ESP-100i
PLASMA CUTTING PACKAGES
INSTRUCTION MANUAL
P/N 33530 - 200 V, 208 V, 230 V, 380 V, 415 V, 460 V, 575 V, 3-Phase, 50/60 Hz
Starting with Serial No. PORI537026, October, 1995
F15-249-F 12 / 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
SECTION 1 SAFETY ........................................................................................................................ 5
SECTION 2 DESCRIPTION ............................................................................................................. 17
SECTION 3 INSTALLATION ............................................................................................................ 23
SECTION 4 OPERATION ................................................................................................................. 31
SECTION 5 MAINTENANCE ........................................................................................................... 37
SECTION 6 TROUBLESHOOTING .................................................................................................. 39
SECTION 7 REPLACEMENT PARTS ................................................................................................ 45
3
TABLE OF CONTENTS
4
SECTION 1 SAFETY PRECAUTIONS
1.0 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, cuess 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 cus, 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.
1.1 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 conned, or if there is danger
of falling.
5
SECTION 1 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.
9. Turn off the power before removing your
gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed
on next page) for specic grounding recommendations. Do not mistake the work lead for
a ground cable.
ELECTRIC AND MAGNETIC FIELDS
— May be dangerous. Electric cur-
rent 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.
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 conned spaces. Do
not breathe fumes and gases. Shielding gases can cause asphyxiation.
Therefore:
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.
2. Exposure to EMF may have other health eects
which are unknown.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specic ventilation recommendations.
6
SECTION 1 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.
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.
1. Always have qualied personnel perform the
installation, troubleshooting, and maintenance
work. Do not perform any electrical work unless
you are qualied 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.
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.
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
Jeerson Davis Highway, Arlington, VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
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
SECTION 1 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
SECTION 1 SEGURIDAD
1.2 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 inamables o vapores tóxicos. No trabaje dentro o fuera de contenedores o tanques cerrados. Estos
pueden explotar si contienen vapores inamables.
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
connado en lugares estrechos o si hay
posibilidad de caer al suelo.
9
SECTION 1 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 especícas 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 MAGNETI-
COS - 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 ven-
tilación. 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
substancias 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 Stan-
dard Z49.1 (Vea la lista a continuación) para
recomendaciones especícas en la ventilación.
10
SECTION 1 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 cualicado para
efectuar l a instalación, diagnóstico, y mantenimiento del equipo. No ejecute ningún trabajo
eléctrico a menos que usted esté cualicado
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 modique 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
SECTION 1 SEGURIDAD
SIGNIFICADO DE LOS SIMBOLOS
-- Según usted avanza en la lectura
de este folleto: Los Símbolos Signican ¡Atención! ¡Esté Alerta! Se
trata de su seguridad.
Signica riesgo inmediato que,
de no ser evadido, puede resultar
inmediatamente en serio daño
personal o la muerte.
Signica el riesgo de un peligro
potencial que puede resultar en
serio daño personal o la muerte.
Signica el posible riesgo que
puede resultar en menores daños
a la persona.
12
SECTION 1 SÉCURITÉ
1.3 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 an 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 an 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 ininammable an 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 ininammable.
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 susamment tous les matériaux combustibles de l'aire de travail et recouvrez les matériaux
avec un revêtement protecteur ininammable. 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 inammables 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 surchauer 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
SECTION 1 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 an 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 porte-électrode/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 eectuer votre travail dans un
espace restreint ou humide, ne tenez vous pas
directement sur le métal ou sur la terre; tenezvous 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
spéciques 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 conducteur 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 mag-
nétiques peut avoir des eets 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'eectuez 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
ecaces. Ne respirez pas les vapeurs de ces matériaux.
2. N'eectuez 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 an 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 spéciques
concernant la ventilation.
14
SECTION 1 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 Jeerson 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 qualié. N'eectuez aucune réparation électrique à moins d'être qualié à cet
eet.
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'eectuez aucune modication.
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
SECTION 1 SÉCURITÉ
SIGNIFICATION DES SYMBOLES
Ce symbole, utilisé partout dans ce manuel,
signie "Attention" ! Soyez vigilant ! Votre
sécurité est en jeu.
DANGER
Signie un danger immédiat. La situation peut
entraîner des blessures graves ou mortelles.
AVERTISSEMENT
Signie un danger potentiel qui peut entraîner des
blessures graves ou mortelles.
ATTENTION
Signie un danger qui peut entraîner des blessures
corporelles mineures.
16
SECTION 2 DESCRIPTION
The ESP-100i is a multipurpose 100 amp plasma cutting system
for both manual and mechanized cutting. ESAB's proprietary
ESP (ESAB Smart Plasmarc) technology yields a machine that
is the perfect solution for production cutting, plasma gouging,
and mechanized applications such as cutting machines, robotics, retrots, etc.
With PT-25 manual torch, production cuts 1-1/4 •
inch carbon steel and severs 1-1/2 inches (see PT20AM data sheet for mechanized cutting parameters)
Low-current-draws technology minimizes power •
consumption for low cost of operation
Compact size and standard casters facilitate •
movement around the shop so you can take the
console to the job
Continuously variable output from 10 to 100 •
amps gives the ability to tailor the cutting current
to the job
E• SAB Smart Plasmarc automation interface is
standard in all machines enabling it to be used
for both manual and mechanized cutting
Universal voltage input. The standard machine •
accepts all voltages from 200 to 575 volts at both
50 and 60 Hz line frequencies
Available in pre-engineered packages with all •
necessary components included
Digital ammeter for accurate current setting•
Dual gas plumbing to use with Dual Gas PT-25 •
manual torch
Plumbing box packages available where remote •
HF is desired for automation or retrot applications
Three-year warranty on console•
One-year warranty on torch•
How To Order
The ESP-100i comes with console, torch, torch parts kit,
required cylinder regulators and hoses for gas operation,
lter/regulator for air, work cable, and wheels. Mechanized
packages also include an interface connector. Plumbing box
packages also include plumbing box, interconnect cables,
plus a shielded PT-20AM. See optional accessories.
Ordering Information
Specications
Output 100 amps @ 100% duty cycle
Cut capacity: See PT-25 or PT-20AM data sheets
Input Voltage .....................200/230/380/415/460/575v 50/60hz 3ph
Input Current .........................................65/60/45/40/30/25 amps 3ph
Power Factor ....................................................................................96%
Output Current ........................................................10 to 100 amps DC
Rated Output Voltage ...........................................200vdc @ 100 amps
Duty Cycle ..................................................................................... 100%
Max OCV ..................................................................................... 325 vdc
Dimensions
................22 in. (550mm) w x 28 in. (700mm) h x 32 in. (800mm) d
Weight ..........................................................................380 lbs. (173kg)
Torch
Uses PT-25 or PT-20AM
ESP-100i Console Only .............................................................. 33530
ESP-100i/PT-25 Manual Packages
(See optional regulators for other gases)
ESP-100i, 25 ft. PT-25 90° Air/Air ............................................ 604625
ESP-100i, 50 ft. PT-25 90° Air/Air ............................................ 604626
ESP-100i, 25 ft. PT-25 90° N2/N2 .............................................. 604627
ESP-100i, 25 ft. PT-25 90° Ar-H2/N2 ......................................... 604628
ESP-100i, 50 ft. PT-25 90° N2/N2 .............................................. 604629
ESP-100i, 50 ft. PT-25 90° Ar-H2/N2 ......................................... 603630
17
SECTION 2 DESCRIPTION
Ordering Information (continued)
ESP-100i/PT-20AM Mechanized Packages
ESP-100i, 50 ft. shielded PT-20AM
With Rack and Torch Holder ................................................. 35836
ESP-100i w/arc starter, 50 ft. interconnect cables and
4 ft. shielded PT-20AM .......................................................... 35837
ESP-100i w/arc starter, 100 ft. interconnect cables and
4 ft. shielded PT-20AM .......................................................... 35838
ESP-100i w/arc starter, 50 ft. interconnect cables and
17 ft. shielded PT-20AM ........................................................ 35839
ESP-100i w/arc starter, 100 ft. interconnect cables and
17 ft. shielded PT-20AM ........................................................ 35840
Optional Accessories
Plasma Flow Measuring Kit
This valuable troubleshooting tool allows measurement of the
actual plasma gas ow through the torch .......................... 19765
Torch Guide Kit - PT-25
This complete kit, in a rugged plastic carrying case, includes
attachments for circle and straight line cutting on ferrous and
non-ferrous metals, 1 3/4" - 42" Radius ............................. 604624
PT-25 90° Plasmit Torch Head Protector
For gouging ........................................................................... 20801
Leather Sheath
For service line protection, 10-ft. length ............................. 20812
Dual Cylinder Rack for ESP-100i
Attaches to rear of ESP-100i and allows the carrying of
two full size cylinders ............................................................ 35833
Remote Hand Switch (Optional)
Permits remote starting and stopping of the cutting process
during dual gas operation ................................................ 2075600
for mechanized single gas .................................................. 680982
Optional Regulators and Hoses
Regulator for CO2 Secondary Gas......................................... 19629
Regulator for O2 Secondary Gas ......................................... 998336
Hose for CO2 Secondary Gas ................................................. 40V77
Hose for O2 Secondary Gas ................................................. 678125
Remote
Arc Starter
0558002634 - 50'
0558002635 - 100'
Work Cable
30741 (7.6m)
PT-20AM -
0558002632 (4')
0558002633 (17')
System With Arc Starter
18
ESP-100i
PILOT
ARC
POWER
ON
OFF
GAS
TEST
TRIGGER
LOCK
CONTROL
REMOTE
PANEL
LOCK
UNLOCK
TEST
OPERATE
CURRENT
A
HIGH
LOW
V
PLASMA
GAS FLOW
PLASMA GAS
PRESSURE
COOLING GAS
PRESSURE
P/S
TEMP
P/S
FAULT
OVER/UNDER
VOLTAGE
DANGER
ELECTRIC SHOCK at workpiece
or work cable can kill you.
