ESAB ESP-50 Instruction Manual Download Page 1

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ESP-50

Plasma Arc Cutting Package

0558004311

01 / 2006

Instruction Manual

This manual provides installation and operation instructions for the following ESP-50 cutting packages starting with Serial No.: PxxJ403xxx

Consoles:

P/N 0558004371 - 208/230 V, 50/60 Hz, 1 or 3-phase
P/N 0558004372 - 400CE/460 V, 50/60 Hz, 3-phase, CE

Summary of Contents for ESP-50

Page 1: ...truction Manual This manual provides installation and operation instructions for the following ESP 50 cutting packages starting with Serial No PxxJ403xxx Consoles P N 0558004371 208 230 V 50 60 Hz 1 o...

Page 2: ...e 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...

Page 3: ...ion 23 3 4 Inspection 23 3 5 Primary Electrical Input Connections 23 3 6 Secondary Electrical Output Connections 24 3 7 Connecting ESP 50 for 200 208 Vac Input 27 3 8 Connecting ESP 50 for 400 460 Vac...

Page 4: ...TABLE OF CONTENTS...

Page 5: ...othing 5 Protect other personnel from arc rays and hot sparks with a suitable non flammable partition or curtains 6 Usegogglesoversafetyglasseswhenchippingslag orgrinding Chippedslagmaybehotandcanflyf...

Page 6: ...2 ExposuretoEMFmayhaveotherhealtheffectswhich 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...

Page 7: ...available from Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 EQUIPMENT MAINTENANCE Faulty or improperly maintained equipment can cause injury or death Therefore 1 Alwaysha...

Page 8: ...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 Meansimmedi...

Page 9: ...s del arco y chis pascalientesconunacortina adecuadano flamable como divisi n 6 Usecaretaprotectoraadem sdesusgafasdesegu ridad cuando est removiendo escoria o puliendo La escoria puede estar caliente...

Page 10: ...2 Exponerseacamposelectromagn ticos EMF puede causar otros efectos de salud a n desconocidos 3 Los soldadores deber n usar los siguientes proced imientos para minimizar exponerse al EMF A Mantenga el...

Page 11: ...IMIENTO DEL EQUIPO Equipo defectuoso o mal mantenido puede cau sar da o o muerte Por lo tanto 1 Siempre tenga personal cualificado para efec tuar l a instalaci n diagn stico y mantenimiento del equipo...

Page 12: ...n Est Alerta Se trata de su seguridad Significa riesgo inmediato que de no ser evadido puede resultar inmediatamente en serio da o personal o la muerte Significa el riesgo de un peligro potencial que...

Page 13: ...on Ils r capitulent les informations de pr caution provenant des r f rences dans la section desInformationsdes curit suppl mentaires Avantde proc der l installationoud utiliserl unit assurez vous de l...

Page 14: ...laise persiste 4 Consultez ANSI ASC Standard Z49 1 la page suivante pour des recommandations sp cifiques concernant la ventilation 1 Assurez vous que le ch ssis de la source d alimentation est branch...

Page 15: ...z contenant des chimiques consi d resparl tatdelaCaliforniecomme tant une cause des malformations cong nitales et dans certains cas du cancer California Health Safety Code 25249 5 et seq MANIPULATION...

Page 16: ...Soyez vigilant Votre s curit est en jeu Signifie un danger imm diat La situation peut entra ner des blessures graves ou mortelles Signifieundangerpotentielquipeutentra nerdes blessures graves ou mort...

Page 17: ...e cutting package Use only ESAB torches that are designed for use with this console Use of torches not de signed for use with this console couldcreateanELECTRICSHOCK HAZARD Do NOT use or modify any ot...

Page 18: ...15 2m with rack 0558004352 PT 35 Torch 25 ft 7 6m without rack 0558004353 PT 35 Torch 50 ft 15 2m without rack 0558004354 Cutting Parameters for the PT 35 Torch Carbon Steel 50 AMP Data Nozzle P N 055...

Page 19: ...ir Pressure psig bar 60 60 60 60 60 60 60 60 60 4 1 4 1 4 1 4 1 4 1 4 1 4 1 4 1 4 1 in mm 3 175 3 175 3 175 3 175 3 175 3 175 3 175 3 175 3 175 125 125 125 125 125 125 125 125 125 Cutting Height Pierc...

