ESAB ESP-50 Instruction manual

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
PARAGRAPH
TITLE
PAGE
SECTION 1
SAFETY.........................................................................................................................
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
5
table of contents
4
section 1safety precautions
1.0
Safety Precautions
1.1
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.
Safety - English
FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot
slag or sparks can also cause fires and
explosions. Therefore:
1. Remove all combustible materials well away from
the work area or cover the materials with a protective non-flammable 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 floors or wall openings and cause a
hidden smoldering fire or fires on the floor 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 flammable or toxic vapors.
Do not do hot work on closed containers. They
may explode.
4.Have fire extinguishing equipment handy for
instant use, such as a garden hose, water pail,
sand bucket, or portable fire 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 fire 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 fire. Use fire
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.
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 fitted with the correct filter 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 flameproof gauntlet type gloves, heavy
long-sleeve shirt, cuffless 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 flameproof apron may
also be desirable as protection against radiated
heat and sparks.
4.Hot sparks or metal can lodge in rolled up sleeves,
trouser cuffs, 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-flammable partition
or curtains.
6.Use goggles over safety glasses when chipping
slag or grinding. Chipped slag may be hot and
can fly far. Bystanders should also wear goggles
over safety glasses.
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 confined, or if there is danger
of falling.
5
section 1safety precautions
1. Be sure the power source frame (chassis) is
connected to the ground system of the input
power.
3.Welders should use the following procedures to
minimize exposure to EMF:
A.Route the electrode and work cables together.
Secure them with tape when possible.
2. Connect the work piece to a good electrical
ground.
B.Never coil the torch or work cable around your
body.
3. Connect the work cable to the work piece. A
poor or missing connection can expose you or
others to a fatal shock.
C.Do not place your body between the torch and
work cables. Route cables on the same side of
your body.
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.
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.
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.
Therefore:
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shielding gases can cause asphyxiation.
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.
9. Turn off the power before removing your
gloves.
10. R efer to ANSI/ASC Standard Z49.1 (listed
on next page) for specific grounding recommendations. Do not mistake the work lead for
a ground cable.
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.
ELECTRIC AND MAGNETIC FIELDS
— May be dangerous. Electric current flowing 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.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 effects
which are unknown.
4.Refer to ANSI/ASC Standard Z49.1 (see listing below) for specific ventilation recommendations.
6
section 1safety 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.)
1.Always have qualified personnel perform the
installation, troubleshooting, and maintenance
work. Do not perform any electrical work unless
you are qualified 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.
CYLINDER HANDLING -- Cylinders,
if mishandled, can rupture and violently release gas. Sudden rupture
of cylinder, valve, or relief device can
injure or kill. Therefore:
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.
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 fittings
in good condition. Follow manufacturer's operating instructions for mounting regulator to a
compressed gas cylinder.
5.Keep all safety devices and cabinet covers in
position and in good repair.
6.Use equipment only for its intended purpose. Do
not modify it in any manner.
2.Always secure cylinders in an upright position by
chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure
cylinders to work tables or fixtures where they
may become part of an electrical circuit.
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.
3.When not in use, keep cylinder valves closed.
Have valve protection cap in place if regulator
is not connected. Secure and move cylinders by
using suitable hand trucks. Avoid rough handling
of cylinders.
4.Locate cylinders away from heat, sparks, and
flames. Never strike an arc on a cylinder.
The following publications, which are available from
the American Welding Society, 550 N.W. LeJuene
Road, Miami, FL 33126, are recommended to you:
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
Jefferson Davis Highway, Arlington, VA 22202.
1.ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2.AWS C5.1 - "Recommended Practices for Plasma
Arc Welding"
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
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 1safety 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 1sEGURIDAD
1.2
Safety - Spanish
La escoria puede estar caliente y desprenderse
con velocidad. Personas cercanas deberán usar
gafas de seguridad y careta protectora.
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.
FUEGO Y EXPLOSIONES -- El calor de
las flamas 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 flamables, 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 inflamables o vapores tóxicos. No trabaje dentro o fuera de contenedores o tanques cerrados. Estos
pueden explotar si contienen vapores inflamables.
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.
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 filtro 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 chispas calientes con una cortina adecuada no-flamable
como división.
6. Use careta protectora además de sus gafas de seguridad cuando esté removiendo escoria o puliendo.
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
confinado en lugares estrechos o si hay
posibilidad de caer al suelo.
9
section 1sEGURIDAD
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 específicas de
como conectar el equipo a tierra. No confunda
el cable de soldar a la pieza de trabajo
con el cable a tierra.
3.Los soldadores deberán usar los siguientes procedimientos para minimizar exponerse al EMF:
A.Mantenga el electrodo y el cable a la pieza
de trabajo juntos, hasta llegar a la pieza que
usted quiere soldar. Asegúrelos uno junto al
otro con cinta adhesiva cuando sea posible.
B.Nunca envuelva los cables de soldar alrededor
de su cuerpo.
C.Nunca ubique su cuerpo entre la antorcha y el
cable, a la pieza de trabajo. Mantega los cables
a un sólo lado de su cuerpo.
D.Conecte el cable de trabajo a la pieza de
trabajo lo más cercano posible al área de la
soldadura.
E. Mantenga la fuente de poder y los cables de
soldar lo más lejos posible de su cuerpo.
HUMO Y GASES -- El humo y los gases,
pueden causar malestar o daño,
particularmente en espacios sin ventilación. No inhale el humo o gases. El
gas de protección puede causar falta de oxígeno. Por lo tanto:
1.Siempre provea ventilación adecuada en el
área de trabajo por medio natural o mecánico.
No solde, corte, o ranure materiales con hierro galvanizado, acero inoxidable, cobre, zinc,
plomo, berílio, o cadmio a menos que provea
ventilación mecánica positiva . No respire los
gases producidos por estos materiales.
2.No opere cerca de lugares donde se aplique
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 Standard Z49.1 (Vea la lista a continuación) para
recomendaciones específicas en la ventilación.
CAMPOS ELECTRICOS Y MAGNETICOS - Son peligrosos. La corriente
eléctrica fluye 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.
10
section 1sEGURIDAD
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.)
1.Siempre tenga personal cualificado para
efectuar l a instalación, diagnóstico, y mantenimiento del equipo. No ejecute ningún trabajo
eléctrico a menos que usted esté cualificado
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 modifique el equipo en ninguna
manera.
