ESAB ESP-1000 Plasmarc System Instruction manual

INSTRUCTION MANUAL

ESP - 1000 PLASMARC SYSTEM

MECHANIZED CUTTING WITH PT-15XL OR PT-19XLS

F15-116-D 07/2007

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

CAUTION

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding and cutting 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.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompa­nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc­tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment
should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme­diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone
or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a ser­vice facility designated by the manufacturer.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

2

TABLE OF CONTENTS

SECTION TITLE PAGE
PARAGRAPH

SAFETY PRECAUTIONS .....................................................................................................................................5

SECTION 1 INTRODUCTION ...................................................................................................................17

1.1 General ................................................................................................................................................................... 17

1.2 Features .................................................................................................................................................................. 17

1.3 Component Description ..................................................................................................................................18

SECTION 2 INSTALLATION ......................................................................................................................23

2.1 General ................................................................................................................................................................... 23

2.2 System Component Location ......................................................................................................................... 23

2.3 System Connections ..........................................................................................................................................24

2.4 Torch Components ............................................................................................................................................. 30

2.5 Installing Air Curtain ..........................................................................................................................................31

2.6 Bubble Muer Installation .............................................................................................................................. 32

2.7 WATER MUFFLER SYSTEM FOR THE PT-19XLS .......................................................................................... 33

2.8 AIR CURTAIN/BUBBLE MUFFLER CONTROL BOX INSTALLATION ........................................................ 33

2.9 WATER INJECTION PUMP .................................................................................................................................33

2.10 INSTALLATION OF THE SECONDARY GAS METERING BOX ...................................................................34

SECTION 3 OPERATION.......................................................................................................................................................... 39

3.1 General ................................................................................................................................................................... 39

3.2 Controls and Indicators .................................................................................................................................... 39

3.3 Pre-Operation Test and Checkout ................................................................................................................41

3.4 Oxygen Cutting with PT-15XL ........................................................................................................................ 44

3.5 Nitrogen Cutting with PT-15XL ......................................................................................................................49

3.6 H-35 Cutting with PT-15XL .............................................................................................................................. 51

3.7 CUTTING WITH THE PT-19XLS and PT-600 TORCHES ............................................................................ 52

3.8 High Current Cutting with PT-19XLS ...........................................................................................................55

PT-19XLS Cutting Tables ................................................................................................................................... 56

3.9 Operating Techniques ....................................................................................................................................... 70

SECTION 4 TROUBLESHOOTING ....................................................................................................................................... 75

4.1 Programmable Logic Controller ....................................................................................................................75

4.2 Sequence Description ....................................................................................................................................... 75

4.3 Operating Information......................................................................................................................................77

4.4 Troubleshooting Guide .................................................................................................................................... 78

3

TABLE OF CONTENTS

4

SAFETY PRECAUTIONS

Safety Precautions

WARNING: These Safety Precautions are
for your protection. They summarize
precautionary information from the

references listed in Additional Safety
Information section. Before performing any instal­lation or operating procedures, be sure to read and
follow the safety precautions listed below as well
as all other manuals, material safety data sheets,
labels, etc. Failure to observe Safety Precautions
can result in injury or death.

PROTECT YOURSELF AND OTHERS -­Some welding, cutting, and gouging
processes are noisy and require ear

protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation and can injure
skin and eyes. Hot metal can cause burns. Training
in the proper use of the processes and equipment
is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in

any work area, even if welding helmets, face
shields, and goggles are also required.

2. Use a face shield tted with the correct lter and

cover plates to protect your eyes, face, neck, and
ears from sparks and rays of the arc when oper­ating or observing operations. Warn bystanders
not to watch the arc and not to expose themselves
to the rays of the electric-arc or hot metal.

3. Wear ameproof gauntlet type gloves, heavy

long-sleeve shirt, cuess trousers, high-topped
shoes, and a welding helmet or cap for hair
protection, to protect against arc rays and hot
sparks or hot metal. A ameproof apron may
also be desirable as protection against radiated
heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cus, or pockets. Sleeves and collars
should be kept buttoned, and open pockets
eliminated from the front of clothing.

5. Protect other personnel from arc rays and hot

sparks with a suitable non-ammable partition
or curtains.

6. Use goggles over safety glasses when chipping

slag or grinding. Chipped slag may be hot and
can y far. Bystanders should also wear goggles
over safety glasses.

Safety - English

FIRES AND EXPLOSIONS -- Heat from
ames and arcs can start res. Hot
slag or sparks can also cause res and
explosions. Therefore:

1. Remove all combustible materials well away from
the work area or cover the materials with a pro­tective non-ammable covering. Combustible
materials include wood, cloth, sawdust, liquid
and gas fuels, solvents, paints and coatings,
paper, etc.

2. Hot sparks or hot metal can fall through cracks
or crevices in oors or wall openings and cause a
hidden smoldering re or res on the oor below.
Make certain that such openings are protected
from hot sparks and metal.“

3. Do not weld, cut or perform other hot work until
the work piece has been completely cleaned so
that there are no substances on the work piece
which might produce ammable or toxic vapors.
Do not do hot work on closed containers. They
may explode.

4. Have re extinguishing equipment handy for
instant use, such as a garden hose, water pail,
sand bucket, or portable re extinguisher. Be
sure you are trained in its use.

5. Do not use equipment beyond its ratings. For
example, overloaded welding cable can overheat
and create a re hazard.

6. After completing operations, inspect the work
area to make certain there are no hot sparks or
hot metal which could cause a later re. Use re
watchers when necessary.

7. For additional information, refer to NFPA Stan­dard 51B, "Fire Prevention in Use of Cutting and
Welding Processes", available from the National
Fire Protection Association, Battery march Park,
Quincy, MA 02269.

ELECTRICAL SHOCK -- Contact with
live electrical parts and ground can
cause severe injury or death. DO

NOT use AC welding current in damp
areas, if movement is conned, or if there is danger
of falling.

5

SAFETY PRECAUTIONS

1. Be sure the power source frame (chassis) is con­nected to the ground system of the input power.

2. Connect the work piece to a good electrical
ground.

3. Connect the work cable to the work piece. A poor
or missing connection can expose you or others
to a fatal shock.

4. Use well-maintained equipment. Replace worn or
damaged cables.

5. Keep everything dry, including clothing, work
area, cables, torch/electrode holder, and power
source.

6. Make sure that all parts of your body are insulated
from work and from ground.

7. Do not stand directly on metal or the earth while
working in tight quarters or a damp area; stand
on dry boards or an insulating platform and wear
rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the
power.

3. Welders should use the following procedures to
minimize exposure to EMF:

A. Route the electrode and work cables together.

Secure them with tape when possible.

B. Never coil the torch or work cable around your

body.

C. Do not place your body between the torch and

work cables. Route cables on the same side of
your body.

D. Connect the work cable to the work piece as close

as possible to the area being welded.

E. Keep welding power source and cables as far

away from your body as possible.

FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in conned spaces. Do
not breathe fumes and gases. Shield­ing gases can cause asphyxiation.

Therefore:

9. Turn o the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on
next page) for specic grounding recommenda­tions. Do not mistake the work lead for a ground
cable.

ELECTRIC AND MAGNETIC FIELDS
— May be dangerous. Electric cur­rent owing through any conduc­tor causes localized Electric and

Magnetic Fields (EMF). Welding and
cutting current creates EMF around welding cables
and welding machines. Therefore:

1. Welders having pacemakers should consult their

physician before welding. EMF may interfere with
some pacemakers.

