ESAB ESP-100i Plasma Cutting Packages User manual

Brand: ESAB

Model: ESP-100i Plasma Cutting Packages

Category: Welding System

Type: User manual

This manual is also suitable for

ESP-50

F15-249-F 12 / 2007

INSTRUCTION MANUAL

P/N 33530 - 200 V, 208 V, 230 V, 380 V, 415 V, 460 V, 575 V, 3-Phase, 50/60 Hz

Starting with Serial No. PORI537026, October, 1995

ESP-100i

PLASMA CUTTING PACKAGES

This equipment will perform in conformity with the description thereof contained in this manual and

accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance

with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly

maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contami-

nated should be replaced immediately. Should such repair or replacement become necessary, the man-

ufacturer 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 manu-

facturer. 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.

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!

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TABLE OF CONTENTS

1.0 Safety Precautions

1.1 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.

SECTION 1 SAFETY PRECAUTIONS

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

connected 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 insu-

lated 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 specic grounding recom-

mendations. Do not mistake the work lead for

a ground cable.

ELECTRIC AND MAGNETIC FIELDS

— May be dangerous. Electric cur-

rent owing 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 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 galva-

nized steel, stainless steel, copper, zinc, lead,

beryllium, or cadmium unless positive mechani-

cal ventilation is provided. Do not breathe fumes

from these materials.

2. Do not operate near degreasing and spray-

ing operations. 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

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 be-

low) for specic ventilation recommendations.

SECTION 1 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 oper-

ating 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, 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 connected. 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 Stan-

dard P-1, "Precautions for Safe Handling of

Compressed Gases in Cylinders", which is avail-

able 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

installation, 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 fur-

naces, 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 Cut-

ting"

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 Car-

bon Arc Gouging and Cutting"

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 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.

SECTION 1 SAFETY PRECAUTIONS

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The ESP-100i is a multipurpose 100 amp plasma cutting system

for both manual and mechanized cutting. ESAB's proprietary

ESP (ESAB Smart Plasmarc) technology yields a machine that

is the perfect solution for production cutting, plasma gouging,

and mechanized applications such as cutting machines, robot-

ics, retrots, etc.

With PT-25 manual torch, production cuts 1-1/4 •

inch carbon steel and severs 1-1/2 inches (see PT-

20AM data sheet for mechanized cutting param-

eters)

Low-current-draws technology minimizes power •

consumption for low cost of operation

Compact size and standard casters facilitate •

movement around the shop so you can take the

console to the job

Continuously variable output from 10 to 100 •

amps gives the ability to tailor the cutting current

to the job

E• SAB Smart Plasmarc automation interface is

standard in all machines enabling it to be used

for both manual and mechanized cutting

Universal voltage input. The standard machine •

accepts all voltages from 200 to 575 volts at both

50 and 60 Hz line frequencies

Available in pre-engineered packages with all •

necessary components included

Digital ammeter for accurate current setting•

Dual gas plumbing to use with Dual Gas PT-25 •

manual torch

Plumbing box packages available where remote •

HF is desired for automation or retrot applica-

tions

Three-year warranty on console•

One-year warranty on torch•

Specications

Output 100 amps @ 100% duty cycle

Cut capacity: See PT-25 or PT-20AM data sheets

Input Voltage ..................... 200/230/380/415/460/575v 50/60hz 3ph

Input Current .........................................65/60/45/40/30/25 amps 3ph

Power Factor ....................................................................................96%

Output Current ........................................................10 to 100 amps DC

Rated Output Voltage ...........................................200vdc @ 100 amps

Duty Cycle ..................................................................................... 100%

Max OCV .....................................................................................325 vdc

Dimensions

................22 in. (550mm) w x 28 in. (700mm) h x 32 in. (800mm) d

Weight ..........................................................................380 lbs. (173kg)

Torch

Uses PT-25 or PT-20AM

How To Order

The ESP-100i comes with console, torch, torch parts kit,

required cylinder regulators and hoses for gas operation,

lter/regulator for air, work cable, and wheels. Mechanized

packages also include an interface connector. Plumbing box

packages also include plumbing box, interconnect cables,

plus a shielded PT-20AM. See optional accessories.

