ESAB EPP-200 Instruction Manual [en, es, fr]

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EPP-200

Precision Plasmarc Cutting Console

Instruction ManualInstruction Manual

Instruction Manual

Instruction ManualInstruction Manual

0558004676 10 / 2007

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BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

CAUTION

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 before installing or operating this equipment.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions 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 immediately. 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 service facility designated by the manufacturer.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

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TABLE OF CONTENTS

SECTIONSECTION

SECTION

SECTIONSECTION

PARAGRAPHPARAGRAPH

PARAGRAPH

PARAGRAPHPARAGRAPH

SECTION 1SECTION 1

SECTION 1

SECTION 1SECTION 1

SECTION 2SECTION 2

SECTION 2

SECTION 2SECTION 2

SECTION 3SECTION 3

SECTION 3

SECTION 3SECTION 3

SECTION 4SECTION 4

SECTION 4

SECTION 4SECTION 4

SECTION 5SECTION 5

SECTION 5

SECTION 5SECTION 5

SECTION 6SECTION 6

SECTION 6

SECTION 6SECTION 6

SECTION 7SECTION 7

SECTION 7

SECTION 7SECTION 7

TITLETITLE

TITLE

TITLETITLE

SAFETYSAFETY

SAFETY

SAFETYSAFETY

DESCRIPTIONDESCRIPTION

DESCRIPTION

DESCRIPTIONDESCRIPTION

INSTALLATIONINSTALLATION

INSTALLATION

INSTALLATIONINSTALLATION

OPERATIONOPERATION

OPERATION

OPERATIONOPERATION

MAINTENANCEMAINTENANCE

MAINTENANCE

MAINTENANCEMAINTENANCE

TROUBLESHOOTINGTROUBLESHOOTING

TROUBLESHOOTING

TROUBLESHOOTINGTROUBLESHOOTING

REPLACEMENT PARTSREPLACEMENT PARTS

REPLACEMENT PARTS

REPLACEMENT PARTSREPLACEMENT PARTS

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TABLE OF CONTENTSTABLE OF CONTENTS

TABLE OF CONTENTS

TABLE OF CONTENTSTABLE OF CONTENTS

Page 5

SECTION 1 SAFETY PRECAUTIONS

WARNING: These Safety Precautions are for

your protection. They summarize precautionary 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.

PROTECT YOURSELF AND OTHERS Some welding, cutting, and gouging processes are noisy and require ear protection. The 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 equipment 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.

2. 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 not to watch the arc and not to expose themselves to the rays of the electric-arc or hot metal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeve

shirt, cuffless trousers, high-topped shoes, and a welding 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.

4. 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

5. Protect other personnel from arc rays and hot sparks with

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 safety glasses.

FIRES AND EXPLOSIONS -- Heat from flames and arcs can start fires. Hot slag or sparks can also cause fires and explosions. Therefore:

1. Remove all combustible materials well away from the

work area or cover the materials with a protective nonflammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc.

2. 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.“

3. 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 produce flammable or toxic vapors. Do not do hot work on closed containers. They may explode.

4. 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.

5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and create a fire hazard.

6. 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 necessary.

7. For additional information, refer to NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Pro-

cesses", available from the National Fire Protection Association, 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 movement is confined, or if there is danger of falling.

1. 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 damaged 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. Put on dry, hole-free gloves before turning on the power.

9. Turn off the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specific grounding recommendations. Do not mistake the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS — May be dangerous. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding and cutting current creates EMF around welding cables and welding machines. Therefore:

1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.

2. Exposure to EMF may have other health effects which 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 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.

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SECTION 1 SAFETY PRECAUTIONS

FUMES AND GASES -- Fumes and gases, can cause discomfort or harm, particularly in confined spaces. Do not breathe fumes and gases. Shielding 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 positive mechanical ventilation is provided. Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and 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 improve 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 &

Safety Code

CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release 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 regulator to a compressed gas cylinder.

