0558 003 744 US / 110222

0558 003 744 US / 110222
ESP-150
Plasma Cutting System
Instruction manual
This manual provides installation and operation instructions for the following componenets
beginning with Serial Number 015:
0558 003 744
110222
Valid for serial no. 015-xxx-xxxx
1 USER RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 SAFETY PRECAUTIONS - English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 PRECAUCION DE SEGURIDAD - Spanish . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 MESURES DE SECURITE - French . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ESP-150 Plasmarc™ System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications ESP-150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1
3
3
7
11
15
15
16
PT-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
6 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
6.1
6.2
6.3
6.4
6.5
6.6
6.7
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Primary input electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torch connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas supply connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Work and earth connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torch collant preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
19
20
26
27
29
30
7 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
Controls and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ESP-150 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standoff and cut quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dross formation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commun cutting problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cutting speed conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended gas and current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cutting Parameters for the PT-26 and ESP-150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
32
33
35
36
36
37
38
38
39
8 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
8.1
8.2
8.3
8.4
Inspection and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark gap adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing and replacing brdige assembly components . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
43
44
44
9 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45
9.1
9.2
9.3
Troubleshooting guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sequence of operation (see fig 22) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Status light troubleshooting chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46
48
50
10 ORDERING AND REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52
10.1
10.2
Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ordering numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52
52
11 ASSEMBLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 REVISION HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCHEMATIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53
54
56
62
Rights reserved to alter specifications without notice.
TOCa
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Be sure this information reaches the operator.
You can get extra copies through your supplier.
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding equipment, we urge you to read
our booklet, “Precations and Safe Practices for Arc, 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.
1
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and
accompanying labels and/or insert when installed, operated, maintained and repaired in accordance
with the instruction 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.
2
SAFETY PRECAUTIONS - English
WARNING: These Safety Precautions are for your protection. They summarize precautionary
information from the references listed in Additional Safety Information section. Before performing any
installation or operating procedures, be sure to read and follow the safety precautions listed below as
well as all other manuals, material safety data sheets, labels, etc. Failure to observe Safety
Precautions can result in injury or death.
PROTECT YOURSELF AND OTHERS
Some welding, cutting and gouging precesses are noisy and require ear
protection. The arc, like the sun, emits ultraviolet (UV) and other radiation
and can injure skin and eyes. Hot metal can cause burns. Training in the
proper use of the processes and equipment is essential to prevent accidents.
Therefore:
1. Always wear safety glasses with side shields in any work area, even if welding helmets face
shields and goggles are also required.
2. Use a face shield fitted with the correct filter and cover plates to protect your eyes, face, neck
and ears from sparks and rays of the arc when operating or observing operations. Warn
bystanders not to watch the arc and not to expose themselves to the rays of the electric-arc or
hot metal.
3. Wear flameproof gauntlet type gloves, heavy long-sleeve shirt, cuffless trousers, high-topped
shoes and a welding helmet or cap for 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.
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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 nonflammable 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.
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 nonflammable covering. Combusible materials include wood, clot, sawdust, liquid and
gas fuels, solvents, pants and coatings papper, 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.
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. Therefore:
1. Be sure the power source frame (chassis) is connected to the ground system of the input power.
2. Connect the workpiece to a good electrical ground.
3. Connect the work cable to the workpiece. A poor or missing connection can expose you or others
to a fatal shock.
4. Use well-maintained equipment. Replace worn or damaged cables.
5. Keep everything dry, including clothing, work area, cables, torch/electrode holder and power
source.
6. Make sure that all parts of your bady are insulated from work and from ground.
7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand
on dry boards or an insulating platform and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specific grounding
recommendations. Do not mistake the work lead for a ground cable.
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ELECTRIC AND MAGNETIC FIELDS
May be dangerous. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding and cutting current
creates EMF around welding cables and welding machines.
Therefore:
1. Welders having pacemakers should consult their physician before welding. EMF may interfere
with some pacemakers.
2. Exposure to EMF may have other health effects which are unknown.
3. Welders should use the following procedures to minimize exposure to EMF:
a. Route the electrode and work cables together. Secure them with tape when possible.
b. Never coil the torch or work cable around your body.
c. Do not place your body between the torch and work cables. Route cables on the same side
of your body.
d. Connect the work cable to the workpiece as close as possible to the area being welded.
e. Keep welding power source and cables as far away from your body as possible.
FUMES AND GASES
Fumes and gases, can cause discomfort or harm, particularly in confined
spaces. Do not breathe fumes and gases. Shielding gases can cause
asphyxiation.
Therfore:
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, cooper, zinc, lead
beryllium or cadmium unless positive mechanical ventilation is provided. Do not breathe fumes
from these materials.
2. Do not operate near degreasing and spraying operations. The heat or arc can react with
chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas and other irritant gases.
3. If you develop momentary eye, nose or throat irritation while operating, this is an indication that
ventilation is not adequate. Stop work and take necessary steps to improve ventilation in the work
area. Do not continue to operate if physical discomfort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specific ventilation recommendations.
5. WARNING: This product when used for welding or cutting, produces fumes or gases which
contain chemicals known to the State of Californa to cause birth defects and in some cases
cancer (California Health & Safety Code §25249.5 et seq.)
CYLINDER HANDLING
Cylinders, if mishandled, can rupture and violently release gas. Sudden
rupture of cylinder valve or relief device can injure or kill.
Therefore:
1. Use the proper gas for the process and use the proper pressure reducing regulator designed to
operate from the compressed gas cylinder. Do not use adaptors. Maintain hoses and fittings in
good condition. Follow manufacturer's operating instructions for mounting regulator to a
compressed gas cylinder.
2. Always secure cylinders in an upright position by chain or strap to suitable hand trucks,
undercarriages, benches, wall, post or racks. Never secure cylinders to work tables or fixtures
where they may become part of an electrical circuit.
3. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is
not connected. Secure and move cylinders by using suitable hand trucks.
4. Locate cylinders away from heat, sparks and flames. Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1, “Precations for Safe Handling of
Comporessed Gases in Cylinders”, which is available from Compressed Gas Association, 1235
Jefferson Davis Highway, Arlington, VA 22202.
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EQUIPMENT MAINTENANCE
Faulty or improperly maintained equipment can cause injury or death. Therefore:
1. Always have qualified personnel perform the installaion, troubleshooting and maintenance work.
Do not perform any electrical work unless you are qualified to perform such work.
2. Before performing any maintenance work inside a power source, disconnect the power source
from the incoming electrical power.
