ESP-150 - ESAB Welding &

ESP-150
Plasma Cutting System
Instruction Manual
This manual provides installation and operation instructions for the following components beginning with Serial
Number PORJ129127:
F15-687-H 02/2015
Be sure this information reaches the operator.
You can get extra copies through your supplier.
caution
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding and cutting equipment, we urge
you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and
Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain
this equipment. Do NOT attempt to install or operate this equipment until you have read
and fully understand these instructions. If you do not fully understand these instructions,
contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment
should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone
or written request for service advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
2
table of contents
Section / Title
Page
1.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Safety - English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Safety - Spanish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Safety - French . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.0Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.0Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1 Inspection and Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2 Primary Input Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3 Voltage Divider Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.4 Torch Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.5 Gas Supply Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.6 Work and Earth Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.7 Torch Coolant Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.0Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.1 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.2 ESP-150 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.4 Standoff and Cut Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.5 Dross Formation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.6 Common Cutting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.7 Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.8 Cut Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.0Maintenence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.1Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.0 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.1General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.2Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3
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
workpiece has been completely cleaned so that there
are no substances on the workpiece 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, Batterymarch 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 longsleeve 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:
2.Connect the workpiece to a good electrical
ground.
A.Route the electrode and work cables together.
Secure them with tape when possible.
3. Connect the work cable to the workpiece. A poor
or missing connection can expose you or others to
a fatal shock.
B.Never coil the torch or work cable around your
body.
C.Do not place your body between the torch and
work cables. Route cables on the same side of
your body.
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 workpiece as close
as possible to the area being welded.
6. Make sure that all parts of your body are insulated
from work and from ground.
E. Keep welding power source and cables as far away
from your body as possible.
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:
9. Turn off the power before removing your gloves.
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.
10. Refer to ANSI/ASC Standard Z49.1 (listed on next
page) for specific grounding recommendations. Do
not mistake the work lead for a ground cable.
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:
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.
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
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.
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.)
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"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
EQUIPMENT MAINTENANCE -- Faulty or improperly
maintained equipment can cause injury
or death. Therefore:
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 1safety precautions
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 1safety precautions
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 1safety precautions
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 1safety precautions
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 1safety precautions
1.3
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.
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 :
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 1safety precautions
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 porteélectrode/torche et la source d'alimentation.
6.Assurez-vous que tout votre corps est bien isolé
de la pièce à traiter et des pièces de la mise à la
terre.
7. Si vous devez effectuer votre travail dans un espace
restreint ou humide, ne tenez vous pas directement sur le métal ou sur la terre; tenez-vous sur
des planches sèches ou une plate-forme isolée et
portez des chaussures à semelles de caoutchouc.
8. Avant de mettre l'équipement sous tension, isolez
vos mains avec des gants secs et sans trous.
9. Mettez l'équipement hors tension avant d'enlever
vos gants.
10. Consultez ANSI/ASC Standard Z49.1 (listé à la
page suivante) pour des recommandations 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 :
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.
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
section 1safety precautions
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.)
ENTRETIEN DE L'ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou
inadéquate peut causer des blessures
graves ou mortelles. Par conséquent :
1.Efforcez-vous de toujours confier les tâches
d'installation, de dépannage et d'entretien à un
personnel 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 1safety precautions
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.
caution
Class A equipment is not intended for use in residential locations
wherethe electrical power is provided by the public low-voltage supply system.There may be potential difficulties in ensuring electromagneticcompatibility of class A equipment in those locations, due to conductedas well as radiated disturbances.
caution
This product is solely intended for plasma cutting.
caution
Do not dispose of electrical equipment together with normal waste! In
observance of European Directive 2002/96/EC on Waste Electrical and
Electronic Equipment and its implementation in accordance with national law, electrical equipment that has reached the end of its life must
be collected separately and returned to an environmentally compatible
recycling facility. As the owner of the equipment, you should get information on approved collection systems from our local representative.
By applying this European Directive you will improve the environment
and human health!
16
section 2description
2.0Description
ESP-150 PlasmarcTM System
This versatile, all encompassed heavy duty water cooled plasma
cutting and gouging system is ideal for manual and mechanized
applications.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Greater productivity - high speed cutting of most metals
from gauge thickness to 2” (50 mm) thick plate Versatility - 230/460/575 volt three-phase input Greater variation - adjustable output - 25 to 150 amps
Built-In Water Cooler - simplifies maintenance, less hookup, no wiring issues, no extra hoses. Water flow is controlled with power supply
Water cooled Torch PT-26
Leather sheath wrapped torch - protects torch leads from
abrasion and molten metal
Cuts with air, nitrogen, argon-hydrogen mixtures or nitrogen-hydrogen mixtures
Built-In CNC interface provides easy connection of automation applications
Torch design provides perfect electrode centering - provides longer tip life by minimizing the possibility of double-arcing
Torch spare parts kit supplied with each outfit - ample
supply of spare parts to minimize downtime at no additional cost
Thermal overload switches - prevents damage if unit
overheats due to insufficient air flow
Line voltage compensation
Automatic intermittent cutting - additional capability,
permits continuous cutting of grates, expanded metal,
heavy screen material, etc.
Wheels and cylinder rack - all provided standard for portability and greater utilizationat no additional cost
Ideal for plasma gouging
Three year warranty on console
One Year warranty on torch
Torch
PT-26 - 70°, 90° or In-Line
Specifications
Input Current and Input Voltage at Rated Load
................................................112/56/45 amps, 230/460/575 Vac, 60 Hz, 3 Ph
Output Rating
90% duty cycle..........................................................................150 amps @ 120 V
100% duty cycle.......................................................................140 amps @ 120 V
Open circuit Voltage......................................................................................... 370 vdc
Dimensions............................................................................. w = 21.75 in. (552mm)
...................................................................................................h = 31.5 in. (800mm)
....................................................................................................d = 40 in. (1016mm)
Weight...................................................................................................766 lbs. (348 kg)
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period
that you can weld at a cer­tain load without overloading. The duty cycle is
valid for 40°C.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection
against penetration by solid objects or water.
2.1Equipment
The power source is supplied with coolant and instruction
manual.
17
section 2description
How to Order
Optional Accessories
The ESP-150 package includes console, PT-26 torch with leather
sheath, torch spare parts kit, 25 ft. or 50 ft. work cable, TR-21 truck
with dual cylinder rack, regulators and gas hoses and torch coolant.
150 amp Spare Parts Kit ............................................................... 0558002864
Remote Hand Switch
Permits remote starting and stopping of cutting process;
used primarily for mechanized cutting..........................................2075600
25 ft. Leather Sheath*
Protects torch leads from abrasion and molten metal; particularly .....
recommended for plasma gouging.............................................. 0558002921
50 ft. Leather Sheath* .................................................................... 0558002922
Plasma Flow Measuring Kit
This valuable troubleshooting tool allows measurement of the ..........
actual plasma gas flow through the torch......................................... 19765
Plasma Torch Head Protector
For gouging.................................................................................................. 20806
Trigger Latch Kit
(Factory Installed Only)................................................................... 0588000939
ESAB can provide you with all necessary welding protection and
accessories.
Ordering Information
ESP-150 Packages
230/460/575 V, 60Hz, 3 Phase
ESP-150, 25’ PT-26 70° Air.................................................................. 0558002909
ESP-150, 50’ PT-26 70° Air.................................................................. 0558002910
ESP-150, 25’ PT-26 90° Air.................................................................. 0558002911
ESP-150, 50’ PT-26 90° Air.................................................................. 0558002912
ESP-150, 25’ PT-26 Inline/Air............................................................. 0558002913
ESP-150, 50’ PT-26 Inline/Air............................................................. 0558002914
ESP-150, 25’ PT-26 70° Ar+H2 Mix.................................................... 0558002915
ESP-150, 50’ PT-26 70° Ar+H2 Mix.................................................... 0558002916
ESP-150, 25’ PT-26 90° Ar+H2 Mix.................................................... 0558002917
ESP-150, 50’ PT-26 90° Ar+H2 Mix.................................................... 0558002918
ESP-150, 25’ PT-26 Inline/Ar+H2 Mix.............................................. 0558002919
ESP-150, 50’ PT-26 Inline/Ar+H2 Mix.............................................. 0558002920
*Standard on manual torches.
ESP-150 Console Only
230/460/575V, 60 Hz, 3 Phase.......................................................... 0558002677
NOTE: Contact your ESAB Representative to substitute console.
18
section 2description
Assembly of PT-26 Front End Parts
PT-26 Manual Models
O-Ring Location - 2029450
Torch Head 90°................................ 34599
70°.....................0558002204
Includes O-Rings:
2110706 (1)
2029450 (3)
O-Ring Location - 2110706
Electrode Holder - 34583
Includes O-Rings
85W49 (Upper)
948317 (Lower)
Electrode
36565 - Air, Nitrogen, Nitrogen/Hydrogen
36566 - Argon/Hydrogen (H-35)
Heat Shield
Manual Torch - 34592
*Close Proximity - 37146
Baffle Tube - 34585
Insulator - 34593
Includes O-Ring - 84W87
Stand-Off Guide - 36648
AMPS
P/NORIFICE SIZE
Cutting Nozzle
**5036567 .052
15036568 .078
20036569 .089
30036570 .104
Gouging Nozzle
20036571 .125
30036572 .144
* Close proximity Heat Shield. Optional for
Manual Torch when cutting or gouging in close
proximity of workpiece.
**For 65 Amp Mechanized Cutting use Heat Shield
34592 or 37146
All include O-Rings 2110578 (Upper)
994092 (Lower)
PT-26 In-Line Models
Torch Head IN-LINE....... 0558002110
Includes O-Rings:
2110706 (1)
2029450 (3)
O-Ring Location - 2029450
Baffle Tube - 34585
O-Ring Location - 2110706
**These items along with a baffle installation tool (0558003584) are shipped with
all mechanized versions of this torch.
