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DATE: March 7, 2003 BULLETIN NO:P_03_006
TITLE/ PRODUCT NAME:
ESP Flow Control Cut Water Switch Sticking
RATING:
_
_ DIRECTIVE _X_ ALERT
(Action is Required) (Potential Problem)
_
X_ INFORMATION _ _ PRODUCT IMPROVEMENT
(Action is Optional) (Enhanced Product)
_
X_ General Distribution _ _ Business Confidential
(Unrestricted) (Restricted Distribution)
PRODUCT SERIES/ MODEL:
ESP 1000 Plasma Cutting System - ESP Flow Control models:
PCC-90 (P/N 21294) original PLC and software
PCC90D (P/N 0558003629) New PLC
SERIAL NO:
All units built prior to February, 2003
SUMMARY:
In the summer of 2002 the original ESP Flow control (PCC-90) was upgraded to a new PLC and
software (PCC-90D). During development, it was observed a stuck cut water flow switch (in the closed
or flowing position) could fool the PLC into thinking the start gas was flowing when it was not. The arc
would mistakenly transfer resulting in inconsistent arc starting accompanied by nozzle and electrode
damage due to the lack of start gas flow during arc initiation. This failure mode could occur using either
the PT-19 dry torch or PT-15 water injection torch.
OPERATIONAL IMPACT:
Consistent arc starting and improved consumable life will result. Inconsistent and erratic arc stating
followed by nozzle and electrode damage will be eliminated
ACTION:
PCC-90 Flow Control (P/N-21294) with Original PLC
For systems cutting with a PT 19 torch, the flow switch wire to input 6 of the PLC should be
disconnected.
OR
For systems cutting with a PT-15 torch, replace the sticking cut gas flow switch (P/N-950612).
PCC-90D Flow Control (P/N-0558003629) with New PLC
For all systems, an upgrade to the flash memory is available (Ver1.01) for units manufactured before
February 2003. Contact ESAB at the number below. All units manufactured in February 2003 or later have
the upgraded software installed. Replace the sticking cut gas flow switch (P/N-950612).
CONTACT:
ESAB Welding & Cutting Products
Product & Service Information Group
843-664-4416
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