3. Maintain cables, grounding wire, connections, power cord and power supply in safe working
order. Do not operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such as
furnaces, wet conditions such as water puddles, oil or grease, corrosive atmospheres and
inclement weather.
5. Keep all safety devices and cabinet covers in position and in good repair.
6. Use equipment only for its intended purpose. Do not modify it in any manner.
ADDITIONAL SAFETY INFORMATION
For more information on safe practices for electric arc welding and cutting equipment,
ask your supplier for a copy of “Precautions and Safe Practices for Arc Welding,
Cutting and Gouging”, Form 52-529.
The following publications, which are available from the American Welding Society, 550 N.W. LeJuene
Road, Miami, FL 33126, are recommended to you:
1.
2.
3.
4.
5.
6.
7.
8.
ANSI/ASC Z49.1 - “Safety in Welding and Cutting”
AWS C5.1 . “Recommended Practices for Plasma Arc Welding”
AWS C5.2 - “Recommended Practices for Plasma Arc Cutting“
AWS C5.3 - “Recommended Practices for Air Carbon, Arc Gouging and Cutting”
AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding”
AWS C5.6 - “Recommended Practices for Gas Metal Arc welding”
AWS SP - “Safe practices” - Reprint, Welding Handbook
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!
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.
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3
PRECAUCION DE SEGURIDAD - Spanish
ADVERTENCIA: Estas Precauciones de Seguridad son para su protección. Ellas hacen
resumen de información proveniente de las referencias listadas en la sección ”Información Adicional
Sobre La Seguridad”. Antes de hacer cualquier instalación o procedimiento de operación, asegúrese
de leer y seguir las precauciones de seguridad listadas a continuación así como también todo manual,
hoja de datos de seguridad del material, calcomanias, etc. El no observar las Precauciones de
Seguridad puede resultar en daño a la persona o muerte.
PROTEJASE USTED Y A LOS DEMAS
Algunos procesos de soldadura, corte y ranurado son ruidosos y requiren
protección para los oídos. El arco, como el sol , emite rayos ultravioleta (UV)
y otras radiaciones que pueden dañar la piel y los ojos. El metal caliente
causa quemaduras. EL entrenamiento en el uso propio de los equipos y sus
procesos es esencial para prevenir accidentes.
Por lo tanto:
1. Utilice gafas de seguridad con protección a los lados siempre que esté en el área de trabajo, aún
cuando esté usando careta de soldar, protector para su cara u otro tipo de protección.
2. Use una careta que tenga el 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. La escoria puede estar caliente y desprenderse con velocidad. Personas cercanas
deberán usar gafas de seguridad y careta protectora.
FUEGO Y EXPLOSIONES
El calor de las 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.
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7. Para información adicional , haga referencia a la publicación NFPA Standard 51B, “Fire
Prevention in Use of Cutting and Welding Processes”, available from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
CHOQUE ELECTRICO
El contacto con las partes eléctricas energizadas y tierra puede causar daño
severo o muerte. NO use soldadura de corriente alterna (AC) en áreas
húmedas, de movimiento confinado en lugares estrechos o si hay posibilidad
de caer al suelo.
Por lo tanto:
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. RUse 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.
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 marcapasos.
2. Exponerse a campos electromagnéticos (EMF) puede causar otros efectos de salud aún
desconocidos.
3. Los soldadores deberán usar los siguientes procedimientos para minimizar exponerse al EMF:
a. Mantenga el electrodo y el cable a la pieza de trabajo juntos, hasta llegar a la pieza que
usted quiere soldar. Asegúrelos uno junto al otro con cinta adhesiva cuando sea posible.
b. Nunca envuelva los cables de soldar alrededor de su cuerpo.
c. Nunca ubique su cuerpo entre la antorcha y el cable, a la pieza de trabajo. Mantega los
cables a un sólo lado de su cuerpo.
d. Conecte el cable de trabajo a la pieza de trabajo lo más cercano posible al área de la
soldadura.
e. Mantenga la fuente de poder y los cables de soldar lo más lejos posible de su cuerpo.
-8US warnings
US
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 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.
5. ADVERTENCIA-Este producto cuando se utiliza para soldaduras o cortes, produce humos o
gases, los cuales contienen químicos conocidos por el Estado de California de causar defectos
en el nacimiento, o en algunos casos, Cancer. (California Health & Safety Code §25249.5 et
seq.)
MANEJO DE CILINDROS
Los cilindros, si no son manejados correctamente, pueden romperse y liberar
violentamente gases. Rotura repentina del cilindro, válvula, o válvula de
escape puede causar daño o muerte.
Por lo tanto:
1. Utilize el gas apropiado para el proceso y utilize un regulador diseñado para operar y reducir la
presión del cilindro de gas. No utilice adaptadores. Mantenga las mangueras y las conexiones en
buenas condiciones. Observe las instrucciones de operación del manufacturero para montar el
regulador en el cilindro de gas comprimido.
2. Asegure siempre los cilindros en posición vertical y amárrelos con una correa o cadena
adecuada para asegurar el cilindro al carro, transportes, tablilleros, paredes, postes, o armazón.
Nunca asegure los cilindros a la mesa de trabajo o las piezas que son parte del circuito de
soldadura. Este puede ser parte del circuito elélectrico.
3. Cuando el cilindro no está en uso, mantenga la válvula del cilindro cerrada. Ponga el capote de
protección sobre la válvula si el regulador no está conectado. Asegure y mueva los cilindros
utilizando un carro o transporte adecuado. Evite el manejo brusco de los
4. Localize los cilindros lejos del calor, chispas, y flamas. Nunca establezca un arco en el cilindro.
5. Para información adicional, haga referncia a la publicación CGA Standard P-1, “Precations for
Safe Handling of Comporessed Gases in Cylinders”, disponible através del Compressed Gas
Association, 1235 Jefferson Davis Highway, Arlington, VA 22202.
MANTENIMIENTO DEL EQUIPO
Equipo defectuoso o mal mantenido puede causar daño o muerte.
Por lo tanto:
1. Siempre tenga personal cualificado para efectuar la 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.
-9US warnings
US
6. Use el equipo sólo para el propósito que fue diseñado. No modifique el equipo en ninguna
manera.
INFORMACION ADICIONAL DE SEGURIDAD
Para más información sobre las prácticas de seguridad de los equipos de arco eléctrico
para soldar y cortar, pregunte a su suplidor por una copia de “Precautions and Safe
Practices for Arc Welding, Cutting and Gouging”, Form 52-529.
Las siguientes publicaciones, disponibles através de la American Welding Society, 550 N.W. LeJuene
Road, Miami, FL 33126, son recomendadas para usted:
1.
2.
