F-15-335-C

February, 2002

INSTRUCTION MANUAL
PCM-875
PLASMA ARC CUTTING PACKAGE

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

P/N 36590 - 208/230 V, 1 & 3-Phase, 50/60 Hz

P/N 36592 - 460 V, 3-Phase, 50/60 Hz
P/N 36714 - 575 V, 3-Phase, 60 Hz
P/N 36725 - 400 V, 3-Phase, 50/60 Hz

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

Be sure this information reaches the operator.

You can get extra copies through your supplier.
 USER RESPONSIBILITY

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

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The
user of this equipment shall have the sole responsibility for any malfunction which results from improper use,
faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service
facility designated by the manufacturer.

TABLE OF CONTENTS

SECTION TITLE PAGE

PARAGRAPH

SECTION 1 DESCRIPTION ................................................................................................. 7

1.1 General ............................................................................................................. 7
1.2 Scope ................................................................................................................ 7
1.3 Packages Available ........................................................................................... 7
1.4 Specifications .................................................................................................... 8

SECTION 2 INSTALLATION ................................................................................................ 10

2.1 General ............................................................................................................. 10
2.2 Equipment Required ......................................................................................... 10
2.3 Location ............................................................................................................ 10
2.4 Inspection .......................................................................................................... 10
2.5 Primary Electrical Input Connections ................................................................ 10
2.6 Secondary Output Connections ........................................................................ 11
2.7 Connecting PCM-875 for 200(208)Vac Input .................................................... 13
2.8 Mechanized Cutting Installation with the PT-20AM Torch ................................. 14

SECTION 3 OPERATION..................................................................................................... 16
3.1 Operation .......................................................................................................... 16
3.2 PCM-875 Controls ............................................................................................ 16
3.3 Cutting with the PT-27 ....................................................................................... 16
3.4 Common Cutting Problems ............................................................................... 18

SECTION 4 MAINTENANCE ............................................................................................... 19

4.1 General ............................................................................................................. 19
4.2 Inspection and Cleaning .................................................................................... 19
4.3 PT-27 Torch Consumable Parts ........................................................................ 19
4.4 Flow Switch ....................................................................................................... 20
4.5 IGBT Handling and Replacement ...................................................................... 20

SECTION 5 TROUBLESHOOTING ..................................................................................... 21

5.1 Troubleshooting ................................................................................................ 21
5.2 Troubleshooting Guide ...................................................................................... 21
5.3 Reference Voltage Checks ............................................................................... 25
5.4 Sequence of Operation ..................................................................................... 26

SECTION 6 REPLACEMENT PARTS ................................................................................. 37

6.1 General ............................................................................................................. 37
6.2 Ordering ............................................................................................................ 37
2
 SAFETY PRECAUTIONS

WARNING: These Safety Precautions are for 5. Do not use equipment beyond its ratings. For example,
your protection. They summarize precaution- overloaded welding cable can overheat and create a fire
ary information from the references listed in hazard.
Additional Safety Information section. Before 6. After completing operations, inspect the work area to
performing any installation or operating procedures, be make certain there are no hot sparks or hot metal which
sure to read and follow the safety precautions listed below could cause a later fire. Use fire watchers when neces-
as well as all other manuals, material safety data sheets, sary.
labels, etc. Failure to observe Safety Precautions can result 7. For additional information, refer to NFPA Standard 51B,
in injury or death. "Fire Prevention in Use of Cutting and Welding Pro-
cesses", available from the National Fire Protection Asso-
PROTECT YOURSELF AND OTHERS -- ciation, Batterymarch Park, Quincy, MA 02269.
Some welding, cutting, and gouging
processes are noisy and require ear ELECTRICAL SHOCK -- Contact with live
protection. The arc, like the sun, emits electrical parts and ground can cause
ultraviolet (UV) and other radiation and severe injury or death. DO NOT use AC
can injure skin and eyes. Hot metal can cause burns. welding current in damp areas, if move-
Training in the proper use of the processes and equip- ment is confined, or if there is danger of
ment is essential to prevent accidents. Therefore: falling.
1. Always wear safety glasses with side shields in any work 1. Be sure the power source frame (chassis) is connected
area, even if welding helmets, face shields, and goggles
to the ground system of the input power.
are also required.
2. Use a face shield fitted with the correct filter and cover 2. Connect the workpiece to a good electrical ground.
plates to protect your eyes, face, neck, and ears from 3. Connect the work cable to the workpiece. A poor or
sparks and rays of the arc when operating or observing missing connection can expose you or others to a fatal
operations. Warn bystanders not to watch the arc and shock.
not to expose themselves to the rays of the electric-arc 4. Use well-maintained equipment. Replace worn or dam-
or hot metal. aged cables.
3. Wear flameproof gauntlet type gloves, heavy long-sleeve 5. Keep everything dry, including clothing, work area,
shirt, cuffless trousers, high-topped shoes, and a weld- cables, torch/electrode holder, and power source.
ing helmet or cap for hair protection, to protect against 6. Make sure that all parts of your body are insulated from
arc rays and hot sparks or hot metal. A flameproof apron work and from ground.
may also be desirable as protection against radiated 7. Do not stand directly on metal or the earth while working
heat and sparks.
in tight quarters or a damp area; stand on dry boards or
4. Hot sparks or metal can lodge in rolled up sleeves,
an insulating platform and wear rubber-soled shoes.
trouser cuffs, or pockets. Sleeves and collars should be
kept buttoned, and open pockets eliminated from the 8. Put on dry, hole-free gloves before turning on the power.
front of clothing 9. Turn off the power before removing your gloves.
5. Protect other personnel from arc rays and hot sparks 10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)
with a suitable non-flammable partition or curtains. for specific grounding recommendations. Do not mis-
6. Use goggles over safety glasses when chipping slag or take the work lead for a ground cable.
grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety glasses. ELECTRIC AND MAGNETIC FIELDS —
May be dangerous. Electric current flow-
FIRES AND EXPLOSIONS -- Heat from ing through any conductor causes lo-
flames and arcs can start fires. Hot slag calized Electric and Magnetic Fields
or sparks can also cause fires and ex- (EMF). Welding and cutting current cre-
plosions. Therefore: ates EMF around welding cables and
welding machines. Therefore:
1. Remove all combustible materials well away from the
work area or cover the materials with a protective non- 1. Welders having pacemakers should consult their physi-
flammable covering. Combustible materials include wood, cian before welding. EMF may interfere with some pace-
cloth, sawdust, liquid and gas fuels, solvents, paints and makers.
coatings, paper, etc.
2. Exposure to EMF may have other health effects which are
2. Hot sparks or hot metal can fall through cracks or
crevices in floors or wall openings and cause a hidden unknown.
smoldering fire or fires on the floor below. Make certain 3. Welders should use the following procedures to minimize
that such openings are protected from hot sparks and exposure to EMF:
metal.“ A. Route the electrode and work cables together. Secure
3. Do not weld, cut or perform other hot work until the them with tape when possible.
workpiece has been completely cleaned so that there B. Never coil the torch or work cable around your body.
are no substances on the workpiece which might pro- C. Do not place your body between the torch and work
duce flammable or toxic vapors. Do not do hot work on cables. Route cables on the same side of your body.
closed containers. They may explode. D. Connect the work cable to the workpiece as close as
4. Have fire extinguishing equipment handy for instant use, possible to the area being welded.
such as a garden hose, water pail, sand bucket, or E. Keep welding power source and cables as far away
portable fire extinguisher. Be sure you are trained in its
use. from your body as possible.
11/95
3
 FUMES AND GASES -- Fumes and perform any electrical work unless you are qualified to
gases, can cause discomfort or harm, perform such work.
particularly in confined spaces. Do 2. Before performing any maintenance work inside a power
not breathe fumes and gases. Shield- source, disconnect the power source from the incoming
ing gases can cause asphyxiation. electrical power.
Therefore: 3. Maintain cables, grounding wire, connections, power cord,
and power supply in safe working order. Do not operate
1. Always provide adequate ventilation in the work area by any equipment in faulty condition.
natural or mechanical means. Do not weld, cut, or gouge 4. Do not abuse any equipment or accessories. Keep
on materials such as galvanized steel, stainless steel, equipment away from heat sources such as furnaces, wet
copper, zinc, lead, beryllium, or cadmium unless posi- conditions such as water puddles, oil or grease, corrosive
tive mechanical ventilation is provided. Do not breathe atmospheres and inclement weather.
fumes from these materials. 5. Keep all safety devices and cabinet covers in position and
2. Do not operate near degreasing and spraying opera- in good repair.
tions. The heat or arc rays can react with chlorinated 6. Use equipment only for its intended purpose. Do not
hydrocarbon vapors to form phosgene, a highly toxic modify it in any manner.
gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat irritation ADDITIONAL SAFETY INFORMATION -- For
while operating, this is an indication that ventilation is not more information on safe practices for elec-
adequate. Stop work and take necessary steps to im- tric arc welding and cutting equipment, ask
prove ventilation in the work area. Do not continue to your supplier for a copy of "Precautions and
operate if physical discomfort persists. Safe Practices for Arc Welding, Cutting and
4. Refer to ANSI/ASC Standard Z49.1 (see listing below) Gouging", Form 52-529.
for specific ventilation recommendations.
The following publications, which are available from the
American Welding Society, 550 N.W. LeJuene Road, Miami,
CYLINDER HANDLING -- Cylinders, if FL 33126, are recommended to you:
mishandled, can rupture and violently 1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
release gas. Sudden rupture of cylin- 2. AWS C5.1 - "Recommended Practices for Plasma Arc
der, valve, or relief device can injure or Welding"
kill. Therefore: 3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
1. Use the proper gas for the process and use the proper 4. AWS C5.3 - "Recommended Practices for Air Carbon Arc
pressure reducing regulator designed to operate from Gouging and Cutting"
the compressed gas cylinder. Do not use adaptors. 5. AWS C5.5 - "Recommended Practices for Gas Tungsten
Maintain hoses and fittings in good condition. Follow Arc Welding“
manufacturer's operating instructions for mounting regu- 6. AWS C5.6 - "Recommended Practices for Gas Metal Arc
lator to a compressed gas cylinder. Welding"“
2. Always secure cylinders in an upright position by chain 7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.
or strap to suitable hand trucks, undercarriages, benches, 8. ANSI/AWS F4.1, "Recommended Safe Practices for Weld-
walls, post, or racks. Never secure cylinders to work ing and Cutting of Containers That Have Held Hazardous
tables or fixtures where they may become part of an Substances."
electrical circuit.
3. When not in use, keep cylinder valves closed. Have This symbol appearing throughout this manual
valve protection cap in place if regulator is not con- means Attention! Be Alert! Your safety is
nected. Secure and move cylinders by using suitable involved.
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder. The following definitions apply to DANGER, WARNING,
5. For additional information, refer to CGA Standard P-1, CAUTION found throughout this manual:
"Precautions for Safe Handling of Compressed Gases in
Used to call attention to immediate haz-
Cylinders", which is available from Compressed Gas
ards which, if not avoided, will result in
Association, 1235 Jefferson Davis Highway, Arlington,
immediate, serious personal injury or
VA 22202.
loss of life.
EQUIPMENT MAINTENANCE -- Faulty or im- Used to call attention to potential haz-
properly maintained equipment can cause ards which could result in personal injury
injury or death. Therefore: or loss of life.

