ESAB ESP-150 User manual

0558003744

This manual provides installation and operation

instructions for the following components begin-

ning with Serial Number PORJ129127:

ESP-150

Plasma Cutting System

Instruction Manual (GB)

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!

SECTION TITLE PAGE

PARAGRAPH

SECTION 1 SAFETY ..................................................................................................................... 125

SECTION 2 DESCRIPTION .......................................................................................................... 127

Specifications ............................................................................................................. 127

Features ..................................................................................................................... 127

SECTION 3 INSTALLATION ......................................................................................................... 131

General ....................................................................................................................... 131

Inspection and Placement .......................................................................................... 131

Primary Input Electrical Connections.......................................................................... 132

Torch Connections ...................................................................................................... 137

Gas Supply Connections ............................................................................................ 138

Work and Earth Connections ..................................................................................... 139

Torch Coolant Preparation .......................................................................................... 139

SECTION 4 OPERATION .............................................................................................................. 141

Controls and Indicators ............................................................................................... 141

ESP-150 Adjustments ................................................................................................ 142

Operation .................................................................................................................... 142

Standoff and Cut Quality ............................................................................................. 144

Dross Formation......................................................................................................... 146

Common Cutting Problems ........................................................................................ 147

Standard Conditions ................................................................................................... 148

Recommended Gas and Current ............................................................................... 150

SECTION 5 MAINTENANCE ......................................................................................................... 241

Inspection and Cleaning ............................................................................................. 241

Flow Testing ................................................................................................................ 241

Spark Gap Adjustment ................................................................................................ 241

Testing and Replacing Bridge Assembly Components ............................................... 242

Troubleshooting .......................................................................................................... 242

Troubleshooting Guide ................................................................................................ 243

Sequence of Operation ............................................................................................... 244

Status Light Troubleshooting Chart ............................................................................. 246

SECTION 6 REPLACEMENT PARTS .......................................................................................... 247

TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS

1.0 Safety Precautions

Users of ESAB welding and plasma cutting 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 welding or plasma cutting equipment. The following recommendations

should be observed 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 welding or plasma

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

injury to the operator and damage to the equipment.

1. Anyone who uses welding or plasma cutting equipment must be familiar with:

- its operation

- location of emergency stops

- its function

- relevant safety precautions

- welding and / or plasma cutting

2. The operator must ensure that:

- no unauthorized person stationed within the working area of the equipment when it is started up.

- no one is unprotected when the arc is struck.

3. The workplace must:

- be suitable for the purpose

- be free from drafts

4. Personal safety equipment:

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

clothing, safety gloves.

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

trapped or cause burns.

5. General precautions:

- Make sure the return cable is connected securely.

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

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

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

SECTION 1 SAFETY PRECAUTIONS

WELDING AND PLASMA CUTTING CAN BE INJURIOUS TO YOURSELF AND

OTHERS. TAKE PRECAUTIONS WHEN WELDING OR CUTTING. ASK FOR

YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE BASED ON

MANUFACTURERS’ HAZARD DATA.

ELECTRIC SHOCK - Can kill.

- Install and earth (ground) the welding or plasma cutting unit in accordance with applicable standards.

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

- Insulate yourself from earth and the workpiece.

- Ensure your working stance is safe.

FUMES AND GASES - Can be dangerous to health.

- Keep your head out of the fumes.

- 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.

- Protect your eyes and body. Use the correct welding / plasma cutting screen and ﬁlter lens and wear

protective clothing.

- Protect bystanders with suitable screens or curtains.

FIRE HAZARD

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

NOISE - Excessive noise can damage hearing.

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

- Warn bystanders of the risk.

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

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

WARNING

127

ESP-150 POWER SUPPLY SPECIFICATIONS

Input Voltage ..................................................... 380-400 / 415 Vac, 3 Phase 50/60 Hz

Input Current ................................................................ 78A @ 380-400V, 71A @ 415V

Power Factor .........................................................................................................54%

Output Current Rating ............................... 150 Amps (40% Duty), 110A (100% Duty)

Output Voltage ....................................... 140 VDC (40% Duty), 124VDC (100% Duty)

Open Circuit Voltage ...................................................................................... 370V DC

Power Source Size ............. 31.5” (800mm) H, 21.75” (552mm) W, 40” (1,016mm) L

Power Source Weight ........................................................................ 792 lbs. (360 kg)

Plasma Gas (Cutting) ................... N2or Air @ 25psi (25 cfh) or H-35 @ 65psi (75 cfh)

Plasma Gas (Gouging) .................................................. H-35 or Air @ 20 psi (130 cfh)

FEATURES

• High speed cutting of most metals from gauge thickness to 2 in. thick

• 380-400/415 volt three-phase input - versatility

• Adjustable output - 25 to 150 amps for greater versatility

• Water cooled Torch PT-26 and PT-26 Inline

• Cuts with air, nitrogen, argon-hydrogen or nitrogen-hydrogen mixtures

• Torch design provides perfect electrode centering - provides longer tip life by

minimizing the possibility of double-arcing

• Torch spare parts kit supplied with each outfit - ample supply of spare parts

at no additional cost to minimize downtime

• Thermal overload switches - prevents damage if unit overheats due to insuf-

ficient air flow

• Line voltage compensation

• Automatic intermittent cutting - additional capability, permits continuous

cutting of grates, expanded metal, heavy screen material, etc.