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.
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.
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.
Las siguientes publicaciones, disponibles através
de la American Welding Society, 550 N.W. LeJuene
Road, Miami, FL 33126, son recomendadas para
usted:
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.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 1sEGURIDAD
SIGNIFICADO DE LOS sImbolOs
-- Según usted avanza en la lectura
de este folleto: Los Símbolos Significan ¡Atención! ¡Esté Alerta! Se
trata de su seguridad.
Significa riesgo inmediato que,
de no ser evadido, puede resultar
inmediatamente en serio daño
personal o la muerte.
Significa el riesgo de un peligro
potencial que puede resultar en
serio daño personal o la muerte.
Significa el posible riesgo que
puede resultar en menores daños
a la persona.
12
section 1sÉCURITÉ
1.3
INCENDIES ET EXPLOSIONS -- La
chaleur provenant des flammes ou de
l'arc peut provoquer un incendie. Le
laitier incandescent ou les étincelles
peuvent également provoquer un
incendie ou une explosion. Par conséquent :
Safety - French
AVERTISSEMENT : Ces règles de sécurité
ont pour but d'assurer votre protection.
Ils récapitulent les informations de précaution 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
fiches 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.
1. Éloignez suffisamment tous les matériaux combustibles de l'aire de travail et recouvrez les matériaux
avec un revêtement protecteur ininflammable. 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 fissures 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 inflammables 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'extinction
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 surchauffer 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.
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 latéraux 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 filtrants et de
plaques protectrices appropriées afin 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 afin 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 ininflammable afin 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 ininflammable.
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.
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 1sÉCURITÉ
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 afin 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 effectuer 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
spécifiques concernant les procédures de mise
à la terre. Ne pas confondre le câble de masse
avec le câble de mise à la terre.
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 :
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 magnétiques peut avoir des effets néfastes inconnus
pour la santé.
14
1.Assurez en permanence une ventilation adéquate
dans l'aire de travail en maintenant une ventilation naturelle ou à l'aide de moyens mécanique.
N'effectuez jamais de travaux de soudage, de
coupage ou de gougeage sur des matériaux tels
que l'acier galvanisé, l'acier inoxydable, le cuivre,
le zinc, le plomb, le berylliym ou le cadmium en
l'absence de moyens mécaniques de ventilation
efficaces. Ne respirez pas les vapeurs de ces matériaux.
2.N'effectuez 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 afin 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 spécifiques
concernant la ventilation.
section 1sÉCURITÉ
ENTRETIEN DE L'ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou
inadéquate peut causer des blessures
graves ou mortelles. Par conséquent :
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.)
1.Efforcez-vous de toujours confier les tâches
d'installation, de dépannage et d'entretien à
un personnel qualifié. N'effectuez aucune réparation électrique à moins d'être qualifié à cet
effet.
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 fils 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 flaques 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'effectuez aucune modification.
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
fixez 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
flammes. 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 Jefferson Davis Highway, Arlington, VA
22202.
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 1sÉCURITÉ
SIGNIFICATION DES SYMBOLES
Ce symbole, utilisé partout dans ce manuel,
signifie "Attention" ! Soyez vigilant ! Votre
sécurité est en jeu.
DANGER
Signifie un danger immédiat. La situation peut
entraîner des blessures graves ou mortelles.
AVERTISSEMENT
Signifie un danger potentiel qui peut entraîner des
blessures graves ou mortelles.
ATTENTION
Signifie 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, retrofits, 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
Esab 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 retrofit 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,
filter/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
ESP-100i Console Only............................................................... 33530
ESP-100i/PT-25 Manual Packages
Specifications
(See optional regulators for other gases)
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)
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
Torch
Uses PT-25 or PT-20AM
17
SECTION 2
DESCRIPTION
Ordering Information (continued)
ESP-100i/PT-20AM Mechanized Packages
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
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 flow 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
Remote
Arc Starter
0558002634 - 50'
0558002635 - 100'
PT-20AM 0558002632 (4')
0558002633 (17')
Work Cable
30741 (7.6m)
System With Arc Starter
18
SECTION 2
DESCRIPTION
INSPECTION
A.
B.
C.
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 fixed caster wheels. Immediately notify the
carrier of any defects or damage.
Check container for any loose parts prior to disposing of shipping materials.
Check air louvers and any other opening to ensure
that any obstruction is removed.
30"
MINIMUM
HOISTING
CONTROL
30"
MINIMUM
A
REMOTE
HIGH
PILOT
ARC
PANEL
The ESP-100i is equipped with two lifting eyes that
enable the unit to be hoisted.
LOW
CURRENT
TRIGGER
LOCK
LOCK
GAS
TEST
TEST
PLASMA
GAS FLOW
PLASMA GAS
PRESSURE
UNLOCK
OPERATE
COOLING GAS
PRESSURE
P/S
TEMP
P/S
FAULT
ON
POWER
V
OVER/UNDER
VOLTAGE
OFF
ESP-100i
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 figure 2-1.
TORCH
!
DANGER
!
ELECTRIC
SHOCK at
or work cable
workpiece
can kill you.
Work cable
to workpieceMUST be connected
to avoid shock.
WORK
Figure 2-1. ESP-100i Hoisting Set-Up
FIG. 2-7
9541A030.EPS
19
SECTION 2
DESCRIPTION
2.1 General
2.3 Packages Available
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 specifications.
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.
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
ESP-100i Package with:
PT-20AMMechanized
TorchAir/Air
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
33530
21649
21946
30338
30741
31503
050356
33530
21371
21376
30338
30741
PT-25/100 A Spare Parts Kits, P/N 21946
Quantity
Description
Electrode Air/N2
Swirl Baffles
Nozzle-100A
21595
21667
21597
2
Nozzle-Gouging
21599
2
1
1
Heat Shield
Gouging Guard
Stand-Off Guide
21654
21656
21943
PT-25/150 A Spare Parts Kits, P/N 21947
Quantity
Description
PT-20 AM Spare Parts Kits
P/N
5
2
5
P/N
5
Electrode Air/N2
21780
2
5
Swirl Baffles
Nozzle-150A
21667
21598
2
2
Nozzle-Gouging
Heat Shield
21599
21654
1
1
Gouging Guard
Stand-Off Guide
21656
21943
678152
P/N
Description
Standard
P/N
"CE" P/N
50 A
21370
Heat Shield (70/100 A)
Heat Shield (50 A)
Cutting Nozzle (50 A)
Cutting Nozzle (70 A)
Cutting Nozzle (100 A)
Electrode
Electrode Seat
Electrode Insulator
Electrode Holder Assy
Baffle Tube
Pilot Arc Adaptor
O-Ring
Lubricant (1 oz.)
