ESAB PCM-1125 Plasma Arc Cutting Package Instruction manual

F-15-482-B

February, 2002

PCM-1125 PLASMA ARC
CUTTING PACKAGE

This manual provides installation and operation instructions for the following PCM-1125 cutting packages starting with
Serial No. PHJ205001 :

P/N 37496 - 208/230 V, 1 & 3-Phase, 50/60 Hz
P/N 37498 - 460 V, 3-Phase, 50/60 Hz
P/N 37500 - 575 V, 3-Phase, 60 Hz
P/N 0558002834 - 400 V, 3-Phase, 50/60 Hz

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

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

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompanying
labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions pro­vided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not
be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should
such repair or replacement become necessary, the manufacturer recommends that a telephone or written request
for service advice be made to the Authorized Distributor from whom purchased.

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

TABLE OF CONTENTS

SECTION TITLE PAGE

PARAGRAPH

SECTION 1 DESCRIPTION ................................................................................................. 7

1.1 General ............................................................................................................. 7

1.2 Scope ................................................................................................................ 7

1.3 Packages Available ........................................................................................... 7

1.4 Specifications .................................................................................................... 8

SECTION 2 INSTALLATION ................................................................................................ 10

2.1 General ............................................................................................................. 10

2.2 Equipment Required ......................................................................................... 10

2.3 Location ............................................................................................................ 10

2.4 Inspection .......................................................................................................... 10

2.5 Primary Electrical Input Connections ................................................................. 10

2.6 Secondary Output Connections ......................................................................... 11

2.7 Connecting PCM1125 for 200(208)Vac Input .................................................... 13

2.8 Mechanized Cutting Installation with the PT-20AM Torch ................................. 14

SECTION 3 OPERATION ..................................................................................................... 16

3.1 Operation .......................................................................................................... 16

3.2 PCM-1125 Controls........................................................................................... 16

3.3 Cutting with the PT-27 ....................................................................................... 17

3.4 Common Cutting Problems ............................................................................... 18

SECTION 4 MAINTENANCE ................................................................................................ 19

4.1 General ............................................................................................................. 19

4.2 Inspection and Cleaning .................................................................................... 19

4.3 PT-27 Torch Consumable Parts ........................................................................ 19

4.4 Flow Switch ....................................................................................................... 20

4.5 1GBT Handling and Replacement ..................................................................... 20

SECTION 5 TROUBLESHOOTING ..................................................................................... 21

5.1 Troubleshooting ................................................................................................ 21

5.2 Troubleshooting Guide ...................................................................................... 21

5.3 Reference Voltage Checks ............................................................................... 22

5.4 Sequence of Operation ..................................................................................... 26

SECTION 6 REPLACEMENT PARTS .................................................................................. 37

6.1 General ............................................................................................................. 37

6.2 Ordering ............................................................................................................ 37

6.3 Literature Revisions .......................................................................................... 37

6.4 Parts Diagrams & Lists...................................................................................... 38

2

SAFETY PRECAUTIONS

WARNING: These Safety Precautions are for

your protection. They summarize precaution­ary information from the references listed in

Additional Safety Information section. Before
performing any installation or operating procedures, be
sure to read and follow the safety precautions listed below
as well as all other manuals, material safety data sheets,
labels, etc. Failure to observe Safety Precautions can result
in injury or death.

PROTECT YOURSELF AND OTHERS
Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits

ultraviolet (UV) and other radiation and
can injure skin and eyes. Hot metal can cause burns.
Training in the proper use of the processes and equip­ment is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any work

area, even if welding helmets, face shields, and goggles
are also required.

2. Use a face shield fitted with the correct filter and cover

plates to protect your eyes, face, neck, and ears from
sparks and rays of the arc when operating or observing
operations. Warn bystanders not to watch the arc and
not to expose themselves to the rays of the electric-arc
or hot metal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeve

shirt, cuffless trousers, high-topped shoes, and a weld­ing helmet or cap for hair protection, to protect against
arc rays and hot sparks or hot metal. A flameproof apron
may also be desirable as protection against radiated
heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cuffs, or pockets. Sleeves and collars should be
kept buttoned, and open pockets eliminated from the
front of clothing

5. Protect other personnel from arc rays and hot sparks

with a suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag or

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

FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot slag
or sparks can also cause fires and ex­plosions. Therefore:

1. Remove all combustible materials well away from the

work area or cover the materials with a protective non­flammable covering. Combustible materials include wood,
cloth, sawdust, liquid and gas fuels, solvents, paints and
coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or

crevices in floors or wall openings and cause a hidden
smoldering fire or fires on the floor below. Make certain
that such openings are protected from hot sparks and
metal.“

3. Do not weld, cut or perform other hot work until the

workpiece has been completely cleaned so that there
are no substances on the workpiece which might pro­duce flammable or toxic vapors. Do not do hot work on
closed containers. They may explode.

4. Have fire extinguishing equipment handy for instant use,

such as a garden hose, water pail, sand bucket, or
portable fire extinguisher. Be sure you are trained in its
use.

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

6. After completing operations, inspect the work area to
make certain there are no hot sparks or hot metal which
could cause a later fire. Use fire watchers when neces­sary.

7. For additional information, refer to NFPA Standard 51B,
"Fire Prevention in Use of Cutting and Welding Pro-

--

cesses", available from the National Fire Protection Asso­ciation, Batterymarch Park, Quincy, MA 02269.

ELECTRICAL SHOCK -- Contact with live
electrical parts and ground can cause
severe injury or death. DO NOT use AC
welding current in damp areas, if move­ment is confined, or if there is danger of
falling.

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

2. Connect the workpiece to a good electrical ground.

3. Connect the work cable to the workpiece. A poor or
missing connection can expose you or others to a fatal
shock.

4. Use well-maintained equipment. Replace worn or dam­aged cables.

5. Keep everything dry, including clothing, work area, cables,
torch/electrode holder, and power source.

6. Make sure that all parts of your body are insulated from
work and from ground.

7. Do not stand directly on metal or the earth while working
in tight quarters or a damp area; stand on dry boards or
an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

9. Turn off the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)
for specific grounding recommendations. Do not mis­take the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS —
May be dangerous. Electric current flow­ing through any conductor causes lo­calized Electric and Magnetic Fields
(EMF). Welding and cutting current cre­ates EMF around welding cables and
welding machines. Therefore:

1. Welders having pacemakers should consult their physi­cian before welding. EMF may interfere with some pace­makers.

2. Exposure to EMF may have other health effects which are
unknown.

3. Welders should use the following procedures to minimize
exposure to EMF:
A. Route the electrode and work cables together. Secure

them with tape when possible.
B. Never coil the torch or work cable around your body.
C. Do not place your body between the torch and work

cables. Route cables on the same side of your body.
D. Connect the work cable to the workpiece as close as

possible to the area being welded.
E. Keep welding power source and cables as far away

from your body as possible.

3

10/98

FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shield­ing gases can cause asphyxiation.
Therefore:

1. Always provide adequate ventilation in the work area by
natural or mechanical means. Do not weld, cut, or gouge
on materials such as galvanized steel, stainless steel,
copper, zinc, lead, beryllium, or cadmium unless posi­tive mechanical ventilation is provided. Do not breathe
fumes from these materials.

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

3. If you develop momentary eye, nose, or throat irritation
while operating, this is an indication that ventilation is not
adequate. Stop work and take necessary steps to im­prove ventilation in the work area. Do not continue to
operate if physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specific ventilation recommendations.

5. WARNING: This product, when used for welding or

cutting, produces fumes or gases which
contain chemicals known to the State of
California to cause birth defects and, in
some cases, cancer. (California Health &

Safety Code

§25249.5 et seq.)

EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:\

1. Always have qualified personnel perform the installation,
troubleshooting, and maintenance work. Do not perform
any electrical work unless you are qualified to perform
such work.

2. Before performing any maintenance work inside a power
source, disconnect the power source from the incoming
electrical power.

3. Maintain cables, grounding wire, connections, power cord,
and power supply in safe working order. Do not operate
any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep equip­ment away from heat sources such as furnaces, wet
conditions such as water puddles, oil or grease, corrosive
atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position and
in good repair.

6. Use equipment only for its intended purpose. Do not
modify it in any manner.

ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for electric
arc welding and cutting equipment, ask your
supplier for a copy of "Precautions and Safe
Practices for Arc Welding, Cutting and Goug­ing", Form 52-529.

CYLINDER HANDLING -- Cylinders, if
mishandled, can rupture and violently
release gas. Sudden rupture of cylin­der, valve, or relief device can injure or
kill. Therefore:

1. Use the proper gas for the process and use the proper
pressure reducing regulator designed to operate from
the compressed gas cylinder. Do not use adaptors.
Maintain hoses and fittings in good condition. Follow
manufacturer's operating instructions for mounting regu­lator to a compressed gas cylinder.

2. Always secure cylinders in an upright position by chain
or strap to suitable hand trucks, undercarriages, benches,
walls, post, or racks. Never secure cylinders to work
tables or fixtures where they may become part of an
electrical circuit.

