ESAB PCM-875 Plasma Arc Cutting Package Instruction manual

PCM-875

Plasma Arc Cutting Package

Instruction Manual

This manual provides installation and operation instructions for the following PCM-875 cutting packages starting with
Serial No. PHJ205001:

Consoles:

P/N 0558001167 - 208/230 V, 50/60 Hz, 1 or 3-phase
P/N 0558001169 - 460 V, 50/60 Hz, 3-phase
P/N 0558001170 - 575 V, 60 Hz, 3-phase
P/N 0558001171 - 400 V, 50/60 Hz, 3-phase
P/N 0558001172 - 230 V, 50 Hz, CE, 3-phase

The above consoles are used in the following packages

P/N 36590 - 208/230 V Console w/25' PT-27 Torch
P/N 36592 - 460 V Console w/25' PT-27 Torch
P/N 36714 - 575 V Console w/25' PT-27 Torch
P/N 36725 - 400 V Console w/25' PT-27 Torch
P/N 36883 - 230 V CE Console w/25' PT-27 Torch

F15-605-D 12 / 2005

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

CAUTION

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

USER RESPONSIBILITY

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

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

TABLE OF CONTENTS

Section / Title Page

1.0 Safety Precautions.............................................................................................................................................................................................5

1.1 Safety - English ......................................................................................................................................................................................5

1.2 Safety - Spanish .....................................................................................................................................................................................9

1.3 Safety - French .......................................................................................................................................................................................13

2.0 Description...........................................................................................................................................................................................................17

2.1 General ..................................................................................................................................................................................................... 17

2.2 Scope ........................................................................................................................................................................................................17

2.3 Packages Available ............................................................................................................................................................................... 17

2.4 Specifications .........................................................................................................................................................................................18

2.5 Optional Accessories ...........................................................................................................................................................................18

3.0 Installation ........................................................................................................................................................................................................... 21

3.1 General .....................................................................................................................................................................................................21

3.2 Equipment Required ........................................................................................................................................................................... 21

3.3 Location ...................................................................................................................................................................................................21

3.4 Inspection................................................................................................................................................................................................ 21

3.5 Primary Electrical Input Connections ............................................................................................................................................21

3.6 Secondary Output Connections ..................................................................................................................................................... 22

3.7 Connecting PCM-875 for 200(208)Vac Input .............................................................................................................................. 24

3.8 Mechanized Cutting Installation with the PT-20AM Torch .................................................................................................... 25

4.0 Operation ............................................................................................................................................................................................................. 27

4.1 Operation ................................................................................................................................................................................................27

4.2 PCM-875 Controls ................................................................................................................................................................................. 27

4.3 Cutting with the PT-27 ........................................................................................................................................................................ 27

4.4 Common Cutting Problems .............................................................................................................................................................. 29

5.0 Maintenance ........................................................................................................................................................................................................ 31

5.1 General ..................................................................................................................................................................................................... 31

5.2 Inspection and Cleaning .................................................................................................................................................................... 31

5.3 PT-27 Torch Consumable Parts ........................................................................................................................................................31

5.4 Flow Switch ............................................................................................................................................................................................. 32

5.5 IGBT Handling and Replacement .................................................................................................................................................... 32

5.6 Troubleshooting ................................................................................................................................................................................... 33

5.7 Troubleshooting Guide ...................................................................................................................................................................... 34

5.8 Reference Voltage Checks ................................................................................................................................................................. 38

5.9 Sequence of Operation ......................................................................................................................................................................39

6.0 Replacement Parts ............................................................................................................................................................................................ 41

6.1 General ..................................................................................................................................................................................................... 41

6.2 Ordering................................................................................................................................................................................................... 41

3

TABLE OF CONTENTS

4

SECTION 1 SAFETY PRECAUTIONS

1.0 Safety Precautions

WARNING: These Safety Precautions are

for your protection. They summarize pre­cautionary information from the references

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

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

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

1. Always wear safety glasses with side shields in any

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

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

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

3. Wear flameproof gauntlet type gloves, heavy long-

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

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

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

5. Protect other personnel from arc rays and hot

sparks with a suitable non-flammable partition or
curtains.

6. Use goggles over safety glasses when chipping slag

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

1.1 Safety - English

FIRES AND EXPLOSIONS -­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 non-flammable covering. Combustible materials
include wood, cloth, sawdust, liquid and gas fuels,
solvents, paints and coatings, paper, etc.

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

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

4. Have fire extinguishing equipment handy for instant
use, such as a garden hose, water pail, sand bucket,
or portable fire extinguisher. Be sure you are trained
in its use.

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

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

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

Heat from

5

SECTION 1 SAFETY PRECAUTIONS

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.

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.

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:

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.

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.

6

SECTION 1 SAFETY PRECAUTIONS

5. WARNING: This product, when used for welding
or cutting, produces fumes or gases
which contain chemicals known to
the State of California to cause birth
defects and, in some cases, cancer.
(California Health & Safety Code

§25249.5 et seq.)

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.

1. Always have qualified personnel perform the instal
lation, 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.

-

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.

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

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"

7

SECTION 1 SAFETY PRECAUTIONS

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.

8

SECTION 1 SEGURIDAD

1.2 Safety - Spanish

ADVERTENCIA: Estas Precauciones de Se-

guridad son para su protección. Ellas hacen

resumen de información proveniente de las
referencias listadas en la sección "Información Adi­cional Sobre La Seguridad". Antes de hacer cualquier
instalación o procedimiento de operación , asegúrese
de leer y seguir las precauciones de seguridad listadas
a continuación así como también todo manual, hoja
de datos de seguridad del material, calcomanias, etc.
El no observar las Precauciones de Seguridad puede
resultar en daño a la persona o muerte.

PROTEJASE USTED Y A LOS DEMAS-­Algunos procesos de soldadura, corte
y ranurado son ruidosos y requiren
protección para los oídos. El arco,

como el sol , emite rayos ultravioleta
(UV) y otras radiaciones que pueden dañar la piel
y los ojos. El metal caliente causa quemaduras. EL
entrenamiento en el uso propio de los equipos y
sus procesos es esencial para prevenir accidentes.
Por lo tanto:

1. Utilice gafas de seguridad con protección a los lados

siempre que esté en el área de trabajo, aún cuando
esté usando careta de soldar, protector para su cara
u otro tipo de protección.

2. Use una careta que tenga el filtro correcto y lente

para proteger sus ojos, cara, cuello, y oídos de las
chispas y rayos del arco cuando se esté operando y
observando las operaciones. Alerte a todas las per­sonas cercanas de no mirar el arco y no exponerse
a los rayos del arco eléctrico o el metal fundido.

3. Use guantes de cuero a prueba de fuego, camisa

pesada de mangas largas, pantalón de ruedo liso,
zapato alto al tobillo, y careta de soldar con capucha
para el pelo, para proteger el cuerpo de los rayos y
chispas calientes provenientes del metal fundido.
En ocaciones un delantal a prueba de fuego es
necesario para protegerse del calor radiado y las
chispas.

4. Chispas y partículas de metal caliente puede alojarse

en las mangas enrolladas de la camisa , el ruedo del
pantalón o los bolsillos. Mangas y cuellos deberán
mantenerse abotonados, bolsillos al frente de la
camisa deberán ser cerrados o eliminados.

5. Proteja a otras personas de los rayos del arco y chis

pas calientes con una cortina adecuada no-flamable
como división.

6. Use careta protectora además de sus gafas de segu

ridad cuando esté removiendo escoria o puliendo.

La escoria puede estar caliente y desprenderse con
velocidad. Personas cercanas deberán usar gafas
de seguridad y careta protectora.

FUEGO Y EXPLOSIONES -­las flamas y el arco pueden ocacionar
fuegos. Escoria caliente y las chispas
pueden causar fuegos y explosiones.
Por lo tanto:

1. Remueva todo material combustible lejos del área
de trabajo o cubra los materiales con una cobija a
prueba de fuego. Materiales combustibles incluyen
madera, ropa, líquidos y gases flamables, solventes,
pinturas, papel, etc.

2. Chispas y partículas de metal pueden introducirse en
las grietas y agujeros de pisos y paredes causando
fuegos escondidos en otros niveles o espacios.
Asegúrese de que toda grieta y agujero esté cubierto
para proteger lugares adyacentes contra fuegos.

3. No corte, suelde o haga cualquier otro trabajo
relacionado hasta que la pieza de trabajo esté to­talmente limpia y libre de substancias que puedan
producir gases inflamables o vapores tóxicos. No
trabaje dentro o fuera de contenedores o tanques
cerrados. Estos pueden explotar si contienen vapores
inflamables.

4. Tenga siempre a la mano equipo extintor de fuego
para uso instantáneo, como por ejemplo una
manguera con agua, cubeta con agua, cubeta con
arena, o extintor portátil. Asegúrese que usted esta
entrenado para su uso.

5. No use el equipo fuera de su rango de operación. Por
ejemplo, el calor causado por cable sobrecarga en
los cables de soldar pueden ocasionar un fuego.

6. Después de termirar la operación del equipo, inspec
cione el área de trabajo para cerciorarse de que las
chispas o metal caliente ocasionen un fuego más
tarde. Tenga personal asignado para vigilar si es
necesario.

