ESAB PCM-875A Plasmarc Mechanized Cutting System Installation manual / Instruction manual

Download

November, 2002

Installation, Operation and Maintenance Manual for the

PCM-875A Plasmarc Mechanized

Cutting System

F-15-753

Cutting Systems

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

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

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

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

This manual is ESAB Part Number F15753

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

Printed in U.S.A.

PCM-875A System Table of Contents

Section 1 Safety Page 1-(_)

1.1 Introduction ................................................................................................... 1

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

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

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

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

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

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

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

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

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

Section 2 Description Page 2-(_)

2.1 General........................................................................................................... 1

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

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

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

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

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

2.3.2 Dimensions and Weight.......................................................................... 3

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

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

2.4.2 Dimensions and Weight.......................................................................... 5

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

PCM-875A System Table of Contents

Section 3 Installation Page 3-(_)

3.1 General .......................................................................................................... 1

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Section 4 Operation Page 4-(_)

4.1 PCM-875A Console Operation -- General ....................................................... 1

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

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

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

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

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

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

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

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

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

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

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

PCM-875A System Table of Contents

Section 5 Maintenance Page 5-(_)

5.1 PCM-875A Console ....................................................................................... 1

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

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

5.1.3 Flow Switch 4

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

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

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

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

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

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

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

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

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

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

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

iii

PCM-875A System Table of Contents

Section 6 Troubleshooting Page 6-(_)

6.1 Troubleshooting PCM-875A Plasmarc System ................................................ 1

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

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

6.2.2 No Air Flow............................................................................................. 2

6.2.3 Power Light is on but nothing happens when signal is given to fire with

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Section 7 Replacement Parts Page 7-(_)

7.1 General .......................................................................................................... 1

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

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

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

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

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

Back Manual

Customer/Technical Information

Cover

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY

1.1 Introduction

The process of cutting metals with plasma

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

1-1

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY

1.2 Safety Notations And Symbols

DANGER

The following words and symbols are used throughout this manual. They indicate different levels of required safety involvement.

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

Used to call attention to immediate hazards which, if not avoided, will result in serious personal injury o r lo ss o f life.

WARNING

CAUTION

NOTICE

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

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

Used to call attention to minor hazards to equipment.

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

1-2

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY

1.3 General Safety Information

NOTICE

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

Machinery may start automatically.

WARNING

Equipment positioning mechanized plasma torch moves in various directions and speeds.

· Moving machinery can crush.

· Only qualified personnel should operate or

service this power source.

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

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

· Post appropriate WARNING signs at every work cell entrance.

· Follow lockout procedure before servicing any

equipment.

Failure to follow operating instructions could result in death or serious injury.

Read and understand this operator’s manual before using machine.

· Read entire procedure before operating or

performing any system maintenance.

· Special attention must be given to all hazard

warnings that provide essential information regarding personnel safety and/or possible equipment damage.

· All safety precautions relevant to electrical

equipment and process operations must be strictly observed by all having system responsibility or access.

· Read all safety publications made available by

your company.

1-3

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY

Failure to follow safety warning label

WARNING

1.4 Installation Precautions

instructions could result in death or serious injury.

Read and understand all safety warning labels on machine.

Refer to operator’s manual for additional safety information.

WARNING

Improperly Installed Equipment Can Cause Injury Or Death.

Follow these guidelines while installing machine:

· Contact your ESAB representative before

installation. He can suggest certain precautions regarding piping installation and machine lifting, etc. to ensure maximum security.

· Never attempt any machine modifications or

apparatus additions without first consulting a qualified ESAB representative.

· Observe machine clearance requirements for

proper operation and personnel safety.

· Always have qualified personnel perform

installation, troubleshooting and maintenance of this equipment.

· Provide a wall mounted disconnect switch with

proper fuse sizes close to the power supply.

1-4

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY

1.5 Electrical Grounding

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

Electric shock hazard.

WARNING

1.6 Operating A Plasma Cutting Machine

Improper grounding can cause severe injury or death.

Machine must be properly grounded before put into service.

Flying debris and loud noise

WARNING

hazards.

· Hot spatter can burn and injure eyes. Wear goggles to protect eyes from burns and flying debris generated during operation.

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

· Noise from plasma arc can damage hearing.

Wear correct ear protection when cutting above water.

Burn hazard.

WARNING

Hot metal can burn.

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

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

1-5

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY

Hazardous voltages. Electric shock

WARNING

can kill.

· Do NOT touch plasma torch, cutting table or cable connections during plasma cutting process.

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

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

· Do not touch live electrical parts.

· Keep all panels and covers in place when

machine is connected to power source.

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

· Keep gloves, shoes, clothing, work area, and

equipment dry.

· Replace worn or damaged cables.

Fume hazard.

WARNING

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

· Do NOT breathe fumes.

· Do not operate plasma torch without fume

removal system operating properly.

· Use additional ventilation to remove fumes if necessary.

· Use approved respirator if ventilation is not

adequate.

· Provide positive mechanical ventilation when

cutting galvanized steel, stainless steel, copper, zinc, beryllium, or cadmium. Do not breathe these fumes.

operations. Heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas and other irritant gases.

Do not operate near degreasing and spraying

1-6

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY

Radiation hazard.

WARNING

Arc rays can injure eyes and burn skin.

· Wear correct eye and body protection.

· Wear dark safety glasses or goggles with side

shields. Refer to following chart for recommended lens shades for plasma cutting:

Arc Current Lens Shade

Up to 100 Amps Shade No. 8

100-200 Amps Shade No. 10

200-400 Amps Shade No. 12

Over 400 Amps Shade No. 14

· Replace glasses/goggles when lenses are

pitted or broken

· Warn others in area not to look directly at the

arc unless wearing appropriate safety glasses.

· Prepare cutting area to reduce reflection and

transmission of ultraviolet light.

§ Use special paint on walls to absorb UV light.

§ Install protective screens or curtains to

reduce ultraviolet transmission.

CAUTION

Do Not Use this Torch Under Water.

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

Cutting under water may result in:

· reduced consumable life

· degradation of cut quality

· possible damaged torch

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

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

1-7

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY

Burn Hazard.

WARNING

Heat, spatter, and sparks cause fire and burns.

· Do not cut near combustible material.

· Do not have on your person any combustibles

(e.g. butane lighter).

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

· Wear correct eye and body protection.

· Wear gauntlet gloves, safety shoes and hat.

· Wear flame-retardant clothing covering all

exposed areas.

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

· Have fire extinguishing equipment available for use.

Explosion hazard.

WARNING

· Certain molten aluminum-lithium (Al-Li) alloys

can cause explosions when plasma cut OVER water.

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

§ DO NOT dry cut over water.

§ Contact your aluminum supplier for

additional safety information regarding hazards associated with these alloys

Do not cut in atmospheres containing

explosive dust or vapors.

Do not carry any combustibles on your person

(e.g. butane lighter)

· Do not cut containers that have held

combustibles.

1-8

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY

1.7 Service Precautions

Hazardous voltages. Electric shock

WARNING

can kill.

· Do NOT touch plasma torch, cutting table or cable connections during plasma cutting process.

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

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

· Do not touch live electrical parts.

· Keep all panels and covers in place when

machine is connected to power source.

· Keep gloves, shoes, clothing, work area, and

equipment dry.

· Inspect power and ground leads cables for

wear or cracking. Replace worn or damaged cables. Do not use if damaged.

WARNING

· Never bypass safety interlocks.

· Follow lock-out procedures.

Hot Torch can cause skin burns.

