EPP-200 Precision Plasmarc Cutting Console
Contents
1. OR A ND MODI P4 7 RED fe J7 T RED 1 2 S1 1 BLU G Q P1 1 J4 14 RED P1 2 Ta ian J4 12 BLU gt 3 P1 3 TB3 1 P1 6 MODI TB3 1 BLK e PA PILOT ARC YEL e Y D ZN q TI XS YEL TI X6 YEL X T1 X14 GRY T1 X15 BLK T1 X16 GRY J7 C VI0 T1 X11 WHT J7 D WHT T1 X12 RED T1 X10 ORN TI X13 WHT T1 X9 ORN T1 X2 VI0 TI X1VI0 K1 A BLK K1 B BLU J7 P GRY K9 L1 BLK e SEE DETAIL M2 MOD1 TB3 1 BLK PCB2 P1 6 BLK amp CO REAR VIEW J5 2 GRY REAR PANEL J5 1 GRY J7 B YEL J5 4 YEL J5 3 YEL J7 E RED J7 F VI0 J7 G BLU J7 H BRN J7 J YEL FS1 1 SPLICE BLK J7 K BLK FS1 2 SPLICE BLK J7 L BLK TB3 16 WHT J7 M WHT ie pla as SHEET 2 OF 3 IT V VIO J5 16 BRN J7 R BRN VIEWED FROM FRONT OF MACHINE FIRST woe rr APA BAM ue mn EE D 0558004317 D 0558004317 MOD2 SH1 2 BLK MOD1 SH1 2 BLK DISCLOSED EXCEPT DRAWING IS LOANED AND ON A CONFIDENTIAL BASIS POO _ P Ho 2081 P1 16 VI0 P4 1 BRN MODI P1 1 GRY P4 2 GRY K7 4 BRN P4 9 ORN PCB1 P3 15 RED P4 10 WHT P5 1 BLK P5 2 VIO P4 7 BLU P4 8 GRY P4 17 WHT P4 18 BLK TD1 WORK BLK MOD2 P2 5 WHT MOD2 P2 4 WHT MOD2 P1 6 ORN MOD2 P2 6 ORN MOD2. M1 GND GRN GND J8 C GRN NOTES 1 INDICATES SELF LEADS 2 INDICATES 16 GA WIRE 3 INLINE SPLICE BILL UF MATERIALS QUANTITIES ARE IN U M ESTIMATED BY INVENTORY J8 J6 1 GRY K6 4 RED J6 2 YEL J4 5 VIO J4 6 WHT J6 5 RED J6 6 VI0 J6 7 BLU J6 B BRN J6 9 YEL K6 6 BLU GND2 GRN J4 13 GRY J6 15 BRN J6 16 BRN F3 2 RED MOD1 P4 8 BLK J6 14 VI0 B C D E F 6 H J K L M N R 5 T U Y 914 18 134 1 013 SHEET 1 OF 3 ENGLISH DWG REFERENCE DRAWINGS UNLESS ITERVISE 11713703 PA 6900 03 19 ME OT RED ER we D 0558004333 SCHEM DIAG 200 A 0558004337 W SEC FRONT EPP 200 A 0558004336 WIRE KIT PRI EPP 200 A O558004339 W LOOSE 200 0558004338 W SEC REAR EPP 200 sur FIRST MADE FOR EPP 200 se sie m D 0558004317 D 0558004317 ESE BILL DF MATERIALS PRODUCTS AND CD EXCEPT DRAWING 15 LOANED AND ON A CONFIDENTIAL BASIS QUANTITIES ARE IN U M ESTIMATED BY INVENTURY MOD PM FN1 LINE L1 T2 AH3B BLK MOD1 TB2 1 RED L2 T2 BH3B BLK M1 1 BLK L1 T2 AH3A BLK MOD2 TB2 1 RED L3 T2 CH3B BLK MODI TB2 2 GRY TB3 8 YEL L2 T2 BH3A BLK M2 1 RED K9 A YEL L3 T2 CH3A BLK TB3 9 BLU TB5 1 BLK TB3 11 RED TB3 12 VIO F3 1 RED J7 U BLK TB3 18 VIO D
3. 200 Precision Plasmarc Cutting Console Instruction Manual 0558004676 10 2007 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 USER RESPONSIBILITY 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
4. Power switch is ON Power LED is OFF Fan is OFF Pump is OFF 1 Bad Power switch S1 2 Open Fuse FA 3 Open Jumper at TB2 Check continuity of power switch Check Fuse F4 and related wiring N 3 Check jumper and wiring of TB2 Power switch is ON Power LED in ON Pump is OFF Fan is ON 1 Bad or open CB2 2 Pump Motor Failed Reset CB2 Check wiring and check free rotation of pump fan 2 Replace Pump motor Fan is ON LEDs in power modules are OFF Power LED is OFF Pump is ON 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 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 amp PS2 and PCB1 P1 9 and P1 10 35 TROUBLESHOOTING SECTION 6 Problem Possible Cause Corrective Action Power Source Temp fault 1 Poor ventilation at rear of 1 Make sure that there is 2 feet of indicator is ON console clearance on each side of console closed No OCV or arc transfer 2 Open thermal switch 2 With power OFF check each thermal switch Normal operation is switch closed below 194 F 3 Open wire bet
5. MOD2 182 1 POWER MODULE 2 TB2 2 C 0558004333 SCHEMATIC D 0558004320 ASSEMBLY 8 lt a BEE LT xD 119 A FAULT SIGNAL PCB p3 1 80558004656 RES CM FILM AL 50W 1 4 99K SWITCH TGGL DPDT 2 POS 15A POT 10K 2W ral L s2 L Rt c4 CAPACITOR METPOLY 20uf 120VDC o R 8 17 L e R 10 9 R6 120VAC RELAY RECTIFIER SILICON FORWARD 85A RESISTOR 10 OHM BW CAPACITOR 4200uF 350V RESISTOR 8 OHM 300W RESISTOR 47K 12W RIS 14 5 19 RESISTOR 20 OHM 300W 6 TB1 TERMINAL BOARD PLUG 16 PN moD1 Pi modi P2 _______ P3 4 PLUG 10 PN __ 53 SWITCH TGGL SPST 2 POS 15 125V R 9 20 RESISTOR 20 OHM SON R 8 7 1 RESISTOR 8 OHM 300 RESISTOR 100 OHM 100W F5 FUSE 4 AMP 600v m Z01 180V a STV CH 12 CH63 Latsve MOV2 610V MOV3 6107 FNT PNL LOCAL N CURRENT SETTING POT 10 CURRENT SENSOR D 0558004317 WIRING DIAG EPP 200 A 0558004337 WIRE KIT SEC FRONT 200 A 0558004336 WIRE KIT PRI EPP 200 A 0558004339 WIRE KIT LOOSE EPP 200 0558004558 WIRE KIT SEC REAR 200 PILOT ARC 1234567 8 9101112131415 16 FRONT PNL PILOT ARC SELECTOR 53 TO JUNCTION pi Pas BOX J1
6. 12300 A s 200v AH w TB1 MODI POWER MODULE 1 C 0558004333 SCHEMATIC D 0558004319 ASSEMBLY palta gt __ B 063149 CN 153186 TOG ay MEA fom CI CIC FIRST MADE FOR EPP 200 jw ux D 0558004316 THIS DRAVING CONTAINS PROPRIETORIAL INFORMATION ESAB VELDING AGREEMENT 1 0558004317 DI DRAVING 15 LOANED AND ON A CONFIDENTIAL BASIS K4 1 un 1 P4 11 GRY P4 9 WHT 2 P4 12 BLU PS 11 RED 3 P4 8 ORN 4 P1 6 BLK P4 7 ORN 5 PCB1 P1 S BLK MOD1 P2 3 BLU Li 8 9 0 4 UN WN P5 15 BLK P5 16 BLK P3 3 GRY P5 1 GRY 9 t PS 2 YEL 10 MODI P2 2 VIO 121001 P1 3 BRN 15 MOD1 P1 4 WHT 14 15 MOD2 P1 4 RED 16 P3 2 YEL 16 K3 8 ORN 17 PCB3 P1 1 BLK 18 MOD1 P1 7 BLI 12 15 MOD1 P1 5 BLK 14 MOD1 P1 6 RED 15 MOD1 P1 2 VIO 16 MOD2 P1 1 VIO 17 PCB1 P1 18 Bi 18PCB1 P1 17 BLK SEE CHART AO FE E 008148 OW I WER CN 055069 2 __ MOD2 P3 1 BRN MOD2 P3 2 GRY MOD2 P3 7 BLU MOD2 P3 8 GRY MOD2 P3 3 ORN 10 MOD2 P3 4 WHT 11 MOD1 P3 7 RED 12 MOD1 P3 8 BLK 15 MOD1 P3 9 VIO 12 MODI P3 10 YEL 16 17 MOD2 P3 9 WHT 18 MOD2 P3 10 BLK P10 1 P3 5 BLK 1 P4 14 WHT 2 MOD2 P3 6 VIO 2 3 TB4 10 YEL 110 1 TD1 4 BLK 2 TD1 3 RED 3 TD1 2 GRN 4 TD1 1 WHT
7. 61325882 AR SCREW PHTF 8 32 X 75LG 64304887 WASHER PLAIN 8 64302887 WASHER LOCK 8 132 AR NUT HEX 8 32 133 61325902 SCREW PHTF 10 24 X 50LG 61325903 SCREW PHTF 10 24 X 63LG 64304050 WASHER PLAIN 10 64302920 WASHER LOCK 10 63300916 NUT HEX 10 24 63300862 NUT HEX 6 32 9 61328087 AR SCREW HWH 1 4 20 X 50LG 0 61341089 AR SCREW HEX HD 1 4 20 X 7516 Y WY RO IN c J DI on ___64304075 TAR WASHER PAN a OOOO 689296 aR WSR ock ye 145 64507886 AR WASHER DX TOOTH a 68800700 145 9910008 AR Senant Pipe TEON 61325904 AR SCREW PHIT 10 24 _ 32584 AR SCREW 148 75585980 AR ELEC NT ALCOAZEIC _ i EEE gt N _ gt c 52 SECTION 7 REPLACEMENT PARTS BILL OF MATERIALS QUANTITIES ARE IN U M ESTIMATED BY INVENTORY SYMBOL AE PART OF CODE DESCRIPTION 15 71200732 M ADH SRR OR _ 6 10881006 M SOLDER 60 40 19 0863008 70 TUBING HEATSHRNK 50 0 _ 8 AR i 02 COUPON TEST STEEL 18 X SENS U 0858004817 REF WIRING DIAGRAM EPP 200 055804316 _ REF SCHEMATIC DIAGRAM 20 157 05580087 WIRE KIT SEC FRONT EPP 200 HOSE ASSY PUMP OUT TO GRE 32 HOSE ASSY FLOW SWITCH
8. MOTOR XFRM CNTRL PLASMA INTERFACE BLOCK TERM 8 POS PLUG 8 PIN SWITCH GAS TEST DPDT DIODE ZENER 62V 5 00W 7 1A 4 843 6 4 6 RELAY ENCLOSE 240VAC 20A 8 cas wg D 2 8 CONN BOX RECPT 3FS 185 CIRCUIT BREAKER F3 RECPT 19 POS RECPT 16 POS CIRCUIT BREAKER 3AMP 182 TERM STRIP 15 081 T5 P C BRD ISOLATON AMPL amp FAULT SIGNAL ET E PLUG 10 PIN ys ON SIGNAL FROM WOD2 P2 PWG 8 PN PS TO CHE TRANSISTOR MOD2 PT PLUG PA HIGH RANGE mes TERM 24 POS ISP 22 PANEL 14 PN 3 F4 FUSE 154 GOOVAC FAST ACTING T CURRENT HIGH RANGE Pss SWITCH PRESSURE 1 120VAC NEUTRAL RECPT PANEL 16 PIN Puen SIM FROM CNC TOPS Tu CORE sua OR RES ou AM ALAN AK CAVE a 51 SWIcH Tool SPST 2 POS H voce over pru mi TORCH f2 acmvare 120vac L VOLTMETER Bir STOP FROM OC TO PS PS CONTACTOR WORMALLY coso RECPT 16 PO OPEN IN CASE OF EMERGENCY FST FLOW _ _________ FROM P S TO CM 20 5 62 ZENER DIODE 187 120 VAC ___ 1 2 CAPACITOR 20 40V AI RES 10K 2W 7 FWON ZENER DIODE 180V L5 MOV 12 3 VARISTOR METAL OXIDE 6257