Ordering Information

ESP-100i Console Only .............................................................. 33530

ESP-100i/PT-25 Manual Packages

(See optional regulators for other gases)

ESP-100i, 25 ft. PT-25 90° Air/Air ............................................ 604625

ESP-100i, 50 ft. PT-25 90° Air/Air ............................................ 604626

ESP-100i, 25 ft. PT-25 90° N

.............................................. 604627

ESP-100i, 25 ft. PT-25 90° Ar-H

......................................... 604628

ESP-100i, 50 ft. PT-25 90° N

.............................................. 604629

ESP-100i, 50 ft. PT-25 90° Ar-H

......................................... 603630

SECTION 2 DESCRIPTION

System With Arc Starter

PT-20AM -

0558002632 (4')

0558002633 (17')

Remote

Arc Starter

0558002634 - 50'

0558002635 - 100'

PT-25 90° Plasmit Torch Head Protector

For gouging ........................................................................... 20801

Leather Sheath

For service line protection, 10-ft. length ............................. 20812

Dual Cylinder Rack for ESP-100i

Attaches to rear of ESP-100i and allows the carrying of

two full size cylinders ............................................................ 35833

Remote Hand Switch (Optional)

Permits remote starting and stopping of the cutting process

during dual gas operation ................................................ 2075600

for mechanized single gas .................................................. 680982

Optional Regulators and Hoses

Regulator for CO

Secondary Gas......................................... 19629

Regulator for O

Secondary Gas ......................................... 998336

Hose for CO

Secondary Gas .................................................40V77

Hose for O

Secondary Gas ................................................. 678125

Ordering Information (continued)

ESP-100i/PT-20AM Mechanized Packages

ESP-100i, 50 ft. shielded PT-20AM

With Rack and Torch Holder ................................................. 35836

ESP-100i w/arc starter, 50 ft. interconnect cables and

4 ft. shielded PT-20AM .......................................................... 35837

ESP-100i w/arc starter, 100 ft. interconnect cables and

4 ft. shielded PT-20AM .......................................................... 35838

ESP-100i w/arc starter, 50 ft. interconnect cables and

17 ft. shielded PT-20AM ........................................................ 35839

ESP-100i w/arc starter, 100 ft. interconnect cables and

17 ft. shielded PT-20AM ........................................................ 35840

Optional Accessories

Plasma Flow Measuring Kit

This valuable troubleshooting tool allows measurement of the

actual plasma gas ow through the torch .......................... 19765

Torch Guide Kit - PT-25

This complete kit, in a rugged plastic carrying case, includes

attachments for circle and straight line cutting on ferrous and

non-ferrous metals, 1 3/4" - 42" Radius ............................. 604624

Work Cable

30741 (7.6m)

SECTION 2 DESCRIPTION

INSPECTION

A. Remove the shipping container and all packing

material and inspect for evidence of concealed

damage which may not have been apparent upon

receipt of the ESP-100i. The ESP-100i is crate

shipped and fully assembled with the exception

of the xed caster wheels. Immediately notify the

carrier of any defects or damage.

B. Check container for any loose parts prior to dispos-

ing of shipping materials.

C. Check air louvers and any other opening to ensure

that any obstruction is removed.

Figure 2-1. ESP-100i Hoisting Set-Up

ESP-100i

PILOT

ARC

POWER

OFF

GAS

TEST

TRIGGER

LOCK

CONTROL

REMOTE

PANEL

LOCK

UNLOCK

TEST

OPERATE

CURRENT

HIGH

LOW

PLASMA

GAS FLOW

PLASMA GAS

PRESSURE

COOLING GAS

PRESSURE

P/S

TEMP

P/S

FAULT

OVER/UNDER

VOLTAGE

DANGER

ELECTRIC SHOCK at workpiece

or work cable can kill you.

Work cable MUST be connected

to workpiece to avoid shock.

TORCH

WORK

FIG. 2-7

9541A030.EPS

30"

MINIMUM

30"

MINIMUM

HOISTING

The ESP-100i is equipped with two lifting eyes that

enable the unit to be hoisted.

When lifting the ESP-100i be sure to use the proper

chain length and both lifting eyes. Failure to take

precautions when lifting will result in damage to

the internal components in the power source. The

chain length must be at least 60" to ensure that the

30" minimum is maintained from the chain hoist to

each lifting eye. See gure 2-1.