3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not con­nected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases in
Cylinders", which is available from Compressed Gas
Association, 1235 Jefferson Davis Highway, Arlington,
VA 22202.

The following publications, which are available from the
American Welding Society, 550 N.W. LeJuene Road, Miami,
FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon Arc
Gouging and Cutting"

5. AWS C5.5 - "Recommended Practices for Gas Tungsten
Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal Arc
Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.

8. ANSI/AWS F4.1, "Recommended Safe Practices for Weld­ing and Cutting of Containers That Have Held Hazardous
Substances."

MEANING OF SYMBOLS - As used throughout
this manual: Means Attention! Be Alert! Your
safety is involved.

Means immediate hazards which, if
not avoided, will result in immediate,
serious personal injury or loss of life.

Means potential hazards which could
result in personal injury or loss of life.

Means hazards which could result in
minor personal injury.

4

SP98-10

PRÉCAUTIONS DE SÉCURITÉ

AVERTISSEMENT: Ces règles de sécurité ont pour objet
d’ assurer votre protection. Veillez à lire et à observer les
précautions énoncées ci-dessous avant de monter l’
équipement ou de commercer à l’utiliser. Tout défaut
d’observation de ces précautions risque d’entraîner des
blessures graves ou mortelles.

1. PROTECTION INDIVIDUELLE-- Les brûlures de la
peau et des yeux dues au rayonnement de l’arc
électrique ou du métal incandescent, lors du soudage
au plasma ou à l’électrode ou lors du gougeage à
l’arc, peuvent s’avérer plus graves que celles
résultant d’une exposition prolongée au soleil. Aussi
convient-il d’observer les précautions suivantes:

a. Portez un écran facial adéquat muni des plaques

protectrices et des verres filtrants appropriés afin de
vous protéger les yeux, le visage, le cou et les oreilles
des étincelles et du rayonnement de l’arc électrique
lorsque vous effectuez des soudures ou des coupes
ou lorsque vous en observez l’exécution.

AVERTISSEZ les personnes se trouvant à proximité

de façon à ce qu’elles ne regardent pas l’arc et à ce
qu’elles ne s’exposent pas à son rayonnement, ni à
celui du métal incandescent.

b. Portez des gants ignifugés à crispins, une tunique

épaisse à manches longues, des pantalons sans
rebord, des chaussures à embout d’acier et un
casque de soudage ou une calotte de protection, afin
d’éviter d’exposer la peau au rayonnement de l’arc
électrique ou du métal incandescent. ll est également
souhaitable d’utiliser un tablier ininflammable de
façon à se protéger des étincelles et du rayonnement
thermique.

c. Les étincelles ou les projections de métal incandes-

cent risquent de se loger dans des manches
retroussées, des bords relevés de pantalons ou dans
des poches. Aussi convient-il de garder boutonnés le
col et les manches et de porter des vêtements sans
poches à l’avant.

d. Protégez des étincelles et du rayonnement de l’arc

électrique les autres personnes travaillant à proximité
à l’aide d’un écran ininflammable adéquat.

e. Ne jamais omettre de porter des lunettes de sécurité

lorsque vous vous trouvez dans un secteur où l’on
effectue des opérations de soudage ou de coupage à
l’arc. Utilisez des lunettes de sécurité à écrans ou
verres latéraux pour piquer ou meûler le laitier. Les
piquetures incandescentes de laitier peuvent être
projetées à des distances considérables. Les
personnes se trouvant à proximité doivent également
porter des lunettes de protection.

f. Le gougeage à l’arc et le soudage à l’arc au plasma

produisent un niveau de bruit extrêmement élevé (de
100 à 114 dB) et exigent par conséquent l’emploi de
dispositifs appropriés de protection auditive.

2. PRÉVENTION DES INCENDES-- Les projections de
laitier incandescent ou d’étincelles peuvent
provoquer de graves incendies au contact de
matériaux combustibles solides, liquides ou gazeux.
Aussi faut-il observer les précautions suivantes:

a. Éloigner suffisamment tous les matériaux combus-

tibles du secteur où l’on exécute des soudures ou des
coupes à l’arc, à moins de les recouvrir complètement
d’une bâche non-inflammable. Ce type de matériaux
comprend notamment le bois, les vêtements, la sciure,
l’essence, le kérosène, les peintures, les solvants, le
gaz naturel, l’acétylène, le propane et autres sub­stances combustibles semblables.

b. Les étincelles ou les projections de métal incandes-

cent peuvent tomber dans des fissures du plancher ou
dans des ouvertures des murs et y déclencher une
ignition lente cachée. Veiller à protéger ces ouvertures
des étincelles et des projections de métal.

c. N’exécutez pas de soudures, de coupes, d’opérations

de gougeage ou autres travaux à chaud à la surface
de barils, bidons, réservoirs ou autres contenants
usagés, avant de les avoir nettoyés de toute trace de
substance susceptible de produire des vapeurs
inflammables ou toxiques.

d. En vue d’assurer la prévention des incendies, il

convient de disposer d’un matériel d’extinction prêt à
servir immédiatement, tel qu’un tuyau d’arrosage, un
seau à eau, un seau de sable ou un extincteur portatif.

e. Une fois le travail à l’arc terminé, inspectez le secteur

de façon à vous assurer qu’aucune étincelle ou projec­tion de métal incandescent ne risque de provoquer
ultérieurement un feu.

3. CHOC ÉLECTRIQUE-- Le gougeage à l’arc et à l’arc
au plasma exige l’emploi de tensions à vide
relativement importantes; or, celles-ci risquent de
causer des dommages corporels graves et même
mortels en cas d’utilisation inadéquate. La gravité du
choc électrique reçu dépend du chemin suivi par le
courant à travers le corps humain et de son intensité.

a. Ne laissez jamais de surfaces métalliques sous ten-

sion venir au contact direct de la peau ou de
vêtements humides. Veillez à porter des gants bien
secs.

b. Si vous devez effectuer un travail sur une surface

métallique ou dans un secteur humide, veillez à assu­rer votre isolation corporelle en portant des gants secs
et des chaussures à semelles de caoutchouc et en
vous tenant sur une planche ou une plate-forme
sèche.

c. Mettez toujours à la terre le poste de soudage/coupage

en le reliant par un câble à une bonne prise de terre.

d. N’utilisez jamais de câbles usés ou endommagés. Ne

surchargez jamais le câble. Utilisez toujours un
équipement correctement entretenu.

e. Mettez l’équipement hors tension lorsqu’il n’est pas en

service. une mise à la masse accidentelle peut en effet
provoquer une surchauffe de l’équipement et un dan­ger d’incendie. Ne pas enrouler ou passer le câble
autour d’une partie quelconque du corps.

f. Vérifiez si le câble de masse est bien relié à la pièce en

un point aussi proche que possible de la zone de
travail. Le branchement des câbles de masse à
l’ossature du bâtiment ou en un point éloigné de la
zone de travail augmente en effet le risque de pas­sage d’un courant de sortie par des chaînes delevage

5

9/97

des câbles de grue ou divers chemins électriques.

g. Empêchez l’apparition de toute humidité, notamment

sur vos vêtements, à la surface de l’emplacement de
travail, des câbles, du porte-électrode et du poste de
soudage/coupage. Réparez immédiatement toute
fuite d’eau.

4. VENTILATION-- La respiration prolongée des fumées
résultant des opérations de soudage/coupage, à
l’intérieur, d’un local clos, peut provoquer des mal­aises et des dommages corporels. Aussi convient-il
d’observer les précautions suivantes:

a. Assurez en permanence une aération adéquate de

l’emplacement de travail en maintenant une ventila­tion naturelle ou à l’aide de moyens mécaniques.
N’effectuez jamais de travaux de soudage ou de
coupage sur des matériaux de zinc, de plomb, de
beryllium ou de cadmium en l’absence de moyens
mécaniques de ventilation capables d’empêcher
l’inhalation des fumées dégagées par ces matériaux.

b. N’effectuez jamais de travaux de soudage ou de

coupage à proximité de vapeurs d’hydrocarbure
chloré résultant d’opérations voisines de dégraissage
ou de pulvérisation. La chaleur dégagée ou le
rayonnement de l’arc peut déclencher la formation de
phosgène -- gaz particulièrement toxique -- et d’autres
gaz irritants, à partir des vapeurs de solvant.

c. Une irritation momentanée des yeux, du nez ou de la

gorge constatée au cours de l’utilisation de
l’équipement dénote un défaut de ventilation. Arrêtez­vous de travailler afin de prendre les mesures néces­saires à l’amélioration de la ventilation. Ne poursuivez
pas l’opération entreprise si le malaise persiste.

d. Certaines commandes comportent des canalisations

où circule de l’hydrogène. L’armoire de commande est
munie d’un ventilateur destiné à empêcher la forma­tion de poches d’hydrogène, lesquelles présentent un
danger d’explosion; ce ventilateur ne fonctionne que
si l’interrupteur correspondant du panneau avant se
trouve placé en position ON (Marche). Veillez à
manœuvrer cette commande en vérifiant si le
couvercle est bien en place, de façon à assurer
l’efficacité de la ventilation ainsi réalisée. Ne jamais
débrancher le ventilateur.

e. Les fumées produites par l’opération de soudage ou

de coupage peuvent s’avérer toxiques. Aussi est-il
nécessaire de disposer en permanence d’un dispositif
adéquat de ventilation de type aspirant, afin d’élimi­ner du voisinage de l’opérateur tout dégagement de
fumée visible.

f. Consultez les recommandations particulières en

matière de ventilation indiquées à l’alinéa 6 de la
norme Z49.1 de l’AWS.