1. Always have qualified personnel perform the installa- Used to call attention to hazards which
tion, troubleshooting, and maintenance work. Do not could result in minor personal injury.

4
 PRÉCAUTIONS DE SÉCURITÉ
AVERTISSEMENT: Ces règles de sécurité ont pour objet a. Éloigner suffisamment tous les matériaux combus-
d’ assurer votre protection. Veillez à lire et à observer les tibles du secteur où l’on exécute des soudures ou des
précautions énoncées ci-dessous avant de monter l’ coupes à l’arc, à moins de les recouvrir complètement
équipement ou de commercer à l’utiliser. Tout défaut d’une bâche non-inflammable. Ce type de matériaux
d’observation de ces précautions risque d’entraîner des comprend notamment le bois, les vêtements, la sciure,
blessures graves ou mortelles. l’essence, le kérosène, les peintures, les solvants, le
1. PROTECTION INDIVIDUELLE-- Les brûlures de la gaz naturel, l’acétylène, le propane et autres sub-
peau et des yeux dues au rayonnement de l’arc stances combustibles semblables.
électrique ou du métal incandescent, lors du soudage b. Les étincelles ou les projections de métal incandes-
au plasma ou à l’électrode ou lors du gougeage à cent peuvent tomber dans des fissures du plancher ou
l’arc, peuvent s’avérer plus graves que celles dans des ouvertures des murs et y déclencher une
résultant d’une exposition prolongée au soleil. Aussi ignition lente cachée. Veiller à protéger ces ouvertures
convient-il d’observer les précautions suivantes: des étincelles et des projections de métal.
a. Portez un écran facial adéquat muni des plaques c. N’exécutez pas de soudures, de coupes, d’opérations
protectrices et des verres filtrants appropriés afin de de gougeage ou autres travaux à chaud à la surface
vous protéger les yeux, le visage, le cou et les oreilles de barils, bidons, réservoirs ou autres contenants
des étincelles et du rayonnement de l’arc électrique usagés, avant de les avoir nettoyés de toute trace de
lorsque vous effectuez des soudures ou des coupes substance susceptible de produire des vapeurs
ou lorsque vous en observez l’exécution. inflammables ou toxiques.
AVERTISSEZ les personnes se trouvant à proximité d. En vue d’assurer la prévention des incendies, il
de façon à ce qu’elles ne regardent pas l’arc et à ce convient de disposer d’un matériel d’extinction prêt à
qu’elles ne s’exposent pas à son rayonnement, ni à servir immédiatement, tel qu’un tuyau d’arrosage, un
celui du métal incandescent. seau à eau, un seau de sable ou un extincteur portatif.
b. Portez des gants ignifugés à crispins, une tunique e. Une fois le travail à l’arc terminé, inspectez le secteur
épaisse à manches longues, des pantalons sans de façon à vous assurer qu’aucune étincelle ou projec-
rebord, des chaussures à embout d’acier et un tion de métal incandescent ne risque de provoquer
casque de soudage ou une calotte de protection, afin ultérieurement un feu.
d’éviter d’exposer la peau au rayonnement de l’arc 3. CHOC ÉLECTRIQUE-- Le gougeage à l’arc et à l’arc
électrique ou du métal incandescent. ll est également au plasma exige l’emploi de tensions à vide
souhaitable d’utiliser un tablier ininflammable de relativement importantes; or, celles-ci risquent de
façon à se protéger des étincelles et du rayonnement causer des dommages corporels graves et même
thermique. mortels en cas d’utilisation inadéquate. La gravité du
c. Les étincelles ou les projections de métal incandes- choc électrique reçu dépend du chemin suivi par le
cent risquent de se loger dans des manches courant à travers le corps humain et de son intensité.
retroussées, des bords relevés de pantalons ou dans a. Ne laissez jamais de surfaces métalliques sous ten-
des poches. Aussi convient-il de garder boutonnés le sion venir au contact direct de la peau ou de
col et les manches et de porter des vêtements sans vêtements humides. Veillez à porter des gants bien
poches à l’avant. secs.
d. Protégez des étincelles et du rayonnement de l’arc b. Si vous devez effectuer un travail sur une surface
électrique les autres personnes travaillant à proximité métallique ou dans un secteur humide, veillez à assu-
à l’aide d’un écran ininflammable adéquat. rer votre isolation corporelle en portant des gants secs
e. Ne jamais omettre de porter des lunettes de sécurité et des chaussures à semelles de caoutchouc et en
lorsque vous vous trouvez dans un secteur où l’on vous tenant sur une planche ou une plate-forme
effectue des opérations de soudage ou de coupage à sèche.
l’arc. Utilisez des lunettes de sécurité à écrans ou c. Mettez toujours à la terre le poste de soudage/coupage
verres latéraux pour piquer ou meûler le laitier. Les en le reliant par un câble à une bonne prise de terre.
piquetures incandescentes de laitier peuvent être d. N’utilisez jamais de câbles usés ou endommagés. Ne
projetées à des distances considérables. Les surchargez jamais le câble. Utilisez toujours un
personnes se trouvant à proximité doivent également équipement correctement entretenu.
porter des lunettes de protection. e. Mettez l’équipement hors tension lorsqu’il n’est pas en
f. Le gougeage à l’arc et le soudage à l’arc au plasma service. une mise à la masse accidentelle peut en
produisent un niveau de bruit extrêmement élevé (de effet provoquer une surchauffe de l’équipement et un
100 à 114 dB) et exigent par conséquent l’emploi de danger d’incendie. Ne pas enrouler ou passer le câble
dispositifs appropriés de protection auditive. autour d’une partie quelconque du corps.
2. PRÉVENTION DES INCENDES-- Les projections de f. Vérifiez si le câble de masse est bien relié à la pièce en
laitier incandescent ou d’étincelles peuvent un point aussi proche que possible de la zone de
provoquer de graves incendies au contact de travail. Le branchement des câbles de masse à
matériaux combustibles solides, liquides ou gazeux. l’ossature du bâtiment ou en un point éloigné de la
Aussi faut-il observer les précautions suivantes: zone de travail augmente en effet le risque de pas-
sage d’un courant de sortie par des chaînes delevage

