ESAB ESP-101 User manual

Brand: ESAB

Model: ESP-101

Type: User manual

ESAB ESP-101 is a reliable and efficient plasma power source designed for precise cutting and gouging applications. Its impressive cutting range from 20 to 100 amps allows for versatile use on various metal thicknesses. The power source ensures a stable arc, leading to high-quality cuts and reduced operator fatigue. Additionally, its user-friendly interface and comprehensive protection features make it suitable for both professional and hobbyist users.

Valid for serial no. 015-xxx-xxxx0558 007 871 01 GB 20110809

ESP-101

Instruction manual

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TOCe

Rights reserved to alter specifications without notice.

1 SAFETY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 INTRODUCTION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Equipment 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 TECHNICAL DATA 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 INSTALLATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Necessary equipment 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Location 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Lifting instructions 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Delivery check 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 Mains supply 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5.1 Recommended fuse sizes and minimum cable area 9. . . . . . . . . . . . . . . . . . . . . . .

4.5.2 Mains cable configuration. 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 Connecting air supply 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7 Connecting secondary outputs for automated cutting 11. . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8 Connection of torch 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9 Installation of free-standing distribution box 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.1 Modification of power source 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.2 Installation of free-standing distribution box 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.3 Connection to the power source 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 OPERATION 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Connections and control devices 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.1 Symbol key 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.2 Pressure regulator (1) (accessory) 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.3 Function selector switch MODE (11) 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.4 Process switch (PROCESS) (12) 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.5 Overheating protection (9) 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.6 Fault indication (8) 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.7 Display window (6, 10) 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Cutting 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 MAINTENANCE 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Inspection and cleaning 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 FAULT TRACING 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 Fault codes 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 ORDERING SPARE PARTS 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIAGRAM 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ORDER NUMBER 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1 SAFETY

Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on or

near the equipment observes all the relevant safety precautions. Safety precautions must meet the

requirements that apply to this type of equipment. The following recommendations should be ob

served in addition to the standard regulations that apply to the workplace.

All work must be carried out by trained personnel well-acquainted with the operation of the equip

ment. Incorrect operation of the equipment may lead to hazardous situations which can result in in

jury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:

S its operation

S location of emergency stops

S its function

S relevant safety precautions

S welding and cutting

2. The operator must ensure that:

S no unauthorised person is stationed within the working area of the equipment when it is

started up.

S no-one is unprotected when the arc is struck

3. The workplace must:

S be suitable for the purpose

S be free from drafts

4. Personal safety equipment

S Always wear recommended personal safety equipment, such as safety glasses, flame-proof

clothing, safety gloves.

S Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautions

S Make sure the return cable is connected securely.

S Work on high voltage equipment may only be carried out by a qualified electrician.

S Appropriate fire extinquishing equipment must be clearly marked and close at hand.

S Lubrication and maintenance must not be carried out on the equipment during operation.

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WARNING

Read and understand the instruction manual before installing or operating.

Arc welding and cutting can be injurious to yourself and others. Take precausions when welding and

cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard

data.

ELECTRIC SHOCK - Can kill

S Install and earth the unit in accordance with applicable standards.

S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

S Insulate yourself from earth and the workpiece.

S Ensure your working stance is safe.

FUMES AND GASES - Can be dangerous to health

S Keep your head out of the fumes.

S Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone

and the general area.

ARC RAYS - Can injure eyes and burn skin.

S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.

S Protect bystanders with suitable screens or curtains.

FIRE HAZARD

S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE - Excessive noise can damage hearing

S Protect your ears. Use earmuffs or other hearing protection.

S Warn bystanders of the risk.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

WARNING

Do not use the power source for thawing frozen pipes.

WARNING

Plasma torch PT-37 must be used with plasma power source for automatic cutting.

Use of a torch that is not intended for this type of power source causes a risk of

electric shock.

CAUTION

Class A equipment is not intended for use in residential locations where

the electrical power is provided by the public low-voltage supply system.

There may be potential difficulties in ensuring electromagnetic

compatibility of class A equipment in those locations, due to conducted

as well as radiated disturbances.

CAUTION

This product is solely intended for plasma cutting.

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CAUTION

Read and understand the instruction manual before

installing or operating.

Dispose of electronic equipment at the recycling facility!

In observance of European Directive 2002/96/EC on Waste Electrical and Electronic

Equipment and its implementation in accordance with national law, electrical and/or

electronic equipment that has reached the end of its life must be disposed of at a

recycling facility.

