ESAB 100i User Manual

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100i, 200i, 300i, and 400i

Plasma Systems

Instruction Manual

Article Number: 0560956430

Revision Date: May 13, 2016

Revision Number: AB

Language: ENG

Table of Contents

Default Chapter4
- User Responsibility4
- Table of Contents7
Section 1: Safety11
- Safety Precautions - ENGLISH11
- Précautions de Sécurité - FRENCH CANADIAN16
Section 2: Specifications21
- General Description of the System21
- Plasma Power Supply21
- Remote Arc Starter21
- Gas Control Module21
- Precision Plasma Cutting Torch21
- Specifications & Electrical Requirements22
- Power Supply Dimensions24
- Power Supply Rear Panel Features25
- Gas Requirements26
- Gas Applications28
- Torch Specifications29
Section 3: Installation31
- Installation Requirements31
- System Layout 100I - 200I Amp32
- System Layout 300I Amp33
- System Layout 400I Amp33
- Recommended Gas Supply Hose34
- Leads and Cables All Amperage34
- Lift the Power Supply35
- Connect Input Power and Ground Cables36
- Connect Work Cable and Pilot and Negative Leads37
- Ground Connections38
- Connect Coolant Leads41
- Connect Cables for CNC, Remote Arc Starter, Gas Selection, and Heat Exchanger42
- Handling and Installation of Fiber Optics43
- Correct Installation44
- Connect Cable and Gas Section Console Fiber Optic Cable to CCM47
- Set Switches on the Command - Control Module49
- Height Control Connections51
- Gas Selection Console Installation52
- Gas Control Unit Installation55
- Fiber Optic Cable Installation from CCM to Gas Selection Console58
- Fiber Optic Cable Installation from Gas Selection Console to Gas Control Unit60
- Install Touch Screen CNC63
- External Cooler64
- Install Remote Arc Starter66
- Connecting Torch74
- Install Consumable Torch Parts75
- Voltage Divider for Ihc Torch Height Control78
Section 4: Operation79
- Power Supply Control Panel79
- System Operation79
- CCM Status Codes81
- Gas Selection Console Status Codes89
- Gas Control Unit Status Codes91
- Remote Arc Starter Trouble Shooting94
Section 5: Maintenance95
- General Maintenance95
- External Coolant Filter Cleaning Procedure95
- Coolant Replacement Procedure96
Section 6: Replacement Assemblies & Parts97
- Replacement Power Supply97
- System Layout 100 - 200 Amp98
- System Layout 300 Amp98
- System Layout 400 Amp99
- Recommended Gas Supply Hose99
- Leads and Cables All Amperages100
- Power Supply External Replacement Parts102
- Power Supply Replacement Parts - Upper Right Side103
- Power Supply Replacement Parts - Lower Right Side104
- Power Supply Replacement Parts - Rear Panel105
- Power Supply Replacement Parts - Left Side106
- Automated Gas Control System Replacement Components107
- Gas Selection Console Replacement Parts108
- Gas Control Unit Replacement Parts109
- Remote Arc Starter (RAS) Replacement Parts110
Torch Maintenance111
- Consumable Removal111
- Section 7: Torch Maintenance111
- O-Ring Lubrication112
- Parts Wear113
- Torch Consumables Installation114
- Coolant Leak Trouble-Shooting116
Torch Operation119
- Standard Cutting up to 100 Amp125
- Bevel and Robotic Cutting up to 100 Amp147
- Standard Cutting 150 - 200 Amp155
- Robotic and Bevel Cutting 150 - 200 Amp167
- Standard Cutting 250 - 300 Amp177
- Robotic and Bevel Cutting 250 - 300 Amp185
- Standard Cutting 400 Amp195
- Robotic and Bevel Cutting 400 Amp205
- Torch Parts List217
- Torch Consumables Installation220
- Patent Information223
Appendix 1: Cnc - Control Module Pcb Connections225
Appendix 2: Cnc226
- CNC Functions226
- CNC Input / Output Descriptions228
- Simplified CNC Circuit230
- CNC Connections232
- CNC Cable Color Code233
Appendix 3: Cooling Diagram234
Appendix 4: System Schematic 100A, 380-415V Pg 1236
Appendix 4: System Schematic 100A, 380-415V238
Appendix 5: System Schematic 100A, 380-415V Pg 2238
Appendix 6: System Schematic 200A, 380-415V240
Appendix 7: System Schematic 200A, 380-415V242
Appendix 8: System Schematic 300A, 380-415V244
Appendix 9: System Schematic 300A, 380-415V246
Appendix 10: System Schematic 400A, 380-415V248
Appendix 11: System Schematic 400A, 380-415V250

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ESAB 100i Specifications

General

Brand	ESAB
Model	100i
Category	Welding System
Language	English

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