Allow torch to cool before servicing.

1-9

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY

Danger of Electric Shock.

DANGER

CAUTION

Torch may be electrically active.

Turn off Plasma Power Console before servicing torch.

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

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

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

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

1-10

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY

1.8 Safety References -- Regulations, Standards, Guidelines

1.8.1 USA

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

· “Precautions and Safe Practices in Welding and Cutting with

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

· “Precautions and Safe Practices for Electric Welding and Cutting,”

Form 52-529. ESAB Cutting Systems.

· “Safety in Welding and Cutting” - ANSI Z 49.1, American Welding

Society, 2501 NW 7th Street, Miami, Florida, 33125.

· “Recommended Safe Practices for Shielded Gases for Welding and

Plasma Arc Cutting” - AWS C5.10-94, American Welding Society.

· “Recommended Practices for Plasma Arc Welding” - AWS C5.1,

American Welding Society.

· “Recommended Practices for Arc Cutting” - AWS C5.2, American

Welding Society.

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

· “Standard for Fire Protection in Use of Cutting and Welding

Procedures” - NFPA 51B, National Fire Protection Association, 60 Batterymarch Street, Boston, Massachusetts, 02110.

· “Standard for Installation and Operation of Oxygen - Fuel Gas

Systems for Welding and Cutting” - NFPA 51, National Fire Protection Association.

· “Safety Precautions for Oxygen, Nitrogen, Argon, Helium, Carbon

Dioxide, Hydrogen, and Acetylene,” Form 3499. ESAB Cutting Systems. Obtainable through your ESAB representative or local distributor.

· "Design and Installation of Oxygen Piping Systems," Form 5110.

ESAB Cutting Systems.

· “Precautions for Safe Handling of Compressed Gases in

Cylinders”, CGA Standard P-1, Compressed Gas Association.

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

1-11

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY

1.8.2 International

Accident Prevention

VBG- Unfallverhütungsvorshriften

General Provisions

VBG 1

Allgemeine Unfallverhütungsvorshriften Electrical Equipment and operating Equipment

VBG 4

Elektrische Anlagen Welding, Cutting and related working methods

VBG 15

Schweißen un Schneiden un verwandte Verfahren Shot Blasting Works

VBG 48

Strahlarbeiten Gases

VBG 61

Gase Oxygen

VBG 62

Sauerstoff Operating liquid jet cutting machines

VBG 87

Arbeiten mit Flüssigkeitsstrahlem

VBG 93

Laser beams, accident prevention and Electrotechnology

Laserstrahlung, Unfallverhütungs-vorschriften für Feinmechnik und Elektrotechnik

Noise

VBG 121

Lärm

1-12

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY

VDE Regulations

VDE - Vorschriften

VDE 0100

Erection of power installations with normal voltages up to 1000 volts Bestimmungen für das Errichten von Stakstromanlagen mit Nennspannungen bis 1000 Volt

Electrical equipment of industrial machines

VDE0113

VDE 0837

VDE 0837-

Elektrishe Ausrüstung von Industriemaschinen Radiation safety of laser products; users guide (DIN EN

60825) Strahlungssicherheit von Lasereinrichtungen und Benutzungsrichtlinen (DIN EN 60825)

Specification for laser guards Anforderung an Lasershcutzwänden

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

Acetylene lines

TRAC-204

Azetylenleitungen Acetylene cylinder battery systems

TRAC-206

Azetylenflaschenbatterieanlagen Safety devices

TRAC-207

Sicherheitseinrichtungen

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

TRG 100

TRG 101

TRG 102

TRG 104

General regulations for pressure gases Allgemeine Bestimmungen für Druckgase Pressure gases Druckgase Technical gas mixtures Technishe Gasgemische Pressure gases; alterative use of compressed gas tanks

Druckgase, wahlweise Verwendung von Druckgasbehältem

1-13

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY

TRGS – Technische Richtlinien für Gefahrstoffe

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

DIN Standards

DIN-Normen

TRGS-402 TRGS-900 Grenzwerte in der Luft am Arbeitsplatz (Luftgrenzwerte)

TA TA-Luft un TA-Lärm (BLm SchV)

DIN 2310

Part 1

Teil 1

DIN 2310

Part 2

Teil 2

DIN 2310

Part 4

Teil 4

DIN 2310

Part 5

Teil 5

DIN 2310

Part 6

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

Thermal cutting; terminology and nomenclature Thermsiches Schneiden, Allgemeine Begriffe und

Bennungen Thermal cutting; determination of quality of cut faces Thermsiches Schneiden, Ermittein der Güte von

Schnittflächen Thermal cutting; arc plasma cutting; process principles, quality, dimensional tolerances Thermsiches Schneiden, Plasmaschneiden, Verfahrensgrundlagen, Güte, Maßtoleranzen Thermal cutting; laser beam cutting of metallic materials; process principles Laserstrahlschneiden von metallischen Werkstoffen, Verfahrensgrundlagen, Güte, Maßtoleranzen

Thermal cutting; Classification, processes

1-14

Teil 6 Einführung, Verfahren

DIN 4844

Part 1

Teil 1 Sicherheitskennzeichen (Siehe EN 7287)

Safety markings (DIN EN 7287)

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY

DIN EN ISO Harmonized Standards DIN EN ISO-Harmonisierte Normen

DIN EN

292/1 and 2

DIN EN 559

DIN EN 560

DIN EN 561

DIN EN

626-1

DIN EN

848-1

Safety of machinery Sicherheit von Maschinen, Geräten und Anlagen Hoses for welding, cutting and allied processes

Schläuche für Schweißen, Schneiden und verwandte Verfahren Hose connections and hose couplings for equipment for welding, cutting and allied processes Schlauchanschlüsse und Schlauchverbindungen für Geräte zum Schweißen, Schneiden und verwandte Verfahren

Gas welding equipment hose couplings Gasschweißgeräte, Kupplungen Safety of machines, reduction of risks to health

Sichereit von Maschinen, Reduzierung des Gesundheitsrisikos

Single spindle vertical milling machines Fräsmaschine für einseitige Bearbeitung mit drehendem

Werkzeug

DIN EN

1829

DIN EN

9013

DIN EN

12584

DIN EN

12626

DIN EN

28206

DIN EN

31252

High pressure water jet machines Hochdruckwasserstrahlschneidmaschine

Thermal cutting, oxygen cutting, process principles, dimensional tolerances Thermisches Schneiden, Autogenes Brennschneiden, Verfahrensgrundlagen, Güte, Maßtoleranzen

Imperfections in oxy/fuel flame cuts, laser beam cuts and plasma Unregeimäßigkeiten an Brennschnitten, Laserstrahl- und Plasmaschnitten

Laser processing machines Laserbearbeitungsmaschinen Acceptance testing for oxygen cutting machines Abnahmeprüfung für Brennschneidmaschinen Laser Equipment

Lasergeräte

1-15

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY

VDI Guidelines

DIN EN

31553

DIN EN

60204-1

DIN EN

60825

DIN EN 999

VDI 2906

VDI 2084

Laser and laser related equipment Laser und Laseranlagen Electrical equipment of machines Elekrische Ausrüstung von Maschinen Radiation safety of laser products Strahlensicherheit von Laseranlagen Arrangement of protection devices Anordnung von Schutzeinrichtungen

Quality of cut faces on metallic workpieces; abrasive water jet cutting and arc plasma cutting Schnittflächenqualität beim Schneiden von Werkstücken aus Metall, Abrasiv- Wasserstrahischneiden und Plasmastrahischneiden

