ESAB ESP-50 User manual

ESP-50
Plasma Arc Cutting Package
0558004720
Instruction Manual (GB)
This manual provides installation and operation instructions for the following ESP-50 cutting packages starting with Serial No. :
Consoles:
P/N 0558004371 - 208/230 V, 50/60 Hz, 1 or 3-phase
P/N 0558004372 - (380-400)/460 V, 50/60 Hz, 3-phase, CE

74
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!

75
TABLE OF CONTENTS
SECTION TITLE PAGE
SECTION 1 SAFETY PRECAUTIONS.................................................................................................................................77
1.0 Safety Precautions..........................................................................................................................................77
SECTION 2 DESCRIPTION......................................................................................................................................................79
2.1 General...................................................................................................................................................................79
2.2 Scope ......................................................................................................................................................................79
2.3 Packages Available.............................................................................................................................................79
2.4 Specications.......................................................................................................................................................79
2.5 Ordering Information........................................................................................................................................80
2.6 Torch Data .............................................................................................................................................................80
2.7 Torch Specications...........................................................................................................................................82
2.8 Optional Accessories.........................................................................................................................................83
2.9 Spare Parts Kits....................................................................................................................................................84
SECTION 2 INSTALLATION....................................................................................................................................................85
3.1 General...................................................................................................................................................................85
3.2 Equipment Required.........................................................................................................................................85
3.3 Location .................................................................................................................................................................85
3.4 Inspection..............................................................................................................................................................85
3.5 Primary Electrical Input Connections..........................................................................................................85
3.6 Secondary Electrical Output Connections ................................................................................................86
3.7 Connecting ESP-50 for 200(208)Vac Input ................................................................................................89
3.8 Connecting ESP-50 for 400(460)Vac Input ................................................................................................90
SECTION 3 OPERATION .........................................................................................................................................................91
4.1 ESP-50 Controls...................................................................................................................................................91
4.2 Common Cutting Problems............................................................................................................................93

76
TABLE OF CONTENTS

77
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
therequirements thatapplytothistypeofweldingor plasmacuttingequipment. Thefollowingrecommendations
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.

78
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

79
2.1 GENERAL
The ESP-50 is a compact, completely self-contained plasma cutting system. As
shipped, the system is ready to cut after being connected to input power, a source
of compressed air (60 - 100 psi / 4.1 - 6.9 bars) and a PT-35 torch.The ESP-50 package
uses the PT-35 torch to deliver cutting power for severing materials up to 5/8 inch
(15.9 mm) thick. Refer to the following paragraphs for descriptions of the ESP-50
packages available as well as performance specications.
2.2 SCOPE
Thepurposeofthismanualistoprovidetheoperatorwithalltheinformationrequired
to install and operate the ESP-50 plasma arc cutting package. Technical reference
material is also provided to assist in troubleshooting the 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 other torch for use on this
console.
WARNING
The ESP-50 plasma cutting package combines the ESP-50 and PT-35 torch. A typical
package includes: ESP-50 Console/Power Source,PT-35Torch - 25' (7.6m) or 50' (15.2
m), Torch Spare Parts Kit and a power cable. See Section 3 for installation details.
2.3 PACKAGES AVAILABLE
2.3.1 ESP50 Mechanized Cutting Packages
2.4 SPECIFICATIONS: ESP50
Cuts ................................................................................................................................................................50 in. (12.7 mm)
1 ph. Input........................................................................................................... 208/230 vac, 1 ph, 50/60 Hz, 46/41 A
3 ph. Input..................................................................................................................208/230 vac, 3 ph, 50/60 Hz, 22 A
.......................................................................................................................400/460 vac, 3 ph, 50/60 Hz, (10-9)/8 A
Output @ 100% duty cycle...............................................................................................................50 amps @ 100 vac
Dimensions ..........................................................................................................................................W = 10.1” (275 mm)
..............................................................................................................................................................H = 18.3”(465 mm)
..............................................................................................................................................................D = 20.3” (576 mm)
Weight...........................................................................................................................................................85 lbs. (38.6 kg)
Minimum Air Requirements ...............................................................250 cfh @ 60 psig (117.9 l/min @ 4.1 bars)
SECTION 2 DESCRIPTION

