PCM-500i - ESAB Welding & Cutting Products
Contents
1. PCB3 ke e C1 SS oo c2 E el 1 2 VIO A 22 Ka amp IBR 19 Ti H2 E 3 le TS 07 PCBA 2 BLU Texte c4 2 i SEMEN oi m s 002 ER 01 51 3 I E Cio H es 55 BP qi IC 9 EJ P sg 4 75 2 ORN 1 1 8 SL 2 n zl 8 ER i PI R7 1 au c4 Ss RED 6 11 2 P2 14 070 TOPUPCBI P5 3 _ P2 11 P5 4 YEL 9 WHT 01 3 BRN De lt F110 WHT P2 4 ORN D xs 0281 Pi 5 BLU PCBI P2 1 ORN PCBT 6 BLU s VIEW C C 1 5 2 BLK TP 1 5 1 CLR TP 1 53 STANDARD 400V UNITS LEFT SIDE VIEW TOP AND BOTTOM Hac IBR R BLU _ 1 1 GRY x Ha e H2rj Hig Fi 1 RED x T5 H2 BLK 1 P2 13 BLU 15 0 0 4 gt SHUNT e 4 2 sl d amp 1 01 2 1 5 8 0 3 I2. P1 P2 P5 P6 1 151 1 1 pm 1 Ji 1 CLR 52 1 2 14 2 VO 2 SOLI 1 WHT 2 Ji 2 BIK T 2 52 2 BLU 3 7 58 BRN 5 SOLI 2 5 pm YE 3 4 T2 X10 BRN 3 4 5 4 pm wje 5 7255 BLU 4 T2 X8 OR 5 PL2 5 6 12506 BLU 4 8 2 6 P2 7 4 5 IBR G 0 P6 108LK 7 8 2 188 BN 7 8 72 3 WHT 7 8 8 10 T22 WHT 9 9 11 FS 1 RED 9 10 10 PCBA 5 TP 12 Si 4 10 4 5 6 T2 x11 12 11 PCB4 4 RED 1 Hi YEL 12 Ri 1 BRN 12 mi au 18 Ri 3 RED 12 2 WHT 18 81 2 13 14 PLi 2 YEL 14 T2 X12 0 F1 BRN INPUT POWER CABLE BLU RED 2 1 1 2 IBR T BLK kum GRY BLK Figure 3 6 Wiring Diagram PCM 500i 380 415 Vac 50 60 Hz 3 Phase Sheet 1 of 2 NOTES 1 DENOTES SELF LEADS 0 D 36524 D Sheet 2 FN1 LOAD C BLK FNI LOAD BLK FNI LOAD A S do ALL OTHER CONNECTIONS REMAIN THE SAME FOR CE MARKED UNITS ONLY CE MARKED UNITS T2 H4 BLU 4 ASTON TERMINAL PINK FEMALE P N 950906 PCB4 SHUNT P6 10 PCBS 1 1 RED VIEW
3. C4 16 20UF 400VDC R7 10 OHM SOW T ALALALA 2 fie alt 4 Mes 21 _ 20 25 20 259 at T4 Figure 3 5 Schematic Diagram PCM 500i 380 415 Vac 50 60 Hz 3 Phase 61 D 36524 D Sheet 1 YEL 2 11 YEL PCBI 2 14 Ru d 5 5 RED P5 6 BLK 1 12 kafe 6 6 BLU 2 B PCBi P6 13 RED P6 14 WHT 1 P6 12 2 5 51 R1 7 GND2 Jt SHIELD es 5 5 o s j l LE PS PCBI SEE CHART 5 PR P2 Li H2 BLK PCBS 7 1 PCBA 1 RED E o Th RED n 1 11 RED FS 2 ee PI 2BKXK T SPLICE 181 1 x E o 8 B4 g n x 8 8 STANDARD 400V UNITS 2K L2 CH2 BLK Gan ce MARKED UNITS X L2 AH2 n ONLY 83 ALL OTHER CONNECTIONS REMAIN THE SAME CE MARKED UNITS GRN YEL 77 GND1 DETAIL A
4. 7 14 1 ORN IR G YEL P6 10BLK 7 8 174 2 ORN 7 8 9 WHT 8 8 DA WHT 9 9 FS 1 RED 10 10 PCB4A 3 TP 51 4 BK n P5 6 Dm 12 11 PCB4 4 RED TP 12 RI 1 BRN 1 1 13 81 3 RED 14 81 2 WHT TBi 2 2 T2 Ki2 12 RED 12 4 1 1 2 eX IBR T BLK 2 ger 1 BLK BRN BLU INPUT POWER CABLE Figure 3 4 Wiring Diagram PCM 500i 220 Vac 50 60 Hz 3 Phase Sheet 1 of 2 NOTES 1 DENOTES SELF LEADS ZI D 36531 D Sheet 2 e z i 1 d sp 5 2 RI 2 P2 14 110 TOP PCI P5 3 YEL m rz eps Eis i d 12 epia P2 LO o PCB1 P2 4 ORN D gs 15 1 BLK i 1 2 1 ORN FOR 200 VAC INPUT ii db A 8 1 6 o 3 l EN LEAD FROM 8 5 D D REVERSE T1 X2 amp T1 X3 LEADS H a m dorm In VIEW B B __ VIEW CL P N 950906 AND BOTTOM 1 5 2 BLK TP 5 1 CL