**Swirl Baffle, In-line - 0558003583
Includes O-Ring - 2110578 & 14K07
Electrode Holder - 34583
Includes O-Rings
85W49 (Upper)
948317 (Lower)
Electrode
36565 - Air, Nitrogen, Nitrogen/Hydrogen
36566 - Argon/Hydrogen (H-35)
AMPS
P/NORIFICE SIZE
Cutting Nozzle
5036567 .052
15036568 .078
20036569 .089
30036570 .104
Gouging Nozzle
20036571 .125
30036572 .144
All include O-Rings 2110578 (Upper)
994092 (Lower)
19
Heat Shield Manual Torch - 34592
Shield Cup, Mechanized - 0558003582
section 2description
PT-26 Technical Specifications (Plasma Gas)
Type of Gas
N2, Air, AR-H2, N2-H2
Pressure
100 psig (6.9 bar)
Flow
240 cfh (6.8 M3/h)
Purity Required
O2 - 99.5% min., N2-99.995% min., Air - clean and dry
Recommended Liquid Cylinder Service Regulators
Inert Gas
R-76-150-580LC
19977
Recommended cylinder 2-Stage Regulators
Argon-Hydrogen
R-77-75-350
998341
Nitrogen
R-77-75-580
998343
Recommended Heavy-Duty Hi-Flow
Station or Pipeline Regulators
Industrial Air
R-77-150-590
998348
Nitrogen
R-76-75-034
19155
PT-26 Technical Specifications (Starting Gas/Cutting Gas)
Type
N2, Air (for Ar-H2 Cut Gas Use N2 or Ar-H2)
Pressure
100 psig (6.9 bar
Flow
200 cfh (5.66M3/h) @ 60 psig (4.1 bar)
Purity Required
N2 - 99% min., Air - clean and dry
PT-26 Technical Specifications (Shield Gas)
Type
N2 or Air
Pressure
100 psig (6.9 bar) maximum
Flow
200 cfh (5.66 M3/h) @ 85 psig (5.86 bar)
Purity Required
Nitrogen - 99% minimum, Air - clean and dry
16.5”
(419mm)
2”
(50.8)
Figure 1 - PT-26 In-line Torch Dimensions
Figure 2 - PT-26 Manual Torch Dimensions
20
section 2description
The ESP-150 system is available as pre-engineered basic packages or can be ordered as individual parts and pieces for a custom system.
The basic pre-engineered systems contain the ESP-150 console, plasma torch, appropriate regulators for the gases indicated, and torch
coolant. For torch information, refer to the PT-26 manual F-15-345.
Ar/H2 PACKAGES
ESP-150 MANUAL PLASMA CUTTING PACKAGES
AIR PACKAGES
0558002915 - ESP-150 / PT-26 25’ 70° / Ar+H2 Mix
P/N
QTY
DESCRIPTION
0558002677
1
ESP-150 Console
0558002208
1
PT-26, 70°, 25’ Plasma Torch
0558002864
1
PT-26 Spare Parts Kit, 150A
998341
2
Argon/Hydrogen Mix Regulator
998343
1
Nitrogen Regulator
33122
3
Hoses
678723
1
Work Cable, 25’
19X54
2
Adaptors
156F05
4
Coolant (4 gallons)
680794
1
Truck & CyIinder Rack
0558002909 - ESP-150 / PT-26 25’ 70° / Air
P/N
QTY
DESCRIPTION
0558002677
1
ESP-150 Console
0558002208
1
PT-26, 70°, 25’ Plasma Torch
0558002864
1
PT-26 Spare Parts Kit, 150A
0558003242
1
Air Reg. Assembly
678724
1
Work Cable, 50’
156F05
4
Coolant (4 gallons)
680794
1
Truck & CyIinder Rack
0558002916 - ESP-150 / PT-26 50’ 70° / Ar+H2 Mix
0558002910 - ESP-150 / PT-26 50’ 70° / Air
P/N
QTY
P/N
DESCRIPTION
QTY
DESCRIPTION
0558002677
1
ESP-150 Console
0558002209
1
PT-26, 70°, 50’ Plasma Torch
0558002864
1
PT-26 Spare Parts Kit, 150A
998341
2
Argon/Hydrogen Mix Regulator
998343
1
Nitrogen Regulator
33122
3
Hoses
0558002677
1
ESP-150 Console
0558002209
1
PT-26, 70°, 50’ Plasma Torch
0558002864
1
PT-26 Spare Parts Kit, 150A
0558003242
3
Air Reg. Assembly
678724
1
Work Cable, 50’
74S76
3
Adaptors
678724
1
Work Cable, 50’
19416
3
Gas Hose
19X54
2
Adaptors
36933GY
1
Reg. Mount
156F05
4
Coolant (4 gallons)
156F05
4
Coolant (4 gallons)
680794
1
Truck & CyIinder Rack
680794
1
Truck & CyIinder Rack
0558002917 - ESP-150 / PT-26 25’ 90° / Ar+H2 Mix
P/N
QTY
DESCRIPTION
0558002677
1
ESP-150 Console
36558
1
PT-26, 90°, 25’ Plasma Torch
0558002864
1
PT-26 Spare Parts Kit, 150A
998341
2
Argon/Hydrogen Mix Regulator
998343
1
Nitrogen Regulator
33122
3
Hoses
678723
1
Work Cable, 25’
19X54
2
Adaptors
156F05
4
Coolant (4 gallons)
680794
1
Truck & CyIinder Rack
0558002911 - ESP-150 / PT-26 25’ 90° / Air
P/N
QTY
DESCRIPTION
0558002677
1
ESP-150 Console
36558
1
PT-26, 90°, 25’ Plasma Torch
0558002864
1
PT-26 Spare Parts Kit, 150A
0558003242
3
Air Reg. Assembly
678723
1
Work Cable, 25’
156F05
4
Coolant (4 gallons)
680794
1
Truck & CyIinder Rack
0558002918 - ESP-150 / PT-26 50’ 90° / Ar+H2 Mix
P/N
QTY
DESCRIPTION
0558002677
1
ESP-150 Console
36559
1
PT-26, 90°, 50’ Plasma Torch
0558002864
1
PT-26 Spare Parts Kit, 150A
998341
2
Argon/Hydrogen Mix Regulator
998343
1
Nitrogen Regulator
33122
3
Hoses
678724
1
Work Cable, 50’
19X54
2
Adaptors
156F05
4
Coolant (4 gallons)
680794
1
Truck & CyIinder Rack
0558002912 - ESP-150 / PT-26 50’ 90° / Air
P/N
0558002677
QTY
1
DESCRIPTION
ESP-150 Console
36559
1
PT-26, 90°, 50’ Plasma Torch
0558002864
1
PT-26 Spare Parts Kit, 150A
0558003242
3
Air Reg. Assembly
678724
1
Work Cable, 50’
156F05
4
Coolant (4 gallons)
680794
1
Truck & CyIinder Rack
21
section 2description
ESP-150 Mechanized PLASMA CUTTING PACKAGES
Ar/H2 PACKAGES
AIR PACKAGES
0558002913 - ESP-150 / PT-26 25’ Inline / Air
0558002919 - ESP-150 / PT-26 25’ Inline / Ar+H2 Mix
P/N
P/N
QTY
DESCRIPTION
QTY
DESCRIPTION
0558002677
1
ESP-150 Console
0558002677
1
ESP-150 Console
0558002320
1
PT-26, 25’ Inline Plasma Torch
0558002320
1
PT-26, 25’ Inline Plasma Torch
0558002864
1
PT-26 Spare Parts Kit, 150A
0558002864
1
PT-26 Spare Parts Kit, 150A
0558003242
3
Air Reg. Assembly
998341
2
Argon/Hydrogen Mix Regulator
678723
1
Work Cable, 25’
998343
1
Nitrogen Regulator
33053
1
Strain Relief
33122
3
Hoses
951188
1
Locknut
678723
1
Work Cable, 25’
156F05
4
Coolant (4 gallons)
33053
1
Strain Relief
680794
1
Truck & CyIinder Rack
951188
1
Locknut
19X54
2
Adaptors
0558002914 - ESP-150 / PT-26 50’ Inline / Air
156F05
4
Coolant (4 gallons)
P/N
680794
1
Truck & CyIinder Rack
QTY
DESCRIPTION
0558002677
1
ESP-150 Console
0558002321
1
PT-26, 50’ Inline Plasma Torch
0558002920 - ESP-150 / PT-26-50’ Inline / Ar+H2 Mix
0558002864
1
PT-26 Spare Parts Kit, 150A
P/N
0558003242
3
Air Reg. Assembly
0558002677
1
ESP-150 Console
678724
1
Work Cable, 50’
0558002321
1
PT-26, 50’ Inline Plasma Torch
33053
1
Strain Relief
0558002864
1
PT-26 Spare Parts Kit, 150A
951188
1
Locknut
998341
2
Argon/Hydrogen Mix Regulator
156F05
4
Coolant (4 gallons)
998343
1
Nitrogen Regulator
680794
1
Truck & CyIinder Rack
33122
3
Hoses
678724
1
Work Cable, 50’
33053
1
Strain Relief
951188
1
Locknut
19X54
2
Adaptors
156F05
4
Coolant (4 gallons)
680794
1
Truck & CyIinder Rack
22
QTY
DESCRIPTION
section 3installation
caution
This product is intended for industrial use. In a domestic environment
this product maycause radio interference. It is the user's responsibility
to take adequate precautions.
3.0Installation
Precautionary measures should be taken
to provide maximum protection against
electrical shock. Be sure that all power is
off by opening the line (wall) disconnect
switch and unplug the power cord to the
unit when primary electrical connections
are made to the power supply.
Proper installation can contribute materially to satisfactory and trouble-free
operation of the cutting outfit. Each step in this section should be studied
carefully and followed as closely as possible.
3.1
Inspection and Placement
1. Having removed the shipping container, and before removing the skid,
inspect for evidence of concealed damage which may not have been
apparent upon receipt of the unit. Notify the carrier of any defects or
damage at once.
ELECTRIC SHOCK CAN KILL! Precautionary measures should be taken to provide
maximum protection against electric
shock. Be sure that all power is off by
opening the line (wall) disconnect switch
and by unplugging the power cord to the
unit when connections are made inside of
the power source.
2. Check the container for any loose parts. Check air passages on rear panel
of cabinet for any packing materials that may obstruct air flow through
the power supply.
The ESP-150 Power Source is equipped with one lifting eye that enables
hoisting the unit. Be sure the lifting device has adequate capacity to lift
the unit safely. Refer to the SPECIFICATIONS for the unit weight.
3. Mount the components of the TR-21 Truck Kit to the unit as covered by
Form F-14-413 packed with the truck kit.
4. The machine components are maintained at proper operating temperatures by forced air which is drawn through the front panel louvers and
holes in the base and out the rear panel by a heavy-duty fan. Locate this
machine in an open area where air can circulate freely through the openings. Leave at least two feet of clearance between the unit and wall or
other obstruction. The area around the unit should be relatively free of
dust, fumes and excessive heat. (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.)