Seat/Baffle Wrench
1/16: Hex-Key Wrench (1,6 mm)
Box tool
21326
21447
21330
21329
21328
21150
21372
21373
21332
21374
19497
488157
17672
21375
93750006
950272
4485831
4485832
4485833
4485834
4485835
0558004249
4485839
21373
4485840
4485838
4485843
4485841
0558000443
4485842
4485651
950272
2
5
5
1
1
1
1
1
5
1
1
1
1
20
Quantity
70 A
100 A
21369 21376
2
1
5
5
5
1
1
1
1
1
5
1
1
1
1
2
1
5
5
5
5
1
1
1
1
1
5
1
1
1
1
SECTION 2
DESCRIPTION
2.4 Specifications
Refer to tables 2-2 thru 2-6, and figures 2-1 and 2-2 for
ESP-100i and torch technical specifications.
Table 2-2. ESP-100i Power Source Specifications
Rated Output
100% Duty Cycle
Output Current Range
100 A @ 120 V dc
10 to 100 Amperes
Open Circuit Voltage
325 V dc
Rated Primary Input, 3 phase, 50/60 Hz@ 12
kW Max. Output Power (100 A @120 V dc)
200 V
208 V
230 V
380 V
415 V
460 V
575 V
49 A / Phase
47 A / Phase
40 A / Phase
25 A / Phase
23 A / Phase
20 A / Phase
16 A / Phase
Power Factor @ 12kW Output
0.96
Efficiency @ 12kW Output
93% typical
Length
Height
Width
Dimensions
33.0" (838 mm)
27.3" (693 mm)
21.5" (546 mm)
Weight
408 lbs. (185 kg)
Shipping Weight
420 lbs. (191 kg)
Table 2-3. PT-25 Manual Torch andPT-20AM Mechanized Torch Specifications
Plasma/Cooling Gas
Shipping Weight
Length of Service Lines
Instruction Booklet
PT-20AM
PT-25
Air @ 85 psi (380 cfh)
20 lbs
Air @ 70 psi (560 cfh) *
14 lbs (25 ft)
25 lbs (50 ft)
25 or 50 ft
Form 15-266
50-ft
Form 15-114
* 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.
12.15"
7 5/8" min. - 14 1/2" max.
1 3/8" Dia.
4.48"
1.38" Dia.
1.60" Dia.
5/8" Mounting Stud
1.22" Dia.
1.47" Dia.
PT-25
17 1/2" With Rack
Figure 2-1. Cutting Torch Specifications
9406A001.eps
Figure 2-1 21
PT-20AM
6404A015.EPS
Figure 2-1
SECTION 2
DESCRIPTION
Cutting Parameters for the PT-20AM Torch on Carbon Steel
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
PT-25 150 amp, H-35 / N2
PT-25 100 amp, Air / Air
175
75
125
Cutting Speed (ipm)
Cutting Speed (ipm)
150 amp Cutting Data
H-35 Plasma at 70 psig
Nitrogen Cooling at 70 psig
100 amp Cutting Data
Air Plasma at 70 psig
Air Cooling at 70 psig
150
Carbon Steel
Aluminum
Stainless
100
75
50
50
Aluminum
Stainless
25
25
0
0.00
0.25
0.50
0.75
1.00
1.25
1.50
1.75
2.00
0
0.00
0.25
0.50
0.75
1.00
1.25
1.50
1.75
2.00
Material Thickness (in.)
Material Thickness (in.)
Figure 2-2. PT-25 Cutting Data
9406A002.eps
22
Figure 2-2
9406A003.eps
Figure 2-2
SECTION 3
INSTALLATION
3.1 General
As shipped, the ESP-100i is configured 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 figure 3-1.)
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.
A line (wall) disconnect switch with fuses or circuit breakers should be provided at the main power panel (see
figure 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.
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 filter-regulator supplied with
the package).
3.3 Location
Table 3-1. Recommended Sizes For
Input Conductors and Line Fuses
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.
Input Requirements
Installing or placing any type of filtering device will
restrict the volume of intake air, thereby subjecting the
power source internal components to overheating. Use
of any type of filter device voids the warranty.
Volts
Phase
Amps
Input & Gnd
Conductor
CU/AWG
Fuse Ratings
/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.
3.4 Primary Electrical Input Connections. (Figure 3-1.)
The following procedure explains the proper installation
ELECTRIC SHOCK CAN KILL! Precautionary measures steps for connecting primary electrical power to the ESPshould be taken to provide maximum protection against 100i. (See figure 3-1.)
electrical shock. Be sure that all power is off by opening
the line (wall) disconnect switch and by unplugging A. Remove right side panel.
the power cord to the unit when connections are made
B. Ensure input power cable is deenergized from all
inside of the power source.
electrical sources.
Be sure that the power source is properly configured
for your input power supply. DO NOT connect a power
source configured for 230 V to a 460 V input power supply. Damage to the machine may occur.
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 sufficient 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
SECTION 3
INSTALLATION
H.
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.
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.
Connect jumper wire to the proper input voltage
connector located on the 7-position terminal block.
(See figure 3-1.)
3.5 secondary (output) connec-
tions FOR MANUAL AND MECHANIZED CUTTING
Before making any connections to the power source
output terminals, make sure that all primary input
power to the machine is deenergized (off) at the main
disconnect switch.
Ensure three input power jumper cables are connected properly to the auto transformer for your input
power.
Input Power
Connections
Main
Contactor
Jumper
Power
Cables
575
200
230
380
415
460
460
575
415
380
230
200
460
PHASE C
575
415
230
200
460
575
415
380
230
200
380
PHASE B
PHASE A
7-POSITION
TERMINAL BLOCK
Move jumper to
proper input
voltage.
AUTO TRANSFORMER
Move the 3 jumpers
to proper input voltage.
NOTE: Jumpers are shown in the 575V positions.