5. 5001 CJ a PLASMA CUTTING CONSOLE POWER SOURCES with CE Compliances 220 V 50 Hz 1 Phase 220 V 50 Hz 3 Phase 400 V 50 Hz 3 Phase Service Manual 558000 891 9712 WELDING AND CUTTING BE INJURIOUS TO YOURSELF AND OTHERS TAKE PRECAU TIONS WHEN WELDING ASK FOR YOUR EMPLOYER S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANUFACTURERS HAZARD DATA ELECTRIC SHOCK Can kill Install and earth the welding unit in accordance with applicable standards Donottouch live electrical parts or electrodes with bare skin wet gloves or wet clothing e Insulate yourself from earth and the workpiece e Ensure your working stance is safe FUMES AND GASES Can be dangerous to health e Keep your head out of the fumes e Use ventilation extraction at the arc or both to keep fumes and gases from your breathing zone and the general area ARC RAYS Can injure eyes and burn skin e Protect your eyes body Use the correct welding screen and filter lens and wear protective clothing e Protect bystanders with suitable screens or curtains FIRE HAZARD e Sparks spatter can cause fire Make sure therefore that there are no inflammable materials nearby NOISE Excessive noise can damage hearing e Protect your ears Use ear defenders or other hearing protection e Warn bystanders of the risk MALFUNCTION Call for exp
6. B ie UC d BLK e 56 1 RED le H2 B2 RED Lu TORCH x TI D RIGHT SIDE VIEW Figure 3 6 Wiring Diagram PCM 500i 380 415 Vac 50 60 Hz 3 Phase Sheet 2 of 2 SECTION 4 4 1 GENERAL Replacement Parts are illustrated on the following fig ures When ordering replacement parts order by part number and part name as illustrated on the figure Always provide the series or serial number of the unit on which the parts will be used The serial number is stamped on the unit nameplate 21 REPLACEMENT PARTS 4 2 ORDERING To assure proper operation itis recommended that only genuine ESAB parts and products be used with this equipment The use of non ESAB parts may void your warranty SECTION 4 REPLACEMENT PARTS CURRENT CONTROL 2 3 12 14 Ss 19 E 10 1 3 d Figure 4 1 Front View PCM 500i 558000590 CHASSIS 558000372 POTENTIOMETER 10K 2W 558000373 KNOB 558000591 COVER TOP 558000562 WARNING LABEL 558000592 HANDLE Screws and Lockwashers included 558000385 SWITCH TOGGLE DPDT 2POS 15A 558000384 LAMP WHITE 558000383 LAMP YELLOW 558000593 GROMMET 1 5 ID 558000594 GAUGE PRESSURE 558000698 SWITCH TOGGLE SPST 2 POS 15A 558000178 STRAIN RELIEF 5580
7. C4 zz oor ikv 3 ki P N 38092 2500 pris 1182 2 iC 4 1 2530 diu 20 400 0 20 01 H j TORCH 10 OHM 50W DU b az 2 Ro Re 6 H2 x 1 1 O1UF IKV 20 25W 20 25W 01UF 1KV Figure 3 3 Schematic Diagram PCM 500i 220 Vac 50 60 Hz 3 Phase 91 D 36531 D Sheet 1 YEL 2 11 YEL 2 14 sa PCB P5 5 RED 9 PCB 5 6 BLK 4 P6 1 52 LU 6 1 P6 13 RED 6 14 DI J1 SHIELD 5i P4 PCBI SEE CHART s P6 P2 o o L1 H2 BLK PCBS 6 Bk n JBR R ko m 188 5 xe ax mer PCBA 1 RED ED cy POL 1 11 RED xe FS RED 1 5 RED 2 1 2 BLK SPLICE 181 1 5 A Ime z 7 2 86 cj GRN YEL DND DETAIL A P1 P2 P5 P6 1 151 1 Du ORN 1 1 52 1 BW 2 151 2 vio SOLI 1 WHT 2 2 BLK 2 52 2 3 10 58 BRN SOLI 2 GRY 3 pn YE 3 4 2 10 BRN 8 5 lun YL 4 5 12 5 BU 2 ORN 5 PL2 WIR 6 T2 X6 51 2 ORN 6 aal
