ESAB EPP-200 Instruction Manual
Read Online
Read the ESAB EPP-200 Instruction Manual online using the built-in PDF viewer.
Text of the manual
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!
SAFETY .................................................................................................................................... 5
SECTION 2
DESCRIPTION ..........................................................................................................................................................7
SECTION 3
INSTALLATION ......................................................................................................................................................13
SECTION 4
OPERATION ............................................................................................................................................................21
TABLE OF CONTENTS
DECLARATION OF CONFORMITY
According to
The Low Voltage Directive 2006/95/EC of 12 December 2006, entering into force 16 January 2007
The EMC Directive 2004/108/EC
FÖRSÄKRAN OM ÖVERENSSTÄMMELSE
Lågspänningsdirektivet 2006/95/EG från 12 december 2006, ikrafsat 16 januari 2007
EMC-Direktivet 2004/108/EG
Type of equipment Materialslag
Plasma Cutting Console
Brand name or trade mark Fabrikatnamn eller varumärke
ESAB
Type designation etc. Typbeteckning etc.
EPP-200, (0558004315)
Manufacturer or his authorised representative established within the EEA
Name, address, telephone No, telefax No: Tillverkarens namn, adress, telefon, telefax:
ESAB AB
Esabvägen, SE-695 81 Laxå, Sweden
Phone: +46 586 81000, Fax: +46 584 411 924
The following harmonised standard in force within the EEA has been used in the design:
Följande harmoniserande standarder har använts i konstruktionen:
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: / Tilläggsinformation: 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.
Genom att underteckna detta dokument försäkrar undertecknad såsom tillverkare, eller tillverkarens representant inom
EES, att angiven materiel uppfyller säkerhetskraven angivna ovan.
Date / Datum
Laxå 2009-02-18
Signature / Underskrift Position / Befattning
Global Director
Equipment and Automation
Kent Eimbrodt
Clarification
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.
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
The EPP-200 Power Console is designed for mechanized plasma
applications. It can be used with other ESAB products such as the
PT-24 and PT-600 torches, an optional plumbing box and a remote
set-up pendant.
t
UP"NQFSFTDVUUJOHDVSSFOUSBOHF
t
'PSDFEBJSDPPMFE
t
4PMJETUBUF%$QPXFS
t
*OUFHSBMXBUFSDPPMFS
t
*OQVUWPMUBHFQSPUFDUJPO
t
-PDBMPSSFNPUFGSPOUQBOFMDPOUSPM
t
5IFSNBMTXJUDIQSPUFDUJPOGPSNBJOUSBOTGPSNFSBOE
power semiconductor components
t
-&%TUBUVTUSPVCMFTIPPUJOH
2.1 Introduction
2.2 General Specifications
EPP-200 Power Console (0558004315):
OUTPUT (100% duty cycle)
Voltage ......................................................................................................... 160VDC
Current range DC .................................................................................50A to 200A
Power ................................................................................................. 8000 W to 32000 W
Open Circuit Voltage (OCV) .................................................................. 325VDC
INPUT
Voltage (3-phase) ..............................................................200/230/380/415/460/575 Volts
Current (3-phase) ...............................................................115/100/60/55/50/40 Amperes
'SFRVFODZ ....................................................................................................50/60Hz
KVA .................................................................................................................39.8 kW
Power .............................................................................................................37.8 kW
1PXFS'BDUPS ...................................................................................................95%
*OQVU'VTF .................................................................................. See Section 3, Installation
Electric Shock Can Kill!
Use of torches not designed for this console could result in a haz-
ardous electric shock.
Use only torches designed for the EPP-200 Console.
WARNING
2.3 Dimensions and Weight
44 in. (1100mm)
42in. (1050mm)
22in. (550mm)
Weight = 725 lbs. (330 kg)
SECTION 2
DESCRIPTION
2.4 EPP-200 Options and Accessories
Options
5 ft. (1.5m)
10 ft. (3.0m)
20 ft. (6.1m)
25 ft. (7.6m)
30 ft. (9.1m)
40 ft. (12.2m)
50 ft. (15.2m)
75 ft. (22.9m)
100 ft. (30.5m)
125 ft. (38.1m)
150 ft. (45.7m)
* Cooling Water Hoses (2)
Console to Plumbing Box
Control Cable
Plumbing Box to Console
Pilot Arc Lead
Plumbing Box to Console
Power Lead
Console to Plumbing Box
0558003979
0558003980
0558003981
33132
0558003982
0558003983
33133 (4495019)
33134 (4495020)
33135 (4495021)
33136 (4495022)
0558003984
N / A
N / A
N / A
0558004651
N / A
N / A
0558004652
0558004653
0558004654
0558003978
0558004655
0558003985
0558003986
0558003987
33303
0558003988
0558003989
33304 (4495034)
33305 (4495035)
33306 (4495036)
33307 (4495037)
0558003990
0558003991
0558003992
0558003993
22001 (4495038)
0558003994
0558003995
22002 (4495039)
22003 (4495040)
22004 (4495041)
22005 (4495042)
0558003996
SECTION 2
DESCRIPTION
NOTE:
Part Numbers in parenthesis apply to "CE"/European units only.
