ESAB ESP-150 User manual

Brand: ESAB

Model: ESP-150

Category: Welding System

Type: User manual

ESAB ESP-150 is a powerful and versatile plasma cutter that offers high-speed cutting up to 50 mm. It can cut with air, nitrogen, mixed gas argon/hydrogen or mixed gas nitrogen/hydrogen, making it suitable for a wide range of cutting applications. The ESP-150 features automatic intermittent cutting for continuous operation when cutting gratings, expanded metal, and other durable materials.

Valid for serial no. 015-xxx-xxxx0558 004 122 GB 20110708

ESP-150

Instruction manual

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TOCe

Rights reserved to alter specifications without notice.

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

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

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

2.2 Functions 6.................................................................

3 TECHNICAL DATA 7.................................................

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

4.1 Delivery check and location 8.................................................

4.2 Mains supply 9..............................................................

4.3 Connection of torch 12........................................................

4.4 Gas connection 14...........................................................

4.5 Connection for return cable 15.................................................

5 OPERATION 16.......................................................

5.1 Control device and indicators 17................................................

5.2 Setting the power source 19...................................................

5.3 Recommended gas and current 20.............................................

6 MAINTENANCE 21....................................................

6.1 Inspection and cleaning 21....................................................

6.2 Filling the coolant 22..........................................................

6.3 Flow control 22..............................................................

6.4 Spark gap adjustment 23......................................................

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

8 ORDERING SPARE PARTS 23.........................................

DIAGRAM 25............................................................

ORDERING NUMBER 29.................................................

ACCESSORIES 30.......................................................

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1SAFETY

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 unauthorized 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 c orrect 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.

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.

CAUTION

Read and understand the instruction manual before

installing or operating.

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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.

ESAB can provide you with all n ecessary welding protection and accessories.

2 INTRODUCTION

The plasma power source ESP-150 and plasma cutting torch PT-26 are a complete

and safe plasma cutting system for cutting and gouging.

ESAB's accessories for the product can be found on page 30.

2.1 Equipment

The power source is supplied with:

S instruction m anual

2.2 Functions

S High speed cutting up to 50 mm.

S Cut with air, nitrogen, mixed gas argon/hydrogen or mixed gas nitrogen/hydro-

gen.

S Overheating protection.

S Mains voltage compensation.

S The extra function, automatic intermittent cutting, enables continuous operation

when cutting gratings, expanded metal, durable sieve gratings etc.

S Wheel and gas bottle shelf to make the equipment portable.

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3 TECHNICAL DATA

ESP 150

Mains voltage

3μ 380–400 / 415 V ±10 % 50 Hz

Primary current I

max.

78 A at 380–400 V, 71 A at 415 V

No-load power 600 W

Setting range

25 A/90 V–150 A/140 V

Permitted load

40 % duty cycle

60 % duty cycle

100 % duty cycle

150 A / 140 V

120 A / 128 V

110 A / 124 V

Efficiency at maximum current 54 %

Open-circuit voltage U

370 V

Operating temperature

–10 to 40 °C

Transportation temperature

–20 to 55 °C

Dimensions, l x w x h 1016 x 552 x 800 mm

Weight 360 kg

Insulation class transformer H

Enclosure class IP 21

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 ou t by a p rofession al.

Correct installation is very important for trouble-free operation and good cutting

results. Carefully read and follow each step in this chapter.

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

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.

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WARNING

Poor connections or failure to connect the return cable to the workpiece can result

in fatal electric shock.

If the workpiece is not earthed, fuse F3 and switch CB1 deploy, which disables the

power source.

WARNING

Do NOT start the equipment with the cover removed.

Do NOT connect the equipment under tension or when you are holding it or

carrying it.

Do NOT touch any of the torch's parts when the power supply is on.

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.

CAUTION

Place the power source at least 3 metres from the cutting area as sparks and slag spray

can damage the power source

4.1 Delivery check and location

1. Remove the packaging, but leave the transit bolts in place. Inspect the

equipment for damage that was not immediately apparent upon reception of the

delivery. Immediately r eport any damage to the delivery company.

2. Check for any loose parts in the packaging. Check that the air ducts in the

cover's rear panel are not blocked with packaging material that can prevent the

air flow through the power source.

The power source has a lifting eyelet and can be lifted easily. Check that the

lifting equipment that is to be used can withstand the weight of the power source.

The weight is stated in TECHNICAL DATA.

WARNING

The product must be lifted using a fork

lift truck or as follows:

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3. Install the wheel set on the power source, as described in the instruction that is

supplied in the wheel set.

4. Position the power source so that its cooling air inlets and outlets are not

obstructed. Minimum permitted distance to wall or other obstruction is 60 cm.

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 use

of air filter devices, regardless of type, invalidates the warranty.

5. An air source that gives clean and dry air, at least 7.08 m

/h at 76 KPa (11 psi),

is required for cutting. T he cutting air pressure must not exceed 1000 KPa (150

psi), which is the maximum inlet pressure for the filter regulator that is included in

the delivery.