Earth
Ground
Connection
Figure 3-1. ESP-100i Primary Power Connection Diagram
24
Customer Supplied Input
Power Cable
SECTION 3
INSTALLATION
CONTROL
REMOTE
A
PANEL
HIGH
PILOT
ARC
CURRENT
TRIGGER
LOCK
LOCK
GAS
TEST
TEST
LOW
PLASMA
GAS FLOW
PLASMA GAS
PRESSURE
UNLOCK
OPERATE
COOLING
PRESSUREGAS
P/S
TEMP
P/S
FAULT
ON
POWER
OVER/UND
VOLTAGE ER
V
OFF
ESP-100i
No Adaptor required,
remove Adaptor (21803)
supplied with console.
TORCH
!
DANG
ER
ELECTRIC
!
SHOCK
or work
at
cable
can kill workpiece
you.
Work
cable
to workpiec
MUST
be connecte
e to avoid
shock. d
WORK
Switch Lead
Work Cable
Plasma Gas /
Power Cable
PT-25 Torch
Safety Sensor
Tube
Cooling Gas /
Pilot Arc Cable
Figure 3-2. ESP-100i/PT-25 Interconnection Diagram
Shop Air
100 psi min.
150 psi max.
560 CFH
"Y" Connector
REMOTE
CONTROL
Filter-Regulator
30338
set pressure to
65-75 psig
Plasma Gas
Cooling Gas
CO2/N2
Air/CO2/N2
OXYGEN
COOLING
PLASMA
Ar-H2
GAS
GAS
Wall Disconnect
Figure 3-2. ESP-100i/PT-25 Interconnection Diagram -- Option 1
(For Use When Cutting Only; Not for Gouging)
25
6406A010.EPS
Figure 3-3 / sht. 1
SECTION 3
INSTALLATION
R-76 Regulators
Set pressure at
65-75 psig for cutting.
40-45 psig for gouging.
Cooling Gas
Shop Air
100 psi min.
150 psi max.
360 CFH
Filter-Regulator
30338
REMOTE
CONTROL
CO2/N2
Air/CO2/N2
OXYGEN
COOLING
PLASMA
Plasma Gas
N2
H-35 or
N2-H2
Ar-H2
GAS
GAS
200 CFH
Wall Disconnect
Figure 3-2. ESP-100i/PT-25 Interconnection Diagram -- Option 2
(For Use When Cutting or Gouging)
Set pressure at
65-75 psig for cutting.
40-45 psig for gouging.
Set pressure at
65-75 psig
REMOTE
CONTROL
CO2/N2
Air/CO2/N2
OXYGEN
COOLING
PLASMA
Ar-H2
GAS
Plasma Gas
N2
H-35
N2-H2
or Air
Cooling Gas
N2
CO2 or
Air
200 CFH
360 CFH
GAS
Wall Disconnect
1. DO NOT use Oxygen at all.
2. DO NOT use Argon or Ar-H2
mix for Cooling Gas.
NOTE;
This option will require a few
cylinders manifolded or a bulk system
to maintain flow requirements of torch.
Figure 3-2. ESP-100i/PT-25 Interconnection Diagram -- Option 3
(For Use When Cutting or Gouging)
26
6406A011.EPS
Figure 3-3 / sht. 2
SECTION 3
INSTALLATION
F.
3.5.1 Using PT-25 Torch. (Refer to figure
3-2.)
A.
B.
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.
3.5.2 Using PT-20AM Torch. (Refer to figure 3-3.)
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 fitting and tighten firmly
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 fitting and tighten firmly with a wrench; (3)
Connect the 5-pin switch lead to the mating receptacle. Make sure plug is firmly locked in place.
(4) Insert safety sensor tube into tube fitting until
fully seated.
C.
Reinstall right side panel.
D.
Referring to the interconnection diagram (figure
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.
Do NOT use argon or argon mixtures as cooling gas in
the PT-25 torch. Internal arcing in the torch head may
occur.
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
firmly 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 bushing 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
fitting and tighten firmly with a wrench; (2) Connect
pilot arc cable to the adaptor assembled on PILOT
ARC fitting at the most convenient tapped hole
position of adaptor. With washer and lockwasher
in place, tighten screw firmly with a screwdriver.
D.
Reinstall right side panel.
E.
Assemble the filter-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 filterregulator outlet fitting and to the Air/N2 plasma gas
fitting 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 fitting) of the filter-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 figure
3-4).
Do NOT use oxygen as cooling or plasma gas. The
torch may catch fire.
E.
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.
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 figure
3-4).
A poor connection or failure to connect work cable to
workpiece can result in fatal shock.
27
SECTION 3
INSTALLATION
I.
A poor connection or failure to connect work cable to
workpiece can result in fatal shock.
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.
CONTROL
REMOTE
A
PANEL
HIGH
PILOT
ARC
CURRENT
TRIGGER
LOCK
LOCK
GAS
TEST
TEST
LOW
PLASMA
GAS FLOW
P/S
TEMP
PLASMA GAS
PRESSURE
UNLOCK
P/S
FAULT
OPERATE
COOLING
PRESSUREGAS
ON
POWER
OVER/UND
VOLTAGE ER
V
OFF
ESP-100i
Pilot Arc Adaptor
21803
TORCH
!
DANG
ER
ELECTRIC
!
SHOCK
or work
cable can at workpiec
kill you.
e
Work cable
to workpiec MUST
be connecte
e to avoid
shock. d
WORK
Work Cable
PT-20AM
Interface Cable (PT-20AM only)
Shop Air
150 psi max.
100 psi min.
REMOTE
CONTROL
Hose
678152
Filter-Regulator
30338
CO2/N2
Air/CO2/N2
OXYGEN
COOLING
PLASMA
Ar-H2
GAS
GAS
Wall Disconnect
Figure 3-3. ESP-100i Interconnection Diagram
28
SECTION 3
INSTALLATION
EARTH GROUND
INSULATING GLOVE
DO NOT ATTACH WORK
CABLE TO PIECE BEING CUT
FREE
WORK CABLE
GROUNDED
WORK TABLE
BE SURE WORK IS IN GOOD
CONTACT WITH TABLE.
WORK CABLE
EARTH GROUND
Figure 3-4. Ground and Work Cable Connections
29
SECTION 3
INSTALLATION
30
SECTION 4
OPERATION
4.1 Operation
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 illuminate due to the power source being locked out
for operator safety.
G.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
Digital Ammeter Readout. Indicates actual cutting
current 0-100 amps.
H.
• Wear welding helmet with No. 6 or 7 lens shade.
