any connections inside the power console.

Remove outside cover Insert power cable, pilot arc, and air hose through power cable bushing.

Power Cable Bushing TB1


3-6

1Pilot Arc

2Cut Gas

3Arc Current

1 Bolt pilot arc cable ring connection to the copper terminal.

2 Connect air hose to air/power connector (left hand threads).

3 Connect power cable to air/power connector using #10 screw

NOTICE

The console cover does not have to be removed to make the three connections above. Remove access panel if replacing cables or checking connections.


3-7

TB1

Insert115VAC Pilot Arc Cable Insert 115VAC RAS cable through strain relief located in the lower right corner of the front panel.

115VAC RAS Cable

Rout 115VAC RAS cable along inside edge in notches in insulating material to TB1.

2 conductor 115VAC cable routed through notch


3-8

Remove connection for internal arc start from TB1

TB1

Plug terminal connectors into 2 available lugs on TB1.

CAUTION!Cable Terminals to TB1 should be insulated to prevent possible damage due to internal arcing in the power console. The above illustration shows the terminals un-insulated for clarity of wire positions.

Replace cover if next step is not required.


3-9

3.3 Connecting the Remote Arc Starter

3.3.1 Mounting RAS2

Mounting location of RAS unit is restricted by the length of torch leads, 1,2 m -- 5,4 m or 7,6 m.

13,5mm203,2mm

55,9mm

12,7mm228,6mm

82,6mm

8mm


3-10

3.3.2 Connecting Service Lines to Remote Arc Starter 2

Remove end covers on RAS2 box.

115 VAC Arc Start Cable Connector

Pilot Arc Lug

Air Connection

Power Cable Lug

�� Connect arc start cable to RAS2 box.

�� Connect pilot arc cable to pilot arc lug using #10 screw and nut with lock washers.

�� Connect power cable to power cable lug using ¼” screw with washers and nut.

�� Connect air hose fitting (left hand threads). Note that this hose has the same fittings on both ends and orientation does not matter.

Arc Start Cable

Pilot Arc Cable

Power Cable

Air Hose


3-11

3.3.3 Setting the Spark Gap in the RAS2

1 mm

”a”

Factory set to 1mm. Adjustment procedure:

1. Loosen screw “a” using a 1/8” (0.125”) internal hex wrench.

2. Insert 1mm feeler gage between the tungsten electrodes.

3. Slide electrodes till slight pressure is felt on the gage.

4. Tighten locking screws on spark gap assembly.


3-12

3.3.4 RAS2 Output Connections to Torch

�� Pilot Arc – Connect pilot arc cable in torch bundle to pilot arc output lug using #10 screw, lock washers and nut.

�� Torch – left hand threads connect the torch gas (air) and plasma arc current. (Cable inside gas hose conducts the plasma cutting current)

Torch Lead Pilot Arc Connector

Torch Lead Voltage/Gas Hose


3-13

3.3.5 Terminating Shield Braid at RAS2

1. Insert Braid and hose bundle through RAS cover hole.

Insert bundle

2. Flare braid by bending it back at 90 degrees about 25 mm from the end.

Flair Braid


3-14

3. Insert ground plate over torch leads.

Insert Ground Plate

4. Fasten ground plate with 4 screws inserted from the outside. Trim braid strands if desired.

Fasten Ground Plate


3-15

3.4.1 Installing Torch Front End Parts

WARNING!

Make sure power switch on console is in OFF position and primary input power is de-energized.

Seat

Wrench

21375

1. The seat comes assembled to the front end of the torch. IF the seat becomes damaged, the torch body must be replaced. DO NOT attempt to remove the seat from torch body.

Electrode Holder Assembly

Baffle Tube

2. Electrode holder assembly (21332) includes the baffle tube (21374). If baffle tube becomes damaged, it can be replaced by un-threading the damaged tube out of the holder. Use small hex end of the wrench (21375) in hex broach on the tube. Tighten tube securely but do not over-tighten.


3-16

21332

21373

21150

3. Install the electrode insulator (21373) onto electrode holder assembly (21332) and then thread electrode (21150) onto the electrode holder assembly. Assemble electrode firmly by hand. Do not use wrenches or pliers. These three parts combined are the electrode assembly.

4. Install nozzle onto the electrode assembly by inserting small shoulder on electrode insulator into nozzle’s rear opening. Place nozzle and electrode assembly into the heat shield as shown in page 6. If front end of the torch is facing down as normal in a setup, the nozzle and electrode assembly can be stacked in the heat shield and then assembled to the torch. Be sure to use proper heat shield and nozzle combination as noted in page 18.

O-ring (488157)

5. Apply a thin film of lubricant (17672) to O-ring (488157).

17672


3-17

6.Tighten heat shield fully to hold the parts in firm contact with each other and to the torch head. “Fully” means at least 5mm rotation after electrode seat contacts electrode holder.

7. After retainer/heat shield is tightened, try to rotate the nozzle with your finger tips. If it rotates, the sealing of components is not tight enough and will likely leak gas.

NOTICE

See “Section 6 – Maintenance” for torch lead installation or replacement.

CAUTION!

IMPORTANT: See Maintenance section. Follow all instructions in the booklet packed with your unit. DO NOT install or attempt to operate this torch without following these instructions.


3-18

3.5 Interconnecting Diagram

4

6

14

15

1716

18

8

5

13

12

7

9

6

5

107

19

20

21

22

1

2

3

11


3-19

1 Air Supply

2 Wall Disconnect Switch (Grounded)

3 PCM-875A Power Supply Cable

4 Work Cable (Negative)

5 Pilot Arc Cable

6 Gas Connection

7 Power Supply Cable

8 115 V High Frequency Start Cable

9 RAS Input Bulkhead

10 Remote Arc Starter

11 RAS Output Bulkhead

12 Pilot Arc Cable

13 Power/Gas Hose

14 Torch Lead Bundle Shield Ground

15 PT-20 AMX Plasmarc Torch

16 Work Cable Clamp

17 Work Piece

18 Earth Ground

19 ATAS Start/Stop CSR

20 CSR Cable

21 Height Control Cable (Voltage Divider)

22 Voltage Divider (Height Control)


3-20

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SECTION 4 PCM-875A Mechanized Plasma Cutting System Operation

4-1

4.1 PCM-875A Console Operation -- General

WARNING!

Electric Shock Can Kill!

�� Do not operate the console with the cover removed.

�� Do not apply power to the unit while holding or carrying the console.

�� Do not touch the torch while console power switch is on.

WARNING!

�� Plasma Arc Emits Hazardous UV and Visible Radiation.

�� Damage to skin and eyes is possible.

�� Do not ever look directly at a plasma arc. Blindness could result.

�� Wear Safety Approved eye protection.

�� Comply to all local and national regulations for safety equipment.

WARNING!

Noise Levels May Exceed Safe Limits.

Sparks and Slag May Be Hazardous.

�� Wear Safety Approved Hearing Protection.

�� Wear Safety Approved Eye Protection.

CAUTION Possible Damage to Console from Sparks and Slag. Position PCM-875A at least 3 meters form the Cutting Area.


4-2

4.2 PCM-875A Plasma Console Controls

Power Switch -- Rear Panel

�� Located on the rear panel.

�� On Position – Front panel green pilot light will glow indication control circuit is energized and cooling fan will run.

�� Off Position – No Power to the control circuit.

Power Switch White Pilot Light

Output Current Control – Front Panel

�� Adjustable from 10 to 60 Amperes

Current Output Control

Air Test Switch – Front Panel

�� Test Position

Air filter-regulator can be adjusted to desired pressure 4,6 to 5,3 kgf/cm2 (65 to 75 PSI). Allow a few minutes for air to flow to remove an accumulated condensation.

�� Operate Position

Place the toggle switch in this position for normal operation.

Air Test Switch


4-3

Fault Light – Operations are stopped.

Will illuminate amber under the following conditions:

�� Light mostly ON but will blink off 1/10 of a second every second. Indicates airflow is low.

�� Light is mostly Off but will blink on for 1/10 of a second every second. Indicates over temperature and duty cycle has been exceeded. Allow power console to cool before returning to operation.

�� Light will blink off and on 5 times a second. Indicates the input voltage is outside the plus or minus 15% range of input rating.

�� Light will be on continuously. Indicates input current has been exceeded. Over Current.

Fault Light

NOTICE

All fault lights will remain on for a minimum of 10 seconds. If fault is resolved, all will reset automatically except for over current. To clear over current, power must be shut off for 5 seconds and turned back on.

4.3 RAS Operation

The RAS is a self-contained unit and requires no operator intervention to function.


4-4

4.4 PT-20AMX Plasma Torch.

WARNING!

Electric Shock Can Kill! Plasma incorporates high voltages at dangerous amperage.

Do not touch the;

�� Plasma torch

�� Torch lead

�� RAS

�� RAS supply lines

�� Console

while power is applied to console.

WARNING!

Electric shock Can Kill! Do not service torch or otherwise touch the plasma torch unless the power source has been disconnected or turned off.

CAUTION!

Hot Torch May Burn Skin. Allow torch to cool before servicing.


4-5

4.5 Cut Quality

4.5.1 Introduction

Causes affecting cut quality are interdependent. Changing one variable affects all others. Determining a solution may be difficult. The following guide offers possible solutions to undesirable cutting results. To begin select the most prominent condition:

�� 4.5.2 Cut angle, negative or positive

�� 4.5.3 Cut not flat, rounded or undercut

�� 4.5.4 Surface roughness

�� 4.5.5 Dross

�� 4.5.6 Dimensional Accuracy

�� Process Data

Usually the recommended cutting parameters will give optimal cut quality. Occasionally conditions may vary and slight adjustments will be required. If so:

�� Make small incremental adjustments when making corrections.

