ESAB PCM-750i, Instruction Manual

Page 1: ...rienced operators If you are not fully familiar with the principles of operation and safe practices for electric welding equipment we urge you to read our booklet Precautions and Safe Practices for Arc Welding Cutting and Gouging Form 52 529 Do NOT permit untrained persons to install operate or maintain this equipment Do NOT attempt to install or operate this equipment until you have read and full...

Page 2: ...user of this equipment shall have the sole responsibility for any malfunction which results from improper use faulty maintenance damage improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer TABLE OF CONTENTS SECTION TITLE PAGE PARAGRAPH SECTION 1 DESCRIPTION 5 1 1 General 5 1 2 Scope 5 1 3 Packages Available 5 1 4 Specifications 6 ...

Page 3: ...es on the workpiece which might pro duce flammable or toxic vapors Do not do hot work on closed containers They may explode 4 Have fire extinguishing equipment handy for instant use such as a garden hose water pail sand bucket or portable fire extinguisher Be sure you are trained in its use SAFETY PRECAUTIONS 10 98 5 Do not use equipment beyond its ratings For example overloaded welding cable can ...

Page 4: ... Never strike an arc on a cylinder 5 For additional information refer to CGA Standard P 1 Precautions for Safe Handling of Compressed Gases in Cylinders which is available from Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 EQUIPMENT MAINTENANCE Faulty or improperly maintained equipment can cause injury or death Therefore 1 Always have qualified personnel perform the in...

Page 5: ...du bâtiment ou en un point éloigné de la zone de travail augmente en effet le risque de PRÉCAUTIONS DE SÉCURITÉ AVERTISSEMENT Ces règles de sécurité ont pour objet d assurer votre protection Veillez à lire et à observer les précautions énoncées ci dessous avant de monter l équipement ou de commercer à l utiliser Tout défaut d observation de ces précautions risque d entraîner des blessures graves o...

Page 6: ...ltez les recommandations particulières en matière de ventilation indiquées à l alinéa 6 de la norme Z49 1 de l AWS 5 ENTRETIEN DE L ÉQUIPEMENT Un équipement entretenu de façon défectueuse ou inadéquate risque non seulement de réaliser un travail de mauvaise qualité mais chose plus grave encore d entraîner des dommages corporels graves voire mortels en déclenchant des incendies ou des chocs électri...

Page 7: ...eofthismanualistoprovidetheoperatorwith all the information required to install and operate the PCM 750i plasma arc cutting package Technical refer ence material is also provided to assist in troubleshoot ing the cutting package 1 3 PACKAGES AVAILABLE Table 1 1 lists PCM 750i packages available through your ESAB dealer Package contents are indented un der each complete system description Table 1 1...

Page 8: ...s the machine may operate continuously Rated Output 40 Duty Cycle 50 A 105 V dc 60 Duty Cycle 40 A 104 V dc 100 Duty Cycle 30 A 103 V dc Output Current Range 10 to 50 Amperes Open Circuit Voltage 265 V dc Rated Primary Input 50 Amperes Output 208 230 Volt 45 42 A 50 60 Hz 1 Phase 460 Volt 12A 50 60 Hz 1 or 3 Phase Power Factor 50 Amperes Output 70 Efficiency 50 Amperes Output 88 Current Capacity P...

Page 9: ... Specifications 1 25 4 mm 3 76 mm 1 25 4 mm 7 3 185 mm 75 Figure 1 1 PT 27 Dimensions Figure 1 2 PT 27 Cutting Performance Current Capacity 100 duty 80 A DCSP Length of Service Llines 25 ft or 50 ft Weight 25 ft 5 2 lbs 2 3 kg 50 ft 9 6 lbs 4 4 kg ...

