ESAB ESP-1000 Plasmarc System User manual

F15-116-D 07/2007

INSTRUCTION MANUAL

ESP - 1000 PLASMARC SYSTEM

MECHANIZED CUTTING WITH PT-15XL OR PT-19XLS

2

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. 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 imme-

diately. 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 ser-

vice facility designated by the manufacturer.

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 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.

CAUTION

USER RESPONSIBILITY

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

3

TABLE OF CONTENTS

SECTION TITLE PAGE

PARAGRAPH

SAFETY PRECAUTIONS .....................................................................................................................................5

SECTION 1 INTRODUCTION ...................................................................................................................17

1.1 General ................................................................................................................................................................... 17

1.2 Features .................................................................................................................................................................. 17

1.3 Component Description .................................................................................................................................. 18

SECTION 2 INSTALLATION ......................................................................................................................23

2.1 General ................................................................................................................................................................... 23

2.2 System Component Location ......................................................................................................................... 23

2.3 System Connections .......................................................................................................................................... 24

2.4 Torch Components ............................................................................................................................................. 30

2.5 Installing Air Curtain ..........................................................................................................................................31

2.6 Bubble Muer Installation .............................................................................................................................. 32

2.7 WATER MUFFLER SYSTEM FOR THE PT-19XLS ..........................................................................................33

2.8 AIR CURTAIN/BUBBLE MUFFLER CONTROL BOX INSTALLATION ........................................................ 33

2.9 WATER INJECTION PUMP ................................................................................................................................. 33

2.10 INSTALLATION OF THE SECONDARY GAS METERING BOX ...................................................................34

SECTION 3 OPERATION.......................................................................................................................................................... 39

3.1 General ................................................................................................................................................................... 39

3.2 Controls and Indicators .................................................................................................................................... 39

3.3 Pre-Operation Test and Checkout ................................................................................................................41

3.4 Oxygen Cutting with PT-15XL ........................................................................................................................ 44

3.5 Nitrogen Cutting with PT-15XL ...................................................................................................................... 49

3.6 H-35 Cutting with PT-15XL ..............................................................................................................................51

3.7 CUTTING WITH THE PT-19XLS and PT-600 TORCHES ............................................................................ 52

3.8 High Current Cutting with PT-19XLS ...........................................................................................................55

PT-19XLS Cutting Tables ................................................................................................................................... 56

3.9 Operating Techniques ....................................................................................................................................... 70

SECTION 4 TROUBLESHOOTING .......................................................................................................................................75

4.1 Programmable Logic Controller .................................................................................................................... 75

4.2 Sequence Description .......................................................................................................................................75

4.3 Operating Information......................................................................................................................................77

4.4 Troubleshooting Guide ....................................................................................................................................78

4

TABLE OF CONTENTS

5

SAFETY PRECAUTIONS

Safety Precautions

Safety - 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 instal-

lation 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

processes are noisy and require ear

protection. The arc, like the sun, emits

ultraviolet (UV) and other radiation and can injure

skin and eyes. Hot metal can cause burns. Training

in the proper use of the processes and equipment

is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in

any work area, even if welding helmets, face

shields, and goggles are also required.

2. Use a face shield tted with the correct lter and

cover plates to protect your eyes, face, neck, and

ears from sparks and rays of the arc when oper-

ating 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 ameproof gauntlet type gloves, heavy

long-sleeve shirt, cuess trousers, high-topped

shoes, and a welding helmet or cap for hair

protection, to protect against arc rays and hot

sparks or hot metal. A ameproof apron may

also be desirable as protection against radiated

heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cus, or pockets. Sleeves and collars

should be kept buttoned, and open pockets

eliminated from the front of clothing.

5. Protect other personnel from arc rays and hot

sparks with a suitable non-ammable partition

or curtains.

6. Use goggles over safety glasses when chipping

slag or grinding. Chipped slag may be hot and

can y far. Bystanders should also wear goggles

over safety glasses.