80
2.6 TORCH DATA
ESP-50 uses the PT-35 torch. For complete list and breakdown of parts, refer to Figure 2.1 and 2.2.
2.5 ORDERINGINFORMATION:
ESP-50, 230/230V, 25 ft. (7.6m), PT-35, with rack...............................................................................................................................................................................0558004378
ESP-50, 208/230V, 50 ft. (15.2m), PT-35, with rack............................................................................................................................................................................0558004379
ESP-50, 230/230V, 25 ft. (7.6m), PT-35, without rack........................................................................................................................................................................0558004973
ESP-50, 208/230V, 50 ft. (15.2m), PT-35, without rack.....................................................................................................................................................................0558004974
ESP-50, 400CE/460V, 25 ft. (7.6m), PT-35, with rack .........................................................................................................................................................................0558004376
ESP-50, 400CE/460V, 50 ft. (15.2m), PT- 35, with rack......................................................................................................................................................................0558004377
ESP-50, 400CE/460V, 25 ft. (7.6m), PT-35, without rack..................................................................................................................................................................0558004374
ESP-50, 400CE/460V, 50 ft. (15.2m), PT- 35, without rack ..............................................................................................................................................................0558004375
The components that are included in the ESP-50 packages may be purchased separately by using the appropriate P/N when placing orders. Individual part
numbers are listed below:
Consoles:
ESP-50 208/230 V, 50/60 Hz, 1/3-ph...............................................................................................................................................................................................................0558004371
ESP-50 (380-400)/460 V, 50/60 Hz, 3-ph.......................................................................................................................................................................................................0558004372
PT-35 Torches:
PT-35 Torch, 25 ft. (7.6m), with rack ................................................................................................................................................................................................................0558004351
PT-35 Torch, 50 ft. (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 0558004356, Heat Shield P/N 0558004357, Electrode P/N 0558005200
Metal
Thickness
15.875
12.700
9.525
6.350
3.175
2.515
1.499
1.067
0.610
mm
in.
Travel Speed
Optimum Maximum
18
30
48
86
200
250
450
600
750+
457
762
1219
2184
5080
6350
11430
15240
19050+
12
25
42
82
150
225
375
450
750+
304
635
101
2082
3810
5715
9525
11430
19050+
ipm (mm/min) ipm (mm/min)
.625
.500
.375
.250
.125
.099
(12/13 ga.)
.059
( 16 ga.)
.042
(19 ga.)
.024
(24 ga.)
Amps
50
50
50
50
50
50
50
50
50
Air
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
Cutting
Height
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
Pierce
Height
in. mm
NR
NR
4.750
3.962
3.962
3.175
3.175
3.175
3.175
NR
NR
.187*
.156*
.156*
.125
.125
.125
.125
NR = Not Recommended
* = If using a xed height torch or plate rider, set cutting height equal to pierce height; cutting speed may
have to be reduced due to increased cut height.
SECTION 2 DESCRIPTION

81
50 AMP Data, Nozzle P/N 0558004356, Heat Shield P/N 0558004357, Electrode P/N 0558005200
STAINLESS STEEL
Cutting Parameters for the PT-35 Torch
GALVANIZED STEEL
50 AMP Data, Nozzle P/N 0558004356, Heat Shield P/N 0558004357, Electrode P/N 0558005200
Metal
Thickness
12.700
9.525
6.350
4.763
3.175
2.515
1.499
1.067
0.610
mm
in.
Travel Speed
Optimum Maximum
18
30
60
93
162
195
390
750+
750+
457
762
1524
2362
4114
4953
9906
19050+
19050+
13
22
50
70
125
172
345
750+
750+
330
558
1270
1778
3175
4368
8763
19050+
19050+
ipm (mm/min) ipm (mm/min)
.500
.375
.250
.188
.125
.105
(12/13 ga.)
.060
(16 ga.)
.043
(19 ga.)
.025
(24 ga.)
Amps
50
50
50
50
50
50
50
50
50
Air
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
Pierce
Height
in. mm
NR
NR
4.750
4.750
3.962
3.175
3.175
3.175
3.175
NR
NR
.187*
.187*
.156*
.125
.125
.125
.125
NR = Not Recommended
* = If using a xed height torch or plate rider, set cutting height equal to pierce height; cutting speed may
have to be reduced due to increased cut height.
Metal
Thickness
1.803
1.575
0.635
mm
in.
Travel Speed
Optimum Maximum
210
352
750
5334
8940
19050
170
315
450
4318
8001
11430
ipm (mm/min) ipm (mm/min)
.071
(15 ga.)
.062
(16 ga.)
.025
(25 ga.)
Amps
50
50
50
Air
Pressure
psig bar
60
60
60
4.1
4.1
4.1
in. mm
3.175
3.175
3.175
.125
.125
.125
Cutting
Height
Pierce
Height
in. mm
3.175
3.175
3.175
.125
.125
.125
SECTION 2 DESCRIPTION