2. Exposure to EMF may have other health eects which

are unknown.

1. Always provide adequate ventilation in the work area
by natural or mechanical means. Do not weld, cut, or
gouge on materials such as galvanized steel, stain­less steel, copper, zinc, lead, beryllium, or cadmium
unless positive mechanical ventilation is provided.
Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying opera­tions. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly
toxic gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat ir­ritation while operating, this is an indication that
ventilation is not adequate. Stop work and take
necessary steps to improve ventilation in the work
area. Do not continue to operate if physical discom­fort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specic ventilation recommendations.

6

SAFETY PRECAUTIONS

5. WARNING: This product, when used for welding
or cutting, produces fumes or gases
which contain chemicals known to
the State of California to cause birth
defects and, in some cases, cancer.
(California Health & Safety Code

§25249.5 et seq.)

CYLINDER HANDLING -- Cylinders,
if mishandled, can rupture and vio­lently release gas. Sudden rupture
of cylinder, valve, or relief device can
injure or kill. Therefore:

1. Use the proper gas for the process and use the

proper pressure reducing regulator designed to
operate from the compressed gas cylinder. Do not
use adaptors. Maintain hoses and ttings in good
condition. Follow manufacturer's operating instruc­tions for mounting regulator to a compressed gas
cylinder.

1. Always have qualied personnel perform the instal­lation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualied to perform such work.

2. Before performing any maintenance work inside a
power source, disconnect the power source from
the incoming electrical power.

3. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do
not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position
and in good repair.

6. Use equipment only for its intended purpose. Do
not modify it in any manner.

2. Always secure cylinders in an upright position by
chain or strap to suitable hand trucks, undercar­riages, benches, walls, post, or racks. Never secure
cylinders to work tables or xtures where they may
become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not con­nected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and ames.
Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases
in Cylinders", which is available from Compressed
Gas Association, 1235 Jeerson Davis Highway,
Arlington, VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:

ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for

electric arc welding and cutting equip­ment, ask your supplier for a copy of
"Precautions and Safe Practices for Arc
Welding, Cutting and Gouging", Form
52-529.

The following publications, which are available from
the American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"

7

SAFETY PRECAUTIONS

5. AWS C5.5 - "Recommended Practices for Gas Tung­sten Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal
Arc Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Hand­book.

8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."

MEANING OF SYMBOLS - As used
throughout this manual: Means Atten­tion! Be Alert! Your safety is involved.

Means immediate hazards which,
if not avoided, will result in im­mediate, serious personal injury
or loss of life.

Means potential hazards which
could result in personal injury or
loss of life.

Means hazards which could result
in minor personal injury.

8

SEGURIDAD

Safety - Spanish

ADVERTENCIA: Estas Precauciones de
Seguridad son para su protección. Ellas

hacen resumen de información prove­niente de las referencias listadas en la sección
"Información Adicional Sobre La Seguridad". Antes
de hacer cualquier instalación o procedimiento
de operación , asegúrese de leer y seguir las pre­cauciones de seguridad listadas a continuación
así como también todo manual, hoja de datos de
seguridad del material, calcomanias, etc. El no
observar las Precauciones de Seguridad puede
resultar en daño a la persona o muerte.

PROTEJASE USTED Y A LOS DEMAS-­Algunos procesos de soldadura, corte
y ranurado son ruidosos y requiren

protección para los oídos. El arco, como
el sol , emite rayos ultravioleta (UV) y otras radiaciones
que pueden dañar la piel y los ojos. El metal caliente
causa quemaduras. EL entrenamiento en el uso propio
de los equipos y sus procesos es esencial para prevenir
accidentes. Por lo tanto:

1. Utilice gafas de seguridad con protección a los lados

siempre que esté en el área de trabajo, aún cuando
esté usando careta de soldar, protector para su cara
u otro tipo de protección.

2. Use una careta que tenga el ltro correcto y lente

para proteger sus ojos, cara, cuello, y oídos de las
chispas y rayos del arco cuando se esté operando y
observando las operaciones. Alerte a todas las per­sonas cercanas de no mirar el arco y no exponerse a
los rayos del arco eléctrico o el metal fundido.

3. Use guantes de cuero a prueba de fuego, camisa

pesada de mangas largas, pantalón de ruedo liso,
zapato alto al tobillo, y careta de soldar con capucha
para el pelo, para proteger el cuerpo de los rayos y
chispas calientes provenientes del metal fundido. En
ocaciones un delantal a prueba de fuego es necesario
para protegerse del calor radiado y las chispas.

4. Chispas y partículas de metal caliente puede alojarse

en las mangas enrolladas de la camisa , el ruedo del
pantalón o los bolsillos. Mangas y cuellos deberán
mantenerse abotonados, bolsillos al frente de la
camisa deberán ser cerrados o eliminados.

5. Proteja a otras personas de los rayos del arco y chis-

pas calientes con una cortina adecuada no-amable
como división.

6. Use careta protectora además de sus gafas de segu-

ridad cuando esté removiendo escoria o puliendo.

La escoria puede estar caliente y desprenderse
con velocidad. Personas cercanas deberán usar
gafas de seguridad y careta protectora.

FUEGO Y EXPLOSIONES -- El calor de
las amas y el arco pueden ocacionar
fuegos. Escoria caliente y las chispas
pueden causar fuegos y explosiones.
Por lo tanto:

1

. Remueva todo material combustible lejos del área

de trabajo o cubra los materiales con una cobija a
prueba de fuego. Materiales combustibles incluyen
madera, ropa, líquidos y gases amables, solventes,
pinturas, papel, etc.

2. Chispas y partículas de metal pueden introducirse
en las grietas y agujeros de pisos y paredes cau­sando fuegos escondidos en otros niveles o espacios.
Asegúrese de que toda grieta y agujero esté cubierto
para proteger lugares adyacentes contra fuegos.

3. No corte, suelde o haga cualquier otro trabajo rela­cionado hasta que la pieza de trabajo esté totalmente
limpia y libre de substancias que puedan producir
gases inamables o vapores tóxicos. No trabaje den­tro o fuera de contenedores o tanques cerrados. Estos
pueden explotar si contienen vapores inamables.

4. Tenga siempre a la mano equipo extintor de fu­ego para uso instantáneo, como por ejemplo una
manguera con agua, cubeta con agua, cubeta con
arena, o extintor portátil. Asegúrese que usted esta
entrenado para su uso.

5. No use el equipo fuera de su rango de operación. Por
ejemplo, el calor causado por cable sobrecarga en los
cables de soldar pueden ocasionar un fuego.

6. Después de termirar la operación del equipo, inspec­cione el área de trabajo para cerciorarse de que las
chispas o metal caliente ocasionen un fuego más
tarde. Tenga personal asignado para vigilar si es
necesario.

7. Para información adicional , haga referencia a la
publicación NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible
a través de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.

CHOQUE ELECTRICO -- El contacto con
las partes eléctricas energizadas y tierra
puede causar daño severo o muerte.
NO use soldadura de corriente alterna
(AC) en áreas húmedas, de movimiento
connado en lugares estrechos o si hay

posibilidad de caer al suelo.

9

SEGURIDAD

1. Asegúrese de que el chasis de la fuente de poder
esté conectado a tierra através del sistema de
electricidad primario.

2. Conecte la pieza de trabajo a un buen sistema de
tierra física.

3. Conecte el cable de retorno a la pieza de trabajo.
Cables y conductores expuestos o con malas
conexiones pueden exponer al operador u otras
personas a un choque eléctrico fatal.