Room air; Technical systems for welding workshops Raumluft techn. Anlagen für Schweißwerkstätten

1-16

SECTION 2 PCM-875A Mechanized Plasma Cutting System Description

2.1 General

The PCM-875A Mechanized Plasma Cutting

2.2 PCM-875A Power Console

2.2.1 Technical Specifications: PCM-875A

230V 50Hz, 3 Phase

Options

1 phase 3 phase

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

There are 2 power console options available:

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

400 V 50 Hz, 3 phase P/N 0558003357

400V 50Hz, 3 phase

P/N 0558003356

P/N 0558003357

60% Duty Cycle 60 A at 120 VDC

Rated Output

100 % Duty Cycle 50 A at 120 VDC

Output Current Range 10 to 60 A/phase

Open Circuit Voltage 275 VDC

Rated Primary Input at 7,2 kW Maximum

Output Power, 60 A at 120 VDC

Power Factor at 60 Amperes Output

55/49 A

(230V, 1

phase)

74% (230 V,

1 phase)

26/24 A per

phase

(230V, 3

phase)

90% (230 V, 3

phase)

13 A/phase

92% (400 V, 3 phase)

Efficiency at 60 Amperes Output 90% typical

Current Capacity 60 A DCSP

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

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

2-1

SECTION 2 PCM-875A Mechanized Plasma Cutting System Description

2.2.2 Dimensions and Weight: PCM-875A Power Console

465 mm

Weight = 39,5 kg

516 mm

275 mm

2-2

SECTION 2 PCM-875A Mechanized Plasma Cutting System Description

2.3 Remote Arc Starter (RAS-2)

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

RAS-2 with 15,2 m leads

RAS-2 with 30,4 m leads

Technical Specifications

P/N 0558003601

P/N 0558003602

Input: 110 VAC, 50/60 Hz. Control power provided by

PCM-875A console.

Spark Gap: 1mm

Dimensions and Weight

123,8mm

184,2mm

374mm

Weight = 3,4kg

2-3

SECTION 2 PCM-875A Mechanized Plasma Cutting System Description

2.4 PT-20AMX

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

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

PT-20AMX Torch with 1,2 m lead P/N 0558002632 PT-20AMX Torch with 5,7 m lead P/N 0558002633 PT-20AMX Torch with 7,6 m lead P/N 0558003381

DO NOT use oxygen with this torch!

WARNING

2.4.1 Technical Specifications

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

A hazardous fire may result.

Rating: 100 Amperes at 100% Duty Cycle

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

Nitrogen: 99.995% clean

Gs Type: Air, nitrogen

2-4

SECTION 2 PCM-875A Mechanized Plasma Cutting System Description

2.4.2 Dimensions

34,9 mm

435 mm

2-5

SECTION 2 PCM-875A Mechanized Plasma Cutting System Description

2.4.3 Torch Spare Part Kit

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

P/N 0558002319

Description

Heat Shield (70/100 A) Cutting Nozzle (50 A) Cutting Nozzle (70 A)

Electrode 50Hz 0558001617 5

Electrode Insulator 21373 1

Electrode Holder Assembly 21332 1

Baffle Tube 21374 1

Pilot Arc Adaptor 19497 1

O-ring 488157 5

Lubricant (1 oz.) 17672 1

Seat/Baffle Wrench 21375 1

1/16: Hex-Key Wrench 93750006 1

NOTICE

P/Number Quantity

21326 3 21330 5 23129 5

The description of the heat shield (P/N

21326) listed above indicates a range of 70 to 100 amperes. Testing has proven satisfactory results when used at 60 amps and lower.

2-6

NOTICE

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

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

SECTION 3 PCM-875A Mechanized Plasma Cutting System Installation

3.1 General

Proper installation is important for satisfactory and

trouble free operation. Follow these instructions carefully.

Failure to follow these directions

WARNING

carefully may lead to injury or death.

Read this entire manual before proceeding.

Damage to property or equipment may occur.

3.2 Installation of the PCM-875A Power Console

3.2.1 Equipment Required

A source of clean dry air at 153,4 liters/minute at

5,2 to 5,9 bar. The maximum inlet pressure of the air filter-regulator is 10,4 bar and should not be exceeded.

3-1

SECTION 3 PCM-875A Mechanized Plasma Cutting System Installation

3.2.2 Location

Console

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

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

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

Restricting airflow into the power console through

CAUTION

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

3.2.3 Inspection of Power Console Before installation

A. Remove equipment from the shipping

containers.

B. Remove all packing material and inspect for

evidence of concealed damage, which may not have been initially apparent. Notify the shipping carrier of any damage at once.

C. Check container for any loose parts prior to

disposing of shipping materials.

D. Check air louvers and all other openings to

ensure that any obstruction is removed.

3-2

SECTION 3 PCM-875A Mechanized Plasma Cutting System Installation

3.2.4 Primary electrical Input Connections

Electric Shock Can Kill!

WARNING

CAUTION

The PCM-875A Power Console is equipped with a

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

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

3 m 4 conductor power cable for 3- phase connection. If single-phase 230V is required, tape back red wire on the input power cable.

A line (wall) disconnect switch with fuses or circuit breakers should be provided at the main power panel.

Input Requirements

Volts Phase Amps

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

Input and

Ground

Conductor

(mm

)

Fuse Size

(A)

3-3

SECTION 3 PCM-875A Mechanized Plasma Cutting System Installation

Failure to connect chassis to an

WARNING

approved electrical ground may result in electrical shock, severe burns or death.

The chassis must be connected to an approved electrical ground.

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

Console Power Lead

3.2.5 Connection of Plasma Console To CNC Interface

The CNC interface (TB4) is mounted on the front left corner of the console base.

· Arc On Signal – This signal originates in the plasma console. It is a normally open contact, which closes on main arc transfer. Used to activate machine motion and arc voltage control.

1234567

Relay

Signal

Arc On

Start

Closing

Signal

Relay

Closing

20:1 (+)

Divider

Voltage

Not Used

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

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

· Not Used

3-4

SECTION 3 PCM-875A Mechanized Plasma Cutting System Installation

3.2.6 Secondary (Output) Connections to Power Console

Electric Shock Can Kill!

WARNING

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

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

Power Cable Bushing TB1

3-5

SECTION 3 PCM-875A Mechanized Plasma Cutting System Installation

Pilot Arc

Cut Gas

Arc Current

NOTICE

Bolt pilot arc cable ring connection to the copper

terminal. Connect air hose to air/power connector (left hand

threads). Connect power cable to air/power connector using

#10 screw

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

3-6

SECTION 3 PCM-875A Mechanized Plasma Cutting System Installation

115VAC RAS Cable

Insert115VAC Pilot Arc Cable

TB1

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

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

2 conductor 115VAC cable routed through notch

3-7

SECTION 3 PCM-875A Mechanized Plasma Cutting System Installation

Remove connection for internal arc start from TB1

TB1

CAUTION

Replace cover if next step is not required.

Plug terminal connectors into 2 available lugs on TB1.

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

3-8

SECTION 3 PCM-875A Mechanized Plasma Cutting System Installation

3.3 Connecting the Remote Arc Starter

3.3.1 Mounting RAS2

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

228,6mm

203,2mm

12,7mm 13,5mm

82,6mm

8mm

55,9mm

3-9

SECTION 3 PCM-875A Mechanized Plasma Cutting System Installation

3.3.2 Connecting Service Lines to Remote Arc Starter 2

Remove end covers on RAS2 box.

