Valid from Serial NO 35952, 35954
35959, 35961
0455 602 001 GB 970212
LPG 50
PCM 1000i
101103105107109111102021110025108024042106023061104022041100020040060001
Bruksanvisning
Brugsanvisning
Bruksanvisning
Kätyttöohjeet
Instruction manual
Betriebsanweisung
Manuel d’instructions
Gebruiksaanwijzing
Instrucciones de uso
Istruzioni per l’uso
Manual de instruções
Ïóçãßåò÷ñÞóåùò
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Rätt till ändring av specifikationer utan avisering förbehålles.
Ret til ændring af specifikationer uden varsel forbeholdes.
Rett til å endre spesifikasjoner uten varsel forbeholdes.
Oikeudet muutoksiin pidätetään.
Rights reserved to alter specifications without notice.
Änderungen vorbehalten.
Sous réserve de modifications sans avis préalable.
Recht op wijzigingen zonder voorafgaande mededeling voorbehouden.
Reservado el derecho de cambiar las especificaciones sin previo aviso.
Specifiche senza preavviso.
Reservamo--nos o direito de alterar as especificações sem aviso prévio.
Äéáôçñåßôáé ôï äéêáßùìá ôñïðïðïßçóçò ðñïäéáãñáöþí ×ùñßò ðñïåéäïðïßçóç.
SVENSKA 3..............................................
DANSK 12................................................
NORSK 21................................................
SUOMI 30................................................
ENGLISH 39..............................................
DEUTSCH 48.............................................
FRANÇAIS 57.............................................
NEDERLANDS 66.........................................
ESPAÑOL 75..............................................
ITALIANO 84..............................................
PORTUGUÊS 93..........................................
ÅËËÇÍÉÊÁ 102.............................................
ENGLISH
TOCe
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1 DIRECTIVE 40........................................................
2SAFETY 40...........................................................
3 INTRODUCTION 41...................................................
3.1 Technical data 41............................................................
3.2 Delivery specification LPG 50 42...............................................
3.3 Delivery specification PCM 1000i 42............................................
4 INSTALLATION 43....................................................
5 OPERATION 45.......................................................
5.1 Cutting with the PT27 torch 45.................................................
5.2 Hole cutting 46...............................................................
5.3 Common cutting problems 46..................................................
6 ORDERING OF SPARE PARTS 47......................................
SPARE PARTS LIST 130................................................
DIAGRAM 166.........................................................
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1 DIRECTIVE
DECLARATION OF CONFORMITY
Esab Welding Equipment AB, 695 81 Laxå, Sweden, gives its unreserved guarantee
that plasma cutting equipment LPG 50 / PCM 1000i from serial number 35952,
35954, 35959, 35961 complies with standard EN 50192, in accordance with the re-
quirements of directive (73/23/EEA) and addendum (93/68/EEA), and standard EN
50199, in accordance with the requirements of directive (89/336/EEA) and adden-
dum (93/68/EEA).
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Paul Karlsson
Managing Director
Esab Welding Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 12336
Laxå 97--02--11
2SAFETY
WARNING
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
ARC WELDING AND CUTTING CAN 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
S Install and earth the welding unit in accordance with applicable standards.
S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
S Insulate yourself from earth and the workpiece.
S Ensure your working stance is safe.
FUMES AND GASES -- Can be dangerous to health
S Keep your head out of the fumes.
S 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.
S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
S Protect bystanders with suitable screens or curtains.
FIRE HAZARD
S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE -- Excessive noise can damage hearing
S Protect your ears. Use ear defenders or other hearing protection.
S Warn bystanders of the risk.
MALFUNCTION -- Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
GB
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3 INTRODUCTION
NB!
This manual is intended for personnel with experience of plasma cutting. The oper-
ator using the cutting equipment must always be aware of the risks and safety re -
gulations that this process entails.
National safety regulations for plasma cutting are generally recommended.
Unauthorised personnel are not permitted to install, use or service the equipment. It
is important that the following instructions are read and properly understood before
the equipment is installed and used.
In the event of uncertainty please contact ESAB Sverige AB or your nearest agent.