Work cable MUST be connected
to workpiece to avoid shock.
!
!
TORCH
WORK
30"
MINIMUM
30"
MINIMUM
SECTION 2 DESCRIPTION
INSPECTION
A. Remove the shipping container and all packing
material and inspect for evidence of concealed
damage which may not have been apparent upon
receipt of the ESP-100i. The ESP-100i is crate
shipped and fully assembled with the exception
of the xed caster wheels. Immediately notify the
carrier of any defects or damage.
B. Check container for any loose parts prior to dispos-
ing of shipping materials.
C. Check air louvers and any other opening to ensure
that any obstruction is removed.
HOISTING
The ESP-100i is equipped with two lifting eyes that
enable the unit to be hoisted.
When lifting the ESP-100i be sure to use the proper
chain length and both lifting eyes. Failure to take
precautions when lifting will result in damage to
the internal components in the power source. The
chain length must be at least 60" to ensure that the
30" minimum is maintained from the chain hoist to
each lifting eye. See gure 2-1.
Figure 2-1. ESP-100i Hoisting Set-Up
19
SECTION 2 DESCRIPTION
2.1 GENERAL
The ESP-100i is a self-contained plasma cutting system.
As shipped, the system is fully assembled and ready to
cut after being connected to input power and a source of
compressed air (90-150 psi). The ESP-100i package uses
the heavy duty PT-25 dual gas manual torch or PT-20AM
mechanized torch to deliver cutting power for materials
up to 1-1/4" inch thick. Refer to the following paragraphs
for descriptions of the ESP-100i packages available and
performance specications.
2.2 SCOPE
The purpose of this manual is to provide the operator
with all the information required to install and operate
the ESP-100i plasma arc cutting package. Technical reference material is also provided to assist in troubleshooting
the cutting package.
Table 2-1. Available ESP-100i Cutting Packages
PT-25, 90° Hd.Dual Gas ManualAir/Air
25' Lines 50' Lines 50' Lines
ESP-100i Package, P/N 604625 604626 35836
includes:
Power Source, ESP-100i
PT-25 or -20AM Torch
Torch Spare Parts Kit (See contents below)
Air-Filter Regulator w/Mtg. Brkt.
Work Cable, 25 ft
Hose Assy, I.G., 6 ft (2)
Gas Hose Coupler "Y"
Air Hose Assy, 2.5 ft
33530
21648
21946
30338
30741
31503
050356
2.3 PACKAGES AVAILABLE
Table 1-1 lists ESP-100i packages available through your
ESAB dealer. Package contents are indented under each
complete system description.
Use only torches designed for use with this unit.
Use of torches not designed for use with this console could create an electrical shock hazard.
ESP-100i Package with:
PT-20AMMechanized
TorchAir/Air
33530
21649
21946
30338
30741
31503
050356
33530
21371
21376
30338
30741
678152
PT-25/100 A Spare Parts Kits, P/N 21946
Quantity Description
5
Elec trode Air/ N2
2
Swir l Baf fles
5
Nozzl e-1 00A
2
Nozzl e- Gougi ng
2
Heat Shie ld
1
Goug ing G uard
1
Stan d-Of f Gui de
PT-25/150 A Spare Parts Kits, P/N 21947
Quantity Description
5
Elec trode Air/ N2
2
Swir l Baf fles
5
Nozzl e-1 50A
2
Nozzl e- Gougi ng
2
Heat Shie ld
1
Goug ing G uard
1
Stan d-Of f Gui de
P/N
21595
21667
21597
21599
21654
21656
21943
P/N
21780
21667
21598
21599
21654
21656
21943
PT-20 AM Spare Parts Kits
P/N Quantity
Description
Heat Shield (70/100 A) 21326 4485831 - 2 2
Heat Shield (50 A) 21447 4485832 2 1 1
Cutting Nozzle (50 A) 21330 4485833 5 5 5
Cutting Nozzle (70 A) 21329 4485834 - 5 5
Cutting Nozzle (100 A) 21328 4485835 - - 5
Electrode 21150 0558004249 5 5 5
Electrode Seat 21372 4485839 1 1 1
Electrode Insulator 21373 21373 1 1 1
Electrode Holder Assy 21332 4485840 1 1 1
Bae Tube 21374 4485838 1 1 1
Pilot Arc Adaptor 19497 4485843 1 1 1
O-Ring 488157 4485841 5 5 5
Lubricant (1 oz.) 17672 0558000443 1 1 1
Seat/Bae Wrench 21375 4485842 1 1 1
1/16: Hex-Key Wrench (1,6 mm) 93750006 4485651 1 1 1
Box tool 950272 950272 1 1 1
Standard
P/N
"CE" P/N
50 A
21370
70 A
21369
100 A
21376
20
12.15"
1.60" Dia.
1.38" Dia.
4.48"
1.47" Dia.
1.22" Dia.
17 1/2" With Rack
1 3/8" Dia.
5/8" Mounting Stud
7 5/8" min. - 14 1/2" max.
SECTION 2 DESCRIPTION
2.4 SPECIFICATIONS
Refer to tables 2-2 thru 2-6, and gures 2-1 and 2-2 for
ESP-100i and torch technical specications.
Table 2-2. ESP-100i Power Source Specications
Rated Output 100% Duty Cycle 100 A @ 120 V dc
Output Current Range 10 to 100 Amperes
Open Circuit Voltage 325 V dc
200 V
Rated Primary Input, 3 phase, 50/60 Hz@ 12
kW Max. Output Power (100 A @120 V dc)
Power Factor @ 12kW Output 0.96
Eciency @ 12kW Output 93% typical
Dimensions
Weight 408 lbs. (185 kg)
Shipping Weight 420 lbs. (191 kg)
208 V
230 V
380 V
415 V
460 V
575 V
Length
Height
Width
49 A / Phase
47 A / Phase
40 A / Phase
25 A / Phase
23 A / Phase
20 A / Phase
16 A / Phase
33.0" (838 mm)
27.3" (693 mm)
21.5" (546 mm)
* PT-25 can also be used with the following plasma/cooling gas combinations: N2/Air, H-35/N2, and 40H2 - 60N2/
Air. See Instruction Manual F-15-266 for details.