�� Adjust arc voltage in one volt increments, up or down as required.

Adjust cutting speed 5% or less as required, until conditions improve.

NOTICE Before attempting ANY corrections, check cutting variables with the factory recommended settings/consumable part numbers listed in Process Data.


4-6

4.5.2 Cut Angle

Part

Drop Part

Negative Cut Angle Top dimension is greater than the bottom.

�� Misaligned torch

�� Bent or warped material

�� Worn or damaged consumables

�� Standoff low (arc voltage)

�� Cutting speed slow (machine travel rate)

Part

Drop Part

Positive Cut Angle Top dimension is less than the bottom dimension.

�� Misaligned torch

�� Bent or warped material


�� High standoff high (arc voltage)

�� Cutting speed fast

�� Current high or low. (See process data for recommended current level for specific nozzles).

�� Wrong secondary gas flow.


4-7

4.5.3 Cut Flatness

Drop Part

Top And Bottom Rounded Condition usually occurs when material is 0.25" thick (6,4mm) or less.

�� High current for given material thickness (See process data for proper settings).

Drop Part

Top Edge Undercut Standoff low (arc voltage)


4-8

4.5.4 Surface Finish

Top View

Cut Face

Process Induced Roughness Cut face is consistently rough and may be confined to one axis.


Process Induced

Roughness

Or Machine Induced

Roughness

Machine Induced Roughness Can be difficult to distinguish from process induced roughness and is often confined to one axis. Roughness is inconsistent.

�� Dirty rails, wheels and/or drive rack/pinion. (Refer to maintenance section in machine owner’s manual).

�� Carriage wheel adjustment


4-9

4.5.5 Dross Dross is a by-product of the cutting process. It is the

undesirable material that remains attached to the part. In most cases, dross can be reduced or eliminated with proper torch and cutting parameter setup. Refer to Process Data.

Cut Face

Lag Lines

Roll Over

Side View

High Speed Dross Material weld or rollover on bottom surface along kerf. Difficult to remove. May require grinding or chipping. “S” shaped lag lines.

�� Standoff high (arc voltage)


Cut Face

Lag Lines

Globules

Side View

Slow Speed Dross Forms as globules on bottom along kerf. Removes easily.

�� Cutting speed slow


4-10

Side View Splatter

Cut Face

Top Dross Appears as splatter on top of material. Usually removes easily.


�� Standoff high (arc voltage).

Intermittent Dross

Appears on top or bottom along kerf. Non-continuous. Can appear as any kind of dross

�� Possible worn consumables

Other Factors Affecting Dross:

�� Material temperature

�� Heavy mill scale or rust

�� High carbon alloys

�� Gas Purity


4-11

4.5.6 Dimensional Accuracy

Generally, using the slowest possible speed (within approved levels) will optimize part accuracy. Most material thickness overlap for different voltages. Select consumables to allow a lower arc voltage and slower cutting speed.

4.6 Process Data

NOTICERecommended cutting speed and arc voltage will give optimal cutting performance. Small incremental adjustments may be needed due to material quality, material temperature and specific alloy. The operator should remember that all cutting variables are interdependent. Changing one setting affects all others and cut quality could deteriorate. Always start at the recommended settings. Before attempting ANY corrections, check cutting variables with the factory recommended settings/ consumable part numbers listed in the process data.


4-12

Material: Mild Steel Amperes: 40

PT-20AMX Plasmarc Torch Gas: Air

Lock Ring P/N 57N70

Handle with Sleeve

P/N 05508003419

Torch Body P/N 21359

Electrode Holder

Assembly P/N 21332

Electrode Insulator

P/N 21373

Electrode 50Hz

P/N 0558001617

Nozzle 50A P/N 21330

Heat Shield – Blue

P/N 21326

Note: Heat shield rated at 70 to 100A is used for this application


4-13

40 AmperesPT-20AMX

Process Data Mild Steel

Material Thickness

mm 2,0 3,0

Air Pressure

Bar 5 5

Height Readings

Initial Height mm 3,0 3,0

Arc Voltage (Stand-off) 110 110

Travel Speed

mm per minute 3810 2540

Kerf Width

Millimeters 1,1 1,1


4-14

Material: Mild Steel Amperes: 50


Lock Ring P/N 57N70

Handle with Sleeve

P/N 05508003419


Electrode Holder

Assembly P/N 21332

Electrode Insulator

P/N 21373

Electrode 50Hz

P/N 0558001617



P/N 21326



4-15

50 AmperesPT-20AMX

Process Data Mild Steel

Material Thickness

mm 5,0 6,0 10,0 13,0

Air Pressure

Bar 6,0 6,0 6,0 6,0

Height Readings

Initial Height mm 3,0 5,0 6,0 8,0

Arc Voltage (Stand-off) 110 120 130 150

Travel Speed

mm per minute 2540 1651 1016 457

Kerf Width

Millimeters 1,6 1,9 3,2 4,0


4-16

Material: Aluminum Amperes: 40


Lock Ring P/N 57N70

Handle with Sleeve

P/N 05508003419


Electrode Holder

Assembly P/N 21332

Electrode Insulator

P/N 21373

Electrode 50Hz

P/N 0558001617



P/N 21326



4-17

40 AmperesPT-20AMX

Process Data Aluminum

Material Thickness

mm 2,0 3,0

Air Pressure

Bar 5 5

Height Readings



Travel Speed


Kerf Width

Millimeters 1,57 1,57


4-18

Material: Aluminum Amperes: 50


Lock Ring P/N 57N70

Handle with Sleeve

P/N 05508003419


Electrode Holder

Assembly P/N 21332

Electrode Insulator

P/N 21373

Electrode 50Hz

P/N 0558001617



P/N 21326



4-19

50 AmperesPT-20AMX

Process Data Aluminum

Material Thickness

mm 5,0 6,0 10,0 13,0

Air Pressure

Bar 6,0 6,0 6,0 6,0

Height Readings



Travel Speed

mm per minute 2286 1905 762 203

Kerf Width

Millimeters Not

Available 3,2 4,7 4,7


4-20

Material: Stainless Steel

Amperes: 40


Lock Ring P/N 57N70

Handle with Sleeve

P/N 05508003419


Electrode Holder

Assembly P/N 21332

Electrode Insulator

P/N 21373

Electrode 50Hz

P/N 0558001617



P/N 21326



4-21

40 AmperesPT-20AMX

Process Data Stainless Steel

Material Thickness

mm 2,0 3,0

Air Pressure

Bar 5 5

Height Readings



Travel Speed


Kerf Width

Millimeters Not

Available 1,6


4-22

Material: Stainless Steel

Amperes: 50


Lock Ring P/N 57N70

Handle with Sleeve

P/N 05508003419


Electrode Holder

Assembly P/N 21332

Electrode Insulator

P/N 21373

Electrode 50Hz

P/N 0558001617



P/N 21326



4-23

50 AmperesPT-20AMX

Process Data Stainless Steel

Material Thickness

mm 5,0 6,0 10,0 13,0

Air Pressure

Bar 6,0 6,0 6,0 6,0

Height Readings



Travel Speed

mm per minute 1270 762 203 152

Kerf Width

Millimeters Not

available 3,2 4,7 4,7


4-24


SECTION 5 PCM-875A Plasmarc Cutting System Maintenance

5-1

5.1 PCM-875A Console

5.1.1 General

CAUTION!Stop work immediately if this equipment does not operate properly. Equipment damage or personal injury may result.

CAUTION!Do not permit untrained persons to inspect, clean, or repair this equipment. Maintenance must be performed by specially trained personnel.

NOTICE

Use of replacement parts other than ESAB replacement parts may void warranty.

WARNING!

Electric Shock Can Kill! Disconnect wall switch before inspection and maintenance of the power console.


5-2

5.1.2 Inspection and Cleaning

A CB

D

FF

F

FF

EE

Frequent inspection and cleaning of the PCM 875A system is recommended for safe and proper operation.

A. Check work cable for secure connection to workpiece.

B. Check safety earth ground at workpiece and at power console chassis.

C. Check heat torch heat shield. Replace if damaged.

D. Check torch electrode and cutting nozzle for wear at least once per 8 hours operation.

E. Ensure cable and hoses are not damaged or kinked.

F. Ensure all plugs, fittings and ground connections are tight.

WARNING!

Wear safety eye protection when using compressed air. Serious eye injury may result.


5-3

CAUTION

Water and oil may accumulate in compressed air lines. Direct the first air blast away from equipment to avoid possible damage.

G. With all input power disconnected, wearing proper eye and face protection, blow out the inside of the console using low-pressure dry compressed air.

H. Periodically drain water from the filter beneath the air-filter regulator.


5-4

5.1.3 Flow Switch

AA

View A-A

2

1

The Flow Switch (P/N 951202) may need to be cleaned if excessive contamination is found in the air supply.

1

Flow Switch Location

2

Solenoid Location

Note: The flow switch can be disassembled and cleaned without extraction from the power supply.

Piston Plug

Spring

Piston

Flow Switch Body

1) Turn Off power supply

2) Remove piston plug

3) Remove the spring. Use care when handling spring to prevent distortion.

4) Remove the piston.