* Use with one adaptor fitting (41V12) included with unit.
2.5 Gas Hoses
Gas Type
25 ft.
50 ft.
75 ft.
100 ft.
125 ft.
(7.6m)
(15.2m)
(22.8m)
(30.4m)
(38.1m)
Nitrogen (clear)
33122
33123
33124
33125
33126
Oxygen (clear - USA)
33117
33118
33119
33120
33121
Oxygen (blue - Euro)
0558002973
0558002974
0558002975
0558002976
0558002977
Argon/Hydrogen (H-35) (1)
33122*
33123*
33124*
33125*
33126*
Air (clear - USA)
33122**
33123**
33124**
33125**
33126**
Air (black - Euro) (2)
0558002978**
0558002979**
0558002980**
0558002981**
0558002982**
Note: * = Requires adapter P/N 19X54 (4494001) (order separately)
** = Requires adapter P/N 74S76 (0558004057) (order separately)
2.6 Gas Regulators
Station Regulator
Cylinder Regulator
Nitrogen .....................................................19155 ............................................998343
Oxygen .......................................................19151 .............................................998336
Argon/Hydrogen (H-35) .......................19153 .............................................998341
Air .................................................................30338 (4492008) .......................N/A
A separate start gas regulator is always required:
t
'PSBJSQMBTNBVTFBJSTUBSUHBT
t
'PSPYZHFOPSOJUSPHFOVTFOJUSPHFOTUBSUHBT
t
'PS) BSHPOIZESPHFO
)PSOJUSPHFOTUBSUHBT
A total of 3 regulators will be required (plasma, start and
secondary).
When using a plumbing box:
t
(BTIPTFTGSPNTVQQMZDZMJOEFSTHPEJSFDUMZUPUIF
plumbing box.
t
$POTPMFHBTNBOJGPMEJTOPUVTFE
NOTICE
NOTICE
SECTION 2
DESCRIPTION
NOTE:
Part Numbers in parenthesis apply to "CE"/European units only.
2.7 Basic Packages
The EPP-200 system is available as a pre-engineered package or can
be ordered as individual parts as listed.
Basic Packages include:
t
&11$POTPMF
t
1MBTNB5PSDI
t
"QQSPQSJBUFSFHVMBUPSTGPSUIFHBTFTJOEJDBUFE
t
(BTIPTFTGSPNSFHVMBUPSTUPDPOTPMF
t
5PSDIDPPMBOU
Torch Coolant (25%) – 1 gallon (3.8 L) P/N 0558004297
25% PG coolant improves electrode life in applications using oxygen or
BJSDVUHBTCVUPOMZQSPWJEFTGSFF[FQSPUFDUJPOEPXOUP¡' ¡$
5PSDI$PPMBOU
oHBMMPO -
1/'
&(DPPMBOUQSPWJEFTGSFF[FQSPUFDUJPOEPXOUP¡'
(-40.0° C)
SECTION 2
DESCRIPTION
NOTE:
Part Numbers in parenthesis apply to "CE"/European units only.
Failure To Follow Instructions Could Lead To Death,
Injury Or Damaged Property
'PMMPXUIFTFJOTUSVDUJPOTUPQSFWFOUJOKVSZPSQSPQFSUZEBNBHF
You must comply with local, state and national electrical and safety
codes.
WARNING
Use Lifting Eye When Hoisting From Overhead
Use safe practices when transporting with overhead method.
Unit weighs over 700 lbs (318 kg). Use approved straps or cables
in good condition.
CAUTION
3.2 Unpacking
t
*OTQFDUGPSUSBOTJUEBNBHFJNNFEJBUFMZVQPOSFDFJQU
t
3FNPWFBMMDPNQPOFOUTGSPNTIJQQJOHDPOUBJOFSBOE
check for loose parts in container.
t
*OTQFDUMPVWFSTGPSBJSPCTUSVDUJPOT
Do Not Restrict Air Flow
Restricting intake air with any type of filter on or around the Plasma
console will result in overheating and may void the warranty.