• Wear eye, ear, and body protection.
Plasma Gas Flow Fault Indicator. Indicates insufficient plasma gas flow to torch.
I.
Plasma Gas Pressure Fault Indicator. Indicates
insufficient plasma gas pressure to torch.
J.
Cooling Gas Pressure Fault Indicator. Indicates
insufficient cooling gas pressure to torch.
NOTE: Operator must check input gas into ESP100i.
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.
ELECTRIC SHOCK can kill.
• Do NOT operate the unit with the cover removed.
• 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.
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/Off Switch. Turns unit on/off.
B.
Power On Indicator. Indicates unit is on.
C.
Pilot Arc Current Selector Switch. In the low position (down) unit is used for cutting. In the high
position (up) unit is used for gouging.
M. Over/Under Voltage Fault Indicator. Indicates
applied input voltage is out of tolerance from the
required input voltage.
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
NOTE
Light will flash until unit power is cycled.
31
SECTION 4
OPERATION
D
G
CONTROL
C
A
REMOTE
4
5
6
3
2
1
PANEL
K
HIGH
7
8
9
PILOT
ARC
10
0
LOW
CURRENT
TRIGGER
LOCK
GAS
TEST
UNLOCK
E
F
PLASMA
GAS FLOW
T T
LOCK
PLASMA GAS
PRESSURE
P/S
TEMP
P/S
FAULT
COOLING GAS
PRESSURE
OVER/UNDER
VOLTAGE
POWER
V
OFF
OPERATE
H
I
J
L
M
B
A
Figure 4-1. ESP-100i Controls
FIG 3-1
9541A016.EPS
Figure 4-2. Recommended Torch Angle of 5° to 15° Leading
32
SECTION 4
OPERATION
4.3 MANUAL Cutting with the PT-25
NOTE
Use the following procedures to cut with the PT-25 torch.
(Figures 4-2 thru 4-4).
If cutting arc does not start within 5 seconds, the pilot
arc will shut off. Release torch switch. Check to be sure
gas pressures are adequate (particularly the cooling gas
pressure), work cable is firmly connected to workpiece,
torch was about 1/8 to 1/4-in. above workpiece, etc.
Then start from step 1 again.
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 filter lens shade No. 8
should provide adequate protection for your eyes.
D.
For ease of operation, use the stand-off guide. If
using the standard shield guard, maintain a standoff (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 figure 4-2), and move it at a rate
that produces the desired cut quality (See figure
4-3). The cutting should produce a straight fine
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 off 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-off 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.
Too Fast
Push down on the torch switch button mounted
on the torch handle. Main contactor will come
on; gas will start flowing. Two seconds later, the
pilot arc contactor and high frequency will energize. The cutting arc should then transfer to the
workpiece.
Too Slow
Correct
Figure 4-3. Effect of Cutting Speed
33
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
Disconnect two existing
terminals from plug (J5).
Then connect the Arc Starter cable.
HOSE/ CABLE ADAPTOR - 36743
PILOT ARC ADAPTOR - 21803
“E”
“D”
“C”
WORK CABLE - 30741 (25’)
“B”
“A” (ToWork)
(4) .250”
(6 mm)
2.125”
(54mm)
.035” (0.9mm)
7.0”
(178mm)
SPARK GAP ASSEMBLY
(Torch end of Arc Starter)
MOUNTING DIMENSIONS
Figure 4-5. Connection Diagram - ESP-100i/PT-20AM with Arc Starter
35
SECTION 4
OPERATION
2 WHEN THE ARC BREAKS
THROUGH THE WORK, BRING
THE TORCH TO AN UPRIGHT
POSITION AND PROCEED TO
CUT.
1 TO START A PIERCE. TILT THE
TORCH TO PREVENT MOLTEN
MATERIAL FROM COMING BACK
AGAINST AND DAMAGING THE
TORCH.
Figure 4-6. Typical Piercing Technique
2.
3.
4.
5.
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.
Insufficient Penetration.
1.
2.
3.
Main Arc Extinguishes.
Cutting speed too slow.
C.
Dross Formation. (In some materials and thicknesses, it may be impossible to get dross-free
cuts.)
1.
2.
3.
D.
Uneven Arc.
Damaged cutting nozzle or worn electrode.
F.
Unstable Cutting Conditions.
1.
2.
3.
G.
Cutting speed too fast or too slow.
Improper air pressure.
Faulty nozzle or electrode.
H.
Low air pressure.
Front panel fault light tripped.
Loose connections.
Work clamp not connected.
Cooling gas pressure not sufficient
Torch safety connection not connected.
Poor Consumable Life.
1.
2.
3.
36
Incorrect cutting speed.
Loose cable or hose connections.
Electrode and/or cutting nozzle in poor condition.
Main Arc Does Not Strike.
1.
2.
3.
4.
5.
Double Arcing. (Damaged Nozzle Orifice.)
1.
E.
Cutting speed too fast.
Damaged cutting nozzle.
Improper air pressure.
B.
Damaged cutting nozzle.
Loose cutting nozzle.
Heavy spatter.
Nozzle touches work while cutting.
Improper gas pressure.
Contaminated air supply.
Improper gas/electrode combination.
SECTION 5
MAINTENANCE
H.
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.
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:
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
Check work cable to workpiece connection.
B.
Check safety earth ground at workpiece and at
power source chassis.
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, fittings, and ground connections are tight.
Torch
Booklet
PT-25
PT-20AM
F-15-266
F-15-114
5.4 PREFLOW CONTROL
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.
Occasionally, bleed all water from the filter beneath the air filter-regulator.
A.
With manual torches: Preflow 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 preflow, place jumper J1 on interface
pc board (PCB4), P/N 38098.
C.
With mechanized torch and with Computer Numerical Control (CNC) controlling preflow, remove
jumper J1 from interface pc board (PCB4), P/N
38098.
5.5 Flow Switch (Figure 5-1.)
When excessive contamination is found in the air, the
flow 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 flow switch from the
system for cleaning.
Water or oil occasionally accumulates in compressed air
lines. Be sure to direct the first blast of air away from
the equipment to avoid damage to the ESP-100i.
A.
Ensure the system is shut down and there is no
trapped air under pressure in the piping.
G.
B.
Remove the piston plug.
C.
Remove the spring (FS-4 only). Use care when
handling spring to prevent distortion.
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.
37
SECTION 5
MAINTENANCE
D.