5) Clean all parts with warm water and a mild detergent. Allow parts to dry thoroughly before reassembly.

6) Reassemble switch in reverse order.


5-5

5.2. Remote Arc Starter

5.2.1 General

Check input and output bulkhead connections for tightness.

5.2.2 Spark Gap

1 mm

”a”

Factory set to 1mm. Adjustment procedure:

1. Loosen screw “a” using a 1/8” (0.125”) internal hex wrench.

2. Insert 1mm feeler gage between the tungsten electrodes.

3. Slide electrodes till slight pressure is felt on the gage.

4. Tighten locking screws on spark gap assembly.


5-6

5.3 PT-20AMX Plasmarc Torch

WARNING!

Before any maintenance is attempted on this torch, make sure the POWER SWITCH on the console is in the OFF position and the PRIMARY INPUT POWER is DE-ENERGIZED.

5.3.1 General

1. Periodically check heat shield, electrode holder assembly, electrode nozzle seat, and electrode insulator. Replace if worn or damaged.

2. Apply a thin film of lubricant 17672 (supplied in spare parts kit) to O-ring. Check O-ring for damage whenever shield is removed. Replace if necessary.

3. Power and pilot arc cables should be inspected periodically. If cuts through protective sheath or if gas leaks are noted, replace damaged component.


5-7

5.3.2 Dirt or Contamination Dirt or other contamination in the torch and loose

consumable parts can cause premature failure of the PT-20AM Torch through internal arcing. To avoid this, users are instructed to do the following:

1. Ensure that clean, dry, or oil-free air is being used.

2. Avoid excessive use of the silicone o-ring grease used to lubricate the torch o-ring. A thin film is sufficient.

3. Wipe the torch body insulator clean with a cloth before installing each fresh set of consumables. The ability of the insulator to resist arc tracking over its surface is reduced when dirt or other contamination is allowed to collect there.

5.3.3 Loose Consumables

Tests have shown that with proper use of the torch within rated operating conditions (especially arc current and gas flow rate), the torch consumable parts do not become loose if they are firmly installed in the first place.

1. Tighten heat shield fully at each consumable change or inspection. “Fully” means at least 5 mm of rotation after electrode seat contacts electrode holder.

NOTE: trying to rotate the portion of the nozzle extending outside heat shield can check consumable tightness.

2. Check consumable tightness at beginning of each work shift, even if everything was working normally at the end of the previous shift.

3. Ensure that the torch electrode seat and electrode holder are clean and free of dust or dirt Debris may prevent mating surfaces from having solid contact.


5-8

CAUTION

The torch requires good electrical contact between the electrode seat and electrode holder. If good contact is not maintained, then the resulting potential difference causes internal arcing and possible torch damage.

5.3.4 Damage Caused by Loose Parts and Torch Overheating.

Electrode Insulator (21373) Arc tracking indicates loose parts. Make sure heat shield is tightened fully, at least 5mm of rotation after electrode seat contacts electrode holder. Check tightness again after a few minutes of use. Parts damaged by arcing will cause destruction of torch. Parts damaged by arcing must be replaced.

Deformation at this edge indicates torch overheating. Check gas pressure, gas flow rate and current setting. Deformation leads to loose parts and internal arcing. Do not operate torch with a deformed insulator.

5.3.5 Consumables- Remove and Replace

1. Bring torch to a position where it is easily accessed by machine operator, in its normal vertical position and at least 6 inches above the workpiece or the edge of the water table.

WARNING!

Make sure that the power source has been turned off and that the power cable has been unplugged at the wall receptacle before proceeding.

2. Unscrew the heat shield and lower it away from the torch, allowing nozzle and electrode assembly to remain with shield.


5-9

3. Remove the nozzle and electrode assembly from the shield and inspect for wear. The nozzle orifice should be round at both the entrance and the exit. If the nozzle orifice is worn in an oval shape or shows other signs of damage at either end, it should be replaced. The inside of the nozzle may have light gray deposits from the electrode. These may be removed with steel wool but care must be taken to remove all traces of the steel wool afterward.

1,5 mm

If the electrode has a pit that is more than 1.5mm deep at its center, replace it. Grasp the electrode holder with the fingers using the two flats and grasp the electrode between the thumb and finger of the other hand and twist.

Inspect electrode insulator and electrode holder assembly for signs of damage such as arc tracking or cracking and replace them if any are found. Insure that the baffle tube is securely threaded into the electrode holder, but do not over tighten. Use the small hex end of the plastic wrench in the spare parts kit. After installing the electrode insulator onto the electrode holder assembly, install electrode by reversing the procedure used to remove it. Note that firm tightening of the electrode by hand is sufficient. The use of tools such as wrenches or pliers is not required or recommended.

4. Inspect heat shield for signs of damage or wear. The gas holes inside shield should not be blocked by debris, and there should be no signs of arcing anywhere inside the shield. The outer insulating jacket of the shield should not be severely charred or eroded. Replace the heat shield if any of the above damage is found. .


5-10

Inspect o-ring of torch

5. Inspect the o-ring on the torch. If it shows signs of wear or damage, replace it. If it is dry, lubricate it with a thin film of lubricant supplied with spare parts kit

6. Install the nozzle and the electrode assembly into heat shield and thread heat shield onto torch. The shield should be tightened fully to insure good electrical contact for electrode and nozzle. "Fully" means at least 3/16 inch of rotation after electrode seat contacts electrode holder.

5.3.6 Measuring Torch Gas Flows

Flow Measuring Kit -- P/N 19765

Check gas flow if suspected of causing poor cutting performance. Use Plasma Torch Flow Measuring Kit. (P/N 19765)The kit includes a hand held rotameter (flowmeter) that indicates the gas flow rate exiting the torch. The kit also includes a set of instructions that should be followed exactly to insure safe and accurate use of the rotameter. Total air flow rate in the PT-20AMX should be 325cfh minimum with any nozzle at 75 psi.


5-11

5.3.7 Removal and Replacement of the Torch Body

WARNING!

Make sure that the power source has been turned off and that the power cable has been unplugged at the wall receptacle before proceeding.

PT-20AMX Torch

1. Cut and remove the shrink wrap at the back end of the torch handle. Unscrew the handle from the torch body and slide it back onto the torch cable assembly in order to expose the torch connections.

2. Remove the electrical tape that secures the short piece of vinyl tubing on the pilot arc cable. Slide the tubing away from the torch and onto the pilot arc cable to expose the pilot arc connector.

3. Use the 1/16" Allen Wrench supplied in the spare parts kit to loosen the pilot arc connector set screw closest to the torch body, being careful not to totally remove the screw. Slip the torch’s pilot arc lead out of the connector.

4. Unscrew the power cable fitting from the torch’s power lead using a 7/16" open-end wrench and remove the torch body.

5. Connect the pilot arc cable and the power cable to the new torch body’s pilot arc lead and power lead by reversing the steps taken to disconnect them. Tighten the pilot arc connector set screw fitting firmly but do not overtighten. Torque the power fitting to 20 lb. in.

6. Slide the vinyl tubing forward to cover the pilot arc connector and secure in place with electrical tape.

7. Slide the handle forward and thread it firmly onto the torch body.

8. Slide the new piece of shrink tube over the torch handle and shrink in place over the handle’s end and the cable sheath.


5-12

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SECTION 6 PCM-875A Plasmarc System Troubleshooting

6-1

6.1 Troubleshooting PCM-875A Plasmarc System

WARNING!

Electric Shock Can Kill! Ensure that all primary power to the machine has been externally disconnected.

Open the line disconnect switch or circuit breaker before inspection, maintenance or repair inside power console.

Match the problem with the conditions below.

If problem is not listed,

�� shut off input power,

�� open unit by removing cover

�� Visual inspection of all components and wiring

�� Check for loose terminal connections

�� Burned wiring or other components

�� Bulged or leaking capacitors

�� Any other signs of damage or discoloration.


6-2

6.2 Troubleshooting guide for PCM-875A Plasmarc System

6.2.1 Power Light (PL1) does not come on

�� Visually inspect the machine for damage.

�� Check if the cooling fan is running. If not running, check the following:

�� Check if machine input power is still connected.

�� Measure input power at the receptacle. If not present, then check the wall disconnect switch and it’s fuses.

�� Check fuse (F1). If it is:

�� Check input circuit breaker (CB1).

�� If cooling fan is running, measure voltage between pins P2-11 and P2-14 of control board (should be 115VAC). If no voltage, replace transformer T2.

�� If voltage is present, power light may be burned out.

The problem is internal if above items are ok. Send unit to Authorized Repair Station.

6.2.2 No air flow

�� Check air inlet supply. Unit requires 9,2 3m/h at 4,48 bar.

�� Check air hose and connections. Tighten if leaking.

�� Does air flow when “Air Test” switch is in test position?

�� If not, check torch consumables, replace if necessary.

If above items are OK, the problem is internal. Return to authorized repair station for service.


6-3

6.2.3 The Power light is on, but nothing happens when the torch is signaled to fire. Fault light does not activate. NOTE: Unplug high frequency connection before

attempting to work on this problem.

�� Check the Pilot Arc fuse (F2) located on the rear panel. An open fuse will indicate a short in the torch. If the fuse is all right, then check the following:

�� With the machine power on, depress the torch switch. On the control board the LED 1 should be lit as long as the switch is depressed. If not then check:

�� Turn power off to the machine. Unplug Control board. Put an ohmmeter across P5-1 and P5-2 to take resistance reading. Depress torch switch. Meter should read a short. If not, then one of the following is not working properly:

�� Torch switch or the leads. Unplug the torch switch leads at the machine. Put a meter across the two plug pins. Should read a short when the torch switch is depressed. If not, then either broken switch leads or malfunctioning switch.