4.2 Mains supply

1. At the switch (wall socket or similar) there m ust be a securely m ounted circuit

breaker with fuses or switch , see fig. 1. The mains cable m ust have insulated

copper conductors – three phase conductors and protective earth. Thick rubber

insulated cable can be used. The cable can be routed in rigid cable pipes or in

flexible cable conduits. Suitable conductors and fuse dimensions are given in

table 1 .

Fig. 1. Typical installation with user-supplied three-phase circuit breaker box with socket and plug.

Recommended fuse sizes and minimum cable area

ESP 150 50 Hz

Mains voltage 380 - 400 V 415 V

Mains cable area mm

4G25 4G16

Phase current I

1eff

49 A 44 A

Fuse, anti-surge 100 A 90 A

Table 1.

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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2. The power source is factory configured for the highest connectable voltage. If the

equipment will be operated by any other power supply, the jumpers on the

terminal board in the power source must be moved to the correct position for the

relevant voltage. T he different jumper positions are displayed in fig. 2a and 2b.

The terminal board is accessible when the access door on the left side is

removed.

Fig. 2a. Terminal block on models for 380/415

VAC, configured for 380

–400 VAC.

Fig. 2b. Terminal block on models for 380/415

VAC, configured for 415 VAC.

1 4-core cable (supplied by

customer)

2 Green/yellow conductor 3 Main earth terminal

Fig. 4. Mains cable connection

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3. Control selection with free-standing distribution box: The power source is

supplied with contact P45 connected to socket J4 MAN (manual) (torch gases

and torch are directly connected to the power source). If the power source is to

be used with a free-standing distribution box, P45 must be moved to socket J5

MECH (mechanical).

Delivery configuration

–

P45 connected to J4

(MAN).

P45 moved to J5 (MECH) when free-standing

distribution box is to be moved.

Fig. 5. Manual respectively mechanical operation.

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ERROR

SIGNAL

TO CNC UNIT

GAS PREFLOW

SIGNAL

FROM CNC UNIT

TERMINAL J1

ARC LIGHTING-

SIGNAL

TO CNC UNIT

PLASMA START

SIGNAL

FROM CNC UNIT

Note! J1 Suitable plug and clamp

CABLE SUPPLIED BY CUSTOMER

14-pin straight

*) EMERGENCY

STOP SIGNAL

FROM CNC UNIT

ARC VOLTAGE

SIGNAL

DIVIDER 20:1

* NOTE If the CNC unit's emergency stop switch does not having breaking contact, a jumper must be

made between TB1-16 and TB1-20.

Fig. 6. Pin configuration for remote control connection J1 for connection of CNC unit.

4.3 Connection of torch

1. Torch connection see fig. 7and 8.

a. If only an arc lighting signal is required, the supplied remote control switch

(option) must be connected to the torch control socket on the terminal panel

on the front of the switch, see fig. 8.

b. If torch type PT-26 straight is to be used in mechanic CNC operation, see fig.

6 for pin configuration regarding in and output signals r espectively fig. 5

regarding selection of control method.

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Fig. 7. If the torch is to be used manually, insert the connection cables through the rubber seal on the

front of ESP-150 and connect according to the figure.

Fig. 8. If mechanical operation with shielded straight torch is applicable, remove the rubber seal, insert

the collar in the front panel and tighten with the lock nut.

1 Shielding gas 4

Water OUT (

–

)(torch)

2 Water IN (+) (pilot arc) 5 Torch control socket

3 Plasma/start gas

Fig. 9. Connection of torch

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4.4 Gas connection

1. Connect the gas supply. The gas bottles can be positioned and locked on the

power source's gas bottle shelf. Connect the regulators according to the

instructions supplied with the relevant regulator.

2. Connect the gas hoses to the regulators and to the correct gas connections

(option: adapters for air, 19 x 54 for Ar/H2) at the back of the power source. The

connections must be tightened with a wrench. Terminals that are not used must

be plugged and the plugs tightened with a wrench. See fig. 11.

Fig. 10. Air filter regulator connections.

*) ONLY connect 1 of the inlets, NEVER both, when using plasma gas.

1 Start gas 2 Cutting gas 3 Shielding gas

Fig. 11. Gas connections.

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4.5 Connection for return cable

1. Connect the return cable's cable terminal to the return cable's terminal block at

the bottom left on the front of the power source.

2. Connect the return cable electrically to the workpiece. The connection must be

made to a clean metallic surface, free from contamination, paint, rust, millscale

etc

1 Work bench 2 Return cable 3 Torch PT-26

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5OPERATION

General safety regulations for handling of the equipment can be found on

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

WARNING

If the switch under the upper, hinged cover has tripped, dangerous voltage may

exist between the return cable and earth. This is usually caused by poor or broken

contact between the return cable and the workpiece. The return cable must always

be in electrical contact with the workpiece, otherwise there is a risk of dangerous

electric shock.

WARNING

Always ensure that the power supply to the torch is off before performing any

adjustments or maintenance on the torch.

CAUTION

Do NOT start the power source under any circumstances with the cover removed.

Operating without a cover does not just cause personal safety risks but also reduces

cooling and can therefore damage the equipment.

The side panels must be closed when the equipment is powered.