8. F1 2 1 Lu 5 5011 SOLENOID SWITCH GAS TS1 THERMAL SWITCH 80 C 3A 600VAC CONTROL BOARD 6 01 IGBT MODULE 1200V 75 PCB3 IGBT DRIVER BOARD PL2 PILOT LIGHT LED 127 91 RECEPTACLE 2 POLE Zeg An 43 TEST JACK 151 SWITCH PUSHBUTTON SPDT 120V 10A L3 INDUCTOR R15 10K 20W R2 C15 3 1 uF 7 74 CURRENT TRANSFORMER 630 04 630VDC C2 2100044 C1 10 8 SH SHUNT BOARD 4 HIGH VOLTAGE IGNITER d wg PCB1 400VDC 400VDC CONTROL BOARD 9 Tt TRANSFORMER 01 DIODE MOD 60A 600V 100NS P1 2 P N 38087 LI INDUCTOR PCBS START UP P C BOARD 15 REACTOR ASSY P3 3 P3 4 PCB3 P5 1 P N 38099 L3 al 17 l 022UF 1 GEN TORCH SWITCH 250V 2 C184 SHIELD 5 2 2 12 115 VAC 7 RED O1UF 250 VAC C R5 1216 C8 DT 4 SH OTUF IKV 20 254 20 259 5 0 1 C13 C14 2500 15 P N 38092 2500 PF TSKV be UNIT ONLY H2 H1 oouF
9. i NOTES 1 Whenthetorch switch is pushed during postflow period the postflow and preflow times are canceled and the HF is energized immediately 2 When the amber 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 CL D 36704 B 208 230 VAC 50 60 Hz Wi C20 T2 D P N 958247 F1 xj 9 S T Dei a ACI ca C25 gnat p gm d e 18V 3 5 Dig R M 12 Tos sz E A d R15 60K 126 xi P2 5 R2 m 12 Ww 3 1 83090 is 5 1 LC moren 4 RI C2 10000645000 4 10K 2W MEET le He cow B TSI 600V 2 poc p PA 5 6 fi 2 2 2 O J P N 3801 mi BK 1 1 SH P N 31488 39K 2W C10 O O1UF 1KV 2 VW 4 1 200F 400VDC 2 pO T4 10 OHM 50W 2 H2 x x8 9 X10 20V amp 1 CONTROL BO
10. H2 X2 11 Ze 5 12 02 SG 1 RED iq 8 8 4 TORCH X e 1 C2E1 RED LT K E JN 5 LEFT SIDE VIEW 5 RIGHT SIDE VIEW eS amp ISO Figure 3 2 Wiring Diagram PCM 500i 220 Vac 50 60 Hz 1 Phase Sheet 2 of 2 S D 36530 D CB1 1 CIRCUIT BREAKER 20A 480V 1 FAN MOTOR T2 CONTROL TRANSFORMER 9 FILTER 12 3 PHASE UNE REACTOR Ae 2 F1 FUSE FAST ACTING 952217 PLI PILOT LIGHT 1257 1 E BRIDGE DIODE MODULE 40A 1600V 51 SWITCH TOGGLE AR CHECK 2 X5 X7 x9 FS FLOW SWITCH Fi co 4 52 SWITCH TOGGLE LOCK IN 3A600VAC R1 POTENTIOMETER 10K 2W P2 3 4 5 1087 MODULE 600v 50 lev 24 eov H 1 43 2 CRT DRVER BOARD i Ba 751 THERMAL SWITCH 80 C p E rest el gy 5011 SOLENOID SWITCH GAS S
11. Schematic Diagram PCM 500i 220 Vac 50 60 Hz 1 Phase SHIELD l D 36703 B Sheet 1 DETAIL A P1 P2 P5 P6 J1 SHIELD 1 vo 1 7 0 om nu 1 ai 2 14 2 2 5 1 2 J1 2 2 52 2 1 99 BRN 3 SOLI 2 GRY 3 pn 5 4 2 10 BRN 3 51 5 4 T2 x2 5 0 5 BU 4 T2 X8 ORN 5 PL2 RD 5 9 5 6 T2 X6 BU 4 51 2 6 PL2 6 FTH P o 7 ou ORN 5 88 6 YEL BK 7 2 6 BR 7 8 9 T 3 WHT 7 8 8 5 10 12 X4 WHT 8 9 9 M RED 9 10 10 PCB4 3 TP 9 SEE CHART 2 12 51 4 Bk 10 11 T2 X11 12 11 PCB4 4 RED TP ui YEL 12 RI 1 BRN 12 81 1 15 RI 3 RED P2 12 14 2 WHT P6 15 181 2 13 14 2 YEL 14 T2 Xi2 VIO x U T amp amp 5 Si S Lt H2 BLK gd 77 5 B1 N 3 5 5 FNI UNE
