Plasma Essab PLS 50

7222019 Plasma Essab PLS 50

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This manual provides installation and operation instructions for the following PCM-875 cutting packages starting withSerial No PHJ205001

Consoles

PN 0558001167 - 208230 V 5060 Hz 1 or 3-phasePN 0558001169 - 460 V 5060 Hz 3-phasePN 0558001170 - 575 V 60 Hz 3-phasePN 0558001171 - 400 V 5060 Hz 3-phase

PCM-875Plasma Arc Cutting Package

Instruction Manual



This equipment will perform in conformity with the description thereof contained in this manual and accompa-

nying labels andor inserts when installed operated maintained and repaired in accordance with the instruc-

tions provided This equipment must be checked periodically Malfunctioning or poorly maintained equipmentshould not be used Parts that are broken missing worn distorted or contaminated should be replaced imme-

diately 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 ser-

vice facility designated by the manufacturer

BE SURE THIS INFORMATION REACHES THE OPERATOR

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER

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 urgeyou to read our booklet ldquoPrecautions and Safe Practices for Arc Welding Cutting and

Gougingrdquo 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 be-

fore installing or operating this equipment

CAUTION

USER RESPONSIBILITY



TABLE OF CONTENTS

10 Safety Precautions 5 11 Safety - English 5

12 Safety - Spanish 9 13 Safety - French 13

20 Description 17 21 General 17 22 Scope 17 23 Packages Available 17 24 Specifications 18 25 Optional Accessories 18

30 Installation 21 31 General 21 32 Equipment Required 21 33 Location 21 34 Inspection 21 35 Primary Electrical Input Connections 21 36 Secondary Output Connections 22 37 Connecting PCM-875 for 200(208)Vac Input 24 38 Mechanized Cutting Installation with the PT-20AM Torch 25 40 Operation 27 41 Operation 27 42 PCM-875 Controls 27 43 Cutting with the PT-27 27 44 Common Cutting Problems 29

50 Maintenance 31 51 General 31 52 Inspection and Cleaning 31 53 PT-27 Torch Consumable Parts 31 54 Flow Switch 32

55 IGBT Handling and Replacement 32 56 Troubleshooting 33 57 Troubleshooting Guide 34 58 Reference Voltage Checks 38 59 Sequence of Operation 39

R l P

Section Title Page



TABLE OF CONTENTS



SECTION 1 SAFETY PRECAUTIONS

10 Safety Precautions 11 Safety - English

WARNING These Safety Precautions arefor your protection They summarize pre-cautionary information from the referenceslisted in Additional Safety Information sec-

tion Before performing any installation or operatingprocedures be sure to read and follow the safetyprecautions listed below as well as all other manualsmaterial safety data sheets labels etc Failure to observeSafety Precautions can result in injury or death

PROTECT YOURSELF AND OTHERS --Some welding cutting and gougingprocesses are noisy and require earprotection The arc like the sun emitsultraviolet (UV) and other radiation

and can injure skin and eyes Hot metal can causeburns Training in the proper use of the processesand equipment is essential to prevent accidentsTherefore

1 Always wear safety glasses with side shields in anywork area even if welding helmets face shields andgoggles are also required

2 Use a face shield fitted with the correct filter and

cover plates to protect your eyes face neck andears from sparks and rays of the arc when operat-ing or observing operations Warn bystanders notto watch the arc and not to expose themselves tothe rays of the electric-arc or hot metal

3 Wear flameproof gauntlet type gloves heavy long-sleeve shirt cuffless trousers high-topped shoesand a welding helmet or cap for hair protection to

protect against arc rays and hot sparks or hot metalA flameproof apron may also be desirable as protec-tion against radiated heat and sparks

4 Hot sparks or metal can lodge in rolled up sleevestrouser cuffs or pockets Sleeves and collars shouldbe kept buttoned and open pockets eliminated from

FIRES AND EXPLOSIONS -- Heat fromflames and arcs can start fires Hotslag or sparks can also cause fires andexplosions Therefore

1 Remove all combustible materials well away fromthe work area or cover the materials with a protec-

tive non-flammable covering Combustible materialsinclude wood cloth sawdust liquid and gas fuelssolvents paints and coatings paper etc

2 Hot sparks or hot metal can fall through cracks orcrevices in floors or wall openings and cause a hid-den smoldering fire or fires on the floor below Makecertain that such openings are protected from hotsparks and metalldquo

3 Do not weld cut or perform other hot work until theworkpiece has been completely cleaned so that thereare no substances on the workpiece which mightproduce flammable or toxic vapors Do not do hotwork on closed containers They may explode

4 Have fire extinguishing equipment handy for instantuse such as a garden hose water pail sand bucketor portable fire extinguisher Be sure you are trainedin its use

5 Do not use equipment beyond its ratings For ex-ample overloaded welding cable can overheat andcreate a fire hazard

6 After completing operations inspect the work areato make certain there are no hot sparks or hot metalwhich could cause a later fire Use fire watchers whennecessary

7 For additional information refer to NFPA Standard51B Fire Prevention in Use of Cutting and WeldingProcesses available from the National Fire Protec-tion Association Batterymarch Park Quincy MA02269




1 Be sure the power source frame (chassis) is con-nected to the ground system of the input power

2 Connect the workpiece to a good electricalground

3 Connect the work cable to the workpiece A pooror missing connection can expose you or othersto a fatal shock

4 Use well-maintained equipment Replace worn ordamaged cables

5 Keep everything dry including clothing workarea cables torchelectrode holder and powersource

6 Make sure that all parts of your body are insulatedfrom work and from ground

7 Do not stand directly on metal or the earth whileworking in tight quarters or a damp area standon dry boards or an insulating platform and wearrubber-soled shoes

8 Put on dry hole-free gloves before turning on thepower

9 Turn off the power before removing your gloves

10 Refer to ANSIASC Standard Z491 (listed onnext page) for specific grounding recommenda-tions Do not mistake the work lead for a groundcable

ELECTRIC AND MAGNETIC FIELDSmdash May be dangerous Electric cur-rent flowing through any conduc-tor causes localized Electric andMagnetic Fields (EMF) Welding and

3 Welders should use the following procedures tominimize exposure to EMF

A Route the electrode and work cables togetherSecure them with tape when possible

B Never coil the torch or work cable around yourbody

C Do not place your body between the torch and

work cables Route cables on the same side ofyour body

D Connect the work cable to the workpiece as closeas possible to the area being welded

E Keep welding power source and cables as faraway from your body as possible

FUMES AND GASES -- Fumes andgases can cause discomfort or harmparticularly in confined spaces Donot breathe fumes and gases Shield-ing gases can cause asphyxiation

Therefore

1 Always provide adequate ventilation in the work areaby natural or mechanical means Do not weld cut orgouge on materials such as galvanized steel stain-less steel copper zinc lead beryllium or cadmiumunless positive mechanical ventilation is providedDo not breathe fumes from these materials

2 Do not operate near degreasing and spraying opera-tions The heat or arc rays can react with chlorinatedhydrocarbon vapors to form phosgene a highlytoxic gas and other irritant gases

3 If you develop momentary eye nose or throat ir-




5 WARNING This product when used for weldingor cutting produces fumes or gases

which contain chemicals known tothe State of California to cause birthdefects and in some cases cancer(California Health amp Safety Codesect252495 et seq)

CYLINDER HANDLING -- Cylindersif mishandled can rupture and vio-lently release gas Sudden ruptureof cylinder valve or relief device caninjure or kill Therefore

1 Use the proper gas for the process and use theproper pressure reducing regulator designed to

operate from the compressed gas cylinder Do notuse adaptors Maintain hoses and fittings in goodcondition Follow manufacturers operating instruc-tions for mounting regulator to a compressed gascylinder

2 Always secure cylinders in an upright position bychain or strap to suitable hand trucks undercar-riages benches walls post or racks Never securecylinders to work tables or fixtures where they maybecome part of an electrical circuit

3 When not in use keep cylinder valves closed Havevalve protection cap in place if regulator is not con-nected Secure and move cylinders by using suitablehand trucks Avoid rough handling of cylinders

4 Locate cylinders away from heat sparks and flamesNever strike an arc on a cylinder

5 For additional information refer to CGA Standard P-1Precautions for Safe Handling of Compressed Gasesin Cylinders which is available from Compressed

1 Always have qualified personnel perform the instal-lation troubleshooting and maintenance work

Do not perform any electrical work unless you arequalified to perform such work

2 Before performing any maintenance work inside apower source disconnect the power source fromthe incoming electrical power

3 Maintain cables grounding wire connections power

cord and power supply in safe working order Donot operate any equipment in faulty condition

4 Do not abuse any equipment or accessories Keepequipment away from heat sources such as furnaceswet conditions such as water puddles oil or greasecorrosive atmospheres and inclement weather

5 Keep all safety devices and cabinet covers in positionand in good repair

6 Use equipment only for its intended purpose Donot modify it in any manner

ADDITIONAL SAFETY INFORMATION -- Formore information on safe practices forelectric arc welding and cutting equip-ment ask your supplier for a copy ofPrecautions and Safe Practices for ArcWelding Cutting and Gouging Form52-529

The following publications which are available fromthe American Welding Society 550 NW LeJuene RoadMiami FL 33126 are recommended to you

1 ANSIASC Z491 - Safety in Welding and Cutting




5 AWS C55 - Recommended Practices for Gas Tung-sten Arc Weldingldquo

6 AWS C56 - Recommended Practices for Gas MetalArc Weldingldquo

7 AWS SP - Safe Practices - Reprint Welding Hand-book

8 ANSIAWS F41 Recommended Safe Practices for

Welding and Cutting of Containers That Have HeldHazardous Substances

MEANING OF SYMBOLS - As usedthroughout this manual Means Atten-tion Be Alert Your safety is involved

Means immediate hazards whichif not avoided will result in im-mediate serious personal injuryor loss of life

Means potential hazards which

could result in personal injury orloss of life

Means hazards which could resultin minor personal injury



SECTION 1 SEGURIDAD12 Safety - Spanish

ADVERTENCIA Estas Precauciones de Se-guridad son para su proteccioacuten Ellas hacen

resumen de informacioacuten proveniente de lasreferencias listadas en la seccioacuten Informacioacuten Adi-cional Sobre La Seguridad Antes de hacer cualquierinstalacioacuten o procedimiento de operacioacuten aseguacuteresede leer y seguir las precauciones de seguridad listadasa continuacioacuten asiacute como tambieacuten todo manual hojade datos de seguridad del material calcomanias etcEl no observar las Precauciones de Seguridad puede

resultar en dantildeo a la persona o muerte

PROTEJASE USTED Y A LOS DEMAS--Algunos procesos de soldadura cortey ranurado son ruidosos y requirenproteccioacuten para los oiacutedos El arcocomo el sol emite rayos ultravioleta

(UV) y otras radiaciones que pueden dantildear la piely los ojos El metal caliente causa quemaduras ELentrenamiento en el uso propio de los equipos ysus procesos es esencial para prevenir accidentesPor lo tanto

1 Utilice gafas de seguridad con proteccioacuten a los ladossiempre que esteacute en el aacuterea de trabajo auacuten cuandoesteacute usando careta de soldar protector para su carau otro tipo de proteccioacuten

2 Use una careta que tenga el filtro correcto y lentepara proteger sus ojos cara cuello y oiacutedos de laschispas y rayos del arco cuando se esteacute operando yobservando las operaciones Alerte a todas las per-sonas cercanas de no mirar el arco y no exponersea los rayos del arco eleacutectrico o el metal fundido

3 Use guantes de cuero a prueba de fuego camisapesada de mangas largas pantaloacuten de ruedo liso

zapato alto al tobillo y careta de soldar con capuchapara el pelo para proteger el cuerpo de los rayos ychispas calientes provenientes del metal fundidoEn ocaciones un delantal a prueba de fuego esnecesario para protegerse del calor radiado y laschispas

4 Chispasypartiacuteculasdemetalcalientepuedealojarse

La escoria puede estar caliente y desprenderse convelocidad Personas cercanas deberaacuten usar gafasde seguridad y careta protectora

FUEGO Y EXPLOSIONES -- El calor delas flamas y el arco pueden ocacionarfuegos Escoria caliente y las chispaspueden causar fuegos y explosionesPor lo tanto

1 Remueva todo material combustible lejos del aacutereade trabajo o cubra los materiales con una cobija a

prueba de fuego Materiales combustibles incluyenmadera ropa liacutequidos y gases flamables solventespinturas papel etc

2 Chispas y partiacuteculas de metal pueden introducirse enlas grietas y agujeros de pisos y paredes causandofuegos escondidos en otros niveles o espaciosAseguacuterese de que toda grieta y agujero esteacute cubiertopara proteger lugares adyacentes contra fuegos

3 No corte suelde o haga cualquier otro trabajorelacionado hasta que la pieza de trabajo esteacute to-talmente limpia y libre de substancias que puedanproducir gases inflamables o vapores toacutexicos Notrabaje dentro o fuera de contenedores o tanquescerrados Estos pueden explotar si contienen vaporesinflamables

4 Tenga siempre a la mano equipo extintor de fuegopara uso instantaacuteneo como por ejemplo una

manguera con agua cubeta con agua cubeta conarena o extintor portaacutetil Aseguacuterese que usted estaentrenado para su uso

5 No use el equipo fuera de su rango de operacioacuten Porejemplo el calor causado por cable sobrecarga enlos cables de soldar pueden ocasionar un fuego

6 Despueacutes de termirar la operacioacuten del equipo inspec-cione el aacuterea de trabajo para cerciorarse de que las

chispas o metal caliente ocasionen un fuego maacutestarde Tenga personal asignado para vigilar si esnecesario

7 Para informacioacuten adicional haga referencia a lapublicacioacuten NFPA Standard 51B Fire Prevention inUse of Cutting and Welding Processes disponiblea traveacutes de la National Fire Protection Association



SECTION 1 SEGURIDAD

1 Aseguacuterese de que el chasis de la fuente de poderesteacute conectado a tierra atraveacutes del sistema de

electricidad primario 2 Conecte la pieza de trabajo a un buen sistema de

tierra fiacutesica 3 Conecte el cable de retorno a la pieza de trabajo

Cables y conductores expuestos o con malasconexiones pueden exponer al operador u otraspersonas a un choque eleacutectrico fatal

4 Use el equipo solamente si estaacute en buenas condi-

ciones Reemplaze cables rotos dantildeados o conconductores expuestos 5 Mantenga todo seco incluyendo su ropa el aacuterea de

trabajo los cables antorchas pinza del electrodoy la fuente de poder

6 Aseguacuterese que todas las partes de su cuerpo estaacuteninsuladas de ambos la pieza de trabajo y tierra

7 No se pare directamente sobre metal o tierra mien-

tras trabaja en lugares estrechos o aacutereas huacutemedastrabaje sobre un pedazo de madera seco o unaplataforma insulada y use zapatos con suela degoma