3.3 Placement
t
"NJOJNVNPGGU N
DMFBSBODFGPSDPPMJOHBJSøPX
t
1MBOGPSUPQQBOFMBOETJEFQBOFMTIBWJOHUPCFSFNPWFE
for maintenance, cleaning and inspection.
t
-PDBUFUIF&11SFMBUJWFMZDMPTFUPBQSPQFSMZGVTFE
electrical power supply.
t
,FFQBSFBCFOFBUIQPXFSTPVSDFDMFBSGPSDPPMJOHBJS
flow.
t
&OWJSPONFOUTIPVMECFSFMBUJWFMZGSFFPGEVTU
GVNFTBOE
excessive heat. These factors will affect cooling
efficiency.
Conductive Dust And Dirt Inside Power Source May
Cause Arc Flash Over
Equipment damage may occur. Electrical shorting may occur if
dust is allowed to buildup inside power source. See maintenance
section.
Electric Shock Can Kill!
Provide maximum protection against electrical shock.
Before any connections are made inside the machine, open the
line wall disconnect switch to turn power off.
3.4 Input Connections to Console
Plasma
Console
SECTION 3
INSTALLATION
3.4.1 Primary Power Specifications
EPP-200 is a 3-phase unit. Input power must be provided from a line
(wall) disconnect switch that contains fuses or circuit breakers in
accordance to local or state regulations.
Recommended input conductor and line fuse sizes:
Dedicated power line may be necessary.
EPP-200 is equipped with line voltage compensation but to avoid
impaired performance due to an overloaded circuit, a dedicated
power line may be required.
4J[FTQFS/BUJPOBM&MFDUSJDBM$PEFGPSB¡$ ¡'
SBUFEDPQQFS
DPOEVDUPST!¡$ ¡'
BNCJFOU/PUNPSFUIBOGPVSDPOEVDUPST
in raceway or cable. Local codes should be followed if they specify sizes
other than those listed above. Input current values given in this table
are at maximum output power (32kW) 200 amps at 160VDC.
Rated Load
Input and Ground
conductor*
CU/AWG
Time delay
'VTFTJ[F
(amperes)
Volts
Amperes
200/208
115
1
150
230
100
2
125
380
60
4
80
415
55
6
70
460
50
6
70
575
40
8
60
SECTION 3
INSTALLATION
3.4.2 Primary Power Hookup Procedure
The following procedure explains the proper installation steps for
connecting primary electrical power to the plasma console.
NOTE: Safety codes specify the power ground wire be the last
connection to break should the cable be pulled out of the unit.
When preparing the cable for connection, make the ground wire
6 inches (152mm) longer than the three pr primary wires.
1. Ensure input power cable is disconnected from all electrical
sources.
2. Remove right side panel (as viewed from front of console).
3. Route input power cable through the strain relief located at the rear
panel.
4. Pull input power cable through the strain relief to allow cable wires
sufficient length to connect to main contactor. Tighten strain relief to
ensure input power cable is secured.
5. Connect input power cable ground wire to the ground lug provided
above TB2 (7 position terminal block).
6. Connect three power leads of input power cable to terminals located
atop the main contactor. Secure the leads by tightening each screw.
7. Connect jumper power cables from bottom of the main contactor
to proper input voltage marked on auto transformer. Unit is factory set
for 575V as shown at the left.
8. Connect jumper on TB2 to proper input voltage. This 7 position
terminal block jumper is factory set to 575V.
Input Power Jumper Connection
Ensure each input power jumper cable is connected to correct input
voltage on autotransformer and on TB2.
'BDUPSZXJSFEGPS7PMUT
CAUTION
Input Power Cable
Strain Relief
Main
Contactor
Ground
Connection
7 Position
Terminal
Block
Auto
Transformer
'BDUPSZXJSFE
for 575 volts
SECTION 3
INSTALLATION
9. Connect input conductors to line (wall) disconnect.
10. Replace side panel. Replace only if all connections have made.
Output connections require this panel to be removed.
11. Connect the other end of work cable to workpiece or cutting table.
Connection must be made to a clean, exposed metal surface, free of
paint, rust, mill scale, etc.
Electric Current Is Hazardous.
It is important to have a good earth ground connected to the
workpiece or cutting table.