5. A source of clean, dry air that supplies a minimum of 250cfh (7.08 M3H at
110 psig) is required for the cutting operation. The air supply should not
exceed 150psig (10.3 bars) - maximum inlet pressure rating of the filter
regulator supplied with the package.
23
section 3installation
Precautionary measures should be taken
to provide maximum protection against
electrical shock. Be sure that all power is
off by opening the line (wall) disconnect
switch and unplug the power cord to the
unit use proper lock out safety procedures
when making primary electrical connections to the power supply.
3.2
Primary Input Electrical Connections
1. A line (wall) disconnect switch, with fuse or circuit breakers, should be
provided at the main power panel. See Fig. 3. The primary power leads
should be insulated copper conductors, and include three power leads
and one ground wire. The wires may be heavy rubber covered cable, or
may be run in a solid or flexible conduit. Refer to Table 1 for recommended
input conductors and line fuse sizes.
FIG 3. Typical Installation - User
Supplied 3 Phase Fused Power
Disconnect Box with Recepticle
and Plug
It is of the utmost importance that the
chassis be connected to an approved
electrical ground to prevent accidental
shocking. Take care not to connect the
ground wire to any of the primary leads.
Table 3-1. Input Conductor and Line Fuse Size
Recommendations
Input Requirements
Input & Gnd.
Conductor
Volts PhaseAmpsCU/AWG
220
230
380
415
460
575
3
3
3
3
3
3
121
116
70
64
58
45
No. 1
No. 1
No. 4
No. 6
No. 6
No. 6
Fuse Ratings
/Phase, Amps
150
150
100
90
80
70
Sizes per National Electrical Code for 75o rated conductors @ 30oC ambient.
Not more than three conductors in raceway or cable. Local codes should be
followed if they specify sizes other than those listed above.
24
section 3installation
ELECTRIC SHOCK CAN KILL! Precautionary measures should be taken to provide
maximum protection against electric
shock. Be sure that all power is off by
opening the line (wall) disconnect switch
by unplugging the power cord to the unit
or use proper lock out safety procedures
when making connections inside of the
power source.
2. 60 Hz Models - As shipped from the factory, the ESP-150 is configured
for the highest connectable voltage. If using other input voltages, the
links on the terminal board (TB) inside the unit must be repositioned
for the appropriate input voltage. See the figures 4a,b & c input voltage
configurations. To gain access to the terminal board, open the access
panel on the left side.
Fig. 4a
Input Terminal Board
230/460/575 Vac Models
230 Vac Configuration
Fig. 4b
Input Terminal Board
230/460/575 Vac Models
460 Vac Configuration
Fig. 4c
Input Terminal Board
230/460/575 Vac Models
575 Vac Configuration
(Factory Supplied)
25
section 3installation
3. Safety codes specify that the Power Cable GROUND wire be the last to
break connection should the cable be pulled out of the unit. Be sure to
cut and strip wire as shown in Figure 6.
Before making any connections to the
power source output terminals, make
sure that all primary input power to the
machine is de-energized (off) at the disconnect switch.
Fig. 6 - Primary Power Cable Configuration
A poor connection or failure to connect
work cable to workpiece can result in
fatal shock.
Failure to connect the workpiece to earth
ground will result in the opening of FUSE
F3 and CIRCUIT BREAKER CB1, disabling
the console.
4. Thread the input conductor cable from the wall disconnect switch through
the strain relief in the rear panel of the main contactor (MC). Connect the
primary power leads to the main contactor terminals (see Figure 7) using
UL listed pressure wire connectors. Also connect the ground wire to the
stud provided on the chassis base inside the left-rear of the cabinet. Secure
the input cable by tightening the strain relief coupling.
4-Conductor
InputCable
(Customer Supplied)
Green Conductor
Ground Stud
Fig. 7 Input Power Cable - Detail View, Left Side
5. Recheck all connections to make sure that they are tight, well insulated,
and the proper connection has been made. Then close access panel and
reinstall fasteners.
26
section 3installation
6. Control Mode Selection for Operation with Remote Plumbing Box
The ESP-150 is supplied from the factory with Plug P45 connected to the
J4 (MAN) receptacle (torch gases and torch connected directly to the
ESP-150 power source). If the unit is to be used with a remote plumbing
box, move P45 to the J5 (MECH) receptacle.
P45 moved to the J5 (MECH)
position to allow use of
remote plumbing box
Factory supplied for standard
operation - P45 to J4 (MAN)
Figure 8. Manual vs. Mechanized Operation
NOTE: If CNC does not have a normally closed emergency stop switch,
a jumper must be installed between
TB1-16 and TB1-20.
J1
CONNECTOR
Note: J1 Mating Plug and Clamp
USER SUPPLIED CABLE
14-PIN Straight
Connector.................................. 636667
Clamp........................................6271127
Figure 9. J1 Remote Control
Receptacle Pin Configuration for CNC Connection
27
section 3installation
WARNING
3.3
Make sure power switch on console is in OFF position and
primary input power is de-energized.
Voltage Divider Adjustment
It may be necessary to adjust the Voltage Divider or VDR to match the particular height control system. There are
two default settings for the PowerCut models as shipped from the factory:
•
STANDARD UNITS (Non-CE): 750 ohms (21:1)
•
CE UNITS (Europe): 789 ohms (20:1)
If the height control system does not match the factory default setting, matching can be accomplished by adjusting the VDR potentiometer.
1. Place ohm meter leads between W2 (arc voltage) & W3 (work). Adjust R1 to achieve the desired divide
ratio for the particular height control system used. For example:
• 16:1 ratio 1000 ohms
• 21:1 ratio 750 ohms
• 18:1 ratio 882 ohms
• 20:1 ratio 789 ohms
2. If desired, additional minor adjustments of the VDR potentiometer may be made. Any adjustments
should be performed by a qualified technician.
Potentiometer
28
section 3installation
3.4
Torch Connections
1. Open top front cover to gain access to the torch connections.(Fig. 10)
2. Thread the five service lines (gas, power, and switch lead) of the PT-26 torch through bushing at upper left corner of the
front panel and connect them to the matching fittings on output terminal. Hose connections should be wrench-tight.
Make sure plug of the switch lead is firmly locked in place. Then close and reinstall the hinged cover.
a. If a PT-26 In-line Torch is being used in a mechanized installation where only an arc start signal is required, connect
the optional Remote Hand Switch, ESAB part number 2075600, to the Torch Switch Receptacle on the hook-up panel
in the front of the ESP-150 console. Fig. 11.
b. If a PT-26 In-line Torch is being used in a mechanized installation with a CNC device, see Fig. 9 for Remote Control
Receptacle I/O signal pin configuration and Fig. 8 for Control Mode Selection instructions.
1
2
3
4
5
Fig. 10 - For manual torch applications, pass the service connections through the
rubber grommet in the front of ESP-150 and make connections as shown.
Fig. 11 - For Mechanized applications using a shielded in-line torch, remove
the rubber grommet slide body through sheet metal front of ESP-150 and tighten
with locknut.
+
-
2
Water IN (+)
(Pilot Arc)
4
Water OUT (-)
(Torch)
3 Plasma/Start
Shield
Gas
Gas
1
5
Fig. 12 - Interconnection Diagram - Front of ESP-150
29
Torch Switch
Receptacle
section 3installation
3.5Gas Supply Connections
1. Connect the gas supplies. The cylinders may be placed and secured on the cylinder rack of the truck. Before connecting
the regulators, be sure to read, understand, and follow all instructions packed with each regulator.
2. Connect the gas hoses to the regulators and to the proper fittings (Adaptors: 74S76, Air; 19X54, Ar/H2) on the rear panel
of the ESP-150. Connections should be wrench tight including those that are plugged. (Fig. 14)
(3) Air Filter Regulators
P/N-36932
Fig. 13 - Air Filter Regulator Connections
Select ONLY ONE (1)
Inlet Connection,
NEVER BOTH, when
selecting Plasma
Gas
Fig. 14 - Gas Connections
30
section 3installation
3.6
Operating the unit without coolant will
cause permanent damage to coolant
pump.
Work and Earth Connections
1. Connect terminal lug end of the work cable assembly to stud on lower left corner
of front panel. Nut should be wrench tight. (Fig. 15). Electrically connect work
cable to work piece. The connection must be made to a clean, exposed metal
surface free of paint, rust, mill scale, etc. (Fig. 15).
2. Make sure workpiece is connected to an approved earth ground. Use copper
ground cable equal to or larger than the power supply chassis ground listed in
Table 1.
3.7
Torch Coolant Preparation
1. Remove the cap from the coolant filter tank. Fill coolant tank with 2 gallons (7.5
liters) of plasma system coolant (P/N 156F05) - supplied with the package. The
coolant also provides antifreeze protection down to -34°.
Do not use commercial antifreeze or tap
water. Equipment will malfunction and
damage will occur.
Due to high electrical conductivity, use of tap water or commercial antifreeze is
NOT recommended for torch cooling. Use of tap water can result in algae growth
in the water cooler and torch. Automotive type antifreeze will adversely affect
starting and will form deposits in the torch that will cause damage.
2. With installation completed, check all gas and coolant fittings for leaks using a
standard solution.
TORCH COOLANT FILL
ACCESS
LEVEL INDICATOR
PT-26
Grounded
Work
Table
Work Cable 25 ft. - 23120589
50 ft. - 23120590
Earth
Ground
Fig. 15 - Access for filling Torch Coolant Tank
31
section 3installation
32
section 4operation
4.0Operation
4.1Controls and Indicators
This section provides descriptions of the power source controls and general operating procedures plus, some tips
on cut quality.
8
9
1
7
6
2
5
4
3
1
2
3
4
5
6
7
8
9
Topping up the coolant
Level indicator for the coolant
Connection for return cable
Ampere and Voltmeter
Connection for torch
Mains voltage switch
Switch for gas
Current setting control
Indicator lamps
33
section 4operation
The status lights located on the front of the top lid of the ESP-150 console provide
the conditions of the circuitry during a normal plasma arc cutting operation. By
knowing the proper sequencing of events and by observing the status lights one
can troubleshoot the console in a short time to minimize downtime.
None of these lights will function unless proper input voltage is applied with the
links on the input terminal board (TB) properly connected for the input voltage; the
ON-OFF power switch is ON; and the top lid of the console is closed firmly.
The following are the functions of each light:
POWER (ROS) — Energizes power to the Fan, Water Cooler and Control Circuitry.