SECTION 2 DESCRIPTION

2.1 GENERAL

The ESP-100i is a self-contained plasma cutting system.

As shipped, the system is fully assembled and ready to

cut after being connected to input power and a source of

compressed air (90-150 psi). The ESP-100i package uses

the heavy duty PT-25 dual gas manual torch or PT-20AM

mechanized torch to deliver cutting power for materials

up to 1-1/4" inch thick. Refer to the following paragraphs

for descriptions of the ESP-100i packages available and

performance specications.

2.2 SCOPE

The purpose of this manual is to provide the operator

with all the information required to install and operate

the ESP-100i plasma arc cutting package. Technical refer-

ence material is also provided to assist in troubleshooting

the cutting package.

Use only torches designed for use with this unit.

Use of torches not designed for use with this con-

sole could create an electrical shock hazard.

Table 2-1. Available ESP-100i Cutting Packages

2.3 PACKAGES AVAILABLE

Table 1-1 lists ESP-100i packages available through your

ESAB dealer. Package contents are indented under each

complete system description.

Quantity Description

P/N

Electrode Air/N2

Swirl Baffles

Nozzle-100A

Nozzle-Gouging

Heat Shield

Gouging Guard

Stand-Off Guide

21595

21667

21597

21599

21654

21656

21943

ESP-100i Package with:

PT-25, 90° Hd.Dual Gas ManualAir/Air

PT-20AMMechanized

TorchAir/Air

25' Lines 50' Lines 50' Lines

ESP-100i Package, P/N 604625 604626 35836

includes:

Power Source, ESP-100i

PT-25 or -20AM Torch

Torch Spare Parts Kit (See contents below)

Air-Filter Regulator w/Mtg. Brkt.

Work Cable, 25 ft

Hose Assy, I.G., 6 ft (2)

Gas Hose Coupler "Y"

Air Hose Assy, 2.5 ft

33530

21648

21946

30338

30741

31503

050356

33530

21649

21946

30338

30741

31503

050356

33530

21371

21376

30338

30741

678152

PT-25/150 A Spare Parts Kits, P/N 21947

PT-25/100 A Spare Parts Kits, P/N 21946

Quantity Description

P/N

Electrode Air/N2

Swirl Baffles

Nozzle-150A

Nozzle-Gouging

Heat Shield

Gouging Guard

Stand-Off Guide

21780

21667

21598

21599

21654

21656

21943

Description

P/N Quantity

Standard

P/N

"CE" P/N

50 A

21370

70 A

21369

100 A

21376

Heat Shield (70/100 A) 21326 4485831 - 2 2

Heat Shield (50 A) 21447 4485832 2 1 1

Cutting Nozzle (50 A) 21330 4485833 5 5 5

Cutting Nozzle (70 A) 21329 4485834 - 5 5

Cutting Nozzle (100 A) 21328 4485835 - - 5

Electrode 21150 0558004249 5 5 5

Electrode Seat 21372 4485839 1 1 1

Electrode Insulator 21373 21373 1 1 1

Electrode Holder Assy 21332 4485840 1 1 1

Bae Tube 21374 4485838 1 1 1

Pilot Arc Adaptor 19497 4485843 1 1 1

O-Ring 488157 4485841 5 5 5

Lubricant (1 oz.) 17672 0558000443 1 1 1

Seat/Bae Wrench 21375 4485842 1 1 1

1/16: Hex-Key Wrench (1,6 mm) 93750006 4485651 1 1 1

Box tool 950272 950272 1 1 1

PT-20 AM Spare Parts Kits

SECTION 2 DESCRIPTION

2.4 SPECIFICATIONS

Refer to tables 2-2 thru 2-6, and gures 2-1 and 2-2 for

ESP-100i and torch technical specications.

Table 2-2. ESP-100i Power Source Specications

Figure 2-1. Cutting Torch Specications

PT-20AM

PT-25

12.15"

1.60" Dia.

1.38" Dia.

4.48"

1.47" Dia.

1.22" Dia.

9406A001.eps

Figure 2-1

17 1/2" With Rack

1 3/8" Dia.

5/8" Mounting Stud

7 5/8" min. - 14 1/2" max.

6404A015.EPS

Figure 2-1

* PT-25 can also be used with the following plasma/cooling gas combinations: N2/Air, H-35/N2, and 40H2 - 60N2/

Air. See Instruction Manual F-15-266 for details.