3.
4.
5.
6.
7.
8.
ANSI/ASC Z49.1 - “Safety in Welding and Cutting”
AWS C5.1 . “Recommended Practices for Plasma Arc Welding”
AWS C5.2 - “Recommended Practices for Plasma Arc Cutting“
AWS C5.3 - “Recommended Practices for Air Carbon, Arc Gouging and Cutting”
AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding”
AWS C5.6 - “Recommended Practices for Gas Metal Arc welding”
AWS SP - “Safe practices” - Reprint, Welding Handbook
ANSI/AWS F4.1 - “Recommended Safe Practices for Welding and Cutting of Containers That
Have Held Hazardous Substances”
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.
- 10 US warnings
US
4
MESURES DE SECURITE - French
ATTENTION : ces règles de sécurité ont pour objet d'assurer votre protection. Elles constituent
une synthèse des mesures de sécurité contenues dans les ouvrages de référence repris au chapitre
Informations complémentaires relatives à la Sécurité. Avant toute installation ou utilisation du matériel,
veillez à lire et à respecter les règles de sécurité énoncées ci-dessous ainsi que dans les divers
manuels, fiches de sécurité du matériel, étiquettes, etc. Le non-respect de ces précautions risque
d'entraîner des blessures graves ou mortelles.
PROTECTION INDIVIDUELLE ET DE L'ENTOURAGE
Certains procédés de soudage, découpage et gougeage sont bruyants et
requièrent le port de protections auditives. L'arc, tout comme le soleil, émet
des ultraviolets (UV) et d'autres rayonnements susceptibles de provoquer des
lésions oculaires et dermatologiques. Le métal chaud peut être à l'origine de
brûlures. Une formation à l'utilisation correcte des procédés et équipements
est essentielle pour prévenir les accidents. En conséquence :
1. Porter impérativement des lunettes avec écrans latéraux dans les zones de travail, même
lorsque le port du casque de soudage, de l'écran facial et des lunettes de protection est
obligatoire
2. Tant pour exécuter les travaux que pour y assister, porter un écran facial muni de plaques
protectrices et de verres filtrants appropriés pour protéger les yeux, le visage, le cou et les
oreilles des étincelles et du rayonnement de l'arc. Avertir les personnes se trouvant à proximité
qu'elles ne doivent pas regarder l'arc, ni s'exposer à son rayonnement ou à celui du métal
incandescent.
3. Porter des gants ignifuges à crispins, une tunique épaisse à longues manches, des pantalons
sans rebord, des chaussures à embout d'acier et un casque de soudage ou une casquette pour
se protéger du rayonnement de l'arc, des étincelles et du métal incandescent. Le port d'un tablier
ininflammable est également recommandé afin de se protéger des étincelles et du rayonnement
thermique.
4. Les étincelles ou projections de métal en fusion risquent de se loger dans les manches
retroussées, les bords relevés de pantalons ou dans les poches. Il convient donc de boutonner
complètement les manches et le col, et de porter des vêtements sans poches à l'avant.
5. Protéger du rayonnement de l'arc et des étincelles les personnes se trouvant à proximité à l'aide
d'un écran ou d'un rideau ininflammable approprié.
6. Porter des oculaires et des lunettes de protection pendant le meulage du laitier. Les particules
meulées, souvent brûlantes, peuvent être projetées à des distances importantes, de sorte que
les personnes se trouvant à proximité doivent également porter des lunettes de protection.
INCENDIES ET EXPLOSIONS
La chaleur dégagée par les flammes et les arcs peuvent être à l'origine
d'incendies. Le laitier incandescent et les étincelles peuvent également
provoquer incendies et explosions. En conséquence :
1. Éloigner suffisamment tous les matériaux combustibles de la zone de travail ou les recouvrir
complètement d'une bâche ignifuge. Ce type de matériaux comprend le bois, les vêtements, la
sciure, les carburants sous forme liquide et gazeuse, les peintures, les enduits, le papier, etc.
2. Les étincelles ou projections de métal en fusion peuvent tomber dans les fissures du sol ou des
murs et déclencher une combustion lente dans les planchers ou à l'étage inférieur. Veiller à
protéger ces ouvertures pour que les étincelles et projections n'y pénètrent pas.
3. Ne pas procéder à des travaux de soudage, de découpage et autres travaux à chaud tant que la
surface n'est pas complètement nettoyée et débarrassée des substances susceptibles de
produire des vapeurs inflammables ou toxiques. Ne pas effectuer de travaux à chaud sur des
conteneurs fermés pour éviter tout risque d'explosion.
4. Conserver à portée de main un équipement d'extinction – tuyau d'arrosage, seau d'eau ou de
sable, extincteur portatif, etc. et s'assurer d'en connaître l'utilisation.
5. Ne pas utiliser l'équipement au-delà de ses spécifications. Par exemple, un câble de soudage
surchargé est susceptible de surchauffer et d'être à l'origine d'un incendie.
- 11 US warnings
US
6. Une fois le travail terminé, inspecter la zone de travail pour s'assurer qu'aucune étincelle ou
projection de métal ne risque de déclencher un incendie. Le cas échéant, utiliser des systèmes
de détection d'incendie.
7. Pour toute information supplémentaire, voir la norme NFPA 51B relative à la prévention des
incendies lors de travaux de découpage et de soudage, disponible auprès de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269 – USA.
CHOC ELECTRIQUE
Tout contact avec des éléments sous tension et la masse peut provoquer des
blessures graves ou mortelles. NE PAS utiliser de courant de soudage CA
dans des zones humides, des lieux exigus ou lorsqu'il existe un risque de
chute. En conséquence :
1. Vérifier que le châssis du générateur est bien relié au dispositif de mise à la masse de
l'alimentation.
2. Assurer une mise à la masse correcte de la pièce à souder.
3. Connecter le câble de soudage à la pièce à souder. Un raccordement médiocre ou inexistant
constitue un risque mortel pour l'utilisateur et son entourage.
4. Utiliser du matériel correctement entretenu. Remplacer les câbles usés ou endommagés.
5. Empêcher l'apparition de toute humidité, notamment sur les vêtements, dans la zone de travail,
sur les câbles, la torche de soudage, le porte-électrode et le générateur.
6. S'assurer que le corps est totalement isolé de la pièce à souder et de la masse.
7. Éviter tout contact direct avec du métal ou la masse lors de travaux dans des endroits exigus et
en zone humide ; se tenir sur des panneaux ou sur une plate-forme isolante et porter des
chaussures à semelles en caoutchouc.
