Esab PCM-875 Plasma Cutter Troubleshooting
Tue, 31 Aug 2021 09:05:52 GMT
So just tonight I picked up a used, non working 875 from craigslist. The price was just too good to pass up, the consumables it came with and the torch is worth more than what I paid if the machine is total junk! Anyways... I am not familiar with these machines at all. I'm going to start taking it apart tonight and see if there is anything obvious, and am posting to see if anybody has any ideas of what to look for.I need to get another plug for the unit before I can test it, but the gentleman I bought it from said that he used it sparingly, it was working one day and the next it didn't... He said it "starts out sounding fine, like it's in its high frequency start mode, then it never kicks over to start cutting."Any ideas?
Reply:Originally Posted by TBWeldorSo just tonight I picked up a used, non working 875 from craigslist. The price was just too good to pass up, the consumables it came with and the torch is worth more than what I paid if the machine is total junk! Anyways... I am not familiar with these machines at all. I'm going to start taking it apart tonight and see if there is anything obvious, and am posting to see if anybody has any ideas of what to look for.I need to get another plug for the unit before I can test it, but the gentleman I bought it from said that he used it sparingly, it was working one day and the next it didn't... He said it "starts out sounding fine, like it's in its high frequency start mode, then it never kicks over to start cutting."Any ideas?
Reply:875 has a high freq start, and is a inverter too. (IGBT type)Not the correct service manual, but you get the idea.. Look through Esab manuals for the exact one you need..http://www.esabna.com/literature/pla...f-15-424-a.pdfLast edited by Brand X; 12-04-2015 at 12:18 AM.Esab/Lorch ET-220iEsab 160i caddyThermal LM-200 Lincoln feedersThermal Pee-Wee 85sThermal 60i- 3phase /RPC powered (Beast)Thermal Drag-gun 35CINE 1500 Klutch 140i
Reply:Originally Posted by Brand X875 has a high freq start, and is a inverter too. (IGBT type)Not the correct service manual, but you get the idea.. Look through Esab manuals for the exact one you need..http://www.esabna.com/literature/pla...f-15-424-a.pdf
Reply:Sq model.. Just for your info the first blowback torch came on the ESP-50 machine.. It had a power supply based on the 875.. round or Sq, they all are the same IGBT type, with High freq start with pilot arc.. Had a 1125 sq case -70 amp machine, and a round case 1500 also..You can see in the manual it uses the same torch as yours. The rounded models used the PT-32 torch. I believe even on the 60 amp machine.. The older model you could not retro the newer style torch, That is why so many 875, and 1125 have the SL-60/100 thermal dynamics torch on them. The lower power 60 amp machine was not terrible with consumables, if cutting at 50 amps. The 70 amp machine would eat them like candy..Electrodes would about vaporize.. I still thing the older sq machines are good to this day.. I even like the powercut 650 really well.. That's after using most new machines. The tiny torch is king . (IMO)Last edited by Brand X; 12-04-2015 at 12:44 AM.Esab/Lorch ET-220iEsab 160i caddyThermal LM-200 Lincoln feedersThermal Pee-Wee 85sThermal 60i- 3phase /RPC powered (Beast)Thermal Drag-gun 35CINE 1500 Klutch 140i
Reply:Originally Posted by Brand XSq model.. Just for your info the first blowback torch came on the ESP-50 machine.. It had a power supply based on the 875.. round or Sq, they all are the same IGBT type, with High freq start with pilot arc.. Had a 1125 sq case -70 amp machine, and a round case 1500 also..You can see in the manual it uses the same torch as yours. The rounded models used the PT-32 torch. I believe even on the 60 amp machine.. The older model you could not retro the newer style torch, That is why so many 875, and 1125 have the SL-60/100 thermal dynamics torch on them. The lower power 60 amp machine was not terrible with consumables, if cutting at 50 amps. The 70 amp machine would eat them like candy..Electrodes would about vaporize.. I still thing the older sq machines are good to this day.. I even like the powercut 650 really well.. That's after using most new machines. The tiny torch is king . (IMO)
Reply:Originally Posted by Brand XSq model.. Just for your info the first blowback torch came on the ESP-50 machine.. It had a power supply based on the 875.. round or Sq, they all are the same IGBT type, with High freq start with pilot arc.. Had a 1125 sq case -70 amp machine, and a round case 1500 also..You can see in the manual it uses the same torch as yours. The rounded models used the PT-32 torch. I believe even on the 60 amp machine.. The older model you could not retro the newer style torch, That is why so many 875, and 1125 have the SL-60/100 thermal dynamics torch on them. The lower power 60 amp machine was not terrible with consumables, if cutting at 50 amps. The 70 amp machine would eat them like candy..Electrodes would about vaporize.. I still thing the older sq machines are good to this day.. I even like the powercut 650 really well.. That's after using most new machines. The tiny torch is king . (IMO)
Reply:Originally Posted by TBWeldorThank you for the links and information. It is a 60 amp machine, I've taken the cover off and there is nothing glaring... no fried circuits that I can see. I downloaded and printed the manual, man - there sure are a ton of parts in these things! It's pretty dusty inside, so I think I'll clean it out and fire it up tomorrow to see what happens. This may be a very involved troubleshooting... but hey, for $50 I'm willing to spend a good amount of time on it.