2. Always secure cylinders in an upright position by chain or strap to suitable hand trucks, 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 is not connected. 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.

§25249.5 et seq.)

EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death. Therefore:

1. Always have qualified personnel perform the installation, 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 for electric arc welding and cutting equipment, ask your supplier for a copy of "Precautions and Safe Practices 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, Miami, 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 C5.2 - "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, serious personal injury or loss of life.

Means potential hazards which could result in personal injury or loss of life.

Means hazards which could result in minor personal injury.

Page 7

SECTION 1 PRECAUCION DE SEGURIDAD

ADVERTENCIA: Estas Precauciones de Seguridad

son para su protección. Ellas hacen resumen de

en la sección "Información Adicional Sobre La Seguridad". Antes de hacer cualquier instalación o procedimiento de operación , asegúrese de leer y seguir las precauciones de seguridad listadas a continuación así como también todo manual, hoja de datos de seguridad del material, calcomanias, etc. El no observar las Precauciones de Seguridad puede resultar en daño a la persona

ultravioleta (UV) y otras radiaciones que pueden dañar la piel y 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:

información proveniente de las referencias listadas

o muerte

PROTEJASE USTED Y A LOS DEMAS-- Algunos procesos de soldadura, corte y ranurado son ruidosos y requiren protección para los oídos. El arco, como el sol , emite rayos

1. Utilice gafas de seguridad con protección a los lados siempre

que esté en el área de trabajo, aún cuando esté usando careta de soldar, protector para su cara u otro tipo de protección.

2. Use una careta que tenga el filtro correcto y lente para proteger sus ojos, cara, cuello, y oídos de las chispas y rayos del arco cuando se esté operando y observando las operaciones. Alerte a todas las personas cercanas de no mirar el arco y no exponerse a los rayos del arco eléctrico o el metal fundido.

3. Use guantes de cuero a prueba de fuego, camisa pesada de mangas largas, pantalón de ruedo liso, zapato alto al tobillo, y careta de soldar con capucha para 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 partículas de metal caliente puede alojarse en las mangas enrolladas de la camisa , el ruedo del pantalón o los bolsillos. Mangas y cuellos deberán mantenerse abotonados, bolsillos al frente de la camisa deberán ser cerrados o eliminados.

5. Proteja a otras personas de los rayos del arco y chispas calientes con una cortina adecuada no-flamable como división.

6. Use careta protectora además de sus gafas de seguridad cuando esté removiendo escoria o puliendo. La escoria puede estar caliente y desprenderse con velocidad. Personas cercanas deberán usar gafas de seguridad y careta protectora.

usted esta entrenado para su uso.

5. No use el equipo fuera de su rango de operación. Por ejemplo,

el calor causado por cable sobrecarga en los cables de soldar pueden ocasionar un fuego.

6. Después de termirar la operación del equipo, inspeccione el área de trabajo para cerciorarse de que las chispas o metal caliente ocasionen un fuego más tarde. Tenga personal asignado para vigilar si es necesario.

7. Para información adicional , haga referencia a la publicación NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", disponible a través de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

CHOQUE ELECTRICO -- El contacto con las partes eléctricas energizadas y tierra puede causar daño severo o muerte. NO use soldadura de corriente alterna (AC) en áreas húmedas, de movimiento confinado en lugares estrechos o si hay posibilidad de

caer al suelo.

Asegúrese de que el chasis de la fuente de poder esté conectado a tierra através del sistema de electricidad primario.

2. Conecte la pieza de trabajo a un buen sistema de tierra física.

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 eléctrico fatal.

4. Use el equipo solamente si está en buenas condiciones. Reemplaze cables rotos, dañados o con conductores expuestos.

5. Mantenga todo seco, incluyendo su ropa, el área de trabajo, los cables, antorchas, pinza del electrodo, y la fuente de poder.