Page 20: ...50 762 1143 1447 2209 3810 5842 7620 11811 12750 19050 21 36 50 72 110 200 275 420 450 750 533 914 1270 1828 2794 5080 6985 10668 11430 19050 ipm mm min ipm mm min 500 375 313 250 188 125 095 10 11 ga...

Page 21: ...TE Part numbers in parenthesis apply to CE European units only CNC Cable 50 0558004366 Adaptor Cable Adaptor to directly connect HT or TD control cable to ESP 50 0558004363 Torch Holder Assembly 16V83...

Page 22: ...amp A Nozzle 0558004356 15 Consumable Value Pack P N 0558005203 Contents Consumable Value Pack 0558005203 Description P N Quantity Electrode 0558005200 1 50 amp A Nozzle 0558004356 1 Consumable Set P...

Page 23: ...Figure 3 4 If using 400 V input power the ESP 50 must be reconnected as directed in Section 3 8 Figure 3 5 NOTE The208 230Vmodelsareequippedwithaplugforsingle phaseconnection only The plug is mounted...

Page 24: ...workpiece Be sure the workpiece is connected to an approved earth ground with a properly sized ground cable Input Requirements Input Gnd Fuse Volts Phase Amps Conductor Size CU AWG Amps 208 1 55A 6 80...

Page 25: ...egards to chassis ground in Section 3 5 TORCH POWER CABLE CONNECTION TORCH PILOT ARC CONNECTION INPUT POWER CABLE See Table 3 1 Figure 3 2 ESP 50 Interconnection Diagram NOTE The 208 230 V models are...

Page 26: ...3 3 MECHANICAL CUTTING INTERFACE DIAGRAM CNC Interface Connection Located inside console left side of base DETAIL A 1 BLUE RED GREEN ORANGE BLACK WHITE 3 4 5 6 2 FACTORY WIRED MACHINES section 3 inst...

Page 27: ...0 208 vac input X2 is connected to TB3 and X3 is connected to terminal 3 of D1 Make sure the connections are firmly tightened 4 Leave all other wires the same 5 Reinstall the cover and connect the ESP...

Page 28: ...er For 400 vac input X2 is connected toTB3 and X3 is connected to terminal 3 of D1 Make sure the connections are firmly tightened 4 Leave all other wires the same 5 Reinstall cover and connect the ESP...

Page 29: ...at power up This indicates missing or worn consumables Turn power off and inspect torch Over Temperature The fault light will be mostly off but will flick on for about 1 10th of a second every second...

Page 30: ...s greater than 060 1 5 mm replace the electrode If the electrode is used beyond this recommended wear limit damage to the torch and power source may occur Nozzle life is also greatly reduced when usin...

Page 31: ...nsomematerialsandthicknesses itmaybeimpossible to get dross free cuts 1 Current too low 2 Cutting speed too fast or too slow 3 Improper air pressure 4 Faulty nozzle or electrode 5 Low air flow rate D...

Page 32: ...32 section 4 operation...

Page 33: ...ropereyeandfaceprotection blow out the inside of the ESP 50 using low pressure dry compressed air H Occasionally bleed all water from the filter beneath the air filter regulator 5 3 PT 35 Torch Consum...

Page 34: ...inals When mounting IGBT modules on a heatsink certain precautions should be taken to prevent any damage against a sudden torque If a sudden torque one sided tightening is applied at only one mounting...

Page 35: ...ptacle If not present then check the wall disconnect switch and it s fuses c Check Fuse F1 If fuse is ok then check the input switch S1 for proper operation Replace if defective 3 If above items check...

Page 36: ...chematic Replace the transformer if the correct secondary voltages are not present c If everything above checks out all right then the PCB1 Control Board should be replaced E Fault light activates whe...

Page 37: ...ch operation It might be stuck in On position Pilot arc will not initiate if this switch is in the ON position c Measure voltage across C1 or C2 capacitor It should be as follows approx 325 VDC for th...

Page 38: ...oper assembly of the electrode and nozzle Press firmly on the electrode and verify that it retracts when pressed and returns forward when released d Reassemble the electrode and nozzle and turn on pri...

Page 39: ...3 sec Figure 6 1 IGBT Gating Signal section 6 TROUBLESHOOTING 33 CTION 5 TROUBLESHOOTING 5 3 REFERENCE VOLTAGE CHECKS A Control Board Assembly PCB1 1 LED s LED 1 Torch Switch LED 3 Gas Solenoid Valve...