5. ENTRETIEN DE L’ÉQUIPEMENT-- Un équipement
entretenu de façon défectueuse ou inadéquate risque
non seulement de réaliser un travail de mauvaise
qualité mais, chose plus grave encore, d’entraîner des

dommages corporels graves, voire mortels en
déclenchant des incendies ou des chocs électriques.
Observez par conséquent les précautions suivantes:

a. Efforcez-vous de toujours confier à un personnel qua-

lifié l’installation, le dépannage et l’entretien du poste
de soudage et de coupage. N’effectuez aucune
réparation électrique sur l’équipement à moins d’être
qua-lifié à cet effet.

b. Ne procédez jamais à une tâche d’entretien

quelconque à l’intérieur du poste de soudage/
coupage, avant d’avoir débranché l’alimentation
électrique.

c. Maintenez en bon état de fonctionnement les câbles,

le câble de masse, les branchements, le cordon
d’alimentation et le poste de soudage/coupage.
N’utilisez jamais le poste ou l’équipement s’il présente
une défectuosité quelconque.

d. Prenez soin du poste de soudage et de coupage et des

équipements accessoires. Gardez-les à l’écart des
sources de charleur, notamment des fours, de
l’humidité, des flaques d’eau maintenez-les à l’abri des
traces d’huile ou de graisse, des atmosphères corro­sives et des intempéries.

e. Laissez en place tous les dispositifs de sécurité et tous

les panneaux de l’armoire de commande en veillant à
les garder en bon état.

f. Utilisez le poste de soudage/coupage conformément à

son usage prévu et n’effectuez aucune modification.

6. INFORMATIONS COMPLÉMENTAIRES RELATIVES
À LA SÉCURITÉ--

Pour obtenir des informations complémentaires sur les

règles de sécurité à observer pour le montage et
l’utilisation d’équipements de soudage et de coupage
électriques et sur les méthodes de travail
recommandées, demandez un exemplaire du livret N°
52529 “Precautions and Safe Practices for Arc Weld­ing, Cutting and Gouging” publié par ESAB. Nous
conseillons également de consulter les publications
sui-vantes, tenues à votre disposition par l’American
Welding Society, 550 N.W. LeJuene Road, Miami, FL
32126:

a. “Safety in Welding and Cutting” AWS Z49.1
b. “Recommended Safe Practices for Gas-Shielded Arc

Welding “AWS A6. 1.

c. “Safe Practices for Welding and Cutting Containers

That Have Held Combustibles” AWS-A6.0.

d. “Recommended Safe Practices for Plasma Arc Cutting”

AWS-A6. 3.

e. “Recommended Safe Practices for Plasma Arc Weld-

ing” AWS-C5. 1.

f. “Recommended Safe Practices for Air Carbon Arc

Gouging and Cutting” AWS-C5. 3.

g. “Code For Safety in Welding and Cutting”

CSA-Standard W117. 2.

9/97

6

SECTION 1 DESCRIPTION

1.1 GENERAL

The PCM-1125 is a compact, completely self-contained
plasma cutting system. As shipped, the system is fully
assembled and ready to cut after being connected to
input power and a source of compressed air (90-150 psi).
The PCM-1125 package uses the heavy-duty PT-27 torch
to deliver cutting power for severing materials up to 1-1/4
inch thick. Refer to the following paragraphs for descrip­tions of the PCM-1125 packages available as well as
performance specifications.

Use only ESAB Plasmarc torches that are designed
for use with this console. Use of torches not de­signed for use with this console could create an
ELECTRIC SHOCK HAZARD. Do NOT use or modify
the PT-23, PCT-80 or any other torch for use on this
console.

1.2 SCOPE

The purpose of this manual is to provide the operator with
all the information required to install and operate the

PCM-1125 plasma arc cutting package. Technical refer­ence material is also provided to assist in troubleshoot­ing the cutting package.

1.3 PACKAGES AVAILABLE

PCM-1125 listed on the front cover includes the following
components:

PT-27 Torch, 75° head, 25-ft. ..................P/N 21661

PT-27 Spare Parts Kit (see Table 1-1) .... P/N 21623

PCM-1125 Console/Power Source .......... See below

Depending on the choice of input power, each package
includes the following appropriate PCM-1125 Console/
Power Source:

208/230 V, 50/60 Hz, 1 or 3-phase ..........P/N 37495

460 V, 50/60 Hz, 3-phase ........................P/N 37497

575 V, 60 Hz, 3-phase ............................. P/N 37499

Table 1-1. PT-27 Spare Parts Kit, P/N 21623, Contents

Description Part Number Quantity

50 - 70 A Nozzle
Electrode
Swirl Baffle
Heat Shield
Standoff Guide
Valve Pin

33369
33366
33367
21616
21420
21619

4
3

1

2

1
1

7

SECTION 1 DESCRIPTION

1.4 SPECIFICATIONS

PCM-1125

Specifications for Literature

Rated Inputs Rated Outputs

Output Open

Power *Duty Amps @ Circuit

Phases Volts Amps Factor Cycle 120V DC” Voltage Efficiency

208 64 73% #70% 70 280V DC 86%

One 55 #100% 60 280V DC

230 58 73% #90% 70 270V DC 86%

55 #100% 66 270V DC

208 28 93% 100% 70 285V DC 89%

Three 230 25 93% 100% 70 275V DC 89%

460 14 88% 100% 70 275V DC 89%

575 11 87% 100% 70 260V DC 89%

# Duty cycle at 70A output is limited by the factory supplied 6 AWG, 4 conductor input cable having a current rating
of 55A. To obtain 100% duty capability at 70A output, change the input cable to 4 AWG, 3 conductor (or 4 AWG,
2 conductor with ground).

*Duty cycle is based on a 10-minute period; therefore, a 70% duty cycle means the power source may operate for 7
minutes with a cool down period of 3 minutes. 100% duty cycle means the power source may operate continuously.

Current Capacity

Air Requirements

Dimensions

Length
Height

Width

w/ opt. torch storage

PT-27 80 A DCSP

PT-27

320 cfh @ 65 - 75 psig

(150 l/min @ 4.5 - 5.2 bars)

20.3" (516 mm)

16.1" (409 mm)

w/handles

w/o opt. storage

18.3" (465 mm)

10.1" (275 mm)

13.1" (333 mm)

Weight of PCM-1125 System

Shipping Weight

8

SECTION 1 DESCRIPTION

Table 1-3. PT-27 Torch Specifications

7.3" (185 mm)

Current Capacity (100% duty)
Length of Service Lines
Weight
25 ft
50 ft

80 A DCSP

25 ft or 50 ft

5.2 lbs (2.4 kg)

9.6 lbs (4.4 kg)

PT-27, PCM-1125, 70A, air, Carbon Steel

90
80
70
60
50
40
30
20
10

0

Cutting Speed (in/min)

3" (76 mm)

75°

1"

(25.4 mm)

90 in/min max speed of s ide beam

1" (25.4 mm)

Figure 1-1. PT-27 Dimensions

60 A
Nozzle

00.511.5

Plate Thickness (in)

Figure 1-2. PT-27/PCM-1125 Cutting Performance

1.5 OPTIONAL ACCESSORIES

1. Torch Wrap/Spare Parts Kit Holder, P/N 33952GY.

Units have 4 mounting holes on left side for mounting
this accessory holder.

2. Wheel Cart, P/N 34324. This 5 7/8" high cart has
front swivel casters and rear casters to make it
easier to roll the PCM-1125 around the job site.

9

SECTION 2 INSTALLATION

2.1 GENERAL

Proper installation is important for satisfactory and trouble­free operation of the PCM-1125 cutting package. It is
suggested that each step in this section be studied
carefully and followed closely.

2.2 EQUIPMENT REQUIRED

A source of clean, dry air that supplies 320 cfh at 65-75
psig is required for the cutting operation. The air supply
should not exceed 150 psig (the maximum inlet pressure
rating of the air filter-regulator supplied with the pack­age).

2.3 LOCATION

Adequate ventilation is necessary to provide proper
cooling of the PCM-1125. The amount of dirt, dust, and
excessive heat to which the equipment is exposed,
should be minimized. There should be at least one foot
of clearance between the PCM-1125 power source and
wall or any other obstruction to allow freedom of air
movement through the power source.

Installing or placing any type of filtering device will
restrict the volume of intake air, thereby subjecting
the power source internal components to overheat­ing. The warranty is void if any type of filter device
is used.