Page 10: ...ed 2 5 PRIMARY ELECTRICAL INPUT CONNECTIONS FIGURE 2 1 ELECTRIC SHOCK CAN KILL Precautionary mea sures should be taken to provide maximum protec tion against electrical shock Be sure that all power is off by opening the line wall disconnect switch and by unplugging the power cord to the unit when connections are made inside of the power source Besurethatthepowersourceisproperlyconfigured for your ...

Page 11: ...o 12 CU AWG 4 con ductor wire 460 V 3 phase SAFETY GROUND WORK CABLE Allow at least 10 ft 3 m between work and console WORK AIR FILTER REGULATOR set at 65 75 psig HOSE ASSEMBLY ON OFF POWER SWITCH RECEPTACLE P N 674540 supplied w 230 V consoles COVER SAFETY INTERLOCK COVER CUSTOMER FUSED LINE DISCONNECT SWITCH 60 A fuse for 230 V 1 phase 30 A fuse for 460 V 1 or 3 phase ...

Page 12: ...ALLATION 12 Figure 2 2 Ground and Work Cable Connections DO NOT ATTACH WORK CABLE TO PIECE BEING CUT FREE WORK CABLE EARTH GROUND GROUNDED WORK TABLE EARTH GROUND BE SURE WORK IS IN GOOD CONTACT WITH TABLE WORK CABLE ...

Page 13: ...mately1 8inchfrom the work E When ending a cut the torch switch should be released press and release if using LOCK IN mode and lifted off the workpiece just before the end of the cut to minimize double arcing This is to prevent the high frequency from reigniting after cutting arc extinguishes and causing damage to the nozzle 3 1 OPERATION ELECTRIC SHOCK can kill Do NOT operate the unit with the co...

Page 14: ... REGULATOR POWER CORD AIR CHECK POWER LAMP FAULT LAMP WORK CABLE CONNECTION SAFETY INTERLOCK SWITCH AIR HOSE CONNECTION OUTPUT CURRENT CONTROL LOCK IN TORCHGASHOSE CONNECTION TORCH SWITCH CONNECTION AIR SUPPLY Figure 3 1 PCM 750i Controls Figure 3 2 Recommended Torch Angle of 5 to 15 11 16 New Acceptable WRONG Figure 3 3 Electrode Wear Limit PILOT ARC CONNECTION F For rapid re starts such as grate...

Page 15: ... cuts 1 Cutting speed too fast or too slow 2 Improper air pressure 3 Faulty nozzle or electrode D Double Arcing Damaged Nozzle Orifice 1 Low air pressure 2 Damaged cutting nozzle 3 Loose cutting nozzle 4 Heavy spatter E Uneven Arc Damaged cutting nozzle or worn electrode F Unstable Cutting Conditions 1 Incorrect cutting speed 2 Loose cable or hose connections 3 Electrode and or cutting nozzle in p...

Page 16: ...kinked F Make sure all plugs fittings and ground connec tions are tight G Removeorreplacecarryingstrapannually sooner if weekly check shows wear or damage Wateroroiloccasionallyaccumulatesincompressed air lines Be sure to direct the first blast of air away from the equipment to avoid damage to the PCM 750i H With all input power disconnected and wearing propereyeandfaceprotection blowouttheinside ...

Page 17: ...n D Remove the piston E Clean all parts with cleaning agent NOTE Ensure cleaning agent does not contain solvents which can degrade polysulfone Reassemble the flow switch in reverse order PISTON PLUG PISTON SPRING FLOW SWITCH Figure 4 2 Disassembly Assembly of Flow Switch Thevalvepinisacrucialmemberofthesystem Itsfunctionistoopenthegasflowcheck valve that is permanently assembled within the torch h...

Page 18: ...onnected Opentheline wall disconnectswitch or circuit breaker before attempting inspection or work inside of the power source Check the problem against the symptoms in the follow ing troubleshooting guide The remedy may be quite simple If the cause cannot be quickly located shut off the input power open up the unit and perform a simple visual inspection of all the components and wiring Check for s...