8. Enfiler des gants secs et sans trous avant de mettre l'équipement sous tension.
9. Mettre l'équipement hors tension avant de retirer les gants.
10. Voir la norme ANSI/ASC Z49.1 (voir page suivante) pour les recommandations de mise à la
masse. Ne pas confondre le câble de soudage et le câble de masse.
CHAMPS ELECTRIQUES ET MAGNETIQUES
Danger. Le courant électrique parcourant les conducteurs génère localement
des champs électriques et magnétiques (EMF). Le courant de soudage et de
découpe crée des EMF autour des câbles de soudage et des postes à souder.
En conséquence :
1. Les porteurs de stimulateurs cardiaques consulteront leur médecin avant d'effectuer des travaux
de soudage. Les EMF peuvent en effet provoquer des interférences.
2. L'exposition aux EMF peut également avoir des effets méconnus sur la santé.
3. Les soudeurs respecteront les procédures suivantes pour réduire l'exposition aux EMF :
a. Rassembler en faisceau les câbles de soudage et d'électrode. Si possible, les attacher avec
du ruban adhésif.
b. Ne jamais enrouler le câble de la torche ou le câble de soudage autour du corps.
c. L'utilisateur ne doit jamais se trouver entre le câble de la torche et le câble de soudage.
Faire passer tous les câbles du même côté du corps.
d. Connecter le câble de soudage à la pièce à souder, au plus près de l'endroit du soudage.
e. S'éloigner au maximum du générateur et des câbles.
- 12 US warnings
US
1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
6.
FUMEES ET GAZ
L'inhalation des fumées et gaz peut provoquer des malaises et des
dommages corporels, surtout lors de travaux dans les espaces confinés. Ne
pas les respirer. Les gaz inertes peuvent causer l'asphyxie.
En conséquence :
Assurer une aération adéquate de la zone de travail par une ventilation naturelle ou mécanique.
Ne pas effectuer de travaux de soudage, découpage ou gougeage sur des matériaux tels que
l'acier galvanisé, le cuivre, le zinc, le plomb, le béryllium et le cadmium en l'absence d'une
ventilation mécanique adéquate. Ne pas inhaler les fumées dégagées par ces matériaux.
Ne pas travailler à proximité d'opérations de dégraissage et de pulvérisation étant donné que la
chaleur dégagée et l'arc peut réagir avec les hydrocarbures chlorés pour former du phosgène –
un gaz particulièrement toxique – et d'autres gaz irritants.
Une irritation momentanée des yeux, du nez ou de la gorge provoquée par les travaux est le
signe d'une ventilation inappropriée. Dans ce cas, il convient d'arrêter le travail et de prendre les
mesures nécessaires pour améliorer l'aération. Ne pas poursuivre le travail si le malaise persiste.
Voir la norme ANSI/ASC Z49.1 (voir ci-dessous) pour les recommandations de ventilation.
ATTENTION : utilisé dans des opérations de soudage et de découpage, ce produit dégage des
fumées et gaz qui contiennent des substances chimiques reconnues par l'État de Californie
comme pouvant être à l'origine de malformations congénitales et de cancers (California Health &
Safety Code §25249.5 et seq.).
MANIPULATION DES BOUTEILLES DE GAZ
Une erreur de manutention des bouteilles de gaz peut les endommager et
entraîner une libération violente du gaz. La rupture soudaine de la soupape
ou du détendeur peut provoquer des blessures graves ou mortelles.
En conséquence :
Utiliser le gaz approprié à la pression adéquate, celle-ci étant réglée par un détendeur adapté au
type de bouteille utilisée. Ne pas utiliser d'adaptateurs. Garder les tuyaux et accessoires en bon
état. Pour le montage du détendeur sur une bouteille de gaz comprimé, suivre les instructions du
fabricant.
Fixer les bouteilles verticalement – au moyen d'une chaîne ou d'une sangle – à un chariot à bras,
un châssis de roulement, un banc, un mur, un piquet ou un rack. Ne jamais attacher les
bouteilles aux établis et éléments susceptibles de les intégrer à un circuit électrique.
Conserver les bouteilles fermées lorsqu'elles ne sont pas utilisées. Les fermer par un bouchon
lorsqu'elles ne sont pas raccordées. Attacher et déplacer les bouteilles à l'aide de chariots
adéquats.
Éloigner les bouteilles des sources de chaleur, d'étincelles et de flammes nues. Ne jamais
déclencher d'arc sur une bouteille de gaz.
Pour plus d'informations sur les précautions d'utilisation des bouteilles de gaz comprimé, voir la
norme CGA P-1, disponible auprès de la Compressed Gas Association, 1235 Jefferson Davis
Highway, Arlington, VA 22202 – USA.
ENTRETIEN DE L'EQUIPEMENT
Un équipement mal entretenu peut provoquer des blessures graves ou mortelles. En
conséquence :
Confier l'installation, les dépannages et l'entretien à du personnel qualifié. Ne pas effectuer de
travaux électriques si vous ne possédez pas les compétences requises.
Mettre l'équipement hors tension avant toute intervention d'entretien sur le générateur.
Maintenir en bon état de fonctionnement les câbles, câbles de masse, connexions, cordons
d'alimentation et générateurs. Ne jamais utiliser d'équipements défectueux.
Ne jamais surcharger les équipements et accessoires. Conserver les équipements à l'écart des
sources de chaleur – notamment des fours –, des flaques d'eau, des traces d'huile ou de graisse,
des atmosphères corrosives et des intempéries.
Laisser en place tous les dispositifs de sécurité et tous les panneaux du tableau de commande
en veillant à les garder en bon état.
Utiliser l'équipement conformément à l'usage prévu ; n'y apporter aucune modification
quelconque.
- 13 US warnings
US
INFORMATIONS COMPLEMENTAIRES RELATIVES A LA SECURITE Pour plus
d'informations relatives aux règles de sécurité pour les travaux de gougeage, de
découpage et de soudage à l'arc électrique, demander au fournisseur une copie du
formulaire 52/529.
L'American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126 – USA, publie les documents
suivants dont la lecture est également recommandée :
1.
2.
3.
4.
5.
6.
7.
8.
ANSI/ASC Z49.1 - ”Safety in Welding and Cutting”
AWS C5.1 . ”Recommended Practices for Plasma Arc Welding”
AWS C5.2 - ”Recommended Practices for Plasma Arc Cutting”
AWS C5.3 - ”Recommended Practices for Air Carbon, Arc Gouging and Cutting”
AWS C5.5 - ”Recommended Practices for Gas Tungsten Arc Welding”
AWS C5.6 - ”Recommended Practices for Gas Metal Arc welding”
AWS SP - ”Safe practices” - Réédition, Manuel de soudage
ANSI/AWS F4.1 - ”Recommended Safe Practices for Welding and Cutting of Containers That
Have Held Hazardous Substances”
SYMBOLES
Signification des symboles utilisés dans ce manuel : = Attention ! Rester prudent !