This readies the unit for operation.
GAS MODE (OSS) — CUT - Allows for setup of cut gas pressure and flow; START/
SHIELD - allows setup of start and shield gas pressure and flow; and OPERATE - position to use for cutting operations.
CURRENT CONTROL — Controls desired cutting current for optimizing speed and
cut thickness. See Section 4.6 Cut Data.
OVER TEMP — Will light if any (one or more) thermal switch in the console is open
due to overheating. (This light may be dim when the gas flow is in the post-flow
mode.) If light comes on, stop cutting operations and allow unit to cool down (with
fan running) until light goes out. If the light is on and you suspect the unit is cool,
then check for defective thermal switch(es) or loose connections.
READY/LOW GAS — This light serves as a READY light, torch switch and operate/
set switch check as well as low gas flow or pressure indicator. It will light when the
unit is at rest or READY (power ON-OFF switch is ON. It will continue to be lit when
operate/set switch (OSS) is placed in the SET position even when proper gas flow or
pressure is set properly. The light will not go out when the OSS switch is placed in
the OPERATE position (gas solenoid valves will shut off ).
In the operate mode, this light will then function as a LOW GAS light. After depressing the torch switch button and the LOW GAS lights up during a cutting operation,
gas pressure or flow is insufficient.
HIGH FREQ ENERGIZED — This will light when the unit is in the OPERATE mode
and the torch switch button is depressed. It should remain lit until the main cutting
arc is established. It indicates that proper voltage (approx. 115 VAC) is applied to the
primary of the high frequency transformer (HFTR). The voltage is applied to the HFTR
through proper operation of the pilot arc contactor (PAC).
TORCH ON — This will light when the power supply is delivering the voltage to
generate an arc (whether or not the main arc has been established). It is indicating
there is greater than 50 volts between NEG output and WORK terminals. Never touch
the front end parts or make any adjustments to the torch if the TORCH ON light
is on, even when the power ON-OFF is OFF.
34
section 4operation
Never, under any circumstances, operate
the power supply with the cover removed.
In addition to the safety hazard, improper
cooling may cause damage to internal
components. Keep side panels closed
when unit is energized. Also make sure
you are adequately protected before you
start cutting — protective helmet and
gloves should always be worn. Refer to
Safety Section for additional operating
precautions.
Voltage is available at the POWER On-Off
switch on the hinged top cover when voltage is applied to the input terminal board
even when the POWER switch is OFF.
Before making any adjustments or performing any maintenance on the torch,
make sure the power to the torch is shut
off.
4.2ESP-150 Adjustments
1. Slowly open each gas cylinder valve.
2. Place the ESP-150 GAS MODE and POWER switches in the OPERATE and
OFF positions.
3. Place the primary (wall) switch in the ON position.
4. Place POWER to READY position. POWER light should light up. Fan should
be running.
5. With GAS MODE switch in START/SHIELD position gas solenoid valves
should be open. Adjust the START gas and SHIELD regulators to deliver
the pressures specified in Table 2.
Place switch in CUT position and adjust CUT Gas regulator to deliver pressures specified in Table 2.
6. Allow the gases to flow for a few minutes. This should remove any condensation that may have accumulated during shut down.
7. Place the GAS MODE switch in the OPERATE position. This will shut off
the gas flows.
8. Adjust CURRENT CONTROL knob to approximate cutting current desired.
4.3
Operation
1. Position the torch on the workpiece by resting the heatshield on the edge
of the workpiece where you intend to start the cut.
2. Lower your protective helmet and then lift the torch approximately 1/8”
above the workpiece.
3. Push down on the torch switch button mounted on the torch handle. Pilot
arc contactor and high frequency will energize, and gas will start flowing.
Two seconds later, the main contactor will come on. The pilot arc should
then transfer to the cutting arc.
A R C R AYS CA N B U R N E YE S A N D
SKIN,NOISE CAN DAMAGE HEARING!
Wear eye, ear, and body protection.
Wear the usual protective gloves, clothing,
and helmet. Helmet with filter lens shade No.
6 or 7 should provide adequate protection
for your eyes.
Never touch any parts forward of the
torch handle (tip, heat shield, electrode,
etc.) unless the Power switch is in the
OFF position.
NOTE: If cutting arc does not start within 6 seconds, the pilot arc will shut off.
Release torch switch. Check to be sure gas pressures are adequate, work
cable is firmly connected to workpiece, torch was approximately 1/8” to
1/4” above workpiece, etc. Then start from step 1 again.
4. For manual and mechanized cutting, maintain a standoff (torch-to-work
distance) of approximately 3/8”. (stand off guide, P/N 36648, provides that
distance). Keep the torch head vertical, and move it at a rate that produces
the desired cut quality. The cutting should produce a straight fine spray of
molten metal emitting from beneath the workpiece as illustrated in Fig.
16. For mechanized cutting, see Table 2 or 3 for recommended cutting
speed range.
5. If cutting arc is lost during a cut, the pilot arc will immediately reignite
as long as the torch switch is depressed. You then have approximately
6 seconds to move the torch close enough to work to re-establish the
cutting arc.
35
section 4operation
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 with power
switch on.
6. 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.
7. 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.
correct
too fast
too slow
Position the ESP-150 at least 10 feet (3
meters) from the cutting area. Sparks and
hot slag from the cutting operation can
damage the unit.
Fig. 16 - Effect of Cutting Speed
With a positive cut angle, the top dimension is slightly less than the bottom dimension. With a negative cut angle, the top dimension is slightly greater than the bottom
dimension. The cut angle is controlled by the standoff (arc voltage), cutting speed
and cutting current. If the cutting speed and the cutting current are correct and the
part has an excessive positive angle, then the standoff is too high. Begin lowering
the arc voltage in increments of 5 volts, observing cut squareness. There will always
be slight top edge rounding of the part when using Nitrogen.
The optimum torch height is a point just before the part begins to develop a negative
cut angle. To expand upon the other two variables; with the correct torch standoff,
excessive cutting speed will result in a positive cut angle; insufficient cutting speed
will produce a negative cut angle. If the cutting current is too high or low, a positive
cut angle will be produced.
Arc Voltage/Standoff - Interactive parameters that are proportional. The higher the
torch above the plate (standoff ), the higher the operating voltage required and vice
versa.
Lag Lines - These lines appear on the cut surface. They are of assistance in determining if your process parameters are correct.
36
section 4operation
4.4
Standoff and Cut Quality
Standoff (Arc Voltage) has a direct influence on cut quality and squareness. It is recommended that prior to cutting, that all cutting parameters are set to the manufacturer’s
suggested conditions. Refer to the Process Tables for recommendations. A sample
cut should be made using actual part material followed by close examination of
the part.
If the cut face of the part has excessive bevel or rounded top edge, it may be that the
standoff is set too high. When standoff is controlled by an arc voltage height control,
reducing the arc voltage setting will reduce the standoff.
Lower the standoff until the excessive bevel or rounded top edge disappears. The
characteristics of plasma cutting hinder production of a perfectly square cut. On
material thicknesses of 1/4 inch or greater, a standoff too close may result in a negative cut angle.
ARC
VOLTAGE
STANDOFF
LAG LINES
Fig. 17 - Cut Quality
A
POSITIVE (+) CUT ANGLE
Bottom dimension “B”
is greater than dimension “A”
B
NEGATIVE (-) CUT ANGLE
A
Bottom dimension “B”
is less than dimension
“A”
B
Fig. 18 - Cut Angle
37
section 4operation
4.5
Dross Formation
Cutting speed, gas selection and variations in metal composition contribute to dross
formation. The correct cutting standoff also has an influence on dross formation. If the
arc voltage is set too high, the cut angle becomes positive. In addition, dross forms on
the bottom edge of the part. This dross can be very tenacious and require chipping
and grinding for removal. Setting the cutting voltage too low results in undercutting
the parts or negative cut angle. Dross formation occurs but in most cases it is easily
removed.
Top Dross
Top dross usually appears as splatter near the top edge of the kerf. This is a result of
torch standoff (arc voltage) set too high or cutting speed set too fast. Most operators
use the parameter charts for recommended speed. The most common problem is
torch standoff or arc voltage control. Simply lower the voltage settings in increments
of 5 volts until the top dross disappears. If an arc voltage control is not used, the torch
can be lowered manually until the dross disappears.
TOP DROSS:
Splatter appears on the top edge of
both pieces of the plate.
Lower the voltage in increments of 5
volts dc (maximum) until top dross
disappears.
Fig. 19 - Top Dross Formation
HIGH SPEED DROSS:
Fine roll over dross that welds to bottom of edge. Cleaning requires chipping or grinding.
Fig. 20 - High Speed Dross
LOW SPEED DROSS
Globular dross that forms in large deposits. Comes off very easily.
Fig. 21 - Low Speed Dross Formation
SUMMARY
Arc voltage is a dependent variable. It is dependent upon cutting amperage, nozzle
size, torch standoff, cut gas flow rate and cutting speed. An increase in arc voltage can
result from a decrease in cutting speed, an increase in cutting amperage, a decrease
in nozzle size, an increase in gas flow and an increase in torch standoff. Assuming
that all of the variables are set as recommended, torch standoff becomes the most
influential variable to the process. Good and accurate height control is a necessity
in producing excellent cut quality.
38
section 4operation
4.6Common Cutting Problems
Tripped circuit breaker (located under the top
hinged cover) may indicate dangerous high voltage
existed between the work cable and earth ground.
This is usually caused by a missing or poor connection of the work cable to the work piece. The work
cable MUST be electrically connected to the work
piece to prevent dangerous shock conditions.
The following is a listing of common cutting problems and the probable cause.
