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