9. N effectuez jamais de travaux de soudage ou de coupage sur des mat riaux de zinc de plomb de ou de cadmium en l absence de moyens m caniques de ventilation capables d emp cher l inhalation des fum es d gag es par ces mat riaux b N effectuez jamais de travaux de soudage ou de coupage proximit de vapeurs d hydrocarbure chlor r sultant d op rations voisines de d graissage ou de pulv risation La chaleur d gag e ou le rayonnement de l arc peut d clencher la formation de phosg ne gaz particuli rement toxique et d autres gaz irritants partir des vapeurs de solvant c Une irritation momentan e des yeux du nez ou de la gorge constat e au cours de l utilisation de l quipement d note un d faut de ventilation Arr tez vous de travailler afin de prendre les mesures n ces saires l am lioration de la ventilation Ne poursuivez pas l op ration entreprise si le malaise persiste d Certaines commandes comportent des canalisations ou circule de l hydrog ne L armoire de commande est munie d un ventilateur destin formation de poches d hydrog ne lesquelles pr sentent un danger d explosion ce ventilateur ne fonctionne que si l interrupteur correspondant du panneau avant se trouve plac en position ON Marche Veillez manceuvrer cette commande en v rifiant si le couvercle est bien en place de fa on assurer l efficacit de la ventilation ainsi r alis e
10. PARTS PUMP MOTOR SECTION 7 REPLACEMENT PARTS 50 AM1 amp ENLARGED METER ASSY mM 48 SECTION 7 REPLACEMENT PARTS BILL OF MATERIALS QUANTITIES ARE IN U M ESTIMATED BY INVENTORY SYMBOL TE PART OF CODE NO DESCRIPTION AT 2 08580043216 1 PAMLFRONTEPP 20 05580043220 1 PANEL REAR EPP 200 SSC 2 PANEL SIDE 5 n 1 cowo S 3592660 1 BRACKET 7 7 BRKT HEAT EXCHANGER BAFFLE WATER TANK BRKT RENOTE FUER 05580045256 1 BRACKET XFMR AUTO EPP 200 11 8 BRKT MIG DUAL RESISTOR 2 33550 1 BKMVR O 3 ss BRT WATER TN pf 356 SReTMN O 15 0558004319 1 EPP 200 PWR MOD 100A MASTER Pe WRA _ 7 95136 1 FUSE HOLDER PANEL MUN S2 18 1373460 1 9 SPOT 2 POS 15A 125 50 Si 19 672508 1 SWIGGL3PST2 POS 15A 125V 0 0 C3 20 95027 1 CAPACITOR 4200uf s5ovac S4 21 636702 1 SWITCH TOGGLE DPDT 3POS 15A 1257 Rm 2 206208 1 PT HO _____ 25 enen 952182 1 SPOUT REMOTE PILLER 25 90858625 3 67 TUBING VINYL CLEAR 5 8 ID 055800488 1
11. and Cutting of Containers That Have Held Hazardous Substances SIGNIFICADO DELOS SIMBOLOS Seg n ustedavanza la lectura de este folleto Los S mbolos Significan Atenci n Est Alerta Se trata de su seguridad Significa riesgo inmediato que de no ser A Maa evadido puede resultar inmediatamente en serio dafio personal la muerte Significa el riesgo de un peligro potencial EEN que puede resultar en serio da o per sonal o la muerte A Significa el posible riesgo que puede UL resultar en menores da os a la persona 8 SECTION 1 AVERTISSEMENT Ces r gles de s curit ont pour objet d assurer votre protection Veillez lire et observer les pr cautions nonc es ci dessous avant de monter l quipement ou de commercer l utiliser Tout d faut d observation de ces pr cautions risque d entrainer des blessures graves ou mortelles 1 PROTECTION INDIVIDUELLE Les br lures de la peau et des yeux dues au rayonnement de l arc lectrique ou du m tal incandescent lors du soudage au plasma ou l lectrode ou lors du gougeage l arc peuvent s av rer plus graves que celles r sultant d une exposition prolong e au soleil Aussi convient il d observer les pr cautions suivantes a Portez un cran facial ad quat muni des plaques protectrices et des verres filtrants appropri s afin de vous prot ger les yeux le visage le cou et les oreilles des tincelles et du rayonnement de l arc l
12. cutting current creates EMF around welding cables and welding ma chines Therefore 1 Welders having pacemakers should consult their physi cian before welding EMF may interfere with some pace makers Exposure to EMF may have other health effects which are unknown Welders should use the following procedures to minimize exposure to EMF A Route the electrode and work cables together Secure them with tape when possible B Never coil the torch or work cable around your body C Do not place your body between the torch and work cables Route cables on the same side of your body D Connect the work cable to the workpiece as close as possible to the area being welded E Keep welding power source and cables as far away from your body as possible SECTION 1 FUMES AND GASES Fumes and gases cancause discomfort or harm particularly in confined spaces Do not breathe fumes and gases Shield ing gases can cause asphyxiation Therefore 1 Always provide adequate ventilation in the work area by natural or mechanical means Do not weld cut or gouge on materials such as galvanized steel stainless steel copper zinc lead beryllium or cadmium unless posi tive mechanical ventilation is provided Do not breathe fumes from these materials 2 Do not operate near degreasing and spraying opera tions The heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene a highly toxic gas and
13. el pelo para proteger el cuerpo de los rayos y chispas calientes provenientes del metal fundido En ocaciones un delantal a prueba de fuego es necesario para protegerse del calor radiado y las chispas 4 Chispas y part culas de metal caliente puede alojarse en las mangas enrolladas de la camisa el ruedo del pantal n o los bolsillos Mangas y cuellos deber n mantenerse abotonados bolsillos al frente de la camisa deber n ser cerrados o eliminados 5 Proteja a otras personas de los rayos del arco y chispas calientes con una cortina adecuada no flamable como divisi n 6 Use careta protectora adem s de sus gafas de seguridad cuando est removiendo escoria o puliendo La escoria puede estar caliente y desprenderse con velocidad Personas cercanas deber n usar gafas de seguridad y careta protectora FUEGO Y EXPLOSIONES El calor de las flamas y elarco pueden ocacionar fuegos Escoria caliente y las chispas pueden causar fuegos y explosiones Por lo tanto 1 Remueva todo material combustible lejos del rea de trabajo o cubra los materiales con una cobija a prueba de fuego Materiales combustibles incluyen madera ropa l quidos y gases flamables solventes pinturas papel etc 2 Chispas y part culas de metal pueden introducirse en las grietas y agujeros de pisos y paredes causando fuegos escondidos en otros niveles o espacios Aseg rese de que toda grieta y agujero est cubierto para proteger lugares adyacentes contra fu
14. equipment 5 2 Inspection and Cleaning FrequentinspectionandcleaningoftheEPP 200andrelatedequipment are recommended for safety and proper operation Consider the following during inspection and cleaning Check work cable to workpiece connection Check safety earth ground at workpiece and at power source chassis Ensure cable and hoses are not damaged or kinked Ensure all plugs fittings and ground connections are tight Check screen filter in coolant pump located inside console periodically and flush as required 29 SECTION 5 MAINTENANCE WARNING Flying Debris Hazard Flying Debris Can Seriously Injure Eyes Wear protective eyewear when cleaning with compressed air mi Use low pressure air only Avoid Potential Equipment Damage CAUTION Water and or oil can accumulate in compressed air lines Be sure to direct the first air blast awav from equipment to avoid damaging the junction box or flow control box With all input power disconnected and with proper eve and face protection blow out the inside of the power source flow control and junction box using low pressure clean drv compressed air Periodicallv bleed all water from the air filter regulator trap 30 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 switch
15. is not con nected Secure and move cylinders by using suitable hand trucks Avoid rough handling of cylinders 4 Locate cylinders away from heat sparks and flames Never strike an arc on a cylinder 5 For additional information refer to CGA Standard P 1 Precautions for Safe Handling of Compressed Gases in Cylinders which is available from Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 SAFETY PRECAUTIONS EQUIPMENT MAINTENANCE Faulty or im A properly maintained equipment can cause injury or death Therefore 1 Always have qualified personnel perform the installa tion troubleshooting and maintenance work Do not perform any electrical work unless you are qualified to perform such work 2 Before performing any maintenance work inside a power source disconnect the power source from the incoming electrical power 3 Maintain cables grounding wire connections power cord and power supply in safe working order Do not operate any equipment in faulty condition 4 Do not abuse any equipment or accessories Keep equipment away from heat sources such as furnaces wet conditions such as water puddles oil or grease corrosive atmospheres and inclement weather 5 Keep all safety devices and cabinet covers in position and in good repair 6 Use equipment only for its intended purpose Do not modify it in any manner ADDITIONAL SAFETY INFORMATION For more information on safe practices