Table 2-3. PT-25 Manual Torch andPT-20AM Mechanized Torch Specications
PT-20AM PT-25
Plasma/Cooling Gas
Shipping Weight
Length of Service Lines
Instruction Booklet
Air @ 85 psi (380 cfh)
20 lbs
50-ft
Form 15-114
Air @ 70 psi (560 cfh) *
14 lbs (25 ft)
25 lbs (50 ft)
25 or 50 ft
Form 15-266
PT-25
PT-20AM
Figure 2-1. Cutting Torch Specications
21
PT-25 150 amp, H-35 / N
2
150 amp Cutting Data
H-35 Plasma at 70 psig
Nitrogen Cooling at 70 psig
Aluminum
Stainless
2.001.751.501.00 1.250.750.25 0.500.00
Material Thickness (in.)
0
25
50
75
Cutting Speed (ipm)
2.001.751.501.00 1.250.750.25 0.500.00
0
25
50
75
100
125
150
175
Cutting Speed (ipm)
Material Thickness (in.)
PT-25 100 amp, Air / Air
100 amp Cutting Data
Air Plasma at 70 psig
Air Cooling at 70 psig
Carbon Steel
Stainless
Aluminum
Table 2-4. 100 Amp Data, Nozzle P/N 21328, Heat Shield P/N 21326
Metal
Thickness
(in.)
Air
Pressure
(psig)
Stand-off
(in.)
Arc Volts
Travel
Speed
(ipm)
Kerf
Width
Pierce
Time
(sec.)
1/4 85 1/4 110 100 1/8 0.1
1/2 85 1/4 120 45 1/8 0.3
3/4 85 1/4 125 27 1/8 1
1 85 1/4 130 15 1/8 2.75
1-1/4 85 5/16 140 10 5/32 *N.R.
1-1/2 85 5/16 145 7 3/16 *N.R.
Table 2-5. 70 Amp Data, Nozzle P/N 21329, Heat Shield P/N 21326
Metal
Thickness
(in.)
Air
Pressure
(psig)
Stand-off
(in.)
Arc Volts
Travel
Speed
(ipm)
Kerf
Width
Pierce
Time
(sec.)
1/8 75 3/16 95 190 3/32 0.1
1/4 75 3/16 100 80 3/32 0.2
1/2 85 1/4 115 30 3/32 0.6
3/4 85 1/4 130 15 1/8 2.25
1 85 5/16 140 7 5/32 *N.R.
1-1/4 85 5/16 155 5 5/32 *N.R.
Table 2-6. 40 & 50 Amp Data, Nozzle P/N 21330, Heat Shield P/N 21447
Metal
Thickness
(in.)
Arc
Current
(Amps)
Air
Pressure
(psig)
Stand-off
(in.)
Arc Volts
Travel
Speed
(ipm)
Kerf
Width
Pierce
Time
(sec.)
1/16 40 75 1/8 110 150 3/64 0.25
1/8 40 75 1/8 110 100 3/64 0.25
3/16 50 85 1/8 110 100 1/16 0.25
1/4 50 85 3/16 120 65 5/64 0.25
3/8 50 85 1/4 130 40 5/64 0.25
1/2 50 85 5/16 150 18 3/32 1.0
SECTION 2 DESCRIPTION
Cutting Parameters for the PT-20AM Torch on Carbon Steel
Figure 2-2. PT-25 Cutting Data
22
SECTION 3 INSTALLATION
3.1 GENERAL
Proper installation can contribute materially to the
satisfactory and trouble-free operation of the ESP-100i
cutting package. It is suggested that each step in this
section be studied carefully and followed as closely as
possible.
3.2 EQUIPMENT REQUIRED
A source of clean, dry air that supplies 560 cfh at 85
psig is required for the cutting operation. The air supply should not exceed 150 psig (the maximum inlet
pressure rating of the air lter-regulator supplied with
the package).
3.3 LOCATION
Adequate ventilation is necessary to provide proper
cooling of the ESP-100i. Minimize the amount of dirt,
dust, and excessive heat to which the equipment is
exposed. There should be at least 2 feet of clearance
between the ESP-100i power source and wall or any
other obstruction to allow freedom of air movement
through the power source.
Installing or placing any type of ltering device will
restrict the volume of intake air, thereby subjecting the
power source internal components to overheating. Use
of any type of lter device voids the warranty.
3.4 PRIMARY ELECTRICAL INPUT
CONNECTIONS. Figure 31.
As shipped, the ESP-100i is congured for 575 V, 60 Hz
input. If using 200, 230, 380, 415, or 460 V input, the
jumper input power cables located on the auto transformer must be repositioned to the desired input voltage
for safe operation. To gain access to the autotransformer,
remove the right side panel. (See gure 3-1.)
A line (wall) disconnect switch with fuses or circuit breakers should be provided at the main power panel (see
gure 3-2 and table 3-1 for fuse rating). The input power
cable of the console may be connected directly to the
disconnect switch or a proper plug and receptacle may
be purchased from a local electrical supplier. If using
plug/receptacle combination, see table 3-1 for recommended input conductors for connecting receptacle to
line disconnect switch.
Table 3-1. Recommended Sizes For
Input Conductors and Line Fuses
Input Requirements Input & Gnd
Volts Phase Amps
200/208 3 49 No. 8 70
230 3 40 No. 8 60
380 3 25 No. 12 40
415 3 23 No. 12 40
460 3 20 No. 14 30
575 3 16 No. 14 25
*Sizes per National Electric Code for 75 °C rated conductors @
30 °C ambient. Not more than three conductors in raceway or
cable. Follow local codes if they specify sizes other than those
listed above.
Conductor
CU/AWG
Fuse Ratings
/Phase, Amps
ELECTRIC SHOCK CAN KILL! Precautionary measures
should be taken to provide maximum protection against
electrical shock. Be sure that all power is o by opening
the line (wall) disconnect switch and by unplugging
the power cord to the unit when connections are made
inside of the power source.
Be sure that the power source is properly congured
for your input power supply. DO NOT connect a power
source congured for 230 V to a 460 V input power supply. Damage to the machine may occur.
The following procedure explains the proper installation
steps for connecting primary electrical power to the ESP100i. (See gure 3-1.)
A. Remove right side panel.
B. Ensure input power cable is deenergized from all
electrical sources.
C. Route input power cable through the strain relief
located at the rear panel.
D. Pull input power cable through the strain relief to
allow cable wires sucient length to connect to the
main contactor. Tighten strain relief to ensure input
power cable is secured.
E. Connect input power cable ground wire to the ground
lug provided on the base of the ESP-100i.
23
460
575
200
230
380
415
460
575
380
415
200
230
460
380
230
PHASE B
415
575
575
200
415
460
230
380
200
PHASE A PHASE C
SECTION 3 INSTALLATION
H. Connect jumper wire to the proper input voltage
connector located on the 7-position terminal block.
Electric shock can kill! Failure to connect a good electrical ground to the base of the ESP-100i could result in
electric shock.
F. Connect three power leads of the input power cable
to the terminals located atop the main contactor.
Secure the leads by tightening each screw.
(See gure 3-1.)
3.5 SECONDARY OUTPUT CONNEC
TIONS FOR MANUAL AND
MECHANIZED CUTTING
G. Connect jumper power cables from the bottom
of the main contactor to the proper input voltage
marked on the auto transformer. The unit is factory
set for 575 V.
Ensure three input power jumper cables are connected properly to the auto transformer for your input
power.
Before making any connections to the power source
output terminals, make sure that all primary input
power to the machine is deenergized (o) at the main
disconnect switch.
Input Power
Connections
Main
Contactor
Jumper
Power
Cables
AUTO TRANSFORMER
Move the 3 jumpers
to proper input voltage.
NOTE: Jumpers are shown in the 575V positions.
Figure 3-1. ESP-100i Primary Power Connection Diagram
7-POSITION
TERMINAL BLOCK
Move jumper to
proper input
voltage.
