ESAB 0558011310, Instruction Manual

Page 1: ...EPP 202 Plasma Power Source 0558012601 10 2015 Instruction Manual For equipment starting with Serial Number PG xxxxxxxx...

Page 2: ...EPP 202 Plasma Power Source 2...

Page 3: ...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 informa...

Page 4: ...EPP 202 Plasma Power Source 4...

Page 5: ...ment 27 Input Power Connection 28 Input Conductors 29 Coolant Connection Procedure 34 Delivery Pressure Adjustment 35 Output Connections 36 Interface Cable Connectors 38 OPERATION Operation 43 EPP 202...

Page 6: ...02 Plasma Power Source 6 TROUBLESHOOTING Troubleshooting 59 Troubleshooting Guide 59 Help Codes 60 Interface Adaptor Box 62 Fault Isolation 64 REPLACEMENT PARTS Replacement Parts 67 General 67 Orderin...

Page 7: ...SAFETY...

Page 8: ...SAFETY 8...

Page 9: ...ith a suitable non flammable partition or curtains 6 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 saf...

Page 10: ...therhealtheffectswhich are unknown 3 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...

Page 11: ...alifiedpersonnelperformtheinstal lation troubleshooting and maintenance work Do not perform any electrical work unless you are qualified to perform such work 2 Before performing any maintenance work i...

Page 12: ...r equipment damage 15 CAUTION If equipment is placed on a surface that slopes more than 15 toppling over may occur Personal injury and or significant damage to equipment is possible CAUTION To avoid p...

Page 13: ...on 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 conve...

Page 14: ...poselectromagn ticos EMF puede causar otros efectos de salud a n desconocidos 3 Los soldadores deber n usar los siguientes proced imientos para minimizar exponerse al EMF A Mantenga el electrodo y el...

Page 15: ...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...

Page 16: ...uede almacenar pero no se debe usar en el exterior durante periodos de precipitaciones a menos que est protegido Clase de envolvente Este producto s lo se debe usar para corte por plasma Cualquier otr...

Page 17: ...n provenant des r f rences dans lasectiondesInformationsdes curit suppl men taires Avantdeproc der l installationoud utiliser l unit assurez vous de lire et de suivre les pr cau tions de s curit ci de...

Page 18: ...ste 4 Consultez ANSI ASC Standard Z49 1 la page suivante pour des recommandations sp cifiques concernant la ventilation 1 Assurez vous que le ch ssis de la source d alimentation est branch au syst me...

Page 19: ...esurpressionpeutcauser desblessuresgravesoumortelles Parcons quent 1 Utilisez toujours le gaz pr vu pour une op ration et le d tendeur appropri con u pour utilisation sur les cyl indres de gaz comprim...

Page 20: ...entrepos s l ext rieur mais ne sont pas con us pour tre utilis s l ext rieur pendant une pr cipitation moins d tre l abri Classe de protection de l enveloppe Ce produit a t con u pour la d coupe au pl...

Page 21: ...DESCRIPTION...

Page 22: ...description 22...

Page 23: ...t Part Number EPP 202 200 230 460V 60Hz 0558011310 EPP 202 380 400V CCC 50Hz 0558011311 EPP 202 400V CE 50Hz 0558011312 EPP 202 575V 60Hz 0558011313 Output 100 duty cycle Voltage 160 VDC Current range...

Page 24: ...24 Dimensions 40 75 1035 mm 47 25 1200 mm 23 75 603 25 mm Optional Accessories Interface Adaptor allows the EPP 202 362 to be used in place of the EPP 201 360 For installation see help code section p...

Page 25: ...INSTALLATION...

Page 26: ...installation 26...

Page 27: ...nimum of 1 meter 3 ft clearance on front and back for cooling air flow Plan for top panel and side panels having to be removed for maintenance cleaning and inspection Locate the plasma unit relatively...

Page 28: ...verloaded circuit a dedi cated power line may be required NOTICE Input current V arc x I arc x 0 73 V line Recommended input conductor and line fuse sizes Sizes per National Electrical Code for a 90 C...

Page 29: ...ground Be sure ground lead is NOT connected to any pri mary terminal WARNING 1 Remove small rear panel of the plasma unit 2 Thread cables through the access opening in the rear panel 3 Secure cables w...

Page 30: ...age See illustrations below for input voltage configurations To gain access remove the top panel or right side panel Input Terminal Board 230 460 Vac Models 460 Vac Configuration Input Voltage Configu...

Page 31: ...to 200 400 main transformer tap on all 3 coils Be sure to replace insulating vinyl covering over connections 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5...

Page 32: ...ted on the rating plate If using other input voltages it is possible to configure these units for either 380 VAC or 400 VAC input There are 3 steps to follow when making this conversion 1 Reconfigure...

Page 33: ...AC 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 3 Reconfigure secondary taps on all three main transformer coils A removable service panel is located above the transform er connections to imp...

Page 34: ...olant hoses through the openings at the bottom of the power source immediately behind the front panel 3 Connect hoses to designated terminals mounted inside the power source 4 Close front access panel...

Page 35: ...lons per minute 5 7 l min This is an appropriate setting for the PT 36 on an m3 system Ordinarily this should not require further adjustment This relief valve sends bypassed coolant through the IGBT c...