Arc Start

Cable

Pilot Arc

Cable

115 VAC Arc Start Cable Connector

Pilot Arc Lug

Air Connection

Power Cable Lug

Power

Cable

Air Hose

· Connect arc start cable to RAS2 box.

· Connect pilot arc cable to pilot arc lug using

#10 screw and nut with lock washers.

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

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

3-10

SECTION 3 PCM-875A Mechanized Plasma Cutting System Installation

3.3.3 Setting the Spark Gap in the RAS2

1 mm

Factory set to 1mm.

Adjustment procedure:

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

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

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

4. Tighten locking screws on spark gap assembly.

”a”

3-11

SECTION 3 PCM-875A Mechanized Plasma Cutting System Installation

3.3.4 RAS2 Output Connections to Torch

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

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

Torch Lead Pilot Arc

Connector

Torch Lead

Voltage/Gas Hose

3-12

SECTION 3 PCM-875A Mechanized Plasma Cutting System Installation

3.3.5 Terminating Shield Braid at RAS2

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

Insert bundle

Flair Braid

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

3-13

SECTION 3 PCM-875A Mechanized Plasma Cutting System Installation

3. Insert ground plate over torch leads.

Insert Ground Plate

Fasten Ground Plate

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

3-14

SECTION 3 PCM-875A Mechanized Plasma Cutting System Installation

3.4.1 Installing Torch Front End Parts

WARNING

Seat

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

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

Electrode Holder Assembly

Wrench

21375

Baffle Tube

2. Electrode holder assembly (21332) includes

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

3-15

SECTION 3 PCM-875A Mechanized Plasma Cutting System Installation

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

21332

21373

21150

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

O-ring (488157)

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

17672

3-16

SECTION 3 PCM-875A Mechanized Plasma Cutting System Installation

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

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

NOTICE

CAUTION

will likely leak gas.

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

IMPORTANT: See Maintenance section.

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

3-17

SECTION 3 PCM-875A Mechanized Plasma Cutting System Installation

3.5 Interconnecting Diagram

3-18

SECTION 3 PCM-875A Mechanized Plasma Cutting System Installation

1 Air Supply 2 Wall Disconnect Switch (Grounded) 3 PCM-875A Power Supply Cable 4 Work Cable (Negative) 5 Pilot Arc Cable 6 Gas Connection 7 Power Supply Cable 8 115 V High Frequency Start Cable 9 RAS Input Bulkhead 10 Remote Arc Starter 11 RAS Output Bulkhead 12 Pilot Arc Cable 13 Power/Gas Hose 14 Torch Lead Bundle Shield Ground 15 PT-20 AMX Plasmarc Torch 16 Work Cable Clamp 17 Work Piece 18 Earth Ground

19 ATAS Start/Stop CSR 20 CSR Cable 21 Height Control Cable (Voltage Divider) 22 Voltage Divider (Height Control)

3-19

SECTION 3 PCM-875A Mechanized Plasma Cutting System Installation

This page intentionally left blank.

3-20

SECTION 4 PCM-875A Mechanized Plasma Cutting System Operation

4.1 PCM-875A Console Operation -- General

Electric Shock Can Kill!

WARNING

· Do not operate the console with the cover removed.

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

· Do not touch the torch while console

power switch is on.

· Plasma Arc Emi t s Haza rdous UV

WARNING

and Visible Radiation.

· Damage to skin and eyes is possible.

· Do not ever look directly at a plasma

arc. Blindness could result.

· Wear Safety Approved eye protection.

· Comply to all local and national

regulations for safety equipment.

Noise Levels May Exceed Safe

WARNING

Limits. Sparks and Slag May Be Hazardous.

· Wear Safety Approved Hearing Protection.

· Wear Safety Approved Eye Protection.

Possible Damage to Console from

CAUTION

Sparks and Slag.

Position PCM-875A at least 3 meters form the Cutting Area.

4-1

SECTION 4 PCM-875A Mechanized Plasma Cutting System Operation

4.2 PCM-875A Plasma Console Controls

Power Switch -- Rear Panel

· Located on the rear panel.

· On Position – Front panel green pilot light will

glow indication control circuit is energized and cooling fan will run.

· Off Position – No Power to the control circuit.

Power Switch White Pilot Light

Output Current Control – Front Panel

· Adjustable from 10 to 60 Amperes

Current Output Control

Air Test Switch – Front Panel

· Test Position

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

(65

4-2

Air Test Switch

· Operate Position

Place the toggle switch in this position for normal operation.

SECTION 4 PCM-875A Mechanized Plasma Cutting System Operation

Fault Light – Operations are stopped.

Will illuminate amber under the following conditions:

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

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

· Light will blink off and on 5 times a second.

Fault Light

NOTICE

4.3 RAS Operation

Indicates the input voltage is outside the plus or minus 15% range of input rating.

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

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

The RAS is a self-contained unit and requires no

operator intervention to function.

4-3

SECTION 4 PCM-875A Mechanized Plasma Cutting System Operation

4.4 PT-20AMX Plasma Torch.

Electric Shock Can Kill!

WARNING

Plasma incorporates high voltages at dangerous amperage.

Do not touch the;

· Plasma torch

· Torch lead

· RAS

· RAS supply lines

· Console

while power is applied to console.

Electric shock Can Kill!

WARNING

Do not service torch or otherwise touch the plasma torch unless the power source has been disconnected or turned off.

Hot Torch May Burn Skin.

CAUTION

Allow torch to cool before servicing.

4-4

SECTION 4 PCM-875A Mechanized Plasma Cutting System Operation

4.5 Cut Quality

4.5.1 Introduction

NOTICE

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

§ 4.5.2 Cut angle, negative or positive

§ 4.5.3 Cut not flat, rounded or undercut

§ 4.5.4 Surface roughness

§ 4.5.5 Dross

§ 4.5.6 Dimensional Accuracy

§ Process Data

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

· Make small incremental adjustments when making

corrections.

· Adjust arc voltage in one volt increments, up or

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

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

4-5

SECTION 4 PCM-875A Mechanized Plasma Cutting System Operation

4.5.2 Cut Angle

Part

Negative Cut Angle

Top dimension is greater than the bottom.

· Misaligned torch

· Bent or warped material

· Worn or damaged consumables

· Standoff low (arc voltage)

Drop Part

Part

· Cutting speed slow (machine travel rate)

Positive Cut Angle

Top dimension is less than the bottom dimension.

· Misaligned torch

· Bent or warped material

· Worn or damaged consumables

Drop

4-6

Part

· High standoff high (arc voltage)

· Cutting speed fast

· Current high or low. (See process data for

recommended current level for specific nozzles).

· Wrong secondary gas flow.

SECTION 4 PCM-875A Mechanized Plasma Cutting System Operation

4.5.3 Cut Flatness

Top And Bottom Rounded

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

· High current for given material thickness (See

process data for proper settings).

Drop

Part

Top Edge Undercut

Standoff low (arc voltage)

Part

4-7

SECTION 4 PCM-875A Mechanized Plasma Cutting System Operation

4.5.4 Surface Finish

Process Induced

Roughness

Top View

Or Machine

Induced

Roughness

Cut Face

Process Induced Roughness

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

· Worn or damaged consumables

Machine Induced Roughness

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

· Dirty rails, wheels and/or drive rack/pinion. (Refer to

maintenance section in machine owner’s manual).

· Carriage wheel adjustment

4-8

SECTION 4 PCM-875A Mechanized Plasma Cutting System Operation

4.5.5 Dross

Cut Face

Lag Lines

Dross is a by-product of the cutting process. It is the undesirable material that remains attached to the part. In most cases, dross can be reduced or eliminated with proper torch and cutting parameter setup. Refer to Process Data.