12. min at 5 5 bar Dimensions of PCM 500i Weight less torch work cable Duty cycle is based on a 10 minute period therefore a 40 duty cycle means the machine may operate for 4 minutes with a cool down period of 6 minutes a 60 duty cycle means the machine may operate for 6 minutes with a cool down period of 4 minutes a 100 duty cycle means the machine may operate continuously Includes 56 mm high handle SECTION 2 2 1 GENERAL A FTN If this equipment does not operate properly stop work immediately and investigate the cause of the malfunction Maintenance work must be performed by an experienced person and electrical work by a trainedelectrician Do not permit untrained persons to inspect clean or repair this equipment Use only recommended replacement parts AP Be sure that the wall disconnect switch or wall circuit breaker is open before attempting any in spection or work inside of the PCM 500i 2 2 INSPECTION AND CLEANING Frequent inspection and cleaning of the PCM 500i is recommended for safety and proper operation Some suggestions for inspecting and cleaning are as follows A Check work cable to workpiece connection 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 wear on a daily basis Remove spatter or replace if necessary E Make sure cable and
13. 00596 SWITCH SEAL 558000552 FOOT 558000597 ACCESS DOOR 558000536 WARNING LABEL 558000132 LABEL 558000599 WARNING LABEL HI VOLTAGE 1 1 1 1 1 1 1 1 1 2 1 1 1 2 4 1 1 2 1 22 SECTION 4 REPLACEMENT PARTS 42 41 39 32 33 34 51 Figure 4 2 Right Side View PCM 500i ITEM QTY ied NO REQ DESCRIPTION 558000467 HI VOLTAGE TRANSFORMER 558000600 TERMINAL BLOCK 2 POS 558000601 CAPACITOR 0 1uf 250 558000602 CAPACITOR 0 01uf 1 KV C11 C12 558000603 SNAP BUSHING 558000604 CONTROL TRANSFORMER T2 558000388 FAN AC AXIAL M1 558000605 AIR LINE FILTER REGULATOR 558000606 INDUCTOR POWER FACTOR CORRECTION L2 558000584 GROMMET 63 ID 558000607 MAIN TRANSFORMER T1 558000406 INDUCTOR OUTPUT L1 558000608 WORK CABLE 25 FT includes CLAMP 13730862 558000380 RECEPTACLE TWIST LOCK MIDGET 558000609 OUTPUT TERMINAL BOARD 558000523 ADAPTOR B A 1 4 NPTM BULKHEAD 558000403 REACTOR HI FREQ 558000610 SPARK GAP ASS Y includes 2 POINT 32931 STANDOFF 558000611 CAPACITOR 250097 15 KV 558000612 396 3 PH LINE REACTOR 8A PH 400 V 558000613 1 596 3 PH LINE REACTOR 12A PH 220 V 3 PH 558000521 CAPACITOR 0 047uf 660 V 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 Not shown See Wiring Diagram for location 23 REPLACEMENT PARTS i mE c qe y NET x e IN DEES ij 78 76 Pi 79 84 SECTION 4 67 71 67 65 66 UN 65 66 EIS Zah
14. 41199 8 RCB1 2 4 ORN Dy xs 8155 BLU T5 H1 X o H7 2 1 DIU s PCI 1 6 B wel HL RED CHG IBR R LEAD FROM 9 oi CHASSIS 1 teen Tes 5 a 0 0 REVERSE T1 X2 T1 X3 LEADS 1 a Di H H v VIEW C C VIEW B B SEIEN TOP AND BOTTOM P3 1234 12 3 4 PCBS 8 TY R16 R17 a 1 i P5 1 CLR TP J 4 4 X e i 01 1 BK 02 C2E1 DEO 8 x m ar 5 o Droe B U 2 T1 H1 xt H21 0 PCBA 2 BLU d Dm id XDi 3 BK gut a Si EN 185 e D I 02 a i 2 g g n L g ORK Foal em E C25 e E D SCL A i E a g 14 81201 5 CU at _jORN Is 5 n TB R A EL i 4 Li