2.4 INSPECTION

2.5 PRIMARY ELECTRICAL INPUT

CONNECTIONS (FIGURE 2-1)

ELECTRIC SHOCK CAN KILL! Precautionary mea­sures should be taken to provide maximum protec­tion against electrical shock. Be sure that all power
is off by opening the line (wall) disconnect switch
and by unplugging the power cord to the unit when
connections are made inside of the power source.

Be sure that the power source is properly configured
for your input power supply. DO NOT connect a
power source configured for 208/230 V to a 460 V
input power supply. Damage to the machine may
occur.

NOTE: If using 208 V input power, the PCM-1125 must

be reconnected for 208 V use as directed in
Section 2.7 and Fig. 2-2.

The PCM-1125 consoles are equipped with a 10-ft,
4-conductor input power cable for 3-phase connection.
If single-phase connection is desired, tape back the red
wire on the input power cable.

NOTE: The 208/230 V models are equipped with a plug

for single-phase connection only. The plug is
mounted to a 4-conductor cable. If 3-phase
connection is desired, remove and discard the
plug and proceed as described above.

A. Remove the shipping container and all packing

material and inspect for evidence of concealed
damage which may not have been apparent upon
receipt of the PCM-1125. Notify the carrier of any
defects or damage at once.

B. Check container for any loose parts prior to dispos-

ing of shipping materials.

C. Check air louvers and any other openings to ensure

that any obstruction is removed.

A line (wall) disconnect switch with fuses or circuit
breakers should be provided at the main power panel
(see Fig. 2-1 and Table 2-1 for fuse sizes). The input
power cable of the console may be connected directly to
the disconnect switch or you may purchase a proper plug
and receptacle from a local electrical supplier. If using
plug/receptacle combination, see Table 2-1 for recom­mended input conductors for connecting receptacle to
line disconnect switch.

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

10

SECTION 2 INSTALLATION

Table 2-1. Recommended Sizes For

Input Conductors and Line Fuses

Input Requirements Input & Gnd Fuse

Volts Phase Amps Conductor Size

CU/AWG Amps

208 1 64 4 90
208 3 28 10 50
230 1 58 4 90
230 3 25 10 40
460 3 14 10 25
575 3 11 10 20

2.6 SECONDARY (OUTPUT) CONNECTIONS
(REFER TO FIG. 2-1)

Before making any connections to the power source
output terminals, make sure that all primary input
power to the power source is deenergized (off) at the
main disconnect switch and that the input power
cable is unplugged.

1. For operator safety, the torch connections are lo­cated on the output terminal board behind the lower
portion of the front panel. Remove access door to
output terminal board from right panel of power
source.

2. Thread the power cable, pilot arc cable and switch
lead of the PT-27 through the right open bushing of
the front panel. Connect power cable to the torch
fitting (left-hand threads); bolt the pilot arc cable ring
connection to the copper terminal; and plug in the
switch lead to the torch switch receptable on the
output terminal board. Make sure the power and pilot
arc cable connections are wrench-tight. Make sure
plug of switch lead is firmly locked in place.

3. Reassemble the access door to the power source.

4. Connect your air supply to the inlet connection of the
filter-regulator.

5. Clamp the work cable to the workpiece. Be sure the
workpiece is connected to an approved earth ground
with a properly sized ground cable.

11

SECTION 2 INSTALLATION

TORCH
PILOT

Allow at least 10 ft. (3m)

between work and power source

WORK

ARC
CONNECTION

TORCH
POWER
CABLE
CONNECTION

SAFETY

GROUND

PT-27

CUSTOMER FUSED LINE
DISCONNECT SWITCH(See
Table 2.1 and WARNING in
regards to chassis ground in
Section 2.5.)

Prefiltered AIR SUPPLY
(Customer Supplied)
(90 to 150 psig max)

TORCH
SWITCH
RECEPTACLE

ACCESS DOOR FOR
TORCH CONNECTION

ACCESS FOR CNC
INTERFACE CONNEC­TIONS.
(See Detail “A”)

CNC INTERFACE CONNECTION
(INSIDE ON LEFT SIDE OF BASE.)

DETAIL “A”

INPUT POWER CABLE

(See Table 2.1)

NOTE: The 208/230 V model is equipped with a plug for single-

phase connection only. The plug is mounted to a 4­conductor cable. If 3-phase connection is desired, remove
and discard the plug and refer to Sect. 2.5.

Figure 2-1. PCM-1125 Interconnection Diagram

12

SECTION 2 INSTALLATION

Connecting PCM-1125 for 208 Vac Input

ELECTRIC SHOCK CAN KILL! Precautionary mea­sures should be taken to provide maximum protec­tion against electrical shock. Be sure that all power
is off by opening the line (wall) disconnect switch
and by unplugging the power cord to the unit when
reconnecting for 208 VAC Input.

The PCM-1125 power source with 208/230 vac, 1-phase
input capability is factory set for 230 vac input. If using
208 vac input, the PCM-1125 must be reconnected as
follows before connecting to your input power:

Note: Factory set for 230 VAC input.
For 208VAC move Gry wire from TB5-2 to

Fig. 1

(IBR)
INPUT
BRIDGE

R

G

S

+

T

TB5-1, move T1-X2 to TB3 and T1-X3 to D2-3

R2

1. Remove cover from the PCM-1125 power source.

2. Locate the Input Bridge (IBR) and TB5 terminal
block (see Fig. 1) on the left side towards the rear
panel. Disconnect the gray lead from TB5-2 and
then connect it to TB5-1.

3. Locate the output bridge (D2) on left side towards the
front panel (see Fig. 2). Disconnect and interchange
leads X2 and X3 from the main transformer. For 208
vac input, X2 is connected to TB3 and X3 is con­nected to terminal 3 of D2. Make sure the connec­tions are firmly tightened.

4. Leave all other wires the same.

5. Reinstall cover and connect the PCM-1125 to 208
vac input power.

Fig. 2

Figure 2-2. Original Factory Setup for 230 Vac Input on
Power Source with 208/230 Vac Input Power Capability

13

SECTION 2 INSTALLATION

2.8 MECHANIZED CUTTING INSTALLATION WITH THE PT-20AM TORCH

ARC STARTER CABLE - 37410 (50’)

37411 (100’)

POWER CABLE - 37341 (50’)

37342 (100’)

ARC STARTER

37338

PT-20AM - 21785 (4.5’)

21786 (17’)
WORK
CABLE(25’)
(Supplied with
PCM-1125)

AIR HOSE - 37343 (50’)

37344 (100’)

PILOT ARC CABLE - 37339 (50’)

37340 (100’)

SCHEMATIC - MECHANICAL SYSTEM SETUP (See Figure 2-4 for detailed connections)

CNC Interface Connection (Located inside console, left side of base.)

Figure 2.3 - MECHANICAL CUTTING INTERFACE DIAGRAM

14

SECTION 2 INSTALLATION

“D”

ADAPTOR - 999278

“A”

“B”

“C”

Arc Starter

37338

PILOT ARC CABLE - 37339 (50’)

37340 (100’)

SPLICE CONNECTOR*
(Supplied with 37338)

25mm min.

AIR HOSE - 37343 (50’)

37344 (100’)

POWER CABLE - 37341 (50’)

37342 (100’)

ARC STARTER CABLE - 37410 (50’)

37411 (100’)

View A-A

Connect Arc Start Cable As Shown. (See step 5 below).

WHT Arc Start

BLK Arc Start

Make sure all power is off before making following
connections.

1. Remove cover from PCM-1125.

2. Insert the 4 service lines from Arc Starter through
the torch opening of front panel.

3. Connect large hole terminal end of Pilot Arc Cable
("A") to connection where shown. Tighten screw
firmly.

4. Connect adaptor 999278 to fitting where shown.
Connect Air Hose ("C") to adaptor. Connect power
cable ("B") to one of the threaded holes of adaptor.
Tighten all connections firmly.

5. Locate TB1 Terminal Block. Referring to view D-D
above, disconnect the two black wires from TB1.
Connect the black lead of Arc Starter Cable ("D") to
TB1-1 and the white lead to TB1-2.

6. Reassemble cover. Proceed to connect the 4 ser­vice lines to the Arc Starter. Then connect PT-20AM
torch to Arc Stater.

Disconnect These
Two Black Leads

Arc Starter
Cable (Ref.)

25mm min.

PT-20AM
TORCH

*Insulate splice connec­tors with vinyl tubing
and secure with electrical
tape.

Figure 2.4 Connection Diagram - PCM-1125/PT-20AM with Arc Starter

SPLICE CONNECTOR*
(Supplied with 37338)

.035” (0.9mm)

SPARK GAP ASSEMBLY
(Torch end of Arc Starter)

15

(4) .250” (6 mm)

2.125”

(54mm)

7”

(178mm)

MOUNTING DIMENSIONS

SECTION 3 OPERATION

3.1 OPERATION

ELECTRIC SHOCK can kill.

• Do NOT operate the unit with the cover removed.

• Do NOT apply power to the unit while holding or
carrying the unit.

• Do NOT touch any torch parts forward of the torch
handle (nozzle, heat shield, electrode, etc.) with
power switch on.