Roll Over

Side View

Cut Face

Lag Lines

High Speed Dross

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

· Standoff high (arc voltage)

· Cutting speed fast

Side View

Slow Speed Dross

Forms as globules on bottom along kerf. Removes easily.

Globules

· Cutting speed slow

4-9

SECTION 4 PCM-875A Mechanized Plasma Cutting System Operation

Side View Splatter

Cut Face

Top Dross

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

· Cutting speed fast

· Standoff high (arc voltage).

Intermittent Dross

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

· Possible worn consumables

Other Factors Affecting Dross:

· Material temperature

· Heavy mill scale or rust

· High carbon alloys

· Gas Purity

4-10

SECTION 4 PCM-875A Mechanized Plasma Cutting System Operation

4.5.6 Dimensional Accuracy

Generally, using the slowest possible speed (within

approved levels) will optimize part accuracy. Most

material thickness overlap for different voltages.

Select consumables to allow a lower arc voltage

and slower cutting speed.

4.6 Process Data

NOTICE

Recommended cutting speed and arc voltage will

give optimal cutting performance.

Small incremental adjustments may be needed due

to material quality, material temperature and specific

alloy. The operator should remember that all

cutting variables are interdependent. Changing one

setting affects all others and cut quality could

deteriorate. Always start at the recommended

settings.

Before attempting ANY corrections, check cutting

variables with the factory recommended settings/

consumable part numbers listed in the process

data.

4-11

SECTION 4 PCM-875A Mechanized Plasma Cutting System Operation

Material:

Mild Steel

PT-20AMX

Plasmarc Torch

Amperes:

Gas:

Lock Ring P/N 57N70

Handle with

Torch Body P/N 21359

40 Air

Sleeve

P/N 05508003419

Electrode

Holder

Assembly

Electrode

Insulator

Electrode

50Hz

Nozzle 50A P/N 21330

Heat Shield –

Blue

P/N 21332

P/N 21373

P/N 0558001617

P/N 21326

4-12

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

SECTION 4 PCM-875A Mechanized Plasma Cutting System Operation

PT-20AMX

Amperes

Process Data

Material Thickness

2,0 3,0

Air Pressure

Bar

5 5

Height Readings

Initial Height

Arc Voltage (Stand-off)

Travel Speed

3,0 3,0

110 110

Mild Steel

mm per minute

Kerf Width

Millimeters

3810 2540

1,1 1,1

4-13

SECTION 4 PCM-875A Mechanized Plasma Cutting System Operation

Material:

Mild Steel

PT-20AMX

Plasmarc Torch

Amperes:

Gas:

Lock Ring P/N 57N70

Handle with

Torch Body P/N 21359

50 Air

Sleeve

P/N 05508003419

Electrode

Holder

Assembly

Electrode

Insulator

Electrode

50Hz

Nozzle 50A P/N 21330

Heat Shield –

Blue

P/N 21332

P/N 21373

P/N 0558001617

P/N 21326

4-14

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

SECTION 4 PCM-875A Mechanized Plasma Cutting System Operation

PT-20AMX

Amperes

Process Data

Material Thickness

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

Air Pressure

Bar

6,0 6,0 6,0 6,0

Height Readings

Initial Height

Arc Voltage (Stand-off)

Travel Speed

3,0 5,0 6,0 8,0

110 120 130 150

Mild Steel

mm per minute

Kerf Width

Millimeters

2540 1651 1016 457

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

4-15

SECTION 4 PCM-875A Mechanized Plasma Cutting System Operation

Material:

Aluminum

PT-20AMX

Plasmarc Torch

Amperes:

Gas:

Lock Ring P/N 57N70

Handle with

Torch Body P/N 21359

40 Air

Sleeve

P/N 05508003419

Electrode

Holder

Assembly

Electrode

Insulator

Electrode

50Hz

Nozzle 50A P/N 21330

Heat Shield –

Blue

P/N 21332

P/N 21373

P/N 0558001617

P/N 21326

4-16

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

SECTION 4 PCM-875A Mechanized Plasma Cutting System Operation

PT-20AMX

Amperes

Process Data

Material Thickness

2,0 3,0

Air Pressure

Bar

5 5

Height Readings

Initial Height

Arc Voltage (Stand-off)

Travel Speed

3,0 3,0

110 110

Aluminum

mm per minute

Kerf Width

Millimeters

3810 2667

1,57 1,57

4-17

SECTION 4 PCM-875A Mechanized Plasma Cutting System Operation

Material:

Aluminum

PT-20AMX

Plasmarc Torch

Amperes:

Gas:

Lock Ring P/N 57N70

Handle with

Torch Body P/N 21359

50 Air

Sleeve

P/N 05508003419

Electrode

Holder

Assembly

Electrode

Insulator

Electrode

50Hz

Nozzle 50A P/N 21330

Heat Shield –

Blue

P/N 21332

P/N 21373

P/N 0558001617

P/N 21326

4-18

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

SECTION 4 PCM-875A Mechanized Plasma Cutting System Operation

PT-20AMX

Amperes

Process Data

Material Thickness

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

Air Pressure

Bar

6,0 6,0 6,0 6,0

Height Readings

Initial Height

Arc Voltage (Stand-off)

Travel Speed

3,0 5,0 6,0 8,0

110 120 130 150

Aluminum

mm per minute

Kerf Width

Millimeters

2286 1905 762 203

Not

Available

3,2 4,7 4,7

4-19

SECTION 4 PCM-875A Mechanized Plasma Cutting System Operation

Material: Stainless Steel

PT-20AMX

Plasmarc Torch

Amperes:

Gas:

Lock Ring P/N 57N70

Handle with

Torch Body P/N 21359

40 Air

Sleeve

P/N 05508003419

Electrode

Holder

Assembly

Electrode

Insulator

Electrode

50Hz

Nozzle 50A P/N 21330

Heat Shield –

Blue

P/N 21332

P/N 21373

P/N 0558001617

P/N 21326

4-20

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

SECTION 4 PCM-875A Mechanized Plasma Cutting System Operation

PT-20AMX

Amperes

Process Data

Material Thickness

2,0 3,0

Air Pressure

Bar

5 5

Height Readings

Initial Height

Arc Voltage (Stand-off)

Travel Speed

3,0 3,0

110 110

Stainless Steel

mm per minute

Kerf Width

Millimeters

3302 1905

Not

Available

1,6

4-21

SECTION 4 PCM-875A Mechanized Plasma Cutting System Operation

Material: Stainless Steel

PT-20AMX

Plasmarc Torch

Amperes:

Gas:

Lock Ring P/N 57N70

Handle with

Torch Body P/N 21359

50 Air

Sleeve

P/N 05508003419

Electrode

Holder

Assembly

Electrode

Insulator

Electrode

50Hz

Nozzle 50A P/N 21330

Heat Shield –

Blue

P/N 21332

P/N 21373

P/N 0558001617

P/N 21326

4-22

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

SECTION 4 PCM-875A Mechanized Plasma Cutting System Operation

PT-20AMX

Amperes

Process Data

Material Thickness

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

Air Pressure

Bar

6,0 6,0 6,0 6,0

Height Readings

Initial Height

Arc Voltage (Stand-off)

Travel Speed

3,0 5,0 6,0 8,0

110 120 130 150

Stainless Steel

mm per minute

Kerf Width

Millimeters

1270 762 203 152

Not

available

3,2 4,7 4,7

4-23

SECTION 4 PCM-875A Mechanized Plasma Cutting System Operation

This page intentionally left blank.