Earth
Ground
Connection
Customer Supplied Input
Power Cable
24
ESP-100i
PILOT
ARC
POWER
ON
OFF
GAS
TEST
TRIGGER
LOCK
CONTROL
R
EM
OTE
PA
NEL
LOCK
UNLOCK
TEST
OPER
ATE
CURRENT
A
HIG
H
LO
W
V
PLASM
A
G
A
S FLO
W
PLA
SM
A
GAS
P
RESSUR
E
COOLIN
G G
A
S
PRESS
URE
P/S
TEM
P
P/S
FAU
LT
OVER/U
NDER
VOLTAG
E
DAN
GER
ELECTRIC SHOCK at workpiece
or work cable can kill you.
W
ork cable MUST be connected
to workpiece to avoid shock.
!
!
TORCH
WORK
Switch Lead
Work Cable
No Adaptor required,
remove Adaptor (21803)
supplied with console.
PT-25 Torch
Plasma Gas /
Power Cable
Safety Sensor
Tube
Cooling Gas /
Pilot Arc Cable
Air/C
O
2
/N
2
O
XYG
EN
C
O
2
/N
2 Ar-H
2
COOLING GAS
PLASMA GAS
REMOTE
CONTROL
Wall Disconnect
Shop Air
100 psi min.
150 psi max.
560 CFH
Filter-Regulator
30338
set pressure to
65-75 psig
"Y" Connector
Plasma Gas
Cooling Gas
SECTION 3 INSTALLATION
Figure 3-2. ESP-100i/PT-25 Interconnection Diagram
Figure 3-2. ESP-100i/PT-25 Interconnection Diagram -- Option 1
(For Use When Cutting Only; Not for Gouging)
25
Air/C
O
2
/N
2
O
XYG
EN
C
O
2
/N
2 A
r-H
2
COOLING GAS
PLASMA GAS
REMOTE
CONTROL
Wall Disconnect
Set pressure at
65-75 psig
DO NOT use Oxygen at all.1.
DO NOT use Argon or Ar-H
2
mix for Cooling Gas.
2.
Cooling Gas
N
2
CO2 or
Air
Plasma Gas
N
2
H-35
N
2-H2
or Air
200 CFH
360 CFH
NOTE;
This option will require a few
cylinders manifolded or a bulk system
to maintain flow requirements of torch.
A
ir/CO
2
/N
2
O
XYG
E
N
C
O
2
/N
2 A
r-H
2
COOLING GAS
PLASMA GAS
REMOTE
CONTROL
Wall Disconnect
Shop Air
100 psi min.
150 psi max.
360 CFH
Filter-Regulator
30338
R-76 Regulators
Set pressure at
65-75 psig for cutting.
40-45 psig for gouging.
Plasma Gas
N
2
H-35 or
N
2-H2
Cooling Gas
200 CFH
Set pressure at
65-75 psig for cutting.
40-45 psig for gouging.
SECTION 3 INSTALLATION
Figure 3-2. ESP-100i/PT-25 Interconnection Diagram -- Option 2
(For Use When Cutting or Gouging)
Figure 3-2. ESP-100i/PT-25 Interconnection Diagram -- Option 3
(For Use When Cutting or Gouging)
26
SECTION 3 INSTALLATION
3.5.1 Using PT-25 Torch. (Refer to gure
3-2.)
A. With the right side panel removed, connect the
terminal lug end of the work cable assembly to
the WORK terminal in lower right corner behind
front panel. Nut should be wrench-tight.
B. Thread the four torch service lines through the
bushing in the lower right corner of the front panel
and proceed as follows: (1) Connect the plasma
gas/power cable (large male nut with left hand
threads) to the TORCH tting and tighten rmly
with a wrench; (2) Remove pilot arc adapter (21803)
shipped with console and connect cooling gas/
pilot arc cable to the right-hand threaded PILOT
ARC tting and tighten rmly with a wrench; (3)
Connect the 5-pin switch lead to the mating receptacle. Make sure plug is rmly locked in place.
(4) Insert safety sensor tube into tube tting until
fully seated.
C. Reinstall right side panel.
D. Referring to the interconnection diagram (gure
3-2), connect the desired gas to the plasma and
shield gas connections on the rear panel of the
console. Note the various options shown in the
diagram. Use only gases recommended as noted
on the diagram.
F. Make sure workpiece is connected to an approved
earth ground. Use copper ground cable equal to or
larger than the power source chassis ground listed
in Table 3-1.
3.5.2 Using PT-20AM Torch. (Refer to
gure 3-3.)
A. With the right side panel removed, connect the
terminal lug end of the work cable assembly to the
WORK terminal in lower right corner behind front
panel. Nut should be wrench-tight.
B. Connect pilot arc adaptor P/N 21803 (supplied with
console) to the PILOT ARC connection and tighten
rmly with a wrench. Loosely place screw, washer,
and lockwasher in the most convenient tapped hole
in the adaptor.
C. Thread the two torch service lines through the bush-
ing in the lower right corner of the front panel and
proceed as follows: (1) Connect the power cable
(large male nut with left hand threads) to the TORCH
tting and tighten rmly with a wrench; (2) Connect
pilot arc cable to the adaptor assembled on PILOT
ARC tting at the most convenient tapped hole
position of adaptor. With washer and lockwasher
in place, tighten screw rmly with a screwdriver.
D. Reinstall right side panel.
Do NOT use argon or argon mixtures as cooling gas in
the PT-25 torch. Internal arcing in the torch head may
occur.
Do NOT use oxygen as cooling or plasma gas. The
torch may catch re.
E. Electrically connect work cable to workpiece. The
connection must be made to a clean, exposed metal
surface free of paint, rust, mill scale, etc. (See gure
3-4).
A poor connection or failure to connect work cable to
workpiece can result in fatal shock.
E. Assemble the lter-regulator and mounting bracket
(30338) to the upper left corner on the rear panel
(view from rear) as illustrated. Mounting holes are
provided. Hardware is supplied with the mounting
bracket.
F. Connect the air hose assembly (678152) to lter-
regulator outlet tting and to the Air/N2 plasma gas
tting on the rear panel of the ESP-100i unit. Note
that the air hose has left-hand threaded nut on one
end (regulator) and right-hand on the other.
G. Connect your air supply to the inlet connection
(1/4-in. NPT female - customer to supply suitable
end tting) of the lter-regulator.
H. Electrically connect work cable to workpiece. The
connection must be made to a clean, exposed metal
surface free of paint, rust, mill scale, etc. (See gure
3-4).
27
ESP-100i
PILOT
ARC
POWER
ON
OFF
GAS
TEST
TRIGGER
LOCK
CONTROL
REMOTE
PANEL
LOCK
UNLOCK
TEST
OPERATE
CURRENT
A
HIGH
LO
W
V
PLASMA
GAS FLO
W
PLASM
A GAS
PRESSUR
E
CO
OLING GA
S
PRESSUR
E
P/S
TEM
P
P/S
FAULT
O
VER/UNDER
VOLTAGE
DANG
ER
ELECTRIC SHOCK at workpiece
or work cable can kill you.
Work cable M
UST be connected
to workpiece to avoid shock.
!
!
TORCH
WORK
Air/C
O
2
/N
2
O
XYG
EN
C
O
2
/N
2 Ar-H
2
COOLING GAS
PLASMA GAS
REMOTE
CONTROL
Wall Disconnect
Shop Air
150 psi max.
100 psi min.
Interface Cable (PT-20AM only)
Filter-Regulator
30338
Hose
678152
Work Cable
Pilot Arc Adaptor
21803
PT-20AM
SECTION 3 INSTALLATION
I. Make sure workpiece is connected to an approved
earth ground. Use copper ground cable equal to
or larger than the power source chassis ground
A poor connection or failure to connect work cable to
workpiece can result in fatal shock.
listed in table 3-1.
Figure 3-3. ESP-100i Interconnection Diagram
28
DO NOT ATTACH WORK
CABLE TO PIECE BEING CUT
FREE
WORK CABLE
EARTH GROUND
EARTH GROUND
WORK CABLE
BE SURE WORK IS IN GOOD
CONTACT WITH TABLE.
GROUNDED
WORK TABLE
INSULATING GLOVE
SECTION 3 INSTALLATION
Figure 3-4. Ground and Work Cable Connections
29
SECTION 3 INSTALLATION
30
SECTION 4 OPERATION
4.1 OPERATION
ELECTRIC SHOCK can kill.