7. Para información adicional , haga referencia a la
publicación NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible
a través de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.

CHOQUE ELECTRICO -- El contacto
con las partes eléctricas energizadas

-

-

de movimiento confinado en lugares estrechos o
si hay posibilidad de caer al suelo.

y tierra puede causar daño severo o
muerte. NO use soldadura de corri
ente alterna (AC) en áreas húmedas,

El calor de

-

-

9

SECTION 1 SEGURIDAD

1. Asegúrese de que el chasis de la fuente de poder
esté conectado a tierra através del sistema de
electricidad primario.

2. Conecte la pieza de trabajo a un buen sistema de
tierra física.

3. Conecte el cable de retorno a la pieza de trabajo.
Cables y conductores expuestos o con malas
conexiones pueden exponer al operador u otras
personas a un choque eléctrico fatal.

4. Use el equipo solamente si está en buenas condi­ciones. Reemplaze cables rotos, dañados o con
conductores expuestos.

5. Mantenga todo seco, incluyendo su ropa, el área de
trabajo, los cables, antorchas, pinza del electrodo,
y la fuente de poder.

6. Asegúrese que todas las partes de su cuerpo están
insuladas de ambos, la pieza de trabajo y tierra.

7. No se pare directamente sobre metal o tierra mien­tras trabaja en lugares estrechos o áreas húmedas;
trabaje sobre un pedazo de madera seco o una
plataforma insulada y use zapatos con suela de
goma.

8. Use guantes secos y sin agujeros antes de energizar
el equipo.

9. Apage el equipo antes de quitarse sus guantes.

10. Use como referencia la publicación ANSI/ASC
Standard Z49.1 (listado en la próxima página) para
recomendaciones específicas de como conectar el
equipo a tierra. No confunda el cable de soldar a
la pieza de trabajo con el cable a tierra.

CAMPOS ELECTRICOS Y MAGNETI­COS - Son peligrosos. La corriente
eléctrica fluye através de cualquier
conductor causando a nivel local

Campos Eléctricos y Magnéticos
(EMF). Las corrientes en el área de corte y soldadura,
crean EMF alrrededor de los cables de soldar y las
maquinas. Por lo tanto:

1. Soldadores u Operadores que use marca-pasos para

el corazón deberán consultar a su médico antes de
soldar. El Campo Electromagnético (EMF) puede
interferir con algunos marca-pasos.

2. Exponerse a campos electromagnéticos (EMF) puede

causar otros efectos de salud aún desconocidos.

3. Los soldadores deberán usar los siguientes proced
imientos para minimizar exponerse al EMF:

A. Mantenga el electrodo y el cable a la pieza de

trabajo juntos, hasta llegar a la pieza que usted
quiere soldar. Asegúrelos uno junto al otro con
cinta adhesiva cuando sea posible.

B. Nunca envuelva los cables de soldar alrededor

de su cuerpo.

C. Nunca ubique su cuerpo entre la antorcha y el

cable, a la pieza de trabajo. Mantega los cables a
un sólo lado de su cuerpo.

D. Conecte el cable de trabajo a la pieza de trabajo

lo más cercano posible al área de la soldadura.

E. Mantenga la fuente de poder y los cables de soldar

lo más lejos posible de su cuerpo.

HUMO Y GASES -- El humo y los
gases, pueden causar malestar o
daño, particularmente en espacios

sin ventilación. No inhale el humo

o gases. El gas de protección puede
causar falta de oxígeno.
Por lo tanto:

1. Siempre provea ventilación adecuada en el área

de trabajo por medio natural o mecánico. No solde,
corte, o ranure materiales con hierro galvanizado,
acero inoxidable, cobre, zinc, plomo, berílio, o cad­mio a menos que provea ventilación mecánica
positiva . No respire los gases producidos por
estos materiales.

2. No opere cerca de lugares donde se aplique sub-

stancias químicas en aerosol. El calor de los rayos
del arco pueden reaccionar con los vapores de
hidrocarburo clorinado para formar un fosfógeno,
o gas tóxico, y otros irritant es.

3. Si momentáneamente desarrolla inrritación de

ojos, nariz o garganta mientras est á operando, es
indicación de que la ventilación no es apropiada.
Pare de trabajar y tome las medidas necesarias
para mejorar la ventilación en el área de trabajo.
No continúe operando si el malestar físico per­siste.

4. Haga referencia a la publicación ANSI/ASC Standard

Z49.1 (Vea la lista a continuación) para recomen­daciones específicas en la ventilación.

-

10

SECTION 1 SEGURIDAD

5. ADVERTENCIA-- Este producto cuando se uti­liza para soldaduras o cortes,
produce humos o gases, los
cuales contienen químicos
conocidos por el Estado de Cali­fornia de causar defectos en el
nacimiento, o en algunos casos,
Cancer. (California Health &
Safety Code §25249.5 et seq.)

MANEJO DE CILINDROS-- Los

cilindros, si no son manejados
correctamente, pueden romp­erse y liberar violentamente
gases. Rotura repentina del
cilindro, válvula, o válvula de
escape puede causar daño o
muerte. Por lo tanto:

1. Utilize el gas apropiado para el proceso y utilize

un regulador diseñado para operar y reducir la
presión del cilindro de gas . No utilice adapta­dores. Mantenga las mangueras y las conexiones
en buenas condiciones. Observe las instrucciones
de operación del manufacturero para montar el
regulador en el cilindro de gas comprimido.

2. Asegure siempre los cilindros en posición vertical

y amárrelos con una correa o cadena adecuada
para asegurar el cilindro al carro, transportes, tab­lilleros, paredes, postes, o armazón. Nunca asegure
los cilindros a la mesa de trabajo o las piezas que
son parte del circuito de soldadura . Este puede ser
parte del circuito elélectrico.

3. Cuando el cilindro no está en uso, mantenga la

válvula del cilindro cerrada. Ponga el capote de
protección sobre la válvula si el regulador no
está conectado. Asegure y mueva los cilindros
utilizando un carro o transporte adecuado. Evite
el manejo brusco de los

1. Siempre tenga personal cualificado para efec­tuar l a instalación, diagnóstico, y mantenimiento
del equipo. No ejecute ningún trabajo eléctrico a
menos que usted esté cualificado para hacer el
trabajo.

2. Antes de dar mantenimiento en el interior de la
fuente de poder, desconecte la fuente de poder
del suministro de electricidad primaria.

3. Mantenga los cables, cable a tierra, conexciones,
cable primario, y cualquier otra fuente de poder
en buen estado operacional. No opere ningún
equipo en malas condiciones.

4. No abuse del equipo y sus accesorios. Mantenga
el equipo lejos de cosas que generen calor como
hornos, también lugares húmedos como charcos
de agua , aceite o grasa, atmósferas corrosivas y
las inclemencias del tiempo.

5. Mantenga todos los artículos de seguridad y
coverturas del equipo en su posición y en buenas
condiciones.

6. Use el equipo sólo para el propósito que fue
diseñado. No modifique el equipo en ninguna
manera.

INFORMACION ADICIONAL DE SEGU­RIDAD -- Para más información sobre las
prácticas de seguridad de los equipos de
arco eléctrico para soldar y cortar, pregunte
a su suplidor por una copia de "Precautions
and Safe Practices for Arc Welding, Cutting
and Gouging-Form 52-529.

Las siguientes publicaciones, disponibles através de
la American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, son recomendadas para usted:

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

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

MANTENIMIENTO DEL EQUIPO -- Equipo
defectuoso o mal mantenido puede cau­sar daño o muerte. Por lo tanto:

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

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

11

SECTION 1 SEGURIDAD

SIGNIFICADO DE LOS SIMBOLOS

-- Según usted avanza en la lectura
de este folleto: Los Símbolos Sig­nifican ¡Atención! ¡Esté Alerta! Se
trata de su seguridad.

Significa riesgo inmediato que,
de no ser evadido, puede resultar
inmediatamente en serio daño
personal o la muerte.

Significa el riesgo de un peligro
potencial que puede resultar en
serio daño personal o la muerte.

Significa el posible riesgo que
puede resultar en menores daños
a la persona.

12

SECTION 1 SÉCURITÉ

1.3 Safety - French

AVERTISSEMENT :

ont pour but d'assurer votre protection. Ils
récapitulent les informations de précaution

provenant des références dans la section
des Informations de sécurité supplémentaires. Avant de
procéder à l'installation ou d'utiliser l'unité, assurez-vous
de lire et de suivre les précautions de sécurité ci-des­sous, dans les manuels, les fiches d'information sur la
sécurité du matériel et sur les étiquettes, etc. Tout défaut
d'observer ces précautions de sécurité peut entraîner
des blessures graves ou mortelles.

