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ESAB PCM-500i User Manual

ESAB PCM-500i
40 pages
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INSTRUCTION MANUAL
PCM-500i
PLASMA ARC CUTTING PACKAGES
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and
safe practices for arc welding equipment, we urge you to read our booklet, "Precautions and Safe Practices for Arc
Welding, Cutting, and Gouging," Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this
equipment. Do NOT attempt to install or operate this equipment until you have read and 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.
F-15-296-E
Feb., 2004
This manual provides complete instructions for the following PCM-500i cutting packages starting with Serial No. PORI612001:
ESAB P/N 36314 - 208/230 V, 1-Phase, 50/60 Hz
ESAB P/N 36316 - 400 V (380/415 V), 3-Phase, 50/60 Hz
Be sure this information reaches the operator.
You can get extra copies through your supplier.
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ESAB PCM-500i Specifications

General IconGeneral
Input Frequency50/60 Hz
Rated Input Current16 A
Efficiency85 %
Power Factor0.93
Protection ClassIP23
Control TypeDigital
Open Circuit Voltage70 V
Input Voltage400 V

Summary

User Responsibility

Safety Precautions

Protect Yourself and Others

Personal protective measures against arc rays, noise, and burns.

Fire and Explosion Prevention

Safety guidelines to prevent fires and explosions during cutting operations.

Electrical Shock Hazards

Critical warnings and procedures to prevent electrical shock.

Electric and Magnetic Field Safety

Information on EMF exposure effects and mitigation strategies.

Fumes and Gases Safety

Precautions for safe handling of fumes and gases during cutting.

Cylinder Handling Safety

Safe practices for the handling of compressed gas cylinders.

Equipment Maintenance Safety

Safety requirements for performing maintenance on the cutting equipment.

Additional Safety Information

References to further safety publications and resources.

Meaning of Hazard Symbols

Explanation of warning symbols used throughout the manual.

Description and Specifications

PCM-500i Overview

General description and purpose of the PCM-500i plasma cutting system.

Available Cutting Packages

Details on the different PCM-500i package configurations.

Technical Specifications

Comprehensive technical data and performance metrics of the PCM-500i.

Optional Accessories

Listing of optional accessories available for the PCM-500i.

Installation Procedures

General Installation Guidelines

General recommendations for satisfactory and trouble-free installation.

Required Equipment for Setup

List of essential equipment needed for installation.

Installation Location Requirements

Guidelines for choosing an appropriate location for the unit.

Inspection Before Installation

Procedures for inspecting the unit for damage upon receipt.

Primary Electrical Input Connections

Step-by-step instructions for connecting primary electrical power.

Secondary (Output) Connections

Instructions for connecting the torch and work cable to the unit.

Configuring for 208 Vac Input

Specific steps to reconfigure the unit for 208 Vac input power.

Operation and Techniques

General Operation and Safety

Basic operational procedures and associated safety warnings.

PCM-500i Control Functions

Detailed explanation of each control on the PCM-500i unit.

Assembling PT-31XL Consumables

Guide on how to assemble the PT-31XL torch consumable parts.

Cutting with the PT-31XL Torch

Instructions for performing plasma cutting using the PT-31XL torch.

Operating Techniques: Piercing and Grate Cutting

Techniques for piercing materials and grate cutting operations.

Common Cutting Problems and Solutions

Identification and resolution of common cutting issues.

Maintenance and Troubleshooting

General Maintenance Procedures

General recommendations for maintaining the PCM-500i.

Inspection and Cleaning

Routine inspection and cleaning tasks for the unit.

Flow Switch Maintenance

Steps for disassembling, cleaning, and reassembling the flow switch.

Troubleshooting Difficult Starting

Steps to diagnose and resolve issues with starting the plasma arc.

Troubleshooting No Air Supply

Steps to diagnose and resolve problems related to air supply.

Troubleshooting Air Shut-Off Issues

Steps to diagnose and resolve problems with air flow not shutting off.

Troubleshooting Power Light Issues

Steps to diagnose and resolve issues with the power indicator light.

Troubleshooting Amber Fault Light

Steps to diagnose and resolve conditions causing the amber fault light.

Sequence of Operation: Lock-In Modes

Diagrams illustrating operation sequences for Lock-In modes.

Replacement Parts and Ordering

General Replacement Parts Information

Guidance on identifying and ordering replacement parts.

How to Order Replacement Parts

Procedures, contact information, and recommendations for ordering parts.

Customer Support and Communications

Customer Service Contact Information

Directory of contacts for various customer service inquiries.

Engineering and Technical Support

Contact points for engineering, technical assistance, and repairs.

Literature and Training Requests

Contacts for obtaining manuals, documentation, and training information.

Process and Consumables Assistance

Contacts for assistance with welding processes and consumables.

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