= danger immédiat ; risque de blessures graves ou mortelles.
= danger potentiel ; risque de blessures graves ou mortelles.
= danger ; risque de blessures légères.
- 14 US warnings
US
ESP-150 Plasmarc™ System
This versatile, all encompassed heavy duty water cooled plasma cutting and gouging
system is ideal for manual and mechanized applications.
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
Greater productivity - high speed cutting of most
metals from gauge thickness to 2- in. 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 nitrogenhydrogen 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
Specifications ESP-150
Input Current and Input Voltagle at Rated
Load
Output rating
90% duty cycle
100% duty cycle
Open circuit voltage
Operating temperature
Transportation temperature
Dimensions
Weight
112/56/45 amps, 230/460/575 Vac, 60 Hz, 3 Ph
150 amps @ 120 V
140 amps @ 120 V
370 vdc
-10 to +40° C
-20 to +55° C
w = 21.75 in. (552 mm)
h = 31.5 in. (800 mm)
d = 40 in.
(1016 mm)
766 lbs. (348 kg)
Torch: PT-26 - 70°, 90° or In-Line
Instruction Literature 230/460/575 V
Sales Literature
F15-687
PAC-21062
- 15 bp10da1
US
5
INTRODUCTION
The plasma power source ESP-150 and plasma cutting torch PT-26 are a complete
and safe plasma cutting system for cutting and gouging for manual and mechanized
applications.
5.1
PT-26
Plasma Gas
Type of gas
N2, Air, AR-H2, N2-H2
Pressure
Flow
Purity required
Recommended liquid cylinder service
regulators
Recommended cylinder 2-stage
regulators
100 psig (6.9 bar)
240 cfh (6.8 M3/h)
O2 - 99.5% min., N2-99.995% min., Air - clean and dry
Inert Gas R-76-150-580LC 19977
Recommended Heavy-Duty Hi-Flow
station or pipeline regulators
Argon-Hydrogen
Nitrogen
Industrial Air
Nitrogen
R-77-75-350
R-77-75-580
R-77-150-590
R-76-75-034
998341
998343
998348
19155
Starting Gas/Cutting Gas
Type of gas
N2, Air (for Ar-H2 Cut Gas Use N2 or Ar-H2)
Pressure
Flow
Purity required
100 psig (6.9 bar )
200 cfh (5.66M3/h) at 60 psig (4.1 bar)
N2 - 99% min., Air - clean and dry
Shield Gas
Type of gas
N2 or Air
Pressure
Flow
Purity required
100 psig (6.9 bar) maximum
200 cfh (5.66 M3/h) at 85 psig (5.86 bar)
Nitrogen - 99% minimum, Air - clean and dry
Assembly instructions PT-26, see on page 53.
- 16 bp10da2
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.
ESP-150 MANUAL PLASMA CUTTING PACKAGES
AIR PACKAGES
Ar/H2 PACKAGES
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 & Cylinder Rack
0558002910 - ESP-150 / PT-26 50’ 70° / Air
P/N
QTY DESCRIPTION
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
19416
3 Gas Hose
36933GY
1 Reg.Mont
156F05
4 Coolant (4 gallons)
680794
1 Truck & Cylinder Rack
0558002911 - ESP-150 / PT-26 25’ 90° / Air
P/N
QTY DESCRIPTION
0558002677
1 ESP-150 Console
35458
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 & Cylinder Rack
0558002912 - ESP-150 / PT-26 50’ 90° / Air
P/N
QTY DESCRIPTION
0558002677
1 ESP-150 Console
35459
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 & Cylinder Rack
- 17 bp10da3
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 & Cylinder Rack
0558002916 - ESP-150 / PT-26 50’ 70° / Ar+H2 Mix
P/N
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
678724
1 Work Cable, 50'
19X54
2 Adaptors
156F05
4 Coolant (4 gallons)
680794
1 Truck & Cylinder 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
678724
1 Work Cable, 25'
74S76
2 Adaptors
156F05
4 Coolant (4 gallons)
680794
1 Truck & Cylinder Rack
ESP-150 MANUAL PLASMA CUTTING PACKAGES
Ar/H2 PACKAGES
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 & Cylinder Rack
ESP-150 MECHANIZED PLASMA CUTTING PACKAGES
AIR PACKAGES
Ar/H2 PACKAGES
0558002913 - ESP-150 / PT-26 25’ Inline / Air
P/N
QTY DESCRIPTION
0558002677
1 ESP-150 Console
0558002320
1 PT-26, 25’ Inline Plasma torch
0558002864
1 PT-26 Spare Parts Kit, 150A
0558003242
3 Air Reg. Assembly
678723
1 Work Cable, 25'
33053
1 Strain Relief
951188
1 Locknut
156F05
4 Coolant (4 gallons)
680794
1 Truck & Cylinder Rack
0558002914 - ESP-150 / PT-26 50’ Inline / Air
P/N
QTY DESCRIPTION
0558002677
1 ESP-150 Console
0558002321
1 PT-26, 50’ Inline Plasma torch
0558002864
1 PT-26 Spare Parts Kit, 150A
0558003242
3 Air Reg. Assembly
678724
1 Work Cable, 50'
33053
1 Strain Relief
951188
1 Locknut
156F05
4 Coolant (4 gallons)
680794
1 Truck & Cylinder Rack
- 18 bp10da3
0558002919 - ESP-150 / PT-26 25’ Inline / Air
P/N
QTY DESCRIPTION
0558002677
1 ESP-150 Console
0558002320
1 PT-26, 25’ Inline 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, 25'
33053
1 Strain Relief
951188
1 Locknut
19X54
2 Adaptors
156F05
4 Coolant (4 gallons)
680794
1 Truck & Cylinder Rack
0558002920 - ESP-150 / PT-26 50’ Inline / Air
P/N
QTY DESCRIPTION
0558002677
1 ESP-150 Console
0558002321
1 PT-26, 50’ Inline 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'
33053
1 Strain Relief
951188
1 Locknut
19X54
2 Adaptors
156F05
4 Coolant (4 gallons)
680794
1 Truck & Cylinder Rack
US
6
INSTALLATION
The installation must be done by a professional.
6.1
General
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 UNPLUGG THE POWER CORD TO THE UNIT WHEN PRIMARY
ELECTRICAL CONNECTIONS ARE MADE INSIDE OF 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.