PROTÉGEZ-VOUS -- Les processus de
soudage, de coupage et de gougeage

produisent un niveau de bruit élevé et
exige l'emploi d'une protection auditive. L'arc, tout
comme le soleil, émet des rayons ultraviolets en plus
d'autre rayons qui peuvent causer des blessures à la
peau et les yeux. Le métal incandescent peut causer
des brûlures. Une formation reliée à l'usage des
processus et de l'équipement est essentielle pour
prévenir les accidents. Par conséquent:

1. Portez des lunettes protectrices munies d'écrans la-

téraux lorsque vous êtes dans l'aire de travail, même
si vous devez porter un casque de soudeur, un écran
facial ou des lunettes étanches.

2. Portez un écran facial muni de verres filtrants et de

plaques protectrices appropriées afin de protéger
vos yeux, votre visage, votre cou et vos oreilles des
étincelles et des rayons de l'arc lors d'une opération
ou lorsque vous observez une opération. Avertissez
les personnes se trouvant à proximité de ne pas re­garder l'arc et de ne pas s'exposer aux rayons de l'arc
électrique ou le métal incandescent.

3. Portez des gants ignifugiés à crispin, une chemise

épaisse à manches longues, des pantalons sans
rebord et des chaussures montantes afin de vous
protéger des rayons de l'arc, des étincelles et du métal
incandescent, en plus d'un casque de soudeur ou
casquette pour protéger vos cheveux. Il est également
recommandé de porter un tablier ininflammable afin
de vous protéger des étincelles et de la chaleur par
rayonnement.

4. Les étincelles et les projections de métal incandescent

risquent de se loger dans les manches retroussées,
les rebords de pantalons ou les poches. Il est recom­mandé de garder boutonnés le col et les manches et
de porter des vêtements sans poches en avant.

5. Protégez toute personne se trouvant à proximité des

étincelles et des rayons de l'arc à l'aide d'un rideau ou
d'une cloison ininflammable.

6. Portez des lunettes étanches par dessus vos lunettes

de sécurité lors des opérations d'écaillage ou de
meulage du laitier. Les écailles de laitier incandescent
peuvent être projetées à des distances considérables.
Les personnes se trouvant à proximité doivent égale­ment porter des lunettes étanches par dessus leur
lunettes de sécurité.

Ces règles de sécurité

INCENDIES ET EXPLOSIONS -- La
chaleur provenant des flammes ou de

l'arc peut provoquer un incendie. Le
laitier incandescent ou les étincelles

peuvent également provoquer un

incendie ou une explosion. Par conséquent :

1. Éloignez suffisamment tous les matériaux combus
tibles de l'aire de travail et recouvrez les matériaux
avec un revêtement protecteur ininflammable. Les
matériaux combustibles incluent le bois, les vête­ments, la sciure, le gaz et les liquides combustibles,
les solvants, les peintures et les revêtements, le
papier, etc.

2. Les étincelles et les projections de métal incan
descent peuvent tomber dans les fissures dans
les planchers ou dans les ouvertures des murs et
déclencher un incendie couvant à l'étage inférieur
Assurez-vous que ces ouvertures sont bien protégées
des étincelles et du métal incandescent.

3. N'exécutez pas de soudure, de coupe ou autre tra
vail à chaud avant d'avoir complètement nettoyé la
surface de la pièce à traiter de façon à ce qu'il n'ait
aucune substance présente qui pourrait produire
des vapeurs inflammables ou toxiques. N'exécutez
pas de travail à chaud sur des contenants fermés
car ces derniers pourraient exploser.

4. Assurez-vous qu'un équipement d'extinction
d'incendie est disponible et prêt à servir, tel qu'un
tuyau d'arrosage, un seau d'eau, un seau de sable
ou un extincteur portatif. Assurez-vous d'être bien
instruit par rapport à l'usage de cet équipement.

5. Assurez-vous de ne pas excéder la capacité de
l'équipement. Par exemple, un câble de soudage
surchargé peut surchauffer et provoquer un in­cendie.

6. Une fois les opérations terminées, inspectez l'aire de
travail pour assurer qu'aucune étincelle ou projec­tion de métal incandescent ne risque de provoquer
un incendie ultérieurement. Employez des guetteurs
d'incendie au besoin.

7. Pour obtenir des informations supplémentaires,
consultez le NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible au
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.

CHOC ÉLECTRIQUE -- Le contact avec
des pièces électriques ou les pièces
de mise à la terre sous tension peut
causer des blessures graves ou mor-

telles. NE PAS utiliser un courant de
soudage c.a. dans un endroit humide, en espace
restreint ou si un danger de chute se pose.

-

-

-

13

SECTION 1 SÉCURITÉ

1. Assurez-vous que le châssis de la source
d'alimentation est branché au système de mise à
la terre de l'alimentation d'entrée.

2. Branchez la pièce à traiter à une bonne mise de
terre électrique.

3. Branchez le câble de masse à la pièce à traiter et
assurez une bonne connexion afin d'éviter le risque
de choc électrique mortel.

4. Utilisez toujours un équipement correctement
entretenu. Remplacez les câbles usés ou endom­magés.

5. Veillez à garder votre environnement sec, incluant
les vêtements, l'aire de travail, les câbles, le porte­électrode/torche et la source d'alimentation.

6. Assurez-vous que tout votre corps est bien isolé
de la pièce à traiter et des pièces de la mise à la
terre.

7. Si vous devez effectuer votre travail dans un espace
restreint ou humide, ne tenez vous pas directe­ment sur le métal ou sur la terre; tenez-vous sur
des planches sèches ou une plate-forme isolée et
portez des chaussures à semelles de caoutchouc.

8. Avant de mettre l'équipement sous tension, isolez
vos mains avec des gants secs et sans trous.

9. Mettez l'équipement hors tension avant d'enlever
vos gants.

10. Consultez ANSI/ASC Standard Z49.1 (listé à
la page suivante) pour des recommandations
spécifiques concernant les procédures de mise à
la terre. Ne pas confondre le câble de masse avec
le câble de mise à la terre.

CHAMPS ÉLECTRIQUES ET MAGNÉ­TIQUES — comportent un risque
de danger. Le courant électrique
qui passe dans n'importe quel con-

ducteur produit des champs élec­triques et magnétiques localisés. Le soudage et le
courant de coupage créent des champs électriques
et magnétiques autour des câbles de soudage et
l'équipement. Par conséquent :

1. Un soudeur ayant un stimulateur cardiaque doit

consulter son médecin avant d'entreprendre une
opération de soudage. Les champs électriques et
magnétiques peuvent causer des ennuis pour cer­tains stimulateurs cardiaques.

2. L'exposition à des champs électriques et magné-

tiques peut avoir des effets néfastes inconnus pour
la santé.

3. Les soudeurs doivent suivre les procédures suivantes
pour minimiser l'exposition aux champs électriques
et magnétiques :

A. Acheminez l'électrode et les câbles de masse

ensemble. Fixez-les à l'aide d'une bande adhésive
lorsque possible.

B. Ne jamais enrouler la torche ou le câble de masse

autour de votre corps.

C. Ne jamais vous placer entre la torche et les câbles

de masse. Acheminez tous les câbles sur le même
côté de votre corps.

D. Branchez le câble de masse à la pièce à traiter le

plus près possible de la section à souder.

E. Veillez à garder la source d'alimentation pour le

soudage et les câbles à une distance appropriée
de votre corps.

LES VAPEURS ET LES GAZ -- peuvent
causer un malaise ou des dommages

corporels, plus particulièrement
dans les espaces restreints. Ne re­spirez pas les vapeurs et les gaz. Le
gaz de protection risque de causer
l'asphyxie. Par conséquent :

1. Assurez en permanence une ventilation adéquate
dans l'aire de travail en maintenant une ventila­tion naturelle ou à l'aide de moyens mécanique.
N'effectuez jamais de travaux de soudage, de coup­age ou de gougeage sur des matériaux tels que
l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc,
le plomb, le berylliym ou le cadmium en l'absence
de moyens mécaniques de ventilation efficaces. Ne
respirez pas les vapeurs de ces matériaux.

2. N'effectuez jamais de travaux à proximité d'une
opération de dégraissage ou de pulvérisation.
Lorsque la chaleur

ou le rayonnement de l'arc entre en contact avec les

vapeurs d'hydrocarbure chloré, ceci peut déclencher
la formation de phosgène ou d'autres gaz irritants,
tous extrêmement toxiques.

3. Une irritation momentanée des yeux, du nez ou de la
gorge au cours d'une opération indique que la ven­tilation n'est pas adéquate. Cessez votre travail afin
de prendre les mesures nécessaires pour améliorer
la ventilation dans l'aire de travail. Ne poursuivez
pas l'opération si le malaise persiste.

4. Consultez ANSI/ASC Standard Z49.1 (à la page
suivante) pour des recommandations spécifiques
concernant la ventilation.

14

SECTION 1 SÉCURITÉ

5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé
dans une opération de soudage ou de
coupage, dégage des vapeurs ou des
gaz contenant des chimiques consi­déres par l'état de la Californie comme
étant une cause des malformations
congénitales et dans certains cas, du
cancer. (California Health & Safety
Code §25249.5 et seq.)

