ESAB ESP-50 Instruction Manual
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ESAB ESP-50 Instruction Manual

ESAB ESP-50 Instruction Manual

Plasma arc cutting package
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ESP-50
Plasma Arc Cutting Package
Instruction Manual
This manual provides installation and operation instructions for the following ESP-50 cutting packages starting with Serial No.: PxxJ403xxx
Consoles:
P/N 0558004371 - 208/230 V, 50/60 Hz, 1 or 3-phase
P/N 0558004372 - 400CE/460 V, 50/60 Hz, 3-phase, CE
0558004311
01 / 2006

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  • Page 1 ESP-50 Plasma Arc Cutting Package Instruction Manual This manual provides installation and operation instructions for the following ESP-50 cutting packages starting with Serial No.: PxxJ403xxx Consoles: P/N 0558004371 - 208/230 V, 50/60 Hz, 1 or 3-phase P/N 0558004372 - 400CE/460 V, 50/60 Hz, 3-phase, CE 0558004311 01 / 2006...
  • Page 2 BE SurE THIS INforMaTIoN rEaCHES THE oPEraTor. You CaN gET ExTra CoPIES THrougH Your SuPPlIEr. CauTIoN These INSTruCTIoNS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for arc Welding, Cutting, and gouging,” form 52-529. Do NoT permit untrained persons to install, operate, or maintain this equipment. Do NoT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions be- fore installing or operating this equipment. uSEr rESPoNSIBIlITY This equipment will perform in conformity with the description thereof contained in this manual and accompa- nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc- tions provided.

  • Page 3: Table Of Contents

    Location .............................. Inspection .............................. Primary Electrical Input Connections .................... Secondary Electrical Output Connections ..................4 Connecting ESP-50 for 00(08)Vac Input ..................7 Connecting ESP-50 for 400(460)Vac Input ..................8 SECTIoN 4 oPEraTIoN ............................. 9 ESP-50 Controls ............................9 Common Cutting Problems ........................
  • Page 4 TaBlE of CoNTENTS...

  • Page 5: Safety Precautions

    SECTIoN 1 SafETY PrECauTIoNS 1.0 Safety Precautions 1.1 Safety - English WarNINg: These Safety Precautions are fIrES aND ExPloSIoNS -- Heat from for your protection. They summarize pre- flames and arcs can start fires. Hot cautionary information from the references slag or sparks can also cause fires and listed in Additional Safety Information sec- explosions. Therefore: tion.
  • Page 6 SECTIoN 1 SafETY PrECauTIoNS 1. Be sure the power source frame (chassis) is con- . Welders should use the following procedures to nected to the ground system of the input power. minimize exposure to EMF: . Connect the workpiece to a good electrical A.
  • Page 7 SECTIoN 1 SafETY PrECauTIoNS 5. WarNINg: This p roduct, w hen u sed f or w elding 1. Always have qualified personnel perform the instal- or cutting, produces fumes or gases lation, troubleshooting, and maintenance work. which contain chemicals known to Do not perform any electrical work unless you are the State of California to cause birth qualified to perform such work.
  • Page 8 SECTIoN 1 SafETY PrECauTIoNS 5. AWS C5.5 - "Recommended Practices for Gas Tung- sten Arc Welding“ 6. AWS C5.6 - "Recommended Practices for Gas Metal Arc Welding"“ 7. AWS SP - "Safe Practices" - Reprint, Welding Hand- book. 8. ANSI/AWS F4.1, "Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances."...

  • Page 9: Safety - Spanish

    SECTIoN 1 SEgurIDaD 1.2 Safety - Spanish La escoria puede estar caliente y desprenderse con velocidad. Personas cercanas deberán usar gafas aDVErTENCIa: Estas Precauciones de Se- de seguridad y careta protectora. guridad son para su protección. Ellas hacen resumen de información proveniente de las fuEgo Y ExPloSIoNES -- El calor de referencias listadas en la sección "Información Adi- las flamas y el arco pueden ocacionar...
  • Page 10 SECTIoN 1 SEgurIDaD 1. Asegúrese de que el chasis de la fuente de poder . Los soldadores deberán usar los siguientes proced- esté conectado a tierra através del sistema de imientos para minimizar exponerse al EMF: electricidad primario. . Conecte la pieza de trabajo a un buen sistema de A.
  • Page 11 SECTIoN 1 SEgurIDaD 5. aDVErTENCIa-- Este producto cuando se uti- 1. Siempre tenga personal cualificado para efec- liza para soldaduras o cortes, tuar l a instalación, diagnóstico, y mantenimiento produce humos o gases, los del equipo. No ejecute ningún trabajo eléctrico a cuales contienen químicos menos que usted esté...
  • Page 12 SECTIoN 1 SEgurIDaD SIgNIfICaDo DE loS SIMBoloS -- Según usted avanza en la lectura de este folleto: los Símbolos Sig- nifican ¡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.