�� Check T2 transformer secondary voltages at the plugs P1 and P2. 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.


6-4

6.2.4 Fault light activates when torch is signaled to fire

The Fault circuit is used to monitor conditions necessary for the safe operation of the PCM-875. The fault light will glow amber under the following conditions and operations will come to a complete stop:

�� High/Low line voltage. The Fault Light will rapidly blink on and off (5 times per second). This indicates that the input voltage is outside the “+” or “-” 15% safe operating range rating.

�� Flow fault - The fault light will be mostly on but will blink off for 1/10th of a second every second. This indicates that the air flow is low.

�� Check the air pressure at the machine regulator. It should be adjusted to 65 psig. If no air pressure, check the air at the supply point. Also, check for any obstructions in the air hose.

�� Air flow may be blocked at the torch tip. Check the torch consumables. Also check for any obstructions in the torch leads.

�� NOTE: If above items check OK , the problem is internal. send unit to an Authorized Repair Station for repair.

�� Put the ‘Air Check’ switch to On position. Air should flow through torch. If not, then the flow switch may be stuck due to oil in the air. Clean air flow switch per supplier’s instructions or replace switch. To check if the flow switch is open, put voltmeter leads between P1-12 and P1-1. It should read about 12 VDC. When the flow switch closes, the voltage will drop to zero volts.

�� Air Check switch may also be malfunctioning if the air is flowing continuously or putting in the On position does not turn air on.


6-5

Fault light activates (continued)

�� Over Temperature. The fault light will be mostly off but will blink on for 1/10 of a second, every second. This generally indicates that the duty cycle has been exceeded. Allow the power source to cool before returning to operate.

�� Thermal switch may be open. It will open if the temperature at the IGBT base reaches 94oC. With the machine power off, check the continuity between P1-1 and P1-2 of the control board. If the switch is OK, then the ohmmeter should read a direct short. If not then it should read open.

�� If the switch is malfunctioning, replace it. Clean the surface of the heat sink before installing the switch.

�� Over Current. The fault light will be on continuously. This indicates that the input current to the main transformer has exceeded preset limits.

�� To check if the output is shorted, measure the resistance by putting the ohmmeter leads (make sure to disconnect HI Frequency leads):”+” of the meter to Torch “+” output terminal and Work “-” lead of the meter to the “-” output terminal. Reading should be about 2 K Ohms. Reverse the voltmeter leads, the resistance reading should be less than 1.5 K Ohms.

If the resistance reading is different than above, check the torch, the output bridge and Filter Board (PCB-5).


6-6

6.2.5 Air is On but nothing happens when torch is signaled to fire.

�� Check pilot arc fuse located on rear panel. If it is open, nothing will happen when torch switch is depressed.

�� Check torch. Make sure heat shield is very tight.

�� Check to assure high frequency is present at torch. If not, then listen for high frequency at high frequency generator. It is located on bottom/right side of the unit. High frequency gap is set to .040". Disconnect HI FREQUENCY leads. Check for 115 volt supply to high frequency unit between P2-12 & P2-13 of control board with torch switch closed.

�� With HI FREQUENCY leads disconnected, measure open circuit voltage. It should be 275 VDC between “Work” and “Torch” terminals. If it is not present then any one of the following may not be working properly:

�� Check the operation of the Thermal Switch. See D.3.a. above.

�� Check Air Check switch operation. It might be stuck in On position. Pilot arc will not initiate if this switch is in the ON position. (safety reasons)

�� Check air flow switch. There may be internal short. See D.2.c above.

�� Measure voltage across C1 or C2 capacitor. It should be as follows:

approx. 325 VDC for the 208/230 volt unit.

approx. 280 VDC to 325 VDC for 400 volt unit

If not, one of following could be malfunctioning:

�� Check the capacitors C1 and C2 for any damage.

�� Check input bridge/SCR Module (IBR) This can be checked without taking it out of the circuit using an volt/ohmeter. Replace it if found malfunctioning. Follow bridge installation instructions.

�� Check Inrush current resistor, R10 and SCR1. Both are located on the input bridge heat sink. Replace it if malfunctioning.

�� IGBTs (2 on 230 V, and 1 on the 400 V units) may be blown. See IGBT installation procedure. Before replacing IGBTs, make sure to check the zener diodes and pico fuses on the IGBT driver boards.


6-7

6.2.6 High Frequency and Pilot Arc are on but Main Arc does not transfer.

�� Make sure work clamp is connected to work material.

�� Check the torch. Replace consumables if necessary.

�� Make sure the current setting potentiometer is set above 10 amps. If it is, set below 10 amps, then HI FREQUENCY will go on and off at 5 sec intervals.

6.2.7 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.

�� Check the output. Use a calibrated current probe capable of measuring 100 amps in the presence of high frequency.

6.2.8 Air does not shut off.

�� Check air test, the gas solenoid valve is energized when the switch is in the “on” position.

�� Does air flow stop when the torch switch is unplugged? If yes, check and repair the torch. If not, send unit to an Authorized Repair Station for repair.

�� Check voltage to solenoid coil, if present when torch switch is unplugged, replace PCB1. If voltage is “0”, replace solenoid valve.


6-8

6.2.9 Main arc is difficult to start.

�� The most common reason is worn or missing consumables. Check and replace if necessary.

�� Input air must be clean and dry.

�� Input air pressure must be between 65 - 75 psig.

�� Torch connections must be tight.

�� Work cable and clamp must be in good condition and must make a good electrical connection to the material to be cut.

�� If above items check OK , the problem is internal. Send unit to an Authorized Repair Station for repair.

�� Missing or weak pilot arc. Check pilot arc fuse, open circuit voltage, pilot arc resistors and pilot arc wiring.

�� Inoperative starter board (PCB-5).

�� Check Spark gap in RAS unit. 1mm is desired gap. If gap is to large, spark will be weak or non-existent.


6-9

6.3 Reference 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 - +15 vdc TP-2 - +12 vdc TP-3 - -12 vdc TP-4 - +5 vdc TP-9 - IGBT’s driving signal - switching frequency = 16 KHz TP-10 - IGBT’s driving signal - switching frequency = 16 KHz

13 vdc

-13 vdc

5 msec

62 µsec

0

IGBT Gating Signal

For 208/230 VAC input, the IGBT off time is 3msec. For 400/460/575 VAC input, the IGBT off time is 6msec.


6-10

6.4 PT-20AMX Torch Troubleshooting

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-875, refer to the maintenance section of this manual. If the problem is not corrected after referring to the maintenance section, contact your ESAB distributor.

6.4.1 Insufficient Penetration

�� Current too low.

�� Cutting speed too fast.

�� Damaged cutting nozzle.

�� Improper air pressure.

�� Low air flow rate.

6.4.2 Main Arc Extinguishes

�� Cutting speed too slow.

�� Worn electrode.

6.4.3 Dross Formation.

(In some materials and thicknesses, it may be impossible to get dross-free cuts.)

�� Current too low.

�� Cutting speed too fast or too slow.

�� Improper air pressure.

�� Faulty nozzle or electrode.

�� Low air flow rate.


6-11

6.4.4 Double Arcing

�� .Damaged Nozzle Orifice.

�� Low air pressure.

�� Damaged cutting nozzle.

�� Loose cutting nozzle.

�� Heavy spatter accumulation on nozzle.

6.4.5 Uneven Arc.

�� Damaged cutting nozzle or worn electrode.

6.4.6 Unstable Cutting Conditions.

�� Incorrect cutting speed.

�� Loose cable or hose connections.

�� Electrode and/or cutting nozzle in poor condition.

6.4.7 Main Arc Does Not Strike

�� Worn electrode.

�� Loose connections.

�� Worn cable not attached

6.4.8 Poor Consumable Life

�� Improper gas pressure.

�� Contaminated air supply.

�� Low air flow rate


6-12

6.5 230V Power Console Electrical Drawings

6.5.1 230V Console Schematic Part 1

TB5-1

L1

3

1

E2

PCB3

PCB2

92

1

40UF,400VDC

C4

39K,2W

R9

10

4

3

8

7

C2E1

Q2E1G1

6

V

P1-

4 V

P1-

3

E1

V P1-

4

V P1-

3

C7 R5 R6 C8

T4

R710 OHM,50W

11

C100.022UF,1KV

2

H2

2

X1

T1

H1

R4

20,25W

20,25W

(+)

R3

20,25W.01UF,1KV2 1

C51 2 1

1

20,25W.01UF,1KV2 1 1

3

D1

2 1

(-)

.01UF,1KV2 2 1

C6

.01UF,1KV2 2 1

H1

(PCB4)

SH2

230V

230V

G2

C1

E22

3

E2

1uf600V

X2

X3

C16

P1-

1 V

P1-

2 V

P1-

1

G2

VV P1-

2 (-)

P6-

11

P6-

10

208V

TB3

V P1-8

(+)4

RED

VV

P3-5

VV

VV

V

P1-7

P4-2

P4-4P4-1

P4-5

VV

VV P3-2

P3-4

P3-1

275V

4

(+)

5C2E1

Q1

G1

C2C1

R1010,50W

3

2 1

R15R2

C3

IBR(+)