As the person responsible for the equipment, it is your responsibility to obtain

information on approved collection stations.

For further information contact the nearest ESAB dealer.

2 INTRODUCTION

Plasma power source ESP 101 and plasma torch PT-37 are a complete and safe

plasma system for cutting and gouging.

2.1 Equipment

The power source is supplied with:

S Instruction manual

S 4.6 m mains power cable

3 TECHNICAL DATA

ESP101

Mains voltage

3 ~ 380 V, 400 V +/–10 %, 50 Hz

Mains supply Ssc min. 4 MVA

Zmax. 0.039 Ω

Primary current lmax 30 A at 380 V, 29 A at 400 V

Setting range 20 A / 88 V - 100 A / 160 V

Permitted load

Intermittence factor 100 % 100 A/160 V

Efficiency at maximum current 89 %

Power factor at maximum current 92 %

Open-circuit voltage U

266 V at 380 V

280 V at 400 V

Operating temperature

–10 to 40 °C

Transportation temperature -20 to 55 °C

Dimensions, l x w x h 667 x 394 x 493 mm

Weight 57 kg

Enclosure class IP21

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Mains supply, S

min

Minimum short circuit power on the network in accordance with IEC 61000-3-12

Mains supply, Z

max

Maximum permissible line impedance of the network in accordance with IEC 61000-3-11.

Duty cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or cut at

a certain load without overloading. The duty cycle is valid for 40° C.

Enclosure class

The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid

objects or water. Apparatus marked IP21 are intended for indoor use.

4 INSTALLATION

The installation must be carried out by a professional.

WARNING

ELECTRIC SHOCKS CAN KILL Take precautionary measures against electric

shocks. Ensure that all power supplies are disconnected – switch off the switch at

the wall socket and pull out the equipment's power cable from the socket before

making any electrical connections in the power source.

WARNING

Air filter devices may not be used – installation or mounting of any form of air filter

device prevents the cold air flow and causes a risk of overheating. The warranty is

invalidated if any type of air filter is used.

WARNING

Ensure that all power supplies to the power source primary side (input side) are

disconnected and disconnect the equipment's power cable from the socket before

making any electrical connections in the power source.

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WARNING

Check that the mains power switch is off and that the connection from the

supplying network has no power.

CAUTION

This product is intended for industrial use. In a domestic environment this product may

cause radio interference. It is the user's responsibility to take adequate precautions.

4.1 Necessary equipment

A compressor that produces clean, dry and oil free compressed air and can supply

at least 236 l/min at 620 KPa (90 psi) is required for cutting. The cutting air pressure

must not exceed 1030 KPa (150 psi), which is the maximum inlet pressure for the

filter regulator that is included in the delivery.

4.2 Location

WARNING

Secure the equipment - particularly if the

ground is uneven or sloping.

WARNING

It is very important that the chassis is connected to the approved electric protective

earth, to prevent electric shocks and electrical accidents. Ensure that protective

earth is not connected to any phase conductors by mistake.

WARNING

ELECTRIC SHOCKS CAN KILL Always switch off and lock the machine according to

the instructions before making the electrical connections. If conductors are

equipped with mains circuit breakers, the breaker must be set to off and locked with

a padlock to prevent switching on unintentionally. If the included conductors come

from a fuse box, the affected fuses must be removed and the fuse box cover locked

with a padlock. If it is not possible to use a padlock, the mains circuit breaker or

fuse box must have a red notice displayed indicating that the circuit is being

worked on.

CAUTION

Position the power source at least 3 m from the cutting location. Sparks and hot slag from

the cutting can damage the power source

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4.3 Lifting instructions

The power source can be lifted using a crane or a fork lift truck. If a fork lift truck is

used, check first that that forks extend all the way under the base of the power

source. If lifting using lifting straps, two separate straps must be used as illustrated.

WARNING

The product must be lifted as follows:

Good ventilation is required for the power source to get the necessary cooling. The

area around the equipment must be as free of dust and other impurities as possible

and also be as cool as possible. There must be at least 30 cm free space between

the power source and the adjacent walls and other obstacles, in order to ensure free

cooling air flow through the power source.

4.4 Delivery check

1. Remove the packaging and inspect the equipment for damage that was not

immediately apparent upon reception of the delivery.

Immediately report any damage to the delivery company.

2. Check that here are no loose parts in the packaging before is is recycled.

3. Check the cooling air gaps and ensure that any obstructions are removed from

there.

4.5 Mains supply

The power supply is supplied with an approximately 4.6 m long 4-core cable for

connection to 3 phase mains power.

