ESAB ESP-150 Instruction Manual
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ESAB ESP-150 Instruction Manual

Plasma cutting system
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ESP-150
Plasma Cutting System
Instruction Manual
This manual provides installation and operation instructions for the following components beginning with Serial
Number PORJ129127:
F15-687-H
02/2015

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Summary of Contents for ESAB ESP-150

  • Page 1 ESP-150 Plasma Cutting System Instruction Manual This manual provides installation and operation instructions for the following components beginning with Serial Number PORJ129127: F15-687-H 02/2015...

  • Page 2: User Responsibility

    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,”...

  • Page 3: Table Of Contents

    4.2 ESP-150 Adjustments ........
  • Page 4 TaBle OF cONTeNTS...

  • Page 5: Safety Precautions

    SecTION 1 SaFeTY PRecauTIONS Safety Precautions 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.
  • Page 6 SecTION 1 SaFeTY PRecauTIONS 1. Be sure the power source frame (chassis) is con- 3. Welders should use the following procedures to nected to the ground system of the input power. minimize exposure to EMF: 2. Connect the workpiece to a good electrical A.
  • Page 7 SecTION 1 SaFeTY PRecauTIONS 1. Always have qualified personnel perform the installa- 5. WaRNINg: This product, when used for welding tion, troubleshooting, and maintenance work. Do not or cutting, produces fumes or gases perform any electrical work unless you are qualified which contain chemicals known to to perform such work.
  • Page 8 SecTION 1 SaFeTY PRecauTIONS 5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding“ 6. AWS C5.6 - "Recommended Practices for Gas Metal Arc Welding"“ 7. AWS SP - "Safe Practices" - Reprint, Welding Handbook. 8. ANSI/AWS F4.1, "Recommended Safe Practices for Weld- ing and Cutting of Containers That Have Held Hazardous Substances."...

  • Page 9: Safety - Spanish

    SecTION 1 SaFeTY PRecauTIONS Safety - Spanish la escoria puede estar caliente y desprenderse con velocidad. Personas cercanas deberán usar aDVeRTeNcIa: estas Precauciones de gafas de seguridad y careta protectora. Seguridad son para su protección. ellas hacen resumen de información prove- FuegO Y exPlOSIONeS -- el calor de niente de las referencias listadas en la sección...
  • Page 10 SecTION 1 SaFeTY PRecauTIONS 1. Asegúrese de que el chasis de la fuente de poder 3. Los soldadores deberán usar los siguientes proced- esté conectado a tierra através del sistema de elec- imientos para minimizar exponerse al EMF: tricidad primario. 2.
  • Page 11 SecTION 1 SaFeTY PRecauTIONS 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 SaFeTY PRecauTIONS SIgNIFIcaDO De lOS SIMBOlOS -- Según usted avanza en la lec- tura 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.

  • Page 13: Safety - French

    SecTION 1 SaFeTY PRecauTIONS Safety - French aVeRTISSeMeNT : ces règles de sécurité INceNDIeS eT exPlOSIONS -- la ont pour but d'assurer votre protection. chaleur provenant des flammes ou de Ils récapitulent les informations de l'arc peut provoquer un incendie. le précaution provenant des références laitier incandescent ou les étincelles dans la section des Informations de sécurité...
  • Page 14 SecTION 1 SaFeTY PRecauTIONS 1. Assurez-vous que le châssis de la source 3. 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 : 2.
  • Page 15 SecTION 1 SaFeTY PRecauTIONS 5. aVeRTISSeMeNT : ce produit, lorsqu'il est utilisé eNTReTIeN De l'ÉQuIPeMeNT -- un équipe- 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.
  • Page 16 SecTION 1 SaFeTY PRecauTIONS SIgNIFIcaTION DeS SYMBOleS ce symbole, utilisé partout dans ce manuel, signifie "attention" ! Soyez vigilant ! Votre sécurité est en jeu. DANGER Signifie un danger immédiat. la situation peut entraîner des blessures graves ou mortelles. AVERTISSEMENT Signifie un danger potentiel qui peut entraîner des blessures graves ou mortelles.