3.1 Technical data
LPG 50 PCM 1000i
Mains power supply 350Hz Π50 Hz Π50 Hz Π50 Hz
Input Voltage 230 V 400/415 V 230 V 400/415 V
Input Current 22 A 12 A 30 A 18 A
Fuse, slow 30 A 20 A 50 A 30 A
Setting range 10--50 A 10--50 A 10--80 A 10--80 A
Permitted load
40% 50 A 50 A
60% 40 A 40 A 80 A 80 A
100% 30 A 30 A 60 A 60 A
Cable area* 4x4 mm@ 4x2.5 mm@ 4x6 mm@ 4x4 m m@
Current regulator Stepless Stepless
Open circuit voltage, DC 265 V 275 V
Conversion efficiency 89% 89%
Power factor 79% 83%
Air consumption at 4 bar 118 l/min 118 l/min
Protection class IP 23 IP 23
Dimensions l x w x h 475 x 300 x 450 mm 750 x 300 x 530 mm
--without hoses 475 x 225 x 450 mm 750 x 225 x 530 mm
Weight 22 kg 36 kg
*Mains cable area according to Swedish regulations.
The IP code denotes the protection class, i.e. the level of protection against penetra -
tion by solid objects and water.
Equipment marked IP 23 is designed for u se indoors and outdoors.
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3.2 Delivery specification LPG 50
Description Order. no. Qty.
Power supply LPG 50,
230 V 3--phase 558 000--445......................
Power supply LPG 50,
400/415 V 3--phase 558 000--358...................
LPG--50 with cutter PT 27, 75_, 8 m consists of:
Power supply LPG 50
Cutting torch PT 27, 75_, 8 m 558 000--487..........
Earth lead and clamp, 8 m 558 000--360.............
Cutting nozzle 50 A 558 000--363 4................... ..........
Electrode 558 000--364 3............................ ..........
Gas diffuser 558 000--365 1......................... ..........
Protective cone (blue) 558 000--366 2................ ..........
Cutting support 558 000--367 1...................... ..........
Locking ring 558 000--368 1......................... ..........
3.3 Delivery specification PCM 1000i
Description Order. no. Qty.
Power supply PCM 1000i,
230 V 3--phase 558 000--452......................
Power supply PCM 1000i,
400/415 V 3--phase 558 000--455...................
PCM 1000i with cutter PT 27, 75_, 8 m consists of:
Power supply PCM 1000i
Cutting torch PT 27, 75_, 8 m 558 000--487..........
Earth lead and clamp, 8 m 558 000--360.............
Cutting nozzle 50 A 558 000--363 4................... ..........
Cutting nozzle 80 A 558 000--457 4................... ..........
Electrode 558 000--364 3............................ ..........
Gas diffuser 558 000--365 1......................... ..........
Protective cone (blue) 558 000--366 2................ ..........
Cutting support 558 000--367 1...................... ..........
Locking ring 558 000--368 1......................... ..........
GB
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4 INSTALLATION
WARNING
This product is intended for industrial use. In a domestic environment this prod -
uct may cause radio interference. It is the users responsibility to take adequate
precautions.
LPG 50 / PCM 1000i is delivered with 3 m mains cable.
The power supply is connected to a wall socket with isolator and fuses (see techni-
cal data). Extension cables between the wall socket and the power supply should
consist of four insulated wires (3 phases and earth), dimensions (see technical data).
1. Compressed air connection 8. Hold function
(max 10 bar) 9. Current regulation
2. Air regulator and filter 10. Override connection
(set to 4,3 bar) 11. Pilot arc connection
3. Air hose 12. Air connection
4. Main power switch 13.Earth connection
5. Lamp white on/off 14.Safety cut--out
6. Lamp warning
7. Air test
1
2
3
4
5
6
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10
11
12
13
14
COMPRESSED AIR
Always use clean and dry compressed air, do not connect the unit to outlets with mist
lubrication. The air pressure from the compressor or outlet is set to 5 bar and may
under no conditions exceed 10 bar which is the maximum working pressure for the
power supply’s air regulator.
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S Main power switch: IN the ON position the lamp shines white indicating that
the auxillary circuits and the cooling fan are in operation.
S Current regulation: Stepless from 10--50 A/10--80 A.
S Switch--air test: In the ON position the air pressure can be set (4,3 bar) be -
fore cutting. Let the air flow through for several minutes to ensure that any
condensation that may have gathered during a period of little or no flow is
blown clear. Check that the switch is in the OFF position before cutting
starts.