  • Page 13: Safety - French

    SECTIoN 1 SÉCurITÉ INCENDIES ET ExPloSIoNS -- la 1.3 Safety - french chaleur p rovenant d es fl ammes o u d e aVErTISSEMENT : Ces règles de sécurité l'arc peut provoquer un incendie. le ont pour but d'assurer votre protection. Ils laitier incandescent ou les étincelles récapitulent les informations de précaution peuvent également provoquer un provenant des références dans la section incendie ou une explosion. Par conséquent :...
  • Page 14 SECTIoN 1 SÉCurITÉ 1. Assurez-vous que le châssis de la source . Les soudeurs doivent suivre les procédures suivantes d'alimentation est branché au système de mise à pour minimiser l'exposition aux champs électriques la terre de l'alimentation d'entrée. et magnétiques : .
  • Page 15 SECTIoN 1 SÉCurITÉ 5. aVErTISSEMENT : Ce produit, lorsqu'il est utilisé ENTrETIEN D E l 'ÉQuIPEMENT - - u n é quipe- dans une opération de soudage ou de ment entretenu de façon défectueuse ou coupage, dégage des vapeurs ou des inadéquate peut causer des blessures gaz contenant des chimiques consi- graves ou mortelles. Par conséquent : déres p ar l 'état d e l a C alifornie c omme 1.
  • Page 16 SECTIoN 1 SÉCurITÉ SIgNIfICaTIoN DES SYMBolES Ce s ymbole, u tilisé p artout d ans c e m anuel, signifie "attention" ! Soyez vigilant ! Votre sécurité est en jeu. DaNgEr Signifie un danger immédiat. la situation peut entraîner des blessures graves ou mortelles. aVErTISSEMENT Signifie un danger potentiel qui peut entraîner des blessures graves ou mortelles. aTTENTIoN Signifie un danger qui peut entraîner des blessures corporelles mineures.

  • Page 17: Description

    (60 - 100 psi / 4.1 - 6.9 bars) and a PT-5 torch. The ESP-50 package console. use of torches not de-...

  • Page 18: Ordering Information

    ESP-50, 400CE/460 V, 50 ft. (15.2m) PT- 35, with rack ..................................055800477 ESP-50, 400CE/460 V, 25 ft. (7.6m) PT-35, without rack .................................055800474 ESP-50, 400CE/460 V, 50 ft. (15.2m) PT- 35, without rack ................................055800475 The components that are included in the ESP-50 packages may be purchased separately by using the appropriate P/N when placing orders. Individual part numbers are listed below: Consoles: ESP-50 08/0 V, 50/60 Hz, 1/-ph ..........................................055800471 ESP-50 400/460 V, 50/60 Hz, -ph ...........................................05580047...
  • Page 19 SECTIoN 2 DESCrIPTIoN Cutting Parameters for the PT-35 Torch 50 aMP Data, Nozzle P/N 0558004356, Heat Shield P/N 0558004357, Electrode P/N 0558005200 .500 .75 .50 .188 .15 .105 (1/1 ga.) .060 (16 ga.) .04 (19 ga.) .05 (4 ga.) 50 aMP Data, Nozzle P/N 0558004356, Heat Shield P/N 0558004357, Electrode P/N 0558005200 .071 (15 ga.) .06 (16 ga.) .05 (5 ga.) NR = Not Recommended * = If using a fixed height torch or plate rider, set cutting height equal to pierce height; cutting speed may have to be reduced due to increased cut height.

  • Page 20: Torch Specifications

    SECTIoN 2 DESCrIPTIoN Cutting Parameters for the PT-35 Torch 50 aMP Data, Nozzle P/N 0558004356, Heat Shield P/N 0558004357, Electrode P/N 0558005200 .500 .75 .1 .50 .188 .15 .095 (10/11 ga.) .049 (16 ga.) .04 (17 ga.) .01 (0 ga.) NR = Not Recommended * = If using a fixed height torch or plate rider, set cutting height equal to pierce height; cutting speed may have to be reduced due to increased cut height.