16. 00 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 22 SECTION 3 INSTALLATION 3 6 Coolant Installation Electric Current 15 Hazardous WARNING Itis important to have a good earth ground connected to the workpiece or cutting table Commercial Antifreeze Will Cause Torch To CAUTI ON Malfunction Use special torch coolant P N 156F05 Due 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 from freezing to 34 C 29 F 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 P N 156F05 one gallon 3 8 liters Donot fill above indicated maximum level Reinstall cap Coolant Fill Cap 23 SECTION 5 INSTALLATION 24 SECTION 4 OPERATION 4 1 Introduction Operational Safety DA N e E R Electric Shock Can Killl Disconnect current supply at wall disconnect before servicing console torch or plumbing box Donotoperate console or plumbing box with any covers removed open Do not touch any torch front end parts with power on Do not attempt to service
17. 122 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 331227 33123 33124 33125 33126 Air black Euro 2 0558002978 0558002979 0558002980 0558002981 7 0558002982 Note z Requires adapter P N 19X54 order separately Requires adapter 74576 order separately 2 6 Gas Regulators Station Regulator Cylinder Regulator oo ii 998343 DIE 1915 1 kl kes kk ban 998336 Argon Hydrogen 35 TONI des 998341 gem lie C E A separate start gas regulator is always required Forair plasma use air start gas For oxygen or nitrogen use nitrogen start gas For 35 argon hydrogen H 35 or nitrogen start gas A total of 3 regulators will be required plasma start and secondary N OT When using plumbing box Gas hoses from supply cylinders go directly to the plumbing box Console gas manifold is not used SECTION 2 DESCRIPTION 2 7 Basic Packages The EPP 200 systemis available as a pre engineered package or can be ordered as individual parts as listed Basic Packages include EPP 200 Console Plasma Torch Appropriate regulators for the gases indicated Gas hos
18. 611 EMI EN 639525 BRKT WIG CAPACITOR 594876 BUSHNG SNAP 75D 1 00 WH 055800433 1 PANEL RELAY EPP 200 lt 13736013 6 HOSE CAMP W D 3110 88 lt 0558005181 1 BALL POLYPROPYLENE ORG 5001 055800045 1 CIRCUIT BREAKER 2 AP 202348 1 PLUG House O O 0598000006 1 cap House S S _ 33053 1 ADAPTOR B A WM 1 4 NEW BKD 20086 1 951568 1 PLUG 5 8 IB 41012 1 ADAPTOR B A WF B A WF OLD NEW 16 3 CB iB 10 KA 198 LN Revision History Original release February 2004 May 2004 Converted Schematics and Wiring Diagrams to 11 x 17 page size and included at back of manual June 2004 Updated Options Accessories and Hose charts on Pages 13 and 14 November 2004 Changed bom item 69 from clamp hose w d 25d 62d qty 12 to clamp hose w d 31d 884 qty 6 February 2006 Updated Schematic and Replacement Parts per ECN 8053186 November 2006 Updated Replacement Parts December 2006 Updated Replacement Parts October 2007 Updated conductor fuse table in Subsection 3 4 1 Updated disclaimer page ER hl i ni LE api n FH LE d COMPONENT LEGEND USED OTHER THAN 3 D 0558004316 AND JJABCDEFGHJKLMNPRSTUV LI LITITITIT LI D LI H _ 461234567 8 9 10111213141516 DENOTES ESP 200 MODE LI M2 PUMP
19. 7 78 79 0 0558004336 0558004339 0558004338 952137 82 0558954035 995103 2 SPACER LED M1 a mwenn pesi EE p 83 84 90238 2062534 673676 672330GY CB1 2 88 950829 599800 J2 J7 952209 13730763 2 TERMINAL BLOCK 24 POS 15A PLATE SERIAL 954570 LABEL RATING ESP EPP 200 EURE 951061 65509506 36635 952012 4 4 METER LED 5 VDC RIV BLD AL 1 8 GRIP BOLT LAG 1 4 X 2 00 CLIP PALLET CASTER FIXED 952013 CASTER SWIVEL 952144 EX 105 2091514 4 2 3 2 GASKET 106 995227 3 3 4 LABEL WARNING LABEL WARNING EXPOSED HIGH VOLT LUG TERMINAL 2 8 WIRE 1 4 STUD INSULATOR NOMEX PLUG HOLE 875DIA 125 CT NYL BK BUSHING SNAP 1 38ID 1 75 MH 45LG BUSHING SNAP 51 SECTION 7 REPLACEMENT PARTS BILL UF MATERIALS QUANTITIES ARE IN U M ESTIMATED BY INVENTORY SYMBOL PART OF CODE NO DESCRIPTION 647345 BUSHING SNAP 1 31 ID 1 50 MH 44 LG 92W57 GROMMET RUB 63ID X 88 GD X 06W 99512240 1 LABEL WARNING LIFTING EYE 631507 TYWRAP MEDIUM 116 182W58 AR TYWRAP CLAMP STANDARD 120 AR AR 122 AR EEE 5 61325653 M SCREW PHI 6 32 8510 1 124 64504860 AR WASHER PAN 68950 AR WASHER LOCK 126 209158 AR 61325878 A screw 61325880 TAR SCREW 8 32 x506 7643078877 AR WASHER EXT TOOTH g8
20. 933 7070 Hours 7 30 AM to 5 00 PM EST IF YOU DO NOT KNOW WHOM TO CALL Telephone 800 ESAB 123 Fax 843 664 4462 Hours 7 30 AM to 5 00 PM EST or visit us on the web at http www esabna com The ESAB web site offers Comprehensive Product Information Material Safety Data Sheets Warranty Registration Instruction Literature Download Library Distributor Locator Global Company Information Press Releases Customer Feedback amp Support AE ESAB Welding 8 Cutting Products PO Box 100545 Florence SC 29501 0545
21. B1 P3 2 BLU K3 3 BLU S4 6 YEL K5 A YEL PCB1 P7 1 WHT SHEET 3 OF 3 ENGLISH DWG UNLESS OTHERVISE SPECIFIED DIM ARE FIRST MADE FUR EPP 200 SUP DRAWN CHECKED APPROVED s BE me me D 05580043 17 gt 0558004676 10 2007 ESAB Welding amp Cutting Products Florence SC Welding Equipment COMMUNICATION GUIDE CUSTOMER SERVICES CUSTOMER SERVICE QUESTIONS Telephone 800 362 7080 Fax 800 634 7548 Hours 8 00 AM to 7 00 PM EST Order Entry Product Availability Pricing Order Information Returns ENGINEERING SERVICE Telephone 843 664 4416 Fax 800 446 5693 Hours 7 30 AM to 5 00 PM EST Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting TECHNICAL SERVICE Telephone 800 ESAB 123 Fax 843 664 4452 Hours 8 00 AM to 5 00 PM EST Part Numbers Technical Applications Specifications Equipment Recommendations LITERATURE REQUESTS Telephone 843 664 5562 Fax 843 664 5548 Hours 7 30 AM to 4 00 PM EST WELDING EQUIPMENT REPAIRS Telephone 843 664 4487 Fax 843 664 5557 Hours 7 30 AM to 3 30 PM EST Repair Estimates Repair Status WELDING EQUIPMENT TRAINING Telephone 843 664 4428 Fax 843 679 5864 Hours 7 30 AM to 4 00 PM EST Training School Information and Registrations WELDING PROCESS ASSISTANCE Telephone 800 ESAB 123 Hours 7 30 AM to 4 00 PM EST TECHNICAL ASST CONSUMABLES Telephone 800
22. GAUGE 2 00 200 PSI 67 27 0558004656 1 PCB ISOLATION AMP EPP 200 _ 29 99205 6 STANDOFF 96 32 X 7 86 30 BLOCK 13 POS 201 2062567 TERMINAL STRIP MAWER PCBI 33 95208 S S 952035 1 GWRPUGSPS B 5 22458 1 RECEPTACLE 8 POS 49 SECTION 7 REPLACEMENT PARTS AN Ur MATERIAL SYMBOL PART DF ND DESCRIPTION MODI P3 MOD2 P3 4 2234891 4 PLUG 10 POS TIM P1 3 4 40 952030 3 PLUG 18 POS pz 95252 43 952033 1 COVER PLUG 16 POS PER n 46 3266 2 BAG CLOTH POST PT 95096 Di 925 ES M2 51 951215 1 MOTOR CARB 1 3 H P L 5 9508 RE LA 3 S L 2 38 L 63 56538 1 HOSE ASSY PUMP OUTLET 64 90858009 4 5 TBG NYLOBRADE 3 8 ID X 625 OD 5 Vs 2 66 13735961 2 HEAT EXCHANGER 68 952181 1 Y PLASTIC PIPE 69 13734871 6 CLAMP HOSE W D 25 620 70 8994471 5 CLAMP W D 50D 1 06D 2 7 398 70 72 1750008 4 75 sas 1 74 0558004526 3 50 SECTION 7 82 L1 75 76 REPLACEMENT PARTS BILL Or MATERIALS QUANTITIES ARE IN U M ESTIMATED BY INVENTORY SYMBOL PART DF CODE NO DESCRIPTION 1 TERMINAL BLOCK 7 POS 25 12 18 AWG 952026 951198 952095 CORE SATURABLE B3