9/97
5
 des câbles de grue ou divers chemins électriques. des dommages corporels graves, voire mortels en
g. Empêchez l’apparition de toute humidité, notamment déclenchant des incendies ou des chocs électriques.
sur vos vêtements, à la surface de l’emplacement de Observez par conséquent les précautions suivantes:
travail, des câbles, du porte-électrode et du poste de a. Efforcez-vous de toujours confier à un personnel qua-
soudage/coupage. Réparez immédiatement toute lifié l’installation, le dépannage et l’entretien du poste
fuite d’eau. de soudage et de coupage. N’effectuez aucune
4. VENTILATION-- La respiration prolongée des fumées réparation électrique sur l’équipement à moins d’être
résultant des opérations de soudage/coupage, à qua-lifié à cet effet.
l’intérieur, d’un local clos, peut provoquer des mal- b. Ne procédez jamais à une tâche d’entretien
aises et des dommages corporels. Aussi convient-il quelconque à l’intérieur du poste de soudage/
d’observer les précautions suivantes: coupage, avant d’avoir débranché l’alimentation
a. Assurez en permanence une aération adéquate de électrique.
l’emplacement de travail en maintenant une ventila- c. Maintenez en bon état de fonctionnement les câbles,
tion naturelle ou à l’aide de moyens mécaniques. le câble de masse, les branchements, le cordon
N’effectuez jamais de travaux de soudage ou de d’alimentation et le poste de soudage/coupage.
coupage sur des matériaux de zinc, de plomb, de N’utilisez jamais le poste ou l’équipement s’il présente
beryllium ou de cadmium en l’absence de moyens une défectuosité quelconque.
mécaniques de ventilation capables d’empêcher d. Prenez soin du poste de soudage et de coupage et
l’inhalation des fumées dégagées par ces matériaux. des équipements accessoires. Gardez-les à l’écart
b. N’effectuez jamais de travaux de soudage ou de des sources de charleur, notamment des fours, de
coupage à proximité de vapeurs d’hydrocarbure l’humidité, des flaques d’eau maintenez-les à l’abri des
chloré résultant d’opérations voisines de dégraissage traces d’huile ou de graisse, des atmosphères corro-
ou de pulvérisation. La chaleur dégagée ou le sives et des intempéries.
rayonnement de l’arc peut déclencher la formation de e. Laissez en place tous les dispositifs de sécurité et tous
phosgène -- gaz particulièrement toxique -- et d’autres les panneaux de l’armoire de commande en veillant à
gaz irritants, à partir des vapeurs de solvant. les garder en bon état.
c. Une irritation momentanée des yeux, du nez ou de la f. Utilisez le poste de soudage/coupage conformément à
gorge constatée au cours de l’utilisation de son usage prévu et n’effectuez aucune modification.
l’équipement dénote un défaut de ventilation. Arrêtez- 6. INFORMATIONS COMPLÉMENTAIRES RELATIVES
vous de travailler afin de prendre les mesures néces- À LA SÉCURITÉ--
saires à l’amélioration de la ventilation. Ne poursuivez Pour obtenir des informations complémentaires sur les
pas l’opération entreprise si le malaise persiste. règles de sécurité à observer pour le montage et
d. Certaines commandes comportent des canalisations l’utilisation d’équipements de soudage et de coupage
où circule de l’hydrogène. L’armoire de commande électriques et sur les méthodes de travail
est munie d’un ventilateur destiné à empêcher la recommandées, demandez un exemplaire du livret N°
formation de poches d’hydrogène, lesquelles 52529 “Precautions and Safe Practices for Arc Weld-
présentent un danger d’explosion; ce ventilateur ne ing, Cutting and Gouging” publié par ESAB. Nous
fonctionne que si l’interrupteur correspondant du conseillons également de consulter les publications
panneau avant se trouve placé en position ON sui-vantes, tenues à votre disposition par l’American
(Marche). Veillez à manœuvrer cette commande en Welding Society, 550 N.W. LeJuene Road, Miami, FL
vérifiant si le couvercle est bien en place, de façon à 32126:
assurer l’efficacité de la ventilation ainsi réalisée. Ne a. “Safety in Welding and Cutting” AWS Z49.1
jamais débrancher le ventilateur. b. “Recommended Safe Practices for Gas-Shielded Arc
e. Les fumées produites par l’opération de soudage ou Welding “AWS A6. 1.
de coupage peuvent s’avérer toxiques. Aussi est-il c. “Safe Practices for Welding and Cutting Containers
nécessaire de disposer en permanence d’un dispositif That Have Held Combustibles” AWS-A6.0.
adéquat de ventilation de type aspirant, afin d’élimi- d. “Recommended Safe Practices for Plasma Arc Cut-
ner du voisinage de l’opérateur tout dégagement de ting” AWS-A6. 3.
fumée visible. e. “Recommended Safe Practices for Plasma Arc Weld-
f. Consultez les recommandations particulières en ing” AWS-C5. 1.
matière de ventilation indiquées à l’alinéa 6 de la f. “Recommended Safe Practices for Air Carbon Arc
norme Z49.1 de l’AWS. Gouging and Cutting” AWS-C5. 3.
5. ENTRETIEN DE L’ÉQUIPEMENT-- Un équipement g. “Code For Safety in Welding and Cutting”
entretenu de façon défectueuse ou inadéquate risque CSA-Standard W117. 2.
non seulement de réaliser un travail de mauvaise
qualité mais, chose plus grave encore, d’entraîner

9/97
6
SECTION 1 DESCRIPTION

1.1 GENERAL PT-27 Torch, 75° head, 25-ft. .......................... P/N 21661
PT-27 Spare Parts Kit (see Table 1-1) ............ P/N 21623
The PCM-875 is a compact, completely self-contained PCM-875 Console/Power Source .................... See below
plasma cutting system. As shipped, the system is fully
assembled and ready to cut after being connected to Depending on the choice of input power, each package
input power and a source of compressed air (90-150 includes the following appropriate PCM-875 Console/
psi). The PCM-875 package uses the heavy-duty PT-27 Power Source:
torch to deliver cutting power for severing materials up to
208/230 V, 50/60 Hz, 1 or 3-phase ................. P/N 36580
1-1/4 inch thick. Refer to the following paragraphs for
460 V, 50/60 Hz, 3-phase ............................... P/N 36584
descriptions of the PCM-875 packages available as well
575 V, 60 Hz, 3-phase .................................... P/N 36713
as performance specifications. 400 V, 50/60 Hz, 3-phase ............................... P/N 36724

1.3.2 Mechanized Cutting Packages

Use only ESAB Plasmarc torches that are designed Also available are mechanized packages using the
PT-20AM Mechanized Plasma Torch with the PCM-875
for use with this console. Use of torches not de-
Console/Power Source. A typical package includes:
signed for use with this console could create an PCM-875 Console/Power Source, PT-20AM Torch (4.5
ELECTRIC SHOCK HAZARD. Do NOT use or modify or 17 ft.), Remote Arc Starter, Torch Spare Parts Kit,
the PT-23, PCT-80 or any other torch for use on this Pilot Arc Cable (50 or 100 ft.), Power Cable (50 or 100 ft.),
console. Gas Hose (50 or 100 ft.), Arc Starter AC Power Cable (50
or 100 ft.) and a hose adaptor. See Section 2.8 for
1.2 SCOPE installation details and part numbers of components.

The purpose of this manual is to provide the operator The following PCM-875 Mechanized Packages are avail-
with all the information required to install and operate the able:
PCM-875 plasma arc cutting package. Technical refer-
875M, 230V/PT-20AM, 4.5'/50’System ........... P/N 37617
ence material is also provided to assist in troubleshoot-
875M, 230V/PT-20AM, 4.5'/100' System ........ P/N 37618
ing the cutting package.
875M, 230V/PT-20AM, 17'/50' System ........... P/N 37619
875M, 230V/PT-20AM, 17'/100' System ......... P/N 37620
1.3 PACKAGES AVAILABLE 875M, 460V/PT-20AM, 4.5'/50’System ........... P/N 37621
875M, 460V/PT-20AM, 4.5'/100' System ........ P/N 37622
1.3.1 Manual Cutting Packages 875M, 460V/PT-20AM, 17'/50' System ........... P/N 37623
PCM-875 packages listed on the front cover includes the 875M, 460V/PT-20AM, 17'/100' System ......... P/N 37624
following components:

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

Description Part Number Quantity

50 - 60 A Nozzle 33369 4
Electrode 33366 3
Swirl Baffle 33367 1
Heat Shield 21616 2
Standoff Guide 21420 1
Valve Pin 21619 1
Fuse, 15 A, 600 VDC, Fast Acting 952137 1

7
SECTION 1 DESCRIPTION

1.4 SPECIFICATIONS

Table 1-2. PCM-875 Specifications

Rated 60% Duty Cycle* 60 A @ 120 V dc

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

Output Current Range 10 to 60 Amperes

Open Circuit Voltage 275 V dc

208/230 V ac, 50/60

26/24 A/phase
Hz, 3-phase

208/230 V ac, 50/60

55/49 A
Hz, 1-phase
Rated Primary Input
@ 400 V ac, 50/60 Hz, 3-
7.2 kW Max. Output Power 13 A/phase
phase
60 A @ 120 Vdc
460 V ac, 50/60 Hz, 3-
11 A/phase
phase

575 V ac, 50/60 Hz, 9 A/phase

74% (208/230 V, 1-phase)

Power Factor @ 60 Amperes Output 90% (208/230 V, 3-phase)
92% (400/460 & 575 V, 3-phase)

Efficiency @ 60 Amperes Output 90% Typical

Current Capacity PT-27 80 A DCSP

320 cfh @ 65 - 75 psig

Air Requirements PT-27
(150 l/min @ 4.5 - 5.2 bars)

Length 20.3" (516 mm)

Height 16.1" (409 mm)
w/handles 18.3" (465 mm)
Dimensions
Width
w/o opt. storage 10.1" (275 mm)
w/ opt. torch storage 13.1" (333 mm)

Weight of PCM-875 System 87 lbs (39.5 kg)

Shipping Weight 100 lbs (45.4 kg)

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

8
SECTION 1 DESCRIPTION
Table 1-3. PT-27 Torch Specifications
7.3" (185 mm)

Current Capacity (100% duty) 80 A DCSP

Length of Service Lines 25 ft or 50 ft 3" (76 mm)
Weight
25 ft 5.2 lbs (2.4 kg)
50 ft 9.6 lbs (4.4 kg) 75°

1" (25.4 mm)

1"
(25.4 mm)

Figure 1-1. PT-27 Dimensions

120

Steel
100 PT-27 Torch
CUTTING SPEED (IN. PER MIN.)