• DoNOToperatetheunitwiththecoverremoved.
• Do NOT apply power to the unit while holding or
carrying the unit.
• Do NOT touch any torch parts forward of the torch
handle (nozzle, heat shield, electrode, etc.) with power
switch on.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
• WearweldinghelmetwithNo.6or7lensshade.
• Weareye,ear,andbodyprotection.
current adjustment knob on front panel.
E. Trigger Lock. (Used only with manual torches.) In
unlock position operator must depress torch switch
to maintain an arc. In the lock position the torch
will maintain an arc (once established) without
depressing torch switch.
NOTE: The arc will extinguish ONLY by removing
the torch away from the work.
F. Gas Test Switch. In the TEST mode gas is supplied
to torch for pressure adjustments. In the OPERATE
mode, the unit is ready for operation.
NOTE: The Power Source fault indicator will illu-
minate due to the power source being locked out
for operator safety.
G. Digital Ammeter Readout. Indicates actual cutting
current 0-100 amps.
H. Plasma Gas Flow Fault Indicator. Indicates insuf-
cient plasma gas ow to torch.
I. Plasma Gas Pressure Fault Indicator. Indicates
insucient plasma gas pressure to torch.
Position the ESP-100i at least 10 feet (3 meters) from
the cutting area. Sparks and hot slag from the cutting
operation can damage the unit.
4.2 ESP-100i CONTROLS (Figure 4-1.)
A. Power On/O Switch. Turns unit on/o.
B. Power On Indicator. Indicates unit is on.
C. Pilot Arc Current Selector Switch. In the low posi-
tion (down) unit is used for cutting. In the high
position (up) unit is used for gouging.
D. Output Current Control Selector Switch. In the
REMOTE position, output current is controlled
through a 0-10 V remote current setting signal via
a remote control connector (J1) on back panel. In
the PANEL position, output current controlled by
J. Cooling Gas Pressure Fault Indicator. Indicates
insucient cooling gas pressure to torch.
NOTE: Operator must check input gas into ESP-
100i.
K. Power Source Overtemperature Fault Indicator.
Indicates power inlet breaker has opened due to
thermal protection trip.
L. P/S Fault Indicator. Illuminates during test
mode.
M. Over/Under Voltage Fault Indicator. Indicates
applied input voltage is out of tolerance from the
required input voltage.
NOTE
Light will ash until unit power is cycled.
31
LOCK
HIGH
REMOTE
UNLOCK
LOCK
TRIGGER
V
POWER
OFF
TEMP
P/S
FAULT
P/S
PRESSURE
PLASMA GAS
GAS FLOW
PLASMA
OPERATE
TT
TEST
GAS
LOW
ARC
PILOT
A
1
10
9
8
7
6
5
4
3
2
0
PANEL
CURRENT
CONTROL
COOLING GAS
PRESSURE
VOLTAGE
OVER/UNDER
SECTION 4 OPERATION
D
E
F
H
I
J
G
L
M
K
B
C
A
Figure 4-1. ESP-100i Controls
Figure 4-2. Recommended Torch Angle of 5° to 15° Leading
32
SECTION 4 OPERATION
4.3 MANUAL CUTTING WITH THE PT25
NOTE
Use the following procedures to cut with the PT-25 torch.
(Figures 4-2 thru 4-4).
Refer to the torch instruction manual F-15-266 for the
proper way to setup the PT-25 for cutting or gouging.
The torch is now ready for cutting operations.
The torch front end components are designed to send a
gas pressure signal to the console when the heat shield
and nozzle are properly installed. This gas pressure
signal operates in conjunction with circuits provided
in the console. This patented system provides a safety
interlock preventing the torch from being accidentally
energized with high voltage when the heat shield is
removed and the torch switch is accidentally closed.
Occasionally check this system by removing the heat
shield. Turn on console. Do NOT touch the metallic parts
on the torch front end. Close the torch switch and place
the electrode in contact with a properly grounded work
piece. If the torch energizes and arcing occurs between
the electrode and work piece, do not use. Do NOT tamper
with the torch or console. Return torch and console to
your ESAB distributor for repair.
Wear the usual protective gloves, clothing, ear protection, and helmet. Helmet with lter lens shade No. 8
should provide adequate protection for your eyes.
If cutting arc does not start within 5 seconds, the pilot
arc will shut o. Release torch switch. Check to be sure
gas pressures are adequate (particularly the cooling gas
pressure), work cable is rmly connected to workpiece,
torch was about 1/8 to 1/4-in. above workpiece, etc.
Then start from step 1 again.
D. For ease of operation, use the stand-o guide. If
using the standard shield guard, maintain a stando (torch-to-work distance) of about 3/16-in. to
5/16-in. Keep the torch head at an angle of 5° to
15° leading (see gure 4-2), and move it at a rate
that produces the desired cut quality (See gure
4-3). The cutting should produce a straight ne
spray of molten metal emitting from beneath the
workpiece.
E. If cutting arc is lost during cut, the pilot arc will
immediately reignite as long as the torch switch is
depressed. You then have about 5 seconds to move
the torch close enough to work to reestablish the
cutting arc.
F. The cutting arc will extinguish at the end of the
cut; however, the torch switch should be released
to keep the pilot arc from reigniting.
G. When cutting operation is completed, wait a few
minutes before placing the POWER switch to the
OFF position so that the cooling fan has time to
remove the heat from the unit. Then shut o the
primary power at the main disconnect switch.
Never touch any parts forward of the torch handle (cutting tip, heat shield, electrode, etc.) unless the POWER
switch is in the OFF position.
A. Position the torch on the workpiece by resting the
stand-o guide on the edge of the workpiece where
you intend to start the cut.
B. Lower protective helmet and then lift the torch
about 1/8-in. above the workpiece. (Not necessary
to lift when using guard.)
C. Push down on the torch switch button mounted
on the torch handle. Main contactor will come
on; gas will start owing. Two seconds later, the
pilot arc contactor and high frequency will energize. The cutting arc should then transfer to the
workpiece.
33
Too Fast
Too Slow Correct
Figure 4-3. Eect of Cutting Speed
SECTION 4 OPERATION
Schematic - Mechanized System Setup
(See Figure 4-5 for connections)
NOTE: If CNC does not have a normally closed Emergency
switch - a jumper must be installed between TB3-18 and TB3-19.
Figure 4-4. Mechanized Cutting Interface Diagram
34
SECTION 4 OPERATION
Disconnec t two existing
terminals from plug (J5).
Then connect the Arc Starter cable.
“E”
“D”
“C”
“B”
HOSE/ CABLE ADAPTOR - 36743
PILOT ARC ADAPTOR - 21803
WORK CABLE - 30741 (25’)
“A” (ToWork)
.035” (0.9mm)
SPARK GAP ASSEMBLY
(Torch end of Arc Starter)
MOUNTING DIMENSIONS
Figure 4-5. Connection Diagram - ESP-100i/PT-20AM with Arc Starter
(4) .250”
(6 mm)
2.125”
(54mm)
(178mm)
7.0”
35
WHEN THE ARC BREAKS
THROUGH THE WORK, BRING
THE TORCH TO AN UPRIGHT
POSITION AND PROCEED TO
CUT.
2
TO START A PIERCE. TILT THE
TORCH TO PREVENT MOLTEN
MATERIAL FROM COMING BACK
AGAINST AND DAMAGING THE
TORCH.
1
SECTION 4 OPERATION
Figure 4-6. Typical Piercing Technique
4.5 COMMON CUTTING PROBLEMS
Listed below are common cutting problems followed by the probable cause of each. If problems are
determined to be caused by the ESP-100i, refer to the
maintenance section of this manual. If the problem is
not corrected after referring to the maintenance section, contact your ESAB representative.
A. Insucient Penetration.
1. Cutting speed too fast.
2. Damaged cutting nozzle.
3. Improper air pressure.
B. Main Arc Extinguishes.
Cutting speed too slow.
C. Dross Formation. (In some materials and thick-
nesses, it may be impossible to get dross-free
cuts.)