4. Use el equipo solamente si está en buenas condi­ciones. Reemplaze cables rotos, dañados o con
conductores expuestos.

5. Mantenga todo seco, incluyendo su ropa, el área de
trabajo, los cables, antorchas, pinza del electrodo,
y la fuente de poder.

6. Asegúrese que todas las partes de su cuerpo están
insuladas de ambos, la pieza de trabajo y tierra.

7. No se pare directamente sobre metal o tierra mien­tras trabaja en lugares estrechos o áreas húmedas;
trabaje sobre un pedazo de madera seco o una
plataforma insulada y use zapatos con suela de
goma.

8. Use guantes secos y sin agujeros antes de energizar
el equipo.

9. Apage el equipo antes de quitarse sus guantes.

10. Use como referencia la publicación ANSI/ASC
Standard Z49.1 (listado en la próxima página) para
recomendaciones especícas de como conectar el
equipo a tierra. No confunda el cable de soldar a
la pieza de trabajo con el cable a tierra.

CAMPOS ELECTRICOS Y MAGNETI­COS - Son peligrosos. La corriente
eléctrica uye através de cualquier
conductor causando a nivel local

Campos Eléctricos y Magnéticos
(EMF). Las corrientes en el área de corte y soldadura,
crean EMF alrrededor de los cables de soldar y las
maquinas. Por lo tanto:

1. Soldadores u Operadores que use marca-pasos para

el corazón deberán consultar a su médico antes de
soldar. El Campo Electromagnético (EMF) puede
interferir con algunos marca-pasos.

2. Exponerse a campos electromagnéticos (EMF) puede

causar otros efectos de salud aún desconocidos.

3. Los soldadores deberán usar los siguientes proced­imientos para minimizar exponerse al EMF:

A. Mantenga el electrodo y el cable a la pieza de

trabajo juntos, hasta llegar a la pieza que usted
quiere soldar. Asegúrelos uno junto al otro con
cinta adhesiva cuando sea posible.

B. Nunca envuelva los cables de soldar alrededor

de su cuerpo.

C. Nunca ubique su cuerpo entre la antorcha y el

cable, a la pieza de trabajo. Mantega los cables a
un sólo lado de su cuerpo.

D. Conecte el cable de trabajo a la pieza de trabajo

lo más cercano posible al área de la soldadura.

E. Mantenga la fuente de poder y los cables de soldar

lo más lejos posible de su cuerpo.

HUMO Y GASES -- El humo y los
gases, pueden causar malestar o
daño, particularmente en espacios

sin ventilación. No inhale el humo

o gases. El gas de protección puede
causar falta de oxígeno.
Por lo tanto:

1. Siempre provea ventilación adecuada en el área

de trabajo por medio natural o mecánico. No solde,
corte, o ranure materiales con hierro galvanizado,
acero inoxidable, cobre, zinc, plomo, berílio, o cad­mio a menos que provea ventilación mecánica
positiva . No respire los gases producidos por
estos materiales.

2. No opere cerca de lugares donde se aplique sub-

stancias químicas en aerosol. El calor de los rayos
del arco pueden reaccionar con los vapores de
hidrocarburo clorinado para formar un fosfógeno,
o gas tóxico, y otros irritant es.

3. Si momentáneamente desarrolla inrritación de

ojos, nariz o garganta mientras est á operando, es
indicación de que la ventilación no es apropiada.
Pare de trabajar y tome las medidas necesarias
para mejorar la ventilación en el área de trabajo.
No continúe operando si el malestar físico per­siste.

4. Haga referencia a la publicación ANSI/ASC Standard

Z49.1 (Vea la lista a continuación) para recomen­daciones especícas en la ventilación.

10

SEGURIDAD

5. ADVERTENCIA-- Este producto cuando se uti­liza para soldaduras o cortes,
produce humos o gases, los
cuales contienen químicos
conocidos por el Estado de Cali­fornia de causar defectos en el
nacimiento, o en algunos casos,
Cancer. (California Health &
Safety Code §25249.5 et seq.)

MANEJO DE CILINDROS-- Los

cilindros, si no son manejados
correctamente, pueden romp­erse y liberar violentamente
gases. Rotura repentina del
cilindro, válvula, o válvula de
escape puede causar daño o
muerte. Por lo tanto:

1. Utilize el gas apropiado para el proceso y utilize

un regulador diseñado para operar y reducir la
presión del cilindro de gas . No utilice adapta­dores. Mantenga las mangueras y las conexiones
en buenas condiciones. Observe las instrucciones
de operación del manufacturero para montar el
regulador en el cilindro de gas comprimido.

2. Asegure siempre los cilindros en posición vertical

y amárrelos con una correa o cadena adecuada
para asegurar el cilindro al carro, transportes, tablil­leros, paredes, postes, o armazón. Nunca asegure
los cilindros a la mesa de trabajo o las piezas que
son parte del circuito de soldadura . Este puede ser
parte del circuito elélectrico.

3. Cuando el cilindro no está en uso, mantenga la

válvula del cilindro cerrada. Ponga el capote de
protección sobre la válvula si el regulador no
está conectado. Asegure y mueva los cilindros
utilizando un carro o transporte adecuado. Evite
el manejo brusco de los

1. Siempre tenga personal cualicado para efec­tuar l a instalación, diagnóstico, y mantenimiento
del equipo. No ejecute ningún trabajo eléctrico a
menos que usted esté cualicado para hacer el
trabajo.

2. Antes de dar mantenimiento en el interior de la
fuente de poder, desconecte la fuente de poder
del suministro de electricidad primaria.

3. Mantenga los cables, cable a tierra, conexciones,
cable primario, y cualquier otra fuente de poder
en buen estado operacional. No opere ningún
equipo en malas condiciones.

4. No abuse del equipo y sus accesorios. Mantenga
el equipo lejos de cosas que generen calor como
hornos, también lugares húmedos como charcos
de agua , aceite o grasa, atmósferas corrosivas y
las inclemencias del tiempo.

5. Mantenga todos los artículos de seguridad y
coverturas del equipo en su posición y en buenas
condiciones.

6. Use el equipo sólo para el propósito que fue
diseñado. No modique el equipo en ninguna
manera.

INFORMACION ADICIONAL DE SEGURI­DAD -- Para más información sobre las
prácticas de seguridad de los equipos de
arco eléctrico para soldar y cortar, pregunte
a su suplidor por una copia de "Precautions
and Safe Practices for Arc Welding, Cutting
and Gouging-Form 52-529.

Las siguientes publicaciones, disponibles através de
la American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, son recomendadas para usted:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"

MANTENIMIENTO DEL EQUIPO -- Equipo
defectuoso o mal mantenido puede
causar daño o muerte. Por lo tanto:

3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"

11

SEGURIDAD

SIGNIFICADO DE LOS SIMBOLOS

-- Según usted avanza en la lectura
de este folleto: Los Símbolos Sig­nican ¡Atención! ¡Esté Alerta! Se
trata de su seguridad.

Signica riesgo inmediato que,
de no ser evadido, puede resultar
inmediatamente en serio daño
personal o la muerte.

Signica el riesgo de un peligro
potencial que puede resultar en
serio daño personal o la muerte.

Signica el posible riesgo que
puede resultar en menores daños
a la persona.