8 Use guantes secos y sin agujeros antes de energizarel equipo

9 Apage el equipo antes de quitarse sus guantes 10 Use como referencia la publicacioacuten ANSIASC

Standard Z491 (listado en la proacutexima paacutegina) pararecomendaciones especiacuteficas de como conectar elequipo a tierra No confunda el cable de soldar ala pieza de trabajo con el cable a tierra

CAMPOS ELECTRICOS Y MAGNETI-COS - Son peligrosos La corrienteeleacutectrica fluye atraveacutes de cualquierconductor causando a nivel localCampos Eleacutectricos y Magneacuteticos

(EMF) Las corrientes en el aacuterea de corte y soldaduracrean EMF alrrededor de los cables de soldar y lasmaquinas Por lo tanto

1 Soldadores u Operadores que use marca-pasos para

3 Los soldadores deberaacuten usar los siguientes proced-imientos para minimizar exponerse al EMF

A Mantenga el electrodo y el cable a la pieza detrabajo juntos hasta llegar a la pieza que ustedquiere soldar Aseguacuterelos uno junto al otro concinta adhesiva cuando sea posible

B Nunca envuelva los cables de soldar alrededorde su cuerpo

C Nunca ubique su cuerpo entre la antorcha y el

cable a la pieza de trabajo Mantega los cables aun soacutelo lado de su cuerpo

D Conecte el cable de trabajo a la pieza de trabajolo maacutes cercano posible al aacuterea de la soldadura

E Mantenga la fuente de poder y los cables de soldarlo maacutes lejos posible de su cuerpo

HUMO Y GASES -- El humo y losgases pueden causar malestar odantildeo particularmente en espaciossin ventilacioacuten No inhale el humoo gases El gas de proteccioacuten puede

causar falta de oxiacutegenoPor lo tanto

1 Siempre provea ventilacioacuten adecuada en el aacutereade trabajo por medio natural o mecaacutenico No soldecorte o ranure materiales con hierro galvanizadoacero inoxidable cobre zinc plomo beriacutelio o cad-mio a menos que provea ventilacioacuten mecaacutenicapositiva No respire los gases producidos porestos materiales

2 No opere cerca de lugares donde se aplique sub-stancias quiacutemicas en aerosol El calor de los rayosdel arco pueden reaccionar con los vapores dehidrocarburo clorinado para formar un fosfoacutegenoo gas toacutexico y otros irritant es

3 Si momentaacuteneamente desarrolla inrritacioacuten deojos nariz o garganta mientras est aacute operando esindicacioacuten de que la ventilacioacuten no es apropiada



SECTION 1 SEGURIDAD

5 ADVERTENCIA-- Este producto cuando se uti-liza para soldaduras o cortes

produce humos o gases loscuales contienen quiacutemicosconocidos por el Estado de Cali-fornia de causar defectos en elnacimiento o en algunos casosCancer (California Health ampSafety Code sect252495 et seq)

MANEJO DE CILINDROS-- Loscilindros si no son manejadoscorrectamente pueden romp-erse y liberar violentamentegases Rotura repentina delcilindro vaacutelvula o vaacutelvula deescape puede causar dantildeo omuerte Por lo tanto

1 Utilize el gas apropiado para el proceso y utilizeun regulador disentildeado para operar y reducir lapresioacuten del cilindro de gas No utilice adapta-dores Mantenga las mangueras y las conexionesen buenas condiciones Observe las instruccionesde operacioacuten del manufacturero para montar elregulador en el cilindro de gas comprimido

2 Asegure siempre los cilindros en posicioacuten verticaly amaacuterrelos con una correa o cadena adecuadapara asegurar el cilindro al carro transportes tab-lilleros paredes postes o armazoacuten Nunca asegurelos cilindros a la mesa de trabajo o las piezas queson parte del circuito de soldadura Este puede serparte del circuito eleacutelectrico

3 Cuando el cilindro no estaacute en uso mantenga lavaacutelvula del cilindro cerrada Ponga el capote deproteccioacuten sobre la vaacutelvula si el regulador noestaacute conectado Asegure y mueva los cilindrosutilizando un carro o transporte adecuado Eviteel manejo brusco de los

1 Siempre tenga personal cualificado para efec-tuar l a instalacioacuten diagnoacutestico y mantenimiento

del equipo No ejecute ninguacuten trabajo eleacutectrico amenos que usted esteacute cualificado para hacer eltrabajo

2 Antes de dar mantenimiento en el interior de lafuente de poder desconecte la fuente de poderdel suministro de electricidad primaria

3 Mantenga los cables cable a tierra conexcionescable primario y cualquier otra fuente de poder

en buen estado operacional No opere ninguacutenequipo en malas condiciones4 No abuse del equipo y sus accesorios Mantenga

el equipo lejos de cosas que generen calor comohornos tambieacuten lugares huacutemedos como charcosde agua aceite o grasa atmoacutesferas corrosivas ylas inclemencias del tiempo

5 Mantenga todos los artiacuteculos de seguridad y

coverturas del equipo en su posicioacuten y en buenascondiciones6 Use el equipo soacutelo para el propoacutesito que fue

disentildeado No modifique el equipo en ningunamanera

INFORMACION ADICIONAL DE SEGU-RIDAD -- Para maacutes informacioacuten sobre laspraacutecticas de seguridad de los equipos dearco eleacutectrico para soldar y cortar preguntea su suplidor por una copia de Precautionsand Safe Practices for Arc Welding Cuttingand Gouging-Form 52-529

Las siguientes publicaciones disponibles atraveacutes dela American Welding Society 550 NW LeJuene RoadMiami FL 33126 son recomendadas para usted


2 AWS C5 1 - Recommended Practices for Plasma Arc



SECTION 1 SEGURIDAD

SIGNIFICADO DE LOS SIMBOLOS-- Seguacuten usted avanza en la lectura

de este folleto Los Siacutembolos Sig-nifican iexclAtencioacuten iexclEsteacute Alerta Setrata de su seguridad

Significa riesgo inmediato quede no ser evadido puede resultarinmediatamente en serio dantildeo

personal o la muerte

Significa el riesgo de un peligropotencial que puede resultar enserio dantildeo personal o la muerte

Significa el posible riesgo quepuede resultar en menores dantildeosa la persona



SECTION 1 SEacuteCURITEacute13 Safety - French INCENDIES ET EXPLOSIONS -- La

chaleur provenant des flammes ou delarc peut provoquer un incendie Lelaitier incandescent ou les eacutetincelles

peuvent eacutegalement provoquer unincendie ou une explosion Par conseacutequent

1 Eacuteloignez suffisamment tous les mateacuteriaux combus-tibles de laire de travail et recouvrez les mateacuteriauxavec un revecirctement protecteur ininflammable Lesmateacuteriaux combustibles incluent le bois les vecircte-ments la sciure le gaz et les liquides combustibles

les solvants les peintures et les revecirctements lepapier etc2 Les eacutetincelles et les projections de meacutetal incan-

descent peuvent tomber dans les fissures dansles planchers ou dans les ouvertures des murs etdeacuteclencher un incendie couvant agrave leacutetage infeacuterieurAssurez-vous que ces ouvertures sont bien proteacutegeacuteesdes eacutetincelles et du meacutetal incandescent

3 Nexeacutecutez pas de soudure de coupe ou autre tra-

vail agrave chaud avant davoir complegravetement nettoyeacute lasurface de la piegravece agrave traiter de faccedilon agrave ce quil naitaucune substance preacutesente qui pourrait produiredes vapeurs inflammables ou toxiques Nexeacutecutezpas de travail agrave chaud sur des contenants fermeacutescar ces derniers pourraient exploser

4 Assurez-vous quun eacutequipement dextinctiondincendie est disponible et precirct agrave servir tel quuntuyau darrosage un seau deau un seau de sableou un extincteur portatif Assurez-vous decirctre bieninstruit par rapport agrave lusage de cet eacutequipement

5 Assurez-vous de ne pas exceacuteder la capaciteacute deleacutequipement Par exemple un cacircble de soudagesurchargeacute peut surchauffer et provoquer un in-cendie

6 Une fois les opeacuterations termineacutees inspectez laire detravail pour assurer quaucune eacutetincelle ou projec-

tion de meacutetal incandescent ne risque de provoquerun incendie ulteacuterieurement Employez des guetteursdincendie au besoin

7 Pour obtenir des informations suppleacutementairesconsultez le NFPA Standard 51B Fire Prevention inUse of Cutting and Welding Processes disponible auNational Fire Protection Association Batterymarch

AVERTISSEMENT Ces regravegles de seacutecuriteacuteont pour but dassurer votre protection Ilsreacutecapitulent les informations de preacutecaution

provenant des reacutefeacuterences dans la sectiondes Informations de seacutecuriteacute suppleacutementaires Avant deproceacuteder agrave linstallation ou dutiliser luniteacute assurez-vousde lire et de suivre les preacutecautions de seacutecuriteacute ci-des-sous dans les manuels les fiches dinformation sur laseacutecuriteacute du mateacuteriel et sur les eacutetiquettes etc Tout deacutefautdobserver ces preacutecautions de seacutecuriteacute peut entraicircnerdes blessures graves ou mortelles

PROTEacuteGEZ-VOUS -- Les processus desoudage de coupage et de gougeageproduisent un niveau de bruit eacuteleveacute et

exige lemploi dune protection auditive Larc toutcomme le soleil eacutemet des rayons ultraviolets en plusdautre rayons qui peuvent causer des blessures agrave lapeau et les yeux Le meacutetal incandescent peut causerdes brucirclures Une formation relieacutee agrave lusage desprocessus et de leacutequipement est essentielle pourpreacutevenir les accidents Par conseacutequent

1 Portez des lunettes protectrices munies deacutecrans la-teacuteraux lorsque vous ecirctes dans laire de travail mecircmesi vous devez porter un casque de soudeur un eacutecranfacial ou des lunettes eacutetanches

2 Portez un eacutecran facial muni de verres filtrants et deplaques protectrices approprieacutees afin de proteacutegervos yeux votre visage votre cou et vos oreilles deseacutetincelles et des rayons de larc lors dune opeacuteration

ou lorsque vous observez une opeacuteration Avertissezles personnes se trouvant agrave proximiteacute de ne pas re-garder larc et de ne pas sexposer aux rayons de larceacutelectrique ou le meacutetal incandescent

3 Portez des gants ignifugieacutes agrave crispin une chemiseeacutepaisse agrave manches longues des pantalons sansrebord et des chaussures montantes afin de vousproteacuteger des rayons de larc des eacutetincelles et du meacutetalincandescent en plus dun casque de soudeur oucasquette pour proteacuteger vos cheveux Il est eacutegalement

recommandeacute de porter un tablier ininflammable afinde vous proteacuteger des eacutetincelles et de la chaleur parrayonnement

4 Les eacutetincelles et les projections de meacutetal incandescentrisquent de se loger dans les manches retrousseacuteesles rebords de pantalons ou les poches Il est recom-mandeacute de garder boutonneacutes le col et les manches etd d ecirc h



SECTION 1 SEacuteCURITEacute

3 Les soudeurs doivent suivre les proceacutedures suivantespour minimiser lexposition aux champs eacutelectriques

et magneacutetiques A Acheminez leacutelectrode et les cacircbles de masseensemble Fixez-les agrave laide dune bande adheacutesivelorsque possible

B Ne jamais enrouler la torche ou le cacircble de masseautour de votre corps

C Ne jamais vous placer entre la torche et les cacircblesde masse Acheminez tous les cacircbles sur le mecircme

cocircteacute de votre corpsD Branchez le cacircble de masse agrave la piegravece agrave traiter leplus pregraves possible de la section agrave souder

E Veillez agrave garder la source dalimentation pour lesoudage et les cacircbles agrave une distance approprieacuteede votre corps

LES VAPEURS ET LES GAZ -- peuventcauser un malaise ou des dommagescorporels plus particuliegraverementdans les espaces restreints Ne re-spirez pas les vapeurs et les gaz Legaz de protection risque de causerlasphyxie Par conseacutequent

1 Assurez en permanence une ventilation adeacutequatedans laire de travail en maintenant une ventila-tion naturelle ou agrave laide de moyens meacutecaniqueNeffectuez jamais de travaux de soudage de coup-age ou de gougeage sur des mateacuteriaux tels quelacier galvaniseacute lacier inoxydable le cuivre le zincle plomb le berylliym ou le cadmium en labsencede moyens meacutecaniques de ventilation efficaces Nerespirez pas les vapeurs de ces mateacuteriaux

2 Neffectuez jamais de travaux agrave proximiteacute dune

opeacuteration de deacutegraissage ou de pulveacuterisationLorsque la chaleurou le rayonnement de larc entre en contact avec lesvapeurs dhydrocarbure chloreacute ceci peut deacuteclencherla formation de phosgegravene ou dautres gaz irritantstous extrecircmement toxiques

1 Assurez-vous que le chacircssis de la sourcedalimentation est brancheacute au systegraveme de mise agrave

la terre de lalimentation dentreacutee2 Branchez la piegravece agrave traiter agrave une bonne mise deterre eacutelectrique

3 Branchez le cacircble de masse agrave la piegravece agrave traiter etassurez une bonne connexion afin deacuteviter le risquede choc eacutelectrique mortel

4 Utilisez toujours un eacutequipement correctemententretenu Remplacez les cacircbles useacutes ou endom-mageacutes

5 Veillez agrave garder votre environnement sec incluantles vecirctements laire de travail les cacircbles le porte-eacutelectrodetorche et la source dalimentation

6 Assurez-vous que tout votre corps est bien isoleacutede la piegravece agrave traiter et des piegraveces de la mise agrave laterre

7 Si vous devez effectuer votre travail dans un espacerestreint ou humide ne tenez vous pas directe-ment sur le meacutetal ou sur la terre tenez-vous surdes planches segraveches ou une plate-forme isoleacutee etportez des chaussures agrave semelles de caoutchouc

8 Avant de mettre leacutequipement sous tension isolezvos mains avec des gants secs et sans trous

9 Mettez leacutequipement hors tension avant denlevervos gants

10 Consultez ANSIASC Standard Z491 (listeacute agrave

la page suivante) pour des recommandationsspeacutecifiques concernant les proceacutedures de mise agravela terre Ne pas confondre le cacircble de masse avecle cacircble de mise agrave la terre

CHAMPS EacuteLECTRIQUES ET MAGNEacute-TIQUES mdash comportent un risquede danger Le courant eacutelectrique

qui passe dans nimporte quel con-ducteur produit des champs eacutelec-

triques et magneacutetiques localiseacutes Le soudage et lecourant de coupage creacuteent des champs eacutelectriqueset magneacutetiques autour des cacircbles de soudage etleacutequipement Par conseacutequent




1 Efforcez-vous de toujours confier les tacircchesdinstallation de deacutepannage et dentretien agrave unpersonnel qualifieacute Neffectuez aucune reacuteparationeacutelectrique agrave moins decirctre qualifieacute agrave cet effet