FIRES AND EXPLOSIONS -- Heat from

ames and arcs can start res. Hot

slag or sparks can also cause res and

explosions. Therefore:

1. Remove all combustible materials well away from

the work area or cover the materials with a pro-

tective non-ammable covering. Combustible

materials include wood, cloth, sawdust, liquid

and gas fuels, solvents, paints and coatings,

paper, etc.

2. Hot sparks or hot metal can fall through cracks

or crevices in oors or wall openings and cause a

hidden smoldering re or res on the oor below.

Make certain that such openings are protected

from hot sparks and metal.“

3. Do not weld, cut or perform other hot work until

the work piece has been completely cleaned so

that there are no substances on the work piece

which might produce ammable or toxic vapors.

Do not do hot work on closed containers. They

may explode.

4. Have re extinguishing equipment handy for

instant use, such as a garden hose, water pail,

sand bucket, or portable re 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 re 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 re. Use re

watchers when necessary.

7. For additional information, refer to NFPA Stan-

dard 51B, "Fire Prevention in Use of Cutting and

Welding Processes", available from the National

Fire Protection Association, Battery march 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 conned, or if there is danger

of falling.

6

SAFETY PRECAUTIONS

1. Be sure the power source frame (chassis) is con-

nected to the ground system of the input power.

2. Connect the work piece to a good electrical

ground.

3. Connect the work cable to the work piece. 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 body are insulated

from work and from ground.

7. Do not stand directly on metal or the earth while

working in tight quarters or a damp area; stand

on dry boards or an insulating platform and wear

rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the

power.

9. Turn o the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on

next page) for specic grounding recommenda-

tions. Do not mistake the work lead for a ground

cable.

ELECTRIC AND MAGNETIC FIELDS

— May be dangerous. Electric cur-

rent owing through any conduc-

tor 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 eects 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 work piece as close

as possible to the area being welded.

E. Keep welding power source and cables as far

away from your body as possible.

FUMES AND GASES -- Fumes and

gases, can cause discomfort or harm,

particularly in conned spaces. Do

not breathe fumes and gases. Shield-

ing gases can cause asphyxiation.

Therefore:

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, stain-

less steel, copper, 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 opera-

tions. The heat or arc rays 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 ir-

ritation 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 discom-

fort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)

for specic ventilation recommendations.

7

SAFETY PRECAUTIONS

5. WARNING: This product, when used for welding

or cutting, produces fumes or gases

which contain chemicals known to

the State of California to cause birth

defects and, in some cases, cancer.

(California Health & Safety Code

§25249.5 et seq.)

CYLINDER HANDLING -- Cylinders,

if mishandled, can rupture and vio-

lently 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 ttings in good

condition. Follow manufacturer's operating instruc-

tions for mounting regulator to a compressed gas

cylinder.

2. Always secure cylinders in an upright position by

chain or strap to suitable hand trucks, undercar-

riages, benches, walls, post, or racks. Never secure

cylinders to work tables or xtures 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 con-

nected. Secure and move cylinders by using suitable

hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and ames.

Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,

"Precautions for Safe Handling of Compressed Gases

in Cylinders", which is available from Compressed

Gas Association, 1235 Jeerson Davis Highway,

Arlington, VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or

improperly maintained equipment can

cause injury or death. Therefore:

1. Always have qualied personnel perform the instal-

lation, troubleshooting, and maintenance work.

Do not perform any electrical work unless you are

qualied 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 equip-

ment, 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. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc

Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc

Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon

Arc Gouging and Cutting"

8

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."

MEANING OF SYMBOLS - As used

throughout this manual: Means Atten-

tion! Be Alert! Your safety is involved.

Means immediate hazards which,

if not avoided, will result in im-

mediate, 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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16

SÉCURITÉ

SIGNIFICATION DES SYMBOLES

Ce symbole, utilisé partout dans ce manuel,

signie "Attention" ! Soyez vigilant ! Votre

sécurité est en jeu.

Signie un danger immédiat. La situation peut

entraîner des blessures graves ou mortelles.

Signie un danger potentiel qui peut entraîner des

blessures graves ou mortelles.

Signie un danger qui peut entraîner des blessures

corporelles mineures.