Air @75psi
3/16" - 1/4" Stand-off
Maximum Current
80

60
Aluminum

40

Stainless
20

0
1/16 1/8 3/16 1/4 5/16 3/8 7/16 1/2 9/16 5/8 11/16 3/4 13/16 7/8
MATERIAL THICKNESS (IN.)
Figure 1-2. PT-27/PCM 875 Cutting Performance

9000 160
Maximum Output
8000 140
Watts (A x V=W)

7000 120
Arc Voltage

6000 IMPORTANT
Power output Maintain Proper 100
IMPORTANT!!!
5000 increases with Stand-off Distance
Maintain Proper
Stand-off Distance

stand-off distance 80
4000
3/16 to 1/4“
60
3000 Best
2000 Range 40

1000 20

0 0
1/16
0.0625 1/8
0.125 3/16
0.1875 1/4
0.25 5/16
0.3125 3/8
0.375
Stand-Off Distance (in.)
Figure 1-3. Standoff vs. Power Output

1.5 OPTIONAL ACCESSORIES

1. Torch Wrap/Spare Parts Kit Holder, P/N 33952GY. 2. Wheel Cart, P/N 34324. This 5 7/8" high cart has
Units have 4 mounting holes on left side for mounting front swivel casters and rear casters to make it
this accessory holder. easier to roll the PCM-875 around the job site.

9
SECTION 2 INSTALLATION

2.1 GENERAL 2.5 PRIMARY ELECTRICAL INPUT

CONNECTIONS (FIGURE 2-1)
Proper installation is important for satisfactory and trouble-
free operation of the PCM-875 cutting package. It is
suggested that each step in this section be studied
carefully and followed closely.
ELECTRIC SHOCK CAN KILL! Precautionary mea-
sures should be taken to provide maximum protec-
2.2 EQUIPMENT REQUIRED tion against electrical shock. Be sure that all power
is off by opening the line (wall) disconnect switch
A source of clean, dry air that supplies 320 cfh at 65-75 and by unplugging the power cord to the unit when
psig is required for the cutting operation. The air supply connections are made inside of the power source.
should not exceed 150 psig (the maximum inlet pressure
rating of the air filter-regulator supplied with the pack-
age).
Be sure that the power source is properly configured
2.3 LOCATION for your input power supply. DO NOT connect a
power source configured for 208/230 V to a 460 V
Adequate ventilation is necessary to provide proper input power supply. Damage to the machine may
cooling of the PCM-875. The amount of dirt, dust, and occur.
excessive heat to which the equipment is exposed,
should be minimized. There should be at least one foot NOTE: If using 200(208) V input power, the PCM-875
of clearance between the PCM-875 power source and must be reconnected for 200 V use as directed
wall or any other obstruction to allow freedom of air in Section 2.7 and Fig. 2-2.
movement through the power source.
The PCM-875 consoles are equipped with a 10-ft,
4-conductor input power cable for 3-phase connection.
If single-phase connection is desired, tape back the red
Installing or placing any type of filtering device will wire on the input power cable.
restrict the volume of intake air, thereby subjecting
the power source internal components to overheat- NOTE: The 208/230 V models are equipped with a plug
ing. The warranty is void if any type of filter device for single-phase connection only. The plug is
is used. mounted to a 4-conductor cable. If 3-phase
connection is desired, remove and discard the
2.4 INSPECTION plug and proceed as described above.

A. Remove the shipping container and all packing A line (wall) disconnect switch with fuses or circuit
material and inspect for evidence of concealed breakers should be provided at the main power panel
damage which may not have been apparent upon (see Fig. 2-1 and Table 2-1 for fuse sizes). The input
receipt of the PCM-875. Notify the carrier of any power cable of the console may be connected directly to
defects or damage at once. the disconnect switch or you may purchase a proper plug
and receptacle from a local electrical supplier. If using
B. Check container for any loose parts prior to dispos- plug/receptacle combination, see Table 2-1 for recom-
ing of shipping materials. mended input conductors for connecting receptacle to
line disconnect switch.
C. Check air louvers and any other openings to ensure
that any obstruction is removed.

The chassis must be connected to an approved

electrical ground. Failure to do so may result in
electrical shock, severe burns or death.

10
SECTION 2 INSTALLATION

Table 2-1. Recommended Sizes For 1. For operator safety, the torch connections are located
Input Conductors and Line Fuses on the output terminal board behind the lower portion
of the front panel. Remove access door to output
Input Requirements Input & Gnd Fuse terminal board from right panel of power source.
Volts Phase Amps Conductor Size 2. Thread the power cable, pilot arc cable and switch
CU/AWG Amps lead of the PT-27 through the right open bushing of
208 1 55A 6 80 the front panel. Connect power cable to the torch
208 3 26A/Ph. 6 50 fitting (left-hand threads); bolt the pilot arc cable ring
230 1 49A 6 80 connection to the copper terminal; and plug in the
230 3 24A/Ph. 6 50 switch lead to the torch switch receptable on the
400 3 13 10 25 output terminal board. Make sure the power and
460 3 11 10 25 pilot arc cable connections are wrench-tight. Make
575 3 9 10 20 sure plug of switch lead is firmly locked in place.
3. Reassemble the access door to the power source.
2.6 SECONDARY (OUTPUT) CONNECTIONS 4. Connect your air supply to the inlet connection of
(REFER TO FIG. 2-1) the filter-regulator.
5. Clamp the work cable to the workpiece. Be sure
the workpiece is connected to an approved earth
ground with a properly sized ground cable.
Before making any connections to the power source
output terminals, make sure that all primary input
power to the power source is deenergized (off) at
the main disconnect switch and that the input power
cable is unplugged.

Red - NOT USED ON SINGLE PHASE

White
Black
Green
PRIMARY INPUT
POWER CABLE

11
SECTION 2 INSTALLATION

TORCH
PILOT
Allow at least 10 ft. (3m) ARC
between work and power source CONNECTION

TORCH
POWER
CABLE
CONNECTION

WORK

TORCH
SAFETY SWITCH
GROUND RECEPTACLE
ACCESS DOOR FOR
TORCH CONNECTION

ACCESS FOR CNC

PT-27 INTERFACE CONNEC-
TIONS.
(See Detail “A”)
Prefiltered AIR SUPPLY
(Customer Supplied)
(90 to 150 psig max)

CUSTOMER FUSED LINE

DISCONNECT SWITCH(See
Table 2.1 and WARNING in
regards to chassis ground in
Section 2.5.)

INPUT POWER CABLE

(See Table 2.1)

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

single-phase connection only. The plug is mounted to a
4-conductor cable. If 3-phase connection is desired,
remove and discard the plug and refer to Sect. 2.5.
CNC INTERFACE CONNECTION
(INSIDE ON LEFT SIDE OF
BASE.) Figure 2-1. PCM-875 Interconnection Diagram
DETAIL “A”
12
SECTION 2 INSTALLATION

2.7 CONNECTING PCM-875 FOR 200(208)

VAC INPUT 1. Remove cover from the PCM-875 power source.
2. Locate the Input Bridge (IBR) and TB5 terminal
block (see Fig. 1) on the left side towards the rear
panel. Disconnect the gray lead from TB5-2 and
then connect it to TB5-1.
ELECTRIC SHOCK CAN KILL! Precautionary mea-
3. Locate the output bridge (D1) on left side towards
sures should be taken to provide maximum protec-
the front panel (see Fig. 2). Disconnect and swap
tion against electrical shock. Be sure that all power
leads X2 and X3 from the main transformer. For
is off by opening the line (wall) disconnect switch
200(208) vac input, X2 is connected to TB3 and X3
and by unplugging the power cord to the unit when
is connected to terminal 3 of D1. Make sure the
reconnecting for 200(208) VAC Input.
connections are firmly tightened.
4. Leave all other wires the same.
The PCM-875 power source with 200/230 vac, 1-phase
5. Reinstall cover and connect the PCM-875 to 208 vac
input capability is factory set for 230 vac input. If using
input power.
200(208) vac input, the PCM-875 must be reconnected
as follows before connecting to your input power:

Fig. 1
Fig. 2

FROM MAIN
GRY (IBR)
TRANSFORMER
INPUT
BRIDGE
TB5
R R2
X3
BLK
BLK S G ~ 1
X1
+
GRY
T + ~ 2
TB3
OUTPUT ~ 3
X2
BRIDGE (D1)

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

Power Source with 200/230 Vac Input Power Capability

13
 SECTION 2 INSTALLATION
2.8 MECHANIZED CUTTING INSTALLATION WITH THE PT-20AM TORCH

ARC STARTER CABLE - 37410 (50’)

37411 (100’)

POWER CABLE - 37341 (50’)

37342 (100’)

ARC STARTER
37338

PT-20AM - 21785 (4.5’)

AIR HOSE - 37343 (50’) 21786 (17’)
WORK 37344 (100’)
CABLE(25’)
(Supplied with
PCM-875) PILOT ARC CABLE - 37339 (50’)
37340 (100’)

SCHEMATIC - MECHANICAL SYSTEM SETUP (See Figure 2-4 for detailed connections)

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

Figure 2.3 - MECHANICAL CUTTING INTERFACE DIAGRAM
14
 SECTION 2 INSTALLATION

View A-A Disconnect These

Two Black Leads

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

WHT Arc Start
“A”
“B”
“C”
“D”
Arc Starter
BLK Arc Start Cable (Ref.)
ADAPTOR - 999278
PILOT ARC CABLE - 37339 (50’)
“A” 37340 (100’)

SPLICE CONNECTOR* Make sure all power is off before making following
“D” “C” “B”
(Supplied with 37338) connections.
25mm min.
1. Remove cover from PCM-875.
2. Insert the 4 service lines from Arc Starter through the
AIR HOSE - 37343 (50’)
torch opening of front panel.
37344 (100’)
3. Connect large hole terminal end of Pilot Arc Cable
("A") to connection where shown. Tighten screw
firmly.
POWER CABLE - 37341 (50’) 4. Connect adaptor 999278 to fitting where shown.
37342 (100’) Connect Air Hose ("C") to adaptor. Connect power
ARC STARTER CABLE - 37410 (50’) cable ("B") to one of the threaded holes of adaptor.
Tighten all connections firmly.
37411 (100’)
5. Locate TB1 Terminal Block. Referring to view D-D
above, disconnect the two black wires from TB1.
Connect the black lead of Arc Starter Cable ("D") to
TB1-1 and the white lead to TB1-2.
6. Reassemble cover. Proceed to connect the 4 ser-
Arc Starter vice lines to the Arc Starter. Then connect PT-20AM
37338 torch to Arc Starter.