15. ARD P N 38086 1 1 O1UF IKV 20 25 20 25 43 gy lo 6 577 52 Y 701 75 CIRCUIT BREAKER 1PH 40A 277 FAN MOTOR 230 VAC CONTROL TRANSFORMER FILTER FUSE 600 FAST ACTING PILOT LICHT 1257 IBR BRIDGE DIODE MODULE 40A 1600V 51 SWITCH TOGGLE AIR CHECK FLOW SWITCH POWER FACTOR CORRECTION INDUCTOR SWITCH TOGGLE LOCK IN Ri POTENTIOMETER 10K 2W 01 IGBT MODULE 600V 50 be IGBT DRIVER BOARD THERMAL SWITCH 80 C 5011 SOLENOID SWITCH GAS 1 CONTROL BOARD PL2 PILOT LIGHT LED_12VDC MODULE 600V 50 IGBT DRIVER BOARD RECEPTACLE 2 POLE INDUCTOR TERMINAL BOARD TIE POINT SHUNT P C BOARD PCB4 HIGH VOLTAGE IGNITER START UP P C BOARD SPARK MAIN TRANSFORMER BRIDGE 60 ADC 100 600V TIE POINT 10 OUTPUT INDUCTOR REACTOR ASSY CURRENT TRANSFORMER LC17 Goar 250VAC A LSU A L3 3 7729 TORCH SWITCH 2010 250 VAC 9 DIE Cle our Ile 1 Hieeseetz C1 4 2800 Aer 4762 TB1 2 14 2500 PF 15KV Figure 3 1
16. C Fi 1 D Q Bn CBi 3 HEI 2 BH an L1 us RED D 4X 10032 Gelee 1E PCB4 1 RED S m 3 1 2 IBR T n P5 5 RED 2081 4 FNI UNE C20R11 E e 5 6 p ROB P111 RED RED 2 1 12 5 He ics 2 81 2 5 2 GRY P2 3 SPLICE TBi 1 P2 4 51 F BLU Bk RN 6 1 BLU x H 52 P6 8 518 D z GRN YEL P6 13 RED x s i n n n 9 jw 218 77 6 14 WE RI Ki A PLP N R E B E J 5 2 5 NOTES z 1 DENOTES SELF LEADS Figure 3 2 Wiring Diagram PCM 500i 220 Vac 50 60 Hz 1 Phase Sheet 1 of 2 vL D 36703 B Sheet 2 L 1 H H e H S H H A E 185 n o 8 B H H H up gk BH H e H T2 H3 GRY 3 Au 2 PCB4 _ H 1 _ SHUNT 129 PCB P2 14 VIO X 13 5 YEL mn ma HU 15 2 os o Put 9 5 YEL 105 2 GRY x 1 P2 13 BLU d m um 1 P1 9 WHT a c PI S BRN WHT 5 1 ETE
17. R TP EE Gg BLUE FEMALE WE P N 950907 SHUNT D 5 Xoi 1 rs 1 Q2 C2E mer 28 PT P N A 950904 e 88 E Hi 185 TS 2 4 2 Bi G 2 c d D m Jt BCL x CH NG EI TORCH 50 1 RED LED 2 M mm lou ki TRH m Q1 C2E RED Ch Bi LEFT SIDE VIEW RIGHT SIDE VIEW Figure 3 4 Wiring Diagram PCM 500i 220 Vac 50 60 Hz 3 Phase Sheet 2 of 2 81 0 36339 1 1 CIRCUIT BREAKER 20A 480VAC M1 FAN MOTOR D EMC FILTER 12 3 PHASE LINE REACTOR FN1 EMI FILTER 400V MARKING 952217 2 PL1 PILOT LIGHT 125V UNIT ONLY F1 FUSE 3A 600 FAST ACTING T2 CONTROL TRANSFORMER 230V H4 400V SW1 SWITCH TOGGLE AIR CHECK 9 MOV MOV l IBR BRIDGE DIODE MODULE 3PH 40A 1600 1 4 FS FLOW SWITCH 580 415 50 60 HZ SW2 SWITCH TOGGLE LOCK IN 3 PH R1 POTENTIOMETER 10K 2W