2 Avant de proceacuteder agrave une tacircche dentretien agravelinteacuterieur de la source dalimentation deacutebranchez

lalimentation eacutelectrique3 Maintenez les cacircbles les fils de mise agrave la terre les

branchements le cordon dalimentation et la sourcedalimentation en bon eacutetat Nutilisez jamais uneacutequipement sil preacutesente une deacutefectuositeacute quel-conque

4 Nutilisez pas leacutequipement de faccedilon abusive Gardezleacutequipement agrave leacutecart de toute source de chaleur

notamment des fours de lhumiditeacute des flaquesdeau de lhuile ou de la graisse des atmosphegraverescorrosives et des intempeacuteries

5 Laissez en place tous les dispositifs de seacutecuriteacute ettous les panneaux de la console et maintenez-lesen bon eacutetat

6 Utilisez leacutequipement conformeacutement agrave son usagepreacutevu et neffectuez aucune modification

INFORMATIONS SUPPLEacuteMENTAIRES RELA-TIVES Agrave LA SEacuteCURITEacute -- Pour obtenir delinformation suppleacutementaire sur les regraveglesde seacutecuriteacute agrave observer pour leacutequipementde soudage agrave larc eacutelectrique et le coupagedemandez un exemplaire du livret Precau-

tions and Safe Practices for Arc WeldingCutting and Gouging Form 52-529

Les publications suivantes sont eacutegalement recomman-deacutees et mises agrave votre disposition par lAmerican Welding

5 AVERTISSEMENT Ce produit lorsquil est utiliseacutedans une opeacuteration de soudage ou de

coupage deacutegage des vapeurs ou desgaz contenant des chimiques consi-deacuteres par leacutetat de la Californie commeeacutetant une cause des malformationscongeacutenitales et dans certains cas ducancer (California Health amp SafetyCode sect252495 et seq)

MANIPULATION DES CYLINDRES --La manipulation dun cylindre sansobserver les preacutecautions neacutecessairespeut produire des fissures et uneacutechappement dangereux des gaz

Une brisure soudaine du cylindre de la soupape oudu dispositif de surpression peut causer des bles-sures graves ou mortelles Par conseacutequent

1 Utilisez toujours le gaz preacutevu pour une opeacuterationet le deacutetendeur approprieacute conccedilu pour utilisationsur les cylindres de gaz comprimeacute Nutilisez jamaisdadaptateur Maintenez en bon eacutetat les tuyaux etles raccords Observez les instructions dopeacuterationdu fabricant pour assembler le deacutetendeur sur uncylindre de gaz comprimeacute

2 Fixez les cylindres dans une position verticale agravelaide dune chaicircne ou une sangle sur un chariotmanuel un chacircssis de roulement un banc un murune colonne ou un support convenable Ne fixez jamais un cylindre agrave un poste de travail ou toute autredispositif faisant partie dun circuit eacutelectrique

3 Lorsque les cylindres ne servent pas gardez lessoupapes fermeacutees Si le deacutetendeur nest pas bran-cheacute assurez-vous que le bouchon de protection de

la soupape est bien en place Fixez et deacuteplacez lescylindres agrave laide dun chariot manuel approprieacuteToujours manipuler les cylindres avec soin

4 Placez les cylindres agrave une distance approprieacuteede toute source de chaleur des eacutetincelles et desflammes Ne jamais amorcer larc sur un cylindre

ENTRETIEN DE LEacuteQUIPEMENT -- Un eacutequipe-ment entretenu de faccedilon deacutefectueuse ou

inadeacutequate peut causer des blessuresgraves ou mortelles Par conseacutequent




SIGNIFICATION DES SYMBOLESCe symbole utiliseacute partout dans ce manuel

signifie Attention Soyez vigilant Votreseacutecuriteacute est en jeu

Signifie un danger immeacutediat La situation peutentraicircner des blessures graves ou mortelles

Signifie un danger potentiel qui peut entraicircner desblessures graves ou mortelles

Signifie un danger qui peut entraicircner des blessurescorporelles mineures

DANGER

AVERTISSEMENT

ATTENTION



21 GENERAL

The PCM-875 is a compact completely self-contained plasma

cutting system As shipped the system is fully assembledand ready to cut after being connected to input power and asource of compressed air (90-150 psi) The PCM-875 packageuses the heavy-duty PT-27 torch to deliver cutting power forsevering materials up to 1-14 inch thick Refer to the follow-ing paragraphs for descriptions of the PCM-875 packagesavailable as well as performance specifications

Use only ESAB Plasmarc torches that are designed for usewith this console Use of torches not designed for use withthis console could create an ELECTRIC SHOCK HAZARD DoNOT use or modify the PT-23 PCT-80 or any other torchfor use on this console

22 SCOPE

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

23 PACKAGES AVAILABLE

231 Manual Cutting PackagesPCM-875 packages listed on the front cover includes the fol-

lowing components

PT-27 Torch 75deg head 25-ft PN 21661 PT-27 Spare Parts Kit (see Table 2-1) PN 21623 PCM-875 ConsolePower Source See below

Depending on the choice of input power each package

includes the following appropriate PCM-875 ConsolePowerSource

208230 V 5060 Hz 1 or 3-phase PN 0558001167 460 V 5060 Hz 3-phase PN 0558001169 575 V 60 Hz 3-phase PN 0558001170 400 V 5060 Hz 3-phase PN 0558001171 230 V 5060 Hz 3-phase CE PN 0558001172

232 Mechanized Cutting PackagesAlso available are mechanized packages using the PT-20AMMechanized Plasma Torch with the PCM-875 ConsolePowerSource A typical package includes PCM-875 ConsolePower Source PT-20AM Torch (45 or 17 ft) Remote ArcStarter Torch Spare Parts Kit Pilot Arc Cable (50 or 100 ft)Power Cable (50 or 100 ft) Gas Hose (50 or 100 ft) ArcStarter AC Power Cable (50 or 100 ft) and a hose adaptorSee Section 28 for installation details and part numbersof components

The following PCM-875 Mechanized Packages are avail-

able

875M 230VPT-20AM 4550rsquoSystem PN 37617875M 230VPT-20AM 45100 System PN 37618875M 230VPT-20AM 1750 System PN 37619875M 230VPT-20AM 17100 System PN 37620875M 460VPT-20AM 4550rsquoSystem PN 37621

875M 460VPT-20AM 45100 System PN 37622875M 460VPT-20AM 1750 System PN 37623875M 460VPT-20AM 17100 System PN 37624

Table 2-1 PT-27 Spare Parts Kit PN 21623 Contents

SECTION 2 DESCRIPTION

Description Part Number Quantity

50 - 60 A Nozzle 33369 4


httpslidepdfcomreaderfullplasma-essab-pls-50 18722 5 OPTIONAL ACCESSORIES

24 SPECIFICATIONS

Table 2-2 PCM-875 Specifications

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 cooldown period of 4 minutes and a 100-percent duty cycle means the power source may operate continuously


RatedOutput

60 Duty Cycle 60 A 120 V dc


Output Current Range 10 to 60 Amperes

Open Circuit Voltage 275 V dc

Rated Primary Input

72 kW Max Output Power60 A 120 Vdc

208230 V ac 5060 Hz 3-phase 2624 Aphase

208230 V ac 5060 Hz 1-phase 5549 A




Power Factor 60 Amperes Output 74 (208230 V 1-phase)

90 (208230 V 3-phase)

92 (400460 amp 575 V 3-phase)

Efficiency 60 Amperes Output 90 Typical

Current Capacity PT-27 80 A DCSP

Air Requirements PT-27 320 cfh 65 - 75 psig(150 lmin 45 - 52 bars)

Dimensions

Length 203rdquo (516 mm)

Height 161rdquo (409 mm)

whandles 183rdquo (465 mm)

Width

wo opt storage 101rdquo (275 mm)

w opt torch storage 131rdquo (333 mm)

Weight of PCM-875 System 87 lbs (395 kg)

Shipping Weight 100 lbs (454 kg)



Table 2-3 PT-27 Torch Specifications

Figure 2-2 PT-27PCM 875 Cutting Performance

18 316 51614116

MATERIAL THICKNESS (IN)

120

100

60

40

20

0

C U T T I N G S P E

E D ( I N P E R M I N )

80

716 12 5891638 34 1316 781116

PT-27 TorchAir 75psi316 - 14 Stand-off Maximum Current

Steel

Aluminum

Stainless

73 (185 mm)

1 (254 mm)

1(254 mm)

75deg

3 (76 mm)

Figure 2-1 PT-27 Dimensions


Current Capacity (100 duty) 80 A DCSP

Length of Service Lines 25 ft or 50 ft

Weight

25 ft 52 lbs (24 kg)

50 ft 96 lbs (44 kg)

Stand-Off vs Power Output

a t t s ( A x V = W )

A r c V o l t a g e

Maximum Output

120

100

60

80

160

140

7000

6000

5000

9000

8000

4000

3000

Power outputincreases with

stand-off distance 316 to 14 Inch

IMPORTANTMaintain Proper

Stand-Off Distance






31 GENERAL

Proper installation is important for satisfactory and trouble-free operation of the PCM-875 cutting package It is sug-gested that each step in this section be studied carefullyand followed closely

32 EQUIPMENT REQUIRED

A source of clean dry air that supplies 320 cfh at 65-75 psigis required for the cutting operation The air supply shouldnot exceed 150 psig (the maximum inlet pressure rating ofthe air filter-regulator supplied with the package)

33 LOCATION

Adequate ventilation is necessary to provide proper cool-ing of the PCM-875 The amount of dirt dust and exces-sive heat to which the equipment is exposed should be

minimized There should be at least one foot of clearancebetween the PCM-875 power source and wall or any otherobstruction to allow freedom of air movement throughthe power source

Installing or placing any type of filtering device willrestrict the volume of intake air thereby subjecting thepower source internal components to overheating Thewarranty is void if any type of filter device is used

34 INSPECTION

A Remove the shipping container and all packing mate-rial and inspect for evidence of concealed damagewhich may not have been apparent upon receiptof the PCM-875 Notify the carrier of any defects or

damage at once

B Check container for any loose parts prior to disposingof shipping materials

C Check air louvers and any other openings to ensurethat any obstruction is removed

35 PRIMARY ELECTRICAL INPUT

CONNECTIONS 983080FIGURE 39830851983081

ELECTRIC SHOCK CAN KILL Precautionary measuresshould be taken to provide maximum protectionagainst electrical shock Be sure that all power is off by opening the line (wall) disconnect switch and byunplugging the power cord to the unit when connec-

tions are made inside of the power source

Be sure that the power source is properly configuredfor your input power supply DO NOT connect a powersource configured for 208230 V to a 460 V input powersupply Damage to the machine may occur

NOTE If using 200(208) V input power the PCM-875must be reconnected for 200 V use as directed inSection 37 and Fig 3-2

The PCM-875 consoles are equipped with a 10-ft 4-conductor input power cable for 3-phase connection Ifsingle-phase connection is desired tape back the red wireon the input power cable

NOTE The 208230 V models are equipped with a plugfor single-phase connection only The plug ismounted to a 4-conductor cable If 3-phase con-nection is desired remove and discard the plugand proceed as described above

A line (wall) disconnect switch with fuses or circuit breakersshould be provided at the main power panel (see Fig 3-1and Table 3-1 for fuse sizes) The input power cable of the

console may be connected directly to the disconnect switchor you may purchase a proper plug and receptacle from alocal electrical supplier If using plugreceptacle combina-tion see Table 3-1 for recommended input conductors forconnecting receptacle to line disconnect switch

SECTION 3 INSTALLATION



1 For operator safety the torch connections are locatedon the output terminal board behind the lower por-tion of the front panel Remove access door to outputterminal board from right panel of power source

2 Thread the power cable pilot arc cable and switchlead of the PT-27 through the right open bushing ofthe front panel Connect power cable to the torchfitting (left-hand threads) bolt the pilot arc cablering connection to the copper terminal and plug inthe switch lead to the torch switch receptable on theoutput terminal board Make sure the power and pilotarc cable connections are wrench-tight Make sure plugof switch lead is firmly locked in place

3 Reassemble the access door to the power source4 Connect your air supply to the inlet connection of the

filter-regulator5 Clamp the work cable to the workpiece Be sure the

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

Table 3-1 Recommended Sizes ForInput Conductors and Line Fuses

Input Requirements Input amp Gnd Fuse

Volts Phase Amps Conductor Size

CUAWG Amps

208 1 55A 6 80 208 3 26APh 6 50 230 1 49A 6 80 230 3 24APh 6 50 400 3 13 10 25

460 3 11 10 25 575 3 9 10 20

36 SECONDARY 983080OUTPUT983081CONNECTIONS 983080REFER TO FIG 39830851983081

Before making any connections to the power sourceoutput terminals make sure that all primary inputpower to the power source is deenergized (off) at themain disconnect switch and that the input power cableis unplugged


Red - NOT USED ON SINGLE PHASE

White



WORK

SAFETY GROUND

PT-27

Allow at least 10 ft (3m)between work and power source

TORCHSWITCH

RECEPTACLEACCESS DOOR FORTORCH CONNECTION

Prefiltered AIR SUPPLY (Cus-tomer Supplied)

(90 to 150 psig max)

CUSTOMER FUSED LINE DISCON-NECT SWITCH(See Table 3-1 andWARNING in regards to chassisground in Section 35)

TORCH

POWERCABLECONNECTION

TORCHPILOTARCCONNECTION

ACCESS FOR CNCINTERFACE CONNECTIONS(See Detail ldquoArdquo)




1 Remove cover from the PCM-875 power source2 Locate the Input Bridge (IBR) and TB5 terminal block

(see Fig 1) on the left side towards the rear panel Dis-

connect the gray lead from TB5-2 and then connect itto TB5-13 Locate the output bridge (D1) on left side towards the

front panel (see Fig 2) Disconnect and swap leads X2and X3 from the main transformer For 200(208) vacinput X2 is connected to TB3 and X3 is connected toterminal 3 of D1 Make sure the connections are firmlytightened

4 Leave all other wires the same

5 Reinstall cover and connect the PCM-875 to 208 vacinput power

X3

TB3

X2

X1+

FROM MAIN TRANS-FORMER

~

~

~OUTPUT BRIDGE

(D1)

Fig 2

37 CONNECTING PCM983085875 FOR200983080208983081 VAC INPUT

ELECTRIC SHOCK CAN KILL Precautionary measuresshould be taken to provide maximum protectionagainst electrical shock Be sure that all power is offby opening the line (wall) disconnect switch and byunplugging the power cord to the unit when recon-necting for 200(208) VAC Input

The PCM-875 power source with 200230 vac 1-phaseinput capability is factory set for 230 vac input If using200(208) vac input the PCM-875 must be reconnected asfollows before connecting to your input power