12

SÉCURITÉ

Safety - French

AVERTISSEMENT : Ces règles de sécurité
ont pour but d'assurer votre protection.
Ils récapitulent les informations de pré-

caution provenant des références dans
la section des Informations de sécurité supplémen­taires. Avant de procéder à l'installation ou d'utiliser
l'unité, assurez-vous de lire et de suivre les précau­tions de sécurité ci-dessous, dans les manuels, les
ches d'information sur la sécurité du matériel et
sur les étiquettes, etc. Tout défaut d'observer ces
précautions de sécurité peut entraîner des blessures

graves ou mortelles.

PROTÉGEZ-VOUS -- Les processus de

soudage, de coupage et de gougeage
produisent un niveau de bruit élevé et exige l'emploi d'une
protection auditive. L'arc, tout comme le soleil, émet des
rayons ultraviolets en plus d'autre rayons qui peuvent
causer des blessures à la peau et les yeux. Le métal incan­descent peut causer des brûlures. Une formation reliée à
l'usage des processus et de l'équipement est essentielle
pour prévenir les accidents. Par conséquent:

1. Portez des lunettes protectrices munies d'écrans la-

téraux lorsque vous êtes dans l'aire de travail, même
si vous devez porter un casque de soudeur, un écran
facial ou des lunettes étanches.

2. Portez un écran facial muni de verres ltrants et de

plaques protectrices appropriées an de protéger
vos yeux, votre visage, votre cou et vos oreilles des
étincelles et des rayons de l'arc lors d'une opération
ou lorsque vous observez une opération. Avertissez
les personnes se trouvant à proximité de ne pas re­garder l'arc et de ne pas s'exposer aux rayons de l'arc
électrique ou le métal incandescent.

3. Portez des gants ignifugiés à crispin, une chemise

épaisse à manches longues, des pantalons sans rebord
et des chaussures montantes an de vous protéger des
rayons de l'arc, des étincelles et du métal incandescent,
en plus d'un casque de soudeur ou casquette pour
protéger vos cheveux. Il est également recommandé de
porter un tablier ininammable an de vous protéger
des étincelles et de la chaleur par rayonnement.

4. Les étincelles et les projections de métal incandescent

risquent de se loger dans les manches retroussées, les
rebords de pantalons ou les poches. Il est recommandé
de garder boutonnés le col et les manches et de porter
des vêtements sans poches en avant.

5. Protégez toute personne se trouvant à proximité des

étincelles et des rayons de l'arc à l'aide d'un rideau ou
d'une cloison ininammable.

6. Portez des lunettes étanches par dessus vos lunettes de

sécurité lors des opérations d'écaillage ou de meulage
du laitier. Les écailles de laitier incandescent peuvent
être projetées à des distances considérables. Les per­sonnes se trouvant à proximité doivent également
porter des lunettes étanches par dessus leur lunettes
de sécurité.

INCENDIES ET EXPLOSIONS -- La
chaleur provenant des ammes ou de
l'arc peut provoquer un incendie. Le
laitier incandescent ou les étincelles

peuvent également provoquer un

incendie ou une explosion. Par conséquent :

1. Éloignez susamment tous les matériaux combus­tibles de l'aire de travail et recouvrez les matériaux
avec un revêtement protecteur ininammable. Les
matériaux combustibles incluent le bois, les vête­ments, la sciure, le gaz et les liquides combustibles, les
solvants, les peintures et les revêtements, le papier,
etc.

2. Les étincelles et les projections de métal incandescent
peuvent tomber dans les ssures dans les planchers
ou dans les ouvertures des murs et déclencher un
incendie couvant à l'étage inférieur Assurez-vous que
ces ouvertures sont bien protégées des étincelles et
du métal incandescent.

3. N'exécutez pas de soudure, de coupe ou autre tra­vail à chaud avant d'avoir complètement nettoyé la
surface de la pièce à traiter de façon à ce qu'il n'ait
aucune substance présente qui pourrait produire des
vapeurs inammables ou toxiques. N'exécutez pas
de travail à chaud sur des contenants fermés car ces
derniers pourraient exploser.

4. Assurez-vous qu'un équipement d'ex tinction
d'incendie est disponible et prêt à servir, tel qu'un
tuyau d'arrosage, un seau d'eau, un seau de sable
ou un extincteur portatif. Assurez-vous d'être bien
instruit par rapport à l'usage de cet équipement.

5. Assurez-vous de ne pas excéder la capacité de
l'équipement. Par exemple, un câble de soudage sur­chargé peut surchauer et provoquer un incendie.

6. Une fois les opérations terminées, inspectez l'aire de
travail pour assurer qu'aucune étincelle ou projection
de métal incandescent ne risque de provoquer un
incendie ultérieurement. Employez des guetteurs
d'incendie au besoin.

7. Pour obtenir des informations supplémentaires,
consultez le NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible au
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.

CHOC ÉLECTRIQUE -- Le contact avec des
pièces électriques ou les pièces de mise
à la terre sous tension peut causer des
blessures graves ou mortelles. NE PAS
utiliser un courant de soudage c.a. dans
un endroit humide, en espace restreint

ou si un danger de chute se pose.

13

SÉCURITÉ

1. Assurez-vous que le châssis de la source
d'alimentation est branché au système de mise à
la terre de l'alimentation d'entrée.

2. Branchez la pièce à traiter à une bonne mise de
terre électrique.

3. Branchez le câble de masse à la pièce à traiter et
assurez une bonne connexion an d'éviter le risque
de choc électrique mortel.

4. Utilisez toujours un équipement correctement
entretenu. Remplacez les câbles usés ou endom­magés.

5. Veillez à garder votre environnement sec, incluant
les vêtements, l'aire de travail, les câbles, le porte­électrode/torche et la source d'alimentation.

6. Assurez-vous que tout votre corps est bien isolé
de la pièce à traiter et des pièces de la mise à la
terre.

7. Si vous devez eectuer votre travail dans un espace
restreint ou humide, ne tenez vous pas directe­ment sur le métal ou sur la terre; tenez-vous sur
des planches sèches ou une plate-forme isolée et
portez des chaussures à semelles de caoutchouc.

8. Avant de mettre l'équipement sous tension, isolez
vos mains avec des gants secs et sans trous.

9. Mettez l'équipement hors tension avant d'enlever
vos gants.

10. Consultez ANSI/ASC Standard Z49.1 (listé à
la page suivante) pour des recommandations
spéciques concernant les procédures de mise à
la terre. Ne pas confondre le câble de masse avec
le câble de mise à la terre.

CHAMPS ÉLECTRIQUES ET MAGNÉ­TIQUES — comportent un risque de
danger. Le courant électrique qui
passe dans n'importe quel conduc-

teur produit des champs électriques
et magnétiques localisés. Le soudage et le cou­rant de coupage créent des champs électriques
et magnétiques autour des câbles de soudage et
l'équipement. Par conséquent :

1. Un soudeur ayant un stimulateur cardiaque doit

consulter son médecin avant d'entreprendre une
opération de soudage. Les champs électriques et
magnétiques peuvent causer des ennuis pour cer­tains stimulateurs cardiaques.

2. L'exposition à des champs électriques et magné-

tiques peut avoir des eets néfastes inconnus pour
la santé.

3. Les soudeurs doivent suivre les procédures suivantes
pour minimiser l'exposition aux champs électriques
et magnétiques :

A. Acheminez l'électrode et les câbles de masse

ensemble. Fixez-les à l'aide d'une bande adhésive
lorsque possible.

B. Ne jamais enrouler la torche ou le câble de masse

autour de votre corps.

C. Ne jamais vous placer entre la torche et les câbles

de masse. Acheminez tous les câbles sur le même
côté de votre corps.