DANGER

AVERTISSEMENT

ATTENTION

Additional Safety Information for Mechanized Plasmarc Cutting Systems:

Electrical Shock can kill or cause severe burns. Plasmarc cutting uses DC currents at dangerously high voltages.

• DonottouchthetorchorchangetheconsumablesifinputpowertothePlasmarcpowersourcehasnotbeendiscon-

nected.

• Donotstandon,touch,orinanywaycontacttheplatewhilecuttingvoltagesarepresent.

• Theworkpiecemustbeelectricallyconnectedtothepowersourceworkterminalforsafeoperationofthesystem.

• Donotperformmaintenanceon anypartofthePlasmarcsystemunlessallpowerinputshavebeendisconnected

and locked out. This includes 115vac inputs as well as high voltage inputs.

• Troubleshootingrequiringpowertobeonshouldonlybedonebyqualiedpersonnel.

Hydrogen Explosions can cause injury or death.

• Seepage?????.

Fumes and Gases can cause discomfort or death. Do not breath fumes or gases.

• Donotcutcontainersoftoxicmaterialsorcontainersthathaveheldtoxicmaterials.Cleansuchcontainersthorough-

ly before cutting.

• Beforecuttingacoatedmaterial,consultwithitsmanufacturerforpropersafetyprecautions.

Noise and Ultraviolet Light

• Thenoiselevelofplasmarccuttingcanbegreaterthan110dbatadistanceof6feetfromthetorch.Wearproper

hearing protection.

• Reectionofultravioletlightfromareaswallsclosetothecuttingarccanbeminimizedbyselectingpaintshavinga

high percentage of ZnO and TiO

2

pigments. Do not use paints containing metallic akes. Refer to “Ultraviolet Reec-

tance of Paint” from the American Welding Society.

• Underwatercuttingisawellacceptedtechniqueforreducingthenoise,fumes,andUVradiationofthePlasmarccut-

ting process. Often an air curtain or bubble muer is required for underwater cutting. Above water cutting with a

water muer can also achieve much of the benets of underwater cutting.

17

1.1 GENERAL

The ESP-1000 is a full capability plasmarc cutting system

that oers a wide variety of plasma cutting processes

and applications. The system is designed specically for

computer controlled mechanized cutting applications

with expanded interfacing, exible conguration from a

selection of packages and versatile ease of operation. By

selecting the components that best suit your needs the

ESP system can fully automate your cutting process.

1.2 FEATURES

• Thesystemiscapableofwaterinjectioncutting

with the PT-15XL torch and gas shielded un-

derwater cutting can be accomplished at most

current levels with appropriate accessories with

the PT-19XLS torch.

• TheESP-1000canaccommodateallmajorcutting

gases including; oxygen, air, nitrogen or argon/

hydrogen mixture.

• Theseparate component design, owcontrol,

plumbing box, power source provides maximum

flexibility for system layout tailored to your

needs.

• Selection fromavarietyofpowersourcesand

the paralleling capability allows a wide range

of available cutting power to meet virtually any

cutting condition.

• Patented ESAB technologyallowsunderwater

cutting and beveling with excellent results.

• TheESP-1000usessimpleswitchsettingstosetup

process parameters for ow control and cutting

power eliminating the diculty of adjustment

associated with needle valves.

• Theshieldedconstructionoftheplasmatorches

and versatility of component location minimizes

electrical interference with surrounding equip-

ment.

• The ESPsystem usesadvancedtechnology for

high quality cutting for a variety of common

metals while keeping the operating costs at a

minimum.

Figure 1-1. ESP-1000 Major Components

COOLANT

CIRCULATOR

FLOW

CONTROL

POWER SOURCE

(ULTRA LIFE 300, ESP-

400 or ESP-600C)

CUT WATER

PUMP

TORCH

(PT-15XL or PT-19XLS)

PLUMBING

BOX

SECONDARY

GAS METERING

BOX

SECTION 1 DESCRIPTION

18

SECTION 1 DESCRIPTION

ESP-600C Power Source

The ESP-600C is normally used in mechanized cutting ap-

plications for high speed cutting. The ESP-600C is a solid

state DC power source capable of producing 100 to 600

amperes of cutting current at 100% duty cycle (no cool

down requirements). The extremely low ripple current is

produced by a ripple cancellation technique and results

in increased life of plasma consumables. "Current slope

up" is also featured with the ESP-600C.