If problems are determined to be caused by the ESP-150, 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. Cutting speed too fast
2. Damaged cutting nozzle
3. Improper gas settings
4. Inadequate delay for pierce
B. Main Arc Extinguishes:
1. Cutting speed too slow
C. Dross Formation:
1. Cutting speed too fast or too slow
2. Improper air pressure
3. Faulty nozzle or electrode
4. Improper standoff
5. Current too low
D. Double Arcing:
1. Low air pressure
2. Damaged cutting nozzle
3. Loose cutting nozzle
4. Heavy spatter
5. Nozzle touches work while cutting
6. Pierce height too low
7. Current too low
E. Uneven Arc:
1. Damaged cutting nozzle or worn electrode
F. Unstable Cutting Conditions:
1. Incorrect cutting speed
2. Loose cable or hose connections
3. Electrode and/or cutting nozzle in poor condition
G. Main Arc Does Not Strike:
1. Loose connections
2. Work clamp not connected
3. Gas pressures not correct
4. Insufficient coolant to operate flow switch
H. Poor Consumable Life:
1. Improper gas pressure
2. Contaminated air supply
3. Improper gas/electrode combination
4. Torch hitting work piece or turned up parts
5. Parts damaged by double arcing (see D above)
6. Use of non-genuine parts
7. Water leaks in torch
8. Torch not purged after changing consumables or idle period
9. Using wrong consumables for selected gases
39
section 4operation
4.7
Operating Parameters
Recommended Gas Pressures Start ............................................. 30 psig
Plasma (Cutting) ..................... 50 - 70 psig
Plasma (Gouging) ................... 40 - 45 psig
Shield........................................... 40 - 50 psig
Recommended Stand-off 5/16" - 1/2"
Travel Speeds Travel speeds for the PT-26 are given in Tables 4-1 through 4-4.
4.8Cut Data
To ensure optimum cutting performance and aid in troubleshooting any cut quality problems, please refer to
the following cutting parameters charts.
The cutting speeds and conditions in the following tables were selected to give the best quality with a particular gas combination at a specific current.
Consumables - Refer to PT-26 Torch manual for recommended parts for these conditions. Use of parts in combinations and
applications other than as described herein can result in damage to the torch or poor performance.
Gas and Current Selection- Refer to the following tables to choose the most appropriate conditions for your application.
PT-26 in-line torch cutting conditions:
Data taken with Swirl Baffle (0558003583) and Shield Cup (0558003582).
65 Amp data uses standard Heat Shield (34592) or Close Proximity Heat Shield (37146) in place of Shield Cup
(0558003582) and uses a 50 Amp Nozzle (36567).
40
section 4operation
Table 4.1 65 Amp Cut Data
Material
Carbon
Steel
Thickness
inch (mm)
0.12 (3.2)
0.25 (6.4)
0.50 (12.7)
0.12 (3.2)
Aluminum
0.25 (6.4)
0.50 (12.7)
Stainless
Steel
0.12 (3.2)
0.25 (6.4)
0.50 (12.7)
Standoff
inch (mm)
0.19 (4.8)
0.25 (6.4)
0.19 (4.8)
0.25 (6.4)
0.19 (4.8)
0.25 (6.4)
Speed
ipm (mm/m)
Start Gas and
Pressure
psig (bar)
Cut Gas and
Pressure
psig (bar)
Shield
Gas and Pressure
for ESP-150 and 200
psig (bar)
Air
30 (2.1)
Air
60 (4.1)
Air
50 (3.4)
190 (4826)
100 (2540)
30 (762)
50* (1270)
70 (1778)
20 (508)
75 (1905)
50 (1270)
20 (508)
41
section 4operation
Table 4.2 150 Amp Cut Data
Material
Thickness
inch (mm)
Standoff
inch (mm)
0.19 (4.8)
0.25 (6.4)
0.38 (9.7)
0.19 (4.8)
20 (508)
0.19 (4.8)
80 (2032)
0.25 (6.4)
70 (1778)
50 (1270)
0.75 (19.1)
35 (889)
1.00 (25.4)
20 (508)
0.25 (6.4)
0.38 (9.7)
0.19 (4.8)
0.25 (6.4)
0.50 (12.7)
0.62 (15.7)
0.75 (19.1)
0.19 (4.8)
0.25 (6.4)
0.38 (9.7)
0.50 (12.7)
0.31 (7.9)
1.00 (25.4)
130 (3302)
90 (2286)
Air
30 (2.1)
50 (1270)
35 (889)
25 (635)
0.19 (4.8)
0.25 (6.4)
0.31 (7.9)
0.62 (15.7)
0.75 (19.1)
Air
60 (4.1)
175 (4445)
70 (1778)
1.00 (25.4)
Stainless
Steel
150 (3810)
0.38 (9.7)
0.19 (4.8)
Aluminum
35 (889)
130 (3302)
0.62 (15.7)
O2
60 (4.1)
80 (2032)
0.25 (6.4)
0.50 (12.7)
Air / N2
30 (2.1)
Shield
Gas and Pressure for
ESP-150 and 200
psig (bar)
130 (3302)
50 (1270)
0.25 (6.4)
1.00 (25.4)
0.19 (4.8)
Cut Gas and
Pressure
psig (bar)
70 (1778)
0.62 (15.7)
Carbon
Steel
Start Gas and
Pressure
psig (bar)
150 (3810)
0.50 (12.7)
0.75 (19.1)
Speed
ipm
(mm/m)
165 (4191)
125 (3175)
80 (2032)
50 (1270)
35 (889)
0.38 (9.7)
20 (508)
10 (254)
42
Air
60 (4.1)
section 4operation
Table 4.3 200 Amp Cut Data
Material
Thickness
inch (mm)
Standoff
inch (mm)
0.25 (6.4)
0.38 (9.7)
Carbon
Steel
0.19 (4.8)
0.62 (15.7)
65 (1651)
0.75 (19.1)
50 (1270)
1.00 (25.4)
35 (889)
0.25 (6.4)
135 (3429)
0.38 (9.7)
95 (2413)
0.50 (12.7)
85 (2159)
0.25 (6.4)
55 (1397)
1.00 (25.4)
30 (762)
0.25 (6.4)
130 (3302)
0.38 (9.7)
105 (2667)
0.50 (12.7)
85 (2159)
1.00 (25.4)
0.31 (7.9)
0.38 (9.7)
0.25 (6.4)
0.38 (9.7)
Stainless
Steel
60 (1524)
40 (1016)
130 (3302)
0.25 (6.4)
115 (2921)
75 (1905)
0.62 (15.7)
65 (1651)
1.00 (25.4)
75 (1905)
0.50 (12.7)
0.75 (19.1)
Shield
Gas and Pressure for ESP150 and 200
psig (bar)
0.38 (9.7)
Air / N2
30 (2.1)
O2
55 (3.8)
Air
80 (5.5)
Air
60 (4.1)
70 (1778)
0.75 (19.1)
0.75 (19.1)
Cut Gas and
Pressure
psig (bar)
95 (2413)
80 (2032)
0.62 (15.7)
Start Gas and
Pressure
psig (bar)
150 (3810)
0.50 (12.7)
0.62 (15.7)
Aluminum
Speed
ipm
(mm/m)
55 (1397)
20 (508)
Air
30 (2.1)
Air
55 (3.8)
Air
80 (5.5)
section 4operation
Table 4.4 300 Amp Cut Data
Material
Thickness
inch (mm)
0.50 (12.7)
0.62 (15.7)
0.75 (19.1)
1.00 (25.4)
Carbon
Steel
Standoff
inch (mm)
0.25 (6.4)
0.31 (7.9)
Speed
ipm
(mm/m)
80 (2032)
2.00 (50.8)
0.50 (12.7)
10 (254)
0.75 (19.1)
120 (3048)
1.00 (25.4)
O2
75 (5.2)
50 (1270)
20 (508)
0.31 (7.9)
Shield
Gas and Flow
cfh (l/m)
95 (2413)
0.38 (9.7)
0.62 (15.7)
Cut Gas and
Pressure
psig (bar)
130 (3302)
1.50 (38.1)
0.50 (12.7)
Start Gas and
Pressure
psig (bar)
Air
210 (99.1)
Air / N2
30 (2.1)
90 (2286)
80 (2032)
55 (1397)
1.50 (38.1)
0.38 (9.7)
25 (635)
2.00 (50.8)
0.50 (12.7)
12 (305)
44
Air
75 (5.2)
section 4operation
Maximum Manual PT-26 Speeds
PT-26 Steel Cutting Data
45
section 4operation
PT-26 Stainless Steel Cutting Data
225
200
175
Plasma Gas: Air at 60 psig or H-35 at 70 psig.
Shield Gas: Air at 50 psig or Nitrogen at 40 psig.
Start Gas: Air, Nitrogen or H-35 at 30 psig.
Stand-Off: 3/8"
Cutting Speed (ipm)
150
125
200 A. Air
100
150 A. Air
200 A. H-35
75
150 A. H-35
50
25
0
0.25
0.50
0.75
1.00
1.25
1.50
2.00
Material Thickness (in)
PT-26 300 Amp Stainless Steel
125
100
Cutting Speed (ipm)
Plasma Gas: Air at 60 psig or H-35 at 70 psig.
Shield Gas: Air at 50 psig or Nitrogen at 40 psig.
Start Gas: Air, Nitrogen or H-35 at 30 psig.
Stand-Off: 3/8"
75
50
300 A. Air
300 A. H-35
25
0
0.75
1.00
1.25
1.50
1.75
2.00
2.25
2.50
Material Thickness (in)
46
2.75
3.00
3.25
3.50
3.75
4.00
section 5maintenance
5.0Maintenence
Be sure that all primary power to the machine has been externally disconnected.
Open wall disconnect switch or circuit
breaker before attempting inspection or
work inside of the power supply.
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.
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.
A. INSPECTION AND CLEANING
Frequent inspection and cleaning of the ESP-150 cutting machine is recommended. Some suggestions for inspecting and cleaning are as follows:
1.
2.
3.
4.
5.
6.
7.
8.
caution
Check work cable to workpiece connection.
Check safety earth ground at workpiece and at power source chassis.
Check heat shield on torch. It should be replaced if damaged.
Check the torch electrode and cutting tip for wear on a daily basis. Remove
spatter, replace if necessary.
Make sure cable and hoses are not damaged or kinked.
Make sure all plugs, fittings, and ground connection are tight.
CAUTION: Water occasionally accumulates in compressed air lines. Be
sure to direct the first blast of air away from the equipment to avoid
damage.
With all input power disconnected, and wearing proper eye and face
protection, blow out the inside of the cutting power supply using lowpressure dry compressed air.
Occasionally bleed water from the filter beneath the air regulators.
The coolant must be handled as chemical waste.
B. FLOW TESTING
Improper flows can cause short life on the consumables, poor starting, bad
cuts, or overheated torches. The flows given below are “cold” flow (no arc). To
avoid fatal shock, follow the steps below to assure safe flow measurement.
1.
2.
3.
4.
5.
6.
7.
8.
Shut off input power at the main disconnect switch.
Lift the top lid of the ESP-150 and unplug the torch switch cord.
Close the lid.
Turn on the power at the main disconnect switch.
Place gas mode selector switch (OSS) in START/SHIELD position.
Place power ON-OFF switch (ROS) to ON.