4-24

SECTION 5 PCM-875A Plasmarc Cutting System Maintenance

5.1 PCM-875A Console

5.1.1 General

CAUTION

NOTICE

Stop work immediately if this equipment

does not operate properly. Equipment

damage or personal injury may result.

Do not permit untrained persons to

inspect, clean, or repair this equipment.

Maintenance must be performed by

specially trained personnel.

Use of replacement parts other than ESAB

replacement parts may void warranty.

Electric Shock Can Kill!

WARNING

Disconnect wall switch before inspection

and maintenance of the power console.

5-1

SECTION 5 PCM-875A Plasmarc Cutting System Maintenance

5.1.2 Inspection and Cleaning

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

A. Check work cable for secure connection to

workpiece.

B. Check safety earth ground at workpiece and

at power console chassis.

C. Check heat torch heat shield. Replace if

damaged.

D. Check torch electrode and cutting nozzle for

wear at least once per 8 hours operation.

E. Ensure cable and hoses are not damaged

or kinked.

F. Ensure all plugs, fittings and ground

connections are tight.

CBD

Wear safety eye protection when

WARNING

using compressed air. Serious eye injury may result.

5-2

SECTION 5 PCM-875A Plasmarc Cutting System Maintenance

Water and oil may accumulate in

CAUTION

compressed air lines. Direct the first air

blast away from equipment to avoid

possible damage.

G. With all input power disconnected, wearing

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

H. Periodically drain water from the filter

beneath the air-filter regulator.

5-3

SECTION 5 PCM-875A Plasmarc Cutting System Maintenance

5.1.3 Flow Switch

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

Flow Switch Location

Solenoid Location

Piston Plug

Spring

View A-A

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

1) Turn Off power supply

2) Remove piston plug

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

Piston

5-4

Flow Switch Body

4) Remove the piston.

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

6) Reassemble switch in reverse order.

SECTION 5 PCM-875A Plasmarc Cutting System Maintenance

5.2. Remote Arc Starter

5.2.1 General

Check input and output bulkhead connections for

5.2.2 Spark Gap

1 mm

tightness.

Factory set to 1mm.

Adjustment procedure:

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

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

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

4. Tighten locking screws on spark gap assembly.

”a”

5-5

SECTION 5 PCM-875A Plasmarc Cutting System Maintenance

5.3 PT-20AMX Plasmarc Torch

WARNING

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

5.3.1 General

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

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

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

5-6

SECTION 5 PCM-875A Plasmarc Cutting System Maintenance

5.3.2 Dirt or Contamination

Dirt or other contamination in the torch and loose consumable parts can cause premature failure of the PT-20AM Torch through internal arcing. To avoid this, users are instructed to do the following:

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

used.

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

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

5.3.3 Loose Consumables

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

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

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

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

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

5-7

SECTION 5 PCM-875A Plasmarc Cutting System Maintenance

The torch requires good electrical contact

CAUTION

5.3.4 Damage Caused by Loose Parts and Torch Overheating.

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

Electrode Insulator (21373)

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

5.3.5 Consumables- Remove and Replace

1. Bring torch to a position where it is easily

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

accessed by machine operator, in its normal vertical position and at least 6 inches above the workpiece or the edge of the water table.

Make sure that the power source has been

WARNING

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

5-8

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

SECTION 5 PCM-875A Plasmarc Cutting System Maintenance

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

1,5 mm

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

Inspect electrode insulator and electrode holder assembly for signs of damage such as arc tracking or cracking and replace them if any are found. Insure that the baffle tube is securely threaded into the electrode holder, but do not over tighten. Use the small hex end of the plastic wrench in the spare parts kit.

After installing the electrode insulator onto the electrode holder assembly, install electrode by reversing the procedure used to remove it. Note that firm tightening of the electrode by hand is sufficient. The use of tools such as wrenches or pliers is not required or recommended.

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

5-9

SECTION 5 PCM-875A Plasmarc Cutting System Maintenance

Inspect o-ring of torch

6. Install the nozzle and the electrode assembly

5.3.6 Measuring Torch Gas Flows

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

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

Check gas flow if suspected of causing poor cutting performance. Use Plasma Torch Flow Measuring Kit. (P/N 19765)The kit includes a hand held rotameter (flowmeter) that indicates the gas flow rate exiting the torch. The kit also includes a set of instructions that should be followed exactly to insure safe and accurate use of the rotameter.

Total air flow rate in the PT-20AMX should be 325cfh minimum with any nozzle at 75 psi.

Flow Measuring Kit -- P/N 19765

5-10

SECTION 5 PCM-875A Plasmarc Cutting System Maintenance

5.3.7 Removal and Replacement of the Torch Body

Make sure that the power source has been

WARNING

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

PT-20AMX Torch

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

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

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

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

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

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

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

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

5-11

SECTION 5 PCM-875A Plasmarc Cutting System Maintenance

This page intentionally left blank

5-12

SECTION 6 PCM-875A Plasmarc System Troubleshooting

6.1 Troubleshooting PCM-875A Plasmarc System

Electric Shock Can Kill!

WARNING

Ensure that all primary power to the machine has been externally disconnected.

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

Match the problem with the conditions below.

If problem is not listed,

· shut off input power,

· open unit by removing cover

· Visual inspection of all components and wiring

· Check for loose terminal connections

· Burned wiring or other components

· Bulged or leaking capacitors

· Any other signs of damage or discoloration.

6-1

SECTION 6 PCM-875A Plasmarc System Troubleshooting

6.2 Troubleshooting guide for PCM-875A Plasmarc System

6.2.1 Power Light (PL1) does not come on

6.2.2 No air flow

· Visually inspect the machine for damage.

· Check if the cooling fan is running. If not running,

check the following:

§ Check if machine input power is still connected.

§ Measure input power at the receptacle. If not

present, then check the wall disconnect switch and it’s fuses.

§ Check fuse (F1). If it is:

§ Check input circuit breaker (CB1).

§ If cooling fan is running, measure voltage

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

§ If voltage is present, power light may be burned

out.

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

· Check air inlet supply. Unit requires 9,2

4,48 bar.

m/h at

· Check air hose and connections. Tighten if

leaking.

· Does air flow when “Air Test” switch is in test

position?

§ If not, check torch consumables, replace if

necessary.

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

6-2

SECTION 6 PCM-875A Plasmarc System Troubleshooting

6.2.3 The Power light is on, but nothing happens when the torch is signaled to fire. Fault light does not activate.

NOTE: Unplug high frequency connection before

attempting to work on this problem.

· Check the Pilot Arc fuse (F2) located on the rear

panel. An open fuse will indicate a short in the torch. If the fuse is all right, then check the following:

§ With the machine power on, depress the torch

switch. On the control board the LED 1 should be lit as long as the switch is depressed. If not then check:

§ Turn power off to the machine. Unplug Control

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

§ Torch switch or the leads. Unplug the torch

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

§ Check T2 transformer secondary voltages at the

plugs P1 and P2. Refer to system schematic. Replace the transformer if the correct secondary voltages are not present.

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

6-3

SECTION 6 PCM-875A Plasmarc System Troubleshooting

6.2.4 Fault light activates when torch is signaled to fire

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

· High/Low line voltage. The Fault Light will rapidly

blink on and off (5 times per second). This indicates that the input voltage is outside the “+” or “-” 15% safe operating range rating.

· Flow fault - The fault light will be mostly on but will

blink off for 1/10th of a second every second. This indicates that the air flow is low.