1.3 COMPONENT DESCRIPTION

The components that make up an ESP-1000 are designed

specically to interface into a system for use in automated

plasma cutting applications.

Refer tothe specic equipment manual for detailed

information.

Ultra Life 300 Power Source

Designed for high speed plasma cutting, the Ultra Life 300

is basically a silicon controlled rectier (SCR) DC unit with

solid state circuitry. The unit can be operated from 50 to

300 amperes output (cutting) current.

Figure 1-2. Ultra Life 300 Power Source

The solid state circuitry of the Ultra Life 300 produces

stable cutting current and eliminates changes in output

current as components heat up to operating tempera-

ture. Fluctuations in line voltage within +/- 10% of normal

and/are extremely low ripple output current is produced,

which results in longer consumable life.

Refer to Instruction Manual F-15-141 for specic details

for the Ultra Life 300.

ESP-400C Power Source

The ESP-400C Power Source is a solid state DC pwoer source

capable of producing up tp 400 amperes.

Figure 1-3 ESP-400C Power Source

The design of the solid state circuitry produces stable

cutting current and eliminates changes in output current

as components heat up to operating temperature and/or

uctuations in line voltages within + or - 10% of nominal.

If cutting currents above the rating is required, two ESP-

400C units can be paralleled.

Refer to the power source manual for installation instruc-

tions.

VOLTS

AMP S

OUTPUT

ACTUAL AMPS

PRESET AMPS

LOW

HIGH

PIL OT

ARC

50

MIN

100

200

300

400

500

600

MAX

0

MAIN

POWER

CURRENT

PANEL

RE MOTE

OVER

TE MP

CONTACTOR

ON

FAULT

POWER

RESET

FAULT

400C

19

SECTION 1 DESCRIPTION

For currents beyond the ESP-600C capability 2 units can be

connected in a parallel conguration. Refer to Instruction

Manual for specic details of the ESP-600C.

Figure 1-5. Flow Control Assembly

Connections to the ow control are Oxygen In, Nitrogen

In, Start Gas Out, Cut Gas Out, Cut Water In and Cut Water

Out.

Plumbing Box

The ESP Plumbing Box is an interconnecting device

between the torch and other system components. It

also contains the arc starting high frequency genera-

tor. Connection of functions through the plumbing box

include; cut gas, start gas, cut water, torch coolant, pilot

arc, cutting current and height control.

Figure 1-6. Plumbing Box Assembly

Coolant Circulator

The WC-7C circulator is a radiator type cooler for circulat-

ing a coolant uid through the plasma torch providing

heat exchanger action for the internal parts of the torch.

Though the system refers to water, it is not recommended

that water be used. For the protection of internal parts

and lines a specially formulated coolant liquid is avail-

able that prevents production of corrosion and mineral

buildup. Refer to Instruction Manual F-15-138 for detailed

information on the WC-7C unit.

Flow Control

The Flow Control is a programmable Logic Control (PLC)

based unit. This device provides all the necessary control

functions for various uids and signals to and from other

components of the system. Control Inputs/Outputs are

connected to the power source, cut water pump, plumb-

ing box, coolant circulator, air curtain and the cutting

machine control.

Figure 1-4. ESP-600C Power Source

L

O

W

H

I

G

H

L

O

W

H

I

G

H

C

U

T

G

A

S

C

U

T

A

W

T

E

R

T

E

S

T

R

U

N

20

SECTION 1 DESCRIPTION

PT-15XL Plasma Torch

The PT-15XL is designed for high current plasma cut-

ting with water injection. Cutting is accomplished with

nitrogen cut gas up to 750 amps, oxygen cut gas up to

360 amps. Use of H-35 mixture for cut gas extends cur-

rent capability up to 1000 amps. Each condition requires

specic torch components for the type of cut gas and

current level.