ARC RAYS can burn eyes and skin;

NOISE can damage hearing.

• Wear welding helmet with No. 6 or 7 lens shade.

• Wear eye, ear, and body protection.

Position the PCM-1125 at least 10 feet (3 meters)
from the cutting area. Sparks and hot slag from the
cutting operation can damage the unit.

3.2 PCM-1125 CONTROLS (FIGURE 3-1)

E. Fault Light. Will glow amber under the following

conditions and operations will come to a complete
stop.

Flow Fault: The fault light will be mostly on but
will flick off for about 1/10th of a second every
second. This indicates that the air flow supply is
low.

Over Temperature: The fault light will be mostly
off but will flick on for about 1/10th of a second

every second. This indicates that the duty cycle
has been exceeded. Allow the power source to
cool down before returning to operate.

High/Low Line Voltage: The fault light will rap­idly blink on and off (five times per second). This

indicates that the input voltage is outside the “+ or

-” 15% range of the input rating.

Over-Current: The fault light will be on continu­ously. This indicates that input current has been

exceeded.

All fault signals will remain on for a minimum
of 10 seconds. If fault clears, all will reset
automatically except for over-current. To clear
over-current, the power must be shut off for 5
seconds and then turned back on.

A. Power Switch (located on rear panel). When

placed in ON position, the green pilot light will glow
indicating control circuit is energized and the cool­ing fan will run.

B. Output Current Control. Adjustable from 10 to

70 amperes.

C. Air Test Switch. When placed in Test position, air

filter-regulator can be adjusted to desired pres­sure (65-75 psig) before cutting operations. Allow
air to flow for a few minutes. This should remove
any condensation that may have accumulated
during shutdown period. Be sure to place switch
in OPERATE position before starting cutting op­erations.

D. Trigger Lock Switch. When placed in LOCK

position, this permits releasing torch switch button
after cutting arc has been initiated. To extinguish
arc at end of cut, press and release torch switch
button again or pull torch away from work. When
placed in UNLOCK position, torch switch must be
held closed by the operator during the entire
cutting operation and then released at the end of
cut.

3.3 CUTTING WITH THE PT-27

Use the following procedures to cut with the PT-27 torch
(Figure 3-4).

A. Hold the torch nozzle approximately 1/8 to 3/16

inch above the work and tilted at about 15 - 30°.
This reduces the chance of spatter entering the
nozzle. If the PT-27's standoff tool is being used,
set the standoff between 3/16 and 1/4-inch.

B. Depress the torch switch. Air should flow from the

torch nozzle.

C. Two seconds after depressing the torch switch,

the pilot arc should start. The main arc should
immediately follow, allowing the cut to begin. (If
using the trigger LOCK mode, torch switch may be
released after establishing the cutting arc.)

D. After starting the cut, the torch should be main-

tained at a 5-15° forward angle (Figure 3-2). This
angle is especially useful in helping to create a
"drop" cut. When not using the standoff guide, the
nozzle should be held approximately 1/4 inch from
the work.

16

SECTION 3 OPERATION

POWER LIGHT

(WHITE)

FAULT LIGHT

(AMBER)

AIR

PRESSURE

GAUGE

AIR TEST
SWITCH

TRIGGER LOCK

SWITCH

CURRENT
CONTROL

KNOB

AIR REGULATOR
CONTROL KNOB

Figure 3-1. PCM-1125 Controls

E. When ending a cut, the torch switch should be

released (press and release if using trigger LOCK
mode) and lifted off the workpiece just before the
end of the cut. This is to prevent the high frequency
from reigniting after cutting arc extinguishes and
causing damage to the nozzle (double arcing).

REAR VIEW

FUSE (3A)

POWER ON-OFF
(I-O) SWITCH &
CIRCUIT BREAKER

NOTE: When replacing the nozzle, always inspect the

electrode for wear. If less than 19/32" of elec­trode shaft is remaining, replace the electrode.
If the electrode is used beyond this recom­mended wear limit, damage to the torch and
power source may occur. Nozzle life is also
greatly reduced when using the electrode below
the recommended limit. Refer to Figure 3-3.

Figure 3-2. Recommended Torch Angle of 5° to 15°

F. For rapid re-starts, such as grate or heavy mesh

cutting, do not release the torch switch. In the
postflow mode, the arc can be re-started immedi­ately by depressing the torch switch. This avoids
the 2-second preflow portion of the cutting cycle.

19/32"

(15.1 mm)

REPLACE ELECTRODE BEFORE
LENGTH BECOMES SHORTER

ELECTRODE

THAN 19/32 INCH (15.1 MM)

Figure 3-3. Electrode Wear Limit

3.3.1. Drag Cutting with the PT-27/PCM-1125 System

Reduce current to 40 Amperes. Then follow steps in
Section 3.3.

17

SECTION 3 OPERATION

WHEN THE ARC BREAKS

2

THROUGH THE WORK,
BRING THE TORCH TO AN
UPRIGHT POSITION AND
PROCEED TO CUT.

TO START A PIERCE, TILT THE

1

TORCH TO PREVENT MOLTEN MA­TERIAL FROM COMING BACK
AGAINST AND DAMAGING THE
TORCH.

Figure 3-4. Piercing Technique using the PT-27

3.4 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-1125, refer to the maintenance
section of this manual. If the problem is not corrected
after referring to the maintenance section, contact your
ESAB distributor.

A. Insufficient Penetration.

1. Current too low.

2. Cutting speed too fast.

3. Damaged cutting nozzle.

4. Improper air pressure.

5. Low air flow rate.

B. Main Arc Extinguishes.

1. Cutting speed too slow.

2. Worn electrode.

C. Dross Formation. (In some materials and thick-

nesses, it may be impossible to get dross-free cuts.)

1. Current too low.

2. Cutting speed too fast or too slow.

3. Improper air pressure.

4. Faulty nozzle or electrode.

5. Low air flow rate.

D. Double Arcing. (Damaged Nozzle Orifice.)

1. Nozzle contacting work when current is set over
40 amps.

2. Low air pressure.

3. Damaged cutting nozzle.

4. Loose cutting nozzle.

5. Heavy spatter accumulation on nozzle.

E. Uneven Arc.

1. Damaged cutting nozzle or worn electrode.

F. Unstable Cutting Conditions.

1. Incorrect cutting speed.

2. Loose cable or hose connections.

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

G. Main Arc Does Not Strike.

1. Worn electrode.

2. Loose connections.

3. Worn cable not attached.

H. Poor Consumable Life.

1. Improper gas pressure.

2. Contaminated air supply.

3. Low air flow rate.

18

SECTION 4 MAINTENANCE

4.1 GENERAL

If this equipment does not operate properly, stop work
immediately and investigate the cause of the malfunc­tion. Maintenance work must be performed by an
experienced person, and electrical work by a trained
electrician. Do not permit untrained persons to inspect,
clean, or repair this equipment. Use only recommended
replacement parts.

Be sure that the wall disconnect switch or wall
circuit breaker is open before attempting any in­spection or work inside of the PCM-1125.

4.2 INSPECTION AND CLEANING

Frequent inspection and cleaning of the PCM-1125 is
recommended for safety and proper operation. Some
suggestions for inspecting and cleaning are as follows:

A. Check work cable for secured connection to

workpiece.

B. Check safety earth ground at workpiece and at

power source chassis.

C. Check heat shield on torch. It should be replaced

if damaged.

D. Check the torch electrode and cutting nozzle for

wear on a daily basis. Remove spatter or replace
if necessary.

E. Make sure cable and hoses are not damaged or

kinked.

F. Make sure all plugs, fittings, and ground connec-

tions are tight.

G. With all input power disconnected, and wearing

proper eye and face protection, blow out the inside
of the PCM-1125 using low-pressure dry com­pressed air.

The PT-27 torch head contains a gas flow check
valve that acts in conjunction with the flow switch
and circuitry within the power source. This system
prevents the torch from being energized with high
voltage if the torch switch is accidentally closed
when the shield is removed. Always replace torch
with the proper torch manufactured by ESAB since
it alone contains ESAB¹s patented safety interlock.

To assemble the consumable parts, refer to Figure 4-1.
A. Place nozzle, swirl baffle and electrode into the

shield as shown.

B. Thread assembly to the torch body and hand tighten.

Always make sure the shield is very tight before
cutting.

ELECTRODE

SWIRL BAFFLE

NOZZLE

SHIELD

Water or oil occasionally accumulates in compressed
air lines. Be sure to direct the first blast of air away
from the equipment to avoid damage to the PCM-

1125.

H. Occasionally, bleed all water from the filter be-

neath the air filter-regulator.

4.3 PT-27 TORCH CONSUMABLE PARTS

Make sure power switch on PCM-1125 is in OFF
position before working on the torch.

IMPORTANT!

MAKE SHIELD VERY TIGHT!