GR2

D6

D5

D4 R

S

AC3

AC2

MOV3

275V

1

LOAD

LINE

2

A

A

BL

K

T1

L1

MOV2

B

B

275V

MOV1

EMC FILTERFN1

L2 RE

DT2

50/60 HZ3 PH CE

208/230 VAC

3A,600VAC

TS1

1UF,600V

3

2C1

E2

1800UF,450VDC

1800UF,450VDC

600V

2

C151UF

1

1 2 3

10K,2WR1

10K,25W

10K,25W

C19 .22UF,1KV

D3T

D2

D1

(-)

AC1

L2

X1

X2

2 1

P6-5VV

V

P1-2

P1-1

MAX

VV

V

P6-6P6-12

P6-13

VV

P2-8

P2-7

C

C

L3

WH

T

T3

S1

F1

T2

H1

0

2 M1 1

H2

P5-

9

R12

(-)

8 ,300W

R11

8 ,300WBLK

R162W

100K

V

(CONTROL BOARD)

PCB1

400V

H4H2 H3

TB5-2

230V

230V

208V

208V

VV

P5-

3

P5-

4

12V

X2X1

V

P1-

9

V

P1-

10

18V

X3 X4

VV

P2-

11

P2-

14

115V

1 2

X11 X12

VV

P1-

6

P1-

5

12V

X5 X6

V

P2-

1

24V

V

P2-

4

X8X7

VV

P1-

3

P1-

4

20V

X9 X10

1

2

3


6-13

230V Schematic Part 2

V

P5-5

0.047uf660VPCB5

V

P1-3

V

P1-2

P1-6 V

(-)

(+)

GND 5

C23

C14

X2T3 X1

2500 PF,15KVC13

H2

1X1

TB2H1

T5SG

2X2

TORCH

2500 PF,15KV

WORK

L2

.82UF 630VDC

P.A.

L3T3K1

R13

C20

P1-1 V

K1T2 T1

K1C21

L1

.022UF, 1KV

GND 3

PILOTARC

330K ,1W

.022UF

P2-

13

P2-

12

GND 2

TB1-2

GND 4

.01UF,250 VAC

H1

.01UF1KV

C11

TB1-1

.01UFC121KV

H2

C9

115 VAC

V V

250VAC

K1

B

A

SHIELD

P5-1

P5-2 V

C18

V

P5-6 V

PL2

C17250VAC.022UF

4T

L3

-

+

TORCH SWITCH

J1

V2

V1

SIGNAL TO CNCVOLTAGE DIVIDER

SIGNAL TO CNC

(CONTROL BOARD)

PCB1

5

P6-2P2-2

P2-3

SOL1

VV

VP1-12

P1-11

P6-1

V

1

VV

1

NO

T U

SE

D O

N C

ON

SO

LE

S2

1

2

75mA60V

ZD1

S3

FS

2

4

0558

0033

5705

5800

3356

&

P2-3

P2-4

VV

V V

P6-

9

P6-

7

S22

6

1

3

(SEE CHART)TB41 2 3 4

(+) (-)

5 6

TB4-6TB4-5TB4-4TB4-3TB4-2TB4-1

}FROM CNC

}

ARC ON

START SIGNAL

}

12

3


6-14

6.5.2 230V Power Console Wiring Diagrams Part 1

BK1C21

R13

A

T3

BLU

PCB1 P2-12 BLU

T1 T2

R11-2 YEL

PCB1 P2-13 BLU

L3

P.A. BUS ORN

BLU

L1 L2

PCB5 P1-3 VIO

PCB5 P1-2 BLUJ1-2 BLK

PCB1 P6-7 YEL

PCB1 P6-9 ORN

7 6 5 34 2 1TB4

J1-1 GRY

*

T3-H1 RED

NO

T U

SE

D O

N C

ON

SO

LES

0558

0033

5705

5800

3356

&

BLU PCB1 P6-2

32PCB1 P6-6 WHT

R1

1

S3 21

PCB1 P6-13 RED

PCB1 P6-12 BRN

PCB1 P5-6 BLK

PCB1 P6-1 BLU

PCB1 P2-4 ORN321

-

PCB1 P1-12 BLK 4 5 6GRY PCB1 P2-3

S2

RED FS-2

*

T5-

X1

RE

D

TB1-2 BLK

H1TB2 *

S

G-1

RE

D

T5-

X2

RE

D

SG1 2

C14

T3-H2 RED C13

X1

SPLICE

2FS RED1

RED*

TB1-1 BLK

*

PCB1 P1-11 RED

S1-5 RED

S

G-2

RE

D

X2

T5

H2 *

*

YE

L P

CB

1 P

2-14

YE

L P

CB

1 P

2-11

PCB1 P5-5 RED

PL1

+

2

PL2

1

CE MARKED UNITSBLIN

E

S1-T1 BLKA

S1-T3 BLK

S1-T2 BLKC

LO

AD

B

AONLY IBR-R BLK

FN1C IBR-T BLK

IBR-S BLK

P6

P5

P5-2P5-1

(SEE CHART)

PCB1

P4

P2

P3 P1

C18

C17GND 2

J1 SHIELD


6-15

230V Power Console Wiring Diagrams Part 2

GRN

INP

UT

PO

WE

R C

AB

LE

GND1

BRN

BLK

BLU

BL

K

BR

NB

LU

1*

2F1-1 BLK

* BLK TB5-2

M1

6 6 6 R1-2 WHTT2-X6 BLU 4 ORNS1-2 BLKPL2-(-)

FN1 LINE B

FN1 LINE C

FN1 LINE A

3T3

21

T2T1

LO

AD

LIN

E

S1

T2-X1214 VIO

* 1RED T2-H1BLK M1-2 *

F1

2IBR (T) BLK

12

11

10

9 R16-1 GRY

8

7

K1-A BLU12

K1-B

TB1-2

PL1-2

13

14

13

BLUYEL

BLU

TB1-1

PL1-1

T2-X11

12

11

11

BLUYELVIO

9 T2-X3

11 FS-1

12 S1-4

10 T2-X4

8 T4-2

7 T4-1

7 IBR-G YELWHT8 IBR(+) BRN

9RED

BLK 10

WHT

ORN 6ORN 5

13 R1-3

12 R1-1

11 PCB4-4

RED

BRN

RED (TP)

PCB1 P6-5 WHT

8

TB4-29

10 PCB4-3

8

7 TB4-1

ORN

BLK (TP)

YEL

DETAIL "A" (PCB1)

5

4

3

2

T2-X10

5 T2-X5

3

4

T2-X9

1 TS1-1

2 TS1-2

P1

T2-X8

SOL1-2

S1-3

BLU 4

BRN

BRN

3

3

ORN

GRY

GRY

T2-X7

SOL1-1

1VIO

VIO 2

1ORN

WHT

P2

5 PCB1 P6-6 WHTRED

YEL

YEL

PL2-(+)

T2-X2

T2-X1

4

3

CLR (TP)

BLK (TP)

J1-1

J1-2

P5

1 S2-1

2 S2-2

P6

BLU

BLU


6-16


FN

1 L

OA

D C

R101 2

FN1 LOAD B

K1-

L1

OR

N

GND 3

C20

1 2

TB

4-3

GR

Y

LEFT SIDE VIEW

R5

R3

R4

C6

21

2

L1-

H1

BL

K

*

*

R6

C8

2

BLU

12

-

2

3 T1-X2

PCB4-2 BLU

1C

5

*BLU

C7

1

+ 1

D1

T1-X1

T1-H1

T

YE

L

Q1-C2E1 RED

F1-

2 B

LK

PC

B1

P2-

8 B

RN

*L2-X2

MOV1 -

PC

B1

P1-

7 O

RN

C4

R91

2R7-1 BLU

3

4

ORN PCB1 P1-8ORN

T42

ORN 1

*T1-H2

R2-2 BLK

YELC1(

+) R

ED

PC

B1

P2-

7 Y

EL

2MOV

MOV3

C19

+GS

R2R

FN1 LOAD AIBR

*T2-H2 BLKT2-H3 GRY

M1-1 BLK**

TB5

C3

C4-4 BLU

R71

PCB1 P1-2 VIOPCB1 P1-1 VIO

C4-2 REDTS1 Q2Q1

C102

1 2

C2E1 C2E1

PCB2

-

+C1

1 2

C16C15E2

C1

E2

C1

13 4 2 3 4PCB3

TB

4-4

BL

K

P.A. BUS

SOL1

21 J1

1

PC

B1

P2-

2 W

HT

PC

B1

P2-

3 G

RY

ZD12

CL

RB

LK

PCB1 P5-2 BLK(TP)

PCB1 P5-1 CLR(TP)

T1-

X3

*

TB3

R15-1 BLK

C2

-

+

*L3

3456 12

PCB1-P4

GRYL2-X1*

51 42 3

IBR

(+)

RE

D

WH

T

RE

D

R2-1 RED

RE

D

WH

T

WH

T

RE

D

RE

D

WH

T

PCB1- P3 1 2 3 54

R15-2 RED

PCB4

(SHUNT)

VIEW E-E

L1-

H2

BL

K

6 1

C23

GND 5

R11

-1 B

LU

D1(

+)