  • Page 21: Optional Accessories

    SECTIoN 2 DESCrIPTIoN figure 2-2. PT-35 Dimensions 2.8 oPTIoNal aCCESSorIES: Plasma flow Measuring Kit: This valuable troubleshooting tool allows measurement of the actual plasma gas flow through the torch ..........19765 (0558000739) (NoTE: Part numbers in parenthesis apply to "CE"/European units only.) CNC Cable 50' ........................055800466 adaptor Cable - adaptor to directly connect HT or TD control cable to ESP-50 ..05580046 Torch Holder assembly ..................16V8 (055800450) Plate rider - height control for PT-35 ................05609697 Standoff Tool - Designed for use with Plate Rider for setting nozzle standoff height. Can also be used separately......................... 055800464...

  • Page 22: Spare Parts Kits

    SECTIoN 2 DESCrIPTIoN 2.9 SParE ParTS KITS: 50 a Spare Parts Kit ......................055800510 PT-35, 50 a, Spare Parts Kit, P/N 0558005210 Contents: Description P/N Quantity Shield, retaining 0558004357 50 amp "a" Nozzle 0558004356 Electrode 0558005200 fuse 2amp, 600vdc 0558003075 Insulator 0558004387 Consumable Value Pack ....................05580050 Consumable Value Pack, P/N 0558005203 Contents: Description P/N Quantity Electrode 0558005200 50 amp "a" Nozzle 0558004356 Consumable Set ......................055800501 Consumable Set, P/N 0558005201 Contents: Description P/N Quantity Electrode 0558005200 50 amp "a" Nozzle 0558004356 Consumable Set .

  • Page 23: Installation

    INSTallaTIoN 3.1 gENEral CauTIoN Proper installation is important for satisfactory and trouble-free operation of the ESP-50 cutting package. It is suggested that each step in this section be studied Installing or placing any type of carefully and followed closely. filtering device will restrict the volume o f i ntake a ir, t hereby s ub- 3.2 EQuIPMENT rEQuIrED...

  • Page 24: Secondary Electrical Output Connections

    SECTIoN 3 INSTallaTIoN 3.6 SECoNDarY ElECTrICal ouTPuT CoNNECTIoNS (fIgurE 3-2) For operator safety, the torch connections are located on the output terminal board behind the lower portion of the front panel. Remove access door to output terminal board from right panel of power source. Thread the power cable & pilot arc cable of the PT-5 through the right open bushing of the front panel.
  • Page 25 (See Table .1 and WARNING in regards to chassis ground in Section .5.) INPUT POWER CABLE (See Table .1) NoTE: The 208/230 V models are equipped with a plug for single- phase c onnection o nly. T he p lug i s m ounted t o a 4 -conductor cable. If 3-phase connection is desired, remove and discard the plug and refer to Sect. 3.5. figure 3-2. ESP-50 Interconnection Diagram...
  • Page 26 SECTIoN 3 INSTallaTIoN faCTorY WIrED MaCHINES BluE oraNgE BlaCK grEEN WHITE DETaIl "a" figure 3.3 - MECHaNICal CuTTINg INTErfaCE DIagraM CNC Interface Connection (located inside console, left side of base.)

  • Page 27: Connecting Esp-50 For 00(08)Vac Input

    3.7 CoNNECTINg ESP-50 for 200(208) VaC INPuT WarNINg The ESP-50 power source with 00/0 vac, single-phase input capability is factory set for 0 vac input. If using 00(08) vac input, the ESP-50 must be reconnected ElECTrIC SHoCK CaN KIll! Pre- as follows before connecting to your input power: cautionary measures should be taken to provide maximum pro- Remove the cover from the ESP-50 power source.

  • Page 28: Connecting Esp-50 For 400(460)Vac Input

    3.8 CoNNECTINg ESP-50 for 400/460 VaC INPuT WarNINg The ESP-50 power source with 400/460 vac, -phase input capability is factory set for 460 vac input. If using 400 vac input, the ESP-50 must be reconnected as follows before connecting to your input power: ElECTrIC SHoCK CaN KIll! Pre- cautionary measures should be Remove cover from the ESP-50 power source.

  • Page 29: Operation

    Remove start signal to reset. CauTIoN Parts in Place fault: The fault light will be on continuously at power-up. This Position the ESP-50 at least 10 indicates missing or worn consumables. Turn power off and inspect torch. feet (3 meters) from the cutting area. Sparks and hot slag from...
  • Page 30 KNOB AIR TEST SWITCH PILOT ARC SELECT SWITCH POWER ON-OFF (I-O) SWITCH FUSE (A) PRESSURE GAUGE figure 4-1. ESP-50 Controls WORN CauTIoN rEPlaCE ElECTroDE BEforE lENgTH BECoMES SHorTEr Replace when eroded beyond THaN .060" INCH (1.5 MM) .060"(1.5mm) Depth. figure 4-2. Electrode Wear limit NOTE: When replacing the nozzle, always inspect the electrode for wear. If electrode wear is greater than .060"...