Figure 4-1. Assembly of PT-27 Torch Front End Parts

19

SECTION 4 MAINTENANCE

4.4 FLOW SWITCH (FIGURE 4-2)

When excessive contamination is found in the air, the
flow switch (FS-4) should be disassembled and cleaned
as follows:

A. Ensure the system is shut down and there is no

trapped air under pressure in the piping.
B. Remove the piston plug.
C. Remove the spring. Use care when handling spring

to prevent distortion.
D. Remove the piston.
E. Clean all parts with cleaning agent.

NOTE
Ensure cleaning agent does not contain solvents
which can degrade polysulfone. Warm water and
detergent is recommended for cleaning. Allow all
parts to dry thoroughly before reassembly.

Reassemble the flow switch in reverse order.

PISTON PLUG

SPRING

PISTON

FLOW SWITCH

• Use grounded work station with grounded floors and
grounded wrist straps when handling devices.

• Use a 100Ω resistor in series with the gate when
performing curve tracer tests.

• Never install devices into systems with power con­nected to the system.

• Use soldering irons with grounded tips when solder­ing to gate terminals.

When mounting IGBT modules on a heatsink, certain
precautions should be taken to prevent any damage
against a sudden torque. If a sudden torque (“one-sided
tightening”) is applied at only one mounting terminal the
ceramic insulation plate or silicon chip inside the module
may get damaged.

The mounting screws are to be fastened in the order
shown in Figure 4-3. Also, care must be taken to achieve
maximum contact (i.e. minimum contact thermal resis­tance) for the best heat dissipation.

Application of a thermal pad on the contact surface
improves its thermal conductivity. See Replacement
Parts section for the required pad.

A torque wrench should be used. Tighten mounting
screws to 28 in-lbs; wire connecting screws to 19 in-lbs.
If torque is too heavy, the device can damage like the
above “one-sided tightening”.

Q

Two-Point Mounting Type

Temporary tightening  QèR
Final tightening  RèQ

Figure 4-2. Disassembly / Assembly of Flow Switch

4.5 IGBT Handling & Replacement

Since IGBT gates are insulated from any other conduct­ing region, care should be taken to prevent static build
up, which could possibly damage gate oxides. All IGBT
modules are shipped from the factory with conductive
foam contacting the gate and emmiter sense pins.

Always ground parts touching gate pins during installa­tion. In general, standard ESD precautlions application
to FETs should be followed.

Other handling precautions that should also be observed
are as follows:

20

R

Four-Point Mounting Type

Temporary tightening  QèRèSèT

Q

Final tightening  TèSèRèQ

S

T

R

Figure 4-3. Screw Fastening Order

SECTION 5 TROUBLESHOOTING

5.1TROUBLESHOOTING

ELECTRIC SHOCK CAN KILL! Be sure that all pri­mary power to the machine has been externally
disconnected. Open the line (wall) disconnect switch
or circuit breaker before attempting inspection or
work inside of the power source.

Check the problem against the symptoms in the follow­ing troubleshooting guide. The remedy may be quite
simple. If the cause cannot be quickly located, shut off
the input power, open up the unit, and perform a simple
visual inspection of all the components and wiring.
Check for secure terminal connections, loose or burned
wiring or components, bulged or leaking capacitors, or
any other sign of damage or discoloration.

5.2TROUBLESHOOTING GUIDE

The cause of control malfunctions can be found by
referring to the sequence of operations and electrical
schematic diagram (Figure 5-1) and checking the vari­ous components. A volt-ohmmeter will be necessary for
some of these checks.

Voltages in plasma cutting equipment are high
enough to cause serious injury or possibly death. Be
particularly careful around equipment when the cov­ers are removed.

NOTE

Before checking voltages in the circuit, disconnect the
power from the high frequency generator to avoid dam­aging your voltmeter.

A. Power Light (PL1) does not come on.

1. Visually inspect the machine for any damage.

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

a. Check if the machine power cord is plugged into the input power receptacle.

b. Measure the input power at the receptacle. If not present, then check the wall

disconnect switch and it’s fuses.

c. Check Fuse (F1). If fuse is ok, then check the input circuit breaker (CB1) for proper operation. Re-

place if defective.

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

a. If the cooling fan is running, then measure voltage between pins P2-11 and P2-14 of the control

board (should be 115 VAC). If there is no voltage, then replace transformer T2.

b. If the voltage is present, then the pilot light may be burnt out.

B. No Air Flow

A. Check air inlet supply. Unit requires 320 CFH at 65 psig.

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

C. Does air flow when “air test” switch is in test position?

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

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

21

SECTION 5 TROUBLESHOOTING

C. The Power light is on, but nothing happens when the torch switch is depressed. Fault light

does not activate.

NOTE: Unplug high frequency connection before attempting to work on this problem.

1. 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:

a. 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:

i. 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:

ii. 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.

b. 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.

c. If everything above checks out all right, then the PCB1 Control Board should be replaced.

D. Fault light activates when torch switch is closed.

The Fault circuit is used to monitor conditions necessary for the safe operation of the PCM-1125. The fault light
will glow amber under the following conditions and operations will come to a complete stop:

1. 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.

2. 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.
a. 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.

b. 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.

c.. 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.

d. Air Check switch may also be malfunctioning if the air is flowing continuously or putting in the On position

does not turn air on.

3. 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 air flow has been blocked. Clear blockage and allow the power source to cool before
operating.

a. Thermal switch may be open. It will open if the heat sink temperature reaches 80°C. 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

22

SECTION 5 TROUBLESHOOTING

should read a direct short. If not then it should read open.

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

4. Over Current.
former has exceeded preset limits.

a. 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.

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

5).

The fault light will be on continuously. This indicates that the input current to the main trans-

E. Air is On but nothing happens when torch switch is operated.

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

2. Check the torch. Make sure that the heat shield is very tight.

3. Check to assure high frequency is present at the torch. If not, then listen for high frequency at the high frequency
generator. It is located on the bottom/right side of the unit. The high frequency gap is set to 0.040”. Disconnect
HI FREQUENCY leads. Check for 115 volt supply to the high frequency unit between P2-12 & P2-13 of the
control board with torch switch closed.

4. 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:

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

b. 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)

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

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

approx. 325 VDC with 230 V supplied to the 208/230 volt unit.
approx. 294 VDC with 208 V supplied to the 208/230 volt unit
approx. 325 VDC with 460 V supplied to the 460 volt unit
approx. 400 VDC with 575 V supplied to the 575 volt unit

If not, one of following could be malfunctioning:

1). Check the capacitors C1 and C2 for any damage.

2.) 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.

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

e. IGBTs (2 on 230 V, and 1 on the 460 V & 575 V units) may be damaged. See IGBT installation procedure.

Before replacing IGBTs, make sure to check the zener diodes and pico fuses on the IGBT driver boards.

23

SECTION 5 TROUBLESHOOTING

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

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

2. Check the torch. Replace consumables if necessary.

3. 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.

G. Poor Cutting Performance.

1. Check air supply regulator . It should be adjusted to 65-75 psig.

2. The air supplied to the torch should be free of oil and water.

3. Make sure the consumables in the torch are acceptable.

4. Check open circuit voltage. See E.4 above.

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

H. Air does not shut off.

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

2. 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.

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

replace solenoid valve.

I. Main arc is difficult to start.

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

2. Input air must be clean and dry.

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

4. Torch connections must be tight.

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

6. If above items check OK , the problem is internal. send unit to an Authorized Repair Station for repair.
a. Missing or weak pilot arc. Check pilot arc fuse, open circuit voltage, pilot arc resistors and pilot arc wiring.
b. Inoperative starter board (PCB-5).

24

SECTION 5 TROUBLESHOOTING

5.3REFERENCE VOLTAGE CHECKS

A. Control Board Assembly (PCB1)

1. LED’s

LED-1 - Torch Switch
LED-2 - High Frequency
LED-3 - Gas Solenoid Valve

2. 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

Frequency - 16.0 KHz

62.5 µs

40 usec - LPG50

13 vdc

0

50 usec - LPG80

Off Time

5 µs

6 usec - LPG50
9 usec - LPG80

Figure 5.1 IGBT Gating Signal

-13 vdc

25

SECTION 5 TROUBLESHOOTING

5.4SEQUENCE OF OPERATION

A. TRIGGER LOCK “UNLOCK” position

TORCH SWITCH

PUSH RELEASE

OPEN CLOSE

GAS SOLENOID VALVE

2 SEC.

PREFLOW

FLOW SWITCH CLOSE

FAULT OVERLOAD LIGHT

ENERGIZE

HF CIRCUIT

10 SEC

Postflow

OPEN

INVERTER

CUTTING ARC (CURRENT)

NOTES:

1. When the torch switch is pushed during postflow period, the postflow and preflow times are canceled, and

the HF is energized immediately.

2. When the amber fault light comes on, cutting operation should be stopped. The postflow time starts from the

moment the torch switch is released.

26

SECTION 5 TROUBLESHOOTING

B. TRIGGER LOCK "LOCK" position

PUSH RELEASE PUSH RELEASE

TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

2 SEC.

CLOSE OPEN

FLOW SWITCH

PREFLOW

10 SEC

Postflow

POSTFLOW

FAULT LIGHT

ENERGIZE

HF CIRCUIT

INVERTER

CUTTING ARC (CURRENT)

NOTES:

1. When the torch switch is pushed during postflow period, the postflow time is reset, the preflow time is canceled,

and the HF is energized immediately.