Figure 1-8. PT-15XL Plasma Torch

The PT-15XL is designed to eliminate double arcing, high

frequency leakage, and electrolytic corrosion of parts.

The electrode cooling and nozzle concentricity makes arc

ignition more reliable, longer life of the nozzle, electrode

and other consumable parts. Operating details for specic

cutting conditions are presented in later sections of this

manual. Refer to Form F-15-031 for detailed information

of the PT-15XL torch.

PT-19XLS Plasma Torch

The PT-19XLS Torch is designed with all the quality stan-

dards and feature characteristics of the PT-15XL. The

dierences are primarily in applications and conditions

for which the PT-19XLS is to be used. The PT-19XLS is a

mechanized torch designed for high speed, high current

cutting using gas shielding instead ofwater injection.

Figure 1-9. PT-19XLS Plasma Torch

Secondary Gas Metering Box

Figure 1-7A

The secondary shield/PT-19XLS improves the cut square-

ness. The secondary gas metering box measures the ow

rate of shield gas (nitrogen or air).

Adaptor: PT-19XLS to Plumbing Box for shield gas con-

nection to torch.

Figure 1-7A

PT-600 Plasma Torch

The PT-600 torch is a PT-19XLS with reduced manu-

facturing tolerances. The result is improved torch

component concentricity and cut accuracy. Connec-

tions, mounting and process data are identical.

10

9

8

7

6

5

4

3

2

1

0

PRESSURE

FLOW

OFF

ON

AUTO

PRESSURE

ADJUSTMENT

INLET

FLOW

ADJUSTMENT

OUTLET

READ TOP

OF BALL

0

50

100

PLASMARC

SECONDARY SHIELD

GAS FLOW CONTROL

21

Figure 1-11. Bubble Muer Assembly

Figure 1-12. PT-19XLS Water Muer Assembly

The PT-19XLS is intended for applications of dry cutting

using air (clean & dry) for the cut gas at current levels up

to 200 amps. Oxygen (to 360A) or H-35 (to 600A) can be

used with the PT-19XLS, however these gases are not

recommended for some materials. Use of an air curtain

kit permits the PT-19XLS to be used for underwater cut-

ting. Further details of the PT-19XLS are contained in

Form F-15-430.

Water Pump

The Water Pump is used to supply de-ionized cut water

to the PT-15XL torch for water injected cutting.

Air Curtain

The Air Curtain assembly provides improved cutting

performance of the PT-15XL and PT-19XLS plasma torches

when cutting underwater. A source of oil free air at 80

psig is required to the air curtain control box. A curtain

(wall) of air is created around the plasma arc area allowing

operation in a relatively dry zone, even with the end of

the torch submerged 2 - 3 inches.

Underwater Cut quality and speed are enhanced when

using the air curtain for all PT-19XLS cutting applications

and PT-15XL O

2

/water injection cutting.

Bubble Muer

The Bubble Muer system creates a bubble of air sur-

rounded by water that allows the PT-15XL torch to be

used underwater with oxygen cut gas and water injection

cutting without signicant loss of cut quality.

This device also allows above water cutting with reduced

fume, noise and UV radiation from the arc by the ow

of water through the bubble muer. A separate water

pump recycles ltered water from the water cutting table

through the bubble muer.

PT15XL H.D.

AIR CURTAIN

PT-19XLS

AIR CURTAIN

Figure 1-10. Air Curtain Assembly

PT-19XLS Water Muer

The PT-19XLS water muer works much as the bubble

muer described above.

SECTION 1 DESCRIPTION

22

SECTION 1 DESCRIPTION

DESCRIPTION PART NUMBER INSTRUCTION MANUAL

Ultra Life 300 460/575 V, 3-Phase, 60 Hz 33520 F-15-141

ESP-400C 460 V, 3-Phase, 60 Hz 0558001729 F-15-657

400 V, 3-Phase, 50 Hz CE 0558001730 F-15-681

575 V, 3-Phase, 50 Hz 0558001731 F-15-657

ESP-600C 460 V, 3-Phase, 60 Hz 35609 F-15-656

400 V, 3-Phase, 50 Hz CE 35610 F-15-682

575 V, 3-Phase, 60 Hz 35611 F-15-656

TABLE 1-1. ESP 1000 COMPONENTS

Power Sources

Plasma Torches: The basic torch body can be supplied in seven lead lengths between the plumbing box and torch. The replaceable

torch components are selected for the type of cut gas and current level used.