1. Cutting speed too fast or too slow.
2. Improper air pressure.
3. Faulty nozzle or electrode.
D. Double Arcing. (Damaged Nozzle Orice.)
1. Low air pressure.
2. Damaged cutting nozzle.
3. Loose cutting nozzle.
4. Heavy spatter.
5. Nozzle touches work while cutting.
E. Uneven Arc.
Damaged cutting nozzle or worn electrode.
F. Unstable Cutting Conditions.
1. Incorrect cutting speed.
2. Loose cable or hose connections.
3. Electrode and/or cutting nozzle in poor condition.
G. Main Arc Does Not Strike.
1. Front panel fault light tripped.
2. Loose connections.
3. Work clamp not connected.
4. Cooling gas pressure not sucient
5. Torch safety connection not connected.
H. Poor Consumable Life.
1. Improper gas pressure.
2. Contaminated air supply.
3. Improper gas/electrode combination.
36
SECTION 5 MAINTENANCE
5.1 GENERAL
If this equipment does not operate properly, stop
work immediately and investigate the cause of the
malfunction. Maintenance work must be performed
by an experienced person, and electrical work by a
trained electrician. Do not permit untrained persons
to inspect, clean, or repair this equipment. Use only
recommended replacement parts.
Be sure that the wall disconnect switch or wall circuit
breaker is open before attempting any inspection or
work inside of the ESP-100i.
5.2 INSPECTION AND CLEANING
Frequent inspection and cleaning of the ESP-100i
is recommended for safety and proper operation.
Some suggestions for inspecting and cleaning are as
follows:
A. Check work cable to workpiece connection.
B. Check safety earth ground at workpiece and at
power source chassis.
H. Occasionally, bleed all water from the lter be-
neath the air lter-regulator.
5.3 TORCH CONSUMABLE PARTS
Make sure power switch on ESP-100i is in OFF position
before working on the torch.
Refer to the following torch booklets for maintenance,
replacement parts, and additional information:
Torch Booklet
PT-25 F-15-266
PT-20AM F-15-114
5.4 PREFLOW CONTROL
A. With manual torches: Preow can be adjusted
between 1 and 4 seconds by using SW2 on the
main control pc board (PCB1), P/N 38020.
B. With mechanized torch and with power source
controlling preow, place jumper J1 on interface
pc board (PCB4), P/N 38098.
C. Check heat shield on torch. It should be replaced
if damaged.
D. Check the torch electrode and cutting nozzle for
wear on a daily basis. Remove spatter, resharpen
point, or replace if necessary.
E. Make sure cable and hoses are not damaged or
kinked.
F. Make sure all plugs, ttings, and ground connec-
tions are tight.
Water or oil occasionally accumulates in compressed air
lines. Be sure to direct the rst blast of air away from
the equipment to avoid damage to the ESP-100i.
G. With all input power disconnected, and wearing
proper eye and face protection, blow out the
inside of the ESP-100i using low-pressure dry
compressed air.
C. With mechanized torch and with Computer Nu-
merical Control (CNC) controlling preow, remove
jumper J1 from interface pc board (PCB4), P/N
38098.
5.5 FLOW SWITCH Figure 51.
When excessive contamination is found in the air, the
ow switch (FS-4 or FS-5) in the ESP-100i should be
disassembled and cleaned as follows:
NOTE
It is not necessary to remove the ow switch from the
system for cleaning.
A. Ensure the system is shut down and there is no
trapped air under pressure in the piping.
B. Remove the piston plug.
C. Remove the spring (FS-4 only). Use care when
handling spring to prevent distortion.
37
Plasma
Gas Switch
Cooling
Gas Switch
Plasma
Gas Switch
Cooling
Gas Switch
Side View
PISTON PLUG
PISTON
SPRING
FLOW SWITCH
SECTION 5 MAINTENANCE
D. Remove the piston.
E. Clean all parts with cleaning agent.
5.6 ADJUSTMENT OF GAS PRESSURE
SWITCH Figure 5-2.)
The cooling gas pressure switch is factory set for 55 psig
minimum; plasma gas pressure switch is factory set
for 40 psig minimum. If required, the pressure switch
can be custom set to provide precise control of the
cooling gas and plasma gas pressure. The two switches
are located in the rear of the ESP-100i. To access the
switches, remove the right cover.
To INCREASE pressure: turn the gas pressure switch
counterclockwise.
To DECREASE gas pressure: turn the gas pressure
switch clockwise.
Figure 5-1. Disassembly/Assembly of Flow Switch
Figure 52. Gas Pressure Switch
38
SECTION 6 TROUBLESHOOTING
Table 6-1. Troubleshooting Guide
PROBLEM POSSIBLE CAUSE ACTION
I. Power switch is in the ON
position but fan is not
running.
I. If Power-ON indicator light is ON:
a) Broken or disconnected wire in
the fan motor circuit.
b) Faulty fan.
a) Repair wire.
b) Replace the fan motor.
II. If Power-ON indicator light is OFF:
a) Broken or disconnected wires to
the Power-ON/OFF switch.
b) Power is not connected properly
to the input of the auto transformer
and/or the jumper.
a) Repair wire.
b) Correct input power
connections.
6.1 TROUBLESHOOTING
ELECTRIC SHOCK CAN KILL! Be sure that all primary
power to the machine has been externally disconnected. Open the line (wall) disconnect switch or circuit
breaker before attempting inspection or work inside
of the power source.
Capacitors are capable of storing high voltages even
when power is disconnected or unit is deenergized.
Ensure power supply capacitors are grounded prior
to performing maintenance.
6.2 TROUBLESHOOTING PROCEDURES
a simple visual inspection of all the components and
wiring. Check for secure terminal connections, loose or
burned wiring or components, bulged or leaking capacitors, or any other sign of damage or discoloration.
The cause of control malfunctions can be found by
referring to the schematic diagram (gures 6-1) and
wiring diagram (gure 6-2) and checking the various
components. A volt-ohmmeter will be necessary for
some of these checks.
Voltages in plasma cutting equipment are high enough
to cause serious injury or possibly death. Be particularly careful around equipment when the covers are
removed.
NOTE
Before checking voltages in the circuit, disconnect the
power from the high frequency generator to avoid
damaging your voltmeter.
Check the problem against the symptoms in the following troubleshooting guide, table 6-1. The remedy may
be quite simple. If the cause cannot be quickly located,
shut o the input power, open up the unit, and perform
39
Table 6-1. Troubleshooting Guide - (Cont)
PROBLEM POSSIBLE CAUSE ACTION
2 If power switch is ON, fan is
running, and power
indicator is ON but:
a) Plasma gas pressure
fault indicator is ON.
b) Cooling gas pressure
fault indicator is ON.
c) Power source
temperature fault indicator
is ON (happened if unit was
being used previously).
d) Over/under voltage fault
indicator is ON.
e) Power source fault
indicator is ON.
a) Insufficient plasma gas pressure
to the unit.
b) Insufficient cooling gas pressure
to the unit.
c) (1) Insufficient ventilation at the
rear end of the unit.
(2) One or both side covers
removed.
(3) Broken wire on one or two
thermal switches.
d) Input voltage is above or under
15% of the rated voltage connection
to the unit.
e) Gas Test Switch is in Test
position.
a) Increase the cooling gas
pressure or remove restrictions in
the gas flow.
b) Increase the cooling gas
pressure or remove restrictions in
the gas flow.
c) (1) Leave at least 2' between
the back of the unit and the wall for
proper air circulation.
(2) Install and secure both side
covers.
(3) Repair wires.
d) Correct the input voltage and
recycle the power to the unit.
e) Set Gas Test Switch to
OPERATE position.
3. Depress torch switch or
send start signal but:
a) Plasma gas flow fault
indicator comes ON (only in
single gas and PT-20AM
applications).
a) Insufficient plasma gas pressure
or restricted gas flow.
a) (1) Increase gas pressure.
(2) Remove restrictions in the
gas flow.
b) No pilot arc or main arc
established.
(If used with a manual torch:)
b) (1) Current setting switch is in the
remote position.
(2) Current dial is set too low.
(3) Cooling gas pressure is too
low to operate safety system.