18. UN 4 H 6 FS CONTROL BOARD 22UF IKV T LA 4 Li Y H PL2 PILOT LIGHT LED 12 0 a 2 a lt f DE 1 R2 A SOCIN eia 4 6 02 IGBT MODULE 600V 50A LCS 630 d FS PCB2 PCBS 1087 DRVER BOARD at H Ci t 10000 4500 J1 RECEPTACLE 2 POLE U2 j 1000040 C 13 INDUCTOR 1 50K 12W i _ 1 6 1 7 1 TERMINAL BOARD R17 50K 12W P6 13 i 52 PONT 52 P6 14 P6 e P6 12 H 8 5 SHUNT BOARD PCB4 P2 2 ke HIGH VOLTAGE IGNTER START UP BOARD is sot a SG SPARK GV 9 T1 MAN TRANSFORMER CUNTRUL BOARD pa 3 4 D1 BRIDGE 60 0 100ns 6007 FEE PONT P N 38086 Pus 10 OUTPUT INDUCTOR T3 REACTOR ASSY T4 CURRENT TRANSFORMER ES JUMPER BLK 38014 P3 1 P3 3 A 1 P3 4 t E 4 5222 17 3 M TORCH SWITCH 4 1 0220 P N 3801 4 et 250VAC 022UF P1 7 SHIELD Se Sc is 250VAC 7 G et E i 02 ES Be eee 5 cp a RED BLK 600v 1 1 1 2 SEEE NM 220v 183 C1177 612 util o E WORK I C7 R5 LP C8 5 el C MY Ye ce 1 R9 3 Fa TT SH 1 2 a 20254 20 250 Akv SG r E 5 CiPE C14 2500 9
19. den PCB5 TERMINAL LUG GROUND hidden GND1 558000628 EMI FILTER FN1 558000629 VARISTOR METAL OXIDE 510 400 V MOV 1 2 3 2 1 2 1 2 1 1 2 1 1 1 2 1 1 1 1 4 1 1 1 1 1 1 3 25 SECTION 4 REPLACEMENT PARTS Rear View Top View Figure 4 4 Top and Rear View PCM 500i ITEM QTY PART CIRCUIT NO REQ NO DESCRIPTION SYMBOL 558000584 GROMMET 0 63 ID 558000585 CAPACITOR 0 22uf 250 VAC 558000396 PC BOARD SHUNT 558000586 PC BOARD ASS Y CONTROL 220 V 558000587 PC BOARD ASS Y CONTROL 400 V 558000534 ADAPTOR AIR WATER 558000588 CIRCUIT BREAKER 40 A 220 v 1 ph 558000589 CIRCUIT BREAKER 20 A 3 PH 558000686 FUSE 3A 600VAC FAST ACTING 558000537 STRAIN RELIEF 558000620 CABLE INPUT POWER 10 FT 558000516 FUSE HOLDER sch sch S AN 26 27 ES AB ESAB Welding amp Cutting Products PO Box 100545 Florence SC 29501 0545 F 15 423 12 97 Printed in U S A
20. ert assistance in the event of malfunction READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING PROTECT YOURSELF AND OTHERS TABLE OF CONTENTS SECTION 1 e Nell Lean 3 SECTION 2 Gre A General Inspection amp Cleaning Flow Switch SECTIONS IROUBEESHBHOOTIN eed rta ett nnd t e ca e odit 5 Troubleshooting Trouble Shooting Guide Sequence of Operation Schematic and Wire Diagrams SECTION 4 REPLACEMENT PARTS rtr nete re eene purus 22 A Maintenance and Repair work should be performed by an experienced person and electrical work only by a trained electrician Do not permit untrained persons to inspect clean or repair equipment Use only recommended replacement parts For installation and operation instructions see 558000 879 F 15 417 2 SECTION 1 SPECIFICATIONS Table 1 1 PCM 500i Specifications 4096 Duty Cycle 35 120 V dc 6096 Duty Cycle 30 120 V dc 100 Duty Cycle 22 A 120 V dc Output Current Range 10 to 35 Amperes Open Circuit Voltage 265 V dc Nominal Rated Pri inus 200 VAC 1 Phase 30 25 A 50 60 Hz ja Mpu 220 VAC 3 Phase 14 A Phase 50 60 Hz 3P A E 120 VDE Opu 380 415 VAC 3 Phase 8 7 5 A Phase 50 60 Hz Power Factor 35 Amperes Output 81 1 94 3 Phase Rated Output Efficiency 35 Amperes Output 90 Typical Current Capacity PT 31XL 50 ADCSP Air Requirements PT 31XL 120l