(4) .250” (6 mm)

2.125”
(54mm)

.035” (0.9mm)
7”
(178mm)

25mm min.

SPLICE CONNECTOR*
(Supplied with 37338)
PT-20AM
TORCH
*Insulate splice connec-
tors with vinyl tubing
and secure with electrical
SPARK GAP ASSEMBLY MOUNTING DIMENSIONS
tape.
(Torch end of Arc Starter)

Figure 2.4 Connection Diagram - PCM-875/PT-20AM with Arc Starter

15
SECTION 3 OPERATION

3.1 OPERATION E. Fault Light. Will glow amber under the following
conditions and operations will come to a complete
stop.

Flow Fault: The fault light will be mostly on but

ELECTRIC SHOCK can kill. will flick off for about 1/10th of a second every
• Do NOT operate the unit with the cover removed. second. This indicates that the air flow supply is
• Do NOT apply power to the unit while holding or low.
carrying the unit.
• Do NOT touch any torch parts forward of the torch Over Temperature: The fault light will be mostly
handle (nozzle, heat shield, electrode, etc.) with off but will flick on for about 1/10th of a second
power switch on. every second. This indicates that the duty cycle
has been exceeded. Allow the power source to
cool down before returning to operate.

High/Low Line Voltage: The fault light will rap-

ARC RAYS can burn eyes and skin; idly blink on and off (five times per second). This
NOISE can damage hearing. indicates that the input voltage is outside the “+ or
• Wear welding helmet with No. 6 or 7 lens shade. -” 15% range of the input rating.
• Wear eye, ear, and body protection.
Over-Current: The fault light will be on continu-
ously. This indicates that input current has been
exceeded.
Position the PCM-875 at least 10 feet (3 meters) from
the cutting area. Sparks and hot slag from the cut- All fault signals will remain on for a minimum
ting operation can damage the unit. of 10 seconds. If fault clears, all will reset
automatically except for over-current. To clear
3.2 PCM-875 CONTROLS (FIGURE 3-1) over-current, the power must be shut off for 5
seconds and then turned back on.
A. Power Switch (located on rear panel). When
3.3 CUTTING WITH THE PT-27
placed in ON position, the green pilot light will glow
indicating control circuit is energized and the
cooling fan will run. Use the following procedures to cut with the PT-27 torch
(Figure 3-4).
B. Output Current Control. Adjustable from 10 to
60 amperes. A. Hold the torch nozzle approximately 1/8 to 3/16
inch above the work and tilted at about 15 - 30°.
C. Air Test Switch. When placed in Test position, air This reduces the chance of spatter entering the
filter-regulator can be adjusted to desired pres- nozzle. If the PT-27's standoff tool is being used,
sure (65-75 psig) before cutting operations. Allow set the standoff between 3/16 and 1/4-inch.
air to flow for a few minutes. This should remove
any condensation that may have accumulated B. Depress the torch switch. Air should flow from the
during shutdown period. Be sure to place switch torch nozzle.
in OPERATE position before starting cutting op-
erations. C. Two seconds after depressing the torch switch,
the pilot arc should start. The main arc should
D. Trigger Lock Switch. When placed in LOCK immediately follow, allowing the cut to begin. (If
position, this permits releasing torch switch button using the trigger LOCK mode, torch switch may be
after cutting arc has been initiated. To extinguish released after establishing the cutting arc.)
arc at end of cut, press and release torch switch
button again or pull torch away from work. When D. After starting the cut, the torch should be main-
placed in UNLOCK position, torch switch must be tained at a 5-15° forward angle (Figure 3-2). This
held closed by the operator during the entire angle is especially useful in helping to create a
cutting operation and then released at the end of "drop" cut. When not using the standoff guide, the
cut. nozzle should be held approximately 1/4 inch from
the work.
16
SECTION 3 OPERATION

AIR REGULATOR
POWER LIGHT CONTROL KNOB
(WHITE)
FAULT LIGHT
(AMBER)

REAR VIEW

AIR
PRESSURE
GAUGE

FUSE (15A) FUSE (3A)

AIR TEST
SWITCH

TRIGGER LOCK
SWITCH
POWER ON-OFF
CURRENT
(I-O) SWITCH &
CONTROL
CIRCUIT BREAKER
KNOB

Figure 3-1. PCM-875 Controls

E. When ending a cut, the torch switch should be NOTE: When replacing the nozzle, always inspect the
released (press and release if using trigger LOCK electrode for wear. If less than 19/32" of electrode
mode) and lifted off the workpiece just before the shaft is remaining, replace the electrode. If the
end of the cut. This is to prevent the high frequency electrode is used beyond this recommended wear
from reigniting after cutting arc extinguishes and limit, damage to the torch and power source may
causing damage to the nozzle (double arcing). occur. Nozzle life is also greatly reduced when
using the electrode below the recommended
limit. Refer to Figure 3-3.

19/32"
(15.1 mm)

REPLACE ELECTRODE BEFORE

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

Figure 3-3. Electrode Wear Limit

Figure 3-2. Recommended Torch Angle of 5° to 15° 3.3.1. Drag Cutting with the PT-27/PCM-875 System
If drag cutting is desired, the 15 amp pilot arc fuse located
F. For rapid re-starts, such as grate or heavy mesh on the rear panel must be removed. This converts pilot arc
cutting, do not release the torch switch. In the starting to high frequency starting allowing you to cut by
postflow mode, the arc can be re-started immedi- dragging the torch nozzle on the workpiece. Cutting
ately by depressing the torch switch. This avoids thickness should not exceed 3/8" for drag cutting.
the 2-second preflow portion of the cutting cycle.

17
SECTION 3 OPERATION

2 WHEN THE ARC BREAKS

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

1 TO START A PIERCE, TILT THE

TORCH TO PREVENT MOLTEN MA-
TERIAL FROM COMING BACK
AGAINST AND DAMAGING THE
TORCH.

Figure 3-4. Piercing Technique using the PT-27

3.4 COMMON CUTTING PROBLEMS D. Double Arcing. (Damaged Nozzle Orifice.)

Listed below are common cutting problems followed by 1. Low air pressure.
the probable cause of each. If problems are determined 2. Damaged cutting nozzle.
to be caused by the PCM-875, refer to the maintenance 3. Loose cutting nozzle.
section of this manual. If the problem is not corrected 4. Heavy spatter accumulation on nozzle.
after referring to the maintenance section, contact your
ESAB distributor. E. Uneven Arc.

A. Insufficient Penetration. 1. Damaged cutting nozzle or worn electrode.

1. Current too low. F. Unstable Cutting Conditions.

2. Cutting speed too fast.
3. Damaged cutting nozzle. 1. Incorrect cutting speed.
4. Improper air pressure. 2. Loose cable or hose connections.
5. Low air flow rate. 3. Electrode and/or cutting nozzle in poor condi-
tion.
B. Main Arc Extinguishes.
G. Main Arc Does Not Strike.
1. Cutting speed too slow.
2. Worn electrode. 1. Worn electrode.
2. Loose connections.
C. Dross Formation. (In some materials and thick- 3. Worn cable not attached.
nesses, it may be impossible to get dross-free cuts.)
H. Poor Consumable Life.
1. Current too low.
2. Cutting speed too fast or too slow. 1. Improper gas pressure.
3. Improper air pressure. 2. Contaminated air supply.
4. Faulty nozzle or electrode. 3. Low air flow rate.
5. Low air flow rate.

18
SECTION 4 MAINTENANCE

4.1 GENERAL

If this equipment does not operate properly, stop work The PT-27 torch head contains a gas flow check
immediately and investigate the cause of the malfunc- valve that acts in conjunction with the flow switch
tion. Maintenance work must be performed by an and circuitry within the power source. This system
experienced person, and electrical work by a trained prevents the torch from being energized with high
electrician. Do not permit untrained persons to inspect, voltage if the torch switch is accidentally closed
clean, or repair this equipment. Use only recommended when the shield is removed. Always replace torch
replacement parts. with the proper torch manufactured by ESAB since
it alone contains ESAB¹s patented safety interlock.