23. I P1 7 BLU S2 4 BLU MODI P1 8 YEL wh K6 9 YEL MOD2 P2 6 ORN EJ HIT MODI SH1 cid E 2 T3 BLK 1001 FNI LI MOD2 FNI LI BLK MOD1 FN1 L2 BLK MOD2 FN1 L2 BLK P3 16 ORN A MODI FN1 L3 BLK MOD2 FN1 L3 BLK MODI TB3 1 RED TB4 DETAIL BILL DF MATERIALS QUANTITIES ARE IN U M ESTIMATED BY INVENTURY MOD2 P1 2 GRY PCB1 P1 15 VIO PCB1 P3 12 BRN 2 PCB1 P3 13 WHT PCB1 P1 13 BLK PCB1 P1 14 RED P5 4 GRY MOD2 P1 7 BLU PCB1 P3 18 BLU MOD2 P1 8 YEL PCB3 P1 6 YEL R1 1 ORN P5 12 WHT K2 T2 VIO PCB1 P3 10 VI0 P5 9 BLU PCB1 P2 6 BLU P5 3 ORN K3 A GRY K3 B BRN 1 2 3 4 5 6 7 8 3 2 YEL K7 A BLU S2 7 WHT TB4 11 BRN TB4 13 GRY PCB1 P4 11 RED P4 12 BLK P4 13 VI0 PCB1 P4 14 YEL gt P2 15 YEL P2 16 YEL P2 8 GRY P2 9 BLK P2 10 GRY P10 4 WHT P10 3 RED P10 5 WHT PCB1 P1 9 GRY PCB1 P1 10 YEL MODI P2 6 ORN K6 A BLK MOD1 P2 3 BLU K4 9 BLU PCB1 P1 2 BRN PCB1 P1 3 RED MODI P1 11 WHT K2 L2 ORN P5 6 K5 9 PCB1 P1 7 BLK PCB1 P1 8 BLK RB 1 RED TD1 WORK BLK PCB1 P2 14 BLK TB4 5 BLK PCB1 P2 13 BLU TB4 4 BLU PCB1 P2 12 BRN PCB1 P2 11 BRN TB4 4 BLU S4 1 RED K4 A RED PCB1 P2 5 ORN PCB P2 4 0RN PCB1 P2 2 WHT TB4 2 WHT TB4 1 VIO K2 A GRY PCB1 P3 1 GRY PC
24. Ne jamais d brancher le ventilateur e Les fum es produites par l op ration de soudage ou de coupage peuvent s av rer toxiques Aussi est il n cessaire de disposer en permanence d un dispositif ad quat de ventilation de type aspirant afin d limi ner du voisinage de l op rateur tout d gagement de fum e visible f Consultez les recommandations particuli res en mati re de ventilation indiqu es l alin a 6 de la norme Z49 1 de l AWS 5 ENTRETIEN DE L QUIPEMENT Un quipement entretenu de facon d fectueuse ou inad quate risque non seulement de r aliser un travail de mauvaise PR CAUTIONS DE S CURIT qualit mais chose plus grave encore d entrainer des dommages corporels graves voire mortels en d clenchant des incendies ou des chocs lectriques Observez par cons quent les pr cautions suivantes Efforcez vous de toujours confier un personnel qua lifi l installation le d pannage et l entretien du poste de soudage et de coupage N effectuez aucune r paration lectrique sur l quipement moins d tre qua lifi cet effet Ne proc dez jamais une t che d entretien quelconque l int rieur du poste de soudage coupage avant d avoir d branch l alimentation lectrique Maintenez en bon tat de fonctionnement les c bles le c ble de masse les branchements le cordon d alimentation et le poste de soudage coupage N utilisez jamais le poste ou l quipement s il pr se
25. Safe Practices for Plasma Arc Welding AWS C5 1 Recommended Safe Practices for Air Carbon Arc Gouging and Cutting AWS C5 3 g Code For Safety in Welding and Cutting CSA Standard 10 W117 2 SECTION 2 DESCRIPTION 2 1 Introduction 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 50to 200 Amperes cutting current range Forced air cooled Solid state DC power Integral water cooler Input voltage protection Localorremote front panel control Thermal switch protection for main transformer and power semiconductor components LEDstatus troubleshooting 2 2 General Specifications EPP 200 Power Console 0558004315 OUTPUT 100 duty cycle bnc ei S 160VDC Current range DO 50A to 200A 8000 W to 32000 W Open Circuit Voltage OCV 325VDC INPUT Voltage 3 phase 200 230 380 415 460 575 Volts Current 3 phase ac ee 115 100 60 55 50 40 Amperes GU NCard ine 50 60Hz KVA c esse 39 8 kW Re 37 8 Power Factor EE sens ak mm 95 See Section 3 Installation SECTION 2 DESCRIPTION N N G Electric Shock Can Kill Use
26. TO COE N 1 35006 4 TERMINAL 250 X 22 18 AG O 5 _ 6 0863008 38 TUBING HEAT SHR POLY 150 D BK _ 19 859555 6 BUSHING SNAP 1 09 Mi L i65 SRW PHI OD _ 166 0558004320 1 EPP 200 PWR MOD 100A SAVE i i 3859 1 Hose assy ZON 1 3534 1 PMPCHHW SRANR _ 9082552 7 TUBNG PVC 7 8 1 15 172 90861726 75 TUBING VINYL 294 ID X 020 W 173 96W10 1 HOLDER FUSE 17 1 4 2017485 FUSE 5 ROD Me SSR OOOO 176 78 16 WSR FAT 1 25 X 083 WA omo 1809012048 15 15 RUBBER STRIP BE X ret 1 1 182 954010 2 LABEL WARNING CAPACITOR TD1 P1 183 952008 1 HOUSING CRIMP 4 PIN K3 7 8 184 2080196 3 RELAY ENCLOSED 3PDT 120VAC 1185 673013 TERM FAS 187 TS DUAL 53 SECTION 7 REPLACEMENT PARTS BILL UF MATERIALS QUANTITIES ARE IN U M ESTIMATED BY INVENTORY SYMBOL a PART DF CDDE ND DESCRIPTIDN 185 186 950487 1 TERM BLOCK 2 POS 64307860 WSR EXT TOOTH 6 955243 1 LABEL SET EPP 200 673213 1 SW SPST TGGL 182W62 1 CONN BOX RECPT 3FS 185 191 351481 TUBE 173D X 02W X 75LG VIN 55 8 RBTRMPO 17315247 L2 647065 35929 0558004324 T5 E IES 18 NEN R6 0 E iA _____ DIODE FWD 1200V 854 BUSBAR DIODE 37448 4600
27. agn ticos EMF Las corrientes en el rea de corte y soldadura crean EMF alrrededor de los cables de soldar y las maquinas lo tanto 1 Soldadores u Operadores que use marca pasos para el coraz n deber n consultar a su m dico antes de soldar El Campo Electromagn tico EMF puede interferir con algunos marca pasos 2 Exponerse a campos electromagn ticos EMF puede causar otros efectos de salud a n desconocidos 3 Los soldadores deber n usar los siguientes procedimientos para minimizar exponerse al EMF A Mantenga el electrodo y el cable a la pieza de trabajo juntos hasta llegar ala pieza que usted quiere soldar Aseg relos uno junto al otro con cinta adhesiva cuando sea posible B Nunca envuelva los cables de soldar alrededor de su cuerpo C Nunca ubique su cuerpo entre la antorcha y el cable a la pieza de trabajo Mantega los cables a un s lo lado de su cuerpo D Conecte el cable de trabajo ala pieza de trabajo lo m s cercano posible al rea de la soldadura E Mantenga la fuente de poder y los cables de soldar lo m s lejos posible de su cuerpo SECTION 1 HUMO Y GASES El humo y los gases pueden causar malestar particularmente en espacios sin ventilaci n No inhale el humo o gases gas de protecci n puede causar falta de ox geno Por lo tanto 1 Siempre provea ventilaci n adecuada en el rea de trabajo por medio natural o mec nico No solde corte o ranure ma
28. any portion of this plasma system unless power has been disconnected at the wall disconnect This equipment can be hazardous if not properly operated and maintained Read and understand all equipment literature and warning labels before operating this equipment Plasma Arc Cutting Can Be Hazardous To WA M N G Eyes And Ears Wear hearing protection ad Wear eye protection specifically designed for arc AP welding and cutting Lenses should be atleast a No 6 or 7 lens shade Wear protective clothing to avoid skin burns 25 SECTION 4 OPERATION 4 2 Operating the EPP 200 Console 4 2 1 Console Controls Pilot Arc High Low Switch Cutting Voltage and Cutting Current Meters Output Current Control Remote Panel Selection Switch Gas Test Switch Fault Lights 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 th
29. arc like the sun emits ul traviolet UV and other radiation and can injure skin and eyes Hot metal can cause burns Training in the proper use of the processes and equip ment is essential to prevent accidents Therefore 1 Always wear safety glasses with side shields in any work area even if welding helmets face shields and goggles are also required Use a face shield fitted with the correct filter and cover plates to protect your eyes face neck and ears from sparks and rays of the arc when operating or observing operations Warn bystanders notto watch the arc and not to expose themselves to the rays ofthe electric arc or hot metal Wearflameproof gauntlettype gloves heavy long sleeve shirt cuffless trousers high topped shoes and a weld ing helmet or cap for hair protection to protect against arc rays and hot sparks or hot metal A flameproof apron may also be desirable as protection against radiated heat and sparks Hot sparks or metal can lodge in rolled up sleeves trouser cuffs or pockets Sleeves and collars should be kept buttoned and open pockets eliminated from the front of clothing Protect other personnel from arc rays and hot sparks with a suitable non flammable partition or curtains Use goggles over safety glasses when chipping slag or grinding Chipped slag may be hot and can fly far Bystanders should also wear goggles over safety glasses FIRES AND EXPLOSIONS Heat