S Switch--hold function: In the ON position the operator can release the cut-
ting switch once the cutting arc has started. To stop cutting the operator must
press and release the cutting switch once more (4--stroke). In the OF F posi-
tion the operator must keep the cutting switch depressed during the whole
cutting operation and release it to stop cutting. (2--stroke).
S Lamp--warning: If the lamp lights only when you press the cutting switch,
one of the following faults has occurred.
-- Overheating, thermo guard activated (open).
-- Duty factor exceeded, 50A/40% (10 min) / 80A/60% (10 min).
-- Primary over current, faulty power supply.
-- Low pressure (flow), flow guard not activated, air not connected.
S The lamp lights as soon as the machine is switched on:
-- Over/under voltage on the mains <360 eller >460 V.
Connection of work lead
GB
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5OPERATION
LPG 50 / PCM 1000i are portable plasma cutting equipment ready to use once con-
nected to power and air supply.
NB!
Position the power supply at least 3 m away from the cutting area. Sparks and
hot slag products can damage the power supply.
WARNING!
The plasma cutting equipment operates with high open circuit voltages. Only
use the original cutter torch PT27. Do not use the equipment for any other
purpose than plasma cutting.
WARNING!
Touchin g live parts of the cutter can cause loss of life. Always turn the power
supply off before replacing nozzles, electrodes, protective cone etc.
5.1 Cutting with the PT27 torch
1. Hold the torch about 3 m m from the work piece at an angle of 15--30_.Ifthecut-
ting support is used the recommended gap is 1.5 mm for materials under 6 mm
and 4.5 m m for materials over 6 mm.
2. Press in the cutting switch, this starts the air flow and the high frequency current.
3. Two seconds after the cutting switch is pressed the pilot arc is lit. Immediately
after this cutting starts automatically. (If the hold function is activated, 4--stroke,
the cutting switch can be released once the cutting arc has started).
4. Once cutting has started the torch can be righted to vertical. If cutting without the
support a gap of 3 mm between the cutting nozzle and the work piece is recom-
mended.
5. At the end of the cut the cutting switch is released (pressed in and released if the
hold function, 4 stroke, is activated). The torch should be lifted slightly just before
the end of the cut to reduce the risk for twin arcs which can damage the cutting
nozzle. T h is stops the high frequency current from restarting once the cutting arc
has stopped.
6. During the after flow period the cutting arc can be restarted by pressing the cut-
ting switch. The gas flow period of two seconds is automatically bypassed.
GB
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5.2 Hole cutting
1. When cutting holes the torch is angled which prevents molten material from
damaging the cutting nozzle and torch.
2. Once the arc cuts through the material the torch can be righted to vertical and
cutting can commence.
Cuttin
g
s
p
eed’s influence
5.3 Common cutting problems
Listed below are the most common cutting problems and their causes. If the prob -
able cause of the problem is in the power supply and cannot be fixed using the man-
ual contact ESAB Sverige AB or your nearest authorised service workshop.
1. Insufficient cutting penetration
-- Cutting speed too high
-- Worn cutting nozzle
-- Wrong air pressure setting
2. Arc stops during cutting
-- Cutting speed too low
3. Slag accu mulation
(For certain materials and thickness it is impossible to achieve a completely
slag free cut.)
-- Cutting speed too high or too low
-- Wrong air pressure setting
-- Worn cutting nozzle or electrode
4. Twin arc ( cutting nozzle damaged)
-- Air pressure too low
-- Worn cutting nozzle
-- Loose cutting nozzle
-- Large volume of cutting sparks
5. Unstable arc
-- Worn cutting nozzle or electrode
6. Unstable cutting effect
-- Wrong cutting speed
-- Loose cable or hose connections
-- Worn cutting nozzle or electrode
7. Cutting arc does not start
-- Loose cable connections
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8. Consumables wear too quickly
-- Wrong air pressure
-- Impurities in the compressed air
6 ORDERING OF SPARE PARTS
When ordering a spare part, please state the type and serial number of the machine
as well as number of the spare part, according to the spare parts list on page 130.
This will simplify dispatch and ensure you get the right part.
GB
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