Check flow measurements with flow measuring kit, P/N 19765.
Place mode selector switch (OSS) in CUT position and check CUT flow
with flow measuring kit, P/N 19765.
9. Place ROS switch to OFF.
10. Turn off power at main disconnect switch.
11. Reconnect torch switch plug inside console.
PT-26 Plasma Gas Flow (No Arc):
Nitrogen or Air @ 60 psig: 110 cfh; H-35 @ 90 psig: 130 cfh
PT-26 Start Gas Flow:
Nitrogen or Air @ 40 psig: 75 cfh
PT-26 Shield Gas Flow:
Air or Nitrogen @ 85 psig: 200 cfh minimum.
47
section 5maintenance
C. SPARK GAP ADJUSTMENT
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.
The spark gap, which is part of the high frequency generator, is factory set at 0.040-in.
(+/- 0.002). After extended operation or if erratic operation is noted, it may be necessary to readjust or replace the electrodes. Use a feeler gauge when readjusting the
gap. Cleaning or dressing of the spark gap electrodes is not recommended. When
replacement is necessary, both electrodes should be replaced.
D. TESTING AND REPLACING BRIDGE ASSEMBLY COMPONENTS
The silicon diodes and SCR’s used in the power supply are devices which allow current
to flow in only one direction. They block current in the other direction. The diodes and
SCR’s are designed to provide long troublefree operation; however, should a failure
occur, they may require replacement.
Be sure that all primary power to the machine has been externally disconnected.
Open wall disconnect switch or circuit
breaker before attempting inspection or
work inside of the power supply.
1. Testing Diodes
a. Locate the main rectifier assembly containing the silicon diodes and
SCR’s.
b. Electrically isolate main bridge rectifier assembly by disconnecting
the main transformer secondary fuse links F1 and F2.
c. With ohmmeter on RX1 scale, place negative lead on the diode heat
sink and touch positive lead to each pigtail terminal. Meter should
read a low resistance of approximately 3 to 15 ohms on each diode.
d. Reverse leads and check each diode. All readings should show high
resistance of 2 K (2000) ohms or higher. With most ohmmeters on the
RX1 scale, 2K ohms is the highest possible reading available.
e. Since diode resistance is non-linear with voltage (using any scale),
diodes are good when they show low resistance in one direction and
high resistance in the opposite direction. They are bad when they
show no or very low resistance in both directions (shorted), or if they
show very high assistance in both directions (open).
2. Testing SCR’s
a. Follow steps a. and b. under Testing Diodes. Disconnect the SCR pigtail.
b. With ohmmeter on RX1 scale place the negative lead on the anode
(end of SCR with screw threads) and positive lead on the cathode
(pigtail end). Meter should read a high resistance of 2 K (2000) ohms
or higher.
c. Reverse leads and check each SCR. All readings again should show
high resistance. When SCR’s are bad they show low resistance in either
direction.
d. Now check the gate circuit on the SCR’s by placing the negative lead
to the gate (wht wire off SCR) and the positive lead to the cathode.
Meter should read approximately 20 ohms and should vary only
slightly (5 ohms) when leads are reversed. If the meter reads zero or
infinity in either direction the gate circuit is faulty and the SCR should
be replaced.
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.
IMPORTANT: When replacing Diodes or SCR’s make sure mounting surfaces
are clean. Coat mounting surfaces with Alcoa No. 2 EJC Electrical Joint Compound (no substitutes) available in 8 oz. bottles
under P/N 73585980. Use a torque wrench to tighten diodes
and SCR’s. Recommended torques are 20-30 in.-lbs. for diodes;
125-150 in.-lbs. for SCR’s.
48
section 5maintenance
5.1Troubleshooting
Check the problem against the symptoms in the following troubleshooting guide. If the cause cannot be
quickly located, shut off the input power, open up the unit, and perform a simple visual inspection of all the
components and wiring. Check for components, bulged or leaking capacitors, or any other sign of damage or
discoloration.
The cause of control malfunctions can also be found by referring to the sequence of operations and electrical
schematic diagram and check out the various components. A volt-ohmmeter will be necessary for some of
these checks.
NOTE: Before checking voltages in the circuit, disconnect the power from the high frequency generator to avoid damaging your voltmeter.
Be sure unit is set up properly for voltage being used and that the gas supplies are adequate.
A. TROUBLESHOOTING GUIDE
1.Unit Inoperative; fan does not run.
a. Check primary disconnect switch to make sure input power is being supplied.
b. Check links on the input terminal board TB to make sure all are connected to the proper input voltage
being used. (See Form 14-376.)
c. Check for defective power switch (ROS).
2. No gas flow when torch switch is closed.
a. Unplug torch switch plug and check for proper operation with an ohmmeter connected to pins 1 and 2 of
torch switch plug.
b. Defective interlock switch (ISW).
c. Check for defective solenoid valves.
d. Plug (P1) may be loose at control board.
e. Defective logic board.
3. Pilot arc-high frequency sparks noted at spark gap but not at the torch.
a. Check spark gap and readjust electrodes if necessary. Replace spark gap electrodes if worn beyond serviceability.
b. Check with an ohmmeter for continuity between torch nozzle and POS output where torch attaches to
console.
4. No pilot arc-high frequency sparks noted at spark gap and at torch during preflow, but main contactor
does not activate or chatters at end of 2 second preflow time.
a. Check start gas pressure. It must be at least 30 psig.
b. Check cooling gas pressure (PT-26). It must be at least 50 psig.
c. If using PT-26 torch, check jumper plug between J1-5 and J1-4 on the torch switchplug.
d. Thermal switch in bridge, inductor, or main transformer may be open. Allow unit to cool down.
e. Defective logic board (675369).
5. No pilot arc - No spark noted in the spark gap.
a. Check to see that pilot arc contactor (PAC) closes. If it does not, and gas flows when torch switch is closed,
replace logic board.
b. If PAC closes, check for proper spark gap setting (0.040-in.).
c. Check the 120V input to the high voltage transformer (HFTR).
d. Check for arcing or carbon tracking around the spark gap.
e. If all of the above check good, HFTR is most likely defective.
6.Erratic pilot arc - pilot arc contactor (PAC) chatters.
a. Defective logic board.
b. Power supply may be single phasing. Check main disconnect switch and fuses.
49
section 5maintenance
7. No pilot arc - pilot arc contactor (PAC) drops out when main contactor (MC) activates at end of 2-second
preflow.
a. Check for low open circuit voltage. It should be around 370 V at nominal line voltage.
b. Check voltage between each side of resistor R29 and the WORK output connection when MC is activated.
Place negative meter lead on side of resistor being checked and positive meter lead on the WORK output
connection. The voltage on one side should be the open circuit voltage (370 V). The voltage on other side
should be above 175 V. If lower voltage is under 175 V, PAC will drop out.
c. Check the resistance of R29. It should be 133 K ohm.
d. Disconnect R-29 resistor and measure the resistance from P1-1 to shunt (common). Resistance should be
200 K to 250 K ohms.
e. Check for continuity between R29 and electrode (-) torch connections.
f. With power off, mechanically pull in PAC. The resistance between POS and WORK connections should be
8 ohms.
8. Main arc fails to transfer to work.
a. Make sure that work clamp is securely fastened to the work piece.
b. Check for proper function of pilot arc (PT-26) and high frequency unit.
c. Check main disconnect switch and fuses.
d. Check main contactor (MC) by disconnecting primary power and check each contact for closure using an
ohmmeter while physically pulling contactor.
e. Check C24 and C24A capacitors (1900 uf, 450 V) with an ohmmeter. Resistance should be 900-1000 ohms
with capacitor connected in the circuit. If shorted, replace capacitor. Then check R18 resistor. The resistance
of R18 should be 5 ohms. The resistance between “DRB POS” and “CAP (+)” should be 25 ohms. If the stud
mounted rectifier on D/R board is shorted, the 25 ohm will be less than 5 ohms even when meter probes
are reversed.
f. Check open circuit voltage. It should be about 370 volts.
g. Check F1 and F2 fuses. The open circuit can still be 370 volts with one blown fuse.
h. Current control board (674935) may be defective.
9. Short tip life.
a. Check for correct gas pressure.
b. Check gas flow rate using flowmeter (P/N 19765).
c. Check to see if pilot arc contactor (PAC) remains activated after main arc transfers. This can be done by
observing the spark in the spark gap of the high freq. unit. The high freq. spark should shut off as soon as
main arc starts. If spark continues after main arc is established, either main contactor (MC) or logic board
is defective.
d. Arc current is set too high.
e. Wrong cutting tip size. Use larger tip.
f. Defective current control board.
10.Pilot arc cycles on and off when torch switch is not depressed.
a. Unplug torch switch plug. If cycling stops, then torch switch wires or plug or torch switch itself are shorted.
b. Defective logic board.
11.No or limited control of output current.
a. Defective current control potentiometer (CCP). Check by placing negative meter lead on WORK output
connection and positive meter lead on current control board P1-2. (P1 is the larger of the two plugs.) With
the fan running (machine at idle), adjust CCP from min. to max. They read zero at min. (1.1 volts on ESP150); 10 Volts DC at max. The meter should move smoothly from zero to 10 V as CCP is rotated from min.
to max.
b. Defective logic board.
12.Gas does not shut off after 10 seconds of preflow.
a. Turn off ready-off switch (ROS). If gas continues to flow, solenoid valve is defective.
b. Defective logic board.
13. No arc.
Check that the mains power supply switch isturned on.Check that the welding current supply andreturn cables
are correctly connected.Check that the correct current value is set.
14. The welding current is interrupted during welding.
Check whether the thermal overload tripshave operated (indicated by the lamp on thefront panel).Check the
mains power supply fuses.
50
section 5maintenance
15. The thermal cut-out trips frequently.
Make sure that you are not exceeding therated data for the power source (i.e. that theunit is not being overloaded).
16. Poor welding performance.
Check that the welding current supply andreturn cables are correctly connected.Check that the correct current
value is set.Check that the correct electrode is beingused.Check the mains power supply fuses.
B. SEQUENCE OF OPERATION
1.
2.
3.
4.
5.
Close primary disconnect switch.
a. Power supplied to unit.
Place Power Switch (ROS) to “Ready” position.
a. Fan motor (FM) and Pump motor on.
b. Low Gas LED on.
c. Control circuit energizes.
Place Gas Mode Switch (OSS) to “CUT” position.
a. Gas solenoid valves (CGSV) energize. Gases flow to permit setting of pressures and to purge system.