D. Branchez le câble de masse à la pièce à traiter le

plus près possible de la section à souder.

E. Veillez à garder la source d'alimentation pour le

soudage et les câbles à une distance appropriée
de votre corps.

LES VAPEURS ET LES GAZ -- peuvent
causer un malaise ou des dommages
corporels, plus particulièrement
dans les espaces restreints. Ne re­spirez pas les vapeurs et les gaz. Le
gaz de protection risque de causer
l'asphyxie. Par conséquent :

1. Assurez en permanence une ventilation adéquate
dans l'aire de travail en maintenant une ventila­tion naturelle ou à l'aide de moyens mécanique.
N'effectuez jamais de travaux de soudage, de
coupage ou de gougeage sur des matériaux tels que
l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc,
le plomb, le berylliym ou le cadmium en l'absence
de moyens mécaniques de ventilation ecaces. Ne
respirez pas les vapeurs de ces matériaux.

2. N'eectuez jamais de travaux à proximité d'une
opération de dégraissage ou de pulvérisation. Lor­sque la chaleur

ou le rayonnement de l'arc entre en contact avec les

vapeurs d'hydrocarbure chloré, ceci peut déclencher
la formation de phosgène ou d'autres gaz irritants,
tous extrêmement toxiques.

3. Une irritation momentanée des yeux, du nez ou de la
gorge au cours d'une opération indique que la ven­tilation n'est pas adéquate. Cessez votre travail an
de prendre les mesures nécessaires pour améliorer
la ventilation dans l'aire de travail. Ne poursuivez
pas l'opération si le malaise persiste.

4. Consultez ANSI/ASC Standard Z49.1 (à la page
suivante) pour des recommandations spéciques
concernant la ventilation.

14

SÉCURITÉ

5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé
dans une opération de soudage ou de
coupage, dégage des vapeurs ou des
gaz contenant des chimiques consid­éres par l'état de la Californie comme
étant une cause des malformations
congénitales et dans certains cas, du
cancer. (California Health & Safety
Code §25249.5 et seq.)

MANIPULATION DES CYLINDRES --

La manipulation d'un cylindre, sans
observer les précautions nécessaires,
peut produire des fissures et un

échappement dangereux des gaz.
Une brisure soudaine du cylindre, de la soupape ou
du dispositif de surpression peut causer des bles­sures graves ou mortelles. Par conséquent :

1. Utilisez toujours le gaz prévu pour une opération

et le détendeur approprié conçu pour utilisation
sur les cylindres de gaz comprimé. N'utilisez jamais
d'adaptateur. Maintenez en bon état les tuyaux et
les raccords. Observez les instructions d'opération
du fabricant pour assembler le détendeur sur un
cylindre de gaz comprimé.

2. Fixez les cylindres dans une position verticale, à

l'aide d'une chaîne ou une sangle, sur un chariot
manuel, un châssis de roulement, un banc, un mur,
une colonne ou un support convenable. Ne xez
jamais un cylindre à un poste de travail ou toute autre
dispositif faisant partie d'un circuit électrique.

3. Lorsque les cylindres ne servent pas, gardez les

soupapes fermées. Si le détendeur n'est pas bran­ché, assurez-vous que le bouchon de protection de
la soupape est bien en place. Fixez et déplacez les
cylindres à l'aide d'un chariot manuel approprié.
Toujours manipuler les cylindres avec soin.

4. Placez les cylindres à une distance appropriée

de toute source de chaleur, des étincelles et des
ammes. Ne jamais amorcer l'arc sur un cylindre.

5. Pour de l'information supplémentaire, consultez

CGA Standard P-1, "Precautions for Safe Handling
of Compressed Gases in Cylinders", mis à votre dis­position par le Compressed Gas Association, 1235
Jeerson Davis Highway, Arlington, VA 22202.

ENTRETIEN DE L'ÉQUIPEMENT -- Un équipe­ment entretenu de façon défectueuse ou
inadéquate peut causer des blessures
graves ou mortelles. Par conséquent :

1. Efforcez-vous de toujours confier les tâches
d'installation, de dépannage et d'entretien à un
personnel qualié. N'eectuez aucune réparation
électrique à moins d'être qualié à cet eet.

2. Avant de procéder à une tâche d'entretien à
l'intérieur de la source d'alimentation, débranchez
l'alimentation électrique.

3. Maintenez les câbles, les ls de mise à la terre,
les branchements, le cordon d'alimentation et la
source d'alimentation en bon état. N'utilisez ja­mais un équipement s'il présente une défectuosité
quelconque.

4. N'utilisez pas l'équipement de façon abusive. Gardez
l'équipement à l'écart de toute source de chaleur,
notamment des fours, de l'humidité, des aques
d'eau, de l'huile ou de la graisse, des atmosphères
corrosives et des intempéries.

5. Laissez en place tous les dispositifs de sécurité et
tous les panneaux de la console et maintenez-les
en bon état.

6. Utilisez l'équipement conformément à son usage
prévu et n'eectuez aucune modication.

INFORMATIONS SUPPLÉMENTAIRES RELA­TIVES À LA SÉCURITÉ -- Pour obtenir de
l'information supplémentaire sur les règles
de sécurité à observer pour l'équipement
de soudage à l'arc électrique et le coupage,
demandez un exemplaire du livret "Precau­tions and Safe Practices for Arc Welding,
Cutting and Gouging", Form 52-529.

Les publications suivantes sont également recomman­dées et mises à votre disposition par l'American Welding
Society, 550 N.W. LeJuene Road, Miami, FL 33126 :

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"

15

SÉCURITÉ

SIGNIFICATION DES SYMBOLES
Ce symbole, utilisé partout dans ce manuel,
signie "Attention" ! Soyez vigilant ! Votre
sécurité est en jeu.

DANGER

Signie un danger immédiat. La situation peut
entraîner des blessures graves ou mortelles.

AVERTISSEMENT

Signie un danger potentiel qui peut entraîner des
blessures graves ou mortelles.

ATTENTION

Signie un danger qui peut entraîner des blessures
corporelles mineures.

Additional Safety Information for Mechanized Plasmarc Cutting Systems:

Electrical Shock can kill or cause severe burns. Plasmarc cutting uses DC currents at dangerously high voltages.

• DonottouchthetorchorchangetheconsumablesifinputpowertothePlasmarcpowersourcehasnotbeendiscon­nected.

• Donotstandon,touch,orinanywaycontacttheplatewhilecuttingvoltagesarepresent.

• Theworkpiecemustbeelectricallyconnectedtothepowersourceworkterminalforsafeoperationofthesystem.

• Donotperform maintenanceonanypart of the Plasmarc systemunlessall powerinputshavebeendisconnected

and locked out. This includes 115vac inputs as well as high voltage inputs.

• Troubleshootingrequiringpowertobeonshouldonlybedonebyqualiedpersonnel.

Hydrogen Explosions can cause injury or death.

• Seepage?????.

Fumes and Gases can cause discomfort or death. Do not breath fumes or gases.

• Donotcutcontainersoftoxicmaterialsorcontainersthathaveheldtoxicmaterials.Cleansuchcontainersthorough­ly before cutting.

• Beforecuttingacoatedmaterial,consultwithitsmanufacturerforpropersafetyprecautions.

Noise and Ultraviolet Light

• Thenoiselevelofplasmarccutting can be greater than110dbatadistanceof6feetfromthetorch.Wearproper

hearing protection.

