F-14-483-A

MAINTENANCE, TROUBLESHOOTING, March, 2003

and PARTS INFORMATION for
PCM-100 & PCM-150 CONSOLES
This booklet is intended as a supplement to Form F-14-471 (PCM-100) and F-14-474 (PCM-150) which covers the
installation and operating details on these Plasma Arc Cutting Packages. It is recommended to have booklet F-14-
471 or F-14-474 on hand when repairing this equipment.

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. Be sure to read the Safety Precautions on page 2 before repair-
ing this equipment.

Ser. No. ___________________________________ Date of Purchase ___________________________

SPECIFICATIONS PCM-100 Console PCM-150 Console
Input Voltage .......................................... 208/230/460 V, 60 Hz, 3 Phase 230/460/575 V 60 Hz, 3 Phase
Input Current @ rated load ..................... 84/75/37 Amps 112/56/45 Amps
Output Rating (duty cycle %) .................. 100A (@ 100%); 120V DCSP 140A (@ 100%); 150A (@90%)
120V DCSP
Open Circuit Voltage (Nom.) .................. 370 V DC 370 V DC
Power Factor ......................................... 53% 54%
Weight ................................................... 660 lbs (300 kg) 660 lbs (300 kg)
Dimensions ........................................... (31 1/2" (800mm) High x 21 3/4" (552mm) Wide x 32" (813mm) long

Note the high open circuit voltage. Use only torches designed for this equipment. Do
NOT attempt to use this equipment with any process other than plasma arc cutting.
VOLT-AMPERE CURVES
PCM-100 PCM-150
F-14-483-A

VOLTS

VOLTS

AMPERES AMPERES

Be sure this information reaches the operator.

You can get extra copies through your supplier.
D-30822

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Fig. 4 - Wiring Diagram, PCM-100 Console, pg. 1
D-30862

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Fig. 4A - Wiring Diagram, PCM-150 Console, pg. 1
D-30822

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Fig. 4B - Wiring Diagram, PCM-100/150 Console, pg. 2
 VIII. REPLACEMENT PARTS
1. All replacement parts are keyed on the illustrations which follow. Order replacement parts by part number and part
name, as shown on illustrations. DO NOT ORDER BY PART NUMBER ALONE.
2. Always state the series or serial number of the machine on which the parts are to be used. The serial number is
stamped on the unit nameplate.
For maintenance and parts information on the PT-17A and PT-121 torches, see Form 14-441 and 12-794, respectively.

RUBBER MAT - 680797 POTENTIOMETER (CCP) - 639541

KNOB - 950814
TOP PANEL (METAL) - 30846
BOARD ASSY. (SLBD) - 675488
TOP PANEL (PLASTIC) - 680718
PANEL, SILKSCREENED -
30128 (PCM-100)
30986 (PCM-150)

SWITCH (ROS) - 951038

AMMETER (AM) - 950796

SWITCH (OSS) - 950812

GROMMET - 950518

RIGHT SIDE PANEL - 30848

LEFT SIDE PANEL - 30847

FRONT PANEL - 30836 (PCM-100)

OUTPUT TERMINAL ASSY. - 30863 (PCM-150)
676701

DANGER DECAL - 953932

Fig. 5 - Front View - PCM-100 Console - P/N 30820/PCM-150 Console - P/N 31587
INDUCTOR (IND) - 30855 LEFT BAFFLE (PCM-150) - 31545
includes THERMAL SWITCH (INDTS1) - 2062211

CONTACTOR (MC) - 950840 (PCM-150)

950420 (PCM-100)

FAN MOTOR (FM) - 2062301 FILTER NETWORK - 30878

(See Fig. 10)
FAN BLADES - 672058
BRIDGE ASSY. - 680379
(See Fig. 9)
FAN SHROUD - 672002

STRAIN RELIEF - 950219 FILTER BOARD ASSY. (FBD1) -

674970
SHUNT ASSY. -
REAR PANEL - 30838 30857 (PCM-100)
30920 (PCM-150)
TERMINAL BOARD (TB)
- 30827 (PCM-100) TRANSFORMER (CTR) - 680381
680911 (PCM-150) (2) CAPACITOR (C29, 30) - 672348
CAPACITOR (C26) - 950702

GROUND LUG (GND1) 647361 (4) RESISTOR (R20, 21, 30, 31)-
17300008

CAPACITOR (C23) - 950702

TRANSFORMER (MTR) includes

- 30823 (PCM-100) (3) THERMAL SWITCH (MTRTS1, 2, 3) - 2062211 CAPACITOR (C22) - 672348
- 30833 (PCM-150) (2) FUSE, 250V, 150A - 673905

Fig. 6 - PCM-100/150 Console (Left Side View)

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 CAPACITOR
(C25) - 993539

CAPACITOR (C13) - BOARD ASSY.

950702 (CBD) - 674935

DIODE ASSY.
(D5, 6) - 31099
PCM-100 ONLY TERM. BLOCK (T1)-673168

BOARD ASSY. (LBD)-675369

RESISTOR (R28) -
17130310

RELAY (FSR) -
950760

VIEW A-A

RIGHT BAFFLE (PCM-150) - 31544

A A SOL VALVE (PGSV) - 950249
À
À
F.G. CONNECTION - 3390
HI-FREQ. ASSY. DUST CAP 86W41
(See Fig. 8)
PRESS SWITCH (PGPS) -
993991

I.G. CONNECTION - 74S76

DUST CAP - 639582
FLOW SWITCH (FS) - 950761
RESISTOR (R27) - 17140147

I.G. CONNECTION - 74S76

DUST CAP - 639582
CONTACTOR (PAC) - 950247
RESISTOR (R26) - 17140147

SOL. VALVE (CGSV) - 950419

(2) CAPACITOR (C17, 19) - 672772
RESISTOR (R22) - 17130422
OXY. CONNECTION - 3389
DUST PLUG - 86W40

PRESS SWITCH (CGPS) -

(2) CAPACITOR (C27, 28) - 950702 993991
(9) CAPACITOR (C1-9) - 950255
(9) RESISTOR (R1-9) - 17120433

BOARD ASSY. (D/R BD) -

CAPACITOR (C24) - 6355782 675483

Fig. 7 - PCM-100/150 Console (Right Side View)

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05/2003