  • Page 31: Common Cutting Problems

    Listed below are common cutting problems followed by the probable cause of each. If problems are determined to be caused by the ESP-50, refer to the maintenance section of this manual. If the problem is not corrected after referring to the mainte- nance section, contact your ESAB distributor.
  • Page 32 SECTIoN 4 oPEraTIoN...

  • Page 33: Maintenance

    5.2 INSPECTIoN aND ClEaNINg ESP-50. Frequent inspection and cleaning of the ESP-50 is recommended for safety and proper CauTIoN operation. Some suggestions for inspecting and cleaning are as follows: Water or oil occasionally accu- Check work cable for secured connection to workpiece.
  • Page 34 SECTIoN 5 MaINTENaNCE 5.4 IgBT Handling & replacement Since IgBT gates are insulated from any other conducting region, care should be taken to prevent static build up, which could possibly damage gate oxides. all IgBT modules are shipped from the factory with conductive foam contacting the gate and emmiter sense pins. always ground parts touching gate pins during installation. In general, standard ESD precautlions application to fETs should be followed. other handling precautions that should also be observed are as follows: • use grounded work station with grounded floors and grounded wrist straps when handling devices. • use a 100Ω resistor in series with the gate when performing curve tracer tests. • Never install devices into systems with power connected to the system. • Use soldering irons with grounded tips when soldering to gate terminals. When mounting IGBT modules on a heatsink, certain precautions should be taken to prevent any damage against a sudden torque.

  • Page 35: Troubleshooting

    SECTIoN 6 TrouBlESHooTINg 6.1 TrouBlESHooTINg Check the problem against the symptoms in the following troubleshooting guide. The WarNINg 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 ElECTrIC SHoCK CaN KIll! Be and wiring.
  • Page 36 Replace the transformer if the correct secondary voltages are not present. If everything above checks out all right, then the PCB1 Control Board should be replaced. E. fault light activates when torch switch is closed. The fault circuit is used to monitor conditions necessary for the safe operation of the ESP-50. The fault light will glow amber under the following conditions and operations will come to a complete stop: High/Low line voltage. The Fault Light will rapidly blink on and off (5 times per second). This indicates that the input voltage is outside the “+”...
  • Page 37 SECTIoN 6 TrouBlESHooTINg over Current. The fault light will be on continuously. This indicates that the input current to the main transformer has exceeded preset limits. a. To check if the output is shorted, remove the heat shield and nozzle from the torch and measure the resistance by putting the ohmmeter lead ”+” of the meter to “+” output terminal and Work, “-”...
  • Page 38 SECTIoN 6 TrouBlESHooTINg H. Poor Cutting Performance. Check air supply regulator . It should be adjusted to 65 - 75 psig (4.5 - 5. bars). The air supplied to the torch should be free of oil and water. Make sure the consumables in the torch are acceptable. Check the output.

  • Page 39: Reference Voltage Checks

    SECTIoN 6 TrouBlESHooTINg CTION 5 TROUBLESHOOTING REFERENCE VOLTAGE CHECKS 6.3 rEfErENCE VolTagE CHECKS A. Control Board Assembly (PCB1) LED’s a. Control Board assembly (PCB1) LED-1 Torch Switch lED’s LED-3 Gas Solenoid Valve lED-1 Torch Switch Voltage Test Points lED-3 gas Solenoid Valve Tests are made with power on - no arc. 2. Voltage Test Points Tests are made with power on - no arc.

  • Page 40: Sequence Of Operation

    SECTIoN 6 TrouBlESHooTINg 6.4 SEQuENCE of oPEraTIoN START SIGNAL OPEN CLOSE GAS SOLENOID VALVE .5 SEC. 10 SEC POSTFLOW PREFLOW FAULT OVERLOAD LIGHT INVERTER CUTTING ARC (CURRENT) NoTES: When the start signal is turned "on" during postflow period, the postflow and preflow times are canceled. When the amber fault light comes on, cutting operation should be stopped.