PT-15XL - 4.5 ft. 21307 F-15-031

PT-15XL - 6 ft. 21304

PT-15XL - 12 ft. 21305

PT-15XL - 15 ft. 21301

PT-15XL - 17 ft. 21306

PT-15XL - 20 ft. 21302

PT-15XL - 25 ft. 21303

PT-19XLS - 4.5 ft. 37086 F-15-430

PT-19XLS - 6 ft. 37087

PT-19XLS - 12 ft. 37088

PT-19XLS - 15 ft. 37089

PT-19XLS - 17 ft. 37090

PT-19XLS - 20 ft. 37091

PT-19XLS - 25 ft. 37092

PT-600 - 4.5 ft. 0558001827 F-15-646

PT-600 - 6 ft. 0558001828

PT-600 - 12 ft. 0558001829

PT-600 - 15 ft. 0558001830

PT-600 - 17 ft. 0558001831

PT-600 - 20 ft. 0558001832

PT-600 - 25 ft 0558001833

Flow Control: Provides interface for uids, gases and 21294 F-15-106

power.

Plumbing Box: Provides interconnection between torch 21295 F-15-107

and rest of system includes adaptor for

shield gas connection.

WC-7C Water Recirculator: Circulates coolant for the torch 33859 F-15-138

Cut Water Pump:

Supplies cut water to torch for water injection cutting 33772 F-15-131

Air Curtain:

PT-19XLS and PT-600 37440 F-15-475

Heavy Duty PT-15XL 21856 F-15-189

PT-15XL Beveling (PT-19XL and PT-600) 34752 F-15-189

Bubble Muer System 2232615 F-15-127

PT-19XLS (and PT-600) Water Muer 37439 F-15-474

Secondary Gas Metering Box (for PT-19XLS) 22178 See pages 28 - 32 of this manual.

23

READ THIS MANUAL COMPLETELY PRIOR TO

INSTALLING AND OPERATING THE ESAB SMART

PLASMA (ESP) 1000 SYSTEM.

2.1 General

Proper installation substantially contributes to the

satisfactory and trouble-free operation of the ESP-1000

System components. Each step in this section should

be studied carefully and followed as closely as possible.

Immediately upon receipt of the ESP components,

each should be inspected closely for damage which

may have occurred in transit. Notify the carrier of any

damage or defects immediately. Instruction manuals for

each component of the system are included in the pack-

age. It is recommended that these manuals be collected

and compiled in a common location.

NOTE

If the components are not to be immediately

installed, store them in a clean, dry, and well ventilated

area.

2.2 System Component Locations

Power Source

When lifting the Power Source using the lifting

lugs, ensure the lifting means is securely connected

to BOTH lifting lugs to prevent damage to the unit or

injury to personnel. DO NOT USE ANY LEVER DEVICE

WHICH COULD DAMAGE THE UNIT.

The location of the Power Source should be care-

fully selected to ensure satisfactory and dependable

service. The Power Source components are maintained

at the proper operating temperatures by forced air that

is drawn through the cabinet by the fan units. For this

reason, it is important that the Power Source be located

in an indoor-open area where air can circulate freely at

the front, bottom, and rear openings of the cabinet. If

space is a premium, leave at least two feet of clearance

at the rear of the cabinet.

The location should be such that a minimum of

dirt, dust, or moisture will be drawn into the air stream.

It is desirable to locate the unit so that the top and side

panels can be removed for cleaning and troubleshoot-

ing. In relationship to a cutting machine, the power

source can be positioned virtually anywhere that will

not interfere with machine travel. Accessories on the

cutting machine are available to carry hoses and cables

without interference with machine travel.