MANIPULATION DES CYLINDRES --

La manipulation d'un cylindre, sans
observer les précautions nécessaires,
peut produire des fissures et un

échappement dangereux des gaz.
Une brisure soudaine du cylindre, de la soupape ou
du dispositif de surpression peut causer des bles­sures graves ou mortelles. Par conséquent :

1. Utilisez toujours le gaz prévu pour une opération

et le détendeur approprié conçu pour utilisation
sur les cylindres de gaz comprimé. N'utilisez jamais
d'adaptateur. Maintenez en bon état les tuyaux et
les raccords. Observez les instructions d'opération
du fabricant pour assembler le détendeur sur un
cylindre de gaz comprimé.

2. Fixez les cylindres dans une position verticale, à

l'aide d'une chaîne ou une sangle, sur un chariot
manuel, un châssis de roulement, un banc, un mur,
une colonne ou un support convenable. Ne fixez
jamais un cylindre à un poste de travail ou toute autre
dispositif faisant partie d'un circuit électrique.

3. Lorsque les cylindres ne servent pas, gardez les

soupapes fermées. Si le détendeur n'est pas bran­ché, assurez-vous que le bouchon de protection de
la soupape est bien en place. Fixez et déplacez les
cylindres à l'aide d'un chariot manuel approprié.
Toujours manipuler les cylindres avec soin.

4. Placez les cylindres à une distance appropriée

de toute source de chaleur, des étincelles et des
flammes. Ne jamais amorcer l'arc sur un cylindre.

5. Pour de l'information supplémentaire, consultez

CGA Standard P-1, "Precautions for Safe Handling
of Compressed Gases in Cylinders", mis à votre dis­position par le Compressed Gas Association, 1235
Jefferson Davis Highway, Arlington, VA 22202.

ENTRETIEN DE L'ÉQUIPEMENT -- Un équipe­ment entretenu de façon défectueuse ou
inadéquate peut causer des blessures
graves ou mortelles. Par conséquent :

1. Efforcez-vous de toujours confier les tâches
d'installation, de dépannage et d'entretien à un
personnel qualifié. N'effectuez aucune réparation
électrique à moins d'être qualifié à cet effet.

2. Avant de procéder à une tâche d'entretien à
l'intérieur de la source d'alimentation, débranchez
l'alimentation électrique.

3. Maintenez les câbles, les fils de mise à la terre, les
branchements, le cordon d'alimentation et la source
d'alimentation en bon état. N'utilisez jamais un
équipement s'il présente une défectuosité quel­conque.

4. N'utilisez pas l'équipement de façon abusive. Gardez
l'équipement à l'écart de toute source de chaleur,
notamment des fours, de l'humidité, des flaques
d'eau, de l'huile ou de la graisse, des atmosphères
corrosives et des intempéries.

5. Laissez en place tous les dispositifs de sécurité et
tous les panneaux de la console et maintenez-les
en bon état.

6. Utilisez l'équipement conformément à son usage
prévu et n'effectuez aucune modification.

INFORMATIONS SUPPLÉMENTAIRES RELA­TIVES À LA SÉCURITÉ -- Pour obtenir de
l'information supplémentaire sur les règles
de sécurité à observer pour l'équipement
de soudage à l'arc électrique et le coupage,
demandez un exemplaire du livret "Precau­tions and Safe Practices for Arc Welding,
Cutting and Gouging", Form 52-529.

Les publications suivantes sont également recomman­dées et mises à votre disposition par l'American Welding
Society, 550 N.W. LeJuene Road, Miami, FL 33126 :

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"

15

SECTION 1 SÉCURITÉ

SIGNIFICATION DES SYMBOLES
Ce symbole, utilisé partout dans ce manuel,
signifie "Attention" ! Soyez vigilant ! Votre
sécurité est en jeu.

DANGER

Signifie un danger immédiat. La situation peut
entraîner des blessures graves ou mortelles.

AVERTISSEMENT

Signifie un danger potentiel qui peut entraîner des
blessures graves ou mortelles.

ATTENTION

Signifie un danger qui peut entraîner des blessures
corporelles mineures.

16

SECTION 2 DESCRIPTION

2.1 GENERAL

The PCM-875 is a compact, completely self-contained plasma
cutting system. As shipped, the system is fully assembled
and ready to cut after being connected to input power and a
source of compressed air (90-150 psi). The PCM-875 package
uses the heavy-duty PT-27 torch to deliver cutting power for
severing materials up to 1-1/4 inch thick. Refer to the follow­ing paragraphs for descriptions of the PCM-875 packages
available as well as performance specifications.

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

2.2 SCOPE

The purpose of this manual is to provide the operator with all
the information required to install and operate the PCM-875
plasma arc cutting package. Technical reference material is also
provided to assist in troubleshooting the cutting package.

2.3 PACKAGES AVAILABLE

2.3.1 Manual Cutting Packages

PCM-875 packages listed on the front cover includes the fol­lowing components:

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

PT-27 Spare Parts Kit (see Table 2-1) ...............................P/N 21623

PCM-875 Console/Power Source .....................................See below

Depending on the choice of input power, each package
includes the following appropriate PCM-875 Console/Power
Source:

208/230 V, 50/60 Hz, 1 or 3-phase ...................... P/N 0558001167

460 V, 50/60 Hz, 3-phase ........................................ P/N 0558001169

575 V, 60 Hz, 3-phase ............................................... P/N 0558001170

400 V, 50/60 Hz, 3-phase ........................................ P/N 0558001171

230 V, 50/60 Hz, 3-phase CE .................................. P/N 0558001172

2.3.2 Mechanized Cutting Packages

Also available are mechanized packages using the PT-20AM
Mechanized Plasma Torch with the PCM-875 Console/Power
Source. A typical package includes: PCM-875 Console/
Power Source, PT-20AM Torch (4.5 or 17 ft.), Remote Arc
Starter, Torch Spare Parts Kit, Pilot Arc Cable (50 or 100 ft.),
Power Cable (50 or 100 ft.), Gas Hose (50 or 100 ft.), Arc
Starter AC Power Cable (50 or 100 ft.) and a hose adaptor.
See Section 2.8 for installation details and part numbers
of components.

The following PCM-875 Mechanized Packages are avail­able:

875M, 230V/PT-20AM, 4.5'/50’System ...........................P/N 37617

875M, 230V/PT-20AM, 4.5'/100' System .......................P/N 37618

875M, 230V/PT-20AM, 17'/50' System ...........................P/N 37619

875M, 230V/PT-20AM, 17'/100' System ........................P/N 37620

875M, 460V/PT-20AM, 4.5'/50’System ...........................P/N 37621

875M, 460V/PT-20AM, 4.5'/100' System .......................P/N 37622

875M, 460V/PT-20AM, 17'/50' System ...........................P/N 37623

875M, 460V/PT-20AM, 17'/100' System ........................P/N 37624

Table 2-1. PT-27 Spare Parts Kit, P/N 21623, Contents

Description Part Number Quantity
50 - 60 A Nozzle 33369 4
Electrode 33366 3
Swirl Baffle 33367 1
Heat Shield 21616 2
Standoff Guide 21420 1
Fuse, 15 A, 600 VDC, Fast Acting 952137 1

17

SECTION 2 DESCRIPTION

2.4 SPECIFICATIONS

Table 2-2. PCM-875 Specifications

Rated
Output

Output Current Range 10 to 60 Amperes
Open Circuit Voltage 275 V dc
Rated Primary Input

@

7.2 kW Max. Output Power
60 A @ 120 Vdc

Power Factor @ 60 Amperes Output 74% (208/230 V, 1-phase)

Efficiency @ 60 Amperes Output 90% Typical
Current Capacity PT-27 80 A DCSP
Air Requirements PT-27 320 cfh @ 65 - 75 psig

Dimensions

60% Duty Cycle* 60 A @ 120 V dc
100% Duty Cycle* 50 A @ 120 V dc

208/230 V ac, 50/60 Hz, 3-phase 26/24 A/phase
208/230 V ac, 50/60 Hz, 1-phase 55/49 A
400 V ac, 50/60 Hz, 3-phase 13 A/phase
460 V ac, 50/60 Hz, 3-phase 11 A/phase
575 V ac, 50/60 Hz, 3-phase 9 A/phase

90% (208/230 V, 3-phase)
92% (400/460 & 575 V, 3-phase)

(150 l/min @ 4.5 - 5.2 bars)
Length 20.3” (516 mm)
Height 16.1” (409 mm)

w/handles 18.3” (465 mm)

Width

w/o opt. storage 10.1” (275 mm)

w/ opt. torch storage 13.1” (333 mm)
Weight of PCM-875 System 87 lbs (39.5 kg)
Shipping Weight 100 lbs (45.4 kg)

*Duty cycle is based on a 10-minute period; therefore, a 60-percent duty cycle means the power source may operate for 6 minutes with a cool
down period of 4 minutes and a 100-percent duty cycle means the power source may operate continuously.

2.5 OPTIONAL ACCESSORIES

1. Torch Wrap/Spare Parts Kit Holder, P/N 33952GY. Units have 4 mounting holes on left side for mounting this accessory

holder.

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

875 around the job site.