82
Insulator - 0558004387
Electrode - 0558005200
Torch Body Assembly -
0558004390
Cutting "A" Nozzle -
0558004356
Figure 2-1. PT-35 Torch
Heat Shield 50A -
0558004357
2.7 TORCHSPECIFICATIONS:
50 AMP Data, Nozzle P/N 0558004356, Heat Shield P/N 0558004357, Electrode P/N 0558005200
ALUMINUM
Cutting Parameters for the PT-35 Torch
• 0558004356 - Standard "A" Nozzle
• 0558004358 - Special "B" Nozzle for duct
cutting & expanded metal
Nozzles
Cutting "B" Nozzle -
0558004358
Metal
Thickness
12.700
9.525
7.950
6.350
4.763
3.175
2.413
1.245
1.092
0.762
mm
in.
Travel Speed
Optimum Maximum
30
45
57
87
150
230
300
465
502
750+
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.)
.049
(16 ga.)
.043
(17 ga.)
.031
(20 ga.)
Amps
50
50
50
50
50
50
50
50
50
50
Air
Pressure
psig bar
60
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
4.1
in. mm
3.175
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
.125
Cutting
Height
Pierce
Height
in. mm
NR
NR
6.350
4.775
3.962
3.962
3.175
3.175
3.175
3.175
NR
NR
.250*
.188*
.156*
.156*
.125
.125
.125
.125
NR = Not Recommended
* = If using a xed height torch or plate rider, set cutting height equal to pierce height; cutting speed may
have to be reduced due to increased cut height.
SECTION 2 DESCRIPTION

83
Figure 2-2. PT-35 Dimensions
2.8 OPTIONALACCESSORIES:
PlasmaFlow MeasuringKit:
This valuable troubleshooting tool allows measurement of
the actual plasma gas ow through the torch ............................................. 19765 (0558000739)
(NOTE: 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 (0558004250)
Plate Rider - height control for PT-35........................................................................... 0560936972
Stando Tool - Designed for use with Plate Rider for setting nozzle stando height.
Can also be used separately. ................................................................................................................ 0558004364
SECTION 2 DESCRIPTION
11
SECTION 2 DESCRIPTION
2.0 DESCRIPTION
This booklet covers accessories, maintenance, and parts information for the
PT-35 plasma torches. For installation and operating instructions for your
cutting package, refer to your power source instruction manual.
The PT-35 is a 50 amp capacity, pilot-arc mechanized torch available in 4
different versions. The torch uses clean, dry air as the cut gas for cutting carbon
steel, aluminum, or stainless steel.
DO NOT use oxygen with this
torch! A hazardous fire may
result.
PT-35
With Rack; 7.6m (25 ft.) ............................................................. 0558004351
With Rack; 15.2m (50 ft.) ........................................................... 0558004352
Without Rack; 7.6m (25 ft.) ........................................................ 0558004353
Without Rack; 15.2m (50 ft.) ...................................................... 0558004354
WARNINGWARNING
WARNINGWARNING
WARNING

84
Description P/N Quantity
Shield, Retaining 0558004357 1
50 amp "A" Nozzle 0558004356 4
Electrode 0558005200 6
Fuse 2amp, 600vdc 0558003075 1
Insulator 0558004387 1
PT-35, 50 A, Spare Parts Kit, P/N 0558005210
Contents:
Description P/N Quantity
Electrode 0558005200 10
50 amp "A" Nozzle 0558004356 15
ConsumableValue 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/N 0558005201
Contents:
Consumable Set..............................................................................................................0558005201
50 A Spare Parts Kit........................................................................................................0558005210
2.9 SPARE PARTS KITS:
Description P/N Quantity
Electrode 0558005200 1
50 amp "B" Nozzle 0558004358 1
Consumable Set, P/N 0558005202
Contents:
Consumable Set..............................................................................................................0558005202
SECTION 2 DESCRIPTION