  • Page 17: Description

    SecTION 2 DeScRIPTION Description ESP-150 Plasmarc System This versatile, all encompassed heavy duty water cooled plasma cutting and gouging system is ideal for manual and mechanized applications. • Greater productivity - high speed cutting of most metals from gauge thickness to 2” (50 mm) thick plate • Versatility - 230/460/575 volt three-phase input • Greater variation - adjustable output - 25 to 150 amps • Built-In Water Cooler - simplifies maintenance, less hook- up, no wiring issues, no extra hoses. Water flow is con- trolled with power supply •...

  • Page 18: Optional Accessories

    SecTION 2 DeScRIPTION How to Order Optional Accessories The ESP-150 package includes console, PT-26 torch with leather 150 amp Spare Parts Kit .............. 0558002864 sheath, torch spare parts kit, 25 ft. or 50 ft. work cable, TR-21 truck Remote Hand Switch with dual cylinder rack, regulators and gas hoses and torch coolant.
  • Page 19 SecTION 2 DeScRIPTION Assembly of PT-26 Front End Parts PT-26 Manual Models O-Ring Location - 2029450 Torch Head - O-Ring Location - 2110706 90° ....... 34599 70° ....0558002204 Electrode Holder - 34583 Includes O-Rings: Includes O-Rings 2110706 (1) 85W49 (Upper) 2029450 (3) 948317 (Lower) Electrode...
  • Page 20 SecTION 2 DeScRIPTION PT-26 Technical Specifications (Plasma gas) Type of Gas , Air, AR-H Pressure 100 psig (6.9 bar) Flow 240 cfh (6.8 M Purity Required - 99.5% min., N -99.995% min., Air - clean and dry Recommended Liquid Cylinder Service Regulators Inert Gas R-76-150-580LC 19977...
  • Page 21 DeScRIPTION 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.
  • Page 22 SecTION 2 DeScRIPTION eSP-150 MecHaNIZeD PlaSMa cuTTINg PacKageS ar/H PacKageS aIR PacKageS 0558002913 - ESP-150 / PT-26 25’ Inline / Air 0558002919 - ESP-150 / PT-26 25’ Inline / Ar+H2 Mix DESCRIPTION DESCRIPTION 0558002677 ESP-150 Console 0558002677 ESP-150 Console 0558002320 PT-26, 25’...

  • Page 23: Installation

    Be sure that all power is off by opening the line (wall) disconnect switch and by unplugging the power cord to the The ESP-150 Power Source is equipped with one lifting eye that enables unit when connections are made inside of the power source.

  • Page 24: Primary Input Electrical Connections

    SecTION 3 INSTallaTION Primary Input electrical connections Precautionary measures should be taken to provide maximum protection against 1. A line (wall) disconnect switch, with fuse or circuit breakers, should be electrical shock. Be sure that all power is off by opening the line (wall) disconnect provided at the main power panel.
  • Page 25 SecTION 3 INSTallaTION 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 elecTRIc SHOcK caN KIll! Precaution- links on the terminal board (TB) inside the unit must be repositioned ary measures should be taken to provide for the appropriate input voltage.
  • Page 26 SecTION 3 INSTallaTION 3. Safety codes specify that the Power Cable GROUND wire be the last to break connection should the cable be pulled out of the unit. Be sure to cut and strip wire as shown in Figure 6. Before making any connections to the power source output terminals, make sure that all primary input power to the...
  • Page 27 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.

  • Page 28: Voltage Divider Adjustment

    SecTION 3 INSTallaTION WaRNINg MaKe SuRe POWeR SWITcH ON cONSOle IS IN OFF POSITION aND PRIMaRY INPuT POWeR IS De-eNeRgIZeD. Voltage Divider adjustment It may be necessary to adjust the Voltage Divider or VDR to match the particular height control system. There are two default settings for the PowerCut models as shipped from the factory: •...