30. cesses available from the National Fire Protection Asso ciation Batterymarch Park Quincy MA 02269 ELECTRICAL SHOCK Contact with live electrical parts and ground can cause severe injury or death DO NOT use AC welding current in damp areas if move mentis confined orifthere is danger of falling Be sure the power source frame chassis is connected to the ground system of the input power 2 Connect the workpiece to a good electrical ground 3 Connect the work cable to the workpiece A poor or missing connection can expose you or others to a fatal shock 4 Use well maintained equipment Replace worn or dam aged cables 5 Keep everything dry including clothing work area cables torch electrode holder and power source 6 Make sure that all parts of your body are insulated from work and from ground 7 Do not stand directly on metal or the earth while working in tight quarters or a damp area stand on dry boards or an insulating platform and wear rubber soled shoes 8 Puton dry hole free gloves before turning on the power 9 Turn off the power before removing your gloves 10 Referto ANSI ASC Standard Z49 1 listed on next page for specific grounding recommendations Do not mis take the work lead for a ground cable ELECTRIC ANDMAGNETIC FIELDS May be dangerous Electric current flowing through any conductor causes local ized Electric and Magnetic Fields EMF gt Welding and
31. cessive 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 3 4 Input Connections to Console 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 SECTION 5 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 Rated Load Input and Time delay Ground Fuse size Amperes conductor amperes 200 208 2900 100 3800 60 45 55 460 so 575 40 Sizes per National Electrical Code for a 75 C 165 F rated copper conductors 40 C 104 F ambient Not more than four conductors 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 Dedicated power line may be necessary EPP 200 is equipped with line voltage compensation but to avoid impaired performance due to an overloaded circu
32. e 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 26 SECTION 4 LJ a ki 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 Coolant Flow Will show low coolant flow Light will briefly show a fault when console is turned on and then go out Plasma Gas Pressure fault indicator low plasma gas pressure Torch will not fire when illuminated Interlock Fault Indicates Remote Plumbing box door is not properly closed P S Temp fault indicator over temperature condition the inverter power source P S Fault fault indicator Not used 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 27 SECTION 4 4 3 Sequence of Operation OPERATION 1 Apply
33. ectrique lorsque vous effectuez des soudures ou des coupes ou lorsque vous en observez l ex cution AVERTISSEZ les personnes se trouvant proximit de fa on ce qu elles ne regardent pas l arc et ce qu elles ne s exposent pas son rayonnement ni celui du m tal incandescent b Portez des gants ignifug s crispins une tunique paisse manches longues des pantalons sans rebord des chaussures embout d acier et un casque de soudage ou une calotte de protection afin d viter d exposer la peau au rayonnement de l arc lectrique ou du metal incandescent Il est galement souhaitable d utiliser un tablier ininflammable de fa on se prot ger des tincelles et du rayonnement thermique Les tincelles ou les projections de m tal incandes cent risquent de se loger dans des manches retrouss es des bords relev s de pantalons ou dans des poches Aussi convient il de garder boutonn s le col et les manches et de porter des v tements sans poches l avant d Prot gez des tincelles et du rayonnement de l arc lectrique les autres personnes travaillant proximit l aide d un cran ininflammable ad quat e Ne jamais omettre de porter des lunettes de s curit lorsque vous vous trouvez dans un secteur ou l on effectue des op rations de soudage ou de coupage l arc Utilisez des lunettes de s curit crans ou verres lat raux pour piquer ou le laitier Les piquetures incand
34. egos 3 No corte suelde o haga cualquier otro trabajo relacionado hasta que la pieza de trabajo est totalmente limpia y libre de substancias que puedan producir gases inflamables o vapores t xicos No trabaje dentro o fuera de contenedores o tanques cerrados Estos pueden explotar si contienen vapores inflamables 4 Tenga siempre a la mano equipo extintor de fuego para uso instant neo como por ejemplo una manguera con agua cubeta con agua cubeta con arena o extintor port til Aseg rese que PRECAUCION DE SEGURIDAD usted esta entrenado para su uso 5 No use el equipo fuera de su rango de operaci6n Por ejemplo el calor causado por cable sobrecarga en los cables de soldar pueden ocasionar un fuego 6 Despu s de termirar la operaci6n del equipo inspeccione el area de trabajo para cerciorarse de que las chispas o metal caliente ocasionen un fuego mas tarde Tenga personal asignado para vigilar si es necesario 7 Para informaci n adicional haga referencia a la publicaci n NFPA Standard 51B Fire Prevention in Use of Cutting and Welding Processes disponible a trav s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 CHOQUE ELECTRICO El contacto con las partes el ctricas energizadas tierra puede causar muerte NO use soldadura de corriente alterna AC en reas h medas de movimiento confinado en lugares estrechos osihay posibilidad de caer al su
35. elo 1 Aseg rese de que el chasis de la fuente de poder est conectado a tierra atrav s del sistema de electricidad primario 2 Conecte la pieza de trabajo a un buen sistema de tierra f sica 3 Conecte el cable de retorno a la pieza de trabajo Cables y conductores expuestos o con malas conexiones pueden exponer al operador u otras personas a un choque el ctrico fatal 4 Use el equipo solamente si est en buenas condiciones Reemplaze cables rotos da ados o con conductores expuestos 5 Mantenga todo seco incluyendo su ropa el rea de trabajo los cables antorchas pinza del electrodo y la fuente de poder 6 Aseg rese que todas las partes de su cuerpo est n insuladas de ambos la pieza de trabajo y tierra 7 No se pare directamente sobre metal o tierra mientras trabaja en lugares estrechos o reas h medas trabaje sobre un pedazo de madera seco o una plataforma insulada y use zapatos con suela de goma 8 Use guantes secos y sin agujeros antes de energizar el equipo 9 Apage el equipo antes de quitarse sus guantes 10 Use como referencia la publicaci n ANSI ASC Standard Z49 1 listado enla pr xima p gina para recomendaciones espec ficas de como conectar el equipo a tierra No confunda el cable de soldar a la pieza de trabajo con el cable a tierra CAMPOS ELECTRICOS Y MAGNETICOS Son peligrosos La corriente el ctrica fluye atrav s decualquier conductor causando a nivel local Campos El ctricos y M
36. es are preset for 17 psig 1 2 bar shield and start gas switches 22 psig 1 5 bar cut gas switch 5 3 1 Pressure Switch Adjustment Procedure 1 Turn main power switch OFF OFF 2 Remove right side panel 3 Turn wheel Counterclockwise to increase pressure Clockwise to decrease pressure 4 Replace panel 5 Resume operation 5 3 2 Gas Manifold with Non adjustable Pressure Switches reference 31 SECTION 5 32 SECTION 6 6 1 Introduction WARNING 7 6 2 Procedure TROUBLESHOOTING Electric Shock Can Kill Ensure all primary power to machine has been externally disconnected Open line wall switch before attempting inspection or performing work inside the plasma console or plumbing box 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 1 Shut main power switch on the console to OFF position 2 Disconnect main power line wall switch 3 Check for obvious external settings switches and external connections 4 If a problem is found correct and proceed with normal operations 5 If not remove side panels Reminder Power must be disconnected before removing any covers 6 Perform a visual inspection of internal components Check for Loose or burned wiring and components Secure terminal connection