WARNING
Work ground to work piece
Work ground to cutting table
SECTION 3
INSTALLATION
3.5 Connecting Plasma Torches to EPP-200 Console and Options
3.5.1 EPP-200 Output Cables, Hoses and Adapters (customer supplied)
EPP-200:
Lengths vary depending on system.
t
$PPMBOU3FUVSO
t
$PPMBOU4VQQMZ
t
1JMPU"SD$BCMF
t
&MFDUSPEF$BCMF
t
4IJFME(BT EJSFDUMZUPUIF1MVNCJOH#PY
t
4UBSU(BT EJSFDUMZUPUIF1MVNCJOH#PY
t
$VU(BT EJSFDUMZUPUIF1MVNCJOH#PY
t
8PSL$BCMF
t
1FOEBOU$BCMF JGQFOEBOUPQUJPOJTPSEFSFE
See Description, Section 2 for part numbers.
A remote SETUP Panel option is available on Avenger 1 and larger ESAB
cut cutting machines. This panel operates the same as the pendant.
Refer to your machine manual for replacement parts.
SECTION 3
INSTALLATION
Commercial Antifreeze Will Cause Torch To
Malfunction.
Use special torch coolant.
Do to high electrical conductivity, DO NOT use tap water or
commercial automotive type antifreeze for torch cooling. A specially
formulated torch coolant is REQUIRED. This coolant also protects
GSPNGSFF[JOHUP¡$ ¡'
Operating the unit without coolant will cause permanent damage
to the coolant pump.
Check coolant level frequently.
Remove coolant fill cap at front console and fill coolant tank with 4
gallons (15 liters) of plasma torch coolant.
t
%POPUöMMBCPWFJOEJDBUFENBYJNVNMFWFM
t
3FJOTUBMMDBQ
CAUTION
Electric Current Is Hazardous.
It is important to have a good earth ground connected to the
workpiece or cutting table.
WARNING
3.6
Coolant Installation
$PPMBOU'JMM$BQ
SECTION 3
INSTALLATION
4.1 Introduction – Operational Safety
Electric Shock Can Kill!
Disconnect current supply at wall disconnect before servicing
console, torch or plumbing box.
t
%POPUPQFSBUFDPOTPMFPSQMVNCJOHCPYXJUIBOZDPWFST
removed/open.
t
%POPUUPVDIBOZUPSDIGSPOUFOEQBSUTXJUIQPXFSPO
t
%POPUBUUFNQUUPTFSWJDFBOZQPSUJPOPGUIJTQMBTNB
system unless power has been disconnected at the wall
disconnect.
WARNING
This equipment can be hazardous if not properly
operated and maintained.
Read and understand all equipment literature and warning labels
before operating this equipment.
WARNING
Plasma Arc Cutting Can Be Hazardous To Eyes And
Ears.
t
8FBSIFBSJOHQSPUFDUJPO
t
8FBSFZFQSPUFDUJPOTQFDJöDBMMZEFTJHOFEGPSBSD
welding and cutting. Lenses should be at least a No. 6
or No. 7 lens shade.
t
8FBSQSPUFDUJWFDMPUIJOHUPBWPJETLJOCVSOT
4.2 Operating the EPP-200 Console
4.2.1 Console Controls
1
Pilot Arc High/Low Switch
2
Cutting Voltage and Cutting Current Meters
3
Output Current Control
4
Remote/Panel Selection Switch
5
Gas Test Switch
'BVMU-JHIUT
7
Main Power Switch
Pilot Arc Switch
Used to select pilot arc current range when Remote / Panel Switch is in
the Panel position. HIGH position is used for most cutting applications.
Electrode life is adversely affected when used in high position when low
is suitable. Starting may be difficult if set on low when high is required.
Related to the initial torch standoff height.
Cutting Voltage and Current Meters
“A” meter indicates actual cutting current, 0-200 amperes
“V” meter indicates actual output voltage, 0-160 VDC
Output Current Control
Sets the cutting current when current settings are made from the
power console front panel. (The Remote/Panel switch must be in the
Panel position.)
Remote/Panel Switch
Panel position – Output current is set by the output current control
on the console front panel as described above.
Remote position – Output current is set by the CNC with an analog
dc signal.
1
2
3
4
5
6
7
SECTION 4
OPERATION
Gas Test Switch
Cut – Allows for setup of cut gas pressure and flow. Start/Shield – Setup
of gas pressures and flows.
Operate – Default position – Must be in this position for cutting.