85
3.1 GENERAL
Proper installation is important for satisfactory and trouble-free operation of the
ESP-50 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 air that supplies 250 cfh (118.0 l/m) at 60-75 psig (4.1 - 5.2 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 LOCATION
Adequate ventilation is necessary to provide proper cooling of the ESP-50. 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-50
power source and wall or any other obstruction to allow freedom of air movement
through the power source.
3.4 INSPECTION
A. Removetheshippingcontainerandallpackingmaterialandinspectforevidence
of concealed damage which may not have been apparent upon receipt of the
ESP-50. Notify the carrier of any defects or damage at once.
B. Check container for any loose parts prior to disposing of shipping materials.
C. Check air louvers and any other openings to ensure that any obstruction is
removed.
3.5 PRIMARY ELECTRICAL INPUT CONNECTIONS
FIGURE 32
NOTE: If using 200(208) V input power, the ESP-50 must be reconnected for 200 V
use as directed in Section 3.7 and Figure 3-4.
Ifusing(380-400)Vinputpower,theESP-50mustbereconnectedasdirected
in Section 3.8, Figure 3-5.
NOTE: The208/230Vmodelsareequippedwithaplugforsingle-phaseconnection
only. The plug is mounted to a 4-conductor cable. If 3-phase connection is
desired, remove the plug and proceed as described.
Installing or placing any type of
ltering device will restrict the
volumeofintakeair,therebysub-
jectingthepowersourceinternal
componentstooverheating.The
warranty is void if any type of
lter device is used.
ELECTRICSHOCKCANKILL!Precau-
tionary measuresshould betaken
to provide maximum protection
against electrical shock. Be sure
thatallpowerisobyopeningthe
line(wall)disconnectswitchandby
unplugging the power cord to the
unit when connections are made
inside of the power source.
Be sure that the power source is
properlyconguredforyourinput
power supply. DO NOT connect
a power source configured for
208/230 V to a 460 V input power
supply. Damage to the machine
may occur.
Thechassismustbeconnectedto
an approved electrical ground.
Failure to do so may result in
electrical shock, severe burns
or death.
WARNING
CAUTION
WARNING
CAUTION
A line (wall) disconnect switch with fuses or circuit breakers should be provided at
the main power panel (see Table 3-1 for fuse sizes). The input power cable of the
console may be connected directly to the disconnect switch or you may purchase a
proper plug and receptacle from a local electrical supplier. If using plug/receptacle
combination, see Table 3-1 for recommended input conductors for connecting re-
ceptacle to line disconnect switch.
SECTION 3 INSTALLATION

86
3.6 SECONDARY ELECTRICAL OUTPUT CONNECTIONS
FIGURE 32
1. For operator safety, the torch connections are located on the output terminal
board behind the lower portion of the front panel. Remove access door to
output terminal board from right panel of power source.
2. Thread the power cable & pilot arc cable of the PT-35 through the right open
bushing of the front panel. Connect power cable to the torch tting (left-hand
threads); bolt the pilot arc cable ring connection to the copper terminal. Make
sure the power and pilot arc cable connections are wrench-tight.
3. Reassemble the access door to the power source.
4. Connect your air supply to the inlet connection of the lter-regulator.
5. Clamp the work cable to the 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
208 3 26A/Ph. 6 50
230 1 49A 6 80
230 3 24A/Ph. 6 50
400 3 13 10 25
460 3 11 10 25
Before making any connections
to the power source output ter-
minals,makesurethatallprimary
inputpowertothepowersourceis
deenergized (o) at the main dis-
connectswitch andthatthe input
power cable is unplugged.
Table 3-1. Recommended Sizes For Input Conductors and Line Fuses
WARNING
Clamp the work cable to the
workpiece.Besuretheworkpiece
isconnectedtoanapprovedearth
ground with a properly sized
ground cable.
Figure 3-1. PowerCut Interconnection Diagram
F14-080 A
May, 1999
Installation, Operation, and Maintenance Manual for the
SHADOW
GANTRY SHAPE CUTTING MACHINE
411 S. Ebenezer Road
Florence, SC 29501-0545
SAFETY GROUND
PT-35
Torch cable
CNC Control cable
SECTION 3 INSTALLATION