21. hoses are not damaged or kinked F Make sure all fittings and ground connections are tight A rl 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 500i MAINTENANCE H With all input power disconnected and wearing proper eye andface protection blow outthe inside of the PCM 500i using low pressure dry com pressed air 2 3 FLOW SWITCH FIGURE 2 1 When excessive contamination is found in the air the flow switch FS should be removed disassembled and cleaned as follows A Ensure the system is shut down and there is no trapped air under pressure in the piping B Remove the piston plug C Remove the spring FS 4 only Use care when handling spring to prevent distortion D Remove the piston Clean all parts with cleaning agent NOTE Ensure cleaning agent does not contain solvents which can degrade polysulfone Warm water and detergent is recommended for cleaning Allow all parts to dry thoroughly before reassembly Reassemble the flow switch in reverse order AS PISTON PLUG IN PISTON SPRING FLOW SWITCH Figure 2 1 Disassembly Assembly of Flow Switch SECTION 3 3 1 TROUBLESHOOTING APE ELECTRIC SHOCK KILL Be sure that all pri mary power to the machine has been externally disconnected Openthe line wall disconnect switch or circuit breaker before attempting inspection o
22. l _ Ert Or el m Eat ji _ 2 4 HE 62 __ HH E EMI 61 220 V 1 Phase Power Source illustrated 24 SECTION 4 REPLACEMENT PARTS Figure 4 3 Left Side View PCM 500i ITEM QTY PART CIRCUIT NO REQ NO DESCRIPTION SYMBOL 558000405 CAPACITOR O 01uF 1KV C5 6 7 8 10 SNAP BUSHING 558000614 HEATSINK GROMMET 2 12 ID 558000615 CAPACITOR 1000uf 400 VDC C1 C2 558000616 RESISTOR 50K 12W 220 V R2 558000578 RESISTOR 10K 20W 400 V R2 R15 558000617 IGBT 50 A 600 V PAD 951190 220 V Q1 Q2 558000618 DUAL MODULE IGBT 75 A 1200 V includes PAD 951190 400 V Q1 558000494 PC BOARD IGBT DRIVER 220 V PCB2 PCB3 558000619 PC BOARD IGBT DRIVER 400 V PCB3 BUSBAR 230 V BUSBAR 400 V 558000556 CAPACITOR 1uf 600 VDC 220 V C15 C16 558000621 CAPACITOR 5uf 1200 VDC 400 V C22 CAPACITOR 1 630 VDC 220 V C3 CAPACITOR 1 630 VDC 400 V C3 C15 558000709 THERMAL SWITCH D T 176 15 A 120 V 558000622 CAPACITOR 0 22uf 1KV 558000623 MODULE INPUT BRIDGE 50 includes PAD 951191 558000400 RESISTOR 50 W 10 OHM PAD 951194 558000408 CURRENT TRANSFORMER 558000469 CAPACITOR 20uf 400 VDC 558000624 RESISTOR 39K 2 W 558000410 FLOW SWITCH 0 25 GPM SPST 558000404 RESISTOR 20 OHM 25 W PAD 951193 558000409 SOLENOID VALVE 1 4 NPT 24 VAC 558000625 ZENER DIODE 60 V 75 mA 558000626 OUTPUT BRIDGE MODULE includes PAD 951192 558000627 PC BOARD ASSY S START UP hid
23. r 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 secure terminal connections loose or burned wiring or components bulged or leaking capacitors or any other sign of damage or discoloration The cause of control malfunctions can be found by 3 2 TROUBLESHOOTING GUIDE A Difficult Starting e Change electrode Change nozzle TROUBLESHOOTING referring to the sequence of operations and electrical schematic diagram Figure 3 1 and checking the vari ous components A volt ohmmeter will