Be sure that the wall disconnect switch or wall To assemble the consumable parts, refer to Figure 4-1.
circuit breaker is open before attempting any in-
spection or work inside of the PCM-875. A. Place nozzle, swirl baffle and electrode into the
shield as shown.
4.2 INSPECTION AND CLEANING
B. Thread assembly to the torch body and hand tighten.
Frequent inspection and cleaning of the PCM-875 is Always make sure the shield is very tight before
recommended for safety and proper operation. Some cutting.
suggestions for inspecting and cleaning are as follows:

A. Check work cable for secured connection to

workpiece.
B. Check safety earth ground at workpiece and at
power source chassis.
C. Check heat shield on torch. It should be replaced
if damaged.
D. Check the torch electrode and cutting nozzle for ELECTRODE
wear on a daily basis. Remove spatter or replace
if necessary. SWIRL BAFFLE
E. Make sure cable and hoses are not damaged or NOZZLE
kinked. SHIELD
F. Make sure all plugs, fittings, and ground connec-
tions are tight.
G. With all input power disconnected, and wearing
proper eye and face protection, blow out the inside
of the PCM-875 using low-pressure dry com-
pressed air.

Water or oil occasionally accumulates in compressed

air lines. Be sure to direct the first blast of air away
from the equipment to avoid damage to the PCM-
875.

H. Occasionally, bleed all water from the filter be-

neath the air filter-regulator. IMPORTANT!
MAKE SHIELD VERY TIGHT!
4.3 PT-27 TORCH CONSUMABLE PARTS

Make sure power switch on PCM-875 is in OFF

position before working on the torch. Figure 4-1. Assembly of PT-27 Torch Front End Parts

19
SECTION 4 MAINTENANCE

4.4 FLOW SWITCH (FIGURE 4-2) • Use grounded work station with grounded floors and
grounded wrist straps when handling devices.
When excessive contamination is found in the air, the • Use a 100Ω resistor in series with the gate when
flow switch (FS-4) should be disassembled and cleaned performing curve tracer tests.
as follows: • Never install devices into systems with power con-
nected to the system.
A. Ensure the system is shut down and there is no • Use soldering irons with grounded tips when solder-
trapped air under pressure in the piping. ing to gate terminals.
B. Remove the piston plug.
C. Remove the spring. Use care when handling spring When mounting IGBT modules on a heatsink, certain
to prevent distortion. precautions should be taken to prevent any damage
D. Remove the piston. against a sudden torque. If a sudden torque (“one-sided
E. Clean all parts with cleaning agent. tightening”) is applied at only one mounting terminal the
ceramic insulation plate or silicon chip inside the module
NOTE may get damaged.
Ensure cleaning agent does not contain solvents
which can degrade polysulfone. Warm water and The mounting screws are to be fastened in the order
detergent is recommended for cleaning. Allow all shown in Figure 4-3. Also, care must be taken to achieve
parts to dry thoroughly before reassembly. maximum contact (i.e. minimum contact thermal resis-
tance) for the best heat dissipation.
Reassemble the flow switch in reverse order.
Application of a thermal pad on the contact surface
improves it thermal conductivity. See Replacement Parts
section for the required pad.
PISTON PLUG
A torque wrench should be used. Tighten mounting
SPRING
screws to 28 in-lbs; wire connecting screws to 19 in-lbs.
If torque is too heavy, the device can damage like the
above “one-sided tightening”.
PISTON
FLOW SWITCH
 Two-Point Mounting Type
Temporary tightening  è‚
Final tightening  ‚è

Figure 4-2. Disassembly / Assembly of Flow Switch

4.5 IGBT Handling & Replacement

Since IGBT gates are insulated from any other conduct- Four-Point Mounting Type
ing region, care should be taken to prevent static build Temporary tightening  è‚èƒè„
 Final tightening  „èƒè‚è
up, which could possibly damage gate oxides. All IGBT
modules are shipped from the factory with conductive ƒ
foam contacting the gate and emmiter sense pins. „
‚
Always ground parts touching gate pins during installa-
tion. In general, standard ESD precautlions application
to FETs should be followed.

Other handling precautions that should also be ob-

served are as follows:

Figure 4-3. Screw Fastening Order

20
SECTION 5 TROUBLESHOOTING

5.1 TROUBLESHOOTING 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 vari-
ous components. A volt-ohmmeter will be necessary for
some of these checks.
ELECTRIC SHOCK CAN KILL! Be sure that all pri-
mary power to the machine has been externally
disconnected. Open the line (wall) disconnect switch
or circuit breaker before attempting inspection or Voltages in plasma cutting equipment are high
work inside of the power source. enough to cause serious injury or possibly death. Be
particularly careful around equipment when the cov-
Check the problem against the symptoms in the follow- ers are removed.
ing troubleshooting guide. The remedy may be quite
simple. If the cause cannot be quickly located, shut off NOTE
the input power, open up the unit, and perform a simple
visual inspection of all the components and wiring. Before checking voltages in the circuit, disconnect the
Check for secure terminal connections, loose or burned power from the high frequency generator to avoid dam-
wiring or components, bulged or leaking capacitors, or aging your voltmeter.
any other sign of damage or discoloration.

5.2 TROUBLESHOOTING GUIDE

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

1. Visually inspect the machine for any damage.

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

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

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

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

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 P2-14of 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

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

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

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

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

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

21
SECTION 5 TROUBLESHOOTING

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

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

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

a. With the machine power on, depress the torch switch. On the control board the LED 1 should be lit as long as
the switch is depressed. If not then check:

i. Turn power off to the machine. Unplug Control board. Put an ohmmeter across P5-1 and P5-2 to take
resistance reading. Depress torch switch. Meter should read a short. If not, then one of the following is
not working properly:

ii. Torch switch or the leads. Unplug the torch switch leads at the machine. Put a meter across the two plug
pins. Should read a short when the torch switch is depressed. If not, then either broken switch leads or
malfunctioning switch.

b. Check T2 transformer secondary voltages at the plugs P1 and P2. Refer to system schematic. Replace the
transformer if the correct secondary voltages are not present.

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

D. Fault light activates when torch switch is closed.

The Fault circuit is used to monitor conditions necessary for the safe operation of the PCM-875. The fault light
will glow amber under the following conditions and operations will come to a complete stop:

1. High/Low line voltage. The Fault Light will rapidly blink on and off (5 times per second). This indicates that
the input voltage is outside the “+” or “-” 15% safe operating range rating.

2. Flow fault - The fault light will be mostly on but will blink off for 1/10th of a second every second. This indicates
that the air flow is low.
a. Check the air pressure at the machine regulator. It should be adjusted to 65 psig. If no air pressure, check the
air at the supply point. Also, check for any obstructions in the air hose.
b. Air flow may be blocked at the torch tip. Check the torch consumables. Also check for any obstructions in the
torch leads.

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

c.. Put the ‘Air Check’ switch to On position. Air should flow through torch. If not, then the flow switch may be
stuck due to oil in the air. Clean air flow switch per supplier’s instructions or replace switch. To check if the
flow switch is open, put voltmeter leads between P1-12 and P1-1. It should read about 12 VDC. When the
flow switch closes, the voltage will drop to zero volts.
d. Air Check switch may also be malfunctioning if the air is flowing continuously or putting in the On position
does not turn air on.

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

a. Thermal switch may be open. It will open if the temperature at the IGBT base reaches 94oC. With the
machine power off, check the continuity between P1-1 and P1-2 of the control board. If the switch is OK, then

22
SECTION 5 TROUBLESHOOTING

the ohmmeter should read a direct short. If not then it should read open.
b. If the switch is malfunctioning, replace it. Clean the surface of the heat sink before installing the switch.

4. Over Current. The fault light will be on continuously. This indicates that the input current to the main trans-
former has exceeded preset limits.

a. To check if the output is shorted, measure the resistance by putting the ohmmeter leads (make sure to
disconnect HI Frequency leads):”+” of the meter to Torch “+” output terminal and Work “-” lead of the meter
to the “-” output terminal. Reading should be about 2 K Ohms. Reverse the voltmeter leads, the resistance
reading should be less than 1.5 K Ohms.
b. If the resistance reading is different than above, check the torch, the output bridge and Filter Board (PCB-
5).

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

1. Check the pilot arc fuse located on the rear panel. If it is open, nothing will happen when the torch switch is
depressed.

2. Check the torch. Make sure the heat shield is very tight.

3. Check to assure high frequency is present at the torch. If not, then listen for high frequency at the high frequency
generator. It is located on the bottom/right side of the unit. The high frequency gap is set to .040". Disconnect HI
FREQUENCY leads. Check for 115 volt supply to the high frequency unit between P2-12 & P2-13 of the control
board with torch switch closed.

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

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

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

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

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

approx. 325 VDC for the 208/230 volt unit.

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

If not, one of following could be malfunctioning:

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

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

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

e. IGBTs (2 on 230 V, and 1 on the 400 V & 460 V units) may be blown. See IGBT installation procedure. Before
replacing IGBTs, make sure to check the zener diodes and pico fuses on the IGBT driver boards.

23
SECTION 5 TROUBLESHOOTING

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

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

2. Check the torch. Replace consumables if necessary.

3. Make sure the current setting potentiometer is set above 10 amps. If it is, set below 10 amps, then HI FRE-
QUENCY will go on and off at 5 sec intervals.

