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.

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY
1-5
1.5 Electrical Grounding
Electrical grounding is imperative for proper
machine operation and SAFETY. Refer to this
manual’s Installation section for detailed grounding
instructions.
WARNING
!
Electric shock hazard.
Improper grounding can cause severe injury or
death.
Machine must be properly grounded before put
into service.
1.6 Operating A Plasma Cutting Machine
WARNING
!
Flying debris and loud noise
hazards.
· Hot spatter can burn and injure eyes. Wear
goggles to protect eyes from burns and flying
debris generated during operation.
· Chipped slag may be hot and fly far.
Bystanders should also wear goggles and
safety glasses.
· Noise from plasma arc can damage hearing.
Wear correct ear protection when cutting
above water.
WARNING
!
Burn hazard.
Hot metal can burn.
· Do not touch metal plate or parts immediately
after cutting. Allow metal time to cool, or douse
with water.
· Do not touch plasma torch immediately after
cutting. Allow torch time to cool.

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY
1-6
WARNING
!
Hazardous voltages. Electric shock
can kill.
· Do NOT touch plasma torch, cutting table or
cable connections during plasma cutting process.
· Always turn power off to plasma power
supplies before touching or servicing plasma torch.
· Always turn power off to plasma power
supplies before servicing any system component.
· Do not touch live electrical parts.
· Keep all panels and covers in place when
machine is connected to power source.
· Wear insulating gloves, shoes and clothing to
insulate yourself from workpiece and electrical
ground.
· Keep gloves, shoes, clothing, work area, and
equipment dry.
· Replace worn or damaged cables.
WARNING
!
Fume hazard.
Fumes and gases generated by the plasma cutting
process can be hazardous to your health.
· Do NOT breathe fumes.
· Do not operate plasma torch without fume
removal system operating properly.
· Use additional ventilation to remove fumes if
necessary.
· Use approved respirator if ventilation is not
adequate.
· Provide positive mechanical ventilation when
cutting galvanized steel, stainless steel, copper,
zinc, beryllium, or cadmium. Do not breathe these
fumes.
· Do not operate near degreasing and spraying
operations. Heat or arc rays can react with
chlorinated hydrocarbon vapors to form phosgene,
a highly toxic gas and other irritant gases.

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY
1-7
WARNING
!
Radiation hazard.
Arc rays can injure eyes and burn skin.
· Wear correct eye and body protection.
· Wear dark safety glasses or goggles with side
shields. Refer to following chart for recommended
lens shades for plasma cutting:
Arc Current Lens Shade
Up to 100 Amps Shade No. 8
100-200 AmpsShade No. 10
200-400 AmpsShade No. 12
Over 400 Amps Shade No. 14
· Replace glasses/goggles when lenses are
pitted or broken
· Warn others in area not to look directly at the
arc unless wearing appropriate safety glasses.
· Prepare cutting area to reduce reflection and
transmission of ultraviolet light.
§ Use special paint on walls to absorb UV
light.
§ Install protective screens or curtains to
reduce ultraviolet transmission.
CAUTION
Do Not Use this Torch Under Water.
The PT-20AMX is designed to be a dry
cutting process.
Cutting under water may result in:
· reduced consumable life
· degradation of cut quality
· possible damaged torch
Cutting under water may result in poor cutting
performance. Water vapor created when hot material
or sparks contact liquid may cause arcing inside torch.
When cutting on a water table, reduce the water level
to provide maximum clearance between water and
material.

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY
1-8
WARNING
!
Burn Hazard.
Heat, spatter, and sparks cause fire and burns.
· Do not cut near combustible material.
· Do not have on your person any combustibles
(e.g. butane lighter).
· Pilot arc can cause burns. Keep torch nozzle
away from yourself and others when activating
plasma process.
· Wear correct eye and body protection.
· Wear gauntlet gloves, safety shoes and hat.
· Wear flame-retardant clothing covering all
exposed areas.
· Wear cuffless trousers to prevent entry of
sparks and slag.
· Have fire extinguishing equipment available for
use.
WARNING
!
Explosion hazard.
· Certain molten aluminum-lithium (Al-Li) alloys
can cause explosions when plasma cut OVER
water.
§ These alloys should only be dry cut on a
dry table.
§ DO NOT dry cut over water.
§ Contact your aluminum supplier for
additional safety information regarding
hazards associated with these alloys.
· Do not cut in atmospheres containing
explosive dust or vapors.
· Do not carry any combustibles on your person
(e.g. butane lighter)
· Do not cut containers that have held
combustibles.