(4) Torch safety connection is not
connected to power source.
b) (1) Correct current setting
switch to panel position.
(2) Increase the current setting.
SECTION 6 TROUBLESHOOTING
SECTION 6 TROUBLESHOOTING
40
Table 6-1. Troubleshooting Guide - (Cont)
PROBLEM POSSIBLE CAUSE ACTION
(If used with a mechanized torch and
remote current setting signal:)
b) (1) Current setting switch is in the
panel position.
(2) Current setting 0-10 V dc signal
is missing.
b) (1) Correct current setting
switch to remote position.
(2) Check for 0-10 V dc current
setting signal.
4. Arc does not transfer to
work.
(If open circuit voltage is okay between
300-325 V dc and there is pilot arc:)
a) Open connection between the power
source positive output and the work.
b) Power source work clamp not
properly connected to workpiece.
a) Repair connection.
b) Make work clamp connection to
clean bare metal of workpiece.
(If open circuit voltage is okay but there
is no pilot arc:)
b) (1) Pilot arc fuse F1 or F2 or both
are open.
(2) Faulty pilot arc contactor.
(3) Faulty control PCB.
(4) Preflow control is not given to
the CNC.
b) (1) Replace fuse(s).
(2) Replace pilot arc contactor.
(3) Replace PCB #1 P/N 38020.
(4) Remove jumper J1 from the
interface control PCB P/N 38048.
SECTION 6 TROUBLESHOOTING
SECTION 6 TROUBLESHOOTING
41
42
Figure 6-1. ESP-100i Schematic Diagram
D-35656-G
37
D-35706-H
Figure 6-2. ESP-100i Wiring Diagram (Sheet 1 of 2)
43
44
Figure 6-2. ESP-100i Wiring Diagram (Sheet 2 of 2)
D-35706-H
SECTION 7 REPLACEMENT PARTS
7.1 GENERAL
Replacement parts may be ordered from your ESAB
Replacement parts are illustrated in gures 7-1 thru
7-6.
Always provide the series or serial number of the unit
on which the parts will be used. The serial number is
stamped on the unit nameplate.
distributor or from:
ESAB Welding & Cutting Products
Attn: Customer Service Dept.
PO Box 100545, Ebenezer Road
Florence, SC, 29501-0545
7.2 ORDERING
To assure proper operation, it is recommended that
only genuine ESAB parts and products be used with
this equipment. The use of non-ESAB parts may void
your warranty.
Be sure to indicate any special shipping instructions
when ordering replacement parts.
Refer to the Communication Guide located on the last
page of this manual for a list of customer service phone
numbers.
45
LOCK
HIGH
REMOTE
UNLOCK
LOCK
TRIGGER
V
POWER
OFF
TEMP
P/S
FAULT
P/S
VOLTAGE
OVER/UNDER
PRESSURE
PLASMA GAS
GAS FLOW
PLASMA
OPERATE
TT
TEST
GAS
LOW
ARC
PILOT
A
1
10
9
8
7
6
5
4
3
2
0
PANEL
CURRENT
CONTROL
COOLING GAS
PRESSURE
ESP-100i
SECTION 7 REPLACEMENT PARTS
3
6
12, 16
4, 7
2
5
13, 14, 15
8
2
1
11, 16, 17
9
10
Figure 7-1. ESP-100i Front View
ITEM QTY PART CIRCUIT
NO. REQ. NO. DESCRIPTION SYMBOL
1 1 672508 SWITCH TOGGLE 3 PST (SEAL - 951474) S1, 55
2 1 634518 SWITCH TOGGLE DPDT (SEAL - 951474) S3, S4
3 1 673213 SWITCH TOGGLE SPST (SEAL - 951474) S2
4 1 13730611 KNOB
5 1 951061 METER, LED AM1
6 1 32197 PANEL, FRONT (CONTROL LABEL - 954484)
7 1 2062018 POTENTIOMETER, 10K 2W R12
8 2 952080 BOLT, EYE, 3/8" - 16 X 1"
9 1 950518 GROMMET, 2.12" I.D.
10 1 950167 GROMMET, 1.12" I.D.
11 1 35687YL PANEL, RIGHT SIDE
12 1 35686YL PANEL, LEFT SIDE
13 1 35689YL COVER, TOP
14 1 2091514 DECAL, WARNING
15 1 954558 LABEL, CAUTION LIFTING
16 2 13734588 DECAL, ESAB
17 1 995227 LABEL, WARNING EXPOSED TERMINAL
46
28
40
27
26
29
24, 25
23
40
35, 36
30
31
32
34
33
39
38
21
22
37
Spark Gap Setting:
0.036 - 0.040"
SECTION 7 REPLACEMENT PARTS
Figure 7-2. ESP-100i Left Side View
ITEM QTY PART CIRCUIT
NO. REQ. NO. DESCRIPTION SYMBOL
21 1 951179 XFMR HIGH VOLTAGE T7
22 1 0558001180 SPARK GAP ASSY. includes (2) electrodes SG
23 1 17280215 RESISTOR 1.5 KOHMS, 100W R2
24 1 672058 BLADE, FAN
25 1 2062334 MOTOR, FAN M1
26 1 672002GY SHROUD, FAN
27 1 35700 INDUCTOR, P.F. L1
28 1 952015 RESISTOR, PILOT ARC, 5 OHM 200W R10, 11
29 2 952012 CASTER, FIXED
30 2 952013 CASTER, SWIVEL
31 1 37251 BOX, HI FREQ.
32 1 950487 TERM. STRIP 2 POS. TB4
33 1 38131 PC BOARD ASSY. START UP PCB7
34 1 37250 HI FREQ REACTOR T5
35 1 952204 CAPACITOR 0.01uf 250VAC C20
36 2 672348 CAPACITOR 0.01uf 1KV C21, 22
37 2 951342 CAPACITOR 2500pf 1KV C23, 24
38 1 997830 RECEPTACLE 5 POLE J2
39 1 182W64 CONNECTOR TWIST LOCK J1
40 2 23604891 LABEL WARNING HI VOLTAGE
47
57
56
52
51
60, 61
65
55, 59
63
54
53
64
62
SECTION 7 REPLACEMENT PARTS
Figure 7-3. ESP-100i Top View with Top Cover Removed
ITEM QTY PART CIRCUIT
NO. REQ. NO. DESCRIPTION SYMBOL
51 1 32914 TRANSFORMER ASSEMBLY, CONTROL T1
52 1 35679 TRANSFORMER ASSEMBLY, CONTROL T2
53 1 995103 TERMINAL STRIP, 24 POSITION TB3
54 1 13735308 RELAY ENCLOSURE DPDT 120VAC, 20A K3
55 1 950368 PILOT ARC CONTACTOR K2
56 2 951983 CAPACITOR, 3300 µF C3, 4
57 1 38020 PC BOARD (used prior to Nov 07 - see change instructions
in back if replacing with 38214 PCB) PCB1
1 38214 PC BOARD (used after 15 Nov 07)
58 2 951028 CAPACITOR, 1µF 630 VDC C1, 2
59 1 952051 DIODE, ZENER, 180V ZD2
60 1 96W10 HOLDER, FUSE
61 1 2017483 FUSE 1A 250V FAST ACTING F3
62 1 99512078 RESISTOR 25 OHM 50W R1
63 2 951161 CAPACITOR, 20 µF, 400 VDC C18, 19
64 2 951469 CAPACITOR, .022 µF 250 VAC C16, 17
65 1 17140310 RESISTOR, 2W 10K R13
48
SECTION 7 REPLACEMENT PARTS
94
93
74
75
86
85
95
96
84, 80, 79
88
71
91
92
76
75
73
77
78, 87
77
78, 87
90
81, 97
89
72
76
83
Figure 7-4. ESP-100i Top View (PCB1 Removed)
ITEM QTY PART CIRCUIT
NO. REQ. NO. DESCRIPTION SYMBOL
71 1 38047 SHUNT, FEEDBACK PCB5
72 1 32958 TRANSFORMER, CURRENT T6
73 2 38052 PC BOARD ASSEMBLY IGBT DRIVER PCB2,3
74 2 951980 IGBT (PAD - 951191) Q1, Q2
75 2 951940 CAPACITOR, 1µF 600VDC C5, 6
76 2 950711 SWITCH, THERMAL TS1, 2
77 2 951185 MODULE DIODE 100A 600V (PAD - 951518) D1, D2
78 4 17721020 RESISTOR, 20 OHM 25W (PAD - 951193) R6, 7, 8, 9
79 3 951321 VARISTOR, METAL OX. 275V MOV1, 2, 3