4.5.1 Recommended fuse sizes and minimum cable area

ESP 101 50 Hz

Mains voltage 380 V 400 V

Mains cable area mm

4 G 6 4 G 6

Phase current I

1eff

30 A 29 A

Fuse, anti-surge 40 A 40 A

NOTE! The mains cable areas and fuse sizes as shown above are in accordance with Swedish

regulations. Use the power source in accordance with the relevant national regulations.

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WARNING

Check that the power source is switched off before removing the fuse.

4.5.2 Mains cable configuration.

4.6 Connecting air supply

Connect the incoming compressed air line to the air intake on the filterregulator.

Prefiltered DRY AIR (accessory) 620–1030 KPa

(90 - 150 psi)

PT−37

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4.7 Connecting secondary outputs for automated cutting

CNC operating cable

(connects on the

reverse)

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4.8 Connection of torch

1. Open the terminal hatch on the side of the power

source.

2. Insert the torch cable through the opening in front of

the power source

3. Connect the plug for the torch cable in the socket in

the panel (3b). Check that the connectors are correctly

oriented before connecting them.

4. Connect the air hose to the quick release connector.

5. Insert the plug for the return cable into the return cable

socket.

6. Close the terminal hatch.

4.9 Installation of free-standing distribution box

The free-standing distribution box (accessory) makes it possible to connect an

extension cable to torch PT-37. The free-standing distribution box is used together

with a 15, 23 or 30 m long extension cable and PT-37 with any standard cable length

between 1.4 and 15 m. A torch cable length of up to 45 m can be achieved in this

way.

Installation of a free-standing distribution box requires several minor modifications of

the power source ESP-101, installation of the distribution box itself and connection to

the extension cable. Install according to the block diagram and instructions below.

3 phases and protective earth

ESP-101

Free-standing

distribution box

Extension

cable

Torch PT-37

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Modifications of the power source affect both the electrical and air system. The

electrical modification, switching of plugs, reroutes the operation signal from the

solenoid in the power source to the pin in the panel socket for the torch cable. The

operation signal is then routed on to the solenoid in the free-standing distribution

box.

The air system modification, bypassing the air solenoid, leads the air supply to the

solenoid in the free-standing distribution box. This ensures that air with sufficient

pressure is available without delay at the torch.

4.9.1 Modification of power source

Remove the top and side panels of the power source.

1. Reconnecting the solenoid operating cables

a. Localise, disconnect and swap the trigger and solenoid contacts as

illustrated.

Trigger contact (upper)

To trigger

control

from panel

socket

From solen

oid control

To solenoid

Solenoid contact (lower)

2. Bypass of integrated air solenoid

a. Localise and remove the hose connector supplied.

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b. Disconnect both air hoses from the solenoid inlet and outlet, by pressing the

hose ring in and pulling the hose.

c. Route the inlet hose to the outlet side.

d. Connect the inlet hose directly to the outlet hose using the hose connector

provided.

e. NOTE! The air hoses must be properly secured and no closer than 25 mm to

the pilot arc resistor.

f. Secure the hoses properly so that they cannot come into contact with the

pilot arc resistor.

g. Reinstall the top and right hand side panels of the power source.

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4.9.2 Installation of free-standing distribution box

1. Remove the cover and secure the box's bottom plate on a stable surface on the

cutting machine or cutting robot or other suitable location. At least two of the

mounting holes must be used. Orientate the box so that the extension cable is

inserted in the end that is not marked for connecting the torch.

Lead-ins for torch and

extension cable

2. Insert the extension cable through the lead-in in the end of the box and make the

power supply and gas connections as illustrated.

3. Insert the PT-37 torch cable through the lead-in in the end of the box and make

the power supply and gas connections as illustrated.

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1 To torch PT-37 2 Torch cable air connection 3 NOTE! The extension cable

from ESP-101 must be

connected to the end of the

distribution box where the

solenoid wiring is located

(the torch connection end is

marked).

4 The extension cable's

electrical connection

5 The torch cable's electrical

connection

6 The extension cable's air

connection

7 Extension cable from

ESP-101

4. Reinstall all covers and other components.

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4.9.3 Connection to the power source

The extension cable is connected to the power source in the same as the torch

cable.

1. Open the terminal hatch on the left hand side of the power source.

2. Insert the extension cable and the air hose through the cable lead-in on the front

of the unit.

3. Connect the plug for the extension lead (from the free-standing distribution box)

to the socket. Check that the plugs are correctly oriented before connecting

them.

