ESAB ESP-101 Instruction Manual

ESP-101Plasma Arc Cutting System0558007871Instruction Manual (English)This manual provides installation and operation instructions for the following E

14SECTION 2 DESCRIPTION2.6 System and Optional AccessoriesRemote Junction Box ...

153.1 General Proper installation is important for satisfactory and trouble-free operation of the ESP-101 cutting package. It is suggested that

16SECTION 3 INSTALLATION3.5 Primary Input ConnectionsThe ESP-101 460V consoles are equipped with approximately 15 ft. of 4-conductor input

17ESP-101Input Requirements Input & Gnd FuseVolts Phase AmpsConductor SizeCU/AWG Amps380(CE) 3 30 6 mm240400(CE) 3 29 6 mm240460 3 25 8 35Table 3-

183.5.1 TUA2 Auto-Transformer Primary Input ConnectionsSECTION 3 INSTALLATIONConnecting a Multi-Voltage VersionThe ESP-101 460V version is equipped

19SECTION 3 INSTALLATIONThe TUA2 Auto-Transformer is not equipped with an input power cable. A 4/c, type SO (90 °C) cable or equivalent is recom-mend

20SECTION 3 INSTALLATIONFigure 3-4. Input Connections / Fuse ReplacementConnect your air supply to the inlet connection of the lter/regulator.3.5.2

21SECTION 3 INSTALLATIONFigure 3-5. Mechanical Cutting Interface Diagram CNC Interface Connection3.6 CNC Interface ConnectionFront ViewNote:If repla

22SECTION 3 INSTALLATIONStart signal (pin M)Use a relay to connect this pin to “Common” (pin N) to start the cutting process.If a transistor is used

23SECTION 3 INSTALLATIONMAKE SURE POWER SWITCH ON CONSOLE IS IN OFF POSITION AND PRIMARY INPUT POWER IS DEENERGIZED.WARNING3.7 Voltage Divider Ad

6This equipment will perform in conformity with the description thereof contained in this manual and accompa-nying labels and/or inserts when installe

24BEFORE MAKING ANY CONNECTIONS TO THE POWER SOURCE OUTPUT TERMINALS, MAKE SURE THAT ALL PRIMARY INPUT POWER TO THE POWER SOURCE IS DE ENERGIZED OFF

25SECTION 3 INSTALLATIONTorch Cable Male ReceptaclePanel ReceptacleTorch Lead Access DoorAir HoseTorch Lead Access Opening1. Open lead access door o

26SECTION 3 INSTALLATIONThe Remote Junction Box (RJB) provides a means to extend the total length of the PT-37 Torch. A Remote Junction Box is used i

27SECTION 3 INSTALLATIONA. ESP-101 Modications Remove the top and right side panel of the power supply. 1. Redirection of solenoid control wiring

28B. Mounting the Remote Junction Box (RJB)1. With the cover removed from the Remote Junction Box, mount the base to a rigid location on the cut-tin

29SECTION 3 INSTALLATIONFrom ESP-101Extension Cable Air ConnectionExtension CableTo PT-37 TorchExtension CablePower Connection2. Insert the free end

30SECTION 3 INSTALLATIONPanel ReceptacleAir HoseExtension Cable Male ReceptacleC. Connecting to the ESP-101 The Extension Cable is connected to the

31ELECTRIC SHOCK CAN KILL.• Do NOT operate the unit with the cover removed.• Do NOT apply power to the unit while holding or carrying the unit.• Do

32SECTION 4 OPERATIONC. Output Current Control. Adjustable from 20 to 100 amperes. Calibration marks are to provide a guide in setting cur-rent. Fo

33SECTION 4 OPERATIONNote:Most fault signals will remain on for a minimum of 10 seconds. Unit will reset automatically after faults are cleared excep

7TABLE OF CONTENTSSECTION TITLE...

34SECTION 4 OPERATION4.2 Cutting with the ESP-101A. Make sure that the wall disconnect switch is on and air is supplied to machine. B. Turn on the

354.4 Stando and Cut QualityStando (Arc Voltage) has a direct inuence on cut quality and squareness. It is recommended that prior to cuttin

36SUMMARYArc voltage is a dependent variable. It is dependent upon cutting amperage, nozzle size, torch stando, cut gas ow rate and cutting speed. A

374.6 Common Cutting IssuesListed below are common cutting problems followed by the probable cause of each. If problems are determined to be caused

38SECTION 4 OPERATION

8TABLE OF CONTENTS

9SECTION 1 SAFETY PRECAUTIONS1.0 Safety PrecautionsUsers of ESAB welding and plasma cutting equipment have the ultimate responsibility f

10SECTION 1 SAFETY PRECAUTIONSWELDING AND PLASMA CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING OR CUTTING. ASK FOR

11SECTION 2 DESCRIPTION2.1 General As shipped, the ESP-101 is fully assembled and ready to cut after being connected to input power, a source of c

12SECTION 2 DESCRIPTIONThe ESP-101 plasma cutting system combines the newly redesigned ESP-101 console and PT-37 torch. The PT-37 plasma cutting torc

13SECTION 2 DESCRIPTION2.4 Package Ordering Information:The components that are included in the ESP-101 mechanized packages may be purchased separat