• Reectionofultravioletlightfromareaswallsclosetothecuttingarccanbeminimizedbyselectingpaintshavinga

high percentage of ZnO and TiO2 pigments. Do not use paints containing metallic akes. Refer to “Ultraviolet Reec­tance of Paint” from the American Welding Society.

• Underwatercuttingisawellacceptedtechniqueforreducingthenoise,fumes,andUVradiationofthePlasmarccut­ting process. Often an air curtain or bubble muer is required for underwater cutting. Above water cutting with a
water muer can also achieve much of the benets of underwater cutting.

16

SECTION 1 DESCRIPTION

1.1 GENERAL

The ESP-1000 is a full capability plasmarc cutting system
that oers a wide variety of plasma cutting processes
and applications. The system is designed specically for
computer controlled mechanized cutting applications
with expanded interfacing, exible conguration from a
selection of packages and versatile ease of operation. By
selecting the components that best suit your needs the
ESP system can fully automate your cutting process.

1.2 FEATURES

• Thesystemiscapableofwaterinjectioncutting

with the PT-15XL torch and gas shielded un­derwater cutting can be accomplished at most
current levels with appropriate accessories with
the PT-19XLS torch.

• TheESP-1000canaccommodateallmajorcutting

gases including; oxygen, air, nitrogen or argon/
hydrogen mixture.

• The separatecomponent design,ow control,

plumbing box, power source provides maximum
flexibility for system layout tailored to your
needs.

• Selection from a varietyof power sources and

the paralleling capability allows a wide range
of available cutting power to meet virtually any
cutting condition.

• Patented ESAB technology allows underwater

cutting and beveling with excellent results.

• TheESP-1000usessimpleswitchsettingstosetup

process parameters for ow control and cutting
power eliminating the diculty of adjustment
associated with needle valves.

• Theshieldedconstructionoftheplasmatorches

and versatility of component location minimizes
electrical interference with surrounding equip­ment.

• The ESP system uses advanced technologyfor

high quality cutting for a variety of common
metals while keeping the operating costs at a
minimum.

COOLANT

CIRCULATOR

TORCH

(PT-15XL or PT-19XLS)

FLOW

CONTROL

CUT WATER

PUMP

PLUMBING

BOX

SECONDARY

GAS METERING

BOX

POWER SOURCE

(ULTRA LIFE 300, ESP-

400 or ESP-600C)

Figure 1-1. ESP-1000 Major Components

17

SECTION 1 DESCRIPTION

VOLTS

AMPS

OUTPUT

ACTUAL AMPS

PRESET AMPS

LOW

HIGH

PILOT
ARC

50
MIN

100

200

300

400

500

600
MAX

0

MAIN

POWER

CURRENT

PANEL

REMOTE

OVER
TEMP

CONTACTOR

ON

FAULT

POWER

RESET
FAULT

400C

1.3 COMPONENT DESCRIPTION

The components that make up an ESP-1000 are designed
specically to interface into a system for use in automated
plasma cutting applications.

Refer tothe specic equipment manual for detailed
information.

Ultra Life 300 Power Source

Designed for high speed plasma cutting, the Ultra Life 300
is basically a silicon controlled rectier (SCR) DC unit with
solid state circuitry. The unit can be operated from 50 to
300 amperes output (cutting) current.

Figure 1-3 ESP-400C Power Source

Figure 1-2. Ultra Life 300 Power Source

The solid state circuitry of the Ultra Life 300 produces
stable cutting current and eliminates changes in output
current as components heat up to operating tempera­ture. Fluctuations in line voltage within +/- 10% of normal
and/are extremely low ripple output current is produced,
which results in longer consumable life.

Refer to Instruction Manual F-15-141 for specic details
for the Ultra Life 300.

ESP-400C Power Source

The ESP-400C Power Source is a solid state DC pwoer source
capable of producing up tp 400 amperes.

The design of the solid state circuitry produces stable
cutting current and eliminates changes in output current
as components heat up to operating temperature and/or
uctuations in line voltages within + or - 10% of nominal.
If cutting currents above the rating is required, two ESP­400C units can be paralleled.

Refer to the power source manual for installation instruc­tions.

ESP-600C Power Source

The ESP-600C is normally used in mechanized cutting ap­plications for high speed cutting. The ESP-600C is a solid
state DC power source capable of producing 100 to 600
amperes of cutting current at 100% duty cycle (no cool
down requirements). The extremely low ripple current is
produced by a ripple cancellation technique and results
in increased life of plasma consumables. "Current slope
up" is also featured with the ESP-600C.

18

SECTION 1 DESCRIPTION

L

O

W

H

I

G

H

L

O

W

H

I

G

H

C

U
T

G

A

S

C

U

T

A

W

T

E

R

T

E

S

T

R

U

N

Connections to the ow control are Oxygen In, Nitrogen
In, Start Gas Out, Cut Gas Out, Cut Water In and Cut Water
Out.

Plumbing Box

The ESP Plumbing Box is an interconnecting device
between the torch and other system components. It
also contains the arc starting high frequency genera­tor. Connection of functions through the plumbing box
include; cut gas, start gas, cut water, torch coolant, pilot
arc, cutting current and height control.

Figure 1-4. ESP-600C Power Source

For currents beyond the ESP-600C capability 2 units can be
connected in a parallel conguration. Refer to Instruction
Manual for specic details of the ESP-600C.

Flow Control

The Flow Control is a programmable Logic Control (PLC)
based unit. This device provides all the necessary control
functions for various uids and signals to and from other
components of the system. Control Inputs/Outputs are
connected to the power source, cut water pump, plumb­ing box, coolant circulator, air curtain and the cutting
machine control.

Figure 1-6. Plumbing Box Assembly

Coolant Circulator

The WC-7C circulator is a radiator type cooler for circulat­ing a coolant uid through the plasma torch providing
heat exchanger action for the internal parts of the torch.
Though the system refers to water, it is not recommended
that water be used. For the protection of internal parts
and lines a specially formulated coolant liquid is avail­able that prevents production of corrosion and mineral
buildup. Refer to Instruction Manual F-15-138 for detailed
information on the WC-7C unit.

Figure 1-5. Flow Control Assembly

19

SECTION 1 DESCRIPTION

10

9
8
7
6
5
4
3
2
1
0

PRESSURE

FLOW

OFF

ON

AUTO

PRESSURE

ADJUSTMENT

INLET

FLOW

ADJUSTMENT

OUTLET

READ TOP

OF BALL

0

50

100

PLASMARC

SECONDARY SHIELD

GAS FLOW CONTROL

Secondary Gas Metering Box

Figure 1-7A

The secondary shield/PT-19XLS improves the cut square­ness. The secondary gas metering box measures the ow
rate of shield gas (nitrogen or air).

Adaptor: PT-19XLS to Plumbing Box for shield gas con­nection to torch.

PT-15XL Plasma Torch

The PT-15XL is designed for high current plasma cut­ting with water injection. Cutting is accomplished with
nitrogen cut gas up to 750 amps, oxygen cut gas up to
360 amps. Use of H-35 mixture for cut gas extends cur­rent capability up to 1000 amps. Each condition requires
specic torch components for the type of cut gas and
current level.

Figure 1-8. PT-15XL Plasma Torch

The PT-15XL is designed to eliminate double arcing, high
frequency leakage, and electrolytic corrosion of parts.
The electrode cooling and nozzle concentricity makes arc
ignition more reliable, longer life of the nozzle, electrode
and other consumable parts. Operating details for specic
cutting conditions are presented in later sections of this
manual. Refer to Form F-15-031 for detailed information
of the PT-15XL torch.