18

SECTION 2 DESCRIPTION

7.3" (185 mm)

Table 2-3. PT-27 Torch Specifications

3" (76 mm)

Current Capacity (100% duty) 80 A DCSP
Length of Service Lines 25 ft or 50 ft
Weight
25 ft 5.2 lbs (2.4 kg)
50 ft 9.6 lbs (4.4 kg)

120

75°

1"

(25.4 mm)

1" (25.4 mm)

Figure 2-1. PT-27 Dimensions

100

80

PT-27 Torch
Air @75psi
3/16" - 1/4" Stand-off
Maximum Current

60

Aluminum

40

Stainless

Steel

CUTTING SPEED (IN. PER MIN.)

20

0

1/16

3/16 5/16

1/8

1/4

7/16

1/2

5/8

9/163/8

11/16

3/4

13/16

7/8

MATERIAL THICKNESS (IN.)

Figure 2-2. PT-27/PCM 875 Cutting Performance

Stand-Off vs. Power Output

3/8

160

140

120

100

80

60

40

20

0

Arc Voltage

9000

Maximum Output

8000

7000

6000

5000

Power output

increases with

stand-off distance

IMPORTANT!!!

Maintain Proper

Stand-Off Distance

3/16 to 1/4 Inch

4000

3000

Watts (A x V = W)

2000

Best

Range

1000

0

1/16

1/8

3/16 5/16

1/4

Stand-Off Distance (inches)

Figure 2-3. Standoff vs. Power Output

19

SECTION 2 DESCRIPTION

20

SECTION 3 INSTALLATION

3.1 GENERAL

Proper installation is important for satisfactory and trouble­free operation of the PCM-875 cutting package. It is sug­gested that each step in this section be studied carefully
and followed closely.

3.2 EQUIPMENT REQUIRED

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

3.3 LOCATION

Adequate ventilation is necessary to provide proper cool­ing of the PCM-875. The amount of dirt, dust, and exces­sive heat to which the equipment is exposed, should be
minimized. There should be at least one foot of clearance
between the PCM-875 power source and wall or any other
obstruction to allow freedom of air movement through
the power source.

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

3.4 INSPECTION

A. Remove the shipping container and all packing mate-

rial and inspect for evidence of concealed damage
which may not have been apparent upon receipt
of the PCM-875. Notify the carrier of any defects or
damage at once.

B. Check container for any loose parts prior to disposing

of shipping materials.

C. Check air louvers and any other openings to ensure

that any obstruction is removed.

3.5 PRIMARY ELECTRICAL INPUT
CONNECTIONS FIGURE 31

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

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

NOTE: If using 200(208) V input power, the PCM-875

must be reconnected for 200 V use as directed in
Section 3.7 and Fig. 3-2.

The PCM-875 consoles are equipped with a 10-ft, 4­conductor input power cable for 3-phase connection. If
single-phase connection is desired, tape back the red wire
on the input power cable.

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

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

A line (wall) disconnect switch with fuses or circuit breakers
should be provided at the main power panel (see Fig. 3-1
and Table 3-1 for fuse sizes). The input power cable of the
console may be connected directly to the disconnect switch
or you may purchase a proper plug and receptacle from a
local electrical supplier. If using plug/receptacle combina­tion, see Table 3-1 for recommended input conductors for
connecting receptacle to line disconnect switch.

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

21

SECTION 3 INSTALLATION

Table 3-1. Recommended Sizes For

Input Conductors and Line Fuses

Input Requirements Input & Gnd Fuse
Volts Phase Amps Conductor Size
CU/AWG Amps

208 1 55A 6 80
208 3 26A/Ph. 6 50
230 1 49A 6 80
230 3 24A/Ph. 6 50
400 3 13 10 25
460 3 11 10 25
575 3 9 10 20

3.6 SECONDARY OUTPUT
CONNECTIONS REFER TO FIG. 31

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

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

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

3. Reassemble the access door to the power source.

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

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

Red - NOT USED ON SINGLE PHASE

White

Black

Green

PRIMARY INPUT

POWER CABLE

22

SECTION 3 INSTALLATION

TORCH
PILOT

Allow at least 10 ft. (3m)

between work and power source

WORK

ARC
CONNECTION

TORCH
POWER
CABLE
CONNECTION

SAFETY GROUND

PT-27

CUSTOMER FUSED LINE DISCON­NECT SWITCH(See Table 3-1 and
WARNING in regards to chassis
ground in Section 3.5.)

TORCH
SWITCH
RECEPTACLE

ACCESS DOOR FOR
TORCH CONNECTION

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

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

CNC INTERFACE CONNEC TION
INSIDE ON LEFT SIDE OF BASE.

DETAIL “A”

INPUT POWER CABLE

(See Table 3-1)

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

phase connection only. The plug is mounted to a 4-conductor
cable. If 3-phase connection is desired, remove and discard
the plug and refer to Sect. 3.5.

Figure 3-1. PCM-875 Interconnection Diagram

23

SECTION 3 INSTALLATION

3.7 CONNECTING PCM875 FOR
200208 VAC INPUT

ELECTRIC SHOCK CAN KILL! Precautionary measures
should be taken to provide maximum protection
against electrical shock. Be sure that all power is off
by opening the line (wall) disconnect switch and by
unplugging the power cord to the unit when recon­necting for 200(208) VAC Input.

The PCM-875 power source with 200/230 vac, 1-phase
input capability is factory set for 230 vac input. If using
200(208) vac input, the PCM-875 must be reconnected as
follows before connecting to your input power:

Fig. 1

R

(IBR)
INPUT
BRIDGE

G

S

+

T

R2

GRY

TB5

BLK

BLK
GRY

1. Remove cover from the PCM-875 power source.

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

3. Locate the output bridge (D1) on left side towards the
front panel (see Fig. 2). Disconnect and swap leads X2
and X3 from the main transformer. For 200(208) vac
input, X2 is connected to TB3 and X3 is connected to
terminal 3 of D1. Make sure the connections are firmly
tightened.

4. Leave all other wires the same.

5. Reinstall cover and connect the PCM-875 to 208 vac
input power.

OUTPUT BRIDGE

(D1)

Fig. 2

X1

~

1

+

~

2

~

3

FROM MAIN TRANS­FORMER

X3

TB3

X2

Figure 3-2. Original Factory Setup for 230 Vac Input on

Power Source with 200/230 Vac Input Power Capability

24

SECTION 3 INSTALLATION

3.8 MECHANIZED CUTTING INSTALLATION WITH THE PT20AM TORCH

ARC STARTER CABLE - 37410 (50’)

37411 (100’)

POWER CABLE - 37341 (50’)

37342 (100’)

ARC STARTER

37338

WORK
CABLE(25’)
(Supplied with
PCM-875)

SCHEMATIC - MECHANICAL SYSTEM SETUP (See Figure 3-4 for detailed connections)

AIR HOSE - 37343 (50’)

37344 (100’)

PILOT ARC CABLE - 37339 (50’)

37340 (100’)

PT-20AM ­21785 (4.5’)
21786 (17’)

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

Figure 3-3. MECHANICAL CUTTING INTERFACE DIAGRAM

25

SECTION 3 INSTALLATION

“A”
“B”
“C”
“D”

“D”

“A”

“B”

“C”

Arc Starter

37338

ADAPTOR - 999278

PILOT ARC CABLE - 37339 (50’)

SPLICE CONNECTOR*
(Supplied with 37338)

25mm min.

AIR HOSE - 37343 (50’)

POWER CABLE - 37341 (50’)

ARC STARTER CABLE - 37410 (50’)

37340 (100’)

37344 (100’)

37342 (100’)

37411 (100’)

View A-A

Disconnect These
Two Black Leads

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

WHT Arc Start

Arc Starter

BLK Arc Start

Cable (Ref.)

Make sure all power is off before making following con­nections.

1. Remove cover from PCM-875.

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

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

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

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

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

-

25mm min.

SPLICE CONNECTOR*

PT-20AM

(Supplied with 37338)

TORCH

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

Figure 3-4. Connection Diagram - PCM-875/PT-20AM with Arc Starter

.035” (0.9mm)

SPARK GAP ASSEMBLY
(Torch end of Arc Starter)

26

(4) .250” (6 mm)

2.125”

(54mm)

7”

(178mm)

MOUNTING DIMENSIONS

SECTION 4 OPERATION

4.1 OPERATION

ELECTRIC SHOCK can kill.

• Do NOT operate the unit with the cover removed.

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

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

ARC RAYS can burn eyes and skin; NOISE can damage

hearing.

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

• Wear eye, ear, and body protection.

Position the PCM-875 at least 10 feet (3 meters) from
the cutting area. Sparks and hot slag from the cutting
operation can damage the unit.

Flow Fault: The fault light will be mostly on but will

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

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

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

that the input voltage is outside the “+ or -” 15% range
of the input rating.

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

exceeded.

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

4.3 CUTTING WITH THE PT27

4.2 PCM-875 CONTROLS (FIGURE 4-1)

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

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

B. Output Current Control. Adjustable from 10 to 60

amperes.

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

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

D. Trigger Lock Switch. When placed in LOCK position,

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

E. Fault Light. Will glow amber under the following condi-

tions and operations will come to a complete stop.

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

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

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

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

torch nozzle.

