ESAB PCM-875A User manual

F-15-753
November, 2002
Installation, Operation and Maintenance Manual for the
PCM-875A Plasmarc Mechanized
Cutting System
Cutting Systems
411 South Ebenezer Road
Florence, South Carolina, U.S.A.

The equipment described in this manual is
potentially hazardous. Use caution when installing,
operating and maintaining this equipment.
Purchaser is solely responsible for the safe
operation and use of all products purchased,
including compliance with OSHA and other
government standards. ESAB Cutting
Systems has no liability for personal injury or
other damage arising out of the use of any
product manufactured or sold be ESAB. See
standard ESAB terms and conditions of sale
for a specific statement of ESAB’s
responsibilities and limitations on its liability.
ESAB Cutting Systems first priority is total
customer satisfaction. We constantly look for
ways to improve our products, service and
documentation. As a result, we make
enhancements and/or design changes as
required. ESAB makes every possible effort to
ensure our documentation is current. We
cannot guarantee that each piece of
documentation received by our customers
reflects the latest design enhancements.
Therefore, the information contained in this
document is subject to change without notice.
This manual is ESAB Part Number F15753
This manual is for the convenience and use of the
cutting machine purchaser. It is not a contract or
other obligation on the part of ESAB Cutting
Systems.
©ESAB Cutting Systems, 2002
Printed in U.S.A.

PCM-875A System Table of Contents
i
Section 1 Safety Page 1-(_)
1.1 Introduction ................................................................................................... 1
1.2 Safety Notations And Symbols ....................................................................... 2
1.3 General Safety Information ............................................................................. 3-4
1.4 Installation Precautions................................................................................... 4
1.5 Electrical Grounding ....................................................................................... 5
1.6 Operating A Plasma Cutting Machine ............................................................. 5-8
1.7 Service Precautions........................................................................................ 9-10
1.8 Safety References .......................................................................................... 11-16
1.8.1 National Standards................................................................................. 11
1.8.2 International Standards........................................................................... 12-16
Section 2 Description Page 2-(_)
2.1 General........................................................................................................... 1
2.2 PCM-875A Power Console ............................................................................ 1
2.2.1 Technical Specifications – PCM-875A..................................................... 1
2.2.2 Dimensions and Weight.......................................................................... 2
2.3 Remote Arc Starter (RAS2)............................................................................. 3
2.3.1 Technical Specifications ......................................................................... 3
2.3.2 Dimensions and Weight.......................................................................... 3
2.4 PT-20AMX Torch ........................................................................................... 4
2.4.1 Technical Specifications ......................................................................... 4
2.4.2 Dimensions and Weight.......................................................................... 5
2.4.3 Torch Spare Parts Kit ............................................................................. 6

PCM-875A System Table of Contents
ii
Section 3 Installation Page 3-(_)
3.1 General .......................................................................................................... 1
3.2 Installation of power console ........................................................................... 1
3.2.1 Requirements ......................................................................................... 1
3.2.2 Location ................................................................................................. 2
3.2.3 Inspection before installation ................................................................... 2
3.2.4 Primary Electrical Input Connections........................................................ 3
3.2.5 Connection of Plasma Console to CNC Interface..................................... 4
3.2.6 Secondary (Output) Connection .............................................................. 5-8
3.3 Connection of Remote Arc Starter (RAS2) ....................................................... 9
3.3.1 Mounting ............................................................................................... 9
3.3.2 Connecting Service Lines (Input).............................................................. 10
3.3.3 Setting Spark Gap .................................................................................. 11
3.3.4 RAS2 Output Connections...................................................................... 12
3.3.5 Termination of Torch Shield Braid............................................................ 13-14
3.4 Installing Front-end torch Parts ........................................................................ 15-17
3.5 Interconnecting Diagram................................................................................. 18-19
Section 4 Operation Page 4-(_)
4.1 PCM-875A Console Operation -- General ....................................................... 1
4.2 Console Controls............................................................................................ 2-3
4.3 RAS2 ............................................................................................................. 3
4.4 PT-20AMX Plasma Torch................................................................................ 4
4.5 Cut Quality ..................................................................................................... 5
4.5.1 Introduction ............................................................................................ 5
4.5.2 Cut Angle ............................................................................................... 6
4.5.3 Cut Flatness ........................................................................................... 7
4.5.4 Surface Finish (Roughness) ..................................................................... 8
4.5.5 Dross ..................................................................................................... 9-10
4.5.6 Dimensional Accuracy............................................................................. 10-11
4.6 Process Data................................................................................................... 11-23