PT-19XLS Plasma Torch

The PT-19XLS Torch is designed with all the quality stan­dards and feature characteristics of the PT-15XL. The
dierences are primarily in applications and conditions
for which the PT-19XLS is to be used. The PT-19XLS is a
mechanized torch designed for high speed, high current
cutting using gas shielding instead ofwater injection.

Figure 1-7A

Figure 1-9. PT-19XLS Plasma Torch

PT-600 Plasma Torch

The PT-600 torch is a PT-19XLS with reduced manu­facturing tolerances. The result is improved torch
component concentricity and cut accuracy. Connec­tions, mounting and process data are identical.

20

SECTION 1 DESCRIPTION

The PT-19XLS is intended for applications of dry cutting
using air (clean & dry) for the cut gas at current levels up
to 200 amps. Oxygen (to 360A) or H-35 (to 600A) can be
used with the PT-19XLS, however these gases are not
recommended for some materials. Use of an air curtain
kit permits the PT-19XLS to be used for underwater cut­ting. Further details of the PT-19XLS are contained in
Form F-15-430.

Water Pump

The Water Pump is used to supply de-ionized cut water
to the PT-15XL torch for water injected cutting.

Air Curtain

Figure 1-11. Bubble Muer Assembly

The Air Curtain assembly provides improved cutting
performance of the PT-15XL and PT-19XLS plasma torches
when cutting underwater. A source of oil free air at 80
psig is required to the air curtain control box. A curtain
(wall) of air is created around the plasma arc area allowing
operation in a relatively dry zone, even with the end of
the torch submerged 2 - 3 inches.

PT15XL H.D.
AIR CURTAIN

Figure 1-10. Air Curtain Assembly

PT-19XLS
AIR CURTAIN

PT-19XLS Water Muer

The PT-19XLS water muer works much as the bubble
muer described above.

Underwater Cut quality and speed are enhanced when
using the air curtain for all PT-19XLS cutting applications
and PT-15XL O2/water injection cutting.

Bubble Muer

The Bubble Muer system creates a bubble of air sur­rounded by water that allows the PT-15XL torch to be
used underwater with oxygen cut gas and water injection
cutting without signicant loss of cut quality.

This device also allows above water cutting with reduced
fume, noise and UV radiation from the arc by the ow
of water through the bubble muer. A separate water
pump recycles ltered water from the water cutting table
through the bubble muer.

Figure 1-12. PT-19XLS Water Muer Assembly

21

SECTION 1 DESCRIPTION

TABLE 1-1. ESP 1000 COMPONENTS

DESCRIPTION PART NUMBER INSTRUCTION MANUAL

Power Sources

Ultra Life 300 460/575 V, 3-Phase, 60 Hz 33520 F-15-141

ESP-400C 460 V, 3-Phase, 60 Hz 0558001729 F-15-657
400 V, 3-Phase, 50 Hz CE 0558001730 F-15-681
575 V, 3-Phase, 50 Hz 0558001731 F-15-657

ESP-600C 460 V, 3-Phase, 60 Hz 35609 F-15-656
400 V, 3-Phase, 50 Hz CE 35610 F-15-682
575 V, 3-Phase, 60 Hz 35611 F-15-656

Plasma Torches: The basic torch body can be supplied in seven lead lengths between the plumbing box and torch. The replaceable

PT-15XL - 4.5 ft. 21307 F-15-031
PT-15XL - 6 ft. 21304
PT-15XL - 12 ft. 21305
PT-15XL - 15 ft. 21301
PT-15XL - 17 ft. 21306
PT-15XL - 20 ft. 21302
PT-15XL - 25 ft. 21303

PT-19XLS - 4.5 ft. 37086 F-15-430
PT-19XLS - 6 ft. 37087
PT-19XLS - 12 ft. 37088
PT-19XLS - 15 ft. 37089
PT-19XLS - 17 ft. 37090
PT-19XLS - 20 ft. 37091
PT-19XLS - 25 ft. 37092

PT-600 - 4.5 ft. 0558001827 F-15-646
PT-600 - 6 ft. 0558001828
PT-600 - 12 ft. 0558001829
PT-600 - 15 ft. 0558001830
PT-600 - 17 ft. 0558001831
PT-600 - 20 ft. 0558001832
PT-600 - 25 ft 0558001833

Flow Control: Provides interface for uids, gases and 21294 F-15-106
power.

torch components are selected for the type of cut gas and current level used.

Plumbing Box: Provides interconnection between torch 21295 F-15-107
and rest of system includes adaptor for
shield gas connection.

WC-7C Water Recirculator: Circulates coolant for the torch 33859 F-15-138

Cut Water Pump:

Supplies cut water to torch for water injection cutting 33772 F-15-131

Air Curtain:

PT-19XLS and PT-600 37440 F-15-475
Heavy Duty PT-15XL 21856 F-15-189
PT-15XL Beveling (PT-19XL and PT-600) 34752 F-15-189

Bubble Muer System 2232615 F-15-127

PT-19XLS (and PT-600) Water Muer 37439 F-15-474

Secondary Gas Metering Box (for PT-19XLS) 22178 See pages 28 - 32 of this manual.

22

SECTION 2 INSTALLATION

ing. In relationship to a cutting machine, the power
source can be positioned virtually anywhere that will

WARNING

READ THIS MANUAL COMPLETELY PRIOR TO
INSTALLING AND OPERATING THE ESAB SMART
PLASMA (ESP) 1000 SYSTEM.

not interfere with machine travel. Accessories on the
cutting machine are available to carry hoses and cables
without interference with machine travel.

Flow Control

2.1 General

Proper installation substantially contributes to the
satisfactory and trouble-free operation of the ESP-1000
System components. Each step in this section should
be studied carefully and followed as closely as possible.
Immediately upon receipt of the ESP components,
each should be inspected closely for damage which
may have occurred in transit. Notify the carrier of any
damage or defects immediately. Instruction manuals for
each component of the system are included in the pack­age. It is recommended that these manuals be collected
and compiled in a common location.

NOTE

If the components are not to be immediately
installed, store them in a clean, dry, and well ventilated
area.

2.2 System Component Locations

Power Source

WARNING

When lifting the Power Source using the lifting
lugs, ensure the lifting means is securely connected
to BOTH lifting lugs to prevent damage to the unit or
injury to personnel. DO NOT USE ANY LEVER DEVICE
WHICH COULD DAMAGE THE UNIT.

The location of the Power Source should be care­fully selected to ensure satisfactory and dependable
service. The Power Source components are maintained
at the proper operating temperatures by forced air that
is drawn through the cabinet by the fan units. For this
reason, it is important that the Power Source be located
in an indoor-open area where air can circulate freely at
the front, bottom, and rear openings of the cabinet. If
space is a premium, leave at least two feet of clearance
at the rear of the cabinet.

The Flow Control can be placed on the Power
Source or mounted onto the cutting machine. It con­nects to the Power Source by a control cable from 6' to
125' long. The Flow Control needs to be accessible for
setting various cutting parameters. After setting the
cutting conditions, access to the Flow Control is not
required during the cutting operation.

Plumbing Box

The Plumbing Box is normally located on the
cutting machine in close proximity to the torch station.
Since the torch can be equipped with various standard
lengths of cable and hose, the exact location is deter­mined by the conguration and station load capacity of
the machine.