  • Page 29: Section 3 Installation

    If a PT-26 In-line Torch is being used in a mechanized installation where only an arc start signal is required, connect the optional Remote Hand Switch, ESAB part number 2075600, to the Torch Switch Receptacle on the hook-up panel in the front of the ESP-150 console. Fig. 11.

  • Page 30: Gas Supply Connections

    Connect the gas hoses to the regulators and to the proper fittings (Adaptors: 74S76, Air; 19X54, Ar/H ) on the rear panel of the ESP-150. Connections should be wrench tight including those that are plugged. (Fig. 14) (3) air Filter Regulators P/N-36932 Fig.

  • Page 31: Work And Earth Connections

    SecTION 3 INSTallaTION Work and earth connections 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.
  • Page 32 SecTION 3 INSTallaTION...

  • Page 33: Operation

    SecTION 4 OPeRaTION Operation controls and Indicators This section provides descriptions of the power source controls and general operating procedures plus, some tips on cut quality. Topping up the coolant Level indicator for the coolant Connection for return cable Ampere and Voltmeter Connection for torch Mains voltage switch Switch for gas...
  • Page 34 SecTION 4 OPeRaTION 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.

  • Page 35: Esp-150 Adjustments

    In addition to the safety hazard, improper 1. Slowly open each gas cylinder valve. cooling may cause damage to internal 2. Place the ESP-150 GAS MODE and POWER switches in the OPERATE and components. Keep side panels closed OFF positions.
  • Page 36 Do NOT touch any torch parts with power switch on. correct too fast too slow Position the eSP-150 at least 10 feet (3 meters) from the cutting area. Sparks and hot slag from the cutting operation can damage the unit. Fig. 16 - effect of cutting Speed With a positive cut angle, the top dimension is slightly less than the bottom dimen- sion.

  • Page 37: Standoff And Cut Quality

    SecTION 4 OPeRaTION Standoff and cut Quality Standoff (Arc Voltage) has a direct influence on cut quality and squareness. It is recom- mended 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.

  • Page 38: Dross Formation

    SecTION 4 OPeRaTION 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.

  • Page 39: Common Cutting Problems

    Problems 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 mainte- Tripped circuit breaker (located under the top nance section of this manual. If the problem is not corrected after referring to hinged cover) may indicate dangerous high voltage the maintenance section, contact your ESAB representative.

  • Page 40: Operating Parameters

    SecTION 4 OPeRaTION Operating Parameters Recommended Gas Pressures - Start ..........30 psig Plasma (Cutting) ....50 - 70 psig Plasma (Gouging) ....40 - 45 psig Shield .......... 40 - 50 psig Recommended Stand-off - 5/16" - 1/2" Travel Speeds - Travel speeds for the PT-26 are given in Tables 4-1 through 4-4.
  • Page 41 Cut Gas and Thickness Standoff Speed Gas and Pressure Material Pressure Pressure inch (mm) inch (mm) ipm (mm/m) for ESP-150 and 200 psig (bar) psig (bar) psig (bar) 0.12 (3.2) 190 (4826) 0.19 (4.8) Carbon 0.25 (6.4) 100 (2540) Steel 0.50 (12.7)
  • Page 42 Start Gas and Cut Gas and Thickness Standoff Gas and Pressure for Material Pressure Pressure inch (mm) inch (mm) ESP-150 and 200 (mm/m) psig (bar) psig (bar) psig (bar) 0.19 (4.8) 150 (3810) 0.25 (6.4) 130 (3302) 0.19 (4.8) 0.38 (9.7)
  • Page 43 SecTION 4 OPeRaTION Table 4.3 200 amp cut Data Shield Speed Start Gas and Cut Gas and Gas and Pres- Thickness Standoff Material Pressure Pressure sure for ESP- inch (mm) inch (mm) (mm/m) psig (bar) psig (bar) 150 and 200 psig (bar) 0.25 (6.4) 150 (3810)
  • Page 44 SecTION 4 OPeRaTION Table 4.4 300 amp cut Data Speed Start Gas and Cut Gas and Shield Thickness Standoff Material Pressure Pressure Gas and Flow inch (mm) inch (mm) (mm/m) psig (bar) psig (bar) cfh (l/m) 0.50 (12.7) 130 (3302) 0.25 (6.4) 0.62 (15.7) 95 (2413)
  • Page 45 SecTION 4 OPeRaTION Maximum Manual PT-26 Speeds PT-26 Steel cutting Data...
  • Page 46 SecTION 4 OPeRaTION PT-26 Stainless Steel cutting Data Plasma Gas: Air at 60 psig or H-35 at 70 psig. Shield Gas: Air at 50 psig or Nitrogen at 40 psig. Start Gas: Air, Nitrogen or H-35 at 30 psig. Stand-Off: 3/8" 200 A.