BLK

R R2

S G

T +

(IBR)INPUTBRIDGE

GRY

TB5

GRY

BLK

Fig 1

1

2

3




PILOT ARC CABLE - 37339 (50rsquo)37340 (100rsquo)

POWER CABLE - 37341 (50rsquo)37342 (100rsquo)

ARC STARTER37338

WORK

CABLE(25rsquo)(Supplied withPCM-875)

AIR HOSE - 37343 (50rsquo)37344 (100rsquo)

ARC STARTER CABLE - 37410 (50rsquo)37411 (100rsquo)

PT-20AM -21785 (45rsquo)

21786 (17rsquo)

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

38 MECHANIZED CUTTING INSTALLATION WITH THE PT98308520AM TORCH


S C O S O



View A-A

ldquoArdquoldquoBrdquoldquoCrdquoldquoDrdquo

ldquoArdquo

ldquoBrdquoldquoCrdquoldquoDrdquo



AIR HOSE - 37343 (50rsquo)

ARC STARTER CABLE - 37410 (50rsquo)

37411 (100rsquo)

SPLICE CONNECTOR(Supplied with 37338)

25mm min

37344 (100rsquo)

Arc Starter37338

035rdquo (09mm)7rdquo

(178mm)

(4) 250rdquo (6 mm)

Disconnect TheseTwo Black Leads

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

BLK Arc Start

WHT Arc Start

Arc Starter

Cable (Ref)

ADAPTOR - 999278

2125rdquo(54mm)

Make sure all power is off before making following con-nections

1 Remove cover from PCM-8752 Insert the 4 service lines from Arc Starter through the

torch opening of front panel3 Connect large hole terminal end of Pilot Arc Cable (A)

to connection where shown Tighten screw firmly4 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 Tightenall connections firmly

5 Locate TB1 Terminal Block Referring to view D-D abovedisconnect the two black wires from TB1 Connect theblack lead of Arc Starter Cable (D) to TB1-1 and thewhite lead to TB1-2

6 Reassemble cover Proceed to connect the 4 service lines

to the Arc Starter Then connect PT-20AM torch to ArcStarter


SECTION 4 OPERATION



41 OPERATION

ELECTRIC SHOCK can killbull Do NOT operate the unit with the cover removedbull Do NOT apply power to the unit while holding or

carrying the unitbull Do NOT touch any torch parts forward of the torch

handle (nozzle heat shield electrode etc) with powerswitch on

ARC RAYS can burn eyes and skin NOISE can damage

hearingbull Wear welding helmet with No 6 or 7 lens shadebull Wear eye ear and body protection

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

42 PCM-875 CONTROLS (FIGURE 4-1)

A Power Switch (located on rear panel) When placedin ON position the green pilot light will glow indicat-ing control circuit is energized and the cooling fan willrun

B Output Current Control Adjustable from 10 to 60amperes

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

regulator can be adjusted to desired pressure (65-75psig) before cutting operations Allow air to flow fora few minutes This should remove any condensationthat may have accumulated during shutdown periodBe sure to place switch in OPERATE position beforestarting cutting operations

Flow Fault The fault light will be mostly on but willflick off for about 110th of a second every secondThis indicates that the air flow supply is low

Over Temperature The fault light will be mostly off but will flick on for about 110th of a second everysecond This indicates that the duty cycle has beenexceeded Allow the power source to cool down beforereturning to operate

HighLow Line Voltage The fault light will rapidlyblink on and off (five times per second) This indicatesthat the input voltage is outside the ldquo+ or -rdquo 15 rangeof the input rating

Over-Current The fault light will be on continu-ously This indicates that input current has beenexceeded

All fault signals will remain on for a minimum of10 seconds If fault clears all will reset automati-

cally except for over-current To clear over-currentthe power must be shut off for 5 seconds and thenturned back on

43 CUTTING WITH THE PT98308527

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

A Hold the torch nozzle approximately 18 to 316 inchabove the work and tilted at about 15 - 30deg This reducesthe chance of spatter entering the nozzle If the PT-27sstandoff tool is being used set the standoff between316 and 14-inch

B Depress the torch switch Air should flow from thetorch nozzle

C Two seconds after depressing the torch switch the pilotarc should start The main arc should immediately followallowing the cut to begin (If using the trigger LOCKmode torch switch may be released after establishingthe cutting arc)

SECTION 4 OPERATION

SECTION 4 OPERATION



Figure 4-1 PCM-875 Controls

F For rapid re-starts such as grate or heavy mesh cuttingdo not release the torch switch In the postflow mode

the arc can be re-started immediately by depressingthe torch switch This avoids the 2-second preflowportion of the cutting cycle

REAR VIEW

AIR REGULATORCONTROL KNOB

FAULT LIGHT(AMBER)

POWER LIGHT(WHITE)

AIRPRESSURE

GAUGE

AIR TESTSWITCH

TRIGGER LOCK SWITCH

CURRENTCONTROLKNOB

POWER ON-OFF

(I-O) SWITCHFUSE (3A)

NOTE When replacing the nozzle always inspect theelectrode for wear If less than 1932 of electrodeshaft is remaining replace the electrode If the

electrode is used beyond this recommended wearlimit damage to the torch and power source mayoccur Nozzle life is also greatly reduced whenusing the electrode below the recommendedlimit Refer to Figure 4-3

REPLACE ELECTRODE BEFORELENGTH BECOMES SHORTER THAN1932 INCH (151 MM)

(151 mm)

ELECTRODE

1932

SECTION 4 OPERATION

SECTION 4 OPERATION



WHEN THE ARC BREAKSTHROUGH THE WORK BRINGTHE TORCH TO AN UPRIGHT PO-SITION AND PROCEED TO CUT

TO START A PIERCE TILT THE TORCH TOPREVENT MOLTEN MATERIAL FROM COM-ING BACK AGAINST AND DAMAGINGTHE TORCH

1

2

Figure 4-4 Piercing Technique using the PT-27

44 COMMON CUTTING PROBLEMS

Listed below are common cutting problems followed bythe probable cause of each If problems are determinedto be caused by the PCM-875 refer to the maintenancesection of this manual If the problem is not corrected

after referring to the maintenance section contact yourESAB 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

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 andor cutting nozzle in poor condi-

tion

G Main Arc Does Not Strike

1 Worn electrode

SECTION 4 OPERATION

SECTION 4 OPERATION



SECTION 4 OPERATION

SECTION 5 MAINTENANCE



51 GENERAL

If this equipment does not operate properly stop workimmediately and investigate the cause of the malfunction

Maintenance work must be performed by an experiencedperson and electrical work by a trained electrician Do notpermit untrained persons to inspect clean or repair thisequipment Use only recommended replacement parts

Be sure that the wall disconnect switch or wall circuitbreaker is open before attempting any inspection or

work inside of the PCM-875

52 INSPECTION AND CLEANING

Frequent inspection and cleaning of the PCM-875 is recom-mended for safety and proper operation Some suggestionsfor inspecting and cleaning are as follows

A Check work cable for secured connection to work-

pieceB Check safety earth ground at workpiece and at power

source chassisC Check heat shield on torch It should be replaced if

damagedD Check the torch electrode and cutting nozzle for

wear on a daily basis Remove spatter or replace ifnecessary

E Make sure cable and hoses are not damaged or

kinkedF Make sure all plugs fittings and ground connections

are tightG With all input power disconnected and wearing

proper eye and face protection blow out the insideof the PCM-875 using low-pressure dry compressedair

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

H Occasionally bleed all water from the filter beneaththe air filter-regulator

53 PT98308527 TORCH CONSUMABLE PARTS

Make sure power switch on PCM-875 is in OFF positionbefore working on the torch

The PT-27 torch head contains a gas flow check valvethat acts in conjunction with the flow switch and cir-cuitry within the power source This system preventsthe torch from being energized with high voltage if the

torch switch is accidentally closed when the shield isremoved Always replace torch with the proper torchmanufactured by ESAB since it alone contains ESABsup1spatented 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 tightenAlways make sure the shield is very tight beforecutting

SWIRL BAFFLE

ELECTRODE

NOZZLE

SHIELD





54 FLOW SWITCH 983080FIGURE 59830852983081

When excessive contamination is found in the air theflow switch (FS-4) should be disassembled and cleanedas follows

A Ensure the system is shut down and there is no trappedair under pressure in the piping

B Remove the piston plugC Remove the spring Use care when handling spring

to prevent distortionD Remove the piston

E Clean all parts with cleaning agent

NOTEEnsure cleaning agent does not contain solvents whichcan degrade polysulfone Warm water and detergentis recommended for cleaning Allow all parts to drythoroughly before reassembly

Reassemble the flow switch in reverse order

PISTON PLUG

PISTON

SPRING

FLOW SWITCH

Figure 5-2 Disassembly Assembly of Flow Switch

Other handling precautions that should also be observedare as follows

bull Use grounded work station with grounded floors and

grounded wrist straps when handling devicesbull Use a 100Ω resistor in series with the gate when per-forming curve tracer tests

bull Never install devices into systems with power con-nected to the system

bull Use soldering irons with grounded tips when solderingto gate terminals

When mounting IGBT modules on a heatsink certain

precautions should be taken to prevent any damageagainst a sudden torque If a sudden torque (ldquoone-sidedtighteningrdquo) is applied at only one mounting terminal theceramic insulation plate or silicon chip inside the modulemay get damaged

The mounting screws are to be fastened in the order shownin Figure 5-3 Also care must be taken to achieve maximumcontact (ie minimum contact thermal resistance) for the

best heat dissipation

Application of a thermal pad on the contact surface im-proves it thermal conductivity See Replacement Partssection for the required pad

A torque wrench should be used Tighten mounting screwsto 28 in-lbs wire connecting screws to 19 in-lbs If torqueis too heavy the device can damage like the above ldquoone-

sided tighteningrdquo

55 IGBT Handling amp Replacement

Since IGBT gates are insulated from any other conductingregion care should be taken to prevent static build upwhich could possibly damage gate oxides All IGBT mod-

Two-Point Mounting Type Temporary tightening Final tightening

Four-Point Mounting Type Temporary tightening

Final tightening





56 TROUBLESHOOTING

ELECTRIC SHOCK CAN KILL Be sure that all primary power to the machine has been externally disconnected Open theline (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 thecause cannot be quickly located shut off the input power open up the unit and perform a simple visual inspection of all thecomponents and wiring Check for secure terminal connections loose or burned wiring or components bulged or leakingcapacitors 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 particularlycareful 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 yourvoltmeter


NOTESchematics and Wiring Diagrams on 11rdquo x 17rdquo

paper are includedinside the back cover of this manual




57 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 itrsquosfuses

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 ldquoair testrdquo 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 allright 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 theswitch 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




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 HighLow line voltage The Fault Light will rapidly blink on and off (5 times per second) This indicates that the input

voltage is outside the ldquo+rdquo or ldquo-rdquo 15 safe operating range rating

2 Flow fault - The fault light will be mostly on but will blink off for 110th of a second every second This indicates thatthe 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 atthe 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 torchleads

NOTE If above items check OK the problem is internal send unit to an Authorized Repair Station for repair

c Put the lsquoAir Checkrsquo switch to On position Air should flow through torch If not then the flow switch may be stuckdue to oil in the air Clean air flow switch per supplierrsquos instructions or replace switch To check if the flow switch isopen put voltmeter leads between P1-12 and P1-1 It should read about 12 VDC When the flow switch closes thevoltage 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 110 of a second every second This generallyindicates 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 poweroff check the continuity between P1-1 and P1-2 of the control board If the switch is OK then the ohmmeter shouldread a direct short I f 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 hasexceeded preset limits

a To check if the output is shorted measure the resistance by putting the ohmmeter leads (make sure to disconnectHI Frequency leads)rdquo+rdquo of the meter to Torch ldquo+rdquo output terminal and Work ldquo-rdquo lead of the meter to the ldquo-rdquo outputterminal Reading should be about 2 K Ohms Reverse the voltmeter leads the resistance reading should be lessthan 15 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




c Check air flow switch There may be internal short See D2c above

d Measure voltage across C1 or C2 capacitor It should be as follows approx 325 VDC for the 208230 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 bridgeSCR Module (IBR) This can be checked without taking it out of the circuit using anvoltohmeter 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 ifmalfunctioning

e IGBTs (2 on 230 V and 1 on the 400 V amp 460 V units) may be blown See IGBT installation procedure Before replacingIGBTs 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 HIFREQUENCY 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 E4 above

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




H Air does not shut off

1 Check air test the gas solenoid valve is energized when the switch is in the ldquoonrdquo position

2 Does air flow stop when the torch switch is unplugged If yes check and repair the torch If not send unit to anAuthorized Repair Station for repair

a Check voltage to solenoid coil if present when torch switch is unplugged replace PCB1 If voltage is ldquo0rdquoreplace 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)






58 REFERENCE VOLTAGE CHECKS

A Control Board Assembly (PCB1)

1 LEDrsquos

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 - IGBTrsquos driving signal - switching frequency = 20 KHzTP-10 - IGBTrsquos driving signal - switching frequency = 20 KHz

50 microsec

13 vdc

0

LPG 50LPG 80

5080




TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE

FAULT OVERLOAD LIGHT

HF CIRCUIT

INVERTER

CUTTING ARC (CURRENT)

59 SEQUENCE OF OPERATION

A TRIGGER LOCK ldquoUNLOCKrdquo position

PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC

PUSH RELEASE PUSH RELEASE

TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER


B TRIGGER LOCK LOCK position

ENERGIZE

NOTES

1 Wh h h i h i h d d i fl i d h fl d fl i l d d h HF i

PREFLOW

Postflow

2 SEC

SECTION 6 REPLACEMENT PARTS



61 General

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

To ensure proper operation it is recommended that only genuine ESAB parts and products be used with thisequipment 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 phonenumbers

62 Ordering

Bill of material items that have blank part numbers are provided for customer information onlyHardware items should be available through local sources

Note

60 Replacement Parts




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 KNOB2 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

13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12





151 1 21710 FILTER REGULATOR AIR LINE 152 1 10Z30 ADAPTOR BA-WM x 14 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 208230

1 954667 LABEL RATING PCM-875 400460

Fig 6-2 PCM-875 Power Source Rear View

160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26

Fig 6-3 PCM-875 Power Source Left Side View (208230)

27





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 microf 450VDC C1 2 26 2 994674 GROMMET STRIP 27 2 0558001177 PCB ASSY MOSFET IGBT DRIVER BOARD PCB2 3 28 1 36822 HOSE AY BA-2X 14NPT RUB 2 FT 29 1 36732 BUSBAR POS 30 1 951028 CAPACITOR 1microf 630VDC (Not shown - see wiring) C3 31 1 950487 TERM BLOCK 2 POS TB5