2. When the red fault light comes on, cutting operation should be stopped. The postflow time starts from the moment

the torch switch is released.

3. FAULT light is on during second "turn-off" trigger only. This does not affect performance in any way.

27

Figure 5-1. Schematic Diagram, PCM-1125, 208/230V, 50/60 Hz, 1 and 3-Phase

D-37567

28

Figure 5-2A. Wiring Diagram (Sheet 1 of 2), PCM-1125, 208/230V, 50/60 Hz, 1 and 3-Phase

D-37568

29

Figure 5-2. Wiring Diagram (Sheet 2 of 2), PCM-1125, 208/230V, 50/60 Hz, 1 and 3-Phase

D-37568

30

Figure 5-3. Schematic Diagram, PCM-1125, 460V, 50/60 Hz, 3-Phase

D-37569

31

Figure 5-4A. Wiring Diagram, (Sheet 1 of 2) PCM-1125, 460V, 50/60 Hz, 3-Phase

D-37570

32

Figure 5-4B. Wiring Diagram, (Sheet 2 of 2) PCM-1125, 460V, 50/60 Hz, 3-Phase

D-37570

33

Figure 5-5. Schematic Diagram, PCM-1125, 575V, 60 Hz, 3-Phase

D-37571

34

Figure 5-6A. Wiring Diagram, (Sheet 1 of 2) PCM-1125, 575V, 60 Hz, 3-Phase

D-37572

35

Figure 5-6B. Wiring Diagram, (Sheet 2 of 2) PCM-1125, 575V, 60 Hz, 3-Phase

D-37572

36

SECTION 6 REPLACEMENT PARTS

6.1 GENERAL

Replacement Parts are illustrated on the following fig­ures. When ordering replacement parts, order by part
number and part name.

208/230 V, 50/60 Hz, 1 or 3-phase ............ P/N 37495

460 V, 50/60 Hz, 3-phase .......................... P/N 37497

575 V, 60 Hz, 3-phase ............................... P/N 37499

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

6.2 ORDERING

To assure 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 Welding & Cutting Products
Attn: Customer Service Dept.
P.O. Box 100545, 411 S. Ebenezer Road
Florence, SC 29501-0545

Be sure to indicate any special shipping instructions
when ordering replacement parts.

Refer to the Communication Guide located on the last
page of the manual for a list of customer service phone
numbers.

6.3 LITERATURE REVISIONS

REVISIONS to prior issue dated November, 1998
incorporated into this issue:

Pg. 2, Added Section 6.3 Literature Revisions
Pg. 14, Text Change, PCM-875 to PCM-1125
Pg. 15, Text Change, PCM-875 to PCM-1125
Pg. 28-36, Improved legibility of diagrams
Pg. 37, Added, 6.3 Literature Revisions information
Pg. 43, Item No. 97, P/N Correction, 32969 to 37669
Pg. 45, Item No. 111, Qty, Correction, (1) to 2
Pg. 45, Item No. 126, P/N Correction, 32969 to 37669

37

SECTION 6 REPLACEMENT PARTS

6.4 PARTS DIAGRAMS & LISTS

8, 9

16

10, 11

5, 4

6

7

3, 4

1, 2

15

8

14

12

13

Fig. 6-1. PCM-1125 Power Source, Front View

Item Qty Part Circuit

No. Req. No. Description Symbol

1 1 13730611 KNOB
2 1 2062018 POT. 10K 2W (NOMEX INSUL - 676876 R1
3 1 673213 SWITCH TOGGLE SPST 2 POS 15 A 125 V S3
4 2 951474 SWITCH SEAL BLACK
5 1 634518 SWITCH TOGGLE DPDT 2 POS 15 A 125 V S2
6 1 951754 LAMP LED YEL 12 V PL2
7 1 951526 LAMP NEON WHITE PL1
8 2 993426 GROMMET RUBBER 1.50 ID x 1.76 OD

9 1 21711 GAUGE 1.50 160 PSI WHITE
10 1 23602576 STRAIN RELIEF EYCO #1214
11 1 680560 WORK CABLE 25 FT. . (Not Shown)
12 4 182W12 FOOT RUBBER
13 1 37556GY CHASSIS PCM-1125
14 1 36330YL DOOR ACCESS YEL
15 1 954008 LABEL WARNING HI VOLTAGE
16 2 13734588 LABEL ESAB

38

SECTION 6 REPLACEMENT PARTS

25, 26

29, 30

31

32, 33, 34

35

26

46

36, 49

37 38

27

39

40

41

25, 26

42

43

Fig. 6-2. PCM-1125 Power Source, Left Side View (208/230)

24

23

22

21

44, 45

Item Qty Part Circuit

No. Req. No. Description Symbol

21 2 951185 BRIDGE 100ADC 100NS 600 V (includes PAD - 951518) D1, 2
22 1 952002 CORE SATURABLE L3
23 1 952208 STANDOFF INS. TB3
24 1 36731 BUSBAR NEG
25 2 952237 CAPACITOR 1800µf 450VDC C1, 2
26 2 994674 GROMMET STRIP
27 2 38052 PCB ASS'Y 1GBT DRIVER BOARD PCB2, 3
28 1 36822 HOSE AY B/A-2X 1/4NPT RUB 2 FT
29 1 36730 BUSBAR POS
30 1 951028 CAPACITOR 1µf 630VDC (Not shown - see wiring) C3
31 1 950487 TERM BLOCK 2 POS TB5
32 1 952235 MODULE INPUT BRIDGE/SCR (includes PAD - 952280) IBR
33 1 2062282 CAPACITOR .22µf 1KV (See wiring) C19
34 3 951321 METAL OXIDE VARISTOR 275 V (See wiring) MOV1, 2, 3
35 2 952873 IGBT 600 V 200 A includes (PAD - 951191) Q1, 1
36 2 17750010 RESISTOR 50 W 10 OHM (PAD - 951194) R7
37 1 32958 CURRENT TRANSFORMER ASS'Y T4
38 1 952255 CAPACITOR 40 µf 400 VDC C4
39 1 950711 THERMAL SWITCH 194°F TS1
40 4 17721020 RESISTOR 24 W 20 OHMS (PAD 951193) r3, 4, 5, 6
41 1 951202 FLOW SWITCH .25 GPM FS
42 2 951940 CAPACITOR 1µf 630W VDC C15, 16
43 1 952887 HEATSINK
44 1 950249 SOL. VALVE 1/4NPT 165 PSI 24 VAC SOL1
45 1 951471 DIODE ZENER 60 V 75 MA (See Wiring) ZD1
46 1 17250010 RESISTOR WW FIXED 50 W 10 OHM R10
47 2 37562 BUSBAR OBR
48 4 951313 CAPACITOR PULSE 0.01µf 1 KV C5, 6, 7, 8
49 1 951314 CAPACITOR .022µf 1 KV C10

39

SECTION 6 REPLACEMENT PARTS

56, 57, 58

62

64, 65, 66

63

77

61

67, 79A

68

60

69, 70 71

59

72, 78, 79

73

74

56, 57, 58

55

54

53

52

51

75, 76

Fig. 6-3. PCM-1125 Power Source, Left Side View (460/575)

40

SECTION 6 REPLACEMENT PARTS

Fig. 6-3. PCM-1125 Power Source, Left Side View (460/575)

Item Qty Part Circuit

No. Req. No. Description Symbol

51 2 951185 BRIDGE 100ADC 100NS 600 V (includes PAD - 951518) D1, 2
52 1 952002 CORE SATURABLE L3
53 1 952872 MODULE DUAL IGBT 200A, 1200 V (460 V) Q1

951831 MODULE DUAL IGBT 200A, 1400 V (575 V) Q1

(includes PAD - 951833)
54 1 952208 STANDOFF INS (Not used on 575 V) TB3
55 1 37560 BUSBAR POS
56 2 952237 CAPACITOR 180µf 450 VDC (460 V) C1, 2

2 952562 CAPACITOR 1800µf 500 VDC (575 V) C1, 2
57 2 994674 GROMMET STRIP
58 2 951028 CAPACITOR 1µf 630 VDC (See wiring) C3, 15
59 1 38157 PCB ASS'Y B/A x 1/4 NPT RUB OCB2
60 1 951964 CAPACITOR 2µf 800 VDC (460 V) C16

1 951892 CAPACITOR 0.68µf 1200 VDC (575 V) C16
61 1 36822 HOSE ASS'Y B/A x 1/4 NPT RUB
62 1 37561 BUSBAR NEG
63 1 950487 TERM BLOCK 2 POS (Not used on 575 V) TB5
64 1 952235 MODULE INPUT BRIDGE/SCR

(includes PAD - 952280) IBR
65 1 2062282 CAPACITOR .22µf 1KV (See wiring) C19
66 3 950591 METAL OXIDE VARISTOR 510 V (See wiring) MOV1, 2, 3