Remove the piston.
E.
Clean all parts with cleaning agent.
Plasma
Gas Switch
Cooling
Gas Switch
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.
Side View
To increase pressure: turn the gas pressure switch
counterclockwise.
Cooling
Gas Switch
To decrease gas pressure: turn the gas pressure
switch clockwise.
Plasma
Gas Switch
Figure 5-2. Gas Pressure Switch
PISTON PLUG
SPRING
PISTON
FLOW SWITCH
Figure 5-1. Disassembly/Assembly of Flow Switch
38
SECTION 6
TROUBLESHOOTING
6.1 Troubleshooting
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 (figures 6-1) and
wiring diagram (figure 6-2) and checking the various
components. A volt-ohmmeter will be necessary for
some of these checks.
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.
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.
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.
NOTE
Before checking voltages in the circuit, disconnect the
power from the high frequency generator to avoid
damaging your voltmeter.
6.2 troubleshooting procedures
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 off the input power, open up the unit, and perform
Table 6-1. Troubleshooting Guide
PROBLEM
I.
Power switch is in the ON
position but fan is not
running.
POSSIBLE CAUSE
I.
ACTION
If Power-ON indicator light is ON:
a) Broken or disconnected wire in
the fan motor circuit.
a) Repair wire.
b) Faulty fan.
b) Replace the fan motor.
II. If Power-ON indicator light is OFF:
a) Broken or disconnected wires to
the Power-ON/OFF switch.
a) Repair wire.
b) Power is not connected properly
to the input of the auto transformer
and/or the jumper.
b) Correct input power
connections.
39
33
SECTION 6
SECTION 6
TROUBLESHOOTING
TROUBLESHOOTING
Table 6-1. Troubleshooting Guide - (Cont)
PROBLEM
2
POSSIBLE CAUSE
ACTION
If power switch is ON, fan is
running, and power
indicator is ON but:
a) Plasma gas pressure
fault indicator is ON.
a) Insufficient plasma gas pressure
to the unit.
a) Increase the cooling gas
pressure or remove restrictions in
the gas flow.
b) Cooling gas pressure
fault indicator is ON.
b) Insufficient cooling gas pressure
to the unit.
b) Increase the cooling gas
pressure or remove restrictions in
the gas flow.
c) (1) Insufficient ventilation at the
c) Power source
rear end of the unit.
temperature fault indicator
is ON (happened if unit was
being used previously).
(2) One or both side covers
removed.
(3) Broken wire on one or two
thermal switches.
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) Over/under voltage fault
indicator is ON.
d) Input voltage is above or under
15% of the rated voltage connection
to the unit.
d) Correct the input voltage and
recycle the power to the unit.
e) Power source fault
indicator is ON.
e) Gas Test Switch is in Test
position.
e) Set Gas Test Switch to
OPERATE position.
3. Depress torch switch or
send start signal but:
a) Insufficient plasma gas pressure
a) Plasma gas flow fault
indicator comes ON (only in or restricted gas flow.
single gas and PT-20AM
applications).
b) No pilot arc or main arc
established.
a) (1) Increase gas pressure.
(2) Remove restrictions in the
gas flow.
(If used with a manual torch:)
b) (1) Current setting switch is in the b) (1) Correct current setting
remote position.
switch to panel 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.
34
40
(2) Increase the current setting.
SECTION6 6
SECTION
TROUBLESHOOTING
TROUBLESHOOTING
Table 6-1. Troubleshooting Guide - (Cont)
PROBLEM
POSSIBLE CAUSE
ACTION
(If used with a mechanized torch and
remote current setting signal:)
4. Arc does not transfer to
work.
b) (1) Current setting switch is in the
panel position.
b) (1) Correct current setting
switch to remote position.
(2) Current setting 0-10 V dc signal
is missing.
(2) Check for 0-10 V dc current
setting signal.
(If open circuit voltage is okay between
300-325 V dc and there is pilot arc:)
a) Open connection between the power a) Repair connection.
source positive output and the work.
b) Power source work clamp not
properly connected to workpiece.
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.
b) (1) Replace fuse(s).
(2) Replace pilot arc contactor.
(2) Faulty pilot arc contactor.
(3) Replace PCB #1 P/N 38020.
(3) Faulty control PCB.
(4) Preflow control is not given to
the CNC.
35
41
(4) Remove jumper J1 from the
interface control PCB P/N 38048.
D-35656-G
Figure 6-1. ESP-100i Schematic Diagram
42 36
D-35706-H
Figure 6-2. ESP-100i Wiring Diagram (Sheet 1 of 2)
37
43
D-35706-H
Figure 6-2. ESP-100i Wiring Diagram (Sheet 2 of 2)
44 38
SECTION 7
REPLACEMENT PARTS
7.1 General
Replacement parts may be ordered from your ESAB
distributor or from:
Replacement parts are illustrated in figures 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.
7.2 Ordering
ESAB Welding & Cutting Products
Attn: Customer Service Dept.
PO Box 100545, Ebenezer Road
Florence, SC, 29501-0545
Be sure to indicate any special shipping instructions
when ordering replacement parts.
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.
Refer to the Communication Guide located on the last
page of this manual for a list of customer service phone
numbers.
45
SECTION 7
REPLACEMENT PARTS
4, 7
5
2
13, 14, 15
8
2
CONTROL
3
A
REMOTE
4
5
6
3
2
1
PANEL
HIGH
7
8
9
0
PILOT
ARC
10
LOW
1
CURRENT
TRIGGER
LOCK
6
LOCK
GAS
TEST
T T
PLASMA
GAS FLOW
PLASMA GAS
PRESSURE
COOLING GAS
PRESSURE
UNLOCK
P/S
TEMP
P/S
FAULT
POWER
OVER/UNDER
VOLTAGE
V
OFF
OPERATE
ESP-100i
11, 16, 17
12, 16
9
10
Figure 7-1. ESP-100i Front View
ITEM
NO.
QTY
REQ.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
PART
NO.
DESCRIPTION
672508
634518
673213
13730611
951061
32197
2062018
952080
950518
950167
35687YL
35686YL
35689YL
2091514
954558
13734588
995227
SWITCH TOGGLE 3 PST (SEAL - 951474)
SWITCH TOGGLE DPDT (SEAL - 951474)
SWITCH TOGGLE SPST (SEAL - 951474)
KNOB
METER, LED
PANEL, FRONT (CONTROL LABEL - 954484)
POTENTIOMETER, 10K 2W
BOLT, EYE, 3/8" - 16 X 1"
GROMMET, 2.12" I.D.