Place OSS to “Operate” position.
a. Gas valves (PGSV and CGSV) deenergize to stop gas flows.
Depress torch switch.
a. SHSV and SGSV (shield and start) gas solenoid valves open to allow gases to flow to torch.
b. Pilot Arc Contactor (PAC) closes.
c. High Frequency (HF) energizes.
d. Pressure Switches (PGPS & CGPS) close (provided gas pressures are set above 19 psig on PGPS and 22 psig
on CGPS).
e. Two seconds later, Main Contactor (MC) closes to establish pilot arc.
f. Pilot arc will transfer to cutting arc within 6 seconds as long as torch is close enough (1/8” —1/4”) to
work.
g. HF and PAC deenergizes immediately when cutting arc is established, or after 6 seconds of continuous
pilot arc. If cutting arc is not established after six seconds, MC will open but the HF will remain energized.
MC and pilot arc will then cycle on and off every 3 seconds, MC will open but the HF will remain energized.
MC and pilot arc will then cycle on and off every 3 seconds until torch switch is released.
Dangerous high voltage (over 300 volts) exists aT the torch
front end whenever MC is closed; therefore, release torch
switch when cutting is not established and repeat step 5.
WARNING
PREFLOW & HF****
2 sec.
Push
Torch Switch
PGSV/CGSV opens
PAC closes
HF energizes
PGPS/CGPS closes
FS closes
HF and MC*
6 sec.
MC closes
CUTTING ARC**
PAC opens
HF deenergizes
POSTFLOW***
10 sec.
Release Torch
Switch
MC opens
PGSV/CGSV closes
PGPS/CGPS opens
FS opens
* HF and MC remain on for approximately 6 sec. unless a main arc is established. If a main arc is not established the MC will open after 6
sec. but HF stays on. If torch switch is not released MC will cycle on and off every 3 sec. until torch switch is released.
**Cutting arc actually starts during the HF phase when the arc transfers to the workpiece anywhere between 2 and 6 seconds; Pilot arc
circuit and high-freq. generator will then shut off immediately.
***A new cycle may be started anytime in the Postflow phase, which will cancel remaining postflow time and start again with the normal
preflow time.
**** On units made for Advance Systems cutting machines, HF activates when MC closes at end of 2 second preflow.
Fig. 22 - Torch Operation Sequence Diagram
51
section 5maintenance
6. Release torch switch.
a. MC opens and the cutting arc shuts off.
b. Gases continue to flow (postflow) for approximately another 10 seconds at which time the PGSV and CGSV
will close, opening PCPS and CGPS.
NOTE: A new cutting cycle can be started anytime during the postflow. As soon as the torch switch is depressed, the
remaining postflow time will cancel and the normal preflow time will start.
7. Control circuit will not energize or can deenergize during a cutting cycle when:
a. PGPS or CGPS is open due to insufficient gas pressure (at least 15 psi required).
b. Thermal Switches (TS) are open due to overheating of unit. TS should open at 180° C
(356° F).
8. Place ROS to “OFF” position.
a. Control circuit deenergizes.
b. Fan motor (FM) deenergizes.
c. Low Gas light on status board will go out.
9. Open primary disconnect switch.
a. Input power unit shut off.
52
section 5maintenance
C. STATUS LIGHT TROUBLESHOOTING CHART
Proper Input
Power Applied
ROS ON
Is
OVER TEMP
Light
On?
YES
1. Machine may be overheated.
2. Check connections to thermal switches
(TS).
NO
1. Close top lid.
2. Check ISW switch
3. Check CB1.
NO
YES
Is
Pilot Arc
established
?
NO
Is
READY/LOW GAS
Light
On?
Does
TORCH ON
Light turn
on?
NO
YES
Set Gas(es) at proper
pressure with OSS
switch in CUT/STARTSHIELDmode.
Is
Main Arc
established
?
Place OSS switch in
OPERATE
“A”
YES
Depress Torch
Switch
HIGH FREQ light
goes out
NO
1. Check OSS switch.
2. Check Torch Switch.
3. Check PAC contactor to insure 24 VAC is
applied to coil.
4. Check PC Board.
5. Check HFTR Transformer
Adjust cutting speed
Release torch switch
YES
Does
LOW GAS
Light GO
Off?
NO
1. Check consumables in torch.
2. Check torch connections using
ohmmeter.
3. Check open circuit voltage (325
VDC). (Disconnect HF to avoid
damaging meter.)
4. Check HF at spark gaps. (ISW
switch must be closed when
performing check.) May have to
reset spark gap.
5. Check PAC contactor.
6. Check R20 and R21 resistors.
Touch pilot arc to work piece within
6 sec. after pilot arc is established, or
pilot arc will turn off and begin cycling
on and off about every 3 sec.
YES
Is
HIGH FREQ
Light
On?
1. Check open circuit voltage.
Should be about 370 VDC. (Disconnect HF to avoid damaging
meter.)
2. Check input power.
3. Check MC contactor.
4. Check diodes and SCR’s.
5. Check PC board.
1. Check input gas pressure.
2. Check gas flow of PT-26. Check to be
sure consumables are good and properly in place.
3. Check torch switch for intermittent connection.
4. If using PT-26, check jumper between
pin 4 and 5.
LOW GAS light
turns on
Unit in Post Flow mode
and ready to cut again.
YES
2 second delay
“A”
53
NO
1. Check work lead connection.
2. Check consumables in torch.
3. Check for proper nozzle and
current. At low currents, the arc
length has to be closer to work.
4. Check all input voltages between
lines.
5. Check open circuit voltage.
6. Check diodes and SCR’s.
7. Check PC board.
section 5maintenance
54
section 6replacement parts
6.0
Replacement Parts
6.1General
Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on
the unit nameplate.
6.2Ordering
To ensure 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.
Replacement parts may be ordered from your ESAB Distributor.
Be sure to indicate any special shipping instructions when ordering replacement parts.
Refer to the Communications Guide located on the back page of this manual for a list of customer service phone
numbers.
The ESP-150 is designed and tested in accordance with the international and European standards EN
60974-1 and EN 60974-10. It is the obligation of the service unit which has carried out the service or
repair work to make sure that the product still conforms to the said standard. Repair and electrical work
should be performed by an authorized ESAB serviceman. Use only ESAB original spare and wear parts.
Spare parts may be ordered through your nearest ESAB dealer, see the last page of this publication.
NOTE:
X
Bill of Material item numbers enclosed by a square denote sub-assemblies.
Refer to Bill of Material to identify items that make up the sub-assembly.
Sub-assemblies may be ordered instead of ordering each item individually.
Note
Schematics and Wiring Diagrams are printed on
279.4mm x 431.8mm (11” x 17”) paper and are included
inside the back cover of this manual.
55
section 6replacement parts
2
13
16
14
7
6
9
15
8
10
18
11
19
12
4
17
3
1
20
5
56
section 6replacement parts
ITEM
1
2
3
4
5
QTY
1
1
1
1
1
PART NO
0558002680M
0558002683Y
0558002681Y
0558002682Y
0558002678M
6
1
0558002806
7
8
9
10
11
12
13
14
15
16
17
18
19
20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
680718
0558003773
0558003775
0558003780
0558004052
951474
0558003776
673999
0558003777
0558003778
0558004053
0558003772
0558003769
0558004054
DESCRIPTION
PANEL FRONT
PANEL TOP
PANEL SIDE LEFT
PANEL SIDE RIGHT
PANEL BASE
CONTROL PANEL TOP ASSY
(Includes Items 7 thru 10)
CONTROL PANEL TOP SHELL
PANEL CONTROL SILKSCREENED
PC BOARD - STATUS LIGHTS
SWITCH ROTOR DPST 600V 25A
SWITCH TOGGLE 3 POS DPDT 15A 125V
SEAL SWITCH BLACK
POTENTIOMETER 15K 2W
POTENTIOMETER SHAFT LOCK
KNOB
MAT RUBBER
GROMMET RUBBER
VOLTMETER DC (0-500 VOLTS)
AMMETER DC (0-150 AMPS)
TERMINAL OUTPUT ASSY
57
SYMBOL
SLBD
ROS
OSS
CCP
VM
AM
WORK
section 6replacement parts
22
28
29
23
30
31
24
32
33 REF
26
34
35
25
36
37
27
38
39
41
40
58
section 6replacement parts
ITEM
QTY
PART NO
22
1
0558002800M
23
24
25
26
27
1
1
1
1
4
0558002679M
0558004077
0558004055
0558000749
17300008
28
1
0558002810
29
30
31
32
33
34
35
36
37
38
39
40
41
Ref
3
1
1
1
1
2
1
1
1
1
1
1
1
Ref
0558006864
0558002345
0558006291
0558002346
0558004058
0558006292