87
WORK
SAFETY GROUND
Allow at least 10 ft. (3m)
between work and power source
ACCESS DOOR FOR
TORCH CONNECTION
Preltered AIR SUPPLY
(Customer Supplied)
(100 psig max /6.9 bars max)
CUSTOMER FUSED LINE DISCON-
NECT SWITCH
(See Table 3.1 and WARNING in
regards to chassis ground in Sec-
tion 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 208/230V models are equipped with a plug for single-
phaseconnectiononly.Theplugismountedtoa4-conductor
cable. If 3-phase connection is desired, remove and discard
the plug and refer to Sect. 3.5.
ACCESS FOR CNC
INTERFACE CONNECTIONS.
(See Detail“A”)
SECTION 3 INSTALLATION

88
Figure 3.3 - MECHANICAL CUTTING INTERFACE DIAGRAM
CNC Interface Connection (Located inside console, left side of base.)
DETAIL "A"
1BLUE
RED
GREEN
ORANGE
BLACK
WHITE
3
4
5
6
2
FACTORY WIRED
MACHINES
SECTION 3 INSTALLATION

89
T1-X3
TB3
T1-X2
X1
+
FROM MAIN TRANS-
FORMER
~
~
~
OUTPUT BRIDGE
(D1)
Figure 3.4.B
3.7 CONNECTING ESP50 FOR 200208 VAC INPUT
The ESP-50 power source with 200/230 vac, single-phase input capability is factory
set for 230 vac input. If using 200(208) vac input, the ESP-50 must be reconnected
as follows before connecting to your input power:
1. Remove the cover from the ESP-50 power source.
2. Locate the Input Bridge (IBR) and TB5 terminal block (see Figure 3.4.A) on the
left side towards the rear panel. Disconnect the gray lead fromTB5-2 and then
connect it to TB5-1.
3. Locate the output bridge (D1) on left side towards the front panel (see Figure
3.4.B). Disconnect and swap leads X2 and X3 from the main transformer. For
200(208) vac input, X2 is connected to TB3 and X3 is connected to terminal 3
of D1. Make sure the connections are rmly tightened.
4. Leave all other wires the same.
5. Reinstall the cover and connect the ESP-50 to 208 vac input power.
R
R2
S G
T+
(IBR)
INPUT
BRIDGE
208
VAC
GRY
Figure 3.4.A
Figure 3-4. Original Factory Setup for 230 Vac Input on
Power Source with 200/230 Vac Input Power Capability
1
2
3
ELECTRIC SHOCK CAN KILL! Pre-
cautionary measures should be
taken to provide maximum pro-
tection against electrical shock.
Be sure that all power is o by
opening the line (wall) discon-
nect switch and by unplugging
the power cord to the unit when
primary electrical connections
are made to the power supply.
WARNING
Note: Factory set for 230 VAC input.
For 208VAC move GRY wire fromTB5-2 to TB5-1, moveT1-X2 toTB3 and T1-X3 to D1-3
BLK
TB5
BLK
230
VAC
208 VAC
INPUT
230 VAC
INPUT
GRY
SECTION 3 INSTALLATION

90
FROM MAIN TRANS-
FORMER
3.8 CONNECTING ESP50 FOR 400/460 VAC INPUT
The ESP-50 power source with (380-400)/460 vac, 3-phase input capability is fac-
tory set for 460 vac input. If using 400 vac input, the ESP-50 must be reconnected
as follows before connecting to your input power:
1. Remove cover from the ESP-50 power source.
2. Locate the Input Bridge (IBR) and TB5 terminal block (see Figure 3.5.A) on the
left side towards the rear panel. Disconnect the gray lead fromTB5-2 and then
connect it to TB5-1.
3. Locate the output bridge (D1) on left side towards the front panel (see Figure
3.5.B). Disconnect and swap leads X2 and X3 from the main transformer. For
400 vac input, X2 is connected toTB3 and X3 is connected to terminal 3 of D1.
Make sure the connections are rmly tightened.
4. Leave all other wires the same.
5. Reinstall cover and connect the ESP-50 to 400 vac input power.
Figure 3-5. Original Factory Setup for 460 Vac Input on
Power Source with 400/460 Vac Input Power Capability
ELECTRIC SHOCK CAN KILL! Pre-
cautionary measures should be
taken to provide maximum pro-
tection against electrical shock.
Be sure that all power is o by
opening the line (wall) discon-
nect switch and by unplugging
the power cord to the unit when
primary electrical connections
are made to the power supply.
WARNING
T1-X3
TB3
T1-X2
X1
+~
~
~
OUTPUT BRIDGE
(D1)
Figure 3.5.B
R
R2
S G
T+
(IBR)
INPUT
BRIDGE
400
VAC
Figure 3.5.A
1
2
3
TB5
460
VAC
400 VAC
INPUT
460 VAC
INPUT
GRY
BLU
WHT
SECTION 3 INSTALLATION

