ESAB PCM-625i Plasma Arc Cutting Package Troubleshooting instruction

INSTRUCTIONS for

PLASMA ARC CUTTING PACKAGE

F-15-228

December, 1995

PCM-625i

This manual provides complete instructions on the PCM-625i Power Source, 230V, 50/60 Hz, P/N 35551.
This manual is also suitable for use with L-TEC PCM-VPi (Series A) and ESAB PCS-43 (Series A) made prior to April, 1995.

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation
and safe practices for arc welding 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 on page 2 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. Defective 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.

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 ul-

traviolet (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.

F15-660

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

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.

§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.

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

SECTION 1 DESCRIPTION

1.1 GENERAL

The PCM-625i is the perfect power source for duct work,
construction, automotive, painted panels, holes in cabi­nets, ornamental work,, etc. This unique inverter power
source is loaded with desirable features:

 portable - only 46 lbs (21 kg) plastic case
 uses shop air
 completely variable from 10 amps to 40 amps
 comes with “XT” consumables and heavy duty heat

shield

 recommended maximum thickness 5/8"
 severs up to 3/4"
 trigger lock-in
 heavy-duty air filter-regulator
 air check switch
 proven patented PT-31XL torch - 25 feet (7.6 m)
 spare parts kit
 2 year warranty
 40% duty cycle at rated 40 amps output - fan cooled
 overload light
 power-on light
 circuit breaker protection

 grate cutting capability

 torch connection safety interlock cover

 “XT” nozzle easily follows templates

1.2 SPECIFICATIONS

PCM-625i

Input Voltage .......................... 230 V, 60 Hz, 1 Phase

Input Current @ rated load .................. 37 A @ 230 V

Output Rating ...................................... 10 to 40 amps

Duty Cycle @ Rated Output ................................ 40%

Open Circuit Voltage ............................. 200 DC max.

Plasma Gas ..................... Air @ 75psi (180 - 200 cfh)

Dimensions .......................... 8.3" w x 17.3" h x 16.5" l

.......................... (210 mm w x 438 mm h x 420 mm l)

Weight .................................................. 46 lbs (21 kg)

PT-31XL Torch

Current Capacity ...................................... 50 A SPDC

Shipping Wgt. ........................................... 2 lbs (1 kg)

Length of Service Lines ......................... 25-ft. (7.6 m)

Dimensions:

Note the high open circuit voltage. Use only torches
designed for this equipment. Do NOT attempt to use
this equipment with any process other than plasma
arc cutting.

Do not use any torch with this power source other
than the PT-31XL torch. Serious injury may occur if
used with any other torch.

1.3 EQUIPMENT SUPPLIED

A. PACKAGE AVAILABLE

PCM-625i, 230V, PT-31XL 75° 25' .......... P/N 604473

Package includes:
PCM-625i, 230V,

Inverter Power Source w/cable ................. P/N 35551

PT-31XL 75° Torch w/25-ft. lines ...................... 20080

Torch Spare Parts Kit ................................... 21052

Work Cable, 25-ft............................................ 680560

Air Filter-Regulator ......................................... 21698

Hose Assy., Air 2-ft. ........................................ 680545

 Torch Spare Parts Kit (P/N 21052) contains the following PT-31XL

torch parts in a convenient case:
2—Heat Shield, P/N 20282
4—Nozzle (Tip), P/N 21008
3—Electrode, P/N 20862
1—Swirl Baffle, P/N 20463
2—Plunger, P/N 20324

 Max. inlet pressure to filter-regulator: 150 psig.

1.4 REQUIRED EQUIPMENT

Air Supply - A source of clean, dry air from a compressor
that supplies at least 75 psig (50 psig with standard
consumables). It should not exceed 150 psig which is the
maximum inlet pressure rating of the air filter-regulator
(20963) supplied with the package.

2 1/4"

(57mm)

75° Torch

5 1/4"

(133mm)

Fig. 1-1

5

SECTION 2 INSTALLATION

2.1 INSTALLATION

Proper installation can contribute materially to satisfac­tory and trouble-free operation of the cutting package. It
is suggested that each step in this section be studied
carefully and followed as closely as possible.

2.2. INSPECTION AND PLACEMENT

1. Having removed the shipping container inspect for
evidence of concealed damage which may not have
been apparent upon receipt of the power source.
Notify the carrier of any defects or damage at once.

2. Check the container for any loose parts. Check air
louvers on all panels of cabinet and holes through the
base of any packing materials that may obstruct air
flow through the power source.

3. The components in the PCM-625i power source are
maintained at proper operating temperatures by fan
cooling. Air is drawn through louvers on front and side
panels and then out through the rear panel. Locate the
power source in an open area where air can circulate
freely through the openings. Allow at least one foot of
clearance between the power source and wall or any
other obstruction. The area around the power source
should be relatively free of dust, fumes, and excessive
heat.

2.3. PRIMARY INPUT ELECTRICAL CONNECTION

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 power source
when connections are made inside the power source.

1. The PCM-625i, 230 V power source is equipped with
a 6-ft., 3-conductor input power cord without plug. The
customer must supply and wire a 230V/30A plug to the
input cable (NEMA plug 6-30P is recommended) for
plugging into a 208 or 230 volt receptacle. Do NOT
connect to 460 volt power. A line (wall) disconnect
switch, with a 50 amp fuse or circuit breaker, should
also be provided at a main power panel. The cable
connecting the disconnect switch to the receptacle
should include three (two power and one ground) No.
10 AWG insulated conductors.

2.4. 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 input power cable
is unplugged.

1. For operator safety, the torch and work cable connec-

tions are located on the output terminal board at the
front bottom of power source under the safety inter­lock cover. Remove safety interlock cover.

2. Thread the terminal lug end of the work cable assem-

bly through the right bushing of the safety cover and
connect it to the WORK terminal on the output terminal
board. Connection should be wrench-tight.

3. Thread the power cable and switch lead of the PT-

31XL through the left open bushing of the safety
cover. Connect power cable to the torch fitting (left­hand threads) and plug in the switch lead to the torch
switch receptacle on the output terminal board. Make
sure the power cable connection is wrench-tight.
Make sure plug of switch lead is firmly locked in place.

4.Reassemble the safety interlock cover to the power

source. The power source will not operate without the
safety interlock cover in place nor should you attempt
to bypass the safety interlock circuitry.

5. If necessary, assemble air control equipment as fol-

lows:
a. Assemble the filter-regulator and mounting bracket

to the power source as shown in Fig. 2.

b. Connect the 24-in. long air hose to the filter-regula-

tor outlet and to fitting on the power source. Note
that the regulator end of hose has left-hand threads
and the other end is right-handed. Make sure hose
connections are tightened firmly with a wrench.

c. Connect your air supply to the inlet connection of

the filter-regulator.

6. Clamp the work cable to the workpiece. Be sure the

workpiece is connected to an approved earth ground
with a properly sized ground cable.

3.1. ADJUSTMENTS & OPERATIONS

Never, under any circumstances, operate the power
source with the cover removed. In addition to the safety
hazard, improper cooling may cause damage to internal

6