GROMMET, 1.12" I.D.
PANEL, RIGHT SIDE
PANEL, LEFT SIDE
COVER, TOP
DECAL, WARNING
LABEL, CAUTION LIFTING
DECAL, ESAB
LABEL, WARNING EXPOSED TERMINAL
46
CIRCUIT
SYMBOL
S1, 55
S3, S4
S2
AM1
R12
SECTION 7
REPLACEMENT PARTS
22
21
37
Spark Gap Setting:
0.036 - 0.040"
38
39
33
28
34
40
32
27
31
26
30
40
29
24, 25
23
35, 36
FigureFigure
7-2. ESP-100i
Right
Side
View
7-2. ESP-100i
Left
Side
View
ITEM
ITEM QTYQTY PART
PART
NO.
DESCRIPTION
NO. REQ.REQ. NO. NO.
DESCRIPTION
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
2
2
1
1
2
951179
XFMR HIGH
VOLTAGE
1
951179XFMR
HIGH
VOLTAGE
36431
SPARK
GAP
ASSY.
- 32931
1
0558001180
SPARK GAP
ASSY.includes
includes(2)
(2)electrodes
electrodes
17280215
RESISTOR
1.5
kOHMS,
100W
1
17280215
RESISTOR 1.5 KOHMS, 100W
672058
FAN
1
672058 BLADE,
BLADE,
FAN
2062334
MOTOR,
FANFAN
1
2062334
MOTOR,
FAN
1 672002GY
672002GY SHROUD,
SHROUD,
FAN
35700
INDUCTOR,
P.F.P.F.
1
35700
INDUCTOR,
952015
PILOT
ARC,
1
952015 RESISTOR,
RESISTOR,
PILOT
ARC,55OHN
OHM200W
200W
952012
CASTER,
FIXED
2
952012
CASTER, FIXED
952013
SWIVEL
2
952013 CASTER,
CASTER,
SWIVEL
37251
BOX,
HI
FREQ.
1
37251
BOX, HI FREQ.
950487
STRIP
2 POS.
1
950487 TERM.
TERM.
STRIP
2 POS.
38131
PC
BOARD
ASSY.
START
1
38131
PC BOARD ASSY.
STARTUP
UP
37250
HI
FREQ
REACTOR
1
37250
HI FREQ REACTOR
952204
0.01uf
250VAC
1
952204 CAPACITOR
CAPACITOR
0.01uf
250VAC
672348
CAPACITOR
0.01uf
1KV1KV
2
672348
CAPACITOR 0.01uf
951342
2500pf
1KV1KV
2
951342 CAPACITOR
CAPACITOR
2500pf
997830
RECEPTACLE
5
POLE
1
997830
RECEPTACLE 5 POLE
TWIST
LOCK
1 182W64
182W64 CONNECTOR
CONNECTOR
TWIST
LOCK
23604891
LABEL
WARNING
HI
VOLTAGE
2
23604891
LABEL WARNING HI VOLTAGE
47
CIRCUIT
CIRCUIT
SYMBOL
SYMBOL
T7 T7
SG SG
R2 R2
M1 M1
L1 L1
R10,R10,
11 11
TB4 TB4
PCB7
PCB7
T5 T5
C20 C20
C21,C21,
22 22
C23,C23,
24 24
J2 J2
J1 J1
SECTION 7
REPLACEMENT PARTS
53
60, 61
51
52
54
63
64
65
55, 59
62
56
57
Figure 7-3. ESP-100i Top View with Top Cover Removed
ITEM
NO.
QTY
REQ.
PART
NO.
DESCRIPTION
51
1
32914
ITEM
PART
52
1QTY
35679
NO.
53NO.
1REQ. 995103
54
1
13735308
32914
55 51
1 1
950368
35679
56 52
2 1
951983
995103
57 53
1 1
38020
54
1
13735308
950368
55
1 1
38214
58 56
2 2
951028
951983
59 57
1 1
952051
38020
60 58
1 2
96W10
951028
61 59
1 1
2017483
952051
62 60
1 1
99512078
96W10
63 61
2 1
951161
2017483
64 62
2 1
951469
99512078
65 63
1 2
17140310
951161
64
2
951469
65
1
17140310
TRANSFORMER ASSEMBLY, CONTROL TRANSFORMER ASSEMBLY, CONTROL
DESCRIPTION
TERMINAL STRIP,
24 POSITION
RELAY ENCLOSURE DPDT 120VAC, 20A
TRANSFORMER
ASSEMBLY, CONTROL
PILOT
ARC CONTACTOR
TRANSFORMER
CAPACITOR,
3300 µFASSEMBLY, CONTROL
STRIP,
PC TERMINAL
BOARD (used
prior 24
to POSITION
Nov 07 - see change instructions
RELAY
ENCLOSURE
DPDTPCB)
120VAC, 20A
in back
if replacing
with 38214
CONTACTOR
PC PILOT
BOARDARC
(used
after 15 Nov 07)
CAPACITOR,
1µF 630
CAPACITOR,
3300VDC
µF
DIODE,
ZENER,ASSEMBLY
180V
PC BOARD
CONTROL
HOLDER,
FUSE 1µF 630 VDC
CAPACITOR,
FUSE
1A 250V
FAST 180V
ACTING DIODE,
ZENER,
RESISTOR
25 OHM
HOLDER,
FUSE50W
CAPACITOR,
µF,FAST
400 VDC
FUSE 1A 20
250V
ACTING
CAPACITOR,
.022
25050W
VAC
RESISTOR
25µF
OHM
RESISTOR,
2W 10K
CAPACITOR,
20 µF, 400 VDC
CAPACITOR, .022 µF 250 VAC
RESISTOR, 2W 10K
48
CIRCUIT
SYMBOL
T1
CIRCUIT
T2
SYMBOL
TB3
K3
K2 T1
C3, 4T2
TB3
K3
PCB1
K2
C1,C3,
2 4
ZD2
PCB1
C1, 2
F3ZD2
R1
C18, 19
F3
C16, 17
R1
R13
C18, 19
C16, 17
R13
SECTION 7
REPLACEMENT PARTS
76
75
93
73
94
75
74
86
88
85
95
71
96
92
84, 80, 79
91
77
78, 87
83
77
78, 87
90
81, 97
89
72
76
Figure 7-4. ESP-100i Top View (PCB1 Removed)
ITEM
NO.