32 1 952235 MODULE INPUT BRIDGESCR (includes PAD - 952280) IBR 33 1 2062282 CAPACITOR 22microf 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 ASSY T4 38 1 952255 CAPACITOR 40 microf 400 VDC C4 39 1 950711 THERMAL SWITCH 194degF 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 1microf 630W VDC C15 16 43 1 952558 HEATSINK 44 1 950249 SOL VALVE 14NPT 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

Fig 6-3 PCM-875 Power Source Left Side View (208230) contd




55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874





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 1800microf 450 VDC (400400CE460 V) C1 2 2 952562 CAPACITOR 1800microf 500 VDC (575 V) C1 2 57 2 994674 GROMMET STRIP 58 2 951028 CAPACITOR 1microf 630 VDC (See wiring) C3 15 59 1 0558001178 PCB ASSY IGBT DRIVER BOARD PCB2 60 1 951964 CAPACITOR 2microf 800 VDC (400400CE460V) C16 1 951892 CAPACITOR 068microf 1200 VDC (575 V) C16 61 1 36822 HOSE ASSY BA x 14 NPT RUB 62 1 36733 BUSBAR NEG 63 1 950487 TERM BLOCK 2 POS (Not used on 400CE575 V) TB5 64 1 952235 MODULE INPUT BRIDGESCR

(includes PAD - 952280) IBR 65 1 2062282 CAPACITOR 22microf 1KV C19 66 3 950591 METAL OXIDE VARISTOR 510 V (400400CE460 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 ASSY T4 69 1 952255 CAPACITOR 40microf 400 VDC (400400CE460 V) C4 1 952585 CAPACITOR 20microf 600 VDC (575 V) C4 70 1 0455803880 FILTER EMI (CE only) (not shown) FN1 71 1 950711 THERMAL SWITCH 194degF 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 14 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

Fig 6-4 PCM-875 Power Source Left Side View (400400CE460575)




89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99





80 1 35940 CONTROL TRANSFORMER ASSY T2

81 2 17300012 RESISTOR 300W 12 OHM R1112 82 1 673458 CONTACTOR 3 POLE110 VAC 40A K1 83 1 952557 CAPACITOR 82microf 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 ASSY PCB1 88 1 36586 MAIN TRANSFORMER ASSY T1 89 2 951469 CAPACITOR 022microf 250 VAC (See Wiring) C17 18

90 1 31488 SHUNT BOARD ASSY T1 91 1 951515 CAPACITOR 047microf 660 VAC C23 92 1 38131 START UP BOARD ASSY 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 ASSY HI FREQ T3 98 1 0558001180 SPARK GAP ASSY 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 01microf 1KV (See wiring) C11 12 103 1 952204 CAPACITOR 01microf 250 VAC (See wiring) C9 104 1 36718 BOX HI FREQ

Fig 6-5 PCM-875 Power Source Right Side View (208230) contd




119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116





110 1 32914 CONTROL TRANSFORMER ASSY T2 111 1 17300012 RESISTOR 300W 12 OHM R1112 112 1 673458 CONTACTOR 3 POLE 110VAC 40A K1

113 1 952557 CAPACITOR 82microf 630 VDC (See wiring) C21 114 1 17145433 RESISTOR 2W 330K (See wiring) R13 115

116 1 38214 CONTROL BOARD ASSY PCB1 117 1 36586 MAIN TRANSFORMER ASSY (400400CE460 V) T1 1 36599 MAIN TRANSFORMER ASSY (575 V) T1 118 2 951469 CAPACITOR 022microf 250 VAC (See wiring) C17 18 119 1 31488 SHUNT BOARD ASSY PCB4 120 1 951515 CAPACITOR 047microf 660 VAC C23

121 1 38131 START UP BOARD ASSY 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 ASSY HI FREQ T3 127 1 0558001180 SPARK GAP ASSY 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 01microf 1KV (See wiring) C11 12 132 1 952204 CAPACITOR 01microf 250 VAC (See wiring) C9 133 1 952213 REACTOR 3PH LINE 12 A L2 134 1 36718 BOX HI FREQ 135 1 951314 CAPACITOR 022microf 1KV (See wiring) C20

Fig 6-6 PCM-875 Power Source Right Side View (400400CE460575 V) contd





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 (208230 V) 1 954681 LABEL INPUT (400460 V)

Fig 6-7 PCM-875 (208230V) Power Source Top View with PCB1 and Shelf Removed

143142

141140145144




NOTES



REVISION HISTORY



Revision ldquoArdquo edition (12002) of the manual covers the following changes Control Board Assembly PN38175 was replaced with Control Board Assembly PN 38214

Removes the Valve Pin PN 21619 from the PT-27 Spare Parts Kit and all other references to this partwhich is now obsolete for this package

Revision B - updated replacement parts section

Revision C - Changed 6 foot input power cable part number from 37573 to 0558004221 Added sche-matic drawing 0558001186 and wiring diagram drawing 0558001191

Revision D - 052005 - Updated format Made chgs per change notice s 043155 amp 053013In replacement parts section added filter regulator item 151 pn 0558005394 note addedto item 161 power cable pn 0558002799 and chgd filter EMI item 70 pn from 952253 to0455803880 Updated all views in replacement parts section Moved schematics to 11 x 17 format

Revision D - 122005 - Removed filter regulator item 151 pn 0558005394 note in replacement partssection

1

2

3

4

5

6



A CUSTOMER SERVICE QUESTIONS Telephone (800)362-7080 Fax (800) 634-7548 Hours 800 AM to 700 PM EST Order Entry Product Availability Pricing Order Information Returns

B ENGINEERING SERVICE Telephone (843) 664-4416 Fax (800) 446-5693 Hours 730 AM to 500 PM EST

Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting

C TECHNICAL SERVICE Telephone (800) ESAB-123 Fax (843) 664- 4452 Hours 800 AM to 500 PM EST Part Numbers Technical Applications Specifications Equipment Recommendations

D LITERATURE REQUESTS Telephone (843) 664-5562 Fax (843) 664-5548 Hours 730 AM to 400 PM EST

E WELDING EQUIPMENT REPAIRS

Telephone (843) 664- 4487 Fax (843) 664-5557 Hours 730 AM to 330 PM EST Repair Estimates Repair Status

F WELDING EQUIPMENT TRAINING Telephone (843)664-4428 Fax (843) 679-5864 Hours 730 AM to 400 PM EST Training School Information and Registrations

G WELDING PROCESS ASSISTANCE Telephone (800) ESAB-123 Hours 730 AM to 400 PM EST

H TECHNICAL ASST CONSUMABLES Telephone (800) 933-7070 Hours 730 AM to 500 PM EST

IF YOU DO NOT KNOW WHOM TO CALL

Telephone (800) ESAB-123 Fax (843) 664-4462

Hours 730 AM to 500 PM ESTor

visit us on the web at httpwwwesabnacomThe ESAB web site offers

Comprehensive Product InformationMaterial Safety Data Sheets

Warranty RegistrationInstruction Literature Download Library

ESAB Welding amp Cutting Products Florence SC Welding EquipmentCOMMUNICATION GUIDE - CUSTOMER SERVICES



































This equipment will perform in conformity with the description thereof contained in this manual and accompa-

nying labels andor inserts when installed operated maintained and repaired in accordance with the instruc-

tions provided This equipment must be checked periodically Malfunctioning or poorly maintained equipmentshould not be used Parts that are broken missing worn distorted or contaminated should be replaced imme-

diately 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 ser-

vice facility designated by the manufacturer

BE SURE THIS INFORMATION REACHES THE OPERATOR

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER

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 urgeyou to read our booklet ldquoPrecautions and Safe Practices for Arc Welding Cutting and

Gougingrdquo 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 be-

fore installing or operating this equipment

CAUTION

USER RESPONSIBILITY



TABLE OF CONTENTS







R l P

Section Title Page



TABLE OF CONTENTS














































Therefore



































































SECTION 1 SEGURIDAD































SECTION 1 SEGURIDAD






















SECTION 1 SEGURIDAD




























































































DANGER

AVERTISSEMENT

ATTENTION



21 GENERAL




22 SCOPE




lowing components







able






50 - 60 A Nozzle 33369 4



24 SPECIFICATIONS




RatedOutput





Rated Primary Input



208230 V ac 5060 Hz 1-phase 5549 A





90 (208230 V 3-phase)

92 (400460 amp 575 V 3-phase)




Dimensions




Width









18 316 51614116


120

100

60

40

20

0

C U T T I N G S P E


80

716 12 5891638 34 1316 781116


Steel

Aluminum

Stainless

73 (185 mm)

1 (254 mm)

1(254 mm)

75deg

3 (76 mm)





Weight

25 ft 52 lbs (24 kg)

50 ft 96 lbs (44 kg)


a t t s ( A x V = W )

A r c V o l t a g e

Maximum Output

120

100

60

80

160

140

7000

6000

5000

9000

8000

4000

3000




Stand-Off Distance






31 GENERAL




33 LOCATION




34 INSPECTION


damage at once
























CUAWG Amps

208 1 55A 6 80 208 3 26APh 6 50 230 1 49A 6 80 230 3 24APh 6 50 400 3 13 10 25

460 3 11 10 25 575 3 9 10 20





White



WORK

SAFETY GROUND

PT-27


TORCHSWITCH





TORCH













X3

TB3

X2

X1+


~

~

~OUTPUT BRIDGE

(D1)

Fig 2




BLK

R R2

S G

T +

(IBR)INPUTBRIDGE

GRY

TB5

GRY

BLK

Fig 1

1

2

3






ARC STARTER37338

WORK




PT-20AM -21785 (45rsquo)

21786 (17rsquo)




S C O S O



View A-A


ldquoArdquo






37411 (100rsquo)


25mm min

37344 (100rsquo)

Arc Starter37338


(178mm)

(4) 250rdquo (6 mm)



BLK Arc Start

WHT Arc Start

Arc Starter

Cable (Ref)

ADAPTOR - 999278

2125rdquo(54mm)










SECTION 4 OPERATION



41 OPERATION























SECTION 4 OPERATION

SECTION 4 OPERATION






REAR VIEW


FAULT LIGHT(AMBER)

POWER LIGHT(WHITE)

AIRPRESSURE

GAUGE

AIR TESTSWITCH

TRIGGER LOCK SWITCH

CURRENTCONTROLKNOB

POWER ON-OFF





(151 mm)

ELECTRODE

1932

SECTION 4 OPERATION

SECTION 4 OPERATION





1

2







5 Low air flow rate





E Uneven Arc




tion


1 Worn electrode

SECTION 4 OPERATION

SECTION 4 OPERATION



SECTION 4 OPERATION




51 GENERAL
























as shown


SWIRL BAFFLE

ELECTRODE

NOZZLE

SHIELD













PISTON PLUG

PISTON

SPRING

FLOW SWITCH


















Final tightening





56 TROUBLESHOOTING





NOTE


















B No Air Flow
























not turn air on


















































1 LEDrsquos






50 microsec

13 vdc

0

LPG 50LPG 80

5080




TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE


HF CIRCUIT

INVERTER




PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6






















































TABLE OF CONTENTS







R l P

Section Title Page



TABLE OF CONTENTS














































Therefore



































































SECTION 1 SEGURIDAD































SECTION 1 SEGURIDAD






















SECTION 1 SEGURIDAD




























































































DANGER

AVERTISSEMENT

ATTENTION



21 GENERAL




22 SCOPE




lowing components







able






50 - 60 A Nozzle 33369 4



24 SPECIFICATIONS




RatedOutput





Rated Primary Input



208230 V ac 5060 Hz 1-phase 5549 A





90 (208230 V 3-phase)

92 (400460 amp 575 V 3-phase)




Dimensions




Width









18 316 51614116


120

100

60

40

20

0

C U T T I N G S P E


80

716 12 5891638 34 1316 781116


Steel

Aluminum

Stainless

73 (185 mm)

1 (254 mm)

1(254 mm)

75deg

3 (76 mm)





Weight

25 ft 52 lbs (24 kg)

50 ft 96 lbs (44 kg)


a t t s ( A x V = W )

A r c V o l t a g e

Maximum Output

120

100

60

80

160

140

7000

6000

5000

9000

8000

4000

3000




Stand-Off Distance






31 GENERAL




33 LOCATION




34 INSPECTION


damage at once
























CUAWG Amps

208 1 55A 6 80 208 3 26APh 6 50 230 1 49A 6 80 230 3 24APh 6 50 400 3 13 10 25

460 3 11 10 25 575 3 9 10 20





White



WORK

SAFETY GROUND

PT-27


TORCHSWITCH





TORCH













X3

TB3

X2

X1+


~

~

~OUTPUT BRIDGE

(D1)

Fig 2




BLK

R R2

S G

T +

(IBR)INPUTBRIDGE

GRY

TB5

GRY

BLK

Fig 1

1

2

3






ARC STARTER37338

WORK




PT-20AM -21785 (45rsquo)

21786 (17rsquo)




S C O S O



View A-A


ldquoArdquo






37411 (100rsquo)


25mm min

37344 (100rsquo)

Arc Starter37338


(178mm)

(4) 250rdquo (6 mm)



BLK Arc Start

WHT Arc Start

Arc Starter

Cable (Ref)

ADAPTOR - 999278

2125rdquo(54mm)










SECTION 4 OPERATION



41 OPERATION























SECTION 4 OPERATION

SECTION 4 OPERATION






REAR VIEW


FAULT LIGHT(AMBER)

POWER LIGHT(WHITE)

AIRPRESSURE

GAUGE

AIR TESTSWITCH

TRIGGER LOCK SWITCH

CURRENTCONTROLKNOB

POWER ON-OFF





(151 mm)

ELECTRODE

1932

SECTION 4 OPERATION

SECTION 4 OPERATION





1

2







5 Low air flow rate





E Uneven Arc




tion


1 Worn electrode

SECTION 4 OPERATION

SECTION 4 OPERATION



SECTION 4 OPERATION




51 GENERAL
























as shown


SWIRL BAFFLE

ELECTRODE

NOZZLE

SHIELD













PISTON PLUG

PISTON

SPRING

FLOW SWITCH


















Final tightening





56 TROUBLESHOOTING





NOTE


















B No Air Flow
























not turn air on


















































1 LEDrsquos






50 microsec

13 vdc

0

LPG 50LPG 80

5080




TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE


HF CIRCUIT

INVERTER




PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6






















































TABLE OF CONTENTS














































Therefore



































































SECTION 1 SEGURIDAD































SECTION 1 SEGURIDAD






















SECTION 1 SEGURIDAD




























































































DANGER

AVERTISSEMENT

ATTENTION



21 GENERAL




22 SCOPE




lowing components







able






50 - 60 A Nozzle 33369 4



24 SPECIFICATIONS




RatedOutput





Rated Primary Input



208230 V ac 5060 Hz 1-phase 5549 A





90 (208230 V 3-phase)

92 (400460 amp 575 V 3-phase)




Dimensions




Width









18 316 51614116


120

100

60

40

20

0

C U T T I N G S P E


80

716 12 5891638 34 1316 781116


Steel

Aluminum

Stainless

73 (185 mm)

