ESAB 100i User manual

100i, 200i, 300i, and 400i
Plasma Systems
Instruction Manual
Article Number: 0560956430
Revision Date: May 13, 2016
Revision Number: AB
Language: ENG

WE APPRECIATE YOUR BUSINESS!
Congratulations on your new ESAB product. We are proud to have you as our customer and will
strive to provide you with the best service and reliability in the industry. This product is backed by
our extensive warranty and world-wide service network. To locate your nearest distributor or service
agency call 1-800-ESAB-123, or visit us on the web at www.ESAB.com.
This instruction manual has been designed to instruct you on the correct use and operation of your
ESAB product. Your satisfaction with this product and its safe operation is our ultimate concern.
Therefore please take the time to read the entire manual, especially the Safety Precautions. They will
help you to avoid potential hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
ESAB is a Global Brand of manual and mechanized Plasma Cutting Products.
We distinguish ourselves from our competition through market-leading, dependable products that
have stood the test of time. We pride ourselves on technical innovation, competitive prices, excel-
lent delivery, superior customer service and technical support, together with excellence in sales and
marketing expertise.
Above all, we are committed to developing technologically advanced products to achieve a safer
working environment within the welding industry.

Plasma Cutting Power Supply with Automated Gas Control 100i / 200i / 300i / 400i
Published by:
ESAB Welding and Cutting Products.
2800 Airport Rd.
Denton, Texas 76207
www.ESAB.com
© Copyright 2015 by ESAB Welding and Cutting Products.
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher
is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss
or damage caused by any error or omission in this manual, whether such error results from
negligence, accident, or any other cause.
Original Publication Date: February 26, 2016
Revision Date: May 13, 2016
Record the following information for Warranty purposes:
Where Purchased: ___________________________________
Purchase Date:______________________________________
Power Supply Serial #:_______________________________
Torch Serial #:_______________________________________
!
WARNING
Read and understand this entire Manual and your employer’s safety practices
before installing, operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer’s
best judgement, the Manufacturer assumes no liability for its use.

Be sure this information reaches the operator.
You can get extra copies through your supplier.
CAUTION
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,” Booklet F52-529. Do NOT permit untrained persons to install,
operate, or maintain this equipment. Do NOT attempt to install or operate this equip-
ment 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 before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying
labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions 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 immediately. 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 main-
tenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by
the manufacturer.
!
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR
OPERATING.
PROTECT YOURSELF AN D OTHERS!

ASSUREZ-VOUS QUE CETTE INFORMATION EST DISTRIBUÉE À L’OPÉRATEUR.
VOUS POUVEZ OBTENIR DES COPIES SUPPLÉMENTAIRES CHEZ VOTRE FOURNISSEUR.
ATTENTION
Les INSTRUCTIONS suivantes sont destinées aux opérateurs qualiés seulement.
Si vous n’avez pas une connaissance approfondie des principes de fonctionnement
et des règles de sécurité pour le soudage à l’arc et l’équipement de coupage, nous
vous suggérons de lire notre brochure « Precautions and Safe Practices for Arc Wel-
ding, Cutting and Gouging, » Brochure F52-529. Ne permettez PAS aux personnes
non qualiées d’installer, d’opérer ou de faire l’entretien de cet équipement. Ne tentez
PAS d’installer ou d’opérer cet équipement avant de lire et de bien comprendre ces
instructions. Si vous ne comprenez pas bien les instructions, communiquez avec
votre fournisseur pour plus de renseignements. Assurez-vous de lire les Règles de
Sécurité avant d’installer ou d’opérer cet équipement.
RESPONSABILITÉS DE L’UTILISATEUR
Cet équipement opérera conformément à la description contenue dans ce manuel, les étiquettes d’accompagnement
et/ou les feuillets d’information si l’équipement est installé, opéré, entretenu et réparé selon les instructions fournies. Vous
devez faire une vérication périodique de l’équipement. Ne jamais utiliser un équipement qui ne fonctionne pas bien ou n’est
pas bien entretenu. Les pièces qui sont brisées, usées, déformées ou contaminées doivent être remplacées immédiatement.
Dans le cas où une réparation ou un remplacement est nécessaire, il est recommandé par le fabricant de faire une demande
de conseil de service écrite ou par téléphone chez le Distributeur Autorisé de votre équipement.
Cet équipement ou ses pièces ne doivent pas être modiés sans permission préalable écrite par le fabricant. L’utilisa-
teur de l’équipement sera le seul responsable de toute défaillance résultant d’une utilisation incorrecte, un entretien fautif, des
dommages, une réparation incorrecte ou une modication par une personne autre que le fabricant ou un centre de service
désigné par le fabricant.
!
ASSUREZ-VOUS DE LIRE ET DE COMPRENDRE LE MANUEL D’UTILISATION AVANT
D’INSTALLER OU D’OPÉRER L’UNITÉ.
PROTÉGEZ-VOUS ET LES AUTRES!