§ Check the air pressure at the machine regulator.

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

§ Air flow may be blocked at the torch tip. Check

the torch consumables. Also check for any obstructions in the torch leads.

§ NOTE: If above items check OK , the

problem is internal. send unit to an Authorized Repair Station for repair.

§ Put the ‘Air Check’ switch to On position. Air

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

§ Air Check switch may also be malfunctioning if

the air is flowing continuously or putting in the On position does not turn air on.

6-4

SECTION 6 PCM-875A Plasmarc System Troubleshooting

Fault light activates (continued)

· Over Temperature. The fault light will be mostly off

but will blink on for 1/10 of a second, every second. This generally indicates that the duty cycle has been exceeded. Allow the power source to cool before returning to operate.

§ Thermal switch may be open. It will open if the

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

§ If the switch is malfunctioning, replace it. Clean

the surface of the heat sink before installing the switch.

· Over Current. The fault light will be on continuously.

This indicates that the input current to the main transformer has exceeded preset limits.

§ To check if the output is shorted, measure the

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

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

6-5

SECTION 6 PCM-875A Plasmarc System Troubleshooting

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

· Check pilot arc fuse located on rear panel. If it is

open, nothing will happen when torch switch is depressed.

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

· Check to assure high frequency is present at torch.

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

· With HI FREQUENCY leads disconnected,

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

§ Check the operation of the Thermal Switch. See

D.3.a. above.

§ Check Air Check switch operation. It might be

stuck in On position. Pilot arc will not initiate if this switch is in the ON position. (safety reasons)

§ Check air flow switch. There may be internal

short. See D.2.c above.

§ Measure voltage across C1 or C2 capacitor. It

should be as follows:

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

approx. 280 VDC to 325 VDC for 400 volt unit

If not, one of following could be malfunctioning:

§ Check the capacitors C1 and C2 for any

damage.

§ Check input bridge/SCR Module (IBR) This can

be checked without taking it out of the circuit using an volt/ohmeter. Replace it if found malfunctioning. Follow bridge installation instructions.

§ Check Inrush current resistor, R10 and SCR1.

Both are located on the input bridge heat sink. Replace it if malfunctioning.

§ IGBTs (2 on 230 V, and 1 on the 400 V units) may

be blown. See IGBT installation procedure. Before replacing IGBTs, make sure to check the zener diodes and pico fuses on the IGBT driver boards.

6-6

SECTION 6 PCM-875A Plasmarc System Troubleshooting

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

6.2.7 Poor Cutting Performance.

· Make sure work clamp is connected to work

material.

· Check the torch. Replace consumables if necessary.

· Make sure the current setting potentiometer is set

above 10 amps. If it is, set below 10 amps, then HI FREQUENCY will go on and off at 5 sec intervals.

· Check air supply regulator . It should be adjusted to

65-75 psig.

· The air supplied to the torch should be free of oil

and water.

· Make sure the consumables in the torch are

acceptable.

· Check open circuit voltage.

· Check the output. Use a calibrated current probe

capable of measuring 100 amps in the presence of high frequency.

6.2.8 Air does not shut off.

· Check air test, the gas solenoid valve is energized

when the switch is in the “on” position.

· Does air flow stop when the torch switch is

unplugged? If yes, check and repair the torch. If not, send unit to an Authorized Repair Station for repair.

· Check voltage to solenoid coil, if present when

torch switch is unplugged, replace PCB1. If voltage is “0”, replace solenoid valve.

6-7

SECTION 6 PCM-875A Plasmarc System Troubleshooting

6.2.9 Main arc is difficult to start.

· The most common reason is worn or missing

consumables. Check and replace if necessary.

· Input air must be clean and dry.

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

· Torch connections must be tight.

· Work cable and clamp must be in good condition

and must make a good electrical connection to the material to be cut.

· If above items check OK , the problem is internal.

Send unit to an Authorized Repair Station for repair.

· Missing or weak pilot arc. Check pilot arc fuse,

open circuit voltage, pilot arc resistors and pilot arc wiring.

· Inoperative starter board (PCB-5).

· Check Spark gap in RAS unit. 1mm is desired

gap. If gap is to large, spark will be weak or nonexistent.

6-8

SECTION 6 PCM-875A Plasmarc System Troubleshooting

6.3 Reference Voltage Checks

A. Control Board Assembly (PCB1) LED’s LED-1 - Torch Switch LED-2 - High Frequency LED-3 - Gas Solenoid Valve Voltage Test Points

Tests are made with power on - no arc. Disable High Frequency by disconnecting blue wire with black sleeve

TP-0 - Ground TP-1 - +15 vdc TP-2 - +12 vdc TP-3 - -12 vdc TP-4 - +5 vdc

TP-9 - IGBT’s driving signal - switching frequency = 16 KHz TP-10 - IGBT’s driving signal - switching frequency = 16 KHz

62 µsec

13 vdc

-13 vdc

5 msec

IGBT Gating Signal

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

6-9

SECTION 6 PCM-875A Plasmarc System Troubleshooting

6.4 PT-20AMX Torch Troubleshooting

Common Cutting Problems

Listed below are common cutting problems

followed by the probable cause of each. If problems are determined to be caused by the PCM-875, refer to the maintenance section of this manual. If the problem is not corrected after referring to the maintenance section, contact your ESAB distributor.

6.4.1 Insufficient Penetration

6.4.2 Main Arc Extinguishes

6.4.3 Dross Formation.

· Current too low.

· Cutting speed too fast.

· Damaged cutting nozzle.

· Improper air pressure.

· Low air flow rate.

· Cutting speed too slow.

· Worn electrode.

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

· Current too low.

· Cutting speed too fast or too slow.

· Improper air pressure.

6-10

· Faulty nozzle or electrode.

· Low air flow rate.

SECTION 6 PCM-875A Plasmarc System Troubleshooting

6.4.4 Double Arcing

6.4.5 Uneven Arc.

6.4.6 Unstable Cutting Conditions.

6.4.7 Main Arc Does Not Strike

· .Damaged Nozzle Orifice.

· Low air pressure.

· Damaged cutting nozzle.

· Loose cutting nozzle.

· Heavy spatter accumulation on nozzle.

· Damaged cutting nozzle or worn electrode.

· Incorrect cutting speed.

· Loose cable or hose connections.

· Electrode and/or cutting nozzle in poor

condition.

· Worn electrode.

· Loose connections.

· Worn cable not attached

6.4.8 Poor Consumable Life

· Improper gas pressure.

· Contaminated air supply.