37. es from regulators to console Torch coolant ARA ABE TORO ae Torch Coolant 1 gallon 3 8 L P N 0558004297 SECTION 2 DESCRIPTION SECTION 5 3 1 General INSTALLATION Failure To Follow Instructions Could Lead To Death Injury Or Damaged Property Follow these instructions to prevent injury or property damage You must comply with local state and national electrical and safety codes 3 2 Unpacking Gor A Use Lifting Eye When Hoisting From Overhead Use safe practices when transporting with overhead method Unit weighs over 700 Ibs 318 kg Use approved straps or cables in good condition Inspect for transit damage immediately upon receipt Remove all components from shipping container and check for loose parts in container Inspectlouvers for air obstructions SECTION 5 INSTALLATION Do Not Restrict Air Flow Restricting intake air with any type offilter on or around the Plasma console will result in overheating and may void the warranty 3 3 Placement Plasma Console A minimum of 2 ft 0 61m clearance for cooling air flow Plan for top panel and side panels having to be removed for maintenance cleaning and inspection Locate the EPP 200 relatively close to a properly fused electrical power supply Keep area beneath power source clear for cooling air flow Environment should be relatively free of dust fumes and ex
38. escentes de laitier peuvent tre projet es des distances consid rables Les personnes se trouvant proximit doivent galement porter des lunettes de protection f Le gougeage l arc et le soudage l arc au plasma produisent un niveau de bruit extr mement lev de 100 114 dB et exigent par cons quent l emploi de dispositifs appropri s de protection auditive 2 PREVENTION DES INCENDES Les projections de incandescent ou d tincelles peuvent provoquer de graves incendies au contact de mat riaux com bustibles solides liquides ou gazeux Aussi faut il PR CAUTIONS DE S CURIT observer les pr cautions suivantes loigner suffisamment tous les mat riaux combustibles du secteur o l on ex cute des soudures ou des coupes l arc moins de les recouvrir compl tement d une b che non inflammable Ce type de mat riaux comprend notamment le bois les v tements la sciure l essence le k ros ne les peintures les solvants le gaz naturel l ac tyl ne le propane et autres substances combus tibles semblables Les tincelles ou les projections de m tal incandescent peuvent tomber dans des fissures du plancher ou dans des ouvertures des murs et y d clencher une ignition lente cach e Veiller prot ger ces ouvertures des tincelles et des projections de m tal N ex cutez pas de soudures de coupes d op rations de gougeage ou autres travaux chaud la surface de bar
39. f the unit on which the parts will be used The serial number is stamped on the unit nameplate Toensure proper operation itisrecommended thatonly genuine ESAB 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 Refer to the Communications Guide located on the back page of this manual for a list of customer service phone numbers Bill of material items that have blank part numbers are provided for customer information only Hardware items should be available through local sources 39 SECTION 7 REPLACEMENT PARTS 40 SECTION 7 REPLACEMENT PARTS 8 y CB1 CB2 7 8 8 DE TI ae 7 uj Goes e OR IS UNS DDD 6515951222 41 SECTION 7 REPLACEMENT PARTS 38 MODI MOD2 MOD2 2 2 an ZA K7 OTK a A AN so 2 19 1 99612 29 42 SECTION 7 REPLACEMENT PARTS P4 MOD2 P4 yea SECTION 7 REPLACEMENT PARTS E 8 e y if at L A fal 66 CIE PCB2 a ee DO TI 72 F5 164 E TOLDOS i oo Y 6 eese 9818 SECTION 7 REPLACEMENT PARTS XS XE XXE 03 23 S Fm tJ SECTION 7 REPLACEMENT PARTS SECTION 7 REPLACEMENT
40. for electric arc A welding and cutting equipment ask your sup plier for a copy of Precautions and Safe Prac tices for Arc Welding Cutting and Gouging Form 52 529 The following publications which are available from the American Welding Society 550 N W LeJuene Road Mi ami FL 33126 are recommended to you 1 ANSI ASC Z49 1 Safety in Welding and Cutting 2 AWS C5 1 Recommended Practices for Plasma Arc Welding 3 AWS 05 2 Recommended Practices for Plasma Arc Cutting 4 AWS C5 3 Recommended Practices for Air Carbon Arc Gouging and Cutting 5 AWS C5 5 Recommended Practices for Gas Tungsten Arc Welding 6 AWS C5 6 Recommended Practices for Gas Metal Arc Welding 7 AWS SP Safe Practices Reprint Welding Handbook 8 ANSI AWS F4 1 Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances MEANING OF SYMBOLS As used throughout this manual Means Attention Be Alert Your safety is involved Means immediate hazards which if not avoided will result in immediate seri ous personal injury or loss of life A TEA Means potential hazards which could LEE result in personal injury or loss of life Means hazards which could result in A CAUTION minor personal injury SECTION 1 ADVERTENCIA Estas Precauciones de Seguridad son para su protecci6n Ellas hacen resumen de informaci6n proveniente de las referencias listadas en la secc
41. from flames and arcs can start fires Hot slag sparks can also cause fires and ex plosions Therefore Remove all combustible materials well away from the work area or cover the materials with a protective non flammable covering Combustible materials include wood cloth sawdust liquid and gas fuels solvents paints and coatings paper etc Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hidden smoldering fire or fires on the floor below Make certain that such openings are protected from hot sparks and metal Do not weld cut or perform other hot work until the workpiece has been completely cleaned so that there are no substances on the workpiece which might pro duce flammable or toxic vapors Do not do hot work on closed containers They may explode Have fire extinguishing equipment handy for instant use such as a garden hose water pail sand bucket or portable fire extinguisher Be sure you are trained in its use SAFETY PRECAUTIONS 5 Do not use equipment beyond its ratings For example overloaded welding cable can overheat and create a fire hazard After completing operations inspect the work area to make certain there are no hot sparks or hot metal which could cause a later fire Use fire watchers when neces sary For additional information refer to NFPA Standard 51B Fire Prevention in Use of Cutting and Welding Pro
42. fuente de poder en buen estado operacional No opere ning n equipo en malas condiciones 4 No abuse del equipo y sus accesorios Mantenga el equipo lejos de cosas que generen calor como hornos tambi n lugares h medos como charcos de agua aceite o grasa atm sferas corrosivas y las inclemencias del tiempo 5 Mantenga todos los art culos de seguridad y coverturas del equipo en su posici n y en buenas condiciones 6 Use el equipo s lo para el prop sito que fue disefiado No modifique el equipo en ninguna manera INFORMACION ADICIONAL DE SEGURIDAD Para m s informaci n sobre las pr cticas de seguridad de los equipos de arco el ctrico para soldar y cortar pregunte a su suplidor por una copia de Precautions and Safe Practices for Arc Welding Cutting and Gouging Form 52 529 Las siguientes publicaciones disponibles atrav s de la American Welding Society 550 N W LeJuene Road Miami FL 33126 son recomendadas para usted 1 ANSI ASC 249 1 Safety in Welding and Cutting 2 AWS C5 1 Recommended Practices for Plasma Arc Welding 3 AWS C52 Recommended Practices for Plasma Arc Cutting 4 AWS C5 3 Recommended Practices for Air Carbon Arc Gouging and Cutting 5 AWS C5 5 Recommended Practices for Gas Tungsten Arc Welding 6 AWS C5 6 Recommended Practices for Gas Metal Arc Welding 7 AWS SP Safe Practices Reprint Welding Handbook 8 ANSI AWS F4 1 Recommended Safe Practices for Weld ing
43. i n Informaci n Adicional Sobre La Seguridad Antes de hacer cualquier instalaci n o procedimiento de operaci n aseg rese de leer y seguir las precauciones de seguridad listadas a continuaci n as como tambi n todo manual hoja de datos de Seguridad del material calcomanias etc El no observar las Precauciones de Seguridad puede resultar en a la persona o muerte PROTEJASE USTED Y ALOS DEMAS Algunos p procesos de soldadura corte y ranurado QE son ruidosos requiren protecci n para los oidos El arco como el sol emite rayos ultravioleta UV y otras radiaciones que pueden danar la piel los ojos El metal caliente causa quemaduras EL entrenamiento en el uso propio de los equipos y sus procesos es esencial para prevenir accidentes Por lo tanto 1 Utilice gafas de seguridad con protecci6n a los lados siempre que est en el area de trabajo cuando est usando careta de soldar protector para su u otro tipo de protecci6n 2 Use una careta que tenga el filtro correcto lente para proteger sus ojos cara cuello oidos de las chispas rayos del arco cuando se est operando y observando las operaciones Alerte a todas las personas cercanas de no mirar el arco y no exponerse a los rayos del arco el ctrico o el metal fundido 3 Use guantes de cuero a prueba de fuego camisa pesada de mangas largas pantal n de ruedo liso zapato alto al tobillo y careta de soldar con capucha para