Access to the Plumbing Box is not required during
the standard operating procedures, location near the
operator is not required. Two important considerations
pertain to the location of the plumbing box:

1. There should be space for the box door to be
opened fully .

2. Sucient space should be provided on all
sides to permit easy connection of gas/water
hoses and electrical cables to the box.

Secondary Gas Metering Box

The gas metering box can be mounted on the cut­ting machine or a convenient wall with the owmeter
vertical. The hose supplied is used to connect metering
box to torch shield gas using the adaptor supplied with
the plumbing box. The gas metering box must be con­nected to a source of dry oil free shop air or N2 capable

The location should be such that a minimum of
dirt, dust, or moisture will be drawn into the air stream.
It is desirable to locate the unit so that the top and side
panels can be removed for cleaning and troubleshoot-

23

SECTION 2 INSTALLATION

2.3. SYSTEM CONNECTIONS

Power Source

WARNING

Before making any connections to the output bus bars,
make sure the power source is de-energized by opening
the line (wall) disconnect switch. To be doubly safe, have a
qualied person check the output bus bars with a voltmeter
to be sure all power is o.

Input Power Connections

The power sources (ESP-600C, ESP-400 or Ultra Life 300) used
with the ESP-1000 system are 3-phase units and must be con­nected to a 3-phase power line. Although designed with line
voltage compensation, it is suggested that the unit be operated
on a separate line to ensure the performance of the power
source is not impaired due to an overloaded circuit.

A line (wall) disconnect switch, with fuses or circuit breakers,
shall be used at the main power panel. The primary power input
must have four insulated power leads (three power leads and
one ground wire). The wires may be a heavy rubber covered
cable or may run in a solid or exible conduit.

NOTE

The ground wire must be approximately six inches longer than
the power leads. This is a safety measure to ensure that in the
event the power lines are accidently pulled out the ground wire
will remain connected.

Input conductors must be terminated with ring terminals sized
for 1/2 inch hardware before being connected.

NOTE: Refer to the specic equipment manual for

detailed installation instructions.

Flow Control Connections

The Flow Control serves as a form of interface between the
various process utilities to enable a central location for setup
adjustments. Connections are made to receptacles on the rear
panel and are grouped into two sections, the bottom row is for
gas and water connections while the top row is for electrical
connections. The uid connections should be made rst.

Fluid Hookups (See Table 2-1 for hose assemblies)

1. OXYGEN (O
tting. Connect the supply hose from the oxygen
regulator to this point.

2. NITROGEN (N2) IN - This is a "B" size IAA tting.
Connect the supply hose from the nitrogen
regulator to this point.

3. START GAS OUT - This is a "B" size IAA tting. From
this point connect the hose to Start Gas INPUT on
the Plumbing Box.

4. CUT GAS OUT - This is a "B" size oxygen tting.
The hose is connected from this point to the Cut
Gas INPUT on the Plumbing Box.

Electrical Hookups (See Table 2-2 for cables)

1. PARALLELED POWER SOURCE - A cable from a
second power source connects to this receptacle
whenever two power sources are used in paral­lel. It parallels all control connections between
the power source and ow control.

2. AIR CURTAIN - This is used to connect the coil of
a solenoid valve in the air curtain control (when
used) or to control a relay coil in the water muer
pump unit.

3. CUT WATER PUMP - Provides connection to a relay
coil in the cut water pump unit

4. WATER COOLER - This point is used to connect to
the relay coil in the water cooler.

5. PLUMBING BOX - This cable connection goes to
the gas solenoid valves, ow switch, interlock
switch and provides power to the primary of
the high frequency transformer in the plumbing
box.

6. CUTTING MACHINE NUMERICAL CONTROL (CNC)

- This connection provides a current reference
signal to the plasma power source and provides
control signals to and from the ow control cir­cuits, Start Process Command, Arc On, Process
Fault, and E-Stop Interlock.

7. 115 VAC AUXILIARY POWER - This optional con­nection allows the Flow Control to be energized
without powering up the system. Disconnect
after test function is completed.

) IN - This is a "B" size CGA oxygen

2

24

SECTION 2 INSTALLATION

Oxygen

Nitrogen

Gas Regulators

Cut
Water

Pump

On-O

Flow Control

Wall Box

Input
Power

Cooler and
Pump

Start Gas Solenoid
Cut Gas Solenoid

High Freq. On-O

Interlocks

Injection Water

Start Gas

Cut Gas

Voltage Feedback

Power Source

Coolant Return

Coolant Output

(+) Work

(-) Electrode

Pilot Arc

Plumbing Box

Process OK

Interlocks

Current Ref.

E-Stop

Process
O

Cutting Machine Control

Height
Reference

Legend

Electrical Connections
Fluid Lines

*For use on the PT-19XLS and PT-600 only. For
dry cutting the cut water switch on the ow
control must be in the "OFF" position.

Figure 2-2. ESP-1000 Interface Block Diagram

Workpiece
Voltage

Height
Control

25

Torch
PT-15XL or
PT-19XLS or
PT-600

Work Piece

Gas
Metering
Box

Shield

Air Supply

Gas*

Secondary
Shield Gas

Cut Gas

Pilot Arc High Freq.

Water Injection

Coolant To
(-) Current To
Coolant From
(-) Current To

SECTION 2 INSTALLATION

TO PARALLEL

115 VAC

AUXILIARY POWER

FOR TESTING

(DISCONNECT FOR

CUTTING OPERATION)

POWER SOURCE

TO AIR
CURTAIN

TO CUT WATER
PUMP

O2 IN
FROM
REGULATOR

N2 IN
FROM
REGULATOR

START GAS
OUT TO
PLUMBING
BOX

CUT GAS
OUT TO
PLUMBING
BOX

POWER
SOURCE

CUT WATER
IN FROM CUT
WATER PUMP

Figure 2-4. Flow Control Connections

TO WATER
COOLER

TO PLUMBING
BOX

TO CUTTING
MACHINE CNC

CUT WATER
OUT TO PLUMBING
BOX

26

SECTION 2 INSTALLATION

TABLE 2-1. HOSE ASSEMBLIES

CABLE LENGTH CUT WATER HOSE COOLING WATER START GAS HOSE CUT GAS HOSE

25 FT. 33127 21588 33122 33117
50 FT. 33128 21574 33123 33118
75 FT. 33129 1575 33124 33119
100 FT. 33130 21576 33125 33120
125 FT. 33131 21577 33126 33121

TABLE 2-2. COOLING WATER HOSE ASSEMBLIES

CUT GAS HOSE Hose Assembly

25 FT. 33132
50 FT. 33133
75 FT. 33134
100 FT. 33135
125 FT. 33136

TABLE 2-3. INTERCONNECTION CABLES

CABLE

LENGTH

25 FT. 33219 33224 33253 33303 33253
50 FT. 33220 33225 33254 33304 33254
75 FT. 33221 33226 33255 33305 33255
100 FT. 33222 33227 33256 33306 33256
125 FT. 33223 33228 33257 33307 33257

Flow Control Remote Location- Flow Control to Power Source cable: 30 Ft. - 34378

FLOW CONTROL -

PLUMBING BOX

(Cable, 18 AWG,

8 conductor)

FLOW CONTROL

- CNC

(Cable, 16 AWG

12 conductor)

FLOW CONTROL

- WATER COOLER

(Cable, 18 AWG

3 conductor)

POWER SOURCE -

PLUMBING BOX

(Cable, Pilot Arc)

60 Ft. - 34377

CURTAIN

(Cable, 18 AWG

3 conductor)

AIR

27