BL

U

PC

B5

P1-

1 R

ED

VIEW B-B

WO

RK

1-

3

2

4

+

TB

4-5

BL

UT

B4-

6 V

IO

PC

B4-

1 R

ED

PCB5

P1

BL

K P

CB

1 P

6-10

RE

D P

CB

1 P

6-11

TP


6-17


R111 2F F

H1

TORCH

PILOT ARC

E E H2

L1

T3-

X2

BL

K

D1(

-) B

LK

PC

B5

P1-

6 B

LK

PCB5 B

* *

RIGHT SIDE VIEW SHEET 2 OF 2

CC T2

*

H2TB2 RED

T3-X1

**

TORCH

SG-1 RED

T3

X1

H1

*

L1-H2 BLK X2

D

TB1

C12

C11 D

GND 4

C1(+) RED

* D1-3 BLK

X2

X3X1 H2H1

T1

* TB3 BLK

C2(+) RED

C2(-) BLK

*R152

1

D1-1 BLK *

C1(-) BLK

Q2-C2E1*C4-4 2

R2

1

L2

IBR

(-)

C1(

-)

X1 X2

* *(SHUNT)

PCB4B

1 R11 2

1 R12 2

BL

U

BL

U

VIEW F-F

PCB4-2 BLU K1-T3 YEL

TOP AND BOTTOM

VIEW C-C

X7

X12

PCB1 P1-3 BRNPCB1 P2-4 ORNPCB1 P2-1 ORN

PCB1 P1-4 BRNPCB1 P2-11 VIO

X8

X9X10X11

PCB1 P2-14 VIOTOP

X6

X1PCB1 P5-4 YEL

PCB1 P1-5 BLUPCB1 P1-6 BLU

PCB1 P1-9 WHTPCB1 P1-10 WHTX4

X5

X3X2

T2

PCB1 P5-3 YELTOP

TB5-1 BLK

TB5-2 GRY

F1-1 REDBO

TT

OM

H2

H1

H3 ***

H4*BLU

VIEW D-D

C12

C9GND 4

12

C11 TB1PCB1 P2-13 BLU

PCB1 P2-12 BLUT5-H1 BLK

*

T5-H2 BLK

*

PCB1 P5-9 GRYR16


6-18

6.6 400V Power Console Electrical Drawings

6.6.1 400V Console Schematic Part 1

L1

(PCB4)

3

1R9

92

10

39K,2W

40UF,400VDC

C4

1

4

3

8

7

6

E2

(-)

1

800VDC2 UFC16

C8R6R5C7

T4

R710 OHM,50W

3

1 1

1KV0.022UFC10

2

H2

2

X1

T1

H120,25W

20,25W

(+)

R3

20,25W.01UF,1KV12

C51 2 1

R4

1

20,25W.01UF,1KV2 1 1

3

D1

2 1

(-)

.01UF,1KV2 12

C6

.01UF,1KV2 2 1

H2

SH2

(+)

C13 Q1

X2

X3

G1 4 V

E1 3 V

G2

C2E12

2

1E2 V

V

PCB2P/N-38099

P1-7P

6-11

P6-

10

TB3

V P1-8

(+)4

RED

V V

VV

V

P4-5

P4-4

VV

P3-5

P3-4

FN1

4

5(+)

C2 1800uf

450VDC

C15

R15 10K,25W

1 UF630VDC

(+)

2

3

R10

R2G

1

10,50W

T

R IBRS

MOV

510V

2

510V 510V

2

1

MOV3

MOV1

F13A,600VAC

TS1

1800ufC1450VDC

C3

R2 10K,25W

630VDC1 UF

(-)

2

1

1 2 3

10K,2W

R1

(-)

0.22UF,1KV

C19

50/60 HZ3 PH

400 VAC

2

P6-5VV

VP1-2

P1-1

MAX

VV

V

P6-6P6-12

P6-13

VV

P2-7

P2-8

1

L2

LO

AD

LIN

E

P/N-952253EMC FILTER

AAH2

A

B

C

BH2B

CH2C

AH1 6

CB1

BH1 5

CH1 4

T2

1 1

22

33

2 1

H1

P5-

9

8 ,300W

(-)

R12

8 ,300WBLK

R11100KR16

2

1

2W

V

(CONTROL BOARD)P/N-38109

PCB1

P2-

1

V

P2-

4

V

24V

X2X1

V

P1-

3

P1-

4

V

18V

X3 X4

P2-

11

P2-

14

V V

115V

1 2

X11 X12

V

P1-

6

P1-

5

V

12V

X5 X6 X8

P1-

9

V

18V

X7

P1-

10

V

P5-

3

V

12V

X9 X10

P5-

3

V

0H1

M1

H2 230V H3 400V H4 460V

1

2

3


6-19

400V Console Schematic Part 2

V

P5-5

H2H1WORK

(-)

(+)

.047ufPCB5

VV

V

P1-3

P1-2

P1-6

VP1-1

GND 5

C23X2

TB2

X2 T3 X1

H2

660V

X1

SG

2500 PF,15KVC13

T51 2

TORCH

2500 PF,15KV

H1

C14

PILOTARC

.022UF, 1KV

R13

L3

P.A.

K1T3

K1T2

K1L2 T1

C21

C20GND 3

L1

330K ,1W

.82UF 630VDC

250VAC

P2-

13

P2-

12

TB1-2TB1-1GND 4

C11.01UF1KV

C12.01UF1KV

C9.01UF,250 VAC

V

115 VAC

V

K1

B

GND 2

A

VV

V

P5-2

P5-1

P5-6

C17

.022UFC18

250VAC.022UF

PL2-

+

1

J1

2 VVL3

SHIELD

4T

TORCH SWITCH

START SIGNAL SIGNAL TO CNC

SIGNAL TO CNC VOLTAGE DIVIDER

(CONTROL BOARD)P/N-38109

PCB1

CO

NS

OL

ES

055

8003

356

&

4P1-12V

VV

VV

V

P2-3

P2-2

P6-1

P6-2

P1-11

SOL175mA

2 60V

1 ZD1

2

1 2

NO

T U

SE

D O

N

0558

0033

57

FS1

3 S3

VV

P6-

7

P6-

9

V V

P2-4

P2-3

2

5

S26

1

3

(SEE CHART)TB4

(-)

1 2 3

(+)

54 6

TB4-1

TB4-3TB4-2

TB4-5TB4-6

TB4-4 } FROM CNC

}

ARC ON}

1

2

3


6-20

6.6.2 400V Console Wiring Diagrams Part 1

PCB5 P1-3 VIO

PCB5 P1-2 BLUJ1-2 BLK

PCB1 P6-7 YEL

PCB1 P6-9 ORN

7 6 5 34 2 1

TB4

J1-1 GRY

*

FS S1-5 RED

PCB1 P1-11 RED1

RED

RED

SPLICE

2

T3-H1 RED

NO

T U

SE

D O

N C

ON

SO

LE

S05

5800

3356

&05

5800

3357

BLU PCB1 P6-2

2PCB1 P6-6 WHT

R1

3

1

S2 21

PCB1 P6-13 RED

PCB1 P6-12 BRN

PCB1 P5-6 BLK

4 5 6

PCB1 P6-1 BLU

PCB1 P2-4 ORN321

-

PCB1 P1-12 BLK

GRY PCB1 P2-3

S1

RED FS-2

*

T5-

X1

RE

D

X2

TB2 **

T5-

X2

RE

D

21SG

C14

T3-H2 RED C13

X1

S

G-1

RE

D

T5

*TB1-1 BLK

H1 H2

TB1-2 BLK*

*

H2 H1A

H2

S

G-2

RE

D

H1B

H2 H1C

IBR

-T

IBR

-SIB

R-R

** *

S1-

T3

S1-

T2

S1-

T1

L2

* **

PCB1 P5-5 RED+

PL2

2

1

PL1

YE

L P

CB

1 P

2-14

YE

L P

CB

1 P

2-11

P4 P3

CE MARKED UNITS* S1-T1A

ONLY

S1-T2*S1-T3*

BLIN

E FN1C

IBR-R BLK

A

IBR-S BLK

IBR-T BLK

LO

AD

B

C

P6

P5

P5-2P5-1

(SEE CHART)

PCB1

P2

P1

C18

C17GND 2

J1 SHIELD


6-21

400V Console Wiring Diagrams Part 2

INP

UT

PO

WE

R C

AB

LE

GND1

GRN

BRN

FN1-LINE C

BR

NB

LU

BL

K

BLKBLU

*SPLICE T2-H2 GRY

F1-1* BLK2

1M1

FN1-LINE B

FN1-LINE A

T2T3

T1

321

S1

PL1-2

T2-X121414

*VIOYEL

*RED T2-H1BLK M1-2 *

1 2

F1

IBR (T) BLK

12

11

109

8

7

6

5

12 S1-4

12 TB1-1 BLU

K1-B

K1-A

TB1-2

13

13

12

BLUBLU

BLU

PL1-1

T2-X1111

11

BLK 10

*VIOYEL

8 T4-2

1011

T2-X8FS-1

9 T2-X7

6 T2-X6

7 T4-1

5 T2-X5

6ORNIBR-G

IBR(+)*WHTRED 9

8

*WHT 7BRN

YEL

T2-X2

S1-2*BLU 4

ORN 5

*BLU 4

ORN*ORN

12 R1-1

R1-313

PCB4-411

PCB4-310

BRN

RED

RED (TP)

BLK (TP)

PCB1 P6-5

PCB1 P6-6

TB4-17

GRYR16-1

TB4-29

8

8

RED

BLKPL2-(-)

PL2-(+)

6 R1-25

YEL

ORN

WHTWHTWHT

DETAIL "A" (PCB1)