Flow Control

The Flow Control can be placed on the Power

Source or mounted onto the cutting machine. It con-

nects to the Power Source by a control cable from 6' to

125' long. The Flow Control needs to be accessible for

setting various cutting parameters. After setting the

cutting conditions, access to the Flow Control is not

required during the cutting operation.

Plumbing Box

The Plumbing Box is normally located on the

cutting machine in close proximity to the torch station.

Since the torch can be equipped with various standard

lengths of cable and hose, the exact location is deter-

mined by the conguration and station load capacity of

the machine.

Access to the Plumbing Box is not required during

the standard operating procedures, location near the

operator is not required. Two important considerations

pertain to the location of the plumbing box:

1. There should be space for the box door to be

opened fully .

2. Sucient space should be provided on all

sides to permit easy connection of gas/water

hoses and electrical cables to the box.

Secondary Gas Metering Box

The gas metering box can be mounted on the cut-

ting machine or a convenient wall with the owmeter

vertical. The hose supplied is used to connect metering

box to torch shield gas using the adaptor supplied with

the plumbing box. The gas metering box must be con-

nected to a source of dry oil free shop air or N

2

capable

SECTION 2 INSTALLATION

WARNING

24

SECTION 2 INSTALLATION

2.3. SYSTEM CONNECTIONS

Power Source

Before making any connections to the output bus bars,

make sure the power source is de-energized by opening

the line (wall) disconnect switch. To be doubly safe, have a

qualied person check the output bus bars with a voltmeter

to be sure all power is o.

Input Power Connections

The power sources (ESP-600C, ESP-400 or Ultra Life 300) used

with the ESP-1000 system are 3-phase units and must be con-

nected to a 3-phase power line. Although designed with line

voltage compensation, it is suggested that the unit be operated

on a separate line to ensure the performance of the power

source is not impaired due to an overloaded circuit.

A line (wall) disconnect switch, with fuses or circuit breakers,

shall be used at the main power panel. The primary power input

must have four insulated power leads (three power leads and

one ground wire). The wires may be a heavy rubber covered

cable or may run in a solid or exible conduit.

NOTE

The ground wire must be approximately six inches longer than

the power leads. This is a safety measure to ensure that in the

event the power lines are accidently pulled out the ground wire

will remain connected.

Input conductors must be terminated with ring terminals sized

for 1/2 inch hardware before being connected.

NOTE: Refer to the specic equipment manual for

detailed installation instructions.

Flow Control Connections

The Flow Control serves as a form of interface between the

various process utilities to enable a central location for setup

adjustments. Connections are made to receptacles on the rear

panel and are grouped into two sections, the bottom row is for

gas and water connections while the top row is for electrical

connections. The uid connections should be made rst.

Fluid Hookups (See Table 2-1 for hose assemblies)

1. OXYGEN (O

2

) IN - This is a "B" size CGA oxygen

tting. Connect the supply hose from the oxygen

regulator to this point.

2. NITROGEN (N

2

) IN - This is a "B" size IAA tting.

Connect the supply hose from the nitrogen

regulator to this point.

3. START GAS OUT - This is a "B" size IAA tting. From

this point connect the hose to Start Gas INPUT on

the Plumbing Box.

4. CUT GAS OUT - This is a "B" size oxygen tting.

The hose is connected from this point to the Cut

Gas INPUT on the Plumbing Box.

Electrical Hookups (See Table 2-2 for cables)

1. PARALLELED POWER SOURCE - A cable from a

second power source connects to this receptacle

whenever two power sources are used in paral-

lel. It parallels all control connections between

the power source and ow control.

2. AIR CURTAIN - This is used to connect the coil of

a solenoid valve in the air curtain control (when

used) or to control a relay coil in the water muer

pump unit.

3. CUT WATER PUMP - Provides connection to a relay

coil in the cut water pump unit

4. WATER COOLER - This point is used to connect to

the relay coil in the water cooler.

5. PLUMBING BOX - This cable connection goes to

the gas solenoid valves, ow switch, interlock

switch and provides power to the primary of

the high frequency transformer in the plumbing

box.