80 1 2062282 CAPACITOR .22 µF 1000VDC C15
81 3 951161 CAPACUTIR 29 µF, 400 VDC C7, 8, 9
82 1 35791 BUSBAR CAPACITOR
83 1 951979 SCR (PAD - 951196) SCR 1
84 1 951978 BRIDGE DIODE (PAD - 951192) BR1
85 2 17750020 RESISTOR 20 OHM, 50W (PAD - 951194) R4, 5
86 1 951828 CAPACITOR, 0.033 µF, 630 VDC C10
87 4 951313 CAPACITOR 0.01 µF 630W VDC C11, 12, 13, 14
88 2 951981 HEATSINK
89 1 35791 BUSBAR CAPACITOR
90 1 35787 BUSBAR CAPACITOR/IGBT
91 1 35788 BUSBAR OUTPUT BRIDGE
92 1 35789 BUSBAR OUTPUT BRIDGE/SHUNT
93 1 35792 BUSBAR IGBT (+)/CAPACITOR
94 1 35793 BUSBAR IGBT (-)/CAPACITOR
95 1 35794 BUSBAR INPUT BRIDGE/SCR
96 1 35790 BUSBAR BRIDGE
97 1 17140310 RESISTOR 2W 10K R3
49
114
123
104
103, 111, 113
106
117
116
108
122
109,
115
101
123
102
112
120
121
107
119
118
105
110
SECTION 7 REPLACEMENT PARTS
Figure 7-5. ESP-100i Right Side View
ITEM QTY PART CIRCUIT
NO. REQ. NO. DESCRIPTION SYMBOL
101 1 952026 TERMINAL BLOCK, 7 POSITION TB2
102 1 35682 TRANSFORMER, AUTO T4
103 1 673502 CONTACTOR, MAIN K1
104 1 35681 TRANSFORMER ASSEMBLY, MAIN T3
105 1 35680 INDUCTOR ASSEMBLY, OUTPUT L2
106 1 35705 MANIFOLD
107 1 32947 TERMINAL WORK
108 2 951982 SWITCH, PRESSURE PS1, 2
109 2 952061 VALVE, SOLENOID GAS GSV1, 2
110 1 951202 FLOW SWITCH FS1
111 1 952051 DIODE, ZENER 180V ZD1
112 1 952043 SWITCH PRESSURE PS3
113 3 951963 VARISTOR METAL OX., 625V MOV4, 5, 6
114 1 38048 ISOLATION AMPLIFER PCB PCB4
115 1 951471 DIODE ZENER 62V 5W 7.1A ZD3
116 1 35847 HOSE ASSEMBLY, 24"
117 1 35846 HOSE ASSEMBLY, 22"
118 1 634090 ADAPTOR 1/4NPTM x C/A-W F
119 1 58V58 ADAPTOR 1/4NPTM x B/I-G F
120 1 32194 BOARD OUTPUT TERMINAL
121 1 13730583 TERMINAL BUSHING J5
122 1 647361 GROUND LUG
123 2 23604891 LABEL WARNING HI VOLTAGE
50
136, 137
131
135
143
134
138, 139, 140
136, 142
133
132
SECTION 7 REPLACEMENT PARTS
Figure 7-6. ESP-100i Rear View
ITEM QTY PART CIRCUIT
NO. REQ. NO. DESCRIPTION SYMBOL
131 1 2010277 HOUSING, 14-PIN AMPHENOL J3
132 1 23610197 HOLE PLUG, BLACK
133 1 950829 CIRCUIT BREAKER, 3A CB1
134 1 950937 STRAIN RELIEF
135 1 32196 PANEL, REAR
136 3 952136 FUSE HOLDER
137 2 952056 FUSE 20A 600V F1, F2
138 1 86W40 DUST PLUG - R.H.
139 1 86W41 DUST PLUG - L.H.
140 2 639582 PLUG & NUT
142 1 0558005164 FUSE 4A 600VAC TIME DELAY F4
143 1 954483 LABEL RATING ESP-100I
51
PCB 38020 TO 38214 CHANGE-OVER INSTRUCTIONS
DISCONNECT POWER IN TWO PLACES.1.
REMOVE TOP COVER.2.
REMOVE CONTROL PCB AND REPLACE WITH 38214 PCB. 3.
WARNING
ON THE P2 HARNESS CONNECTOR, REMOVE THE WIRE IN P2-5 AND PUT IT IN P2-7.4.
ON THE P2 HARNESS CONNECTOR, REMOVE THE WIRE IN P2-6 AND PUT IT IN P2-8.5.
INSTALL THE 0558001177 IGBT DRIVER BOARDS ON TO THE IGBTs AND PLUG THE CONNECTORS INTO P3 AND 6.
P4 ON THE 38214 PCB.
REPLACE COVERS AND TEST.7.
ESP-100i
FAILURE TO DO STEP 4&5 WILL CAUSE DAMAGE.
52
NOTES
53
NOTES
54
REVISION HISTORY
The "A Edition of this manual covers the following changes. Some changes were covered by two Inserts dated
March, 1996 and November, 1997.
1, Current ratings were changed to comply with NEMA standards.
2. Using the PT-20AM torch with plumbing box was claried by adding a connection diagram (Figure 4-5).
3. Pilot Arc High-Low switch (S5) was changed from SPST to 3PST for increased current capacity.
4. Starting with Serial No. PD-I742001, the HF/HV Ignition PC Board, 31490, was replaced by Spark Gas Assembly (SG), 36431, and the High Frequency Reactor (T5), 32969, was replaced by a stronger reactor, 37250, for
improved arc starting.
5. Added more replacement parts.
The "B" Edition (8/98) of this manual was printed to cover the change in mechanized cutting from high frequency
box and plumbing box system to the arc starter system. This change was previously covered by an Insert dated
June, 1998.
The "C" Edition (01/01) of this manual covers the updated safety precautions, components designations, descriptions and changed the IGB thermal pad from 951190 to 951191, part number correction for item 8-page 33, and
revised Communication Guide on back page.
The "D" Ediltion (07/02) of this manual done July, 2002
The "E" Edition (11/04) of this manual changed a fuse part number from 952559 to 0558005164 per CN# 043199.
The "F" Edition (12/07) of this manual changed Section 7, BOM item 57, part number to include 38214 per D. Perkins. Also added " ESP-100i PCB 38020 TO 38214 CHANGE-OVER INSTRUCTIONS" to back of manual.
55
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES
A. CUSTOMER SERVICE QUESTIONS:
Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST
Order Entry Product Availability Pricing Order Information Returns
B. ENGINEERING SERVICE:
Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting
C. TECHNICAL SERVICE:
Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Hours: 8:00 AM to 5:00 PM EST
Part Numbers Technical Applications Specications Equipment Recommendations
D. LITERATURE REQUESTS:
Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST
E. WELDING EQUIPMENT REPAIRS:
Telephone: (843) 664-4487 / Fax: (843) 664-5557 Hours: 7:30 AM to 3:30 PM EST
Repair Estimates Repair Status
F. WELDING EQUIPMENT TRAINING
Telephone: (843)664-4428 / Fax: (843) 679-5864 Hours: 7:30 AM to 4:00 PM EST
Training School Information and Registrations
G. WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST
H. TECHNICAL ASST. CONSUMABLES:
Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123
Fax: (843) 664-4462
Hours: 7:30 AM to 5:00 PM EST
or
Visit us on the web at http://www.esabna.com
The ESAB web site oers
Comprehensive Product Information
Material Safety Data Sheets
Warranty Registration
Instruction Literature Download Library
Distributor Locator
Global Company Information
Press Releases
Customer Feedback & Support
F15-249-F 12 / 2007 Printed in U.S.A.
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