G. Poor Cutting Performance.

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

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

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

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

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

H. Air does not shut off.

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

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

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

I. Main arc is difficult to start.

1. The most common reason is worn or missing consumables. Check and replace if necessary.
2. Input air must be clean and dry.
3. Input air pressure must be between 65 - 75 psig.
4. Torch connections must be tight.
5. Work cable and clamp must be in good condition and must make a good electrical connection to the material to
be cut.
6. If above items check OK , the problem is internal. send unit to an Authorized Repair Station for repair.
a. Missing or weak pilot arc. Check pilot arc fuse, open circuit voltage, pilot arc resistors and pilot arc wiring.
b. Inoperative starter board (PCB-5).

24
SECTION 5 TROUBLESHOOTING

5.3REFERENCE VOLTAGE CHECKS

A. Control Board Assembly (PCB1)

1. LED’s

LED-1 - Torch Switch

LED-2 - High Frequency
LED-3 - Gas Solenoid Valve

2. Voltage Test Points

Tests are made with power on - no arc.

Disable High Frequency by disconnecting blue wire with black sleeve

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

50 µsec
40 usec - LPG50
50 usec - LPG80
13 vdc

6 usec - LPG50
9 usec - LPG80
-13 vdc

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

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

Figure 5.1 IGBT Gating Signal

25
SECTION 5 TROUBLESHOOTING

5.4 SEQUENCE OF OPERATION

A. TRIGGER LOCK “UNLOCK” position

PUSH RELEASE
TORCH SWITCH

OPEN CLOSE
GAS SOLENOID VALVE

2 SEC. PREFLOW 10 SEC

Postflow

FLOW SWITCH CLOSE OPEN

FAULT OVERLOAD LIGHT

ENERGIZE
HF CIRCUIT

INVERTER

CUTTING ARC (CURRENT)

NOTES:

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

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

26
SECTION 5 TROUBLESHOOTING

B. TRIGGER LOCK "LOCK" position

PUSH RELEASE PUSH RELEASE

TORCH SWITCH

OPEN CLOSE
GAS SOLENOID VALVE PREFLOW
2 SEC. 10 SEC

Postflow

POSTFLOW
CLOSE OPEN
FLOW SWITCH

FAULT LIGHT

ENERGIZE

HF CIRCUIT

INVERTER

CUTTING ARC (CURRENT)

NOTES:

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

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

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

27
 D-36587

28
Figure 5-1. Schematic Diagram, PCM-875, 208/230 V, 50/60 Hz, 1 or 3-Phase
 D-36595

29
Figure 5-2. Wiring Diagram (Sheet 1 of 2), PCM-875, 208/230 V, 50/60 Hz, 1 or 3-Phase
 D-36595

30
Figure 5-3. Wiring Diagram (Sheet 2 of 2), PCM-875, 208/230 V, 50/60 Hz, 1 or 3-Phase
 D-36597-B

31
Figure 5-4. Schematic Diagram, PCM-875, 400/460 V, 50/60 Hz, 3-Phase
 D-36598

32
Figure 5-5. Wiring Diagram (Sheet 1 of 2), PCM-875, 400/460 V, 50/60 Hz, 3-Phase
 D-36598

33
Figure 5-6. Wiring Diagram (Sheet 2 of 2), PCM-875, 400/460 V, 50/60 Hz, 3-Phase
 D-36715-A

34
Figure 5-7. Schematic Diagram, PCM-875, 575 V, 60 Hz, 3-Phase
 D-36716

35
Figure 5-8. Wiring Diagram (Sheet 1 of 2), PCM-875, 575 V, 60 Hz, 3-Phase
 D-36716

36
Figure 5-9. Wiring Diagram (Sheet 2 of 2), PCM-875, 575 V, 60 Hz, 3-Phase
SECTION 6 REPLACEMENT PARTS

6.1 GENERAL Replacement parts may be ordered from your ESAB dis-
tributor or from:
Replacement Parts are illustrated on the following fig-
ures. When ordering replacement parts, order by part ESAB Welding & Cutting Products
number and part name, as illustrated on the figure. Attn: Customer Service Dept.
P.O. Box 100545, 411 S. Ebenezer Road
208/230 V, 50/60 Hz, 1 or 3-phase ............ P/N 36580 Florence, SC 29501-0545
460 V, 50/60 Hz, 3-phase .......................... P/N 36584
575 V, 60 Hz, 3-phase ............................... P/N 36713 Be sure to indicate any special shipping instructions
400 V, 50/60 Hz, 3-phase .......................... P/N 36724 when ordering replacement parts.

Always provide the series or serial number of the unit To order parts by phone, contact ESAB at 1-843-664-
on which the parts will be used. The serial number is 5540. Orders may also be faxed to 1-800-634-7548. Be
stamped on the unit nameplate. sure to indicate any special shipping instructions when
ordering replacement parts.
6.2 ORDERING
Refer to the Communication Guide located on the last
To assure proper operation, it is recommended that only page of this manual for a list of customer service phone
genuine ESAB parts and products be used with this numbers.
equipment. The use of non-ESAB parts may void your
warranty.

37
SECTION 6 REPLACEMENT PARTS

5, 4 3, 4

6 1, 2

8, 9

16

15

8
10, 11

14

12 13

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

Item Qty. Part Circuit

No. Req. No. Description Symbol

1 1 137630611 KNOB
2 1 2062018 POT. 10K 2W (NOMEX INSUL. - 676876) R2
3 1 673213 SWITCH TOGGLE SPST 2 POS 15 A 125 V S2
4 2 951474 SWITCH SEAL BLACK
5 1 634518 SWITCH TOGGLE DPDT 2 POS 15 A 125 V S1
6 1 951754 LAMP LED YEL 12 V PL2
7 1 951526 LAMP NEON WHITE PL1
8 2 993426 GROMMET RUBBER 1.50 ID x 1.76 OD
9 1 21711 GAUGE 1.50 160 PSI WHITE
10 1 23602576 STRAIN RELIEF HEYCO #1214
11 1 680560 WORK CABLE 25 FT. (Not Shown)
12 4 182W12 FOOT RUBBER
13 1 32237GY CHASSIS PCM-875
14 1 36330YL DOOR ACCESS YEL (ESAB)
15 1 954008 LABEL WARNING HI VOLTAGE
16 2 13734588 LABEL ESAB

38
SECTION 6 REPLACEMENT PARTS

28

27 25, 26

25, 26

29, 30 24

31

23
32, 33, 34

22

21

44, 45
35 36 37 38 39 40 41 42 43

Fig. 6-2. PCM-875 Power Source, Left Side View (208/230)

Item Qty. Part Circuit

No. Req. No. Description Symbol

21 1 952150 BRIDGE 60ADC 100NS 600 V (includes PAD - 951192) D1

22 1 952002 CORE SATURABLE L3
23 1 952208 STANDOFF INS. TB3
24 1 36731 BUSBAR NEG
25 2 952237 CAPACITOR 1800 µf 450VDC C1, 2
26 2 994674 GROMMET STRIP
27 2 38052 PCB ASS'Y 1GBT DRIVER BOARD PCB2, 3
28 1 36822 HOSE AY B/A-2X 1/4NPT RUB 2 FT
29 1 36730 BUSBAR POS
30 1 951028 CAPACITOR 1µf 630VDC (Not shown - see wiring) C3
31 1 950487 TERM BLOCK 2 POS TB5
32 1 952235 MODULE INPUT BRIDGE/SCR (includes PAD - 952280) IBR
33 1 2062282 CAPACITOR .22µf 1KV (See wiring) C19
34 3 951321 METAL OXIDE VARISTOR 275 V (See wiring) MOV1, 2, 3
35 2 951205 IGBT 600 V 100 A (includes PAD - 951190) Q1, 2
36 2 17750010 RESISTOR 50 W 10 OHM (PAD - 951194) R7, 10
37 1 32958 CURRENT TRANSFORMER ASS'Y T4
38 1 952255 CAPACITOR 40 µf 400 VDC C4
39 1 950711 THERMAL SWITCH 194°F TS1
40 4 17721020 RESISTOR 24 W 20 OHMS (PAD 951193) R3, 4, 5, 6
41 1 951202 FLOW SWITCH .25 GPM FS
42 2 951940 CAPACITOR 1µf 630W VDC C15, 16
43 1 952558 HEATSINK
44 1 950249 SOL. VALVE 1/4NPT 165 PSI 24 VAC SOL1
45 1 951471 DIODE ZENER 60 V 75 MA (See Wiring) ZD1

39
SECTION 6 REPLACEMENT PARTS

61 60 59 56, 57, 58

56, 57, 58

62

63
55
64, 65, 66 54
53
52

51

67 68 69 70 71 72 73 74 75, 76

Fig. 6-3. PCM-875 Power Source, Left Side View (400/400CE/460/575)