Page 40: ...mes on cutting operation should be stopped The postflow time starts from the moment the start signal is removed 10 SEC 5 SEC START SIGNAL GAS SOLENOID VALVE OPEN CLOSE PREFLOW OFF ON FAULT OVERLOAD LI...

Page 41: ...non ESAB parts may void your warranty Replacement parts may be ordered from your ESAB Distributor Be sure to indicate any special shipping instructions when ordering replacement parts Refer to the Co...

Page 42: ...POS 15 A 125 V S2 6 1 951754 LAMP LED YEL 12 V PL2 7 1 951814 LAMP NEON WHITE PL1 8 2 0558003378 GAUGE HOUSING 9 1 21711 GAUGE 1 50 160 PSI WHITE 10 1 23606172 STRAIN RELIEF 11 1 680560 WORK CABLE 25...

Page 43: ...LABEL WARNING 156 1 954290 LABEL WARNING 157 158 1 952136 FUSE HOLDER 159 1 952559 FUSE 3 A FAST ACTING F1 160 1 97W63 STRAIN RELIEF 161 1 37573 INPUT POWER CABLE 6 FT 208 230 V 1 0558001181 INPUT PO...

Page 44: ...44 Figure 7 3 ESP 50 Power Source Left Side View 208 230 24 35 29 30 40 21 27 38 23 44 37 36 39 25 26 31 32 33 34 46 47 43 27 35 25 26 41 45 section 7 replacement parts...

Page 45: ...BR 33 1 2062282 CAPACITOR 22 f 1KV See wiring C19 34 3 951321 METAL OXIDE VARISTOR 275 V See wiring MOV1 2 3 35 2 951205 IGBT 600 V 100 A includes PAD 951190 Q1 2 36 1 17750010 RESISTOR 50 W 10 OHM PA...

Page 46: ...46 Figure 7 4 ESP 50 Power Source Left Side View 400CE 460 55 53 56 57 58 72 51 59 69 54 75 68 67 71 56 57 58 61 63 64 65 66 77 78 60 62 74 73 76 48 section 7 replacement parts...

Page 47: ...22 HOSE ASS Y B A x 1 4 NPT RUB 62 1 36733 BUSBAR NEG 63 1 950487 TERM BLOCK 2 POS TB5 64 1 952235 MODULE INPUT BRIDGE SCR includes PAD 952280 IBR 65 1 2062282 CAPACITOR 22 f 1KV C19 66 3 950591 METAL...

Page 48: ...48 Figure 7 5 ESP 50 Power Source Right Side View 208 230 80 88 87 81 86 94 93 96 70 section 7 replacement parts...

Page 49: ...UCTOR PFC L2 87 1 0558038261 CONTROL BOARD ASS Y PCB1 88 1 0558004395 MAIN TRANSFORMER ASS Y T1 89 2 951469 CAPACITOR 022 f 250 VAC See Wiring C17 18 90 91 2 951515 CAPACITOR 047 f 660 VAC C21 C23 92...

Page 50: ...50 Figure 7 6 ESP 50 Power Source Right Side View 400CE 460 117 111 110 133 125 121 123 135 122 116 82 section 7 replacement parts...

Page 51: ...1469 CAPACITOR 022 f 250 VAC See wiring C17 18 119 120 1 951515 CAPACITOR 047 f 660 VAC C23 121 1 0455803881 EMF FILTER BOARD PCB5 122 1 952233 INDUCTOR OUTPUT L1 123 1 36721 BUSBAR OUTPUT 124 125 1 3...

Page 52: ...POS 25 A TB4 142 2 17240310 RESISTOR 10 K 25 W R2 15 143 1 951182 FAN AC AXIAL M1 144 1 2091558 LABEL GROUND BLACK 145 1 954700 LABEL INPUT 208 230 V 1 954681 LABEL INPUT 400CE 460 V Figure 7 7 ESP 5...

Page 53: ...53 section 7 replacement parts...

Page 54: ...54 notes...

Page 55: ...dated spare parts kits with new p n 0558005210 consumable value pack p n 0558005203 consumable set p n 0558005201 consumable set p n 0558005202 Section 4 Updated figure 4 2 to show new electrode draw...

Page 56: ...anty Returns Authorized Repair Stations Welding Equipment Troubleshooting C TECHNICAL SERVICE Telephone 800 ESAB 123 Fax 843 664 4452 Hours 8 00 AM to 5 00 PM EST Part Numbers Technical Applications S...

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