91
4.1 ESP-50 CONTROLS (FIGURE 4-1)
A. PowerSwitch(locatedonrearpanel). When placed in ONposition, the white
pilot light will glow indicating control circuit is energized and the cooling fan
will run.
B. Output Current Control. Adjustable from 20 to 50 amperes.
C. AirTestSwitch. WhenplacedinTestposition,airlter-regulatorcanbeadjusted
to desired pressure (60 - 75 psig / 4.1 - 5.2 bars) before cutting operations. Al-
low air to ow for a few minutes. This should remove any condensation that
may have accumulated during shutdown period. Be sure to place switch in
OPERATE position before starting cutting operations.
D. Pilot Arc Select Switch.
Hi: Set pilot arc current level to "High" when improved stability is needed. May
lessen consumable life.
Low: Maintains "Low" pilot arc current level. May improve consumable life.
Auto: Adjusts pilot arc based on output current selected. Use for standard
cutting.
E. Fault Light. Will glow amber under the following conditions and opera-
tions will come to a complete stop.
Start Signal: On power-up, fault light will be on continuously when a start
signal is present. Remove start signal to reset.
Parts in Place Fault:The fault light will be on continuouslyat power-up.This
indicates missing or worn consumables. Turn power o and inspect torch.
Over Temperature: The fault light will be mostly o but will ick on for
about 1/10th of a second every second.This indicates that the duty cycle has
been exceeded. Allow the power source to cool down before continuing to
operate.
High/Low Line Voltage: The fault light will rapidly blink on and o (ve
times per second). This indicates that the input voltage is outside the“+ or -”
15% range of the input rating.
Over-Current:Thefaultlightwillbeoncontinuously.Thisindicatesthatinput
current has been exceeded.
Allfaultsignalswillremainonforaminimumof10seconds.Iffaultclears,
all will reset automatically except for over-current.To clear over-current,
the power must be shut o for 5 seconds and then turned back on.
ELECTRIC 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NOTtouchanytorchpartsfor-
wardofthetorchhandle (nozzle,
heat shield, electrode, etc.) with
power switch on.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
• WearweldinghelmetwithNo.6
or 7 lens shade.
• Weareye,ear,andbodyprotec-
tion.
Position the ESP-50 at least 10
feet (3 meters) from the cutting
area. Sparks and hot slag from
the cutting operation can damage
the unit.
WARNING
WARNING
CAUTION
SECTION 4 OPERATION

92
Figure 4-1. ESP-50 Controls
REAR VIEW
AIR REGULATOR
CONTROL KNOB
FAULT LIGHT
(AMBER)
POWER LIGHT
(WHITE)
AIR
PRESSURE
GAUGE
AIR TEST
SWITCH
CURRENT
CONTROL
KNOB
POWER ON-OFF
(I-O) SWITCH
FUSE (3A)
NOTE: Whenreplacingthenozzle,alwaysinspecttheelectrodeforwear.Ifelectrode
wear is 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 using
the electrode beyond the recommended limit. Refer to Figure 4-2.
Figure 4-2. Electrode Wear Limit
REPLACE ELECTRODE BEFORE LENGTH
BECOMES SHORTER THAN .060" INCH
(1.5 MM)
PILOT ARC
SELECT SWITCH
CAUTION
Replace when eroded beyond
.060"(1.5mm) Depth.
NEW WORN
SECTION 4 OPERATION