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY
1-9
1.7 Service Precautions
WARNING
!
Hazardous voltages. Electric shock
can kill.
· Do NOT touch plasma torch, cutting table or
cable connections during plasma cutting process.
· Always turn power off to plasma power
supplies before touching or servicing plasma torch.
· Always turn power off to plasma power
supplies before removing covers or panels to
service any system component.
· Do not touch live electrical parts.
· Keep all panels and covers in place when
machine is connected to power source.
· Keep gloves, shoes, clothing, work area, and
equipment dry.
· Inspect power and ground leads cables for
wear or cracking. Replace worn or damaged
cables. Do not use if damaged.
· Never bypass safety interlocks.
· Follow lock-out procedures.
WARNING
!
Hot Torch can cause skin burns.
Allow torch to cool before servicing.

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY
1-10
DANGER
!
Danger of Electric Shock.
Torch may be electrically active.
Turn off Plasma Power Console before
servicing torch.
CAUTION
Establish and adhere to preventive maintenance.
A composite program can be established from
recommended schedules.
Avoid leaving test equipment or hand tools on
machine. Severe electrical or mechanical damage
could occur to equipment or machine.
CAUTION
!
Extreme caution should be used when probing
circuitry with an oscilloscope or voltmeter.
Integrated circuits are susceptible to over voltage
damage. Power off before using test probes to
prevent accidental shorting of components.
All circuit boards securely seated in sockets, all
cables properly connected, all cabinets closed and
locked, all guards and covers replaced before
power is turned on.

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY
1-11
1.8 Safety References -- Regulations, Standards, Guidelines
The following recognized publications on safety in welding and cutting
operations are recommended. These publications have been prepared
to protect persons from injury or illness and to protect property from
damage, which could result from unsafe practices. Although some of
these publications are not related specifically to this type of industrial
cutting apparatus, the principles of safety apply equally.
1.8.1 USA
· “Precautions and Safe Practices in Welding and Cutting with
Oxygen-Fuel Gas Equipment,” Form 2035. ESAB Cutting
Systems.
· “Precautions and Safe Practices for Electric Welding and Cutting,”
Form 52-529. ESAB Cutting Systems.
· “Safety in Welding and Cutting” - ANSI Z 49.1, American Welding
Society, 2501 NW 7th Street, Miami, Florida, 33125.
· “Recommended Safe Practices for Shielded Gases for Welding and
Plasma Arc Cutting” - AWS C5.10-94, American Welding Society.
· “Recommended Practices for Plasma Arc Welding” - AWS C5.1,
American Welding Society.
· “Recommended Practices for Arc Cutting” - AWS C5.2, American
Welding Society.
· “Safe Practices” - AWS SP, American Welding Society.
· “Standard for Fire Protection in Use of Cutting and Welding
Procedures” - NFPA 51B, National Fire Protection Association, 60
Batterymarch Street, Boston, Massachusetts, 02110.
· “Standard for Installation and Operation of Oxygen - Fuel Gas
Systems for Welding and Cutting” - NFPA 51, National Fire
Protection Association.
· “Safety Precautions for Oxygen, Nitrogen, Argon, Helium, Carbon
Dioxide, Hydrogen, and Acetylene,” Form 3499. ESAB Cutting
Systems. Obtainable through your ESAB representative or local
distributor.
· "Design and Installation of Oxygen Piping Systems," Form 5110.
ESAB Cutting Systems.
· “Precautions for Safe Handling of Compressed Gases in
Cylinders”, CGA Standard P-1, Compressed Gas Association.
Literature applicable to safe practices in welding and cutting with
gaseous materials is also available from the Compressed Gas
Association, Inc., 500 Fifth Ave., New York, NY 10036.

