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
i

ii
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