1 (254 mm)

1(254 mm)

75deg

3 (76 mm)





Weight

25 ft 52 lbs (24 kg)

50 ft 96 lbs (44 kg)


a t t s ( A x V = W )

A r c V o l t a g e

Maximum Output

120

100

60

80

160

140

7000

6000

5000

9000

8000

4000

3000




Stand-Off Distance






31 GENERAL




33 LOCATION




34 INSPECTION


damage at once
























CUAWG Amps

208 1 55A 6 80 208 3 26APh 6 50 230 1 49A 6 80 230 3 24APh 6 50 400 3 13 10 25

460 3 11 10 25 575 3 9 10 20





White



WORK

SAFETY GROUND

PT-27


TORCHSWITCH





TORCH













X3

TB3

X2

X1+


~

~

~OUTPUT BRIDGE

(D1)

Fig 2




BLK

R R2

S G

T +

(IBR)INPUTBRIDGE

GRY

TB5

GRY

BLK

Fig 1

1

2

3






ARC STARTER37338

WORK




PT-20AM -21785 (45rsquo)

21786 (17rsquo)




S C O S O



View A-A


ldquoArdquo






37411 (100rsquo)


25mm min

37344 (100rsquo)

Arc Starter37338


(178mm)

(4) 250rdquo (6 mm)



BLK Arc Start

WHT Arc Start

Arc Starter

Cable (Ref)

ADAPTOR - 999278

2125rdquo(54mm)










SECTION 4 OPERATION



41 OPERATION























SECTION 4 OPERATION

SECTION 4 OPERATION






REAR VIEW


FAULT LIGHT(AMBER)

POWER LIGHT(WHITE)

AIRPRESSURE

GAUGE

AIR TESTSWITCH

TRIGGER LOCK SWITCH

CURRENTCONTROLKNOB

POWER ON-OFF





(151 mm)

ELECTRODE

1932

SECTION 4 OPERATION

SECTION 4 OPERATION





1

2







5 Low air flow rate





E Uneven Arc




tion


1 Worn electrode

SECTION 4 OPERATION

SECTION 4 OPERATION



SECTION 4 OPERATION




51 GENERAL
























as shown


SWIRL BAFFLE

ELECTRODE

NOZZLE

SHIELD













PISTON PLUG

PISTON

SPRING

FLOW SWITCH


















Final tightening





56 TROUBLESHOOTING





NOTE


















B No Air Flow
























not turn air on


















































1 LEDrsquos






50 microsec

13 vdc

0

LPG 50LPG 80

5080




TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE


HF CIRCUIT

INVERTER




PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6

































































































Therefore



































































SECTION 1 SEGURIDAD































SECTION 1 SEGURIDAD






















SECTION 1 SEGURIDAD




























































































DANGER

AVERTISSEMENT

ATTENTION



21 GENERAL




22 SCOPE




lowing components







able






50 - 60 A Nozzle 33369 4



24 SPECIFICATIONS




RatedOutput





Rated Primary Input



208230 V ac 5060 Hz 1-phase 5549 A





90 (208230 V 3-phase)

92 (400460 amp 575 V 3-phase)




Dimensions




Width









18 316 51614116


120

100

60

40

20

0

C U T T I N G S P E


80

716 12 5891638 34 1316 781116


Steel

Aluminum

Stainless

73 (185 mm)

1 (254 mm)

1(254 mm)

75deg

3 (76 mm)





Weight

25 ft 52 lbs (24 kg)

50 ft 96 lbs (44 kg)


a t t s ( A x V = W )

A r c V o l t a g e

Maximum Output

120

100

60

80

160

140

7000

6000

5000

9000

8000

4000

3000




Stand-Off Distance






31 GENERAL




33 LOCATION




34 INSPECTION


damage at once
























CUAWG Amps

208 1 55A 6 80 208 3 26APh 6 50 230 1 49A 6 80 230 3 24APh 6 50 400 3 13 10 25

460 3 11 10 25 575 3 9 10 20





White



WORK

SAFETY GROUND

PT-27


TORCHSWITCH





TORCH













X3

TB3

X2

X1+


~

~

~OUTPUT BRIDGE

(D1)

Fig 2




BLK

R R2

S G

T +

(IBR)INPUTBRIDGE

GRY

TB5

GRY

BLK

Fig 1

1

2

3






ARC STARTER37338

WORK




PT-20AM -21785 (45rsquo)

21786 (17rsquo)




S C O S O



View A-A


ldquoArdquo






37411 (100rsquo)


25mm min

37344 (100rsquo)

Arc Starter37338


(178mm)

(4) 250rdquo (6 mm)



BLK Arc Start

WHT Arc Start

Arc Starter

Cable (Ref)

ADAPTOR - 999278

2125rdquo(54mm)










SECTION 4 OPERATION



41 OPERATION























SECTION 4 OPERATION

SECTION 4 OPERATION






REAR VIEW


FAULT LIGHT(AMBER)

POWER LIGHT(WHITE)

AIRPRESSURE

GAUGE

AIR TESTSWITCH

TRIGGER LOCK SWITCH

CURRENTCONTROLKNOB

POWER ON-OFF





(151 mm)

ELECTRODE

1932

SECTION 4 OPERATION

SECTION 4 OPERATION





1

2







5 Low air flow rate





E Uneven Arc




tion


1 Worn electrode

SECTION 4 OPERATION

SECTION 4 OPERATION



SECTION 4 OPERATION




51 GENERAL
























as shown


SWIRL BAFFLE

ELECTRODE

NOZZLE

SHIELD













PISTON PLUG

PISTON

SPRING

FLOW SWITCH


















Final tightening





56 TROUBLESHOOTING





NOTE


















B No Air Flow
























not turn air on


















































1 LEDrsquos






50 microsec

13 vdc

0

LPG 50LPG 80

5080




TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE


HF CIRCUIT

INVERTER




PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6



















































































































SECTION 1 SEGURIDAD































SECTION 1 SEGURIDAD






















SECTION 1 SEGURIDAD




























































































DANGER

AVERTISSEMENT

ATTENTION



21 GENERAL




22 SCOPE




lowing components







able






50 - 60 A Nozzle 33369 4



24 SPECIFICATIONS




RatedOutput





Rated Primary Input



208230 V ac 5060 Hz 1-phase 5549 A





90 (208230 V 3-phase)

92 (400460 amp 575 V 3-phase)




Dimensions




Width









18 316 51614116


120

100

60

40

20

0

C U T T I N G S P E


80

716 12 5891638 34 1316 781116


Steel

Aluminum

Stainless

73 (185 mm)

1 (254 mm)

1(254 mm)

75deg

3 (76 mm)





Weight

25 ft 52 lbs (24 kg)

50 ft 96 lbs (44 kg)


a t t s ( A x V = W )

A r c V o l t a g e

Maximum Output

120

100

60

80

160

140

7000

6000

5000

9000

8000

4000

3000




Stand-Off Distance






31 GENERAL




33 LOCATION




34 INSPECTION


damage at once
























CUAWG Amps

208 1 55A 6 80 208 3 26APh 6 50 230 1 49A 6 80 230 3 24APh 6 50 400 3 13 10 25

460 3 11 10 25 575 3 9 10 20





White



WORK

SAFETY GROUND

PT-27


TORCHSWITCH





TORCH













X3

TB3

X2

X1+


~

~

~OUTPUT BRIDGE

(D1)

Fig 2




BLK

R R2

S G

T +

(IBR)INPUTBRIDGE

GRY

TB5

GRY

BLK

Fig 1

1

2

3






ARC STARTER37338

WORK




PT-20AM -21785 (45rsquo)

21786 (17rsquo)




S C O S O



View A-A


ldquoArdquo






37411 (100rsquo)


25mm min

37344 (100rsquo)

Arc Starter37338


(178mm)

(4) 250rdquo (6 mm)



BLK Arc Start

WHT Arc Start

Arc Starter

Cable (Ref)

ADAPTOR - 999278

2125rdquo(54mm)










SECTION 4 OPERATION



41 OPERATION























SECTION 4 OPERATION

SECTION 4 OPERATION






REAR VIEW


FAULT LIGHT(AMBER)

POWER LIGHT(WHITE)

AIRPRESSURE

GAUGE

AIR TESTSWITCH

TRIGGER LOCK SWITCH

CURRENTCONTROLKNOB

POWER ON-OFF





(151 mm)

ELECTRODE

1932

SECTION 4 OPERATION

SECTION 4 OPERATION





1

2







5 Low air flow rate





E Uneven Arc




tion


1 Worn electrode

SECTION 4 OPERATION

SECTION 4 OPERATION



SECTION 4 OPERATION




51 GENERAL
























as shown


SWIRL BAFFLE

ELECTRODE

NOZZLE

SHIELD













PISTON PLUG

PISTON

SPRING

FLOW SWITCH


















Final tightening





56 TROUBLESHOOTING





NOTE


















B No Air Flow
























not turn air on


















































1 LEDrsquos






50 microsec

13 vdc

0

LPG 50LPG 80

5080




TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE


HF CIRCUIT

INVERTER




PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6






















































SECTION 1 SEGURIDAD






















SECTION 1 SEGURIDAD




























































































DANGER

AVERTISSEMENT

ATTENTION



21 GENERAL




22 SCOPE




lowing components







able






50 - 60 A Nozzle 33369 4



24 SPECIFICATIONS




RatedOutput





Rated Primary Input



208230 V ac 5060 Hz 1-phase 5549 A





90 (208230 V 3-phase)

92 (400460 amp 575 V 3-phase)




Dimensions




Width









18 316 51614116


120

100

60

40

20

0

C U T T I N G S P E


80

716 12 5891638 34 1316 781116


Steel

Aluminum

Stainless

73 (185 mm)

1 (254 mm)

1(254 mm)

75deg

3 (76 mm)





Weight

25 ft 52 lbs (24 kg)

50 ft 96 lbs (44 kg)


a t t s ( A x V = W )

A r c V o l t a g e

Maximum Output

120

100

60

80

160

140

7000

6000

5000

9000

8000

4000

3000




Stand-Off Distance






31 GENERAL




33 LOCATION




34 INSPECTION


damage at once
























CUAWG Amps

208 1 55A 6 80 208 3 26APh 6 50 230 1 49A 6 80 230 3 24APh 6 50 400 3 13 10 25

460 3 11 10 25 575 3 9 10 20





White



WORK

SAFETY GROUND

PT-27


TORCHSWITCH





TORCH













X3

TB3

X2

X1+


~

~

~OUTPUT BRIDGE

(D1)

Fig 2




BLK

R R2

S G

T +

(IBR)INPUTBRIDGE

GRY

TB5

GRY

BLK

Fig 1

1

2

3






ARC STARTER37338

WORK




PT-20AM -21785 (45rsquo)

21786 (17rsquo)




S C O S O



View A-A


ldquoArdquo






37411 (100rsquo)


25mm min

37344 (100rsquo)

Arc Starter37338


(178mm)

(4) 250rdquo (6 mm)



BLK Arc Start

WHT Arc Start

Arc Starter

Cable (Ref)

ADAPTOR - 999278

2125rdquo(54mm)










SECTION 4 OPERATION



41 OPERATION























SECTION 4 OPERATION

SECTION 4 OPERATION






REAR VIEW


FAULT LIGHT(AMBER)

POWER LIGHT(WHITE)

AIRPRESSURE

GAUGE

AIR TESTSWITCH

TRIGGER LOCK SWITCH

CURRENTCONTROLKNOB

POWER ON-OFF





(151 mm)

ELECTRODE

1932

SECTION 4 OPERATION

SECTION 4 OPERATION





1

2







5 Low air flow rate





E Uneven Arc




tion


1 Worn electrode

SECTION 4 OPERATION

SECTION 4 OPERATION



SECTION 4 OPERATION




51 GENERAL
























as shown


SWIRL BAFFLE

ELECTRODE

NOZZLE

SHIELD













PISTON PLUG

PISTON

SPRING

FLOW SWITCH


















Final tightening





56 TROUBLESHOOTING





NOTE


















B No Air Flow
























not turn air on


















































1 LEDrsquos






50 microsec

13 vdc

0

LPG 50LPG 80

5080




TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE


HF CIRCUIT

INVERTER




PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6






















































SECTION 1 SEGURIDAD




























































































DANGER

AVERTISSEMENT

ATTENTION



21 GENERAL




22 SCOPE




lowing components







able






50 - 60 A Nozzle 33369 4



24 SPECIFICATIONS




RatedOutput





Rated Primary Input



208230 V ac 5060 Hz 1-phase 5549 A





90 (208230 V 3-phase)

92 (400460 amp 575 V 3-phase)




Dimensions




Width









18 316 51614116


120

100

60

40

20

0

C U T T I N G S P E


80

716 12 5891638 34 1316 781116


Steel

Aluminum

Stainless

73 (185 mm)

1 (254 mm)

1(254 mm)

75deg

3 (76 mm)





Weight

25 ft 52 lbs (24 kg)

50 ft 96 lbs (44 kg)


a t t s ( A x V = W )

A r c V o l t a g e

Maximum Output

120

100

60

80

160

140

7000

6000

5000

9000

8000

4000

3000




Stand-Off Distance






31 GENERAL




33 LOCATION




34 INSPECTION


damage at once
























CUAWG Amps

208 1 55A 6 80 208 3 26APh 6 50 230 1 49A 6 80 230 3 24APh 6 50 400 3 13 10 25

460 3 11 10 25 575 3 9 10 20





White



WORK

SAFETY GROUND

PT-27


TORCHSWITCH





TORCH













X3

TB3

X2

X1+


~

~

~OUTPUT BRIDGE

(D1)

Fig 2




BLK

R R2

S G

T +

(IBR)INPUTBRIDGE

GRY

TB5

GRY

BLK

Fig 1

1

2

3






ARC STARTER37338

WORK




PT-20AM -21785 (45rsquo)

21786 (17rsquo)




S C O S O



View A-A


ldquoArdquo






37411 (100rsquo)


25mm min

37344 (100rsquo)

Arc Starter37338


(178mm)

(4) 250rdquo (6 mm)



BLK Arc Start

WHT Arc Start

Arc Starter

Cable (Ref)

ADAPTOR - 999278

2125rdquo(54mm)










SECTION 4 OPERATION



41 OPERATION























SECTION 4 OPERATION

SECTION 4 OPERATION






REAR VIEW


FAULT LIGHT(AMBER)

POWER LIGHT(WHITE)

AIRPRESSURE

GAUGE

AIR TESTSWITCH

TRIGGER LOCK SWITCH

CURRENTCONTROLKNOB

POWER ON-OFF





(151 mm)