44. ils bidons r servoirs ou autres contenants usag s avant de les avoir nettoy s de toute trace de substance susceptible de produire des vapeurs inflammables ou toxiques En vue d assurer la pr vention des incendies il convient de disposer d un mat riel d extinction pr t servir imm diatement tel qu un tuyau d arrosage un seau eau un seau de sable ou un extincteur portatif Une fois le travail l arc termin inspectez le secteur de facon vous assurer qu aucune tincelle ou projection de m tal incandescent ne risque de provoquer ult rieurement un feu CHOC LECTRIQUE Le gougeage l arc et l arc au plasma exige l emploi de tensions vide relativement importantes or celles ci risquent de causer des dommages corporels graves et m me mortels en cas d utilisation inad quate La gravit du choc lectrique recu d pend du chemin suivi par le courant travers le corps humain et de son intensit Ne laissez jamais de surfaces m talliques sous tension venir au contact direct de la peau ou de v tements humides Veillez porter des gants bien secs Si vous devez effectuer un travail sur une surface m tallique ou dans un secteur humide veillez assu rer votre isolation corporelle en portant des gants secs et des chaussures semelles de caoutchouc et en vous tenant sur une planche ou une plate forme s che Mettez toujours la terre le poste de soudage coupage en le reliant par u
45. it a dedicated power line may be required SECTION 5 INSTALLATION 3 4 2 Primary Power Hookup Procedure Input Power Cable Strain Relief Main Contactor 7 Position Terminal Block Auto Transformer Factory wired for 575 volts CAUTION 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 Connectthree 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 left 8 Con
46. n c ble une bonne prise de terre N utilisez jamais de c bles us s ou endommag s Ne surchargez jamais le c ble Utilisez toujours un quipement correctement entretenu Mettez l quipement hors tension lorsqu il n est pas en service une mise la masse accidentelle peut en effet provoquer une surchauffe de l quipement et un danger d incendie Ne pas enrouler ou passer le c ble autour d une partie quelconque du corps V rifiez si le c ble de masse est bien reli la pi ce en un point aussi proche que possible de la zone de travail Le branchement des c bles de masse l ossature du b timent ou en un point loign de la zone de travail augmente en effet le risque de passage d un courant de sortie par des cha nes de SECTION 1 levage des cables de grue ou divers chemins lectriques g Emp chez l apparition de toute humidit notamment sur vos v tements a la surface de l emplacement de travail des c bles du porte lectrode et du poste de soudage coupage R parez imm diatement toute fuite d eau 4 VENTILATION La respiration prolong e des fum es r sultant des op rations de soudage coupage l int rieur d un local clos peut provoquer des mal aises et des dommages corporels Aussi convient il d observer les pr cautions suivantes a Assurez en permanence une a ration ad quate de l emplacement de travail en maintenant une ventila tion naturelle ou l aide de moyens m caniques
47. nect 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 Factory wired for 575 Volts 20 SECTION 3 INSTALLATION 9 Connectinput conductors to line wall disconnect 10 Replace side panel Replace only if all connections have made Output connections require this panel to be removed RE 11 Connect the other end of work cable to workpiece or cutting table Connection must be made to a clean exposed Work ground to work piece metal surface free of paint rust mill scale etc Work ground to cutting table Electric Current Is Hazardous WARNING Itis important to have a good earth ground connected to the workpiece or cutting table SSS Z EE 21 SECTION 5 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 DUO Mos f A Coolant Return Coolant Supply Pilot Arc Cable Electrode Cable Shield Gas directly to the Plumbing Box Start Gas directly to the Plumbing Box Cut Gas directly to the Plumbing Box Work Cable Pendant Cable if pendant option is ordered See Description Section 2 for part numbers A remote SETUP Panel option P N 220
48. nte une d fectuosit quelconque Prenez soin du poste de soudage et de coupage et des quipements accessoires Gardez les l cart des sources de charleur notamment des fours de l humidit des flaques d eau maintenez les l abri des traces d huile ou de graisse des atmosph res corrosives et des intemp ries Laissez en place tous les dispositifs de s curit et tous les panneaux de l armoire de commande en veillant les garder en bon tat Utilisez le poste de soudage coupage conform ment son usage pr vu et n effectuez aucune modification INFORMATIONS COMPL MENTAIRES RELATIVES A LA S CURIT Pour obtenir des informations compl mentaires sur les r gles de s curit a observer pour le montage et l utilisation d quipements de soudage et de coupage lectriques et sur les m thodes de travail recommand es demandez un exemplaire du livret 52529 Precautions and Safe Practices for Arc Weld ing Cutting and Gouging publi par ESAB Nous conseillons galement de consulter les publications sui vantes tenues votre disposition par l American Welding Society 550 N W LeJuene Road Miami FL 32126 Safety in Welding and Cutting AWS Z49 1 Hecommended Safe Practices for Gas Shielded Arc Welding AWS 1 Safe Practices for Welding and Cutting Containers That Have Held Combustibles AWS A6 0 Recommended Safe Practices for Plasma Arc Cutting AWS A6 3 Recommended
49. of torches not designed for this console could result in a hazardous electric shock Use only torches designed for the EPP 200 Console 2 3 Dimensions and Weight jie 550mm 44 in 1100mm 42in 1050mm Weight 725 lbs 330 kg SECTION 2 2 4 EPP 200 Options and Accessories Cooling Water Hoses 2 Control Cable Pilot Arc Lead Power Lead Consoleto Plumbing Box Plumbing Boxto Console Plumbing Boxto Console Consoleto Plumbing Box 5 ft 1 5m 0558003979 0558003985 DESCRIPTION 0558003991 10 ft 3 0m 0558003980 N A 0558003986 0558003992 20 ft 6 1m 0558003981 N A 0558003987 0558003993 25 ft 7 6m 33132 0558004651 33303 22001 30 ft 9 1m 0558003982 N A 0558003988 0558003994 40 ft 12 2m 0558003983 N A 0558003989 0558003995 50 ft 15 2m 33133 0558004652 33304 22002 75 ft 22 9m 33134 0558004653 33305 22003 100 ft 30 5 33135 0558004654 33306 22004 125 ft 38 1m 33136 0558003978 33307 22005 150 ft 45 7m 0558003984 0558004655 Use with one adaptor fitting 41V12 included with unit Torch Coolant 1gallon 3 8 L 4 required 156F05 0558003990 0558003996 SECTION 2 DESCRIPTION 2 5 Gas Hoses Gas Type 251 50 ft 75 ft 100 ft 125 ft 7 6m 15 2m 22 8m 30 4m 38 1m Nitrogen clear 33
50. other irritant gases 3 If you develop momentary eye nose or throat irritation while operating this is an indication that ventilation is not adequate Stop work and take necessary steps to im prove ventilation in the work area Do not continue to operate if physical discomfort persists 4 Refer to ANSI ASC Standard Z49 1 see listing below for specific ventilation recommendations 5 WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code 25249 5 et seq CYLINDER HANDLING Cylinders if mis handled can rupture and violently re lease gas Sudden rupture of cylinder valve or relief device can injure or kill Therefore 1 Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder Do not use adaptors Maintain hoses and fittings in good condition Follow manufacturer s operating instructions for mounting regu lator to a compressed gas cylinder 2 Always secure cylinders in an upright position by chain orstrapto suitable handtrucks undercarriages benches walls post or racks Never secure cylinders to work tables or fixtures where they may become part of an electrical circuit 3 When not in use keep cylinder valves closed Have valve protection cap in place if regulator