Rated Output 100% Duty Cycle 100 A @ 120 V dc

Output Current Range 10 to 100 Amperes

Open Circuit Voltage 325 V dc

Rated Primary Input, 3 phase, 50/60 Hz@ 12

kW Max. Output Power (100 A @120 V dc)

200 V

208 V

230 V

380 V

415 V

460 V

575 V

49 A / Phase

47 A / Phase

40 A / Phase

25 A / Phase

23 A / Phase

20 A / Phase

16 A / Phase

Power Factor @ 12kW Output 0.96

Eciency @ 12kW Output 93% typical

Dimensions

Length

Height

Width

33.0" (838 mm)

27.3" (693 mm)

21.5" (546 mm)

Weight 408 lbs. (185 kg)

Shipping Weight 420 lbs. (191 kg)

PT-20AM PT-25

Plasma/Cooling Gas

Shipping Weight

Length of Service Lines

Instruction Booklet

Air @ 85 psi (380 cfh)

20 lbs

50-ft

Form 15-114

Air @ 70 psi (560 cfh) *

14 lbs (25 ft)

25 lbs (50 ft)

25 or 50 ft

Form 15-266

Table 2-3. PT-25 Manual Torch andPT-20AM Mechanized Torch Specications

SECTION 2 DESCRIPTION

Cutting Parameters for the PT-20AM Torch on Carbon Steel

Figure 2-2. PT-25 Cutting Data

PT-25 150 amp, H-35 / N

150 amp Cutting Data

H-35 Plasma at 70 psig

Nitrogen Cooling at 70 psig

Aluminum

Stainless

2.001.751.501.00 1.250.750.25 0.500.00

Material Thickness (in.)

Cutting Speed (ipm)

9406A003.eps

Figure 2-2

2.001.751.501.00 1.250.750.25 0.500.00

100

125

150

175

Cutting Speed (ipm)

Material Thickness (in.)

PT-25 100 amp, Air / Air

100 amp Cutting Data

Air Plasma at 70 psig

Air Cooling at 70 psig

Carbon Steel

Stainless

Aluminum

9406A002.eps

Figure 2-2

Table 2-4. 100 Amp Data, Nozzle P/N 21328, Heat Shield P/N 21326

Metal

Thickness

(in.)

Air

Pressure

(psig)

Stand-off

(in.)

Arc Volts

Travel

Speed

(ipm)

Kerf

Width

Pierce

Time

(sec.)

1/4 85 1/4 110 100 1/8 0.1

1/2 85 1/4 120 45 1/8 0.3

3/4 85 1/4 125 27 1/8 1

1 85 1/4 130 15 1/8 2.75

1-1/4 85 5/16 140 10 5/32 *N.R.

1-1/2 85 5/16 145 7 3/16 *N.R.

Table 2-5. 70 Amp Data, Nozzle P/N 21329, Heat Shield P/N 21326

Metal

Thickness

(in.)

Air

Pressure

(psig)

Stand-off

(in.)

Arc Volts

Travel

Speed

(ipm)

Kerf

Width

Pierce

Time

(sec.)

1/8 75 3/16 95 190 3/32 0.1

1/4 75 3/16 100 80 3/32 0.2

1/2 85 1/4 115 30 3/32 0.6

3/4 85 1/4 130 15 1/8 2.25

1 85 5/16 140 7 5/32 *N.R.

1-1/4 85 5/16 155 5 5/32 *N.R.

Table 2-6. 40 & 50 Amp Data, Nozzle P/N 21330, Heat Shield P/N 21447

Metal

Thickness

(in.)

Arc

Current

(Amps)

Air

Pressure

(psig)

Stand-off

(in.)

Arc Volts

Travel

Speed

(ipm)

Kerf

Width

Pierce

Time

(sec.)

1/16 40 75 1/8 110 150 3/64 0.25

1/8 40 75 1/8 110 100 3/64 0.25

3/16 50 85 1/8 110 100 1/16 0.25

1/4 50 85 3/16 120 65 5/64 0.25

3/8 50 85 1/4 130 40 5/64 0.25

1/2 50 85 5/16 150 18 3/32 1.0

SECTION 2 DESCRIPTION

3.1 GENERAL

Proper installation can contribute materially to the

satisfactory and trouble-free operation of the ESP-100i

cutting package. It is suggested that each step in this

section be studied carefully and followed as closely as

possible.