Item Qty. Part Circuit
No. Req. No. Description Symbol
51 1 952150 BRIDGE 60 ADC 100NS 600 V (includes PAD - 951192) D1
52 1 952002 CORE SATURABLE L3
53 1 951800 MODULE DUAL IGBT 150 A, 1200 V
(includes PAD - 951191) Q1
54 1 952208 STANDOFF INS (Not used on 575 V) TB3
55 1 36732 BUSBAR POS
56 2 952237 CAPACITOR 1800µf 450 VDC (400/400CE/460 V) C1, 2
2 952562 CAPACITOR 1800µf 500 VDC (575 V) C2
57 2 994674 GROMMET STRIP
58 2 951028 CAPACITOR 1µf 630 VDC (See wiring) C3, 15
59 1 38099 PCB ASS'Y IGBT DRIVER BOARD PCB2
60 1 951964 CAPACITOR 2µf 800 VDC (400/400CE/460V) C16
1 951892 CAPACITOR 0.68µf 1200 VDC (575 V) C16
61 1 36822 HOSE ASS'Y B/A x 1/4 NPT RUB
62 1 36733 BUSBAR NEG
63 1 950487 TERM BLOCK 2 POS (Not used on 400CE/575 V) TB5
64 1 952235 MODULE INPUT BRIDGE/SCR
(includes PAD - 952280) IBR
65 1 2062282 CAPACITOR .22µf 1KV C19
66 3 950591 METAL OXIDE VARISTOR 510 V (400/400CE/460 V) MOV1, 2, 3
3 951963 METAL OXIDE VARISTOR 625 V (575 V) MOV1, 2, 3
67 2 17750010 RESISTOR 50W 10 OHM (PAD - 951194) R7, 10
68 1 32958 CURRENT TRANSFORMER ASS'Y T4
69 1 952255 CAPACITOR 40µf 400 VDC (400/400CE/460 V) C4
1 952585 CAPACITOR 20µf 600 VDC (575 V) C4
70 1 952253 FILTER EMI (400 V CE only) FN1
71 1 950711 THERMAL SWITCH 194°F TS1
72 4 17721020 RESISTOR 25W 20 OHMS (PAD - 951193) R3, 4, 5, 6
73 1 951202 FLOWSWITCH .25 GPM FS
74 1 952558 HEATSINK
75 1 950249 SOL, VALVE 1/4 NPT 165 PSI 24 VAC SOL1
76 1 951471 DIODE ZENER 60 V 75m A ZD1
40
SECTION 6 REPLACEMENT PARTS
90, 91 86
89 88 87 85

82, 83, 84
92

81

93

80
94

95 101, 102, 103

96 97 104 98, 99 100

Fig. 6-4. PCM-875 Power Source, Right Side View (208/230)

Item Qty. Part Circuit

No. Req. No. Description Symbol

80 1 35940 CONTROL TRANSFORMER ASS'Y T2

81 1 951962 RESISTOR ASS'Y PILOT ARC R11
82 1 952577 RELAY 25 A 120 VAC K1
83 2 952557 CAPACITOR .82µf 630 VDC (See Wiring) C21, 22
84 2 17130310 RESISTOR, 10K OHM 1W (See Wiring) R12, 13
85 1 23604891 LABEL WARNING HI VOLTAGE RED
86 1 952232 INDUCTOR PFC L2
87 1 38108 CONTROL BOARD ASS'Y PCB1
88 1 36586 MAIN TRANSFORMER ASS'Y PCB4
89 2 951469 CAPACITOR .022µf 250 VAC (See Wiring) C17, 18
90 1 31488 SHUNT BOARD ASS'Y PCB4
91 1 951515 CAPACITOR .047µf 660 VAC C23
92 1 38039 START UP BOARD ASS'Y PCB5
93 1 952233 INDUCTOR OUTPUT L1
94 1 36721 BUSBAR OUTPUT
95 1 182W64 LOCK TWIST MIDGET J1
96 1 36717 BRACKET OUTPUT
97 1 32969 REACTOR ASS'Y HI FREQ. T3
98 1 36431 SPARK GAP ASS'Y SG
99 2 951342 CAPACITOR 2500pf 15 K V C13, 14
100 1 951179 TRANSFORMER HI VOLTAGE T5
101 1 950487 TERM. BLOCK 2 POS 20 A TB1
102 2 672348 CAPACITOR .01µf 1KV (See wiring) C11, 12
103 1 952204 CAPACITOR .01µf 250 VAC (See wiring) C9
104 1 36718 BOX HI FREQ.

41
SECTION 6 REPLACEMENT PARTS

119, 120 117 115

118
116

121 112, 113, 114

111
122

123
110

124

125 133
126 134 127, 128 129
130, 131, 132

Fig. 6-5. PCM-875 Power Source, Right Side View (400/400CE/460/575 V)

Item Qty. Part Circuit

No. Req. No. Description Symbol

110 1 32914 CONTROL TRANSFORMER ASS'Y T2

111 1 951962 RESISTOR ASS'Y PILOT ARC R11
112 1 952577 RELAY 25 A 120 VAC K1
113 2 952557 CAPACITOR .82µf 630 VDC (See wiring) C21, 22
114 2 17130310 RESISTOR 10 K OHM 1 W (See wiring) R12, 13
115 1 23604891 LABEL WARNING HI VOLTAGE RED
116 1 38109 CONTROL BOARD ASS'Y PCB1
117 1 36586 MAIN TRANSFORMER ASS'Y (400/400CE/460 V) T1
1 36599 MAIN TRANSFORMER ASS'Y (575 V) T1
118 2 951469 CAPACITOR .022µf 250 VAC (See wiring) C17, 18
119 1 31488 SHUNT BOARD ASS'Y PCB4
120 1 951515 CAPACITOR .047µf 660 VAC C23
121 1 38039 START UP BOARD ASS'Y PCB5
122 1 952233 INDUCTOR OUTPUT L1
123 1 36721 BUSBAR OUTPUT
124 1 182W64 LOCK TWIST MIDJET J1
125 1 36717 BRACKET OUTPUT KYDEX
126 1 32969 REACTOR ASS'Y HI FREQ. T3
127 1 36431 SPARK GAP ASS'Y SG
128 2 951342 CAPACITOR 2500pf 15 K V C13, 14
129 1 951179 TRANSFORMER HI VOLTAGE T5
130 1 950487 TERM. BLOCK 2 POS 20 A TB1
131 2 672348 CAPACITOR .01µf 1KV (See wiring) C11, 12
132 1 952204 CAPACITOR .01µf 250 VAC (See wiring) C9
133 1 952213 REACTOR 3PH LINE 12 A L2
134 1 36718 BOX HI FREQ

42
SECTION 6 REPLACEMENT PARTS
143 142

141

144 145 140

Fig. 6-6. PCM-875 Power Source, Top View with PCB1 and Shelf Removed

Item Qty. Part Circuit

No. Req. No. Description Symbol

140 1 954673 LABEL CNC INTERFACE

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

43
SECTION 6 REPLACEMENT PARTS

154, 155, 156

153
151, 152
157

158, 159

158, 163

160, 161 162

Fig. 6-7. PCM-875 Power Source, Rear View

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

151 1 21710 FILTER REGULATOR

152 1 10Z30 ADAPTOR B/A-WM x 1/4 NPTM
153 2 951575 HANDLE
154 1 36719YL TOP COVER YEL (ESAB)
155 1 2091514 LABEL WARNING
156 1 954290 LABEL WARNING
157 1 954666 LABEL RATING PCM-875 208/230
1 954667 LABEL RATING PCM-875 400/460
1 954668 LABEL RATING PCM-875 575
1 954669 LABEL RATING PCM-875 400CE
158 2 952136 FUSE HOLDER
159 1 952137 FUSE 15 A FAST ACTING F2
160 1 97W63 STRAIN RELIEF
161 1 36823 INPUT POWER CABLE, 10 FT 4-COND. 6AWG (208/230 V)
1 35587 INPUT POWER CABLE, 10 FT 4-COND. 10AWG (400/460/575 V)
1 35582 INPUT POWER CABLE, 10 FT 4-COND. 4 x 4 MM (400 V CE)
162 1 951801 CIRCUIT BREAKER 3P 70 A 250 VAC (208/230 V) CB1
1 951181 CIRCUIT BREAKER 3P 30 A 480 VAC (400/460 V) CB1
1 952046 SWITCH POWER TOGGLE 3PST (575 V) S3
163 1 952559 FUSE 3A FAST ACTING F1

44
SECTION 6 REPLACEMENT PARTS
INSTRUCTION MANUAL CHANGES
The "A" edition (2/98) of this manual covers the following changes:

1. Each replacement IGBT and bridge module now include the appropriate thermal pad.

The "B" edition (9/98) of this manual covers the following changes:

1. Added mechanized cutting installation using PT-20AM torch with the PCM-875.

2. Deleted discontinued L-TEC packages and parts.

The "C" edition (2/02) of this manual covers the following changes:

1. Revises Figure 3-3 to show the changes made to the electrode.

2. Revises Figure 4-1 to show the removal of the Valve Pin which is no longer a part of the PT-27 Torch.

3. The hi frequency gap is changed from "between .027 and .033" to "set to .040". (See page 23, Section E, Step
3).

45
46
47
 ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS:

Order Entry Product Availability Pricing Delivery
Order Changes Saleable Goods Returns Shipping Information

Eastern Distribution Center

Telephone: (800)362-7080 / Fax: (800) 634-7548

Central Distribution Center

Telephone: (800)783-5360 / Fax: (800) 783-5362

Western Distribution Center

Telephone: (800) 235-4012/ Fax: (888) 586-4670

B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693

Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations

C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452

Part Numbers Technical Applications Hours: 8:00 AM to 5:00 PM EST
Performance Features Technical Specifications Equipment Recommendations

D. LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548

Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4487 / Fax: (843) 664-5557

Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST

F. WELDING EQUIPMENT TRAINING:

Telephone: (843)664-4428 / Fax: (843) 679-5864
Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST

G. WELDING PROCESS ASSISTANCE:

Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES:

Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST

IF YOU DO NOT KNOW WHOM TO CALL

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