  • Page 47: Maintenence

    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.

  • Page 48: Section 5 Maintenance

    SecTION 5 MaINTeNaNce c. SPaRK gaP aDJuSTMeNT The spark gap, which is part of the high frequency generator, is factory set at 0.040-in. (+/- 0.002). After extended operation or if erratic operation is noted, it may be neces- Voltages in plasma cutting equipment sary to readjust or replace the electrodes.

  • Page 49: Troubleshooting

    SecTION 5 MaINTeNaNce Troubleshooting Check the problem against the symptoms in the following troubleshooting guide. If the cause cannot be quickly located, shut off the input power, open up the unit, and perform a simple visual inspection of all the components and wiring.
  • Page 50 SecTION 5 MaINTeNaNce 7. No pilot arc - pilot arc contactor (Pac) drops out when main contactor (Mc) activates at end of 2-second preflow. a. Check for low open circuit voltage. It should be around 370 V at nominal line voltage. b.
  • Page 51 SecTION 5 MaINTeNaNce 15. The thermal cut-out trips frequently. Make sure that you are not exceeding therated data for the power source (i.e. that theunit is not being over- loaded). 16. Poor welding performance. Check that the welding current supply andreturn cables are correctly connected.Check that the correct current value is set.Check that the correct electrode is beingused.Check the mains power supply fuses.
  • Page 52 SecTION 5 MaINTeNaNce 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.
  • Page 53 SecTION 5 MaINTeNaNce c. STaTuS lIgHT TROuBleSHOOTINg cHaRT Proper Input Power Applied 1. Check open circuit voltage. ROS ON Should be about 370 VDC. (Dis- connect HF to avoid damaging Does meter.) TORCH ON 2. Check input power. Light turn 3.
  • Page 54 SecTION 5 MaINTeNaNce...