• Wheels and cylinder rack - all provided standard at no additional cost for

portability and greater utilization

• Ideal for plasma gouging

Figure 1 - ESP-150

SECTION 2 DESCRIPTION

128

SECTION 2 DESCRIPTION

Figure 2b - PT-26 Manual Torch Dimensions

PT-26 Technical Specifications (Plasma Gas)

Type of Gas N2, Air, AR-H2, N2-H2

Pressure 100 psig (6.9 bar)

Flow 240 cfh (6.8 M3/h)

Purity Required O2- 99.5% min., N2-99.995% min.,

Air - clean and dry

Recommended Liquid Cylinder

Service Regulators Inert Gas R-76-150-580LC 19977

Recommended cylinder 2-Stage

Regulators Argon-Hydrogen R-77-75-350 998341

Nitrogen R-77-75-580 998343

Industrial Air R-77-150-590 998348

Recommended Heavy-Duty Hi-Flow

Station or Pipeline Regulators Nitrogen R-76-75-034 19155

PT-26 Technical Specifications (Starting Gas/Cutting Gas)

Type N2, Air (for Ar-H2Cut Gas Use N2or Ar-H2)

Pressure 100 psig (6.9 bar

Flow 200 cfh (5.66M3/h) @ 60 psig (4.1 bar)

Purity Required N2- 99% min., Air - clean and dry

PT-26 Technical Specifications (Shield Gas)

Type N2or Air

Pressure 100 psig (6.9 bar) maximum

Flow 200 cfh (5.66 M3/h) @ 85 psig (5.86 bar)

Purity Required Nitrogen - 99% minimum, Air - clean and dry

Figure 2a - PT-26 In-line Torch Dimensions

2.00”

(50.8mm)

16.50”

(419.1mm)

129

ESP-150 CE PLASMA CUTTING PACKAGES

SECTION 2 DESCRIPTION

0558003473 ESP-150 CE PT26 50' 70D AIR 0558003475 ESP-150 CE PT26 50' 90D AIR

Part No. Description Qty. Part No. Description Qty.

0558002717 ESP-150 CONSOLE, CE 1 0558002717 ESP-150 CONSOLE, CE 1

0558002209 PT-26 70DEG 50' 1 36559 PT-26 90DEG 50' 1

0558002864 SPARE PTS. KIT 1 0558002864 SPARE PTS. KIT 1

680794 TRUCK & CYL RACK 1 680794 TRUCK & CYL RACK 1

0558003242 AIR REGULATOR ASSY 1 0558003242 AIR REGULATOR ASSY 1

678724 WORK CABLE, 50' 1 678724 WORK CABLE, 50' 1

156F05 TORCH COOLANT 4 156F05 TORCH COOLANT 4

08030354 HOSE CONNECTION 1 08030354 HOSE CONNECTION 1

136Z08 NUT, B/I-G 3 136Z08 NUT, B/I-G 3

08030247 NIPPLE, B/SIZE 3 08030247 NIPPLE, B/SIZE 3

3380 NUT, B/OXY 1 3380 NUT, B/OXY 1

2064005 NIPPLE, BARBED 1 2064005 NIPPLE, BARBED 1

0558003476 ESP-150 CE PT26 25' INLINE AIR 0558003477 ESP-150 CE PT26 50' INLINE AIR

Part No. Description Qty. Part No. Description Qty.

0558002717 ESP-150 CONSOLE, CE 1 0558002717 ESP-150 CONSOLE, CE 1

0558002320 PT-26 IN-LINE 25' 1 0558002321 PT-26 IN-LINE 50' 1

0558002864 SPARE PTS. KIT 1 0558002864 SPARE PTS. KIT 1

680794 TRUCK & CYL RACK 1 680794 TRUCK & CYL RACK 1

0558003242 AIR REGULATOR ASSY 1 0558003242 AIR REGULATOR ASSY 1

678723 WORK CABLE, 25' 1 678724 WORK CABLE, 50' 1

951188 LOCKNUT CONDUIT 1 951188 LOCKNUT CONDUIT 1

33053 STRAIN RELIEF 1 33053 STRAIN RELIEF 1

156F05 TORCH COOLANT 4 156F05 TORCH COOLANT 4

08030354 HOSE CONNECTION 1 08030354 HOSE CONNECTION 1

136Z08 NUT, B/I-G 3 136Z08 NUT, B/I-G 3

08030247 NIPPLE, B/SIZE 3 08030247 NIPPLE, B/SIZE 3

3380 NUT, B/OXY 1 3380 NUT, B/OXY 1

2064005 NIPPLE, BARBED 1 2064005 NIPPLE, BARBED 1

130

SECTION 2 DESCRIPTION

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