This product is intended for industrial use. In a domestic environment this product
may cause radio interference. It is the user's responsibility to take adequate
precautions.
6.2
Inspection and placement
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.
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 UNPLUGG THE POWER CORD TO THE
UNIT USE LOCK OUT SAFETY PROCEDURES WHEN MAKING
PRIMARY ELECTRICAL CONNECTIONS TO THE POWER SUPPLY.
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.
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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 110psig)
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.
6.3
Primary input electrical connections
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.
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.
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Fig 3 Typical installation - User supplied 3 Phase fused power disconnect box with recepticle and plug.
Recommended fuse sizes and minimum cable area
Input requirements
Volts
Phase
Amps
Input & gnd.
conductor
CU/AWG
Fuse ratings /
Phase, Apms
220
3
121
No. 1
150
230
3
116
No. 1
150
380
3
70
No. 4
100
415
3
64
No. 6
90
460
3
58
No. 6
80
575
3
45
No. 6
70
Table 1. Sizes per “National Electrical Code” for 75° rated conductors at 30° C ambient. Not more
than three conductors in raceway or cable. Local codes should be followed if they specify sizes other
than those listed above.
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.
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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 figures 4a, 4b and 4c for 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)
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.
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.
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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.
Fig 6 Primary power cable configuration
4. Thread the input conductor cable from the wall disconnect switch through the
strainrelief 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.
Fig 7
1
Input Power Cable - Detail View, left side
4-conductor inputcable
(customer supplied)
2
Greed / Yellow
3
Ground Stud
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.
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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.
Fig 8 Manual vs. Mechanized Operation
Factory supplied for standard operation - P45 to
J4 (MAN)
P45 moved to the J5 (MECH) position to allow
use of remote plumbing box
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FAULT
SIGNAL
TO CNC
GAS PREFL0W
SIGNAL
FROM CNC
J1 CONNECTOR
ARC ON
SIGNAL
TO CNC
PLASMA START
SIGNAL
FROM CNC
Note: J1 Mating Plug and Clamp
USER SUPPLIED CABLE
14-pin Straight
Connector
636667
Clamp
6271127
EMERGENCY
STOP SIGNAL
FROM CNC
*)
ARC VOLTAGE
SIGNAL
20:1 DIVIDER
* NOTE: If CNC does not have a normally closed emergency stop switch, a jumper must be installed
between TB1-16 and TB1-20.
Fig 9 J1 remote control receptacle pin configuration for CNC connection
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6.4
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. 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.
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
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Fig 12 Interconnection diagram - frong of ESP-150
1
Shield gas
4
Water OUT (-) (torch)
2
Water IN (+) (pilot arc)
5
Torch switch receptacle
3
Plasma / start gas
6.5
Gas 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)
Fig 13 Air filter regulator connections
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*) Select ONLY ONE (1) inlet connection, NEVER BOTH, when selecting plasma as
1
Start gas
2
Cut gas
Fig 14 Gas connections
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3
Shield gas
US
6.6
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.
Fig 15 Access for filling Torch Coolant Tank
1
Torch coolant fill access
4
Work cable
25 ft. - 23120589, 50ft. - 23120590
2
Level indicator
5
Torch PT-26
3
Grounded work table
OPERATING THE UNIT WITHOUT COOLANT WILL CAUSE
PERMANENT DAMAGE TO COOLANT PUMP.
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6.7
Torch collant preparation
DO NOT USE COMMERCIAL ANTIFREEZE OR TAP WATER.
EQUIPMENT WILL MALFUNCTION AND DAMAGE WILL OCCUR.
The coolant must be handled as chemical waste.
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°F (1.1°C).
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.
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7
OPERATION
General safety regulations for the handling of the equipment can be found on
page 3. Read through before you start using the equipment!
This section provides descriptions of the power source controls and general
operating procedures plus, some tips on cut quality.
7.1
Controls and indicators
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 control:
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 Application Data on pages 27 through 28.
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 postflow 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.
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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.
Note! 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.
7.2
ESP-150 Adjustments
BEFORE MAKING ANY ADJUSTMENTS OR PERFORMING ANY
MAINTENANCE ON THE TORCH, MAKE SURE THE POWER TO THE
TORCH IS SHUT OFF.
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 page 2 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.
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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.
7.3
Operation
ARC RAYS CAN BURN EYES AND 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.
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 about 1/8-in. 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.
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 about 1/8 to 1/4- in. above
workpiece, etc. Then start from step 1 again.
4. For manual and mechanized cutting, maintain a standoff (torch-to-work distance)
of about 3/8-in. (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 about 6 seconds to move the torch
close enough to work to re-establish the cutting arc.
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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.
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.
correct
too fast
too slow
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.
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7.4
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.
Standoff
Arc voltage
Lag lines
Fig 17. Cut Quality
Positive (+) cut angle
A
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
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7.5
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 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
7.6
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.
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7.7
Commun 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.
2.
3.
4.
Cutting speed too fast
Damaged cutting nozzle
Improper gas settings
Inadequate delay for pierce
B. Main arc extinguishes:
1. Cutting speed too slow
C. Dross formation:
1.
2.
3.
4.
5.
Cutting speed too fast or too slow
Improper air pressure
Faulty nozzle or electrode
Improper standoff
Current too low
D. Double arcing:
1.
2.
3.
4.
5.
6.
7.
Low air pressure
Damaged cutting nozzle
Loose cutting nozzle
Heavy spatter
Nozzle touches work while cutting
Pierce height too low
Current too low
E. Uneven arc:
1. Damaged cutting nozzle or worn electrode
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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.
2.
3.
4.
Loose connections
Work clamp not connected
Gas pressures not correct
Insufficient coolant to operate flow switch
H. Poor consumable life:
1.
2.
3.
4.
5.
6.
7.
8.
9.
7.8
Improper gas pressure
Contaminated air supply
Improper gas/electrode combination
Torch hitting work piece or turned up parts
Parts damaged by double arcing (see D above)
Use of non-genuine parts
Water leaks in torch
Torch not purged after changing consumables or idle period
Using wrong consumables for selected gases
Cutting speed conditions
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.
7.9
Recommended gas and current
The following provide the recommended gas and current selection for common
metals to obtain the best cutting results.
Material type: CARBON STEEL
Material type: STAINLESS STEEL
Thickness
Gas and Current Selection
Thickness
Gas and Current Selection
1/8" (3.2mm)
and thinner
50 / 65 Amps, Air Plasma/Air
Shield.
1/4" - 3/8”
(3.2-9.9mm) and
thinner
50 - 65 Amps, N2 Plasma/N2
Shield produces best surface
but light dross on 1/8"
mate­rial.