4. Connect the air hose from the free-standing distribution box to the quick release.

5. Close the terminal hatch.

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5 OPERATION

General safety regulations for handling the equipment can be found on

page 4. Read through before you start using the equipment!

WARNING

ELECTRIC SHOCKS CAN KILL

S Do NOT operate the equipment with the cover removed.

S Do NOT connect the equipment to power when you are holding it or carrying it.

S Do NOT touch any components in front of the torch handle (torch tip, heat shield

electrode etc.) if the main switch is not switched off.

WARNING

Ensure that the mains power switch to the power supply is off before performing

any work on the torch.

WARNING

The operating circuits in the power source are restricted by the torch head on

PT-37, so that the torch will not be exposed to high voltage if the trigger is

accidentally pressed when the heat shield is removed. If the torch must be replaced,

only use the right type of exchange torch manufactured by ESAB, otherwise this

safety function will be lost.

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5.1 Connections and control devices

1 Pressure regulator (accessory) 8 Red indicating lamp, fault

2 Connection for remote control unit 9 Orange indicating lamp, overheating

3 Connection for mains cable 10 Voltmeter

4 Connection for return cable 11 Switch (MODE)

5 Connection for plasma torch 12 Switch (PROCESS)

6 Ampere meter 13 Controls for current settings

7 Mains voltage switch I / 0 14 Fuse 2A, 600V, delayed action

5.1.1 Symbol key

Return cable (4)

Plasma torch

connection (5)

Mains voltage on or off

(7)

Over heating (9)

Fault indication (8) Gas testing (11)

Plasma gouging (12) Air pressure (1)

5.1.2 Pressure regulator (1) (accessory)

The pressure regulator controls the cutting gas pressure. Turn the clockwise to

increase the gas pressure and anticlockwise to reduce the gas pressure. The

pressure reading is shown in the lower display. The pressure unit is show in the

upper display.

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CAUTION

With or without free-standing distribution box: When torches with cable lengths of 1.4 or

5.2 m are used, the plasma gas pressure must be reduced to 35

–69 KPa (5-10 psi) to

maintain the best performance.

NOTE! The unit is supplied from the factory with the regulator set to give 550 KPa (80 psi)

to the torch when the incoming feed pressure is 650 KPa (95 psi). If the incoming supply

pressure to the unit exceeds 6.5 bar (0.65 MPa) (highest recommended pressure is 1030

KPa (150 psi), turn the setting control anticlockwise to reduce the pressure to the torch to

550 KPa (80 psi). Follow the gas testing instructions see D.2.

5.1.3 Function selector switch MODE (11)

1. Check wear components (CONSUMABLE CHECK) – When the switch is in this

position the wear components are checked for correct installation and function

by a series of gas pulses being blown through the torch.

The indication PIP (Parts In Place) in the upper display shows if the installation

and function are correct.

If a fault is detected, the error message Err (Error) is shown in the upper display.

The lower display shows the code for the relevant error. See section 7.1 Fault

codes.

NOTE! Check that the switch is in OPERATE mode before cutting is started.

2. Gas testing (GAS TEST) – The air flow pressure is shown in the display. The

pressure reading is shown in the lower display. The pressure unit is shown in the

upper display.

The air regulator must be set at the recommended pressure before cutting is

started. Allow the air to flow a few minutes to blow out any condensation from

the system.

NOTE! Check that the switch is in OPERATE mode before cutting is started.

3. Operation (OPERATE) – Set the switch in this position when cutting and gouging

is to occur.

5.1.4 Process switch (PROCESS) (12)

With the process selector the output characteristic is selected in the power source,

based on which type of cutting occurs.

1. Gouging mode (GOUGE). In this mode the power source's characteristics for

gouging are optimised. Gouging requires higher arc voltage. In this mode the

power source allows higher arc voltage and limits outgoing current to 85 A.

2. Normal mode (NORMAL). This setting is used for all normal plate cutting. The

pilot arc does not relight automatically – new start signal is required.

5.1.5 Overheating protection (9)

Warning lamp, overheating. This orange warning lamp lights when one of the

thermoswitches is switched off because of overheating in the equipment. When this

occurs the power source switches off automatically to avoid any damage, and the

operator can no longer affect it.

Leave the network mains switch switched on, so that the cooling fan can cool the

power source. When the temperature falls to a safe level the thermoswitch closes

automatically again and the operator can control the equipment again.

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ESAB ESP-101 User manual

ESAB ESP-101 User manual

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