Fault Indicator Lights
t
Coolant Flow – Will show low coolant flow. Light will
briefly show a fault when console is turned on and then
go out.
t
Plasma Gas Pressure — fault indicator – low plasma
gas pressure. Torch will not fire when illuminated.
t
Interlock Fault – Indicates Remote Plumbing box door
is not properly closed.
t
P/S Temp – fault indicator – over temperature condition
in the inverter power source.
t
P/S Fault – fault indicator – Not used.
t
Over/Under Voltage – fault indicator – input voltage is
above or below tolerances of the power source console.
Will stay shut down console until main power switch is
recycled and fault is corrected.
Main Power Switch
Controls the input power to the fan, water cooler, inverter and interface
circuitry. Light illuminates to indicate power is on.
SECTION 4
OPERATION
4.3 Sequence of Operation
1. Apply power by closing the line (wall) switch. Main power light will
OPUJMMVNJOBUFVOUJMDPOTPMFQPXFSTXJUDIJTUVSOFE0/'BVMUMJHIU
should flash and go out.
2. Select the Panel/Remote setting. If current is controlled from cutting
machine CNC, place switch to Remote position. Consult cutting
machine instructions for current setting. If current is not controlled
by the CNC, select Panel and set current on output current dial.
3. Check coolant level. Level must be checked with console main power
JO0''QPTJUJPO$PPMBOUMFWFMNVTUGBMMJOUIFTBGFPQFSBUJOHMFWFM
4. Set pilot arc High/Low switch. Refer to cutting process data of the
torch manual.
5.Turn on console power by placing power switch in ON position. White
light to left of the switch will illuminate.
6. Check coolant pressure. The pressure is factory set between 80 to
90 PSI (5.5-6.2 bars)
7. Begin plasma cutting operation. This may include manually setting
other options, depending on total plasma package.
If using panel mode, after cutting has begun, adjust current to desired
amount.
Check for a fault light. If a fault light illuminates, SHUT OFF POWER
IMMEDIATELY and refer to troubleshooting section.
SECTION 4
OPERATION
Electric Shock Can Kill!
Open wall disconnect switch before attempting any maintenance
on:
t
QMBTNBDPOTPMF
t
JOUFSDPOOFDUJOHDBCMFT
Only trained personnel should perform maintenance or repairs
on this equipment.
5.2 Inspection and Cleaning
Frequent inspection and cleaning of the EPP-200 and related equipment
are recommended for safety and proper operation. Consider the
following during inspection and cleaning:
t
$IFDLXPSLDBCMFUPXPSLQJFDFDPOOFDUJPO
t
$IFDLTBGFUZFBSUIHSPVOEBUXPSLQJFDFBOEBUQPXFS
source chassis.
t
&OTVSFDBCMFBOEIPTFTBSFOPUEBNBHFEPS
LJOLFE
t
&OTVSFBMMQMVHT
öUUJOHT
BOEHSPVOEDPOOFDUJPOTBSF
tight.
t
$IFDLTDSFFOöMUFSJODPPMBOUQVNQ MPDBUFEJOTJEF
console) periodically and flush as required.
Flying Debris Hazard.
Flying Debris Can Seriously Injure Eyes
Wear protective eyewear when cleaning with compressed air.
Use low pressure air only.
Avoid Potential Equipment Damage
Water and/or oil can accumulate in compressed air lines. Be sure
UPEJSFDUUIFöSTUBJSCMBTUBXBZGSPNFRVJQNFOUUPBWPJE
damaging the junction box or flow control box.
t
8JUIBMMJOQVUQPXFSEJTDPOOFDUFEBOEXJUIQSPQFSFZF
BOEGBDFQSPUFDUJPO
CMPXPVUUIFJOTJEFPGUIFQPXFS
TPVSDF
øPXDPOUSPM
BOEKVODUJPOCPYVTJOHMPXQSFTTVSF
clean dry compressed air.
t
1FSJPEJDBMMZCMFFEBMMXBUFSGSPNUIFBJSöMUFSSFHVMBUPS
trap.
SECTION 5
MAINTENANCE
5.3 Gas Manifold Pressure Switches
Newer EPP-200 consoles are equipped with nonadjustable preset gas
manifold pressure switches.
Older ESP-200 consoles have adjustable pressure switches.
Both type switches are preset for:
t
QTJH CBS
TIJFMEBOETUBSUHBTTXJUDIFT
t
QTJH CBS
DVUHBTTXJUDI
5.3.1 Pressure Switch Adjustment Procedure
5VSONBJOQPXFSTXJUDI0''0''
2.