51. power by closing the line wall switch Main power light will not illuminate until console power switch is turned ON Faultlight 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 in OFF position Coolant level must fall in the safe operating level 4 Set pilot arc High Low switch Referto cutting process data ofthe torch manual 5 Turn on console power by placing power switch in ON position White light to left of the switch will illuminate 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 referto troubleshooting section 28 SECTION 5 5 1 General WARN N G Electric Shock Can Kill Open wall disconnect switch before attempting any maintenance on plasma console interconnecting cables Onlytrained personnel should perform maintenanceor repairs CAUTI O N on this
52. regulador dise ado para operar y reducir la presi n del cilindro de gas No utilice adaptadores Mantenga las mangueras y las conexiones en buenas condiciones Observe las instrucciones de operaci n del manufacturero para montar el regulador en el cilindro de gas comprimido 2 Asegure siempre los cilindros en posici n vertical y am rrelos con una correa o cadena adecuada para asegurar el cilindro al carro transportes tablilleros paredes postes o armaz n Nunca asegure los cilindros a la mesa de trabajo o las piezas que son parte del circuito de soldadura Este puede ser parte del circuito el lectrico 3 Cuando el cilindro no est en uso mantenga la v lvula del cilindro cerrada Ponga el capote de protecci n sobre la v lvula si el regulador no est conectado Asegure y mueva los cilindros utilizando un carro o transporte adecuado Evite el manejo brusco de los PRECAUCION DE SEGURIDAD MANTENIMIENTO DEL EQUIPO Equipo defectuoso o mal mantenido puede causar dano o muerte Por lo tanto 1 Siempre tenga personal cualificado para efectuar a instalaci n diagn stico y mantenimiento del equipo No ejecute ning n trabajo el ctrico a menos que usted est cualificado para hacer el trabajo 2 Antes de dar mantenimiento en el interior de la fuente de poder desconecte la fuente de poder del suministro de electricidad primaria 3 Mantenga los cables cable a tierra conexciones cable primario y cualquier otra
53. rrective Action LEDX on MOD1 not ON LEDX on MOD2 not ON LEDX on MOD2 not ON when torch switch is depressed or start signal is sent Arc does not transfer to work Open Circuit Voltage is between 315 and 355 Pilot arc IS 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 does not transfer to work Open Circuit Voltage is between 315 and 355 Pilot arc is NOT 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 ao 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 Bad PCB1 Bad 8 Readjust Current setting Torch to high above workpiece 9 Replace electrode NOTE Schematics and Wiring Diagrams on 11 x 17 paper are included 37 inside the back cover of this manual SECTION 6 TROUBLESHOOTING 38 SECTION 7 7 1 General 7 2 Ordering REPLACEMENT PARTS Always provide the serial number o
54. s Bulged or leaking capacitors Other signs of discoloration 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 33 SECTION 6 TROUBLESHOOTING 6 3 Front Panel Fault Lights Fault Indicator Lights Coolant Flow Will show low coolant flow The light will briefly showa fault when console is turned on and then go out Plasma Gas Pressure fault indicator low plasma gas pressure Torch will not fire when indicated Interlock Fault Indicates Remote Plumbing box door is not properly closed P S Temp fault indicator over temperature condition in the inverter power source P S Fault Not used Over Under Voltage fault indicator input voltage 15 above or below the tolerances of the power source console Will stay shut down console until main power switch is recycled 34 SECTION 6 6 4 Troubleshooting Guide WARNING CAUTION Problem TROUBLESHOOTING 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 checking voltages in the high frequency circuit Possible Cause Corrective Action
55. teriales con hierro galvanizado acero inoxidable cobre zinc plomo berilio cadmio a menos que provea ventilaci n mec nica positiva No respire los gases producidos por estos materiales 2 No opere cerca de lugares donde se aplique substancias qu micas en aerosol El calor de los rayos del arco pueden reaccionar con los vapores de hidrocarburo clorinado para formar un fosf geno o gas t xico y otros irritant es 3 Si moment neamente desarrolla inrritaci n de ojos nariz ogarganta mientras est operando es indicaci n de que la ventilaci n no es apropiada Pare de trabajar y tome las medidas necesarias para mejorar la ventilaci n en el rea de trabajo No contin e operando si el malestar f sico persiste 4 Haga referencia a la publicaci n ANSI ASC Standard 249 1 Vea la lista a continuaci n para recomendaciones espec ficas en la ventilaci n 5 ADVERTENCIA Este producto cuando se utiliza para soldaduras o cortes produce humos o gases los cuales contienen qu micos conocidos por el Estado de California de causar defectos en el nacimiento o en algunos casos Cancer California Health 8 Safety Code 25249 5 et seq MANEJO DE CILINDROS Los cilindros si no son manejados correctamente pueden romperse y liberar violentamente gases Rotura repentina del cilindro v lvula o v lvula de escape puede causar da o o muerte Por lo tanto 1 Utilize el gas apropiado para el proceso y utilize un
56. 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 READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING PROTECT YOURSELF AND OTHERS TABLE OF 5 SECTION TITLE PAGE PARAGRAPH SEC TONA SAFET eus m 5 SECTION 2 DESCRIPTION ee 11 SECTION S INSTALLATO N keksoz kafe linia 17 Sg 2 SECTIONS MAINTENANCE 29 SELTEN TROUBLESHOOTING Zee D SEC TION z REPLACEMENT PART adn ea ii TABLE OF CONTENTS SECTION 1 A WARNING These Safety Precautions are for your protection They summarize precaution ary information from the references listed in Additional Safety Information section Before performing any installation or operating procedures be sure to read and follow the safety precautions listed below as well as all other manuals material safety data sheets labels etc Failure to observe Safety Precautions can result in injury or death TZ PROTECT YOURSELF AND OTHERS Some welding cutting and gouging pro cesses are noisy and require ear pro tection The
57. ween temperature 3 Check wiring between switch and PCB1 temperature switches and PCB1 P1 15 and P1 16 Over Under Voltage fault indicator 1 Input voltage is 1596 above or 1 Provided input voltage must be is ON below the selected console equal to the selected console operating voltage operating voltage Change if necessary 2 Bad PCB1 2 Replace POBI 3 Bad PCB1 in MODI 3 Replace PCB1 in MOD1 Meters M1 or M2 no display 1 Bad Meter 1 Replace Meter meters M Meters M1 amp M2 no display 1 Bad 1 Replace one meter to verify above step did not happen twice If still not working replace PCB1 Press torch switch or send start 1 Gas Test switch is in 1 Place Gas Test switch in signal START SHIELD or CUT OPERATE position positions 2 Set plasma gas pressure per 2 Plasma gas pressure is to LOW torch or application requirements No pilot arc or main arc transfer above 40 psi 3 Improper current command 3 IF in manual mode panel switch signal must be in PANEL and P5 must in J5 connector If in mechanized mode panel switch must be in REMOTE and a current signal above O volts must be present P5 must be in J6 connector 4 LEDX on MOD is not ON 4 Test tbd when torch switch is depressed or start signal sent 5 LEDX is ON but main contactor 5 Test does not close LEDX is ON Main contactor is 6 Test tbd 36 SECTION 6 TROUBLESHOOTING Problem Possible Cause Co
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