4

3

211 TS1-1

3 T2-X3

4 T2-X4

2 TS1-2

P1*1 ORNT2-X1VIO

SOL1-2

SOL1-1

S1-3* 3BRN

*BRN 3

VIO 2

GRY

GRY

WHT

P2 P61CLR (TP) S2-1J1-1

BLK (TP)

YEL

YEL

T2-X9

T2-X10

J1-2

* 3

* 4

S2-22

P5BLUBLU


6-22


LEFT SIDE VIEW

TB

4-3

GR

Y

R3

R4

*FN1-LOAD C BLK

PC

B1

P2-

8 B

RN

MOV 1F1-2 BLK

-

PC

B1

P1-

7 O

RN

C4

R9

C1(+) YEL

1

2 R7-1 BLU

3

4

ORN PCB1 P1-8

T4

R101 2

YEL ORN

2

ORN 1

YEL

C19

PC

B1

P2-

7 Y

EL

FN1-LOAD B BLK

FN1-LOAD A BLK

MOV 2

MOV 3

**

S

+T

G

R R2

IBR

PINK MALEP/N A-950904

FASTON TERMINAL

GR

Y

C3

C2E1

R2-

2 B

LK

PCB1 P1-2 VIOPCB1 P1-1 VIO

C4-4 BLU

BLK

T1-H2*1 R7

C102

TS1

1 2

Q1

-

+C1C1 RED

E2C16

C1

1PCB3

32 4

F2-

2 O

RN*T1-X3

P.A. BUS

J1SOL1

1 2

PC

B1

P2-

2 W

HT

PC

B1

P2-

3 G

RY

ZD1

L1-

H1

BL

K

*1

C6

C8

BLU

R6

21

21

-3

2

TB

4-4

BL

K

BL

KC

LR

L3

PCB1 P5-1 CLR(TP)

PCB1 P5-2 BLK(TP)

T1-X1

R51

2 2

C5

1C

7

2

+ 1

D1

BLU

PCB4-2 BLU

*T1-H1T1-H1* R15-1 RED

TB3

*

+C2 C

15-

T1-X3*

C4-2 YEL

T2-H3 BLU

P/N A-950906PINK FEMALE

FASTON TERMINAL

R2-1 RED

WH

T

WH

T

WHT

RE

D

RE

D

PCB1-P3

21 1543 3 4 52

R15-2 BLK

PCB1-P4

PCB4

(SHUNT)

VIEW E-E

L1-

H2

BL

K

4

6

56

1

213

C23

GND 5

R11

-1 B

LU

D1(

+)

BL

U

PC

B5

P1-

1 R

ED

VIEW B-B

WO

RK

1-

3

2

4

+

TB

4-6

VIO

TB

4-5

BL

UP

CB

4-1

RE

D

P1

PCB5

BL

K P

CB

1 P

6-10

RE

D P

CB

1 P

6-11

TP


6-23


PCB1 P2-13 BLUR11 2 FF 1

PILOT ARC

PCB5

E E

BPCB1 P2-12 BLU

*

TORCH H2TB2 RED

*

TORCH

SG-1 RED

T3-X1 T3

*

X1

H1

L1-H2 BLK X2

C12

C11D

TB1

GND 4

D

C1(-) BLK

**

H1

H2

D1-3*L1 X2

T1

X3X1 H2H1

D1-1

TB3 BLK

T3-

X2

BL

K

D1(

-) B

LK

PC

B5

P1-

6 B

LK

*C2(-) BLK

C2(+) RED

*

1R15

2 *Q1-C2E1

R11C4-4

R13

C T2 C

BL

U

P.A. BUS ORN

C1(+) RED

R22

1

K1

BL

UC21

L1A

T1

BL3

L2 T2

T3R11-2 YEL

TOP

X6

X4

BOTTOM

TOP

B

(SHUNT)

PCB4

TOP AND BOTTOM

VIEW C-C

SPLICE (M1-1) GRY

F1-1 RED **

H1

PCB1 P2-14 VIO

X11X12

*

PCB1 P1-3 BRNPCB1 P1-4 BRN

PCB1 P2-11 VIO

***

PCB1 P1-5 BLU

X5

*PCB1 P1-9 WHT

PCB1 P1-6 BLU

**

VIEW F-F

C12

C11

NOT USED

SPLICE IBR(R) BLU

WHT

*

ORN

H5H3H2 H4

T2

X1X2X3

GND 4 C9

VIEW D-D

T5-H2 BLKPCB1 P2-13 BLU

PCB1 P2-12 BLUT5-H1 BLK1

2

TB1

*

*

PCB1 P5-9 GRY

PCB4-2 BLU

PCB1 P2-4 ORNPCB1 P2-1 ORN**

BL

U

1

1

*PCB1 P5-3 YEL

PCB1 P5-4 YEL

X10X7 X8 X9

*PCB1 P1-10 WHT*

K1-T3 YEL

BL

U

R12 2

R11 2

R16


6-24

6.7 Remote Arc Starter (RAS-2) Schematic

REACTOR

STEP UP

C1, C2 2500 pF

SPARK GAP

CB

A

POWER SUPPLY (-) TORCH (-)

FILTER

TRANSFORMER

0.040

PILOT ARC IN PILOT ARC TO TORCH

VAC120

X1 X3

EMIFILTER

L1

PCB1

P1

FN1

T1

SG1

SECTION 7 Replacement Parts

7-1

7.1 General

Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on the unit nameplate.

7.2 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 or from: ESAB Cutting Systems GmbH Robert-Bosch-Strasse 20 P.O. Box 1128 D-61184 Karben Phone +011 49 60 39 400 Fax +011 49 60 39 40301 02 http://www.esab.de ESAB Welding and Cutting Products ATTN: Customer Service Department PO Box 100545 Ebenezer Road Florence, SC USA 29501-0545 Phone (843) 664-4405 (800) ESAB-123 (372-3123) ESAB Cutting Systems - Canada 6010 Tomken Road Mississauga, Ontario, Canada L5T 1X9 Phone (905) 670-0220 Fax (905) 670-4879 Be sure to indicate any special shipping instructions when ordering replacement parts. Refer to the Communications Guide located on the last page of this manual for a list of customer service phone numbers.


7-2

7.3 PCM-875A Power Console – 230V- (P/N 0558003356)

PCM-875APOWER FAULT

AIRTEST

TEST

OPERATE

CURRENTCONTROL

AIRPRESSURE

0

20

30

40

50

60

TORCH

WORK

1

2

3

4

5

6

7

89

10


7-3

Ref. Part Number Quantity Description Elect.

1 951754 1 Lamp, LED Yellow, 12V PL2

2 0558001176 1 POT, 10K, 30W R1

3 951526 1 Lamp, Neon, White PL1

4 21711 1 Gauge, 1.5 160 PSI WHT CDM STL

5 634518 1 Toggle Switch, 2 pos, 15A, 125V S2

6 Not Required when

RAS-2 is used 1 Reactor Assembly Reference Only

7 182W12 4 Rubber Foot

8 Not Required when

RAS-2 is used Spark Gap Assembly

9 0558003618 1 Wire Kit

10 673458 1 Contactor, 3 pole, 110VAC, 40A K1


7-4

PCM-875A Power Console – 230V- (P/N 0558003356)

230V CE 1 2 3

45

6 78

9 10 11 12


7-5


1 951182 1 Axial Fan, AC M1

2 17240310 2 Resistor, 10K, 25W R2,15

3 952233 1 Output Inductor L1

4 2091558 1 Label

5 Label

6 952026 1 Term block, 7 pos, 25A, 12-18AWG TB4

7 951202 1 Switch, Flow, .25 GPN, SPST FS

8 952597 Filter EMC, 250.440V 3ph FN1

9 950249 1 Valve, Solenoid, ¼ NPT, 165 PSI, 24VAC SOL1

10 Not used in

conjunction with RAS-2

Spark Gap

11 0558003618 Wire Kit

12 673458 Contactor, 3 pole, 110VAC, 40A


7-6

PCM-875A Power Console – 230V- (P/N 0558003356) Top View-and Right Side

123456

Arc

On

Sig

nal

Rel

ayC

losi

ng

Sta

rtS

igna

l

Rel

ayC

losi

ng

20:1

(+)

Vo

ltag

eD

ivid

er (-

)