3.2 EQUIPMENT REQUIRED

A source of clean, dry air that supplies 560 cfh at 85

psig is required for the cutting operation. The air sup-

ply should not exceed 150 psig (the maximum inlet

pressure rating of the air lter-regulator supplied with

the package).

3.3 LOCATION

Adequate ventilation is necessary to provide proper

cooling of the ESP-100i. Minimize the amount of dirt,

dust, and excessive heat to which the equipment is

exposed. There should be at least 2 feet of clearance

between the ESP-100i power source and wall or any

other obstruction to allow freedom of air movement

through the power source.

Installing or placing any type of ltering device will

restrict the volume of intake air, thereby subjecting the

power source internal components to overheating. Use

of any type of lter device voids the warranty.

3.4 PRIMARY ELECTRICAL INPUT

CONNECTIONS. Figure 31.

ELECTRIC SHOCK CAN KILL! Precautionary measures

should be taken to provide maximum protection against

electrical shock. Be sure that all power is o 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.

Be sure that the power source is properly congured

for your input power supply. DO NOT connect a power

source congured for 230 V to a 460 V input power sup-

ply. Damage to the machine may occur.

As shipped, the ESP-100i is congured for 575 V, 60 Hz

input. If using 200, 230, 380, 415, or 460 V input, the

jumper input power cables located on the auto trans-

former must be repositioned to the desired input voltage

for safe operation. To gain access to the autotransformer,

remove the right side panel. (See gure 3-1.)

A line (wall) disconnect switch with fuses or circuit break-

ers should be provided at the main power panel (see

gure 3-2 and table 3-1 for fuse rating). The input power

cable of the console may be connected directly to the

disconnect switch or a proper plug and receptacle may

be purchased from a local electrical supplier. If using

plug/receptacle combination, see table 3-1 for recom-

mended input conductors for connecting receptacle to

line disconnect switch.

The following procedure explains the proper installation

steps for connecting primary electrical power to the ESP-

100i. (See gure 3-1.)

A. Remove right side panel.

B. Ensure input power cable is deenergized from all

electrical sources.

C. Route input power cable through the strain relief

located at the rear panel.

D. Pull input power cable through the strain relief to

allow cable wires sucient length to connect to the

main contactor. Tighten strain relief to ensure input

power cable is secured.

E. Connect input power cable ground wire to the ground

lug provided on the base of the ESP-100i.

SECTION 3 INSTALLATION

Table 3-1. Recommended Sizes For

Input Conductors and Line Fuses

Input Requirements Input & Gnd

Conductor

CU/AWG

Fuse Ratings

/Phase, Amps

Volts Phase Amps

200/208 3 49 No. 8 70

230 3 40 No. 8 60

380 3 25 No. 12 40

415 3 23 No. 12 40

460 3 20 No. 14 30

575 3 16 No. 14 25

*Sizes per National Electric Code for 75 °C rated conductors @

30 °C ambient. Not more than three conductors in raceway or

cable. Follow local codes if they specify sizes other than those

listed above.

H. Connect jumper wire to the proper input voltage

connector located on the 7-position terminal block.

(See gure 3-1.)

3.5 SECONDARY OUTPUT CONNEC

TIONS FOR MANUAL AND

MECHANIZED CUTTING

Before making any connections to the power source

output terminals, make sure that all primary input

power to the machine is deenergized (o) at the main

disconnect switch.

FIG. 2-1A

9541A020.eps - 9/19/95

460

575

200

230

380

415

460

575

380

415

200

230

460

380

230

PHASE B

415

575

200

415

460

230

380

200

PHASE A PHASE C

Main

Contactor

Customer Supplied Input

Power Cable

7-POSITION

TERMINAL BLOCK

Move jumper to

proper input

voltage.

Input Power

Connections

AUTO TRANSFORMER

Move the 3 jumpers

to proper input voltage.

Earth

Ground

Connection

Figure 3-1. ESP-100i Primary Power Connection Diagram

NOTE: Jumpers are shown in the 575V positions.

Jumper

Power

Cables

Electric shock can kill! Failure to connect a good electri-

cal ground to the base of the ESP-100i could result in

electric shock.