3/16 - 1/2
(4.8-12.7mm)
100 Amps, Plasma/Air Shield.
100 Amps, Air Plasma/Air
Shield is also good but there
will be bottom dross on 1/2"
(12.7mm) material
1/2” - 2”
(12.7mm 50mm)
150 Amps, Plasma/Air
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50 - 65 Amps, Air Plasma/Air
Shield can produce dross free
cuts but the surface is rough.
US
Material type: ALUMINUM
Thickness
Gas and Current Selecltion
1/4" (6.4mm)
and thinner
50/65 Amps, N2 Plasma/N22 Shield
usually produces fairly smooth, dross
free cuts.
50/65 Amps, Air Plasma/Air Shield
produces much rougher cut surfaces.
1/4” (6.4mm)
and thinner
7.10
150 Amps, Plasma/N2 H-35
Cutting Parameters for the PT-26 and ESP-150
PT-26 Aluminum Cutting Data
PT-26 Steel Cutting Data
PT-26 Stainless Steel Cutting Data
PT-26 Stainledd Steel 300 Amp Cutting Data
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Cutting Parameters for the PT-26 and ESP-150
Material TypeThickness
in.(mm)
Cur­
Travel
rent
Speed
(Amps) ipm(M/m)
Cutting
Height
in.(mm)
50
5/16 (8)
CS-1/8 (3.2)
195 (4.95)
CS-3/16 (4.7)
150 (3.8)
CS-1/4 (6.35)
100 (2.58)
CS-5/16 (8)
75 (1.9)
CS-3/8 (9.5)
50 (1.27)
CS-1/2 (12.7)
25 (.63)
CS-5/8 (15.9)
12 (.3)
CS-3/4 (19)
6 (.15)
CS-1 (25.4)
2 (.05)
Table 4.1. PT-26 Carbon Steel Cutting Data
Material TypeThickness
in.(mm)
Cur­
Travel
rent
Speed
(Amps) ipm(M/m)
Cutting
Height
in.(mm)
150
5/16 (8)
CS-1/16 (1.6)
175 (4.45)
CS-1/8 (3.2)
155 (3.94)
CS-1/4 (6.3)
137 (3.48)
CS-5/16 (8)
125 (3.17)
CS-3/8 (9.5)
87 (2.2)
CS-1/2 (12.7)
76 (1.93)
CS-5/8 (15.9)
62 (1.57)
CS-3/4 (19)
50 (1.27)
CS-1 (25.4)
30 (.76)
CS-1-1/8 (28.6)
25 (.63)
CS-1-1/4 (31.7)
20 (.5)
CS-1-3/8 (34.9)
15 (.38)
CS-1-1/2 (38)
13 (.33)
CS-1-3/4 (44.5)
6 (.15)
CS-2 (50.8)
4 (.10)
Table 4.1. PT-26 Carbon Steel Cutting Data
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Start Gas
Type/
Pressure
psi(bar)
Air - 30 (2.1)
Plasma Gas
Type/
Pressure
psi(bar)
Air - 60
(4.14)
Shield Gas
Type/
Pressure
psi(bar)
Air - 50
(3.45)
Start Gas
Type/
Pressure
psi(bar)
Air - 30 (2.1)
Plasma Gas
Type/
Pressure
psi(bar)
Air - 60
(4.14)
Shield Gas
Type/
Pressure
psi(bar)
Air - 50
(3.45)
US
Material TypeThickness
in.(mm)
AL-1/4 (6.35)
AL-5/16 (8)
AL-3/8 (9.6)
AL-1/2 (12.7)
AL-5/8 (15.9)
AL-3/4 (19)
AL-1 (25.4)
AL-1-1/8 (28.6)
AL-1-1/4 (31.7)
AL-1-3/8 (34.9)
AL-1-1/2 (38)
AL-1-3/4 (44.5)
AL-2 (50.8)
Cur­
Travel
rent
Speed
(Amps) ipm(M/m)
150
112 (2.84)
100 (2.54)
93 (2.36)
78 (1.98)
63 (1.6)
52 (1.32)
37 (.94)
30 (.76)
25 (.63)
20 (.5)
18 (.46)
12 (.3)
10 (.25)
Cutting
Height
in.(mm)
5/16 (8)
Table 4-2. PT-26 Aluminium Cutting Data
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Start Gas
Type/Pres­
sure
psi(bar)
H-35 or N2
30 (2.1)
Plasma Gas
Type/Pres­
sure
psi(bar)
H-35 - 50
(3.45)
Shield Gas
Type/Pres­
sure
psi(bar)
Air - 50
(3.45)
US
8
MAINTENANCE
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.
8.1
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. Check work cable to work piece connection.
2. Check safety earth ground at workpiece and at power source chassis.
3. Check heat shield on torch. It should be replaced if damaged.
4. Check the torch electrode and cutting tip for wear on a daily basis.
Removespatter, replace if necessary.
5. Make sure cable and hoses are not damaged or kinked.
6. Make sure all plugs, fittings, and ground connection are tight.
CAUTION: Water occasionally accumulates in compressed air lines. Be
sureto direct the first blast of air away from the equipment to avoid
damage.
7. With all input power disconnected, and wearing proper eye and face
protection,blow out the inside of the cutting power supply using low- pressure
drycompressed air.
8. Occasionally bleed water from the filter beneath the air regulators.
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8.2
Flow testing
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
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. Shut off input power at the main disconnect switch.
2. Lift the top lid of the ESP-150 and unplug the torch switch cord.
3. Close the lid.
4. Turn on the power at the main disconnect switch.
5. Place gas mode selector switch (OSS) in START/SHIELD position.
6. Place power ON-OFF switch (ROS) to ON.
7. Check flow measurements with P/N 19765 flow measuring kit.
8. Place mode selector switch (OSS) in CUT position and check CUT flow with P/N
19765 flow measuring kit.
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.
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8.3
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
0.025-in. (+/- 0.002). After extended operation or if erratic operation is noted, it may
be necessary to readjust or replace the electrodes (634098). Use a feeler gauge
when readjusting the gap. (See form 11-831, “Recommended Installation and Test
Procedures for High-Frequency Stabilized Arc Welding Machines”, packed with the
unit.) Cleaning or dressing of the spark gap electrodes is not recommended. When
replacement is necessary, both electrodes should be replaced.
8.4
Testing and replacing brdige assembly components
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
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).
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2. Testing SCR’s
a. 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. The SCR’s are bad is 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.
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.
9
TROUBLESHOOTING
Check the problem against the symptoms in the following troubleshooting guide. The
remedy may be quite simple. 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 (Fig. 3) 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.