6. Asegúrese que todas las partes de su cuerpo están insuladas de ambos, la pieza de trabajo y tierra.

7. No se pare directamente sobre metal o tierra mientras trabaja en lugares estrechos o áreas húmedas; 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 publicación ANSI/ASC Standard Z49.1 (listado en la próxima página) para recomendaciones específicas de como conectar el equipo a tierra. No confunda el cable de

soldar a la pieza de trabajo con el cable a tierra.

FUEGO Y EXPLOSIONES -- El calor de las flamas y el arco pueden ocacionar fuegos. Escoria caliente y las chispas pueden causar fuegos y explosiones. Por lo tanto:

Remueva todo material combustible lejos del área de trabajo o cubra los materiales con una cobija a prueba de fuego. Materiales combustibles incluyen madera, ropa, líquidos y gases flamables, solventes, pinturas, papel, etc.

2. Chispas y partículas de metal pueden introducirse en las grietas y agujeros de pisos y paredes causando fuegos escondidos en otros niveles o espacios. Asegúrese de que toda grieta y agujero esté cubierto para proteger lugares adyacentes contra fuegos.

3. No corte, suelde o haga cualquier otro trabajo relacionado hasta

que la pieza de trabajo esté totalmente limpia y libre de substancias que puedan producir gases inflamables o vapores tóxicos. 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 instantáneo, como por ejemplo una manguera con agua, cubeta con agua, cubeta con arena, o extintor portátil. Asegúrese que

CAMPOS ELECTRICOS Y MAGNETICOS - Son peligrosos. La corriente eléctrica fluye através de cualquier conductor causando a nivel local Campos Eléctricos y Magnéticos (EMF). Las corrientes en el área de corte y soldadura, crean EMF alrrededor de los cables de soldar

y las maquinas. Por lo tanto:

1. S

oldadores u Operadores que use marca-pasos para el corazón deberán consultar a su médico antes de soldar. El Campo Electromagnético (EMF) puede interferir con algunos marcapasos.

2. Exponerse a campos electromagnéticos (EMF) puede causar otros efectos de salud aún desconocidos.

3. Los soldadores deberán usar los siguientes procedimientos para minimizar exponerse al EMF:

A. Mantenga el electrodo y el cable a la pieza de trabajo juntos,

hasta llegar a la pieza que usted quiere soldar. Asegúrelos 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 sólo lado de su cuerpo.

D. Conecte el cable de trabajo a la pieza de trabajo lo más cercano

posible al área de la soldadura. E . Mantenga la fuente de poder y los cables de soldar lo más lejos

posible de su cuerpo.

Page 8

SECTION 1 PRECAUCION DE SEGURIDAD

HUMO Y GASES -- El humo y los gases, pueden causar malestar o daño, particularmente en espacios sin ventilación. No inhale el humo o gases. El gas de protección puede causar falta de oxígeno. Por lo tanto:

1. Siempre provea ventilación adecuada en el área de trabajo por medio natural o mecánico. No solde, corte, o ranure materiales con hierro galvanizado, acero inoxidable, cobre, zinc, plomo, berílio, o cadmio a menos que provea ventilación mecánica positiva . No respire los gases producidos por estos materiales.

2. No opere cerca de lugares donde se aplique substancias químicas en aerosol. El calor de los rayos del arco pueden reaccionar con los vapores de hidrocarburo clorinado para formar un fosfógeno, o gas tóxico, y otros irritant es.

3. Si momentáneamente desarrolla inrritación de ojos, nariz o garganta mientras est á operando, es indicación de que la ventilación no es apropiada. Pare de trabajar y tome las medidas necesarias para mejorar la ventilación en el área de trabajo. No continúe operando si el malestar físico persiste.

4. Haga referencia a la publicación ANSI/ASC Standard Z49.1 (Vea la lista a continuación) para recomendaciones específicas en la ventilación.