0558004057
10Z30
0558004059
0558004060
0558004061
0558002820M
0558004079
0558004056
DESCRIPTION
PANEL REAR ASSY
(Includes Items 23 thru 41)
PANEL REAR
SHROUD MACHINE FAN 16”
BLADE MACHINE FAN 16”
MOTOR MACHINE FAN 1/3 HP
RESISTOR 8 OHM 300W
MANIFOLD GAS CONTROL ASSY
(Includes Items 29 thru 36)
VALVE SOLENOID 165 PSI 24VAC
SWITCH PRESSURE 17 PSI
ELBOW STREET 90 DEGREE 1/8NPT
SWITCH PRESSURE 22 PSI
CONNECTION RH OXYGEN B SIZE
ELBOW STREET 90 DEGREE 1/4NPT
ADAPTOR RH B/I-G*F 1/4NPTM
ADAPTOR RH B/A-W*M 1/4NPTM
RECEPTACLE PANEL 19 SOCKET
RECEPTACLE PANEL 14 SOCKET
RECEPTACLE PANEL 3 SOCKET
SHROUD COOLANT PUMP FAN 10.5”
STRAIN RELIEF 2”
CONNECTION LH FUEL GAS B SIZE
59
SYMBOL
FM
R20,R21,R30,R31
SV-1,2,3
PS1
PS2
J1
J2
J3
section 6replacement parts
51
43
44
45
63
46
52
53
54
55
50
47
57
56
62
66
67
61
60
48
49
68
63
65
70
58
70
64
60
69
section 6replacement parts
ITEM
QTY
PART NO
43
1
0558002803
44
45
46
47
48
49
50
51
52
53
54
1
1
1
1
1
1
1
2
2
1
1
0558002804M
30845M
30859
0558007469
0558007163
0558007470
677905
2062161
182W15
82W43
96W22
55
1
30813
56
1
634090
57
1
58V75
58
59
60
61
2
0558006292
1
1
997830
58V58
62
1
33033
63
64
65
66
67
68
69
70
1
1
1
1
1
1
1
4
674592
674971
0558004069
0558004071
0558004088
56997963
0558002996
950972
DESCRIPTION
HIGH FREQUENCY ASSY
(Includes Items 44 thru 70)
PANEL HIGH FREQUENCY ASSY
PANEL DIVIDER
AUTOTRANSFORMER HIGH FREQUENCY
TRANSFORMER HIGH FREQUENCY
CAPACITOR .002uF 10KWV
CAPACITOR 2500pF 15KV
SPARK GAP ASSY
CIRCUIT BREAKER 5A
FUSE HOLDER
FUSE 1A 250V
FUSE SLO-BLO 3.2A 250V
TORCH CONNECTION PANEL ASSY
(Includes Items 56 thru 58)
ADAPTOR SPECIAL
ADAPTOR BULKHEAD LH B/A-W*F
1/4NPTM
ELBOW STREET 90 DEGREE 1/4NPT
Not Used
RECEPTACLE 5 POLE
ADAPTOR BULKHEAD B/I-G*F 1/4NPTM
ADAPTOR BULKHEAD B/A-W*M
1/4NPTM
SWITCH SNAP ACTION SPDT 15A 125V
PC BOARD - HF FILTER
CAPACITOR 10uF 370VDC
RESISTOR 220K OHM 1W
RELAY 3PDT 240VAC 28VDC 10A
PC BOARD - VOLTAGE DIVIDER
BRACKET VDR
CAPACITOR .022uF 1600VDC
61
SYMBOL
HFATR
HFTR
C18A
C18B
SG
CB1,2
F3
F4
J6
ISW
FBD2
C34
R23
GFIR
C15,C16,C20,C21
section 6replacement parts
79
74
78
73
77
78
75
76
71
72
80
62
section 6replacement parts
ITEM
71
72
73
74
75
76
77
78
79
80
QTY
1
1
1
1
1
1
1
5
1
1
PART NO
0558002689M
0558004085
0558004086
0558004087
0558004090
17111220
0558004088
0558004089
17140310
0558004068
DESCRIPTION
BOX PC BOARD
PC BOARD - CONTROL
PC BOARD - LOGIC
CAPACITOR 1500uF 50VDC
RELAY TIME DELAY DPDT 120VAC 10A
RESISTOR 2K OHM 0.25W
RELAY 3PDT 240VAC 28VDC 10A
RELAY DPDT 24VAC 10A
RESISTOR 10K OHM 2W
CAPACITOR .01uF 250VAC
63
SYMBOL
CBD
LBD
C25
TDR
R50
PFR
SCSR,OSR,CDR,ACR,FR
R28
C13
section 6replacement parts
85
98
81
96
97
86
96
93
89
94
88
95
91
92
90
Not
Shown
Not
Shown
106
87
108
Not
Shown
82
106
83
107
84
99
Not
Shown
100
101
102 103
104
109
109
Not
Shown
Not
Shown
105
110
110
64
section 6replacement parts
ITEM
QTY
PART NO
81
1
0558006906
82
1
0558004076
83
84
2
3
0558004084
0558004075
85
1
0558004074
86
1
0558004075
87
1
680379
88
89
90
91
92
5
3
1
3
3
950703
680452
950711
0558004068
950065
93
1
0558004073
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
4
4
5
1
1
1
1
3
1
1
1
1
2
2
1
2
2
0558004069
0558004071
17280010
17280210
17145410
674970
680381
0558004068
0558010711
0558004070
950627
17315247
0558004069
0558004068
17145422
0558000447
17225310
DESCRIPTION
TRANSFORMER / BRIDGE ASSY
(Includes Items 82 thru 99)
TRANSFORMER MAIN
(Includes Items 83 and 84)
FUSE LINK 150A 250V
SWITCH THERMAL 180C
INDUCTOR
(Includes Item 86)
SWITCH THERMAL 180C
BRIDGE ASSY
(Includes Items 88 thru 92)
DIODE FORWARD 1200V 85A
RECTIFIER SILICON CONTROLLED 1200V
SWITCH THERMAL 194F
CAPACITOR .01uF 250VAC
VARISTOR METAL OXIDE 420VAC 160J
FILTER NETWORK ASSY
(Includes Items 94 thru 98)
CAPACITOR 10uF 370VDC
RESISTOR 220K OHM 1W
RESISTOR 10 OHM 100W
RESISTOR 1K OHM 100W
RESISTOR 100K OHM 2W
PC BOARD - SCR GATE FILTER
TRANSFORMER CONTROL
CAPACITOR .01uF 250VAC
CONTACTOR PILOT ARC 40A 24VAC
RESISTOR 470 OHM 2W
CAPACITOR 4200uF 350VDC
RESISTOR 4.7K OHM 12W
CAPACITOR 10uF 370VDC
CAPACITOR .01uF 250VAC
RESISTOR 220K OHM 2W
CAPACITOR 1900uF 450VDC
RESISTOR 10 OHM 8W
65
SYMBOL
MTR
F1,2
MTRTS1,2,3
IND
INDTS1
BR
D1,D2,D3,D4,D4A
SCR1,2,3
BRTS1
C31,32,33
MOV1,2,3
C10,C11,C12,C14
R10,R11,R12,R17
R13,R14,R15,R16,R18
R19
R32
FBD1
CTR
C26,C29,C30
PAC
R26
C35
R6
C17,C19
C27,28
R22
C24,24A
R36,37
section 6replacement parts
26
118 119
129
121
130
68
69
120
27
122
24
25
125
128
127
126
112
113
114
115
116
117
66
123
124
section 6replacement parts
ITEM
112
113
114
QTY
1
1
1
PART NO
0558010710
0558004070
0558004081
115
1
9680911
116
117
10
1
672065
672227M
118
1
30941
119
120
121
122
123
124
125
126
127
128
129
130
9
9
1
1
1
1
1
1
1
1
1
1
0558004066
0558004067
0558003760
17175413
0558004072
0558004068
0458918880
0558000292
0558002686M
186W91
0558002688
0558002808M
DESCRIPTION
CONTACTOR MAIN 90A 24VAC
RESISTOR 470 OHM 2W
LUG GROUNDING
TERMINAL BOARD ASSY 230/460/575V
(Includes Item 116)
TERMINAL STRAP
BRACKET MOUNTING TERMINAL BOARD
CAPACITOR BANK ASSY
(Includes Items 119 and 120)
CAPACITOR 60uF 370VDC
RESISTOR 330K OHM 0.5W
MODULE POWER SUPPLY 24V
RESISTOR 133K OHM 2W (In-line / Violet Wire)
SHUNT ASSY
CAPACITOR .01uF 250VAC
REED SWITCH
HEAT EXCHANGER
PANEL TOP AIR EXIT CHAMBER
GROMMET RUBBER 2-5/8” I.D.
PLATE MOUNTING CAPACITOR BANK ASSY
BAFFLE LEFT
67
SYMBOL
MC
R25
GND1
TB
C1-C9
R1-R9
R29
SH
C22,23
RSW
section 6replacement parts
Detail Showing
Standard Unit
147
131
35
34
29
65
145
30
34
36
40
106
106
107
108
127
146
135
133
136
136
137
141
139 138
137
140
141
68
132
134
142
144
section 6replacement parts
ITEM
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
QTY
1
1
1
1
1
2
2
1
1
1
2
1
1
1
3
1
1
PART NO
0558004065
0558004064
10Z30
58V75
0558004062
0558006272
67101075
461107
598481
21124
10Z30
0558004063
0558002685M
0558002901
0558004070
0558002687M
0558002807M
DESCRIPTION
TANK COOLANT 6 QUART
SWITCH FLOW 0.25GPM
ADAPTOR RH B/A-W*M 1/4NPTM
ADAPTOR BULKHEAD LH B/A-W*F 1/4NPTM
PUMP COOLANT 60PSI 96GPH
ADAPTOR BUSHING 1/4NPTF 3/8NPTM
NIPPLE 1/4NPT
TEE STREET 1/4NPT
GAGE PRESSURE 200PSI 1400KPa
CHECK VALVE
ADAPTOR RH B/A-W*M 1/4NPTM
MOTOR COOLANT PUMP 1/3 HP
BRACKET MOUNTING COOLANT PUMP MOTOR
BLADE COOLANT PUMP MOTOR 9.75”
RESISTOR 470 OHM 2W
PANEL SIDE AIR EXIT CHAMBER
BAFFLE RIGHT
69
SYMBOL
PM
R51,52,53
section 6replacement parts
70
notes
71
notes
72
revision history
1.
2.
3.
4.
5.
6.
7.
8.
9.
Revision “C” - 07/2004 - Revised with updated schematic diagrams. Made various editorial changes also.
Revision “C” - 08/2006 - Replacement parts section, front view, changed item 11 from: p/n 950812 to: 636702.
Revision “D” - 02/2007 - updated / replaced Replacement Parts section.
Revision “E” - 06/2008 - updated P45 / J5 location functions in Section 3.
Revision “F” - 06/2010 - updated Replacement Parts section with VDR board and bracket info & updated schem
pack. Added VDR adjustment info in INSTALLATION section.
Revision “F” - 11/2010 - Updated schematic pack per DNECO # 103119.
Revision “F” - 08/2012 - Updated contactor BOM p/n’s for J. Magee.
Revision “F” - 08/2014 - Removed “7” prefix from BOM item 50.
Revision “H” - 02/2015 - Updated cut data section.
73
ESAB Welding & Cutting Products, Florence, SC
COMMUNICATION GUIDE - CUSTOMER SERVICES
A.
CUSTOMER SERVICE QUESTIONS:
Telephone: (800)362-7080 / Fax: (800) 634-7548
Hours: 8:00 AM to 7:00 PM EST
Order Entry
Product Availability
Pricing Order Information Returns
B.
ENGINEERING SERVICE:
Telephone: (843) 664-4416 / Fax : (800) 446-5693
Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting
C.
TECHNICAL SERVICE:
Telephone: (800) ESAB-123/ Fax: (843) 664-4452
Part Numbers
Technical Applications
Specifications
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
Material Safety Data Sheets
Warranty Registration
Instruction Literature Download Library
Distributor Locator
Global Company Information
Press Releases
Customer Feedback & Support