Remove right side panel
3.
Turn wheel:
t$PVOUFSDMPDLXJTFUPincrease pressure
t$MPDLXJTFUPdecrease pressure
4.
Replace panel.
5.
Resume operation.
5.3.2 Gas Manifold with Non-adjustable Pressure Switches (reference)
SECTION 5
MAINTENANCE
Electric Shock Can Kill!
Ensure all primary power to machine has been externally
disconnected.
0QFOMJOF XBMM
TXJUDICFGPSFBUUFNQUJOHJOTQFDUJPOPSQFSGPSNJOH
XPSLJOTJEFUIFQMBTNBDPOTPMFPSQMVNCJOHCPY
Capacitors Can Store High Voltages.
Disconnecting plasma console does not ensure capacitors are de-
energized.
Ensure console capacitors are grounded after removing power and
prior to performing maintenance.
6.2 Procedure
4IVUNBJOQPXFSTXJUDIPOUIFDPOTPMFUP0''QPTJUJPO
%JTDPOOFDUNBJOQPXFSMJOF XBMM
TXJUDI
$IFDL GPS PCWJPVT FYUFSOBM TFUUJOHT
TXJUDIFT BOE FYUFSOBM
connections.
*GBQSPCMFNJTGPVOE
DPSSFDUBOEQSPDFFEXJUIOPSNBMPQFSBUJPOT
*GOPU
SFNPWFTJEFQBOFMT(Reminder: Power must be disconnected
before removing any covers.)
1FSGPSNBWJTVBMJOTQFDUJPOPGJOUFSOBMDPNQPOFOUT$IFDLGPS
t -PPTFPSCVSOFEXJSJOHBOEDPNQPOFOUT
t 4FDVSFUFSNJOBMDPOOFDUJPOT
t #VMHFEPSMFBLJOHDBQBDJUPST
t 0UIFSTJHOTPGEJTDPMPSBUJPO
Refer to the troubleshooting guide for identification of many
problems, possible causes and remedies.
Reference wiring diagrams and schematics are found in the last
part of this section.
6.1 Introduction
6.3 Front Panel Fault Lights
Fault Indicator Lights
t
Coolant Flow – Will show low coolant flow. The
light will briefly show a fault when console is turned on
and then go out.
t
Plasma Gas Pressure — fault indicator – low plasma
HBTQSFTTVSF5PSDIXJMMOPUöSFXIFOJOEJDBUFE
t
Interlock Fault – Indicates Remote Plumbing box door
is not properly closed.
t
P/S Temp – fault indicator – over temperature condition
in the inverter power source.
t
P/S Fault – Not used.
t
Over/Under Voltage – fault indicator – input voltage is
above or below the tolerances of the power source
console. Will stay shut down console until main power
switch is recycled.
SECTION 6
TROUBLESHOOTING
6.4 Troubleshooting Guide
High Voltages Can Cause Serious Injury or Death!
Voltages in plasma cutting equipment are high enough to cause
serious injury or death.
Only trained technicians should attempt diagnosis and repair of
this machinery.
Avoid damaging your voltmeter.
Disconnect the power from the high frequency generator before
DIFDLJOHWPMUBHFTJOUIFIJHIGSFRVFODZDJSDVJU
SECTION 6
Troubleshooting
ESP-200 Plasmarc Cutting System
6-3
6.4 Troubleshooting Guide
WARNING
!
High Voltages Can Cause Serious
Injury or Death!
Voltages in plasma cutting equipment are high
enough to cause serious injury or death.
Only trained technicians should attempt
diagnosis and repair of this machinery.
CAUTION
!
Avoid damaging your voltmeter.
Disconnect the power from the high frequency
generator before checking voltages in the high
frequency circuit.
Problem
Problem
Problem
Problem
Possi
Possi
Possi
Possible Cause
ble Cause
ble Cause
ble Cause
Corrective Action
Corrective Action
Corrective Action
Corrective Action
Power switch is ON. Power LED
Power switch is ON. Power LED
Power switch is ON. Power LED
Power switch is ON. Power LED
is OFF. Fan is OFF. Pump is
is OFF. Fan is OFF. Pump is
is OFF. Fan is OFF. Pump is
is OFF. Fan is OFF. Pump is
OFF.
OFF.
OFF.
OFF.
1) Bad Power switch S1.
2) Open Fuse F4.
3) Open Jumper at TB2.
1) Check continuity of power
switch.