C. Two seconds after depressing the torch switch, the pilot

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

D. After starting the cut, the torch should be maintained

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

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

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

27

SECTION 4 OPERATION

POWER LIGHT

(WHITE)

FAULT LIGHT

(AMBER)

AIR

PRESSURE

GAUGE

AIR TEST
SWITCH

TRIGGER LOCK

SWITCH

CURRENT
CONTROL

KNOB

AIR REGULATOR
CONTROL KNOB

Figure 4-1. PCM-875 Controls

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

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

REAR VIEW

POWER ON-OFF

FUSE (3A)

(I-O) SWITCH

NOTE: When replacing the nozzle, always inspect the

electrode for wear. If less than 19/32" of electrode
shaft is remaining, replace the electrode. If the
electrode is used beyond this recommended wear
limit, damage to the torch and power source may
occur. Nozzle life is also greatly reduced when
using the electrode below the recommended
limit. Refer to Figure 4-3.

Figure 4-2. Recommended Torch Angle of 5° to 15°

28

19/32"

(15.1 mm)

ELECTRODE

REPLACE ELECTRODE BEFORE
LENGTH BECOMES SHORTER THAN
19/32 INCH (15.1 MM)

Figure 4-3. Electrode Wear Limit

SECTION 4 OPERATION

WHEN THE ARC BREAKS

2

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

TO START A PIERCE, TILT THE TORCH TO

1

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

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

4.4 COMMON CUTTING PROBLEMS

Listed below are common cutting problems followed by
the probable cause of each. If problems are determined
to be caused by the PCM-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.

A. Insufficient Penetration.

1. Current too low.

2. Cutting speed too fast.

3. Damaged cutting nozzle.

4. Improper air pressure.

5. Low air flow rate.

B. Main Arc Extinguishes.

1. Cutting speed too slow.

2. Worn electrode.

C. Dross Formation. (In some materials and thicknesses,

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

D. Double Arcing. (Damaged Nozzle Orifice.)

1. Low air pressure.

2. Damaged cutting nozzle.

3. Loose cutting nozzle.

4. Heavy spatter accumulation on nozzle.

E. Uneven Arc.

1. Damaged cutting nozzle or worn electrode.

F. Unstable Cutting Conditions.

1. Incorrect cutting speed.

2. Loose cable or hose connections.

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

G. Main Arc Does Not Strike.

1. Worn electrode.

2. Loose connections.

3. Work cable not attached.

1. Current too low.

2. Cutting speed too fast or too slow.

3. Improper air pressure.

4. Faulty nozzle or electrode.

5. Low air flow rate.

H. Poor Consumable Life.

1. Improper gas pressure.

2. Contaminated air supply.

3. Low air flow rate.

29

SECTION 4 OPERATION

30

SECTION 5 MAINTENANCE

5.1 GENERAL

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

Be sure that the wall disconnect switch or wall circuit
breaker is open before attempting any inspection or
work inside of the PCM-875.

5.2 INSPECTION AND CLEANING

Frequent inspection and cleaning of the PCM-875 is recom­mended for safety and proper operation. Some suggestions
for inspecting and cleaning are as follows:

A. Check work cable for secured connection to work-

piece.

B. Check safety earth ground at workpiece and at power

source chassis.

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

damaged.

D. Check the torch electrode and cutting nozzle for

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

E. Make sure cable and hoses are not damaged or

kinked.

F. Make sure all plugs, fittings, and ground connections

are tight.

G. With all input power disconnected, and wearing

proper eye and face protection, blow out the inside
of the PCM-875 using low-pressure dry compressed
air.

5.3 PT27 TORCH CONSUMABLE PARTS

Make sure power switch on PCM-875 is in OFF position
before working on the torch.

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

To assemble the consumable parts, refer to Figure 5-1.

A. Place nozzle, swirl baffle and electrode into the shield

as shown.

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

Always make sure the shield is very tight before
cutting.

ELECTRODE

SWIRL BAFFLE

NOZZLE

SHIELD

Water or oil occasionally accumulates in compressed air
lines. Be sure to direct the first blast of air away from
the equipment to avoid damage to the PCM-875.

H. Occasionally, bleed all water from the filter beneath

the air filter-regulator.

IMPORTANT!

MAKE SHIELD VERY TIGHT!

Figure 5-1. Assembly of PT-27 Torch Front End Parts

31

SECTION 5 MAINTENANCE

5.4 FLOW SWITCH FIGURE 52

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

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

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

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

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

Reassemble the flow switch in reverse order.

PISTON PLUG

SPRING

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

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

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

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

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

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

The mounting screws are to be fastened in the order shown
in Figure 5-3. Also, care must be taken to achieve maximum
contact (i.e. minimum contact thermal resistance) for the
best heat dissipation.

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

FLOW SWITCH

PISTON

Figure 5-2. Disassembly / Assembly of Flow Switch

5.5 IGBT Handling & Replacement

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

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

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



Two-Point Mounting Type

 Temporary tightening  
 Final tightening  

Four-Point Mounting Type
 Temporary tightening  



 Final tightening  









32

Figure 5-3. Screw Fastening Order

SECTION 5 MAINTENANCE

5.6 TROUBLESHOOTING

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

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

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

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

NOTE:

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

NOTE:

Schematics and Wiring Diagrams on 11” x 17”

paper are included

inside the back cover of this manual.

33

SECTION 5 MAINTENANCE

5.7 TROUBLESHOOTING GUIDE

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

1. Visually inspect the machine for any damage.

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

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

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

fuses.

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

tive.

3. If above items check OK , the problem is internal. Send unit to an Authorized Repair Station for repair.
a. If the cooling fan is running, then measure voltage between pins P2-11 and P2-14 of the control board

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

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

B. No Air Flow

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

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

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

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

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

C. The Power light is on, but nothing happens when the torch switch is depressed. Fault light does not activate.

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

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

a. With the machine power on, depress the torch switch. On the control board the LED 1 should be lit as long as the

switch is depressed. If not then check:

i. Turn power off to the machine. Unplug Control board. Put an ohmmeter across P5-1 and P5-2 to take resis-

tance reading. Depress torch switch. Meter should read a short. If not, then one of the following is not working
properly:

ii. Torch switch or the leads. Unplug the torch switch leads at the machine. Put a meter across the two plug pins.

Should read a short when the torch switch is depressed. If not, then either broken switch leads or malfunction­ing switch.

b. Check T2 transformer secondary voltages at the plugs P1 and P2. Refer to system schematic. Replace the transformer

if the correct secondary voltages are not present.

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

34

SECTION 5 MAINTENANCE

D. Fault light activates when torch switch is closed.

The Fault circuit is used to monitor conditions necessary for the safe operation of the PCM-875. The fault light will glow

amber under the following conditions and operations will come to a complete stop:

1. High/Low line voltage. The Fault Light will rapidly blink on and off (5 times per second). This indicates that the input

voltage is outside the “+” or “-” 15% safe operating range rating.

2. Flow fault - The fault light will be mostly on but will blink off for 1/10th of a second every second. This indicates that

the air flow is low.

a. Check the air pressure at the machine regulator. It should be adjusted to 65 psig. If no air pressure, check the air at

the supply point. Also, check for any obstructions in the air hose.

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

leads.

NOTE: If above items check OK , the problem is internal. send unit to an Authorized Repair Station for repair.
c.. Put the ‘Air Check’ switch to On position. Air should flow through torch. If not, then the flow switch may be stuck

due to oil in the air. Clean air flow switch per supplier’s instructions or replace switch. To check if the flow switch is
open, put voltmeter leads between P1-12 and P1-1. It should read about 12 VDC. When the flow switch closes, the
voltage will drop to zero volts.

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

not turn air on.

3. Over Temperature. The fault light will be mostly off but will blink on for 1/10 of a second, every second. This generally

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

a. 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.

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

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

exceeded preset limits.

a. To check if the output is shorted, measure the resistance by putting the ohmmeter leads (make sure to disconnect

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

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

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

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

2. Check to assure high frequency is present at the torch. If not, then listen for high frequency at the high frequency

generator. It is located on the bottom/right side of the unit. The high frequency gap is set to 0.040”. Disconnect HI
FREQUENCY leads. Check for 115 volt supply to the high frequency unit between P2-12 & P2-13 of the control board
with torch switch closed.

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

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

b. Check Air Check switch operation. It might be stuck in On position. Pilot arc will not initiate if this switch is in the

ON position. (safety reasons)

35

SECTION 5 MAINTENANCE

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

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

approx. 325 VDC for the 208/230 volt unit.
approx. 280 VDC to 325 VDC for the 400 or 460 volt unit
approx. 410 VDC for the 575 volt unit

If not, one of following could be malfunctioning:

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

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

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

e. IGBTs (2 on 230 V, and 1 on the 400 V & 460 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.

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

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

2. Check the torch. Replace consumables if necessary.

3. Make sure the current setting potentiometer is set above 10 amps. If it is, set below 10 amps, then HI

FREQUENCY will go on and off at 5 sec intervals.

G. Poor Cutting Performance.

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

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

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

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

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

frequency.