Page 19: ...Yes No Connect Is air adjusted to 65 psig Yes No Adjust Does air come on with air check switch Yes No No electrode in torch No valve pin in torch Replace electrode Check continuity of torch switch Replace valve pin OK No Replace torch switch Repair power source ...

Page 20: ...air check switch OFF Yes No Turn switch OFF Does arc start when nozzle contacts work without depressing torch switch Yes No Check for short in torch switch Does air flow even when PCM 750i power switch is OFF Yes No Replace Repair power solenoid valve source ...

Page 21: ...s main 230 volt switch ON Yes No Turn on main disconnect Is plug in receptacle Yes No Insert plug in receptacle Is cooling fan turning Yes No Replace pilot light Check voltage at receptacle and input power line Yes No Check main fuses Faulty power switch on PCM 750i ...

Page 22: ...e 270 volts Not recommended to operate above 253 V or below 190 V Yes No Adjust voltage Repair power source Fault lightwillenergizeifvoltagefallsbelow175voltsfor0 3secondsorexceeds260voltsevenforaninstant The light will not turn OFF even when correct voltage is restored Reset by placing PCM 750i power switch OFF and then ON again NOTE When in LOCK IN mode the FAULT light will turn on during second...

Page 23: ...f Operation A LOCK IN OFF position PUSH RELEASE ENERGIZE NOTES 1 When the torch switch is pushed during postflow period the postflow and preflow times are canceled and the HF is energized immediately 2 When the red fault pilot light comes on cutting operation should be stopped The postflow time starts from the moment the torch switch is released 10 SEC Postflow OPEN 2 SEC ...

Page 24: ...IZE NOTES 1 When the torch switch is pushed during postflow period the postflow and preflow times are canceled and the HF is energized immediately 2 When the red fault pilot light comes on cutting operation should be stopped The postflow time starts from the moment the torch switch is released 3 FAULT pilot light is on during second turn off trigger only This does not affect performance in any way...

Page 25: ...25 Figure 5 1 PCM 750i Series A Schematic Diagram 460 V 3 Phase Input D 35511 A ...

Page 26: ...26 Figure 5 2 PCM 750i Series A Wiring Diagram 460 V 3 Phase Input D 35510 A ...

Page 27: ...27 Figure 5 3 PCM 750i Series A Schematic Diagram 230 V 1 Phase Input D 35507 A ...

Page 28: ...28 Figure 5 4 PCM 750i Series A Wiring Diagram 230 V 1 Phase Input D 35506 A ...

Page 29: ...d on the unit nameplate 6 2 ORDERING To assure proper operation it is recommended that only genuine ESAB parts and products be used with this equipment The use of non ESAB parts may void your warranty MANUAL CHANGES The A edition of this Instruction Manual covers the following changes or upcoming changes 1 PCB5 PC board assembly P N 38037 was changed to 38039 on the 460V and 400V units starting wi...

Page 30: ...SING HANDLE STRAP LEFT HOUSING HANDLE STRAP RIGHT STRAP HOOK 2 REQ D 951536 CABINET SILKSCREENED POTENTIOMETER 10K 2 W KNOB ALUM 250 SHAFT 1 25 O D DOOR LOCKOUT TERMINAL WORK ADAPTOR BULKHEAD BOARD OUTPUT TERMINAL W STUD NUT HEX BRASS 3 8 16 CONNECTOR TWIST LOCK 2 POLE 2 WIRE SWITCH PUSHBUTTON SPDT 120 V 10 A HOUSING FRONT FUSE 12 A 600 V FAST ACTING FUSEHOLDER LAMP LED YELLOW 12 V LAMP NEON WHITE...