ELECTRODE

1932

SECTION 4 OPERATION

SECTION 4 OPERATION





1

2







5 Low air flow rate





E Uneven Arc




tion


1 Worn electrode

SECTION 4 OPERATION

SECTION 4 OPERATION



SECTION 4 OPERATION




51 GENERAL
























as shown


SWIRL BAFFLE

ELECTRODE

NOZZLE

SHIELD













PISTON PLUG

PISTON

SPRING

FLOW SWITCH


















Final tightening





56 TROUBLESHOOTING





NOTE


















B No Air Flow
























not turn air on


















































1 LEDrsquos






50 microsec

13 vdc

0

LPG 50LPG 80

5080




TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE


HF CIRCUIT

INVERTER




PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6









































































































































DANGER

AVERTISSEMENT

ATTENTION



21 GENERAL




22 SCOPE




lowing components







able






50 - 60 A Nozzle 33369 4



24 SPECIFICATIONS




RatedOutput





Rated Primary Input



208230 V ac 5060 Hz 1-phase 5549 A





90 (208230 V 3-phase)

92 (400460 amp 575 V 3-phase)




Dimensions




Width









18 316 51614116


120

100

60

40

20

0

C U T T I N G S P E


80

716 12 5891638 34 1316 781116


Steel

Aluminum

Stainless

73 (185 mm)

1 (254 mm)

1(254 mm)

75deg

3 (76 mm)





Weight

25 ft 52 lbs (24 kg)

50 ft 96 lbs (44 kg)


a t t s ( A x V = W )

A r c V o l t a g e

Maximum Output

120

100

60

80

160

140

7000

6000

5000

9000

8000

4000

3000




Stand-Off Distance






31 GENERAL




33 LOCATION




34 INSPECTION


damage at once
























CUAWG Amps

208 1 55A 6 80 208 3 26APh 6 50 230 1 49A 6 80 230 3 24APh 6 50 400 3 13 10 25

460 3 11 10 25 575 3 9 10 20





White



WORK

SAFETY GROUND

PT-27


TORCHSWITCH





TORCH













X3

TB3

X2

X1+


~

~

~OUTPUT BRIDGE

(D1)

Fig 2




BLK

R R2

S G

T +

(IBR)INPUTBRIDGE

GRY

TB5

GRY

BLK

Fig 1

1

2

3






ARC STARTER37338

WORK




PT-20AM -21785 (45rsquo)

21786 (17rsquo)




S C O S O



View A-A


ldquoArdquo






37411 (100rsquo)


25mm min

37344 (100rsquo)

Arc Starter37338


(178mm)

(4) 250rdquo (6 mm)



BLK Arc Start

WHT Arc Start

Arc Starter

Cable (Ref)

ADAPTOR - 999278

2125rdquo(54mm)










SECTION 4 OPERATION



41 OPERATION























SECTION 4 OPERATION

SECTION 4 OPERATION






REAR VIEW


FAULT LIGHT(AMBER)

POWER LIGHT(WHITE)

AIRPRESSURE

GAUGE

AIR TESTSWITCH

TRIGGER LOCK SWITCH

CURRENTCONTROLKNOB

POWER ON-OFF





(151 mm)

ELECTRODE

1932

SECTION 4 OPERATION

SECTION 4 OPERATION





1

2







5 Low air flow rate





E Uneven Arc




tion


1 Worn electrode

SECTION 4 OPERATION

SECTION 4 OPERATION



SECTION 4 OPERATION




51 GENERAL
























as shown


SWIRL BAFFLE

ELECTRODE

NOZZLE

SHIELD













PISTON PLUG

PISTON

SPRING

FLOW SWITCH


















Final tightening





56 TROUBLESHOOTING





NOTE


















B No Air Flow
























not turn air on


















































1 LEDrsquos






50 microsec

13 vdc

0

LPG 50LPG 80

5080




TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE


HF CIRCUIT

INVERTER




PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6






















































21 GENERAL




22 SCOPE




lowing components







able






50 - 60 A Nozzle 33369 4



24 SPECIFICATIONS




RatedOutput





Rated Primary Input



208230 V ac 5060 Hz 1-phase 5549 A





90 (208230 V 3-phase)

92 (400460 amp 575 V 3-phase)




Dimensions




Width









18 316 51614116


120

100

60

40

20

0

C U T T I N G S P E


80

716 12 5891638 34 1316 781116


Steel

Aluminum

Stainless

73 (185 mm)

1 (254 mm)

1(254 mm)

75deg

3 (76 mm)





Weight

25 ft 52 lbs (24 kg)

50 ft 96 lbs (44 kg)


a t t s ( A x V = W )

A r c V o l t a g e

Maximum Output

120

100

60

80

160

140

7000

6000

5000

9000

8000

4000

3000




Stand-Off Distance






31 GENERAL




33 LOCATION




34 INSPECTION


damage at once
























CUAWG Amps

208 1 55A 6 80 208 3 26APh 6 50 230 1 49A 6 80 230 3 24APh 6 50 400 3 13 10 25

460 3 11 10 25 575 3 9 10 20





White



WORK

SAFETY GROUND

PT-27


TORCHSWITCH





TORCH













X3

TB3

X2

X1+


~

~

~OUTPUT BRIDGE

(D1)

Fig 2




BLK

R R2

S G

T +

(IBR)INPUTBRIDGE

GRY

TB5

GRY

BLK

Fig 1

1

2

3






ARC STARTER37338

WORK




PT-20AM -21785 (45rsquo)

21786 (17rsquo)




S C O S O



View A-A


ldquoArdquo






37411 (100rsquo)


25mm min

37344 (100rsquo)

Arc Starter37338


(178mm)

(4) 250rdquo (6 mm)



BLK Arc Start

WHT Arc Start

Arc Starter

Cable (Ref)

ADAPTOR - 999278

2125rdquo(54mm)










SECTION 4 OPERATION



41 OPERATION























SECTION 4 OPERATION

SECTION 4 OPERATION






REAR VIEW


FAULT LIGHT(AMBER)

POWER LIGHT(WHITE)

AIRPRESSURE

GAUGE

AIR TESTSWITCH

TRIGGER LOCK SWITCH

CURRENTCONTROLKNOB

POWER ON-OFF





(151 mm)

ELECTRODE

1932

SECTION 4 OPERATION

SECTION 4 OPERATION





1

2







5 Low air flow rate





E Uneven Arc




tion


1 Worn electrode

SECTION 4 OPERATION

SECTION 4 OPERATION



SECTION 4 OPERATION




51 GENERAL
























as shown


SWIRL BAFFLE

ELECTRODE

NOZZLE

SHIELD













PISTON PLUG

PISTON

SPRING

FLOW SWITCH


















Final tightening





56 TROUBLESHOOTING





NOTE


















B No Air Flow
























not turn air on


















































1 LEDrsquos






50 microsec

13 vdc

0

LPG 50LPG 80

5080




TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE


HF CIRCUIT

INVERTER




PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6






















































24 SPECIFICATIONS




RatedOutput





Rated Primary Input



208230 V ac 5060 Hz 1-phase 5549 A





90 (208230 V 3-phase)

92 (400460 amp 575 V 3-phase)




Dimensions




Width









18 316 51614116


120

100

60

40

20

0

C U T T I N G S P E


80

716 12 5891638 34 1316 781116


Steel

Aluminum

Stainless

73 (185 mm)

1 (254 mm)

1(254 mm)

75deg

3 (76 mm)





Weight

25 ft 52 lbs (24 kg)

50 ft 96 lbs (44 kg)


a t t s ( A x V = W )

A r c V o l t a g e

Maximum Output

120

100

60

80

160

140

7000

6000

5000

9000

8000

4000

3000




Stand-Off Distance






31 GENERAL




33 LOCATION




34 INSPECTION


damage at once
























CUAWG Amps

208 1 55A 6 80 208 3 26APh 6 50 230 1 49A 6 80 230 3 24APh 6 50 400 3 13 10 25

460 3 11 10 25 575 3 9 10 20





White



WORK

SAFETY GROUND

PT-27


TORCHSWITCH





TORCH













X3

TB3

X2

X1+


~

~

~OUTPUT BRIDGE

(D1)

Fig 2




BLK

R R2

S G

T +

(IBR)INPUTBRIDGE

GRY

TB5

GRY

BLK

Fig 1

1

2

3






ARC STARTER37338

WORK




PT-20AM -21785 (45rsquo)

21786 (17rsquo)




S C O S O



View A-A


ldquoArdquo






37411 (100rsquo)


25mm min

37344 (100rsquo)

Arc Starter37338


(178mm)

(4) 250rdquo (6 mm)



BLK Arc Start

WHT Arc Start

Arc Starter

Cable (Ref)

ADAPTOR - 999278

2125rdquo(54mm)










SECTION 4 OPERATION



41 OPERATION























SECTION 4 OPERATION

SECTION 4 OPERATION






REAR VIEW


FAULT LIGHT(AMBER)

POWER LIGHT(WHITE)

AIRPRESSURE

GAUGE

AIR TESTSWITCH

TRIGGER LOCK SWITCH

CURRENTCONTROLKNOB

POWER ON-OFF





(151 mm)

ELECTRODE

1932

SECTION 4 OPERATION

SECTION 4 OPERATION





1

2







5 Low air flow rate





E Uneven Arc




tion


1 Worn electrode

SECTION 4 OPERATION

SECTION 4 OPERATION



SECTION 4 OPERATION




51 GENERAL
























as shown


SWIRL BAFFLE

ELECTRODE

NOZZLE

SHIELD













PISTON PLUG

PISTON

SPRING

FLOW SWITCH


















Final tightening





56 TROUBLESHOOTING





NOTE


















B No Air Flow
























not turn air on


















































1 LEDrsquos






50 microsec

13 vdc

0

LPG 50LPG 80

5080




TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE


HF CIRCUIT

INVERTER




PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6
























































18 316 51614116


120

100

60

40

20

0

C U T T I N G S P E


80

716 12 5891638 34 1316 781116


Steel

Aluminum

Stainless

73 (185 mm)

1 (254 mm)

1(254 mm)

75deg

3 (76 mm)





Weight

25 ft 52 lbs (24 kg)

50 ft 96 lbs (44 kg)


a t t s ( A x V = W )

A r c V o l t a g e

Maximum Output

120

100

60

80

160

140

7000

6000

5000

9000

8000

4000

3000




Stand-Off Distance






31 GENERAL




33 LOCATION




34 INSPECTION


damage at once
























CUAWG Amps

208 1 55A 6 80 208 3 26APh 6 50 230 1 49A 6 80 230 3 24APh 6 50 400 3 13 10 25

460 3 11 10 25 575 3 9 10 20





White



WORK

SAFETY GROUND

PT-27


TORCHSWITCH





TORCH













X3

TB3

X2

X1+


~

~

~OUTPUT BRIDGE

(D1)

Fig 2




BLK

R R2

S G

T +

(IBR)INPUTBRIDGE

GRY

TB5

GRY

BLK

Fig 1

1

2

3






ARC STARTER37338

WORK




PT-20AM -21785 (45rsquo)

21786 (17rsquo)




S C O S O



View A-A


ldquoArdquo






37411 (100rsquo)


25mm min

37344 (100rsquo)

Arc Starter37338


(178mm)

(4) 250rdquo (6 mm)



BLK Arc Start

WHT Arc Start

Arc Starter

Cable (Ref)

ADAPTOR - 999278

2125rdquo(54mm)










SECTION 4 OPERATION



41 OPERATION























SECTION 4 OPERATION

SECTION 4 OPERATION






REAR VIEW


FAULT LIGHT(AMBER)

POWER LIGHT(WHITE)

AIRPRESSURE

GAUGE

AIR TESTSWITCH

TRIGGER LOCK SWITCH

CURRENTCONTROLKNOB

POWER ON-OFF





(151 mm)

ELECTRODE

1932

SECTION 4 OPERATION

SECTION 4 OPERATION





1

2







5 Low air flow rate





E Uneven Arc




tion


1 Worn electrode

SECTION 4 OPERATION

SECTION 4 OPERATION



SECTION 4 OPERATION




51 GENERAL
























as shown


SWIRL BAFFLE

ELECTRODE

NOZZLE

SHIELD













PISTON PLUG

PISTON

SPRING

FLOW SWITCH


















Final tightening





56 TROUBLESHOOTING





NOTE


















B No Air Flow
























not turn air on


















































1 LEDrsquos






50 microsec

13 vdc

0

LPG 50LPG 80

5080




TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE


HF CIRCUIT

INVERTER




PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6

























































31 GENERAL




33 LOCATION




34 INSPECTION


damage at once
























CUAWG Amps

208 1 55A 6 80 208 3 26APh 6 50 230 1 49A 6 80 230 3 24APh 6 50 400 3 13 10 25

460 3 11 10 25 575 3 9 10 20





White



WORK

SAFETY GROUND

PT-27


TORCHSWITCH





TORCH













X3

TB3

X2

X1+


~

~

~OUTPUT BRIDGE

(D1)

Fig 2




BLK

R R2

S G

T +

(IBR)INPUTBRIDGE

GRY

TB5

GRY

BLK

Fig 1

1

2

3






ARC STARTER37338

WORK




PT-20AM -21785 (45rsquo)

21786 (17rsquo)




S C O S O



View A-A


ldquoArdquo






37411 (100rsquo)


25mm min

37344 (100rsquo)

Arc Starter37338


(178mm)

(4) 250rdquo (6 mm)



BLK Arc Start

WHT Arc Start

Arc Starter

Cable (Ref)

ADAPTOR - 999278

2125rdquo(54mm)










SECTION 4 OPERATION



41 OPERATION























SECTION 4 OPERATION

SECTION 4 OPERATION






REAR VIEW


FAULT LIGHT(AMBER)

POWER LIGHT(WHITE)

AIRPRESSURE

GAUGE

AIR TESTSWITCH

TRIGGER LOCK SWITCH

CURRENTCONTROLKNOB

POWER ON-OFF





(151 mm)

ELECTRODE

1932

SECTION 4 OPERATION

SECTION 4 OPERATION





1

2







5 Low air flow rate





E Uneven Arc




tion


1 Worn electrode

SECTION 4 OPERATION

SECTION 4 OPERATION



SECTION 4 OPERATION




51 GENERAL
























as shown


SWIRL BAFFLE

ELECTRODE

NOZZLE

SHIELD













PISTON PLUG

PISTON

SPRING

FLOW SWITCH


















Final tightening





56 TROUBLESHOOTING





NOTE


















B No Air Flow
























not turn air on


















































1 LEDrsquos






50 microsec

13 vdc

0

LPG 50LPG 80

5080




TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE


HF CIRCUIT

INVERTER




PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6






























































CUAWG Amps

208 1 55A 6 80 208 3 26APh 6 50 230 1 49A 6 80 230 3 24APh 6 50 400 3 13 10 25

460 3 11 10 25 575 3 9 10 20





White



WORK

SAFETY GROUND

PT-27


TORCHSWITCH





TORCH













X3

TB3

X2

X1+


~

~

~OUTPUT BRIDGE

(D1)