2) Check Fuse F4 and related
wiring
3) Check jumper and wiring of TB2
Power
Power
Power
Power switch is ON. Power LED
switch is ON. Power LED
switch is ON. Power LED
switch is ON. Power LED
in ON. Pump is OFF. Fan is ON.
in ON. Pump is OFF. Fan is ON.
in ON. Pump is OFF. Fan is ON.
in ON. Pump is OFF. Fan is ON.
1) Bad or open CB2.
2) Pump Motor Failed.
1) Reset CB2. Check wiring and
check free rotation of pump fan.
2) Replace Pump motor
Power LED is OFF. Pump is ON.
Power LED is OFF. Pump is ON.
Power LED is OFF. Pump is ON.
Power LED is OFF. Pump is ON.
Fan is ON. LEDs in power
Fan is ON. LEDs in power
Fan is ON. LEDs in power
Fan is ON. LEDs in power
modules are OFF
modules are OFF
modules are OFF
modules are OFF
1) Bad or Open CB1.
1) a. Reset CB1
b. If CB1 fails to reset, check
wiring, bad T1, or PCB1.
Plasma gas fault indicator is ON
Plasma gas fault indicator is ON
Plasma gas fault indicator is ON
Plasma gas fault indicator is ON
1) Plasma gas pressure to console
is below 40 psi.
2) Bad pressure switch
3) Open wire between pressure
switch and PCB1.
1) Adjust gas pressure to proper
level for torch and application
2) Adjust (if adjustable type) or
replace pressure switch.
3) Check wiring between PS1 &
PS2 and PCB1 P1-9 and P1-10.
SECTION 6
TROUBLESHOOTING
ESP-200 Plasmarc Cutting System
6-4
Problem
Problem
Problem
Problem
Possible Cause
Possible Cause
Possible Cause
Possible Cause
Corrective Action
Corrective Action
Corrective Action
Corrective Action
Power Source Temp fault
Power Source Temp fault
Power Source Temp fault
Power Source Temp fault
indicator is ON.
indicator is ON.
indicator is ON.
indicator is ON.
1) Poor ventilation at rear of
console.
2) Open thermal switch.
3) Open wire between temperature
switch and PCB1
1) Make sure that there is 2 feet of
clearance on each side of
console.
2) With power OFF, check each
thermal switch. Normal
operation is: switch closed
below 194!F.
3) Check wiring between
temperature switches and PCB1
P1-15 and P1-16.
Over/Under Voltage fault indicator
Over/Under Voltage fault indicator
Over/Under Voltage fault indicator
Over/Under Voltage fault indicator
is ON
is ON
is ON
is ON
1) Input voltage is 15% above or
below the selected console
operating voltage.
2) Bad PCB1.
3) Bad PCB1 in MOD1.
4) Bad T1 in MOD1.
1) Provided input voltage must be
equal to the selected console
operating voltage. Change if
necessary.
2) Replace PCB1.
3) Replace PCB1 in MOD1
4) Replace T1 in MOD1
Meters M1 or M2, no display.
Meters M1 or M2, no display.
Meters M1 or M2, no display.
Meters M1 or M2, no display.
1) Bad Meter
1) Replace Meter meters M
Meters M1 & M2, no display. 1) Bad PCB1.
1) Replace one meter to verify
above step did not happen
twice. If still not working replace
PCB1.
Press torch switch or send start
Press torch switch or send start
Press torch switch or send start
Press torch switch or send start
signal.
signal.
signal.
signal.
(No pilot arc or main arc transfer.)
(No pilot arc or main arc transfer.)
(No pilot arc or main arc transfer.)
(No pilot arc or main arc transfer.)
1) Gas Test switch is in
START/SHIELD or CUT
positions
2) Plasma gas pressure is to LOW
3) Improper current command
signal
4) LEDX on MOD1 PCB1 is not ON
when torch switch is depressed
or start signal sent.
5) LEDX is ON but main contactor
does not close
6) LEDX is ON. Main contactor is
closed. No OCV or arc transfer.
1) Place Gas Test switch in
OPERATE position.
