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
Loading...