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9.1
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 (674935).
e. Defective logic board (675369).
3. No 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 (675369).
b. If PAC closes, check for proper spark gap setting (0.025-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 (675369).
b. Power supply may be single phasing. Check main disconnect switch and
fuses.
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7. No pilot arc -pilot arc contactor (PAC) drops out when main contactor (MC)
activates at end of 2-second preflow.
a. 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 each capacitor (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. A shorted
rectifier on D/R board can cause C25 capacitor to fail.
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 (675369) is defective.
d. Arc current is set too high.
e. Wrong cutting tip size. Use larger tip.
f.
Defective current control board (675468 or 674940).
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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 (675369).
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 ESP-150); 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 (675369).
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 (675369).
9.2
Sequence of operation (see fig 22)
1. Close primary disconnect switch.
a. Power supplied to unit.
2. Place Power Switch (ROS) to “Ready” position.
a. Fan motor (FM) and Pump motor on.
b. Low Gas LED on.
c. Control circuit energizes.
3. 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.
4. Place OSS to “Operate” position.
a. Gas valves (PGSV and CGSV) deenergize to stop gas flows.
5. 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-in.) to work.
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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. WARNING: Dangerous high voltage (over 300 volts)
exists a the torch front end whenever MC is closed; therefore, release torch
switch when cutting is not established and repeat step 5.
PREFLOW &
HF**** 2 sec.
Push
Torch Switch
HF and MC*
6 sec.
CUTTING ARC**
MC closes PAC opens
HF deenergizes
PAC closes
HF energizes
PGPS/CGPS
closes
FS closes
Release Torch
Switch
MC opens
PGSV/CGSV
opens
POSTFLOW***
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
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.
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9.3
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 Is READY/LOW GAS Light On
1. Close top lid.
NO
2. Check ISW switch
3. Check CB1.
YES Set Gas(es) at proper pressure with
OSS switch in CUT/ START-SHIELD­
mode.
Place OSS switch inOPERATE
“A”
Depress Torch Switch
Is HIGH FREQ Light On?
1. Check OSS switch.
2. Check Torch Switch.
NO
3. Check PAC contactor to insure 24 VAC is applied
to coil.
4. Check PC Board 675369.
5. Check HFTR Transformer
YES Does LOW GAS Light GO Off?
1. Check input gas pressure.
NO
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 and5.
YES 2 second delay
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Does TORCH ON Light turn on?
1. Check open circuit voltage. Should be about 370
VDC.(Disconnect HF to avoid damaging meter.)
NO
2. Check input power.
3. Check MC contactor.
4. Check diodes and SCR’s.
5. Check PC board 675468.
YES Is Pilot Arc established
1. Check consumables in torch.
2. Check torch connections using ohmmeter.
NO
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.
YES 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..
Is Main Arc established?
1. Check work lead connection.
2. Check consumables in torch.
NO
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 675468.
YES HIGH FREQ light goes out
Adjust cutting speed
Release torch switch
LOW GAS light turns on
Unit in Post Flow modeand ready to cut
again.
“A”
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10
ORDERING AND REPLACEMENT PARTS
10.1
Replacement parts
When ordering replacement parts, order by part number and part name, as
illustrated on the figure. Always provide the series or serial number on the unit on
which the parts will be used. The serial number is stamped on the rating plate.
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.
Refer to the Communications Guide located on the back side of this manual for a
lists of customer service phone numbers.
10.2
Ordering numbers
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
Ordering information
ESP-150 Packages
230/460/575 V, 60 Hz, 3 Phase
Optional Accessories
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 gouaging......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) ...........................................588000939
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.
- 52 bp10da6
US
11
ASSEMBLY INSTRUCTIONS
PT-26 Front End Parts
Assembly of PT−26 Front End Parts
Torch Head −
90° ..................... 34599
70° .......... 0558002204
IN−LINE .. 0558002110
Includes O−Rings
2110706 (1)
2029450 (3)
O−Ring Location − 2029450
O−Ring Location − 2110706
Insulator − 34593
Includes O−Ring
− 84W87
Baffle Tube −34585
Electrode
36565 − Air, Nitrogen, Nitrogen/Hydrogen
36566 − Argon/Hydrogen (H−35)
Electrode Holder
− 34583
Includes O−Rings
85W49 (Upper)
948317 (Lower)
Stand−Off Guide − 36648
Std. Heat Shield − 34592
*Close Proximity Heat Shield − 37146
*
AMPS
P/N
Cutting Nozzle
150
36568
200
36569
300
36570 .104
Gouging
Nozzle
200
36571
300
36572
For use when cutting or gouging in close proximity of
workpiece.
Standard on In−line version.
- 53 bp10da6
ORIFICE SIZE
.078
.089
.125
.144
All include O−Rings 2110578 (Upper)
994092 (Lower)
US
12
REVISION HISTORY
1
Revision “C” - 07/2004 - Revised with updated schematic diagrams. Made various
editorial changes also.
2.
Revision “C” - 08/2006 - Replacement parts section, front view, changed item 11
from: p/n 950812 to: 636702
3
Revision “D” - 02/2007 - updated Replacement Parts section.
4
Revision “E” - 06/2008 - updated P45 / J5 location functions in Section 3.
--------------------------------------------------------------------------------------------------------------06/2010
Changed serial number.
Separated the replacement parts list from instruction manual
Changed ordering number for the instruction manual from F15-687-E
to 0558 003 774
07/2010
Included the replacement parts list
- 54 bp10da6
NOTES
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- 55 notes
Schematic diagram
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Replacement parts
bp10s
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ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES
A
B
C
CUSTOMER SERVICE QUESTIONS:
Telephone: (800) 362-7080 / Fax: (800) 634-7548
Order Entry Product Availability
Pricing
Order Information
ENGINEERING SERVICE:
Telephone: (834) 664-4416 / Fax: (800) 446-5693
Warranty Returns
Authorized Repair Stations
Hours: 7.30 AM to 5:00 PM EST
Welding Equipment Troubleshooting
TECHNICAL SERVICE:
Telephone: (800) ESAB-123 / Fax: (843) 664-4452
Part Numbers
Technical Applications
Specifications
Hours: 8.00 AM to 7:00 PM EST
Returns
Hours: 8.00 AM to 5:00 PM EST
Equipment Recommendations
D
LITERATURE REQUESTS:
Telephone: (843) 664-5562 / Fax: (843) 664-5548
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
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
F
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) 664-4452
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
ESAB Welding & Cutting Products
110222
backp3us
PO BOX 100545, Florence SC 29501-0545
- 74 -
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