2) Set plasma gas pressure per
torch or application requirements
(above 40 psi)
3) IF in manual mode, panel switch
must be in PANEL and P5 must
be in J5 connector. If in
mechanized mode, panel switch
must be in REMOTE and a
current signal above 0 volts must
be present. P5 must be in J6
connector
4) Test tbd
5) Test tbd
6) Test tbd
SECTION 6
TROUBLESHOOTING
ESP-200 Plasmarc Cutting System
6-5
Problem
Problem
Problem
Problem
Possible Cause
Possible Cause
Possible Cause
Possible Cause
Corrective Action
Corrective Action
Corrective Action
Corrective Action
LEDX on MOD1 not ON
LEDX on MOD1 not ON
LEDX on MOD1 not ON
LEDX on MOD1 not ON
LEDX on MOD2 not ON
LEDX on MOD2 not ON
LEDX on MOD2 not ON
LEDX on MOD2 not ON
LEDX on MOD2 not ON when
LEDX on MOD2 not ON when
LEDX on MOD2 not ON when
LEDX on MOD2 not ON when
torch switch is depressed or start
torch switch is depressed or start
torch switch is depressed or start
torch switch is depressed or start
signal is sent
signal is sent
signal is sent
signal is sent
Arc does not transfer to work.
Arc does not transfer to work.
Arc does not transfer to work.
Arc does not transfer to work.
(Ope
(Ope
(Ope
(Open Circuit Voltage is between
n Circuit Voltage is between
n Circuit Voltage is between
n Circuit Voltage is between
315 and 355. Pilot arc IS
315 and 355. Pilot arc IS
315 and 355. Pilot arc IS
315 and 355. Pilot arc IS
present.)
present.)
present.)
present.)
1) Open connection between the
console WORK connector and the
workpiece.
1) a) Check continuity of WORK
cable and clamp
b) Attach clamp to workpiece
c) Ground work table to earth
ground
Arc do
Arc do
Arc do
Arc does not transfer to work.
es not transfer to work.
es not transfer to work.
es not transfer to work.
(Open Circuit Voltage is between
(Open Circuit Voltage is between
(Open Circuit Voltage is between
(Open Circuit Voltage is between
315 and 355. Pilot arc is NOT
315 and 355. Pilot arc is NOT
315 and 355. Pilot arc is NOT
315 and 355. Pilot arc is NOT
present.)
present.)
present.)
present.)
1) Pilot arc fuses F1 and/or F2 are
open.
2) Bad pilot arc contactor.
3) Bad K3.
4) Bad PCB1 in MOD2.
5) Nozzle to Electrode short in
torch.
6) Bad control PCB
7) No preflow signal from CNC.
8) Current setting to low
9) Contaminated or worn electrode.
1) Replace F1 and/or F2.
2) Replace pilot arc contactor.
3) Replace K3
4) Replace PCB1 in MOD2.
5) Disconnect torch from console.
Check for open between pilot
arc and torch leads. Repair if
shorted.
6) Replace control PCB.
7) Bad PCB1. Bad MOD1 PCB1.
8) Readjust Current setting. Torch
to high above workpiece.
9) Replace electrode.
SECTION 6
TROUBLESHOOTING
NOTE:
Additional Schematics and Wiring Diagrams on
NNYNN wYw
QBQFS
BSFJODMVEFEJOTJEFUIFCBDLDPWFSPGUIJTNBOVBM
Always provide the serial number of the unit on which the parts will
be used. The serial number is stamped on the unit nameplate.
5PFOTVSFQSPQFSPQFSBUJPO
JUJTSFDPNNFOEFEUIBUPOMZHFOVJOF&4"#
parts and products be used with this equipment. The use of non-ESAB
parts may void your warranty.
Replacement parts may be ordered from your ESAB Distributor.
Be sure to indicate any special shipping instructions when ordering
replacement parts.
3FGFSUPUIF$PNNVOJDBUJPOT(VJEFMPDBUFEPOUIFCBDLQBHFPGUIJT
manual for a list of customer service phone numbers.
#JMMPGNBUFSJBMJUFNTUIBUIBWFCMBOLQBSUOVNCFSTBSFQSPWJEFEGPS
customer information only. Hardware items should be available
through local sources.
Note:
Revision History
3FMFBTFE+BOVBSZ
3FWJTJPO6QEBUFE*OQVU$POEVDUPSBOEMJOF'VTFDIBSUQFS+.BHFF
2.
'PS BEESFTTFT BOE QIPOF OVN
CFST UP PVS EJTUSJCVUPST JO PUIFS
DPVOUSJFT
QMFBTF WJTJU PVS IPNF
QBHF
XXXFTBCDPN
&4"#"#
4&-"9¯
48&%&/
1IPOF
XXXFTBCDPN
YYYY
&4"#TVCTJEJBSJFTBOESFQSFTFOUBUJWFPöDFT