Not

Use

d

7 6 5 4 3 2 1

7 8 9 10

11 12


7-7


1 951340 1 Plug Female, 14 pos, PCB1 P6


3 38214 1 PCB Control PCB1



6 38131 1 PCB Startup PCB5

7 31488 1 PCB Ay, Shunt Board PCB4

8 36586 1 XFMR Assy, Main T1

9 17300012 2 Resistor, 300W, 12 ohm R11,12

10 952232 1 Inductor, PFC (used on 230V unit only) L2

11 32914 1 XFMR Assy Control T2

12 950487 Terminal Block, 2 pos, 20A TB1


7-8

PCM-875A Power Console – 230V- (P/N 0558003356) Left Side

12 3 4

5 6 7 8 9 10 11 12 1314

15 16

230V CE Detail


7-9


1 36822 1 Hose, Assy, B/A-WX1/4NPT Rub

2 0558001177 2 PCB Assy, Mosfet/IGBT Driver Bd PCB2,3

3 952237 2 Capacitor, 1800uf, 400VDC, W/nut C1,2

4 90858003 .75FT Tubing, Plas, .25 od X .04 W BLK

5 950487 1 Terminal Block, 2 pos, 20A TB5

6 952235 1 Module, Input bridge/scr IBR

7 951205 2 IGBT 600V, 100A, Ser H Q1,2

8 17250010 1 Resistor, WW, Fixed, 50W, 10 ohm R10

9 17750010 1 Resistor, WW, 50W, 3%, 10 ohm R7

10 952255 1 Capacitor, 40 uf, 400VDC C4

11 950711 1 Thermal Switch, 194 deg. TS1

12 951940 2 Capacitor, 1uf, 630W VDC C15,16

13 17721020 4 Resistor, WWFAHT, 25W, 1%, 20 ohm Nl R3,4,5,6

14 952150 1 Bridge, 60ADC, 100NS, 600V D1

15 952208 1 Standoff, insulating TB3

16 952002 1 Core, Saturable L3


7-10

7.4 PCM-875A Power Console – 400V- (P/N 0558003357)

PCM-875APOWER FAULT

AIRTEST

TEST

OPERATE

CURRENTCONTROL

AIRPRESSURE

0

20

30

40

50

60

TORCH

WORK

1

2

3

4

5

6

7

89

10


7-11


1 951754 1 Lamp, LED Yellow, 12V PL2

2 0558001176 1 POT, 10K, 30W R1

3 951526 1 Lamp, Neon, White PL1

4 21711 1 Gauge, 1.5 160 PSI WHT CDM STL

5 634518 1 Toggle Switch, 2 pos, 15A, 125V S2

6 Not Required when

RAS-2 is used 1 Reactor Assembly Reference Only

7 182W12 4 Rubber Foot

8 Not Required when

RAS-2 is used Spark Gap Assembly

9 0558003618 1 Wire Kit

See next illustration


7-12


400V CE 1 2 3

45

6

7 8 910


7-13


1 951182 1 Axial Fan, AC M1

2 17240310 2 Resistor, 10K, 25W R2,15

3 952233 1 Output Inductor L1

4 952026 1 Term block, 7 pos, 25A, 12-18AWG TB4

5 951202 1 Switch, Flow, .25 GPN, SPST FS

6 952253 Filter, EMC, 400V FN1

7 950249 1 Valve, Solenoid, ¼ NPT, 165 PSI, 24VAC SOL1

8 Not used in

conjunction with RAS-2

Spark Gap

9 0558003618 Wire Kit

10 0558001193 Wire Kit, 400V CE L2


7-14


123456

Arc

On

Sig

nal

Rel

ayC

losi

ng

Sta

rtS

ign

al

Rel

ayC

losi

ng

20:1

(+)

Vo

ltag

eD

ivid

er (

-)

No

t U

sed

7 6 5 4 3 2 1

7 8 9 10

11 12


7-15




3 38214 1 PCB Control PCB1



6 38131 1 PCB Startup PCB5

7 31488 1 PCB Ay, Shunt Board PCB4

8 36586 1 XFMR Assy, Main T1

9 673458 1 Contactor, 3 pole, 110VAC, 40A K1

10 17300012 2 Resistor, 300W, 12 ohm R11,12

11 32914 1 XFMR Assy Control T2

12 950487 Terminal Block, 2 pos, 20A TB1


7-16


12 3 4

5 6 7 8 910 11 12 13 14 16

400V CE

15


7-17


1 36822 1 Hose, Assy, B/A-WX1/4NPT Rub

2 0558001178 1 PCB Assy, IGBT Driver Bd PCB2

3 952237 2 Capacitor, 1800uf, 400VDC, W/nut C1,2

4 90858003 .75FT Tubing, Plas, .25 od X .04 W BLK

5 950487 1 Terminal Block, 2 pos, 20A TB5

6 952235 1 Module, Input bridge/scr IBR

7 17750010 1 Resistor, WW, 50W, 3%, 10 ohm R7

8 Not used with RAS-2 1 Spark Gap SG

9 951800 1 Module Dual IGBT 150V 1200A Q1

10 952255 1 Capacitor, 40 uf, 400VDC C4

11 950711 1 Thermal Switch, 194 deg. TS1

12 951964 1 Capacitor, 2uf, 800VDC C16

13 17721020 4 Resistor, WWFAHT, 25W, 1%, 20 ohm Nl R3,4,5,6

14 952150 1 Bridge, 60ADC, 100NS, 600V D1

15 952208 1 Standoff, insulating TB3

16 952002 1 Core, Saturable L3


7-18

7.5 Remote Arc Starter (RAS-2) (P/N 0558003670)

A

A

B

B

View B-BView A-A

1

2

3

4

4


7-19


1 674969 1 PC Board Filter PCB1

2 634090 1 Adapt ¼ NPTM C/A W*F Cable

3 0558003679 1 Reactor Assembly H.F.

4 Reference Screw, PHTF #10-32 X .38 inch


7-20

Remote Arc Starter (RAS-2) (P/N 0558003670)

1

2

3

4

5

6

7

5REF. 8

9 1011

12

12


7-21


37410 Cable Assembly, Arc Starter, 15,2m 1

37411 Cable Assembly, Arc Starter, 30,4m

0558003692 Hose Air/Oxy ¼ NPTF RAS2, 15,4m 2

0558003693 Hose Air/Oxy ¼ NPTF RAS2, 30,4m

0558003686 Cable, Pilot Arc, RAS2, 15,2m 3

0558003687 Cable, Pilot Arc, RAS2, 30,4m

37341 Cable, Power RAS, 15,2m 4

37342 Cable, Power RAS, 30,4m

5 0558002818 Spark Gap Electrode Holder Assembly SG1

6 0558003675 2 Grounding Plate

7 0558003672 2 Cover, Torch Connect, RAS2/PT20AMX

8 0558003671 1 Cover, Box Side

9 950853 2 Fitting, 1/4 NPT to 3/8 id Hose

10 952860 2 Clamp, 1-ear w/insert 12.8 GER

11 4600030 30mil Nomex

12 Reference Screw, PHTF #10-32 X .38 inch


7-22

7.6 PT-20AMX Plasmarc Cutting Torch

1

4

6

7

8

9

10

11

12

13

14

16

2

3

5

17

18

1

15


7-23

PT-20 AMX Plasma Torch with Coaxial Pilot Arc Cable

With 4 ft. torch leads, without handle rack P/N 0558002632



Ref. Description .................................................................................................... Part Number

1 Torch Lead Assembly – 4 ft. ........................................................................ 0558002638

Torch Lead Assembly – 17 ft. ...................................................................... 0558002639

Torch Lead Assembly – 25 ft. ...................................................................... 0558003383

4 Lock Ring....................................................................................................... 57N70

5 Rubber Boot .................................................................................................. 0558001157

6 Wrap with electrical tape as shown ..................................................................... Reference

7 H.F. Connector .............................................................................................. 17974

8 Set screw 6-32 X 3/16 ............................................................................................ Reference

9 Insulate with vinyl tubing and secure with electrical tape ................................ Reference

10 Handle and sleeve without rack .................................................................. 22329

11 Handle ..................................................................................................................... Reference

12 Basic Torch Body Assembly ....................................................................... 21359

13 O-ring supplied with torch body ................................................................. 5W92

14 O-ring supplied with torch body ................................................................. 488157

15 Shield Shroud – 25 ft. ................................................................................... 72020003

16 Lubricant........................................................................................................ 17672


7-24

PT-20 AMX Front End and Spare Parts Kit

1

2

3

4

5

8

6

7

9


7-25

Ref. Description Part

Number

1 Wrench Seat/Baffle 21375

2 Baffle Tube 21374

3 Electrode 50Hz 0558001617

4 Electrode Insulator 21373

5 Electrode Holder Assembly 21332

6 Heat Shield (70 and 100 Amp – Blue) 21326

Nozzle (70 Amp) 21329 7

Nozzle (50 Amp) 21330

8 O-Ring 488157

9 PT-20AMX Spare Parts Kit 0558002319

Contents Description Quantity

Heat Shield (70/100 A)* 21326 3

Cutting Nozzle (50 A) 21330 5

Cutting Nozzle (70 A) 23129 5

Electrode 50Hz 0558001617 5

Electrode Insulator 21373 1

Electrode Holder Assembly 21332 1

Baffle Tube 21374 1

Pilot Arc Adaptor 19497 1

O-ring 488157 5

Lubricant (1 oz.) 17672 1

Seat/Baffle Wrench 21375 1

1/16: Hex-Key Wrench 93750006 1

NOTICE

The description of the heat shield (P/N 21326) listed above indicates a range of 70 to 100 amperes. The PCM-875A is capable of a maximum of 60 amperes (60% duty cycle). Testing has proven satisfactory results when using this heat shield at 60 amps and lower.


7-26


See back of Title Page for revision list.

Customer // Technical Support

(843) 664-4405 (800) ESAB-123 (372-2123)

ESAB Welding and Cutting Products

PO BOX 100545 Ebenezer Road Florence, SC 29501-0545

http://www.esab.com

ESAB Cutting Systems – Canada 6010 Tomken Road

Mississauga, Ontario Canada L5T 1X9 Phone: (905) 670-0220

Fax: (905) 670-4879

ESAB Cutting Systems GMBH Robert-Bosch-Strasse 20

Postfach 1128 D-61184 Karben 1

Phone 011-49-6039-400 Fax 011-49-6039-403-02

http://www.esab.de

Printed in U.S.A

Documents

PCM-875A Plasmarc Mechanized Cutting System - esabna.com equipment/cutting packages...F-15-753 November, 2002 Installation, Operation and Maintenance Manual for the PCM-875A Plasmarc