F. Connect three power leads of the input power cable

to the terminals located atop the main contactor.

Secure the leads by tightening each screw.

G. Connect jumper power cables from the bottom

of the main contactor to the proper input voltage

marked on the auto transformer. The unit is factory

set for 575 V.

Ensure three input power jumper cables are con-

nected properly to the auto transformer for your input

power.

SECTION 3 INSTALLATION

Figure 3-2. ESP-100i/PT-25 Interconnection Diagram

Figure 3-2. ESP-100i/PT-25 Interconnection Diagram -- Option 1

(For Use When Cutting Only; Not for Gouging)

ESP-100i

PILOT

ARC

POWER

OFF

GAS

TEST

TRIGGER

LOCK

CONTROL

OTE

NEL

LOCK

UNLOCK

TEST

OPER

ATE

CURRENT

HIG

PLASM

S FLO

PLA

GAS

RESSUR

COOLIN

G G

PRESS

URE

P/S

TEM

P/S

FAU

OVER/U

NDER

VOLTAG

DAN

GER

ELECTRIC SHOCK at workpiece

or work cable can kill you.

ork cable MUST be connected

to workpiece to avoid shock.

TORCH

WORK

Switch Lead

Work Cable

No Adaptor required,

remove Adaptor (21803)

supplied with console.

PT-25 Torch

Plasma Gas /

Power Cable

Safety Sensor

Tube

Cooling Gas /

Pilot Arc Cable

Air/C

XYG

2 Ar-H

COOLING GAS

PLASMA GAS

REMOTE

CONTROL

Wall Disconnect

Shop Air

100 psi min.

150 psi max.

560 CFH

Filter-Regulator

30338

set pressure to

65-75 psig

"Y" Connector

Plasma Gas

Cooling Gas

6406A010.EPS

Figure 3-3 / sht. 1

SECTION 3 INSTALLATION

Figure 3-2. ESP-100i/PT-25 Interconnection Diagram -- Option 3

(For Use When Cutting or Gouging)

Figure 3-2. ESP-100i/PT-25 Interconnection Diagram -- Option 2

(For Use When Cutting or Gouging)

Air/C

XYG

2 A

r-H

COOLING GAS

PLASMA GAS

REMOTE

CONTROL

Wall Disconnect

Set pressure at

65-75 psig

DO NOT use Oxygen at all.1.

DO NOT use Argon or Ar-H

mix for Cooling Gas.

Cooling Gas

Air

Plasma Gas

H-35

-H

or Air

200 CFH

360 CFH

NOTE;

This option will require a few

cylinders manifolded or a bulk system

to maintain flow requirements of torch.

ir/CO

XYG

2 A

r-H

COOLING GAS

PLASMA GAS

REMOTE

CONTROL

Wall Disconnect

Shop Air

100 psi min.

150 psi max.

360 CFH

Filter-Regulator

30338

R-76 Regulators

Set pressure at

65-75 psig for cutting.

40-45 psig for gouging.

Plasma Gas

H-35 or

-H

Cooling Gas

200 CFH

Set pressure at

65-75 psig for cutting.

40-45 psig for gouging.

6406A011.EPS

Figure 3-3 / sht. 2

SECTION 3 INSTALLATION

F. Make sure workpiece is connected to an approved

earth ground. Use copper ground cable equal to or

larger than the power source chassis ground listed

in Table 3-1.

3.5.2 Using PT-20AM Torch. (Refer to

gure 3-3.)

A. With the right side panel removed, connect the

terminal lug end of the work cable assembly to the

WORK terminal in lower right corner behind front

panel. Nut should be wrench-tight.

B. Connect pilot arc adaptor P/N 21803 (supplied with

console) to the PILOT ARC connection and tighten

rmly with a wrench. Loosely place screw, washer,

and lockwasher in the most convenient tapped hole

in the adaptor.

C. Thread the two torch service lines through the bush-

ing in the lower right corner of the front panel and

proceed as follows: (1) Connect the power cable

(large male nut with left hand threads) to the TORCH

tting and tighten rmly with a wrench; (2) Connect

pilot arc cable to the adaptor assembled on PILOT

ARC tting at the most convenient tapped hole

position of adaptor. With washer and lockwasher

in place, tighten screw rmly with a screwdriver.