Reply:Originally Posted by soutthpawI'd be interested in a couple parts, possibly the torch and consumables I'd you can't fix the thing and want to get your money back on it.
Reply:Before I button it up to test it, and because everybody loves pictures...Well it looks like even if a circuit board is bad that there are companies that will fix them, it just might be difficult to track down exactly what is going on.Anybody have an opinion of how much it's worth putting into? It's an older unit, but from a cursory glance, even if I need to put $500 into it it would be worth it I think.
Reply:So I put a new plug on, hooked the air up and turned it on... and yes it does in fact turn on. It pretty much does everything the previous owner said, the air starts and the pilot arc strikes, but no main arc. According to the manual, it could be something super easy as in something wrong with the torch head, or something major, like a control board... I need to do a couple electrical tests with it plugged in, but here are some pictures of the torch head. It looks dirty to me, what's the best way to clean inside the actual torch head?Also, the flow switch is supposed to come apart to clean the spring inside... however so far I can't get it apart.
Reply:Here is a link to the service manual, if you don't already have it.https://www.google.com/url?sa=t&rct=...qLj23fvD0E1LqAHobart Beta-Mig 250T-D Cutmaster 81Miller Maxstar 150STLMiller T-Bolt 225 ACChicago Electric Mig 151Hobart RC-256 Haas-Kamp Conversion(sold)
Reply:My 875 is the round one (yellow torpedo) but sometimes it does the same thing and I just replace the consumables and it fires right back up. I think it's the PT-32 torch though, very picky. I am glad I don't use the hand torch on it much. I think it's a torch issue, these machines are built pretty tough and your looks in real good shape.ESAB Rebels 215 and 235, ESAB HELIARC 281i, ESAB ET 301i, Hypertherm 85 and 45XP, Thermal Arc 185, TD 60i, HTP PRO PULSE 300
Reply:Originally Posted by TBWeldorSo I put a new plug on, hooked the air up and turned it on... and yes it does in fact turn on. It pretty much does everything the previous owner said, the air starts and the pilot arc strikes, but no main arc. According to the manual, it could be something super easy as in something wrong with the torch head, or something major, like a control board... I need to do a couple electrical tests with it plugged in, but here are some pictures of the torch head. It looks dirty to me, what's the best way to clean inside the actual torch head?Also, the flow switch is supposed to come apart to clean the spring inside... however so far I can't get it apart.
Reply:It'd still hi-freq machine with a pilot arc start. Because it can take a additional arc starter for the machine torch does not change that fact..Esab/Lorch ET-220iEsab 160i caddyThermal LM-200 Lincoln feedersThermal Pee-Wee 85sThermal 60i- 3phase /RPC powered (Beast)Thermal Drag-gun 35CINE 1500 Klutch 140i
Reply:Here is the old and new seat and tool.Tiger Sales: AHP Distributor www.tigersalesco.comAHP200x; AHP 160ST; MM350P, Spoolmatic 30A; Everlast PowerTig 185; Thermal Dynamics 60i plasma. For Sale: Cobra Mig 250 w/ Push-pull gun. Lincoln Wirematic 250
Reply:Originally Posted by Brand XIt'd still hi-freq machine with a pilot arc start. Because it can take a additional arc starter for the machine torch does not change that fact..
Reply:Originally Posted by soutthpawHere is the old and new seat and tool.
Reply:double post...
Reply:Thanks to everyone for helping to get TBWeldor up and running with the ESAB Plasma. Feel free to call our tech services line at 1 800 ESAB 123 to get one of our plasma specialists too if you hit a dead end. In case you cannot get the 875 up and running, we have a $12/amp trade in on ESAB plasmas to purchase a Thermal Dynamics one (trade in value at the lower of the 2). Just something to consider if you have to spend anything considerable to get it fixed. Either way a $50 investment was well worth it, great find!
Reply:Originally Posted by TBWeldorExcellent, thanks for taking the time to take a picture. Do you have a good online source for parts/consumables? Some googling doesn't come up with much, and prices are all over the place. It seems like they think Esab parts are gold plated, and the chinese stuff is, well, chinese stuff, getting 100 pieces for the price of one esab branded sort of thing...