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TABLE OF CONTENTS
SECTION 1: SAFETY......................................................................................... 11
1.01 Safety Precautions - ENGLISH..........................................................................11
1.02 Précautions de sécurité - FRENCH CANADIAN .................................................16
SECTION 2: SPECIFICATIONS.............................................................................. 21
2.01 General Description Of The System ..................................................................21
2.02 Plasma Power Supply.......................................................................................21
2.03 Remote Arc Starter ...........................................................................................21
2.04 Gas Control Module..........................................................................................21
2.05 Precision Plasma Cutting Torch........................................................................21
2.06 Specifications & Electrical Requirements .........................................................22
2.07 Power Supply Dimensions................................................................................24
2.08 Power Supply Rear Panel Features ...................................................................25
2.09 Gas Requirements ............................................................................................26
2.10 Gas Applications...............................................................................................28
2.11 Torch Specifications .........................................................................................29
SECTION 3: INSTALLATION ................................................................................ 31
3.01 Installation Requirements.................................................................................31
3.02 System Layout 100i - 200i Amp ......................................................................32
3.03 System Layout 300i Amp..................................................................................33
3.04 System Layout 400i Amp..................................................................................33
3.05 Recommended Gas Supply Hose......................................................................34
3.06 Leads and Cables All Amperage........................................................................34
3.07 Lift the Power Supply .......................................................................................35
3.08 Connect Input Power and Ground Cables .........................................................36
3.09 Connect Work Cable and Pilot and Negative Leads...........................................37
3.10 Ground Connections.........................................................................................38
3.11 Connect Coolant Leads .....................................................................................41
3.12 Connect Cables for CNC, Remote Arc Starter, Gas Selection, and Heat Exchanger
42
3.13 Handling and Installation of Fiber Optics ..........................................................43
3.14 Connect Cable and Gas Section Console Fiber Optic Cable to CCM ..................47
3.15 Set Switches on the Command - Control Module .............................................49
3.16 Height Control Connections..............................................................................51
3.17 Gas Selection Console Installation....................................................................52
3.18 Gas Control Unit Installation.............................................................................55
3.19 Fiber Optic Cable Installation from CCM to Gas Selection Console...................58
3.20 Fiber Optic Cable Installation From Gas Selection Console to Gas Control Unit60
3.21 Install Touch Screen CNC..................................................................................63
3.22 External Cooler .................................................................................................64
3.23 Install Remote Arc Starter.................................................................................66
3.24 Connecting Torch..............................................................................................73
3.25 Install Consumable Torch Parts ........................................................................75
3.26 Voltage Divider for iHC Torch Height Control....................................................78

TABLE OF CONTENTS
SECTION 4: OPERATION.................................................................................... 79
4.01 Power Supply Control Panel .............................................................................79
4.02 System Operation .............................................................................................79
4.03 CCM Status Codes............................................................................................81
4.04 Gas Selection Console Status Codes ................................................................89
4.05 Gas Control Unit Status Codes..........................................................................91
4.06 Remote Arc Starter Trouble Shooting ...............................................................94
SECTION 5: MAINTENANCE ................................................................................ 95
5.01 General Maintenance ........................................................................................95
5.02 External Coolant Filter Cleaning Procedure .......................................................95
5.03 Coolant Replacement Procedure.......................................................................96
SECTION 6: REPLACEMENT ASSEMBLIES & PARTS .................................................. 97
6.01 Replacement Power Supply..............................................................................97
6.02 System Layout 100 - 200 Amp .........................................................................98
6.03 System Layout 300 Amp...................................................................................98
6.04 System Layout 400 Amp...................................................................................99
6.05 Recommended Gas Supply Hose......................................................................99
6.06 Leads And Cables All Amperages....................................................................100
6.07 Power Supply External Replacement Parts ....................................................102
6.08 Power Supply Replacement Parts - Upper Right Side.....................................103
6.09 Power Supply Replacement Parts - Lower Right Side ...................................104
6.10 Power Supply Replacement Parts - Rear Panel ..............................................105
6.11 Power Supply Replacement Parts - Left Side..................................................106
6.12 Automated Gas Control System Replacement Components ...........................107
6.13 Gas Selection Console Replacement Parts......................................................108
6.14 Gas Control Unit Replacement Parts...............................................................109
6.15 Remote Arc Starter (RAS) Replacement Parts................................................110
SECTION 7: TORCH MAINTENANCE...................................................................111
7.01 Consumable Removal.....................................................................................111
7.02 O-Ring Lubrication .........................................................................................112
7.03 Parts Wear......................................................................................................113
7.04 Torch Consumables Installation......................................................................114
7.05 Coolant Leak Trouble-Shooting ......................................................................116
8.0 TORCH OPERATION .................................................................................119
8.01 Standard Cutting Up To 100 Amp ...................................................................125
8.02 Bevel and Robotic Cutting Up To 100 Amp .....................................................147
8.03 Standard Cutting 150 - 200 Amp ....................................................................155
8.04 Robotic and Bevel Cutting 150 - 200 Amp......................................................167
8.05 Standard Cutting 250 - 300 Amp ....................................................................177
8.06 Robotic and Bevel Cutting 250 - 300 Amp......................................................185
8.07 Standard Cutting 400 Amp .............................................................................195
8.08 Robotic and Bevel Cutting 400 Amp ...............................................................205
8.09 TORCH PARTS LIST.......................................................................................217
8.10 Torch Consumables Installation......................................................................220
8.11 PATENT INFORMATION ..................................................................................223

TABLE OF CONTENTS
APPENDIX 1: CNC - CONTROL MODULE PCB CONNECTIONS....................................... A-1
APPENDIX 2: CNC ......................................................................................... A-2
CNC functions............................................................................................................... A-2
CNC Input / Output Descriptions................................................................................... A-4
Simplified CNC Circuit................................................................................................... A-6
CNC Connections.......................................................................................................... A-8
CNC Cable Color Code .................................................................................................. A-9
APPENDIX 3: COOLING DIAGRAM .....................................................................A-10
APPENDIX 4: SYSTEM SCHEMATIC 100A, 380-415V PG 1..........................................A-12
APPENDIX 5: SYSTEM SCHEMATIC 100A, 380-415V PG 2..........................................A-14
APPENDIX 6: SYSTEM SCHEMATIC 200A, 380-415V PG 1..........................................A-16
APPENDIX 7: SYSTEM SCHEMATIC 200A, 380-415V PG 2..........................................A-18
APPENDIX 8: SYSTEM SCHEMATIC 300A, 380-415V PG 1..........................................A-20
APPENDIX 9: SYSTEM SCHEMATIC 300A, 380-415V PG 2..........................................A-22
APPENDIX 10: SYSTEM SCHEMATIC 400A, 380-415V PG 1 ........................................A-24
APPENDIX 11: SYSTEM SCHEMATIC 400A, 380-415V PG 2 ........................................A-26

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