  • Page 41: Replacement Parts

    7.2 ordering To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this equipment. The use of non-ESAB parts may void your warranty. Replacement parts may be ordered from your ESAB Distributor.
  • Page 42 GAUGE 1.50 160 PSI WHITE 60617 STRAIN RELIEF 680560 WORK CABLE 5 FT. (Not Shown) 18W1 FOOT RUBBER 055800414 CHASSIS ESP-50 60YL DOOR ACCESS YEL (ESAB) 954008 LABEL WARNING HI VOLTAGE 174588 LABEL ESAB 9946 GROMMET 1.5 X 1.75 X .06...
  • Page 43 SECTIoN 7 rEPlaCEMENT ParTS 154, 155, 156, 164 151, 15 158, 159 160, 161 figure 7-2. ESP-50 Power Source, rear View Item Qty. Part Circuit Req. Description Symbol 1710 FILTER REGULATOR 10Z0 ADAPTOR B/A-WM x 1/4 NPTM 951575 HANDLE 6719YL TOP COVER YEL 091514 LABEL WARNING 95490 LABEL WARNING...
  • Page 44 SECTIoN 7 rEPlaCEMENT ParTS 9, 0 5, 6 5, 6 , , 4 46, 47 figure 7-3. ESP-50 Power Source, left Side View (208/230)
  • Page 45 SECTIoN 7 rEPlaCEMENT ParTS Item Qty. Part Circuit Req. Description Symbol 95150 BRIDGE 60ADC 100NS 600 V (includes PAD - 95119) 9500 CORE SATURABLE (Not shown - see wiring) 9508 STANDOFF INSULATING NYLON 671 BUSBAR NEG 957 CAPACITOR 1800 µf 450VDC C1,  994674 GROMMET STRIP 0558001177...
  • Page 46 SECTIoN 7 rEPlaCEMENT ParTS 56, 57, 58 56, 57, 58 64, 65, 66 77, 78 figure 7-4. ESP-50 Power Source, left Side View (400CE/460)
  • Page 47 SECTIoN 7 rEPlaCEMENT ParTS Item Qty. Part Circuit Req. Description Symbol 95150 BRIDGE 60 ADC 100NS 600 V (includes PAD - 95119) 9500 CORE SATURABLE (Not shown - see wiring) 951800 MODULE DUAL IGBT 150 A, 100 V (includes PAD - 951191) 9508 STANDOFF INSULATING NYLON 67...
  • Page 48 SECTIoN 7 rEPlaCEMENT ParTS figure 7-5. ESP-50 Power Source, right Side View (208/230)
  • Page 49 SECTIoN 7 rEPlaCEMENT ParTS Item Qty. Part Circuit Req. Description Symbol 5940 CONTROL TRANSFORMER ASS'Y 1700008 RESISTOR 00W 8 OHM R11,1 055800494 INDUCTOR, PILOT ARC 604891 LABEL WARNING HI VOLTAGE RED 95 INDUCTOR PFC 05580861 CONTROL BOARD ASS'Y PCB1 055800495 MAIN TRANSFORMER ASS'Y 951469 CAPACITOR .0µf 50 VAC (See Wiring) C17, 18...
  • Page 50 SECTIoN 7 rEPlaCEMENT ParTS 1, 15 figure 7-6. ESP-50 Power Source, right Side View (400CE/460)
  • Page 51 SECTIoN 7 rEPlaCEMENT ParTS Item Qty. Part Circuit Req. Description Symbol 914 CONTROL TRANSFORMER ASS'Y 1700008 RESISTOR 00W 8 OHM R11,1 604891 LABEL WARNING HI VOLTAGE RED 05580861 CONTROL BOARD ASS'Y PCB1 055800495 MAIN TRANSFORMER ASS'Y (400CE/460 V) 951469 CAPACITOR .0µf 50 VAC (See wiring) C17, 18 951515 CAPACITOR .047µf 660 VAC...
  • Page 52 SECTIoN 7 rEPlaCEMENT ParTS figure 7-7. ESP-50 (208/230V) Power Source, Top View with PCB1 and Shelf removed Item Qty. Part Circuit Req. Description Symbol 95467 LABEL CNC INTERFACE 9506 TERM BLOCK 7 POS 5 A 174010 RESISTOR 10 K 5 W R, 15 95118 FAN AC AXIAL 091558 LABEL GROUND BLACK 954700 LABEL INPUT (08/0 V)
  • Page 53 SECTIoN 7 rEPlaCEMENT ParTS...
  • Page 54 NoTES...
  • Page 55 01/005 Revision - Section  - Chgd electrode p/n from: 055800455 to: 055800500 in cut data charts. Added p/n's 055800497 & 0558004974 for ESP-50 08/0 V PT-5 packages with- out rack. |Updated torch specifications figure -1 & - drawing. Updated spare parts kits with new p/n 055800510, consumable value pack p/n 05580050, consumable set p/n 055800501 &...
  • Page 56 If You Do NoT KNoW WHoM To Call Telephone: (800) ESAB-1 Fax: (84) 664-446 Hours: 7:0 AM to 5:00 PM EST 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...

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