PCM-875A System Table of Contents
iii
Section 5 Maintenance Page 5-(_)
5.1 PCM-875A Console ....................................................................................... 1
5.1.1 General.................................................................................................. 1
5.1.2 Inspection and Cleaning ......................................................................... 2-3
5.1.3 Flow Switch 4
5.2 RAS2 (Remote Arc Starter)............................................................................. 5
5.2.1 General.................................................................................................. 5
5.2.2 Spark Gap Procedure............................................................................. 5
5.3 PT-20AMX Plasmarc Torch ............................................................................ 6
5.3.1 General.................................................................................................. 6
5.3.2 Dirt or Contamination ............................................................................. 7
5.3.3 Loose Consumables............................................................................... 7
5.3.4 Damage Caused by Loose Parts or Overheating ..................................... 8
5.3.5 Consumables- Remove and Replace ..................................................... 8-10
5.3.6 Measuring Torch Gas Flows ................................................................... 10
5.3.7 Removal and Replacement of the Torch Body......................................... 11

PCM-875A System Table of Contents
iv
Section 6 Troubleshooting Page 6-(_)
6.1 Troubleshooting PCM-875A Plasmarc System ................................................ 1
6.2 Console ......................................................................................................... 2-8
6.2.1 Power Light (PL1) does not come on....................................................... 2
6.2.2 No Air Flow............................................................................................. 2
6.2.3 Power Light is on but nothing happens when signal is given to fire with
no fault light ......................................................................................... 3
6.2.4 Fault light activates when torch fire signal is given.................................... 4-5
6.2.5 Air is on but nothing happens when torch fire signal is given .................... 6
6.2.6 High Frequency and Pilot Arc are on but no main arc transfer .................. 7
6.2.7 Poor Cutting Performance....................................................................... 7
6.2.8 Air does not shut off................................................................................ 7
6.2.9 Main arc difficult to start.......................................................................... 8
6.3 Reference Voltage Checks.............................................................................. 9
6.4 PT-20AMX Torch Troubleshooting10 .............................................................. 10-11
6.4.1 Insufficient Penetration ............................................................................ 10
6.4.2 Main Arc Extinguishes............................................................................. 10
6.4.3 Dross Formation ..................................................................................... 10
6.4.4 Double Arcing......................................................................................... 11
6.4.5 Uneven Arc............................................................................................. 11
6.4.6 Unstable Cutting Conditions.................................................................... 11
6.4.7 Main Arc Does Not Strike........................................................................ 11
6.4.8 Poor Consumable Life............................................................................. 11
6.5 230V Power Console Electrical Drawings ........................................................ 12-17
6.5.1 Schematic .............................................................................................. 12-13
6.5.2 Wiring Diagrams ..................................................................................... 14-17
6.6 400V Power Console Electrical Drawings ........................................................ 18-23
6.6.1 Schematic .............................................................................................. 18-19
6.6.2 Wiring Diagrams ..................................................................................... 20-23
6.7 Remote Arc Starter Schematic........................................................................ 24
Section 7 Replacement Parts Page 7-(_)
7.1 General .......................................................................................................... 1
7.2 Ordering......................................................................................................... 1
7.3 PCM875A Power Console – 230V .................................................................. 2-9
7.4 PCM-875A Power Console – 400V ................................................................. 10-18
7.5 Remote Arc Starter......................................................................................... 19-21
7.6 PT-20AMX Plasmarc Cutting Torch................................................................. 22-25
Customer/Technical Information Back Manual
Cover