3 951963 METAL OXIDE VARISTOR 625 V (575 V) (See wiring) MOV1, 2, 3
67 1 17750010 RESISTOR 50W 10 OHM (PAD - 951194) R7
68 1 32958 CURRENT TRANSFORMER ASS'Y T4
69 1 952255 CAPACITOR 40µf 400 VDC (460 V) C4

1 952585 CAPACITOR 20µf 600 VDC (575 V) C4
70 1 17145339 RESISTOR 39K 2W R9
71 1 950711 THERMAL SWITCH 194°F TS1
72 4 17721020 RESISTOR 25W 20 OHMS (PAD - 951193) R3, 4, 5, 6
73 1 951202 FLOWSWITCH .25 GPM FS
74 1 952887 HEATSINK
75 1 950247 SOL, VALVE 1/4 NPT 165 PSI 24 VAC SOL1
76 1 951471 DIODE ZENER 60 V 75M A ZD1
77 1 17250010 RESISTOR WW FIXED 50 W 10 OHM R10
78 4 951313 CAPACITOR PULSE 0.01µf 1KV C5, 6, 7, 8
79 2 37562 BUSBAR OBR

79A 1 951314 CAPACITOR .022µf 1KV C10

41

SECTION 6 REPLACEMENT PARTS

92

93

94, 105

90, 91

89

88

87

86

85

81

80

101, 102, 103

95

96

97

104

98, 99

100

Fig. 6-4. PCM-1125 Power Source, Right Side View (208/230)

42

82, 83, 84

SECTION 6 REPLACEMENT PARTS

Fig. 6-4. PCM-1125 Power Source, Right Side View (208/230)

Item Qty. Part Circuit

No. Req. No. Description Symbol

80 1 35940 CONTROL TRANSFORMER ASS'Y T2
81 2 17300012 RESISTOR 300W 12 OHM R11, 12
82 1 673458 CONTACTOR 3 POLE 110 VAC 40 A K1
83 1 952557 CAPACITOR .82µf 630 VDC (See Wiring) C21, 22
84 2 17130433 RESISTOR, CM FILM AL 1W 330K (See Wiring) R13
85 1 23604891 LABEL WARNING HI VOLTAGE RED
86 1 952232 INDUCTOR PFC L2
87 1 38155 CONTROL BOARD ASS'Y PCB1
88 1 37603 MAIN TRANSFORMER ASS'Y T1
89 2 951469 CAPACITOR .022µf 250 VAC (See Wiring) C17, 18
90 1 31488 SHUNT BOARD ASS'Y PCB4
91 1 951515 CAPACITOR .047µf 660 VAC C23
92 1 38039 START UP BOARD ASS'Y PCB5
93 1 952233 INDUCTOR OUTPUT L1
94 1 36721 BUSBAR OUTPUT
95 1 182W64 LOCK TWIST MIDGET J1
96 1 36717 BRACKET OUTPUT
97 1 37669 REACTOR ASS'Y HI FREQ. T3
98 1 36431 SPARK GAP ASS'Y SG
99 2 951342 CAPACITOR 2500pf 15 K V C13, 14

100 1 951179 TRANSFORMER HI VOLTAGE T5
101 1 950487 TERM. BLOCK 2 POS 20 A TB1
102 2 672348 CAPACITOR .01µf 1KV (See wiring) C11, 12
103 1 952204 CAPACITOR .01µf 250 VAC (See wiring) C9
104 1 36718 BOX HI FREQ.
105 1 951314 CAPACITOR .022µF 1K V C20

43

SECTION 6 REPLACEMENT PARTS

119, 120

118

117

116

115

121

122

123, 135

124

125

126

127, 128134

129

130, 131, 132

Fig. 6-5. PCM-1125 Power Source, Right Side View (460/575 V)

111

112, 113, 114

110

133

44

SECTION 6 REPLACEMENT PARTS

Fig. 6-5. PCM-1125 Power Source, Right Side View (460/575 V)

Item Qty. Part Circuit

No. Req. No. Description Symbol

110 1 32914 CONTROL TRANSFORMER ASS'Y T2
111 2 17300012 RESISTOR 300 W 12 OHM R11, 12
112 1 673458 CONTACTOR 3 POLE 110VAC 40 A K1
113 2 952557 CAPACITOR .82µf 630 VDC (See wiring) C21
114 2 17130433 RESISTOR CM FILM AL 1W 330K (See wiring) R13
115 1 23604891 LABEL WARNING HI VOLTAGE RED
116 1 38155 CONTROL BOARD ASS'Y PCB1
117 1 37603 MAIN TRANSFORMER ASS'Y (460 V) T1

1 36599 MAIN TRANSFORMER ASS'Y (575 V) T1
118 2 951469 CAPACITOR .022µf 250 VAC (See wiring) C17, 18
119 1 31488 SHUNT BOARD ASS'Y PCB4
120 1 951515 CAPACITOR .047µf 660 VAC (See wiring) C23
121 1 38039 START UP BOARD ASS'Y PCB5
122 1 952233 INDUCTOR OUTPUT L1
123 1 36721 BUSBAR OUTPUT
124 1 182W64 LOCK TWIST MIDJET J1
125 1 36717 BRACKET OUTPUT KYDEX
126 1 37669 REACTOR ASS'Y HI FREQ. T3
127 1 36431 SPARK GAP ASS'Y SG
128 2 951342 CAPACITOR 2500pf 15 K V C13, 14
129 1 951179 TRANSFORMER HI VOLTAGE T5
130 1 950487 TERM. BLOCK 2 POS 20 A TB1
131 2 672348 CAPACITOR .01µf 1KV (See wiring) C11, 12
132 1 952204 CAPACITOR .01µf 250 VAC (See wiring) C9
133 1 952213 REACTOR 3PH LINE 12 A L2
134 1 36718 BOX HI FREQ
135 1 951314 CAPACITOR .022µf 1K V C20

45

SECTION 6 REPLACEMENT PARTS

143

142

141

144

145

140

Fig. 6-6. PCM-1125 Power Source, Top View with PCB1 and Shelf Removed

Item Qty. Part Circuit

No. Req. No. Description Symbol

140 1 954673 LABEL CNC INTERFACE
141 1 952026 TERM. BLOCK 7 POS 25 A TB4
142 2 17240310 RESISTOR 10 K 25 W R2, 15
143 1 951182 FAN AC AXIAL M1
144 1 2091558 LABEL GROUND BLACK
145 1 954787 LABEL INPUT (208/230 V)

1 954681 LABEL INPUT (400/460 V)

46

SECTION 6 REPLACEMENT PARTS

154, 155, 156, 164

153

151, 152

157

158, 163

3,4

160, 161

162

Fig. 6-7. PCM-1125 Power Source, Rear View

Item Qty. Part Circuit

No. Req. No. Description Symbol

151 1 21710 FILTER REGULATOR
152 1 10Z30 ADAPTOR B/A-WM x 1/4 NPTM
153 2 951575 HANDLE
154 1 36719YL TOP COVER YEL (ESAB)
155 1 2091514 LABEL WARNING
156 1 954290 LABEL WARNING
157 1 954784 LABEL RATING PCM-1125 208/230

1 954785 LABEL RATING PCM-1125 460

1 954786 LABEL RATING PCM-1125 575
158 2 952136 FUSE HOLDER
160 1 97W63 STRAIN RELIEF
161 1 37573 INPUT POWER CABLE, 6 FT 4-COND. 6AWG w/PLUG (208/230 V)

1 37574 INPUT POWER CABLE, 10 FT 4-COND. 10AWG (460/575 V)
162 1 36107 SWITCH POWER 600 V 63 A S1
163 1 952559 FUSE 3A FAST ACTING F1
164 1 954746 LABEL FAULT INDICATOR

47

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS:

Order Entry Product Availability Pricing Delivery
Order Changes Saleable Goods Returns Shipping Information

Telephone: [phone] / Fax: [phone]

Telephone: [phone] / Fax: [phone]

Telephone: [phone]/ Fax: [phone]

B. ENGINEERING SERVICE: Telephone: [phone] / Fax : [phone]

Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations

C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: [phone]

Part Numbers Technical Applications Hours: 8:00 AM to 5:00 PM EST
Performance Features Technical Specifications Equipment Recommendations

D. LITERATURE REQUESTS: Telephone: [phone] / Fax: [phone]

E. WELDING EQUIPMENT REPAIRS: Telephone: [phone] / Fax: [phone]

Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST

F. WELDING EQUIPMENT TRAINING:

Telephone: [phone] / Fax: [phone]
Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST

G. WELDING PROCESS ASSISTANCE:

Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES:

Telephone : [phone] Hours: 7:30 AM to 5:00 PM EST

Eastern Distribution Center

Central Distribution Center

Western Distribution Center

Hours: 7:30 AM to 4:00 PM EST

Telephone: (800) ESAB-123/ Fax: [phone]/ Web:http://www.esab.com

F-15-482-B 2/02

IF YOU DO NOT KNOW WHOM TO CALL

Hours: 7:30 AM to 5:00 PM EST