Wear appropriate personal protective equipment before you begin cutting

- welding helmet

and gloves must always be worn.

See page 2 for further safety information.

CAUTION

The main switch in the hinged cover is powered when the voltage is input to the terminal

board, even when the main POWER switch is off.

This chapter describes the power source control device and handling and gives

some tips on cutting quality.

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5.1 Control device and indicators

1 Topping up the coolant 6 Mains voltage switch

2 Level indicator for the coolant 7 Switch for gas

3 Connection for return cable 8 Current setting control

4 Ampere and Voltmeter 9 Indicator lamps

5 Connection for torch

The indicator lamps on the front of the power source indicates the status during

plasma cutting. With prior knowledge of the cutting process, you can troubleshoot

the equipment quickly by observing the indicator lamps.

For the indicator lamps to work, the right power supply must be connected, the

jumpers on the input terminal board must be configured for this supply voltage, the

mains power switch must be switched on and the cover properly closed.

The control panel's control device and functions

POWER ON/ OFF

Mains voltage switch for cooling fan, cooling unit and

operating circuits.

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GAS MODE

Gas mode switch with three positions.

S Cutting gas pressure and flow can be set in CUT mode

S in START/SHIELD mode, start and shielding gas

pressure and gas flow can be set.

S The switch must be at OPERATE mode during cutting

CURRENT CONTROL

Control for setting appropriate cutting current.

Also see application information on page 20.

Indicator lamps

OVER TEMP

Indicator lamp for overheating, comes on if one or more of the thermal

cut-outs in the power source breaks due to overheating. The lamp can

illuminate weakly during gas after flow.

Stop cutting if the lamp illum inates, and let the equipment cool. If the

lamp illuminates despite the fact that overheating could not occur,

examine the thermal cut-outs and check for loose connections.

READY/LOW GAS

The lamp indicates that the equipment is ready for operation, but also

serves as an indicator for the torch's trigger, for the gas mode switch as

well as a warning indicator for low gas pressure or low gas flow. The lamp

illuminates when the mains voltage switch is on but not used (cuttin g not in

progress). The lamp stays on when the gas mode switch is set to CUT

mode, even when the gas flow or pressure is correctly set. The lamp does

not go out when the gas mode switch is set to OPERATE mode (the gas

solenoid valves close).

In OPERATE mode, the lamp acts as a warning lamp for LOW GAS. If the lamp

illuminates whilst the torch' s trigger is pr essed, the gas pressure or gas flow is too

low.

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HIGH FREQ ENERGIZED

The lamp illuminates when the equipment is in OPERATE mode and

the torch's trigger is pressed. The lamp should remain lit until the

plasma arc is lit.

TORCH ON

The lamp is lit when the power source sends out voltage to light and

maintain the plasma arc.

NOTE! Never touch the front parts and do not perform any torch

adjustments if the TORCH ON lamp is lit, even if the main switch is off.

5.2 Setting the power source

1. Open all gas valves slowly.

2. Set the gas mode switch to GAS MODE in OPERATE mode and the power

source mains voltage switch to POWER in OFF mode.

3. Set the switch (wall socket or similar) to on.

4. Set the mains voltage switch POWER to ON. The indicator lamp POWER must

illuminate and the cooling fan must run.

5. When the gas mode switch GAS MODE is in START/SHIELD m ode, the gas

solenoid valves must be open. Set the start respectively shielding gas regulator .

Set the switch to CUT mode and set the cutting gas regulator.

6. Allow the gases to flow a few minutes to blow out ant condensation from the

hoses.

7. Set the gas mode switch GAS MODE to OPERATE mode. The gas flow should

then be switched off.

8. Set the CURRENT CONTROL knob to the desired current.

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5.3 Recommended gas and current

The recommended gas and current for the best cutting results for common metals

are given below.

Carbon steel Stainless steel

Up to 3.2 mm.

50–65 A, plasma gas

air/shielding gas air.

Up to 3.2 mm.

50–65 A, plasma gas

N2/shielding gas N2

gives the best surface

with light slag on

material 3.2 mm.

4.8–12.7 mm

100 A, plasma

gas/shielding gas air.

100 A, plasma gas

air/shielding gas air

also works well, but

produces slag at the

lower edge on the

material 12.7 mm.

50–65 A, plasma gas

air/shielding gas air can

give slag free cut but

rough surface.

12.7–50,8 mm

150 A, plasma gas/air

Carbon steel Aluminium

3.2–9,6 mm

100 A, plasma gas

/shielding gas N

cangivesomeorno

slag and good material

surface quality 12.7

mm.

Up to 6,35 mm.

50–65 A, plasma gas

N2/shielding gas N2

gives a relatively

smoothslagfreecut.

100 A, plasma gas

air/shielding gas air can

give some slag at the

lower edge but a

rougher surface.

50–65 A, plasma gas

air/shielding gas air

gives a rougher

surface.

Over 6.35 mm 150 A, plasma gas/N

H-35

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ESAB ESP-150 User manual

Brand: ESAB

Model: ESP-150

Category: Welding System

Type: User manual

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ESAB ESP-150 User manual

ESAB ESP-150 User manual

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