Page 31: ...7313500 993716 674540 COVER RELAY 120 V AC 20 A MOTOR FAN CABLE INPUT POWER 10 FT LG W PLUG STRAIN RELIEF POWER CABLE TRANSFORMER ASSY CONTROL CAPACITOR 1900 µF 450 V DC PC BOARD ASSY HF HV IGNITION TRANSFORMER HIGH VOLTAGE P C BOARD ASSY START UP TRANSFORMER ASSY MAIN P C BOARD ASSY SHUNT RESISTOR ASSY 6 OHM 75 W RECTIFIER SILICON CONT 70 A 1200 V PAD 951196 BRIDGE INPUT 3 PHASE 75 A 1200 V PAD 9...

Page 32: ...0010 993716 17290210 951493 950591 951515 COVER RELAY 120 V AC 20 A MOTOR FAN CABLE INPUT POWER 10 FT LG 4 COND STRAIN RELIEF POWER CABLE TRANSFORMER ASSY CONTROL CAPACITOR 1300 µF 450 V DC PC BOARD ASSY HF HV IGNITION TRANSFORMER HIGH VOLTAGE P C BOARD ASSY START UP TRANSFORMER ASSY MAIN P C BOARD ASSY SHUNT RESISTOR ASSY 6 OHM 75 W RECTIFIER SILICON CONT 70 A 1200 V PAD 951196 BRIDGE INPUT 3 PHA...

Page 33: ...100 NS PAD 951518 REACTOR ASSY HIGH FREQUENCY RESISTOR 20 25 W N I PAD 951193 CAPACITOR 01 µF 1 KV INDUCTOR ASSY ASSEMBLY HOSE TRANSFORMER ASSY CURRENT VALVE SOLENOID GAS SWITCH FLOW IGBT 600 V PAD 951190 SWITCH THERMAL 95 C P C BOARD ASSY CONTROL CORE SATURABLE P C BOARD ASSY IGBT DRIVER includes 2 952014 Fuse 1 2 Amp CAPACITOR 022 µF 1 KV RESISTOR 20 50 W N I PAD 951194 JACK PHONE RESISTOR 39 KO...

Page 34: ...50020 951483 951471 17145339 951161 951917 MODULE DIODE 100 A 600 V 100 NS PAD 951518 REACTOR ASSY HIGH FREQUENCY RESISTOR 20 25 W N I PAD 951193 CAPACITOR 01 µF 1 KV INDUCTOR ASSY ASSEMBLY HOSE TRANSFORMER ASSY CURRENT VALVE SOLENOID GAS SWITCH FLOW IGBT 1200 V PAD 951191 SWITCH THERMAL 95 C P C BOARD ASSY CONTROL CORE SATURABLE P C BOARD ASSY IGBT DRIVER includes 2 952014 Fuse 1 2 Amp CAPACITOR ...

Page 35: ...1 1 1 1 1 1 1 1 1 35903GY 33950GY 33952GY 58V75 951180 951181 950829 950923 950744 182W82 34381 34741 HOUSING REGULATOR HOUSING REAR HOUSING WIRE WRAP UTILITY BOX ADAPTOR BULKHEAD ON OFF SWITCH CIRC BRKR 50 A 230 V ON OFF SWITCH CIRC BRKR 50 A 460 V CIRCUIT BREAKER 3 A FILTER REGULATOR GAUGE AIR 0 160 PSIG ELBOW STREET 90 1 4 NPT ADAPTOR REG 1 4 NPT HOSE ASSY AIR 11 5 LG CB1 CB1 CB2 OFF ...

Page 36: ...ranty Returns Authorized Repair Stations C TECHNICAL SERVICE Telephone 800 ESAB 123 Fax 803 664 4429 Part Numbers Technical Applications Hours 7 30 AM to 5 00 PM EST Performance Features Technical Specifications D LITERATURE REQUESTS Telephone 803 664 5501 Fax 803 664 5548 Hours 7 30 AM to 4 00 PM EST E WELDING EQUIPMENT REPAIRS Telephone 803 664 4469 Fax 803 664 5557 Repair Estimates Repair Statu...