QTY
REQ.
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
1
1
2
2
2
2
2
4
3
1
3
1
1
1
2
1
4
2
1
1
1
1
1
1
1
1
1
PART
NO.
DESCRIPTION
38047
32958
38052
951980
951940
950711
951185
17721020
951321
2062282
951161
35791
951979
951978
17750020
951828
951313
951981
35791
35787
35788
35789
35792
35793
35794
35790
17140310
SHUNT, FEEDBACK
TRANSFORMER, CURRENT
PC BOARD ASSEMBLY IGBT DRIVER
IGBT (PAD - 951191)
CAPACITOR, 1µF 600VDC
SWITCH, THERMAL
MODULE DIODE 100A 600V (PAD - 951518)
RESISTOR, 20 OHM 25W (PAD - 951193)
VARISTOR, METAL OX. 275V
CAPACITOR .22 µF 1000VDC
CAPACUTIR 29 µF, 400 VDC
BUSBAR CAPACITOR
SCR (PAD - 951196)
BRIDGE DIODE (PAD - 951192)
RESISTOR 20 OHM, 50W (PAD - 951194)
CAPACITOR, 0.033 µF, 630 VDC
CAPACITOR 0.01 µF 630W VDC
HEATSINK
BUSBAR CAPACITOR
BUSBAR CAPACITOR/IGBT
BUSBAR OUTPUT BRIDGE
BUSBAR OUTPUT BRIDGE/SHUNT
BUSBAR IGBT (+)/CAPACITOR
BUSBAR IGBT (-)/CAPACITOR
BUSBAR INPUT BRIDGE/SCR
BUSBAR BRIDGE
RESISTOR 2W 10K
49
CIRCUIT
SYMBOL
PCB5
T6
PCB2,3
Q1, Q2
C5, 6
TS1, 2
D1, D2
R6, 7, 8, 9
MOV1, 2, 3
C15
C7, 8, 9
SCR 1
BR1
R4, 5
C10
C11, 12, 13, 14
R3
SECTION 7
REPLACEMENT PARTS
114
103, 111, 113
123
104
117
116
108
105
106
118
110
119
109,
115
107
121
120
101
112
102
123
122
Figure 7-5. ESP-100i Right Side View
ITEM
NO.
QTY
REQ.
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
1
1
1
1
1
1
1
2
2
1
1
1
3
1
1
1
1
1
1
1
1
1
2
PART
NO.
DESCRIPTION
952026
35682
673502
35681
35680
35705
32947
951982
952061
951202
952051
952043
951963
38048
951471
35847
35846
634090
58V58
32194
13730583
647361
23604891
TERMINAL BLOCK, 7 POSITION
TRANSFORMER, AUTO
CONTACTOR, MAIN
TRANSFORMER ASSEMBLY, MAIN
INDUCTOR ASSEMBLY, OUTPUT
MANIFOLD
TERMINAL WORK
SWITCH, PRESSURE
VALVE, SOLENOID GAS
FLOW SWITCH
DIODE, ZENER 180V
SWITCH PRESSURE
VARISTOR METAL OX., 625V
ISOLATION AMPLIFER PCB
DIODE ZENER 62V 5W 7.1A
HOSE ASSEMBLY, 24"
HOSE ASSEMBLY, 22"
ADAPTOR 1/4NPTM x C/A-W F
ADAPTOR 1/4NPTM x B/I-G F
BOARD OUTPUT TERMINAL
TERMINAL BUSHING
GROUND LUG
LABEL WARNING HI VOLTAGE
50
CIRCUIT
SYMBOL
TB2
T4
K1
T3
L2
PS1, 2
GSV1, 2
FS1
ZD1
PS3
MOV4, 5, 6
PCB4
ZD3
J5
SECTION 7
REPLACEMENT PARTS
136, 137
143
135
131
132
133
136, 142
138, 139, 140
134
Figure 7-6. ESP-100i Rear View
ITEM
NO.
QTY
REQ.
131
132
133
134
135
136
137
138
139
140
142
143
1
1
1
1
1
3
2
1
1
2
1
1
PART
NO.
DESCRIPTION
2010277
23610197
950829
950937
32196
952136
952056
86W40
86W41
639582
0558005164
954483
HOUSING, 14-PIN AMPHENOL
HOLE PLUG, BLACK
CIRCUIT BREAKER, 3A
STRAIN RELIEF
PANEL, REAR
FUSE HOLDER
FUSE 20A 600V
DUST PLUG - R.H.
DUST PLUG - L.H.
PLUG & NUT
FUSE 4A 600VAC TIME DELAY
LABEL RATING ESP-100I
51
CIRCUIT
SYMBOL
J3
CB1
F1, F2
F4
ESP-100i
PCB 38020 TO 38214 CHANGE-OVER INSTRUCTIONS
1. DISCONNECT POWER IN TWO PLACES.
2. REMOVE TOP COVER.
3. REMOVE CONTROL PCB AND REPLACE WITH 38214 PCB.
WARNING
FAILURE TO DO STEP 4&5 WILL CAUSE DAMAGE.
4. ON THE P2 HARNESS CONNECTOR, REMOVE THE WIRE IN P2-5 AND PUT IT IN P2-7.
5. ON THE P2 HARNESS CONNECTOR, REMOVE THE WIRE IN P2-6 AND PUT IT IN P2-8.
6. INSTALL THE 0558001177 IGBT DRIVER BOARDS ON TO THE IGBTs AND PLUG THE CONNECTORS INTO P3 AND
P4 ON THE 38214 PCB.
7. REPLACE COVERS AND TEST.
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 clarified 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
Order Entry
Product Availability
Pricing
Hours: 8:00 AM to 7:00 PM EST
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
Part Numbers
Technical ApplicationsSpecifications
Hours: 8:00 AM to 5:00 PM EST
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
Repair Estimates
Repair Status
Hours: 7:30 AM to 3:30 PM EST
F. WELDING EQUIPMENT TRAINING
Telephone: (843)664-4428 / Fax: (843) 679-5864
Training School Information and Registrations
Hours: 7:30 AM to 4:00 PM EST
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 offers
Comprehensive Product Information
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F15-249-F
12 / 2007
Printed in U.S.A.