6. CUTTING MACHINE NUMERICAL CONTROL (CNC)

- This connection provides a current reference

signal to the plasma power source and provides

control signals to and from the ow control cir-

cuits, Start Process Command, Arc On, Process

Fault, and E-Stop Interlock.

7. 115 VAC AUXILIARY POWER - This optional con-

nection allows the Flow Control to be energized

without powering up the system. Disconnect

after test function is completed.

WARNING

25

SECTION 2 INSTALLATION

Figure 2-2. ESP-1000 Interface Block Diagram

Gas Regulators

Wall Box

Power Source

Cooler and

Pump

Plumbing Box

Flow Control

Cut

Water

Pump

Gas

Metering

Box

Air Supply

Height

Control

Cutting Machine Control

Torch

PT-15XL or

PT-19XLS or

PT-600

Work Piece

Legend

(+) Work

(-) Electrode

Pilot Arc

Coolant Return

Coolant Output

Start Gas Solenoid

Cut Gas Solenoid

High Freq. On-O

Interlocks

Injection Water

Start Gas

Cut Gas

Voltage Feedback

Workpiece

Voltage

Cut Gas

Water Injection

Coolant To

(-) Current To

Coolant From

(-) Current To

Pilot Arc High Freq.

Height

Reference

Process

O

E-Stop

Current Ref.

Interlocks

Process OK

Electrical Connections

Fluid Lines

Oxygen

Nitrogen

Input

Power

Shield

Gas*

*For use on the PT-19XLS and PT-600 only. For

dry cutting the cut water switch on the ow

control must be in the "OFF" position.

On-O

Secondary

Shield Gas

26

SECTION 2 INSTALLATION

POWER

SOURCE

TO WATER

COOLER

TO CUT WATER

PUMP

TO PARALLEL

POWER SOURCE

TO AIR

CURTAIN

115 VAC

AUXILIARY POWER

FOR TESTING

(DISCONNECT FOR

CUTTING OPERATION)

O

2

IN

FROM

REGULATOR

Figure 2-4. Flow Control Connections

N

2

IN

FROM

REGULATOR

START GAS

OUT TO

PLUMBING

BOX

CUT GAS

OUT TO

PLUMBING

BOX

CUT WATER

IN FROM CUT

WATER PUMP

CUT WATER

OUT TO PLUMBING

BOX

TO CUTTING

MACHINE CNC

TO PLUMBING

BOX

27

SECTION 2 INSTALLATION

CABLE

LENGTH

FLOW CONTROL -

PLUMBING BOX

(Cable, 18 AWG,

8 conductor)

FLOW CONTROL

- CNC

(Cable, 16 AWG

12 conductor)

FLOW CONTROL

- WATER COOLER

(Cable, 18 AWG

3 conductor)

POWER SOURCE -

PLUMBING BOX

(Cable, Pilot Arc)

AIR

CURTAIN

(Cable, 18 AWG

3 conductor)

25 FT. 33219 33224 33253 33303 33253

50 FT. 33220 33225 33254 33304 33254

75 FT. 33221 33226 33255 33305 33255

100 FT. 33222 33227 33256 33306 33256

125 FT. 33223 33228 33257 33307 33257

Flow Control Remote Location- Flow Control to Power Source cable: 30 Ft. - 34378

60 Ft. - 34377

TABLE 2-2. COOLING WATER HOSE ASSEMBLIES

CABLE LENGTH CUT WATER HOSE COOLING WATER START GAS HOSE CUT GAS HOSE

25 FT. 33127 21588 33122 33117

50 FT. 33128 21574 33123 33118

75 FT. 33129 1575 33124 33119

100 FT. 33130 21576 33125 33120

125 FT. 33131 21577 33126 33121

TABLE 2-1. HOSE ASSEMBLIES

CUT GAS HOSE Hose Assembly

25 FT. 33132

50 FT. 33133

75 FT. 33134

100 FT. 33135

125 FT. 33136

TABLE 2-3. INTERCONNECTION CABLES

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