  • Page 55: Replacement Parts

    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 56 SecTION 6 RePlaceMeNT PaRTS...
  • Page 57 SecTION 6 RePlaceMeNT PaRTS ITeM PaRT NO DeScRIPTION SYMBOl 0558002680M PANEL FRONT 0558002683Y PANEL TOP 0558002681Y PANEL SIDE LEFT 0558002682Y PANEL SIDE RIGHT 0558002678M PANEL BASE CONTROL PANEL TOP ASSY 0558002806 (Includes Items 7 thru 10) 680718 CONTROL PANEL TOP SHELL 0558003773 PANEL CONTROL SILKSCREENED 0558003775...
  • Page 58 SecTION 6 RePlaceMeNT PaRTS...
  • Page 59 SecTION 6 RePlaceMeNT PaRTS ITeM PaRT NO DeScRIPTION SYMBOl PANEL REAR ASSY 0558002800M (Includes Items 23 thru 41) 0558002679M PANEL REAR 0558004077 SHROUD MACHINE FAN 16” 0558004055 BLADE MACHINE FAN 16” 0558000749 MOTOR MACHINE FAN 1/3 HP 17300008 RESISTOR 8 OHM 300W R20,R21,R30,R31 MANIFOLD GAS CONTROL ASSY 0558002810...
  • Page 60 SecTION 6 RePlaceMeNT PaRTS...
  • Page 61 SecTION 6 RePlaceMeNT PaRTS ITeM PaRT NO DeScRIPTION SYMBOl HIGH FREQUENCY ASSY 0558002803 (Includes Items 44 thru 70) 0558002804M PANEL HIGH FREQUENCY ASSY 30845M PANEL DIVIDER 30859 AUTOTRANSFORMER HIGH FREQUENCY HFATR 0558007469 TRANSFORMER HIGH FREQUENCY HFTR 0558007163 CAPACITOR .002uF 10KWV C18A 0558007470 CAPACITOR 2500pF 15KV...
  • Page 62 SecTION 6 RePlaceMeNT PaRTS...
  • Page 63 SecTION 6 RePlaceMeNT PaRTS ITeM PaRT NO DeScRIPTION SYMBOl 0558002689M BOX PC BOARD 0558004085 PC BOARD - CONTROL 0558004086 PC BOARD - LOGIC 0558004087 CAPACITOR 1500uF 50VDC 0558004090 RELAY TIME DELAY DPDT 120VAC 10A 17111220 RESISTOR 2K OHM 0.25W 0558004088 RELAY 3PDT 240VAC 28VDC 10A 0558004089 RELAY DPDT 24VAC 10A...
  • Page 64 SecTION 6 RePlaceMeNT PaRTS Shown Shown Shown Shown 102 103 Shown Shown...
  • Page 65 SecTION 6 RePlaceMeNT PaRTS ITeM PaRT NO DeScRIPTION SYMBOl TRANSFORMER / BRIDGE ASSY 0558006906 (Includes Items 82 thru 99) TRANSFORMER MAIN 0558004076 (Includes Items 83 and 84) 0558004084 FUSE LINK 150A 250V F1,2 0558004075 SWITCH THERMAL 180C MTRTS1,2,3 INDUCTOR 0558004074 (Includes Item 86) 0558004075 SWITCH THERMAL 180C...
  • Page 66 SecTION 6 RePlaceMeNT PaRTS 118 119...
  • Page 67 SecTION 6 RePlaceMeNT PaRTS ITeM PaRT NO DeScRIPTION SYMBOl 0558010710 CONTACTOR MAIN 90A 24VAC 0558004070 RESISTOR 470 OHM 2W 0558004081 LUG GROUNDING GND1 TERMINAL BOARD ASSY 230/460/575V 9680911 (Includes Item 116) 672065 TERMINAL STRAP 672227M BRACKET MOUNTING TERMINAL BOARD CAPACITOR BANK ASSY 30941 (Includes Items 119 and 120) 0558004066...
  • Page 68 SecTION 6 RePlaceMeNT PaRTS Detail Showing Standard Unit...
  • Page 69 SecTION 6 RePlaceMeNT PaRTS ITeM PaRT NO DeScRIPTION SYMBOl 0558004065 TANK COOLANT 6 QUART 0558004064 SWITCH FLOW 0.25GPM 10Z30 ADAPTOR RH B/A-W*M 1/4NPTM 58V75 ADAPTOR BULKHEAD LH B/A-W*F 1/4NPTM 0558004062 PUMP COOLANT 60PSI 96GPH 0558006272 ADAPTOR BUSHING 1/4NPTF 3/8NPTM 67101075 NIPPLE 1/4NPT 461107 TEE STREET 1/4NPT...
  • Page 70 SecTION 6 RePlaceMeNT PaRTS...
  • Page 71 NOTeS...
  • Page 72 NOTeS...

  • Page 73: Revision History

    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 / replaced Replacement Parts section. 4.
  • Page 74 Welding & cutting Products, Florence, Sc cOMMuNIcaTION guIDe - cuSTOMeR SeRVIceS CUSTOMER SERVICE QUESTIONS: Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST Order Entry Product Availability Pricing Order Information Returns ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693...

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