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY
1-12
1.8.2 International
Accident Prevention
VBG- Unfallverhütungsvorshriften
General Provisions
VBG 1 Allgemeine Unfallverhütungsvorshriften
Electrical Equipment and operating Equipment
VBG 4 Elektrische Anlagen
Welding, Cutting and related working methods
VBG 15 Schweißen un Schneiden un verwandte Verfahren
Shot Blasting Works
VBG 48 Strahlarbeiten
Gases
VBG 61 Gase
Oxygen
VBG 62 Sauerstoff
Operating liquid jet cutting machines
VBG 87 Arbeiten mit Flüssigkeitsstrahlem
Laser beams, accident prevention and Electro-
technology
VBG 93
Laserstrahlung, Unfallverhütungs-vorschriften für
Feinmechnik und Elektrotechnik
Noise
VBG 121 Lärm

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY
1-13
VDE Regulations
VDE - Vorschriften
Erection of power installations with normal voltages up to
1000 volts
VDE 0100 Bestimmungen für das Errichten von Stakstromanlagen
mit Nennspannungen bis 1000 Volt
Electrical equipment of industrial machines
VDE0113 Elektrishe Ausrüstung von Industriemaschinen
Radiation safety of laser products; users guide (DIN EN
60825)
VDE 0837 Strahlungssicherheit von Lasereinrichtungen und
Benutzungsrichtlinen (DIN EN 60825)
Specification for laser guards
VDE 0837-
50 Anforderung an Lasershcutzwänden
TRAC Technical Rules for Acetylene and Carbide Stores
TRAC- Techische Regein für Azetylenanlagen und Calciumcargidlager
Acetylene lines
TRAC-204 Azetylenleitungen
Acetylene cylinder battery systems
TRAC-206 Azetylenflaschenbatterieanlagen
Safety devices
TRAC-207 Sicherheitseinrichtungen
TRG Technical Rules for Pressure gases
TRG – Technische Regein für Druckgase
General regulations for pressure gases
TRG 100 Allgemeine Bestimmungen für Druckgase
Pressure gases
TRG 101 Druckgase
Technical gas mixtures
TRG 102 Technishe Gasgemische
Pressure gases; alterative use of compressed gas tanks
TRG 104 Druckgase, wahlweise Verwendung von
Druckgasbehältem

SECTION 1 PCM-875A Mechanized Plasma Cutting System SAFETY
1-14
TRGS – Technische Richtlinien für Gefahrstoffe
TRGS-102 Techn. Richtkonzentration (TRK) für gefährliche Stoffe
TRGS-402 Ermittlung u. Beurteilung der Konzentration gefährlicher
Stoffe in der Luft im Arbeitsbereich
TRGS-900 Grenzwerte in der Luft am Arbeitsplatz (Luftgrenzwerte)
TA TA-Luft un TA-Lärm (BLm SchV)
DIN Standards
DIN-Normen
DIN 2310
Part 1 Thermal cutting; terminology and nomenclature
Teil 1 Thermsiches Schneiden, Allgemeine Begriffe und
Bennungen
DIN 2310
Part 2 Thermal cutting; determination of quality of cut faces
Teil 2 Thermsiches Schneiden, Ermittein der Güte von
Schnittflächen
DIN 2310
Part 4 Thermal cutting; arc plasma cutting; process principles, quality, dimensional tolerances
Teil 4 Thermsiches Schneiden, Plasmaschneiden,
Verfahrensgrundlagen, Güte, Maßtoleranzen
DIN 2310
Part 5 Thermal cutting; laser beam cutting of metallic materials; process principles
Teil 5 Laserstrahlschneiden von metallischen Werkstoffen,
Verfahrensgrundlagen, Güte, Maßtoleranzen
DIN 2310
Part 6 Thermal cutting; Classification, processes
Teil 6 Einführung, Verfahren
DIN 4844
Part 1 Safety markings (DIN EN 7287)
Teil 1 Sicherheitskennzeichen (Siehe EN 7287)