Reply:I never tried the other style electrode with my 1125..(PT-27) I upgraded to the 1500 (PT-32torch) not long after owning the 1125..The China consumables really only work/last in the PT-31XT torches.. on the smaller 30/35/40 amp machines.. My friend did end up with a SL-60 torch on his 1125..(Right off the bat) The Esab is still going strong, and he has my old Thermal 151, and a Hypertherm 85 also.. Can't kill the Esab off if he tried.. He cuts more metal then a 100 average fab guys too....(Roy here knows him too) I think you should fix the 875 if you can reasonably (IMO) it's a powerful true 60 amp machine..Esab/Lorch ET-220iEsab 160i caddyThermal LM-200 Lincoln feedersThermal Pee-Wee 85sThermal 60i- 3phase /RPC powered (Beast)Thermal Drag-gun 35CINE 1500 Klutch 140i
Reply:Originally Posted by Brand XI never tried the other style electrode with my 1125..(PT-27) I upgraded to the 1500 (PT-32torch) not long after owning the 1125..The China consumables really only work/last in the PT-31XT torches.. on the smaller 30/35/40 amp machines.. My friend did end up with a SL-60 torch on his 1125..(Right off the bat) The Esab is still going strong, and he has my old Thermal 151, and a Hypertherm 85 also.. Can't kill the Esab off if he tried.. He cuts more metal then a 100 average fab guys too....(Roy here knows him too) I think you should fix the 875 if you can reasonably (IMO) it's a powerful true 60 amp machine..
Reply:You could probably change out the torch for half that easy. Not that you should, but less $$$ then you think.. The non-ATC torches come up on Ebay once, and a while.. Factory 60 amp Victor tips are not much more then the China Esab stuff.. Bit more, but like $20.00 for ten tips on Ebay.. Just got a batch today.I would not waste my time with aftermarket tips for the Thermal.Esab/Lorch ET-220iEsab 160i caddyThermal LM-200 Lincoln feedersThermal Pee-Wee 85sThermal 60i- 3phase /RPC powered (Beast)Thermal Drag-gun 35CINE 1500 Klutch 140i
Reply:Originally Posted by MrKirby87Thanks to everyone for helping to get TBWeldor up and running with the ESAB Plasma. Feel free to call our tech services line at 1 800 ESAB 123 to get one of our plasma specialists too if you hit a dead end. In case you cannot get the 875 up and running, we have a $12/amp trade in on ESAB plasmas to purchase a Thermal Dynamics one (trade in value at the lower of the 2). Just something to consider if you have to spend anything considerable to get it fixed. Either way a $50 investment was well worth it, great find!Well I called ESAB today and just missed them (darn time zones). I decided to dig a little deeper, as I was baffled that I couldn't see ANYTHING that could give a hint. I took the top Control Board off and took it in my office under really good light, and I couldn't see anything of concern. Back out to the shop to the machine... poking, prodding, peering with a flashlight... wait, what's that? Smoky Residue? (technical term there, right?) it looks like a Power Module might be blown. Quick google and it's readily available at about $120, $55 if I go through Malaysia and Amazon. I'd like to still talk to ESAB to make sure that this isn't a repercussion of a bigger problem, but man... if this is it...
Reply:Sure looks like an IGBT (insulated gate bipolar transistor) failure to me. Often caused by an input line voltage spike. If you are lucky that may be the only issue. Make sure when you replace it that you clean the mounting area well and replace the heat sink grease properly and torque the mounting bolts. Keep us posted!Jim Colt Hypertherm
Reply:I do know in some Esab inverters, Esab recommended replacing other parts (Another board) when the IGBT failed.. That was on a 350 MPI inverter, and might not be true in this case.. It is wise to contact Esab, and it would not hurt to PM. ccawgc at this forum. He is up to date on Esab, along with many more machine brands too..Esab/Lorch ET-220iEsab 160i caddyThermal LM-200 Lincoln feedersThermal Pee-Wee 85sThermal 60i- 3phase /RPC powered (Beast)Thermal Drag-gun 35CINE 1500 Klutch 140i
Reply:[/ATTACH] Originally Posted by jimcoltSure looks like an IGBT (insulated gate bipolar transistor) failure to me. Often caused by an input line voltage spike. If you are lucky that may be the only issue. Make sure when you replace it that you clean the mounting area well and replace the heat sink grease properly and torque the mounting bolts. Keep us posted!Jim Colt Hypertherm
Reply:Maybe an input rectifier?Jim
Reply:I saw the Sanrex, and thought it was a IGBT. Esab/LTec had some Sanrax made plasma's too. The 875 are SC ones.. Attached Imagescvm75bb160_dat.pdf (122.8 KB, 39 views)Esab/Lorch ET-220iEsab 160i caddyThermal LM-200 Lincoln feedersThermal Pee-Wee 85sThermal 60i- 3phase /RPC powered (Beast)Thermal Drag-gun 35CINE 1500 Klutch 140i
Reply:Originally Posted by Brand XI saw the Sanrex, and thought it was a IGBT. Esab/LTec had some Sanrax made plasma's too. The 875 are SC ones..
Reply:Well... no joy. I swapped the part and it's doing the same exact thing. Definitely need to call ESAB now.
Reply:Send me a PM with what this plasma is doing. What tests have been performed.On the line side of the diode assembly there should have been 3 MOVs. They have a bad habit of blowing up when they get old. usually nothing else get damaged. in order for the buss caps to get voltage the resister at the end of the yellow wires must be good. The MOVs can be removed for testing but if left removed the input diode will get damaged.Did you power up this unit and pull the trigger. observed the HF spark gap operating?If so we need to disable the HF, and try to measure the OCV work clamp to electrode and then nozzle. The HF will kill your meter. Send me the PM answer questions, I will give you next steps and how to disable HF.
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