be necessary for some of these checks A ETT Voltages in plasma cutting equipment are high enoughto cause serious injury or possibly death Be particularly careful around equipment when the cov ers are removed NOTE Before checking voltages in the circuit disconnect the power from the high frequency generator to avoid dam aging your voltmeter e Check for good clean connection of work lead to workpiece e Check air pressure 4 5 5 2 bar e Check torch power cable for continuity Depress torch switch After 2 seconds is there a pilot arc Repair power source RM o No Repair replace high frequency unit SECTION 3 NoAir Is air hose connec
24. ted MEN Yes Is air adjusted to 4 5 5 2 bar Yes Does air come on with air check switch Yes No Check continuity of torch switch OK Repair power source TROUBLESHOOTING Connect Adjust No electrode in torch No valve pin in torch Replace electrode Replace valve pin Replace torch switch SECTION 3 TROUBLESHOOTING C Air does not shut off Is air check switch OFF Yes 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 500i power switch is OFF Yes No Replace Repair power solenoid valve source SECTION 3 TROUBLESHOOTING D White Power light not energized Is main 220 or 400 volt switch ON Yes No Turn on main disconnect Is plug in receptacle Yes No Insert plug in receptacle Is cooling fan turning No Replace pilot light Yes Check voltage at receptacle and input power line Yes No Check main fuses Faulty power switch on PCM 500i SECTION 3 TROUBLESHOOTING E Amber FAULT light ON Is the unit overheated Fault lights turns off when Unit cools down Is air flowing Duty cycle exceeded 40 35 A 60 30 A Yes No or 100 22 A output Section 3 2 B Is input voltage within 15 of units input ra
25. ting Yes No e Fault light will energize if input voltage goes below or above 15 of units input rating The light will not turn OFF even when correct voltage is restored Reset by placing PCM 500i power switch OFF and then ON again NOTE When in LOCK IN mode the FAULT light will turn on during second trigger This does not affect performance Turn off SECTION 3 TROUBLESHOOTING 3 3 SEQUENCE OF OPERATION A LOCK IN OFF position PUSH RELEASE TORCH SWITCH 1 a a f CLOSE GAS SOLENOID VALVE ES i PREFLOW l i0SEC i Postflow FLOW SWITCH 5 OREN t 1 FAULT OVERLOAD LIGHT 1 i LI L i RGIZE HF CIRCUIT INVERTER _ CUTTING ARC CURRENT i 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 amber fault pilot light comes on cutting operation should be stopped The postflow time starts from the moment the torch switch is released 10 SECTION 3 TROUBLESHOOTING B LOCK IN ON position 1 PUSH RELEASE PUSH RELEASE TORCH SWITCH OPEN CLOS GAS SOLENOID VALVE PREFLOW 2 SEC 1 10 SEC jp Postflow po POSTF OW CLOSE open FLOW SWITCH 1 1 FAULT PILOT LIGHT ENERGIZE l HF CIRCUIT INVERTER
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