· Low air flow rate

6-11

SECTION 6 PCM-875A Plasmarc System Troubleshooting

6.5 230V Power Console Electrical Drawings

6.5.1 230V Console Schematic Part 1

BLK

LINE

LOAD

10,50W

275V

(+)

C2E1

39K,2W

40UF,400VDC

208/230 VAC

50/60 HZ

RED

3 PH CE

275V

P1-4VP1-3

275V

AC3

P1-4VP1-3

AC2

C3 C1 C2

WHT

AC1

D3T

(-)

10K,25W 10K,25W

1UF,600V

1800UF,450VDC 1800UF,450VDC

P1-1

P1-1VP1-2

C10

0.022UF,1KV

10 OHM,50 W

V V

P1-2

.22UF,1KV

TB5-1

3A,600VAC 2 1

10K,2W

1UF

600V

MAX

230V

E2 2

(-)

C16

1uf 600V

C15

P5-3

V V

V V V V

V V

TB3

208V

C7 R5

1 1

(+)

20,25W.01UF,1KV

12V

P2-7

P2-8

P6-13

P6-6

P6-12

P6-5

P1-1

P1-2

V V V V

V V V V V

P3-2

P3-1

P3-4 P3-5

P4-5

P4-4

P4-1

P4-2

P1-7

P1-8

P5-4

P1-9

18V

20,25W

P1-10

2 21

2 2

X11

115V

P2-11

.01UF,1KV

(-)

.01UF,1KV

X12

V V

P2-14

(CONTROL BOARD)

208V

P1-5

RED

(+)

208V

12V

P6-11

(PCB4)

230V

TB5-2

230V

V V

P1-6

P6-10

V V

BLK

P2-1

(-)

24V

R11

8 ,300W

R12

400V

X10

20V

P2-4

V V

P1-3

P1-4

P5-9

R16

100K

1 2

6-12

SECTION 6 PCM-875A Plasmarc System Troubleshooting

230V Schematic Part 2

(SEE CHART)

1234

V V

P6-9

P6-7

5 6

(+) (-)

TB4-1

ARC ON

}

SIGNAL TO CNC

TB4-2 TB4-3

START SIGNAL

}

TB4-4

FROM CNC VOLTAGE DIVIDER

TB4-5

}

SIGNAL TO CNC

TB4-6

P2-3

P2-4

P1-12

P1-11

P6-1

P6-2

(CONTROL BOARD)

330K ,1W

R13

.82UF 630VDC

C21

L3T3

1 2

T2 T1

P.A.

P1-1

P1-6

P1-2

P1-3

PILOT

ARC

.022UF, 1KV

C20

GND 3

0.047uf 660V

(+)

(-)

P2-2

P2-3 P5-5

P2-12

115 VAC

.01UF,250 VAC

.01UF

1KV

H1 X1

2500 PF,15KV

P5-6

P5-1

P5-2

VVV V

.022UF

250VAC

P2-13

.01UF

1KV

H2 X2

250VAC

2500 PF,15KV

3 1

.022UF

0558003357

0558003356 &

NOT USED ON CONSOLES

75mA

60V

SHIELD

TORCH SWITCH

6-13

SECTION 6 PCM-875A Plasmarc System Troubleshooting

6.5.2 230V Power Console Wiring Diagrams Part 1

J1 SHIELD

PCB5 P1-3 VIO

PCB5 P1-2 BLU

J1-2 BLK J1-1 GRY

T3-H2 RED

T3-H1 RED

T5-X1 RED

765

1 2

GND 2

P5-1 P5-2

TB2

342

1 2

RED RED

SPLICE

TB4

PCB1 P6-7 YEL

PCB1 P6-9 ORN

PCB1 P1-11 RED

T5-X2 RED

(SEE CHART)

S1-T3 BLK S1-T2 BLK

S1-T1 BLK

S1-5 RED

PCB1

LINE

TB1-2 BLK

TB1-1 BLK

SG-1 RED

FN1

CE MARKED UNITS

ONLY

IBR-T BLK

IBR-S BLK

LOAD

IBR-R BLK

P.A. BUS ORN

BLU

L1 L2

SG-2 RED

R13

C21

T1 T2

BLU

PCB1 P2-13 BLU

R11-2 YEL

6-14

PCB1 P2-12 BLU

YEL PCB1 P2-11

YEL PCB1 P2-14

PL1

PCB1 P5-5 RED

PL2

PCB1 P1-12 BLK

PCB1 P2-4 ORN

0558003357

0558003356 &

NOT USED ON CONSOLES

PCB1 P6-1 BLU

PCB1 P6-6 WHT

PCB1 P5-6 BLK

4 1

RED FS-2

GRY PCB1 P2-3

BLU PCB1 P6-2

PCB1 P6-12 BRN

PCB1 P6-13 RED

SECTION 6 PCM-875A Plasmarc System Troubleshooting

230V Power Console Wiring Diagrams Part 2

DETAIL "A" (PCB1)

1TS1-1 2TS1-2 34T2-X9

T2-X10 5T2-X5 6 6 6 R1-2 WHTT2-X6 BLU 4 ORNS1-2 BLKPL2-(-)

7T4-1 8T4-2 9T2-X3 10 T2-X4 11 FS-1 12 S1-4

VIO 2 BRN BRN33 BLU 4

ORN ORN WHT WHT RED BLK

1VIO

5 6 7 IBR-G YEL 8 IBR(+) BRN 9 10 11 11 12 12 13 13 14

T2-X7 SOL1-1 SOL1-2 S1-3 T2-X8

T2-X11 PL1-1 TB1-1 K1-A BLU TB1-2

K1-B PL1-2

T2-X1214 VIO

WHT GRY GRY ORN

VIO YEL BLU

BLU BLU

YEL

1ORN

J1-1

J1-2 T2-X1

T2-X2

PL2-(+)

7 8 9 R16-1 GRY 10 11 12

CLR (TP) BLK (TP)

YEL YEL

1S2-1 2S2-2 3 4 5 PCB1 P6-6 WHTRED

PCB1 P6-5 WHT

TB4-1

8 8

TB4-29

10 PCB4-3

11 PCB4-4 12 R1-1 13 R1-3

BLU BLU

YEL

ORN BLK (TP)

RED (TP) BRN RED

GRN

GND1

INPUT POWER CABLE

FN1 LINE A

FN1 LINE B FN1 LINE C

BLK BLU BRN

T1 T2

LINE

1 2 3

BLK

RED T2-H1 BLK M1-2

BLU

BRN

BLK TB5-2

F1-1

LOAD

* *

BLK

IBR (T) BLK

6-15

SECTION 6 PCM-875A Plasmarc System Troubleshooting

230V Power Console Wiring Diagrams Part 3

TB4-5 BLU

TB4-6 VIO

PCB4-1 RED

PCB5

BLK PCB1 P6-10

345 612

GND 5

PCB4

(SHUNT)

324

RED PCB1 P6-11

TB5

T2-H2 BLK T2-H3 GRY

M1-1 BLK

* *

MOV

FN1 LOAD B

GRY

L1-H2 BLK

VIEW E-E

PCB1-P4

WHT

TS1

R7-1 BLU

12 3 54

WHT

RED

134 234

PCB3

C16

C2E1

C10

WHT

T1-H1

PCB4-2 BLU

PCB1- P3

IBR(+) RED

L2-X1

IBR

R2R

PCB1 P2-8 BRN

C1(+) RED

L2-X2

R2-2 BLK

YEL

C19

Q1-C2E1 RED

PCB1 P2-7 YEL

F1-2 BLK

FN1 LOAD C

R2-1 RED

PCB1 P1-2 VIO PCB1 P1-1 VIO

C4-2 RED

C4-4 BLU

R10

ORN

PCB1 P1-7 ORN

2 1

WHT

PCB2

RED

ORN PCB1 P1-8ORN

T1-H2

51423

RED

C15

C2E1

WORK

R11-1 BLU

D1(+) BLU

PCB5 P1-1 RED

VIEW B-B

R15-2 RED

PCB1 P5-2 BLK(TP)

PCB1 P5-1 CLR(TP)

T1-X3

TB3

P.A. BUS

PCB1 P2-3 GRY

GND 3

K1-L1 ORN

C20

TB4-4 BLK

CLR

BLK

R15-1 BLK

2 1 2

L1-H1 BLK

T1-X1

T1-X2

ZD1

PCB1 P2-2 WHT

SOL1

C23

6-16

LEFT SIDE VIEW

TB4-3 GRY

ESAB PCM-875A Plasmarc Mechanized Cutting System Installation manual / Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual