ESAB ESP-101 User manual

0558007871 06/2011
Instruction Manual (EN)
Manuel d'instruction (FR)
Manual de Instrucciones (ES)
Manual de instruções (PT)
Manuale di istruzioni (IT)
Bedienungsanleitung (DE)
Εγχειρίδιο χρήση (ΕΛ)
Uživatelská příručka (CS)
ESP-101
Plasma Arc Cutting System

2
DECLARATION OF CONFORMITY
According to
The Low Voltage Directive 2006/95/EC, The EMC Directive 2004/108/EC
Type of equipment
Plasma Cutting power source
Brand name or trade mark
ESAB
Type designation etc.
ESP 101 – (0558005215)
Manufacturer positioned outside the EEA:
Name, address, telephone No, telefax No:
ESAB Welding & Cutting Products
411 South Ebenezer Road, Florence, South Carolina 29501, USA
Phone: [phone], Fax: [phone]
Manufacture’s authorised representative established within the EEA
Name, address, telephone No, telefax No:
ESAB AB
Esabvägen, SE-695 81 Laxå, Sweden
Phone: [phone], Fax: [phone]
The following harmonised standard in force within the EEA has been used in the design:
EN 60974-1, Arc welding equipment – Part 1: Welding power sources
EN 60974-10, Arc welding equipment – Part 10: Electromagnetic compatibility (EMC) requirements
Additional information: Restrictive use, Class A equipment, intended for use in locations other than residential
By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorised
representative established within the EEA, that the equipment in question complies with the safety requirements
stated above.
Date / Datum
Laxå 2009-09-03
Signature / Underskrift Position / Befattning
Global Director
Equipment and Automation
Kent Eimbrodt
Clarification

3
TABLE OF CONTENTS
Language / Section Page
English (EN).....................................................................................................................................................................................................................5
French (FR) ................................................................................................................................................................................................................... 39
Spanish (ES) ................................................................................................................................................................................................................. 73
Portuguese (PT) .......................................................................................................................................................................................................107
Italian (IT) ...................................................................................................................................................................................................................141
German (DE) ..............................................................................................................................................................................................................175
Εγχειρίδιο χρήσης (ΕΛ) ..........................................................................................................................................................................................209
Uživatelská příručka (CS) ......................................................................................................................................................................................243
Section 5 Maintenance ..........................................................................................................................................................................................277
Section 6 Troubleshooting ...................................................................................................................................................................................279
Section 7 Replacement Parts ..............................................................................................................................................................................287

4
TABLE OF CONTENTS

ESP-101
Plasma Arc Cutting System
0558007871
Instruction Manual (English)
This manual provides installation and operation instructions for the following ESP-101 cutting packages starting with Serial
No.: PxxJ943xxx
Consoles:
P/N 0558004880 - ESP-101 460V
P/N 0558005215 - ESP-101 380-400V CE

6
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!

7
TABLE OF CONTENTS
SECTION TITLE................................................................................................................................................ PAGE
SECTION 1 SAFETY PRECAUTIONS .........................................................................................................................................................9
SECTION 2 DESCRIPTION .........................................................................................................................................................................11
2.1 General ..................................................................................................................................................................................... 11
2.2 Scope .......................................................................................................................................................................................... 11
2.3 ESP-101 Plasma Arc Cutting System: ..............................................................................................................................12
2.4 Package Ordering Information: .........................................................................................................................................13
2.5 PT-37 Torch Data ..................................................................................................................................................................... 13
2.6 System and Optional Accessories ..................................................................................................................................... 14
SECTION 3 INSTALLATION .......................................................................................................................................................................15
3.1 General ..................................................................................................................................................................................... 15
3.2 Equipment Required .............................................................................................................................................................15
3.3 Placement and Location ...................................................................................................................................................... 15
3.4 Inspection.................................................................................................................................................................................. 15
3.5 Primary Input Connections ................................................................................................................................................. 16
3.5.1 TUA2 Auto-Transformer Primary Input Connections ................................................................................................. 18
3.5.2 Input Air Connection ............................................................................................................................................................. 20
3.6 CNC Interface Connection ................................................................................................................................................... 21
3.6 CNC Interface Connection (continued) .......................................................................................................................... 22
3.7 Voltage Divider Adjustment ............................................................................................................................................... 23
3.7.1 Output Voltage Sample ........................................................................................................................................................ 23
3.8 Secondary Output Connections for Mechanized Cutting ....................................................................................... 24
3.9 PT-37 Torch Installation ........................................................................................................................................................25
3.10 Remote Junction Box Installation ..................................................................................................................................... 26
SECTION 4 OPERATION .............................................................................................................................................................................31
4.1 ESP-101 Controls ..................................................................................................................................................................... 31
4.2 Cutting with the ESP-101 ..................................................................................................................................................... 34
4.3 Electrode Wear ......................................................................................................................................................................... 34
4.4 Stando and Cut Quality ..................................................................................................................................................... 35
4.5 Dross Formation ...................................................................................................................................................................... 36
4.6 Common Cutting Issues ....................................................................................................................................................... 37
SECTION 5 MAINTENANCE ....................................................................................................................................................................243
SECTION 6 TROUBLESHOOTING .........................................................................................................................................................245
SECTION 7 REPLACEMENT PARTS ......................................................................................................................................................253
Diagrams and Parts List .............................................................................................................................attached packet

8
TABLE OF CONTENTS

9
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, ame proof
clothing, safety gloves.
- Do not wear loose tting 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 qualied electrician.
- Appropriate re extinquishing equipment must be clearly marked and close at hand.
- Lubrication and maintenance must not be carried out on the equipment during operation.
The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or
water. Protection is provided against touch with a nger, penetration of solid objects greater than 12mm and
against spraying water up to 60 degrees from vertical. Equipment marked IP23S may be stored, but is not in-
tended to be used outside during precipitation unless sheltered.
Enclosure Class
Maximum
Tilt Allowed
15°
CAUTION
If equipment is placed on a surface that
slopes more than 15°, toppling over may oc-
cur. Personal injury and / or signicant dam-
age to equipment is possible.

10
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 lter lens and wear
protective clothing.
- Protect bystanders with suitable screens or curtains.
FIRE HAZARD
- Sparks (spatter) can cause re. Make sure therefore that there are no inammable materials nearby.
NOISE - Excessive noise can damage hearing.
- Protect your ears. Use earmus 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
This product is solely intended for plasma cutting. Any other
use may result in personal injury and / or equipment damage.
CAUTION
CAUTION
To avoid personal injury and/or equipment
damage, lift using method and attachment
points shown here.

11
SECTION 2 DESCRIPTION
2.1 General
As shipped, the ESP-101 is fully assembled and ready to cut after being connected to input power, a source of
compressed air, and a PT-37 torch. The ESP-101 system uses the heavy-duty PT-37 (Mechanized Plasma) torch to
deliver cutting power for cutting materials up to 1-1/4 inch (32 mm) thick. Refer to the following pages for de-
scriptions of the ESP-101 packages available as well as performance specications.
2.2 Scope
The purpose of this manual is to provide the operator with all the information required to install and operate the
ESP-101 Plasma Arc Cutting System. Technical reference material is also provided to assist in troubleshooting the
cutting system.
USE THE ESAB PT37 PLASMARC TORCH WITH MECHANIZED CON
SOLES. USE OF TORCHES NOT DESIGNED FOR USE WITH THIS CON
SOLE COULD CREATE AN ELECTRIC SHOCK HAZARD.
WARNING

12
SECTION 2 DESCRIPTION
The ESP-101 plasma cutting system combines the newly redesigned ESP-101 console and PT-37 torch. The PT-37 plasma
cutting torch is designed to provide increased performance and longer consumable life resulting in higher production
rates at lower costs.
2.3 ESP-101 Plasma Arc Cutting System:
Pierces 3/4 inch (19.1 mm); Cuts 1-1/4 inch (32 mm) for Carbon & Stainless Steel
Pierces 3/4 inch (19.1 mm); Cuts 1 inch (25 mm) for Aluminum
Input ........................................................................................460 vac, 3 phase 60 Hz, 25 A
....................................................................... 380/400 vac, 3 phase 50/60 Hz, 30/29 A
Output .................................................................... 100 amps @ 160v - 100% duty cycle
Voltage requirements ........................................................ Idle 380-400, 460V, +/- 10%
....................................................................................... Cutting 380-400, 460V, +/- 15%
Air Supply Requirements .........................500 cfh @ 90 psig (236 l/min @ 6.2 bars)
Eciency ..............................................................................................................................89%
Power Factor .......................................................................................................................92%
CE 380-400 vac ................................................................................................ *Ssc min 4 MVA
....................................................................................................................... *Zmax 0.039 
Weight: ............................................................................................................125 lb (56.7 kg)
*Ssc min : Minimum short circuit power on the network in accordance with IEC61000-3-12.
*Zmax : Maximum permissible line on the network impedance in accordance with IEC61000-3-11.
Duty Cycle: The duty cycle refers to the time as a percentage of a ten-minute period that you can cut at a certain load without over-
heating. The duty cycle is valid for 40 degrees C.
Specications: ESP-101

13
SECTION 2 DESCRIPTION
2.4 Package Ordering Information:
The components that are included in the ESP-101 mechanized packages may be purchased separately by using the ap-
propriate P/N when placing orders. Individual part numbers are listed below:
Mechanized Package Ordering Information:
Available Packages:
ESP-101:
460 V CNC PT-37 with rack 25 ft (7.6 m) ............................................................................................................................................... 0558009450
460 V CNC PT-37 with rack 50 ft (15.2 m) ............................................................................................................................................ 0558009451
460 V CNC PT-37 w/o rack 25 ft (7.6 m) ................................................................................................................................................ 0558009452
460 V CNC PT-37 w/o rack 50 ft (15.2 m) ............................................................................................................................................. 0558009453
380-400 V CE CNC PT-37 with rack 25 ft (7.6 m) ................................................................................................................................ 0558009458
380-400 V CE CNC PT-37 with rack 50 ft (15.2 m) ............................................................................................................................. 0558009459
380-400 V CE CNC PT-37 w/o rack 17 ft (5.2 m) ................................................................................................................................. 0558009460
380-400 V CE CNC PT-37 w/o rack 25 ft (7.6 m) ................................................................................................................................. 0558009461
380-400 V CE CNC PT-37 w/o rack 50 ft (15.2 m) .............................................................................................................................. 0558009462
ESP-101 Multi-Voltage:
The ESP-101 multi-voltage console ships as a ESP-101 460 V console and a separate TUA2 Auto-Transformer.
208-575 V CNC PT-37 with rack 25 ft (7.6 m) ...................................................................................................................................... 0558009454
208-575 V CNC PT-37 with rack 50 ft (15.2 m) ................................................................................................................................... 0558009455
208-575 V CNC PT-37 w/o rack 25 ft (7.6 m) ....................................................................................................................................... 0558009456
208-575 V CNC PT-37 w/o rack 50 ft (15.2 m) .................................................................................................................................... 0558009457
2.5 PT-37 Torch Data
ESP-101 mechanized console uses the PT-37 torch. For cut data information, breakdown of parts, dimensions and maintenance refer to
torch manual.
PT-37 Torches:
PT-37 Torch with rack 4.5' (1.4m)...........................0558004860
PT-37 Torch with rack 17' (5.2m)............................0558004861
PT-37 Torch with rack 25' (7.6m)............................0558004862
PT-37 Torch with rack 50' (15.2m) .........................0558004863
PT-37 Torch w/o rack 4.5' (1.4m) ............................0558004894
PT-37 Torch w/o rack 17' (5.2m) ............................0558004895
PT-37 Torch w/o rack 25' (7.6m) ............................0558004896
PT-37 Torch w/o rack 50' (15.2m) .........................0558004897
ESP-101 Consoles:
460 V Console...................................................................................................................................................................................................0558004880
380-400 V CE Console ...................................................................................................................................................................................0558005215
Multi-Voltage Consoles:
The ESP-101 multi-voltage console ships as a ESP-101 460 V console and a separate TUA2 Auto-Transformer.
208, 230, 400, 460, 475, 500, 575 V ...........................................................................................................................................................0558004881
DO NOT USE OXYGEN WITH THIS TORCH! A HAZARDOUS FIRE MAY
RESULT.
WARNING

14
SECTION 2 DESCRIPTION
2.6 System and Optional Accessories
Remote Junction Box ..............................................................................................0558004887
The Remote Junction Box provides a means to extend the total length of the PT-37 Torch. When
used in combination with 50 ft., 75 ft., or 100 ft. extension cables, and any standard length of PT-
37 Plasma Torch from 4.5 ft. to 50 ft., a maximum torch length of 150 feet can be achieved.
TUA2 Auto-Tranformer ...........................................................................................0459145880
Converts an input voltage of 208, 230, 400, 475, 500, or 575 V to 460 V for use with an ESP-101
460 V console.
Torch Holder Assembly ...................................................................................p/n 0558005926
Gas Flow Measuring Kit ................................p/n 19765 ("CE" units - 0558000739)
Valuable troubleshooting tool allows measurement of the actual air ow through the torch.
Remote Hand Switch with 25 ft. (7.6 m) lead .......................................... p/n 0558005548
with 50 ft. (15.2 m) lead ....................................... p/n 0558005549
Enables non-automated mechanized cutting using the PT-37 or PT-38 torch. Connects to the
CNC interface receptacle on the rear panel.
CNC Cable 25 ft. (7.6 m) ...................................................................................p/n 0558008833
50 ft. (15.2 m) ................................................................................p/n 0558008834
Connects between the CNC interface receptacle on the rear panel and the CNC.
Extension Cable 50 ft. (15.2 m) ......................................................................................p/n 0558004888
75 ft. (22.9 m) ..................................................................................... p/n 0558009266
100 ft. (30.5 m) ................................................................................... p/n 0558004889
Plate Rider ..............................................................................................................p/n 0560936972
Used to maintain a constant stando while cutting thin materials or using machines without
automatic height control.

15
3.1 General
Proper installation is important for satisfactory and trouble-free operation of the ESP-101 cutting package. It is
suggested that each step in this section be studied carefully and followed closely.
3.2 Equipment Required
A source of clean, dry, oil-free air that supplies 500 cfh (236 l/m) at 90 psig (6.2 bars) is required for the cutting
operation. The air supply should not exceed 150 psig (10.3 bars) (the maximum inlet pressure rating of the air
lter-regulator supplied with the package).
3.3 Placement and Location
After selecting an installation site, place the ESP-101 in the desired location. The unit may be lifted by either an
overhead crane or forklift truck. If using forklift truck, be sure that the lift forks are long enough to extend com-
pletely under the base. If using straps, use two separate straps as shown in the illustration.
Adequate ventilation is necessary to provide proper cooling of the ESP-101. The amount of
dirt, dust, and excessive heat to which the equipment is exposed, should be minimized. There
should be at least one foot of clearance between the ESP-101 power source and wall or any
other obstruction to allow freedom of air movement through the power source.
3.4 Inspection
1. Remove the shipping container and all packing material and inspect for evidence of
concealed damage which may not have been apparent upon receipt of the ESP-101.
Notify the carrier of any defects or damage at once.
2. Check container for any loose parts prior to disposing of shipping materials.
3. Check air louvers and any other openings to ensure that any obstruction is removed.
SECTION 3 INSTALLATION
CAUTION Position the ESP-101 at least 10 feet (3 meters) from the cutting area.
Sparks and hot slag from the cutting operation can damage the unit.
INSTALLING OR PLACING ANY TYPE OF FILTERING DEVICE WILL RE
STRICT THE VOLUME OF INTAKE AIR, THEREBY SUBJECTING THE POW
ER SOURCE INTERNAL COMPONENTS TO OVERHEATING. THE WAR
RANTY IS VOID IF ANY TYPE OF FILTER DEVICE IS USED.
WARNING
-- 7 --
ba34d1ea
5.1 Lifting instructions
With power source With trolley and power source With trolley2 and power source
5.2 Placing
Position the welding power source such that its cooling air inlets and outlets are not
obstructed.
GB

16
SECTION 3 INSTALLATION
3.5 Primary Input Connections
The ESP-101 460V consoles are equipped
with approximately 15 ft. of 4-conductor
input power cable for 3 phase connection.
See specication section or rating plate.
STANDARD UNITS
(NON-CE)
CE UNITS
(EUROPE)
PHASE 3 PHASE 3
L1 Black L1 Brown
L2 Red L2 Black
L3 White L3 Gray
GND Green GND Green/Yel
ELECTRIC SHOCK CAN KILL! PRECAUTIONARY MEASURES SHOULD
BE TAKEN TO PROVIDE MAXIMUM PROTECTION AGAINST ELECTRI
CAL SHOCK. BE SURE THAT ALL POWER IS OFF BY OPENING THE LINE
WALL DISCONNECT SWITCH AND BY UNPLUGGING THE POWER
CORD TO THE UNIT WHEN CONNECTIONS ARE MADE INSIDE OF THE
POWER SOURCE.
CUSTOMER FUSED LINE DISCONNECT SWITCH
(See Table 3-1)
PRIMARY INPUT
POWER CABLE
Figure 3-1. Input Connections
WARNING
A. 460V
B. 380-400V
L1
L2
L3
GND

17
ESP-101
Input Requirements Input & Gnd Fuse
Volts Phase Amps Conductor Size
CU/AWG Amps
380(CE) 3 30 6 mm240
400(CE) 3 29 6 mm240
460 3 25 8 35
Table 3-1. Recommended Sizes For Input Conductors and Line Fuses
SECTION 3 INSTALLATION
ESP-101
(With Optional Auto-transformer)
Input Requirements Input & Gnd Fuse
Volts Phase Amps Conductor Size
CU/AWG Amps
208 3 53 6 70
230 3 50 6 70
400 3 29 6 mm240
460 3 25 8 35
475 3 24 8 35
500 3 22 10 30
575 3 18 10 25
Before connecting to input power, make sure there is a line (wall) disconnect switch with fuses or circuit break-
ers at the main power panel. You may either use the factory-installed input power cable 4/c, type SO (90 °C), 15
ft (4.6 m) length or provide your own input power leads. If you choose to provide your own, make sure they are
insulated copper conductors. You must have three (3 phase) power leads and one ground wire. The wires may
be heavy rubber covered cable or may be run in a solid or exible conduit. Ensure the ground lead is suciently
long inside the machine. In an event where the power cord is pulled from the machine, the ground lead must
not break from the ground connection before the power leads have broken from their connection. Refer to
Table 3-1 for recommended input conductors and line fuse sizes.
BEFORE MAKING ANY CONNECTIONS TO THE POWER SOURCE OUT
PUT TERMINALS, MAKE SURE THAT ALL PRIMARY INPUT POWER TO
THE POWER SOURCE IS DEENERGIZED OFF AT THE MAIN DISCON
NECT SWITCH AND THAT THE INPUT POWER CABLE IS UNPLUGGED.
THE CHASSIS MUST BE CONNECTED TO AN APPROVED ELECTRICAL
GROUND. FAILURE TO DO SO MAY RESULT IN ELECTRICAL SHOCK, SE
VERE BURNS OR DEATH.
WARNING
WARNING
WARNING
ELECTRIC SHOCK CAN KILL! BEFORE MAKING ELECTRICAL INPUT CON
NECTIONS TO THE POWER SOURCE, "MACHINERY LOCKOUT PRO
CEDURES" SHOULD BE EMPLOYED. IF THE CONNECTIONS ARE TO BE
MADE FROM A LINE DISCONNECT SWITCH, PLACE THE SWITCH IN THE
OFF POSITION AND PADLOCK IT TO PREVENT INADVERTENT TRIPPING.
IF THE CONNECTION IS MADE FROM A FUSEBOX, REMOVE THE CORRE
SPONDING FUSES AND PADLOCK THE BOX COVER. IF IT IS NOT POSSI
BLE TO USE PADLOCKS, ATTACH A RED TAG TO THE LINE DISCONNECT
SWITCH OR FUSE BOX WARNING OTHERS THAT THE CIRCUIT IS BEING
WORKED ON.

18
3.5.1 TUA2 Auto-Transformer Primary Input Connections
SECTION 3 INSTALLATION
Connecting a Multi-Voltage Version
The ESP-101 460V version is equipped with an input power cable which may be used to connect to the output of the TUA2
Auto-Transformer. You may either use the factory-installed input power cable (4/c, type SO (90 °C) or provide your own in-
put power leads. If you choose to provide your own, make sure they are insulated copper conductors. You must have three
(3 phase) power leads and one ground wire. Refer to Table 3-1 for recommended input conductors.
Figure 3-2b. Primary Power Cable from ESP-101 to TUA2 Auto-Transformer
Step 2: Route the power cable through the upper strain relief of the TUA2 Auto-Transformer as shown below. Connect L1,
L2, L3 leads to the 460 V terminals. Connect the ground lead to the forward ground stud. Ensure all connections
are secure. Do not overtighten the strain relief.
10"
(254 mm)
7"
(178 mm)
3"
(76 mm)
16"
(406 mm)
Note:
L1, L2 & L3 strip wires 3/8" (9.5 mm) .
GND wire strip 1" (25.4 mm) or
5/16" ring terminal.
L1
L2
L3
GND
Upper Strain Relief
460 V Terminals
To ESP-101 460 V
console
Primary Power Cable from ESP-101 to TUA2 Auto-Transformer
Step 1: Begin by preparing the power cable,
then positioning in the TUA2 as shown.
Figure 3-2c. Primary Power Cable from ESP-101 to TUA2 Auto-Transformer 460 V Terminals
Figure 3-2a. Connection Diagram for TUA2 Auto-Transformer
from 460 V
terminals
3-phase w/
ground
ESP-101
460V
Console
TUA2
Auto-
Transformer
PT-37 Torch
4.5’, 17', 25', 50’
to appropriate supply
voltage terminals

19
SECTION 3 INSTALLATION
The TUA2 Auto-Transformer is not equipped with an input power cable. A 4/c, type SO (90 °C) cable or equivalent is recom-
mended. Ensure they are insulated copper conductors. You must have three (3 phase) power leads and one ground wire.
Select an input power cable size corresponding to the input supply voltage listed in Table 3.1.
Primary Power Cable from Fused Line Disconnect Switch
to TUA2 Auto-Transformer
Figure 3-3a. Primary Power Cable from Fused Line Disconnect Switch
to TUA2 Auto-Transformer
Note:
L1, L2 & L3 strip wires 3/8" (9.5 mm) .
GND wire strip 1" (25.4 mm) or
5/16" ring terminal.
Step 2: Route the power cable through the lower strain relief of the TUA2 Auto-Transformer as shown below. Connect L1,
L2, L3 leads to the voltage terminals that match your input power supply voltage. Connect the ground lead to the
rear ground stud. Ensure all connections are secure. Do not overtighten the strain relief.
Lower Strain Relief
Step 1: Begin by preparing the power cable, then positioning in the TUA2 as shown:
10"
(254 mm)
10 1/2"
(266.7 mm)
8"
(203.2 mm)
18"
(457.2 mm)
L1
L2
L3
GND
Ensure three input power jumper cables are connected properly to the
Auto-Transformer for your input power.
CAUTION
Appropriate supply
voltage terminals
Ground Connection
Figure 3-3b. Primary Power Cable from Fused Line Disconnect Switch
to TUA2 Auto-Transformer appropriate supply voltage terminals
(575 V pictured)
To Fused Line
Disconnect Switch
To ESP-101 460 V
console

20
SECTION 3 INSTALLATION
Figure 3-4. Input Connections / Fuse Replacement
Connect your air supply to the inlet connection of the lter/regulator.
3.5.2 Input Air Connection
Replace fuse with Slo-Blo, 2 Amp, 600 V only
MAKE SURE THE POWER SOURCE IS
SWITCHED OFF BEFORE REMOVING FUSE.
WARNING
Pre-ltered DRY AIR SUPPLY (Customer Supplied)
(90 - 150 psi / 6.2 - 10.3 bars)