36

SECTION 5 MAINTENANCE

H. Air does not shut off.

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

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

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

I. Main arc is difficult to start.

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

2. Input air must be clean and dry.

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

4. Torch connections must be tight.

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

6. If above items check OK , the problem is internal. send unit to an Authorized Repair Station for repair.
a. Missing or weak pilot arc. Check pilot arc fuse, open circuit voltage, pilot arc resistors and pilot arc wiring.

b. Inoperative starter board (PCB-5).

NOTE:

Schematics and Wiring Diagrams on 11” x 17”

paper are included

inside the back cover of this manual.

37

SECTION 5 MAINTENANCE

5.8 REFERENCE VOLTAGE CHECKS

A. Control Board Assembly (PCB1)

1. LED’s

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

2. Voltage Test Points

Tests are made with power on - no arc.

Disable High Frequency by disconnecting blue wire with black sleeve

TP-0 - Ground
TP-1 - +15 vdc
TP-2 - +12 vdc
TP-3 - -12 vdc
TP-4 - +5 vdc
TP-9 - IGBT’s driving signal - switching frequency = 20 KHz
TP-10 - IGBT’s driving signal - switching frequency = 20 KHz

13 vdc

50 µsec

50
80

0

LPG 50
LPG 80

For 208/230 VAC input, the IGBT off time is 3µsec.

For 400/460/575 VAC input, the IGBT off time is 6µsec.

Figure 5-4. IGBT Gating Signal

38

SECTION 5 MAINTENANCE

5.9 SEQUENCE OF OPERATION

A. TRIGGER LOCK “UNLOCK” position

PUSH RELEASE

TORCH SWITCH

OPEN CLOSE
GAS SOLENOID VALVE

PREFLOW

2 SEC.

FLOW SWITCH CLOSE

FAULT OVERLOAD LIGHT

ENERGIZE

HF CIRCUIT

INVERTER

CUTTING ARC (CURRENT)

10 SEC

Postflow

OPEN

NOTES:

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

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

39

SECTION 5 MAINTENANCE

B. TRIGGER LOCK "LOCK" position

PUSH RELEASE PUSH RELEASE
TORCH SWITCH

OPEN CLOSE
GAS SOLENOID VALVE

2 SEC.

POSTFLOW
CLOSE OPEN
FLOW SWITCH

PREFLOW

10 SEC

Postflow

FAULT LIGHT

ENERGIZE

HF CIRCUIT

INVERTER

CUTTING ARC (CURRENT)

NOTES:

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

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

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

40

SECTION 6 REPLACEMENT PARTS

6.0 Replacement Parts

6.1 General

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

6.2 Ordering

To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this
equipment. The use of non-ESAB parts may void your warranty.

Replacement parts may be ordered from your ESAB Distributor.

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

Refer to the Communications Guide located on the back page of this manual for a list of customer service phone
numbers.

Note

Bill of material items that have blank part numbers are provided for customer information only.

Hardware items should be available through local sources.

41

SECTION 6 REPLACEMENT PARTS

8, 9

16

10, 11

5, 4

6

7

3, 4

1, 2

15

8

14

12

13

Fig. 6-1. PCM-875 Power Source, Front View

Item Qty. Part Circuit
No. Req. No. Description Symbol

PCM-875, Series A
1 1 137630611 KNOB
2 1 0558001176 POT. 10K 3W (NOMEX INSUL. - 676876) R1
3 1 673213 SWITCH TOGGLE SPST 2 POS 15 A 125 V S3
4 2 951474 SWITCH SEAL BLACK
5 1 634518 SWITCH TOGGLE DPDT 2 POS 15 A 125 V S2
6 1 951754 LAMP LED YEL 12 V PL2
7 1 951526 LAMP NEON WHITE PL1
8 2 993426 GROMMET RUBBER 1.50 ID x 1.76 OD
9 1 21711 GAUGE 1.50 160 PSI WHITE
10 1 23606172 STRAIN RELIEF
11 1 680560 WORK CABLE 25 FT. (Not Shown)
12 4 182W12 FOOT RUBBER
13 1 0558001174 CHASSIS PCM-875
14 1 36330YL DOOR ACCESS YEL (ESAB)
15 1 954008 LABEL WARNING HI VOLTAGE
16 2 13734588 LABEL ESAB

42

SECTION 6 REPLACEMENT PARTS

154, 155, 156

153

151, 152

157

158, 159

160, 161 162

Fig. 6-2. PCM-875 Power Source, Rear View

Item Qty. Part Circuit
No. Req. No. Description Symbol

151 1 21710 FILTER, REGULATOR AIR LINE
152 1 10Z30 ADAPTOR B/A-WM x 1/4 NPTM
153 2 951575 HANDLE
154 1 36719YL TOP COVER YEL (ESAB)
155 1 2091514 LABEL WARNING
156 1 954290 LABEL WARNING
157 1 954666 LABEL RATING PCM-875 208/230
1 954667 LABEL RATING PCM-875 400/460
1 954668 LABEL RATING PCM-875 575
1 954669 LABEL RATING PCM-875 400CE
158 1 952136 FUSE HOLDER
159 1 952559 FUSE 3 A FAST ACTING F1
160 1 97W63 STRAIN RELIEF
161 1 0558004221 INPUT POWER CABLE, 6 FT (208/230 V)
1 37574 INPUT POWER CABLE, 10 FT (400/460/575 V)
1 0558001181 INPUT POWER CABLE, 10 FT (400 V CE)
1 0558002799 CABLE POWER 4 COND 16 MM
162 1 36107 SWITCH POWER 600V 63A

43

SECTION 6 REPLACEMENT PARTS

25, 26

31

32, 33, 34

28

29, 30

27

27

25, 26

43

42

24

21

23

35

46,47

39

36

37

38

41

40

44, 45

Fig. 6-3. PCM-875 Power Source, Left Side View (208/230)

22

44

SECTION 6 REPLACEMENT PARTS

Fig. 6-3. PCM-875 Power Source, Left Side View (208/230) cont'd

Item Qty. Part Circuit
No. Req. No. Description Symbol

21 1 952150 BRIDGE 60ADC 100NS 600 V (includes PAD - 951192) D1
22 1 952002 CORE SATURABLE L3
23 1 952208 STANDOFF INS. TB3
24 1 36733 BUSBAR NEG
25 2 952237 CAPACITOR 1800 µf 450VDC C1, 2
26 2 994674 GROMMET STRIP
27 2 0558001177 PCB ASS'Y MOSFET IGBT DRIVER BOARD PCB2, 3
28 1 36822 HOSE AY B/A-2X 1/4NPT RUB 2 FT
29 1 36732 BUSBAR POS
30 1 951028 CAPACITOR 1µf 630VDC (Not shown - see wiring) C3
31 1 950487 TERM BLOCK 2 POS TB5
32 1 952235 MODULE INPUT BRIDGE/SCR (includes PAD - 952280) IBR
33 1 2062282 CAPACITOR .22µf 1KV (See wiring) C19
34 3 951321 METAL OXIDE VARISTOR 275 V (See wiring) MOV1, 2, 3
35 2 951205 IGBT 600 V 100 A (includes PAD - 951190) Q1, 2
36 1 17750010 RESISTOR 50 W 10 OHM (PAD - 951194) R7
37 1 32958 CURRENT TRANSFORMER ASS'Y T4
38 1 952255 CAPACITOR 40 µf 400 VDC C4
39 1 950711 THERMAL SWITCH 194°F TS1
40 4 17721020 RESISTOR 24 W 20 OHMS (PAD 951193) R3, 4, 5, 6
41 1 951202 FLOW SWITCH .25 GPM FS
42 2 951940 CAPACITOR 1µf 630W VDC C15, 16
43 1 952558 HEATSINK
44 1 950249 SOL. VALVE 1/4NPT 165 PSI 24 VAC SOL1
45 1 951471 DIODE ZENER 60 V 75 MA (See Wiring) ZD1
46 1 17250010 RESISTOR WW FIXED 50W 10 OHM R10
47 2 99512068 RESISTOR BRACKET

45

SECTION 6 REPLACEMENT PARTS

61

62

63

64, 65, 66

68

56, 57, 58

67

71

59

56, 57, 58

55

60

53

54

51

52

77, 78

74

70

69

73

75, 76

72

Fig. 6-4. PCM-875 Power Source, Left Side View (400/400CE/460/575)

46

SECTION 6 REPLACEMENT PARTS

Fig. 6-4. PCM-875 Power Source, Left Side View (400/400CE/460/575)