D. Reinstall right side panel.

E. Assemble the lter-regulator and mounting bracket

(30338) to the upper left corner on the rear panel

(view from rear) as illustrated. Mounting holes are

provided. Hardware is supplied with the mounting

bracket.

F. Connect the air hose assembly (678152) to lter-

regulator outlet tting and to the Air/N2 plasma gas

tting on the rear panel of the ESP-100i unit. Note

that the air hose has left-hand threaded nut on one

end (regulator) and right-hand on the other.

G. Connect your air supply to the inlet connection

(1/4-in. NPT female - customer to supply suitable

end tting) of the lter-regulator.

H. Electrically connect work cable to workpiece. The

connection must be made to a clean, exposed metal

surface free of paint, rust, mill scale, etc. (See gure

3-4).

3.5.1 Using PT-25 Torch. (Refer to gure

3-2.)

A. With the right side panel removed, connect the

terminal lug end of the work cable assembly to

the WORK terminal in lower right corner behind

front panel. Nut should be wrench-tight.

B. Thread the four torch service lines through the

bushing in the lower right corner of the front panel

and proceed as follows: (1) Connect the plasma

gas/power cable (large male nut with left hand

threads) to the TORCH tting and tighten rmly

with a wrench; (2) Remove pilot arc adapter (21803)

shipped with console and connect cooling gas/

pilot arc cable to the right-hand threaded PILOT

ARC tting and tighten rmly with a wrench; (3)

Connect the 5-pin switch lead to the mating re-

ceptacle. Make sure plug is rmly locked in place.

(4) Insert safety sensor tube into tube tting until

fully seated.

C. Reinstall right side panel.

D. Referring to the interconnection diagram (gure

3-2), connect the desired gas to the plasma and

shield gas connections on the rear panel of the

console. Note the various options shown in the

diagram. Use only gases recommended as noted

on the diagram.

Do NOT use argon or argon mixtures as cooling gas in

the PT-25 torch. Internal arcing in the torch head may

occur.

Do NOT use oxygen as cooling or plasma gas. The

torch may catch re.

E. Electrically connect work cable to workpiece. The

connection must be made to a clean, exposed metal

surface free of paint, rust, mill scale, etc. (See gure

3-4).

A poor connection or failure to connect work cable to

workpiece can result in fatal shock.

SECTION 3 INSTALLATION

Figure 3-3. ESP-100i Interconnection Diagram

A poor connection or failure to connect work cable to

workpiece can result in fatal shock.

I. Make sure workpiece is connected to an approved

earth ground. Use copper ground cable equal to

or larger than the power source chassis ground

listed in table 3-1.

ESP-100i

PILOT

ARC

POWER

OFF

GAS

TEST

TRIGGER

LOCK

CONTROL

REMOTE

PANEL

LOCK

UNLOCK

TEST

OPERATE

CURRENT

HIGH

PLASMA

GAS FLO

PLASM

A GAS

PRESSUR

OLING GA

PRESSUR

P/S

TEM

P/S

FAULT

VER/UNDER

VOLTAGE

DANG

ELECTRIC SHOCK at workpiece

or work cable can kill you.

Work cable M

UST be connected

to workpiece to avoid shock.

TORCH

WORK

Air/C

XYG

2 Ar-H

COOLING GAS

PLASMA GAS

REMOTE

CONTROL

Wall Disconnect

Shop Air

150 psi max.

100 psi min.

Interface Cable (PT-20AM only)

Filter-Regulator

30338

Hose

678152

Work Cable

Pilot Arc Adaptor

21803

PT-20AM

SECTION 3 INSTALLATION

Figure 3-4. Ground and Work Cable Connections

DO NOT ATTACH WORK

CABLE TO PIECE BEING CUT

FREE

WORK CABLE

EARTH GROUND

WORK CABLE

BE SURE WORK IS IN GOOD

CONTACT WITH TABLE.

GROUNDED

WORK TABLE

INSULATING GLOVE

SECTION 3 INSTALLATION

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ESAB ESP-100i Plasma Cutting Packages User manual

Brand: ESAB

Model: ESP-100i Plasma Cutting Packages

Category: Welding System

Type: User manual

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ESAB ESP-100i Plasma Cutting Packages User manual

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