Fig 2




BLK

R R2

S G

T +

(IBR)INPUTBRIDGE

GRY

TB5

GRY

BLK

Fig 1

1

2

3






ARC STARTER37338

WORK




PT-20AM -21785 (45rsquo)

21786 (17rsquo)




S C O S O



View A-A


ldquoArdquo






37411 (100rsquo)


25mm min

37344 (100rsquo)

Arc Starter37338


(178mm)

(4) 250rdquo (6 mm)



BLK Arc Start

WHT Arc Start

Arc Starter

Cable (Ref)

ADAPTOR - 999278

2125rdquo(54mm)










SECTION 4 OPERATION



41 OPERATION























SECTION 4 OPERATION

SECTION 4 OPERATION






REAR VIEW


FAULT LIGHT(AMBER)

POWER LIGHT(WHITE)

AIRPRESSURE

GAUGE

AIR TESTSWITCH

TRIGGER LOCK SWITCH

CURRENTCONTROLKNOB

POWER ON-OFF





(151 mm)

ELECTRODE

1932

SECTION 4 OPERATION

SECTION 4 OPERATION





1

2







5 Low air flow rate





E Uneven Arc




tion


1 Worn electrode

SECTION 4 OPERATION

SECTION 4 OPERATION



SECTION 4 OPERATION




51 GENERAL
























as shown


SWIRL BAFFLE

ELECTRODE

NOZZLE

SHIELD













PISTON PLUG

PISTON

SPRING

FLOW SWITCH


















Final tightening





56 TROUBLESHOOTING





NOTE


















B No Air Flow
























not turn air on


















































1 LEDrsquos






50 microsec

13 vdc

0

LPG 50LPG 80

5080




TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE


HF CIRCUIT

INVERTER




PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6






















































WORK

SAFETY GROUND

PT-27


TORCHSWITCH





TORCH













X3

TB3

X2

X1+


~

~

~OUTPUT BRIDGE

(D1)

Fig 2




BLK

R R2

S G

T +

(IBR)INPUTBRIDGE

GRY

TB5

GRY

BLK

Fig 1

1

2

3






ARC STARTER37338

WORK




PT-20AM -21785 (45rsquo)

21786 (17rsquo)




S C O S O



View A-A


ldquoArdquo






37411 (100rsquo)


25mm min

37344 (100rsquo)

Arc Starter37338


(178mm)

(4) 250rdquo (6 mm)



BLK Arc Start

WHT Arc Start

Arc Starter

Cable (Ref)

ADAPTOR - 999278

2125rdquo(54mm)










SECTION 4 OPERATION



41 OPERATION























SECTION 4 OPERATION

SECTION 4 OPERATION






REAR VIEW


FAULT LIGHT(AMBER)

POWER LIGHT(WHITE)

AIRPRESSURE

GAUGE

AIR TESTSWITCH

TRIGGER LOCK SWITCH

CURRENTCONTROLKNOB

POWER ON-OFF





(151 mm)

ELECTRODE

1932

SECTION 4 OPERATION

SECTION 4 OPERATION





1

2







5 Low air flow rate





E Uneven Arc




tion


1 Worn electrode

SECTION 4 OPERATION

SECTION 4 OPERATION



SECTION 4 OPERATION




51 GENERAL
























as shown


SWIRL BAFFLE

ELECTRODE

NOZZLE

SHIELD













PISTON PLUG

PISTON

SPRING

FLOW SWITCH


















Final tightening





56 TROUBLESHOOTING





NOTE


















B No Air Flow
























not turn air on


















































1 LEDrsquos






50 microsec

13 vdc

0

LPG 50LPG 80

5080




TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE


HF CIRCUIT

INVERTER




PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6




























































X3

TB3

X2

X1+


~

~

~OUTPUT BRIDGE

(D1)

Fig 2




BLK

R R2

S G

T +

(IBR)INPUTBRIDGE

GRY

TB5

GRY

BLK

Fig 1

1

2

3






ARC STARTER37338

WORK




PT-20AM -21785 (45rsquo)

21786 (17rsquo)




S C O S O



View A-A


ldquoArdquo






37411 (100rsquo)


25mm min

37344 (100rsquo)

Arc Starter37338


(178mm)

(4) 250rdquo (6 mm)



BLK Arc Start

WHT Arc Start

Arc Starter

Cable (Ref)

ADAPTOR - 999278

2125rdquo(54mm)










SECTION 4 OPERATION



41 OPERATION























SECTION 4 OPERATION

SECTION 4 OPERATION






REAR VIEW


FAULT LIGHT(AMBER)

POWER LIGHT(WHITE)

AIRPRESSURE

GAUGE

AIR TESTSWITCH

TRIGGER LOCK SWITCH

CURRENTCONTROLKNOB

POWER ON-OFF





(151 mm)

ELECTRODE

1932

SECTION 4 OPERATION

SECTION 4 OPERATION





1

2







5 Low air flow rate





E Uneven Arc




tion


1 Worn electrode

SECTION 4 OPERATION

SECTION 4 OPERATION



SECTION 4 OPERATION




51 GENERAL
























as shown


SWIRL BAFFLE

ELECTRODE

NOZZLE

SHIELD













PISTON PLUG

PISTON

SPRING

FLOW SWITCH


















Final tightening





56 TROUBLESHOOTING





NOTE


















B No Air Flow
























not turn air on


















































1 LEDrsquos






50 microsec

13 vdc

0

LPG 50LPG 80

5080




TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE


HF CIRCUIT

INVERTER




PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6
























































ARC STARTER37338

WORK




PT-20AM -21785 (45rsquo)

21786 (17rsquo)




S C O S O



View A-A


ldquoArdquo






37411 (100rsquo)


25mm min

37344 (100rsquo)

Arc Starter37338


(178mm)

(4) 250rdquo (6 mm)



BLK Arc Start

WHT Arc Start

Arc Starter

Cable (Ref)

ADAPTOR - 999278

2125rdquo(54mm)










SECTION 4 OPERATION



41 OPERATION























SECTION 4 OPERATION

SECTION 4 OPERATION






REAR VIEW


FAULT LIGHT(AMBER)

POWER LIGHT(WHITE)

AIRPRESSURE

GAUGE

AIR TESTSWITCH

TRIGGER LOCK SWITCH

CURRENTCONTROLKNOB

POWER ON-OFF





(151 mm)

ELECTRODE

1932

SECTION 4 OPERATION

SECTION 4 OPERATION





1

2







5 Low air flow rate





E Uneven Arc




tion


1 Worn electrode

SECTION 4 OPERATION

SECTION 4 OPERATION



SECTION 4 OPERATION




51 GENERAL
























as shown


SWIRL BAFFLE

ELECTRODE

NOZZLE

SHIELD













PISTON PLUG

PISTON

SPRING

FLOW SWITCH


















Final tightening





56 TROUBLESHOOTING





NOTE


















B No Air Flow
























not turn air on


















































1 LEDrsquos






50 microsec

13 vdc

0

LPG 50LPG 80

5080




TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE


HF CIRCUIT

INVERTER




PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6






















































View A-A


ldquoArdquo






37411 (100rsquo)


25mm min

37344 (100rsquo)

Arc Starter37338


(178mm)

(4) 250rdquo (6 mm)



BLK Arc Start

WHT Arc Start

Arc Starter

Cable (Ref)

ADAPTOR - 999278

2125rdquo(54mm)










SECTION 4 OPERATION



41 OPERATION























SECTION 4 OPERATION

SECTION 4 OPERATION






REAR VIEW


FAULT LIGHT(AMBER)

POWER LIGHT(WHITE)

AIRPRESSURE

GAUGE

AIR TESTSWITCH

TRIGGER LOCK SWITCH

CURRENTCONTROLKNOB

POWER ON-OFF





(151 mm)

ELECTRODE

1932

SECTION 4 OPERATION

SECTION 4 OPERATION





1

2







5 Low air flow rate





E Uneven Arc




tion


1 Worn electrode

SECTION 4 OPERATION

SECTION 4 OPERATION



SECTION 4 OPERATION




51 GENERAL
























as shown


SWIRL BAFFLE

ELECTRODE

NOZZLE

SHIELD













PISTON PLUG

PISTON

SPRING

FLOW SWITCH


















Final tightening





56 TROUBLESHOOTING





NOTE


















B No Air Flow
























not turn air on


















































1 LEDrsquos






50 microsec

13 vdc

0

LPG 50LPG 80

5080




TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE


HF CIRCUIT

INVERTER




PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6






















































41 OPERATION























SECTION 4 OPERATION

SECTION 4 OPERATION






REAR VIEW


FAULT LIGHT(AMBER)

POWER LIGHT(WHITE)

AIRPRESSURE

GAUGE

AIR TESTSWITCH

TRIGGER LOCK SWITCH

CURRENTCONTROLKNOB

POWER ON-OFF





(151 mm)

ELECTRODE

1932

SECTION 4 OPERATION

SECTION 4 OPERATION





1

2







5 Low air flow rate





E Uneven Arc




tion


1 Worn electrode

SECTION 4 OPERATION

SECTION 4 OPERATION



SECTION 4 OPERATION




51 GENERAL
























as shown


SWIRL BAFFLE

ELECTRODE

NOZZLE

SHIELD













PISTON PLUG

PISTON

SPRING

FLOW SWITCH


















Final tightening





56 TROUBLESHOOTING





NOTE


















B No Air Flow
























not turn air on


















































1 LEDrsquos






50 microsec

13 vdc

0

LPG 50LPG 80

5080




TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE


HF CIRCUIT

INVERTER




PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6

























































REAR VIEW


FAULT LIGHT(AMBER)

POWER LIGHT(WHITE)

AIRPRESSURE

GAUGE

AIR TESTSWITCH

TRIGGER LOCK SWITCH

CURRENTCONTROLKNOB

POWER ON-OFF





(151 mm)

ELECTRODE

1932

SECTION 4 OPERATION

SECTION 4 OPERATION





1

2







5 Low air flow rate





E Uneven Arc




tion


1 Worn electrode

SECTION 4 OPERATION

SECTION 4 OPERATION



SECTION 4 OPERATION




51 GENERAL
























as shown


SWIRL BAFFLE

ELECTRODE

NOZZLE

SHIELD













PISTON PLUG

PISTON

SPRING

FLOW SWITCH


















Final tightening





56 TROUBLESHOOTING





NOTE


















B No Air Flow
























not turn air on


















































1 LEDrsquos






50 microsec

13 vdc

0

LPG 50LPG 80

5080




TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE


HF CIRCUIT

INVERTER




PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6
























































1

2







5 Low air flow rate





E Uneven Arc




tion


1 Worn electrode

SECTION 4 OPERATION

SECTION 4 OPERATION



SECTION 4 OPERATION




51 GENERAL
























as shown


SWIRL BAFFLE

ELECTRODE

NOZZLE

SHIELD













PISTON PLUG

PISTON

SPRING

FLOW SWITCH


















Final tightening





56 TROUBLESHOOTING





NOTE


















B No Air Flow
























not turn air on


















































1 LEDrsquos






50 microsec

13 vdc

0

LPG 50LPG 80

5080




TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE


HF CIRCUIT

INVERTER




PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6






















































SECTION 4 OPERATION




51 GENERAL
























as shown


SWIRL BAFFLE

ELECTRODE

NOZZLE

SHIELD













PISTON PLUG

PISTON

SPRING

FLOW SWITCH


















Final tightening





56 TROUBLESHOOTING





NOTE


















B No Air Flow
























not turn air on


















































1 LEDrsquos






50 microsec

13 vdc

0

LPG 50LPG 80

5080




TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE


HF CIRCUIT

INVERTER




PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6






















































51 GENERAL
























as shown


SWIRL BAFFLE

ELECTRODE

NOZZLE

SHIELD













PISTON PLUG

PISTON

SPRING

FLOW SWITCH


















Final tightening





56 TROUBLESHOOTING





NOTE


















B No Air Flow
























not turn air on


















































1 LEDrsquos






50 microsec

13 vdc

0

LPG 50LPG 80

5080




TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE


HF CIRCUIT

INVERTER




PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6






























































PISTON PLUG

PISTON

SPRING

FLOW SWITCH


















Final tightening





56 TROUBLESHOOTING





NOTE


















B No Air Flow
























not turn air on


















































1 LEDrsquos






50 microsec

13 vdc

0

LPG 50LPG 80

5080




TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE


HF CIRCUIT

INVERTER




PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6






















































56 TROUBLESHOOTING





NOTE


















B No Air Flow
























not turn air on


















































1 LEDrsquos






50 microsec

13 vdc

0

LPG 50LPG 80

5080




TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE


HF CIRCUIT

INVERTER




PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6
































































B No Air Flow
























not turn air on


















































1 LEDrsquos






50 microsec

13 vdc

0

LPG 50LPG 80

5080




TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE


HF CIRCUIT

INVERTER




PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6
































































not turn air on


















































1 LEDrsquos






50 microsec

13 vdc

0

LPG 50LPG 80

5080




TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE


HF CIRCUIT

INVERTER




PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6



























































































1 LEDrsquos






50 microsec

13 vdc

0

LPG 50LPG 80

5080




TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE


HF CIRCUIT

INVERTER




PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6






















































TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

PREFLOW

FLOW SWITCH CLOSE


HF CIRCUIT

INVERTER




PUSH RELEASE

ENERGIZE

NOTES

10 SEC

Postflow

OPEN

2 SEC




10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6






















































10 SEC


TORCH SWITCH

OPEN CLOSE

GAS SOLENOID VALVE

POSTFLOW

CLOSE OPEN

FLOW SWITCH

FAULT LIGHT

HF CIRCUIT

INVERTER



ENERGIZE

NOTES


PREFLOW

Postflow

2 SEC




61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6






















































61 General






62 Ordering


Note







PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6
























































PCM-875 Series A


13

10 11

16

8 9

7

63 45 4

1 2

15

8

14

12







1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6

























































1 954667 LABEL RATING PCM-875 400460


160 161 162

158 159

151 152

153

154 155 156

157




28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6






















































28

27

24

23

22

21

44 45

43

41

42

3836

35

32 33 34

31

29 30

25 26

39

4037

4647

25 26


27













55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6































































55

53

56 57 58

72

51

59

73

6970

52

54

75 76

68

67 71

60

56 57 58

61

62

63

64 65 66

77 7874













89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6































































89 88 87 8681

80

82 83 84

100104

95

94

93

92

9091

10110210398 99














119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6
































































119 120 118117

111

110

133

130 131 132

129127 128

134126125

124

123 135

122

121

112 113 114

116

















143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6



































































143142

141140145144




NOTES



REVISION HISTORY









1

2

3

4

5

6






















































NOTES



REVISION HISTORY









1

2

3

4

5

6






















































REVISION HISTORY









1

2

3

4

5

6




























































1

2

3

4

5

6




















































Plasma Essab PLS 50

Documents

Transcript of Plasma Essab PLS 50