ESAB ESP Flow Control Cut Water Switch Sticking Troubleshooting instruction

www.esab.com
DATE: March 7, 2003 BULLETIN NO:P_03_006
TITLE/ PRODUCT NAME:
ESP Flow Control Cut Water Switch Sticking
_ (Action is Required) (Potential Problem)
_ (Action is Optional) (Enhanced Product)
_ (Unrestricted) (Restricted Distribution)
PRODUCT SERIES/ MODEL:
ESP 1000 Plasma Cutting System - ESP Flow Control models:
PCC-90 (P/N 21294) original PLC and software
PCC90D (P/N 0558003629) New PLC
SERIAL NO:
All units built prior to February, 2003
SUMMARY:
_ DIRECTIVE _X_ ALERT
X_ INFORMATION _ _ PRODUCT IMPROVEMENT
X_ General Distribution _ _ Business Confidential
In the summer of 2002 the original ESP Flow control (PCC-90) was upgraded to a new PLC and software (PCC-90D). During development, it was observed a stuck cut water flow switch (in the closed or flowing position) could fool the PLC into thinking the start gas was flowing when it was not. The arc would mistakenly transfer resulting in inconsistent arc starting accompanied by nozzle and electrode damage due to the lack of start gas flow during arc initiation. This failure mode could occur using either the PT-19 dry torch or PT-15 water injection torch.
OPERATIONAL IMPACT:
Consistent arc starting and improved consumable life will result. Inconsistent and erratic arc stating followed by nozzle and electrode damage will be eliminated
ACTION:

PCC-90 Flow Control (P/N-21294) with Original PLC

For systems cutting with a PT 19 torch, the flow switch wire to input 6 of the PLC should be disconnected.

OR

For systems cutting with a PT-15 torch, replace the sticking cut gas flow switch (P/N-950612).

PCC-90D Flow Control (P/N-0558003629) with New PLC

For all systems, an upgrade to the flash memory is available (Ver1.01) for units manufactured before February 2003. Contact ESAB at the number below. All units manufactured in February 2003 or later have the upgraded software installed. Replace the sticking cut gas flow switch (P/N-950612).
CONTACT:
ESAB Welding & Cutting Products Product & Service Information Group 843-664-4416
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