Item Qty. Part Circuit
No. Req. No. Description Symbol

51 1 952150 BRIDGE 60 ADC 100NS 600 V (includes PAD - 951192) D1
52 1 952002 CORE SATURABLE L3
53 1 951800 MODULE DUAL IGBT 150 A, 1200 V
(includes PAD - 951191) Q1
54 1 952208 STANDOFF INS (Not used on 575 V) TB3
55 1 36732 BUSBAR POS
56 2 952237 CAPACITOR 1800µf 450 VDC (400/400CE/460 V) C1, 2
2 952562 CAPACITOR 1800µf 500 VDC (575 V) C1, 2
57 2 994674 GROMMET STRIP
58 2 951028 CAPACITOR 1µf 630 VDC (See wiring) C3, 15
59 1 0558001178 PCB ASS'Y IGBT DRIVER BOARD PCB2
60 1 951964 CAPACITOR 2µf 800 VDC (400/400CE/460V) C16
1 951892 CAPACITOR 0.68µf 1200 VDC (575 V) C16
61 1 36822 HOSE ASS'Y B/A x 1/4 NPT RUB
62 1 36733 BUSBAR NEG
63 1 950487 TERM BLOCK 2 POS (Not used on 400CE/575 V) TB5
64 1 952235 MODULE INPUT BRIDGE/SCR
(includes PAD - 952280) IBR
65 1 2062282 CAPACITOR .22µf 1KV C19
66 3 950591 METAL OXIDE VARISTOR 510 V (400/400CE/460 V) MOV1, 2, 3
3 951963 METAL OXIDE VARISTOR 625 V (575 V) MOV1, 2, 3
67 2 17750010 RESISTOR 50W 10 OHM (PAD - 951194) R7
68 1 32958 CURRENT TRANSFORMER ASS'Y T4
69 1 952255 CAPACITOR 40µf 400 VDC (400/400CE/460 V) C4
1 952585 CAPACITOR 20µf 600 VDC (575 V) C4
70 1 0455803880 FILTER EMI (CE only) (not shown) FN1
71 1 950711 THERMAL SWITCH 194°F TS1
72 4 17721020 RESISTOR 25W 20 OHMS (PAD - 951193) R3, 4, 5, 6
73 1 951202 FLOWSWITCH .25 GPM FS
74 1 952558 HEATSINK
75 1 950249 SOL, VALVE 1/4 NPT 165 PSI 24 VAC SOL1
76 1 951471 DIODE ZENER 60 V 75m A ZD1
77 1 17250010 RESISTOR WW FIXED 50W 10 OHM R10
78 2 99512068 RESISTOR BRACKET

47

SECTION 6 REPLACEMENT PARTS

93

92

90,91

89

88

87

81

86

80

94

95

96

97

104

98, 99

100

101,102,103

Fig. 6-5. PCM-875 Power Source, Right Side View (208/230)

48

82, 83, 84

SECTION 6 REPLACEMENT PARTS

Fig. 6-5. PCM-875 Power Source, Right Side View (208/230) cont'd

Item Qty. Part Circuit
No. Req. No. Description Symbol

80 1 35940 CONTROL TRANSFORMER ASS'Y T2
81 2 17300012 RESISTOR 300W 12 OHM R11,12
82 1 673458 CONTACTOR 3 POLE,110 VAC 40A K1
83 1 952557 CAPACITOR .82µf 630 VDC (See Wiring) C21
84 1 17145433 RESISTOR, 2W 5% K330 (See Wiring) R13
85
86 1 952232 INDUCTOR PFC L2
87 1 38214 CONTROL BOARD ASS'Y PCB1
88 1 36586 MAIN TRANSFORMER ASS'Y T1
89 2 951469 CAPACITOR .022µf 250 VAC (See Wiring) C17, 18
90 1 31488 SHUNT BOARD ASS'Y T1
91 1 951515 CAPACITOR .047µf 660 VAC C23
92 1 38131 START UP BOARD ASS'Y PCB5
93 1 952233 INDUCTOR OUTPUT L1
94 1 36721 BUSBAR OUTPUT
95 1 182W64 LOCK TWIST MIDGET J1
96 1 36717 BRACKET OUTPUT
97 1 32969 REACTOR ASS'Y HI FREQ. T3
98 1 0558001180 SPARK GAP ASS'Y SG
99 2 951342 CAPACITOR 2500pf 15 K V C13, 14
100 1 951179 TRANSFORMER HI VOLTAGE T5
101 1 950487 TERM. BLOCK 2 POS 20 A TB1
102 2 672348 CAPACITOR .01µf 1KV (See wiring) C11, 12
103 1 952204 CAPACITOR .01µf 250 VAC (See wiring) C9
104 1 36718 BOX HI FREQ.

49

SECTION 6 REPLACEMENT PARTS

121

122

119, 120

118

117

116

111

112, 113, 114

110

123, 135

124

125

126

127, 128

134

129

130, 131, 132

133

Fig. 6-6. PCM-875 Power Source, Right Side View (400/400CE/460/575 V)

50

SECTION 6 REPLACEMENT PARTS

Fig. 6-6. PCM-875 Power Source, Right Side View (400/400CE/460/575 V) cont'd

Item Qty. Part Circuit
No. Req. No. Description Symbol

110 1 32914 CONTROL TRANSFORMER ASS'Y T2
111 1 17300012 RESISTOR 300W 12 OHM R11,12
112 1 673458 CONTACTOR 3 POLE 110VAC 40A K1
113 1 952557 CAPACITOR .82µf 630 VDC (See wiring) C21
114 1 17145433 RESISTOR 2W 330K (See wiring) R13
115
116 1 38214 CONTROL BOARD ASS'Y PCB1
117 1 36586 MAIN TRANSFORMER ASS'Y (400/400CE/460 V) T1
1 36599 MAIN TRANSFORMER ASS'Y (575 V) T1
118 2 951469 CAPACITOR .022µf 250 VAC (See wiring) C17, 18
119 1 31488 SHUNT BOARD ASS'Y PCB4
120 1 951515 CAPACITOR .047µf 660 VAC C23
121 1 38131 START UP BOARD ASS'Y PCB5
122 1 952233 INDUCTOR OUTPUT L1
123 1 36721 BUSBAR OUTPUT
124 1 182W64 LOCK TWIST MIDJET J1
125 1 36717 BRACKET OUTPUT KYDEX
126 1 32969 REACTOR ASS'Y HI FREQ. T3
127 1 0558001180 SPARK GAP ASS'Y SG
128 2 951342 CAPACITOR 2500pf 15 K V C13, 14
129 1 951179 TRANSFORMER HI VOLTAGE T5
130 1 950487 TERM. BLOCK 2 POS 20 A TB1
131 2 672348 CAPACITOR .01µf 1KV (See wiring) C11, 12
132 1 952204 CAPACITOR .01µf 250 VAC (See wiring) C9
133 1 952213 REACTOR 3PH LINE 12 A L2
134 1 36718 BOX HI FREQ
135 1 951314 CAPACITOR .022µf 1KV (See wiring) C20

51

SECTION 6 REPLACEMENT PARTS

143

144

142

145

140

141

Fig. 6-7. PCM-875 (208/230V) Power Source, Top View with PCB1 and Shelf Removed

Item Qty. Part Circuit
No. Req. No. Description Symbol

140 1 954673 LABEL CNC INTERFACE
141 1 952026 TERM. BLOCK 7 POS 25 A TB4
142 2 17240310 RESISTOR 10 K 25 W R2, 15
143 1 951182 FAN AC AXIAL M1
144 1 2091558 LABEL GROUND BLACK
145 1 954700 LABEL INPUT (208/230 V)
1 954681 LABEL INPUT (400/460 V)

52

SECTION 6 REPLACEMENT PARTS

53

NOTES

54

REVISION HISTORY

Revision “A” edition (1/2002) of the manual covers the following changes: Control Board Assembly, P/N

1.
38175 was replaced with Control Board Assembly, P/N 38214.

Removes the Valve Pin, P/N 21619 from the PT-27 Spare Parts Kit and all other references to this part

2.
which is now obsolete for this package.

Revision B - updated replacement parts section.

3.

Revision C - Changed 6 foot input power cable part number from 37573 to 0558004221. Added sche-

4.
matic drawing 0558001186 and wiring diagram drawing 0558001191.

Revision D - 05/2005 - Updated format. Made chgs per change notice #'s 043155 & 053013.

5.
In replacement parts section added filter regulator, item 151, p/n 0558005394 note, added
to item 161 power cable p/n 0558002799, and chgd filter EMI, item 70, p/n from: 952253 to:

0455803880. Updated all views in replacement parts section. Moved schematics to 11 x 17 format.

Revision D - 12/2005 - Removed filter regulator, item 151, p/n 0558005394 note, in replacement parts

6.
section.

55

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS:
Telephone: [phone] / Fax: [phone] Hours: 8:00 AM to 7:00 PM EST
Order Entry Product Availability Pricing Order Information Returns

B. ENGINEERING SERVICE:
Telephone: [phone] / Fax : [phone] Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting

C. TECHNICAL SERVICE:
Telephone: (800) ESAB-123/ Fax: [phone] Hours: 8:00 AM to 5:00 PM EST
Part Numbers Technical Applications Specifications Equipment Recommendations

D. LITERATURE REQUESTS:
Telephone: [phone] / Fax: [phone] Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS:
Telephone: [phone] / Fax: [phone] Hours: 7:30 AM to 3:30 PM EST
Repair Estimates Repair Status

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

G. WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES:
Telephone : [phone] Hours: 7:30 AM to 5:00 PM EST

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123

Fax: [phone]

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

or

visit us on the web at http://www.esabna.com

The ESAB web site offers

Comprehensive Product Information

Material Safety Data Sheets

Warranty Registration

Instruction Literature Download Library

Distributor Locator

Global Company Information

Press Releases

Customer Feedback & Support

F15-605-D 12 / 2005