Page 36: ...H A VOLTMETER Output Connections WARNING 3 7 1 Output Cables Choose plasma cutting output cables on the basis of one 4 0 AWG 600 volt insulated copper cable for each 400 amps of output current Note Do...

Page 37: ...e immediately behind the front panel 3 Connect cables to designated terminals mounted inside the power source using UL listed pressure wire connectors 4 Close front access panel Front Access Panel Clo...

Page 38: ...Starter RAS unit The cable from this connector carries signals such as Mark Mode and Hi Frequency ON J1 RAS CAN Analog Interface Analog Interface Connector This connector is used when the plasma unit...

Page 39: ...installation 39 J1 RAS Interface Cable CAN Cables...

Page 40: ...installation 40...

Page 41: ...OPERATION...

Page 42: ...OPERATION 42...

Page 43: ...ors 3 Rectifier 1 x 6000uf 450V Capacitors IGBT Driver Board 2 x 400 Amp IGBT s Inductor Output Main Control Board CNC Interface Isolation DangerousVoltagesandCurrent ElectricShockCanKill Beforeoperat...

Page 44: ...the radiators filter flow sensor and IGBTs cold plate respectively The pump has an internal adjustable bypass valve set to 225 psi 15 5 bar There is also an ex ternal adjustable regulator set to 175...

Page 45: ...lt this indicator illuminates This may stay ON continuously or flash with 50 ON OFF intervals depending on the type of fault If the fault is a thermal failure the indicator will stay ON continuously F...

Page 46: ...and to operate the plasma unit either in cutting mode or marking mode A shielded CAN cable as listed in section 3 8 2 is used to connect CAN connector and customer CNC pro cess controller There is 120...

Page 47: ...OPERATION 47 EPP 202 J1 RAS Interface Diagram CAN PS CAN COMMUNICATION ADAPTOR JUNCTION BOX CAN ANALOG INTERFACE...

Page 48: ...a soft start sequence begins The main control board PCB1 is sues the command to close the bus pre charger relay K2 This signal is sent to the Relay Block Module RB1 through ribbon cable connector J6 O...

Page 49: ...ays ON and the K1 contactor remains closed for 5 min utes If another start signal is sent prior to the 5 minutes time out as the bus filter capacitor voltage will be at 360 VDC power supply will not g...

Page 50: ...OPERATION 50...

Page 51: ...MAINTENANCE...

Page 52: ...Maintenance 52...

Page 53: ...e The frequency of cleaning depends on environment and use 1 Turn power off at wall disconnect 2 Remove side panels 3 Use low pressure compressed dry air remove dust from all air passages and componen...

Page 54: ...de open collector Output rise time typical 1 0 second maximum 10 second Output falling time typical 0 3 second maximum 1 5 second Wire connection Termianl 1 Red Vdd Terminal 2 Brown Vout Terminal 3 Bl...

Page 55: ...es are provided to assist with installation for a leak free seal without damage to the unit 1 Apply pipe thread sealant to male pipe threads 2 Thread RotorFlow unit onto male pipe thread until hand ti...

Page 56: ...EAD DO NOT SCALE DRAWING NAME 005 DATE A REV MATERIAL DIMENSIONS ARE IN INCHES TOLERANCES FRACTIONAL 03 ANGULAR MACH 1 BEND 5 TWO PLACE DECIMAL 015 THREE PLACE DECIMAL 10 20 11 MADISON COMPANY M8790 P...

Page 57: ...TROUBLESHOOTING...

Page 58: ...58 TROUBLESHOOTING 58...

Page 59: ...electrical schematics and checking the various components A volt ohmmeter will be necessary for some of these checks When the input power is applied to EPP 202 power source pump motor should turn ON...

Page 60: ...e power supply control wiring for a short to the input 06 Failed to fire ignition did not take place within 4 seconds after HF is turned ON 1 Check the distance from the work piece matches the recomme...

Page 61: ...power supply 2 Replace the control board 27 The servo and supervisor on the control board of the power supply has firmware version mismatch Replace the control board 28 Jumper in the RAS box is missi...

Page 62: ...help code would be 24 See help code lists for explana tion LED indicators Interface Adaptor Box top view Installation Remove existing connections from the EPP 201 360 and connect to the Interface Ada...

Page 63: ...e cover from the WAS4 PRO isolation module to expose the ZERO and SPAN pots DO NOT adjust the ZERO span pot 3 Pick a cutting condition that is about 80 of the maximum power supply output current 4 Whi...

Page 64: ...Controller removes the start signal when the main arc transfers to the work Make sure CNC or Process Controller is sending start signal correctly Remote current values are not pres ent Check if correc...

Page 65: ...REPLACEMENT PARTS...

Page 66: ...Replacement Parts 66...

Page 67: ...t 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 th...

Page 68: ...Replacement Parts 68...

Page 69: ...revision history 1 Originally released 01 2015 2 Revision 10 2015 added RotorFlow Sensor...

Page 70: ...x 843 664 5557 Hours 7 30 AM to 3 30 PM EST Repair Estimates Repair Status F WELDING EQUIPMENT TRAINING Telephone 843 664 4428 Fax 843 679 5864 Hours 7 30 AM to 4 00 PM EST Training School Information...