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY
1-1
1.1 Introduction
The process of cutting metals with plasma
equipment provides industry with a valuable and
versatile tool. ESAB cutting machines are
designed to provide both operation safety and
efficiency. However, as with any machine tool,
sensible attention to operating procedures,
precautions, and safe practices is necessary to
achieve a full measure of usefulness. Whether an
individual is involved with operation, servicing, or
as an observer, compliance with established
precautions and safe practices must be
accomplished. Failure to observe certain
precautions could result in serious personnel injury
or severe equipment damage. The following
precautions are general guidelines applicable when
working with cutting machines. More explicit
precautions pertaining to the basic machine and
accessories are found in the instruction literature.
For a wide scope of safety information on the field
of cutting and welding apparatus, obtain and read
the publications listed in the Recommended
References.

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY
1-2
1.2 Safety Notations And Symbols The following words and symbols are used
throughout this manual. They indicate different
levels of required safety involvement.
!
ALERT or ATTENTION. Your safety is
involved or potential equipment failure exists.
Used with other symbols and information.
DANGER
!
Used to call attention to immediate hazards
which, if not avoided, will result in serious
personal injury or loss of life.
WARNING
!
Used to call attention to potential hazards that
could result in personal injury or loss of life.
CAUTION
!
Used to call attention to hazards that could
result in minor personal injury or equipment
damage.
CAUTION
Used to call attention to minor hazards to
equipment.
NOTICE
Used to call attention to important
installation, operation or maintenance
information not directly related to safety
hazards.

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY
1-3
1.3 General Safety Information
NOTICE
Some subjects listed are not related specifically to
the type of equipment covered in this manual.
However, the safety principles still apply. They are
offered as a reminder that this equipment or
related apparatus should be operated with
alertness and understanding. Safety of operators,
technicians, maintenance workers and observers
should not be taken for granted.
WARNING
!
Machinery may start automatically.
Equipment positioning mechanized plasma torch
moves in various directions and speeds.
· Moving machinery can crush.
· Only qualified personnel should operate or
service this power source.
· Keep all personnel, materials, and equipment
not involved in production process clear of
entire system area.
· Fence off entire work cell to prevent personnel
from passing through area or standing in the
working envelope of the equipment.
· Post appropriate WARNING signs at every
work cell entrance.
· Follow lockout procedure before servicing any
equipment.
WARNING
!
Failure to follow operating instructions
could result in death or serious injury.
Read and understand this operator’s manual
before using machine.
· Read entire procedure before operating or
performing any system maintenance.
· Special attention must be given to all hazard
warnings that provide essential information
regarding personnel safety and/or possible
equipment damage.
· All safety precautions relevant to electrical
equipment and process operations must be
strictly observed by all having system
responsibility or access.
· Read all safety publications made available by
your company.

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY
1-4
WARNING
!
Failure to follow safety warning label
instructions could result in death or
serious injury.
Read and understand all safety warning labels on
machine.
Refer to operator’s manual for additional safety
information.
1.4 Installation Precautions
WARNING
!
Improperly Installed Equipment Can
Cause Injury Or Death.
Follow these guidelines while installing machine:
· Contact your ESAB representative before
installation. He can suggest certain
precautions regarding piping installation and
machine lifting, etc. to ensure maximum
security.
· Never attempt any machine modifications or
apparatus additions without first consulting a
qualified ESAB representative.
· Observe machine clearance requirements for
proper operation and personnel safety.
· Always have qualified personnel perform
installation, troubleshooting and maintenance
of this equipment.
· Provide a wall mounted disconnect switch with
proper fuse sizes close to the power supply.