5. ADVERTENCIA-- Este producto cuando se utiliza para

soldaduras o cortes, produce humos o gases, los cuales contienen químicos conocidos por el Estado de California de causar defectos en el nacimiento, o en algunos casos, Cancer. (California Health & 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, válvula, o válvula de escape puede causar daño o muerte. Por lo tanto:

1. Utilize el gas apropiado para el proceso y utilize un regulador diseñado para operar y reducir la presión del cilindro de gas . No utilice adaptadores. Mantenga las mangueras y las conexiones en buenas condiciones. Observe las instrucciones de operación del manufacturero para montar el regulador en el cilindro de gas comprimido.

2. Asegure siempre los cilindros en posición vertical y amárrelos con una correa o cadena adecuada para asegurar el cilindro al carro, transportes, tablilleros, paredes, postes, o armazón. 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 elélectrico.

3. Cuando el cilindro no está en uso, mantenga la válvula del cilindro cerrada. Ponga el capote de protección sobre la válvula si el regulador no está conectado. Asegure y mueva los cilindros utilizando un carro o transporte adecuado. Evite el manejo brusco de los

MANTENIMIENTO DEL EQUIPO -- Equipo defectuoso o mal mantenido puede causar daño o muerte. Por lo tanto:

1. Siempre tenga personal cualificado para efectuar l a instalación, diagnóstico, y mantenimiento del equipo. No ejecute ningún trabajo eléctrico a menos que usted esté 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 fuente de poder en buen estado operacional. No opere ningún equipo en malas condiciones.

4. No abuse del equipo y sus accesorios. Mantenga el equipo lejos de cosas que generen calor como hornos, también lugares húmedos como charcos de agua , aceite o grasa, atmósferas corrosivas y las inclemencias del tiempo.

5. Mantenga todos los artículos de seguridad y coverturas del equipo en su posición y en buenas condiciones.

6. Use el equipo sólo para el propósito que fue diseñado. No modifique el equipo en ninguna manera.

INFORMACION ADICIONAL DE SEGURIDAD -Para más información sobre las prácticas de seguridad de los equipos de arco eléctrico 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 através de la American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, son recomendadas para usted:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc Welding"

3. AWS C5.2 - "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."

SIGNIFICADO DE LOS SIMBOLOS -- Según usted avanza en la lectura de este folleto: Los Símbolos Significan ¡Atención! ¡Esté Alerta! Se trata de su seguridad.

Significa riesgo inmediato que, de no ser evadido, puede resultar inmediatamente en serio daño personal o la muerte.

Significa el riesgo de un peligro potencial que puede resultar en serio daño personal o la muerte.

Significa el posible riesgo que puede resultar en menores daños a la persona.

Page 9

SECTION 1 PRÉCAUTIONS DE SÉCURITÉ

AVERTISSEMENT: Ces règles de sécurité ont pour objet d’ assurer votre protection. Veillez à lire et à observer les précautions énoncées ci-dessous avant de monter l’ équipement ou de commercer à l’utiliser. Tout défaut d’observation de ces précautions risque d’entraîner des blessures graves ou mortelles.

1. PROTECTION INDIVIDUELLE-- Les brûlures de la peau et des yeux dues au rayonnement de l’arc électrique ou du métal incandescent, lors du soudage au plasma ou à l’électrode ou lors du gougeage à l’arc, peuvent s’avérer plus graves que celles résultant d’une exposition prolongée au soleil. Aussi convientil d’observer les précautions suivantes:

a. Portez un écran facial adéquat muni des plaques

protectrices et des verres filtrants appropriés afin de vous protéger les yeux, le visage, le cou et les oreilles des étincelles et du rayonnement de l’arc électrique lorsque vous effectuez des soudures ou des coupes ou lorsque vous en observez l’exécution.

AVERTISSEZ les personnes se trouvant à proximité

de façon à ce qu’elles ne regardent pas l’arc et à ce qu’elles ne s’exposent pas à son rayonnement, ni à celui du métal incandescent.

b. Portez des gants ignifugés à crispins, une tunique

épaisse à manches longues, des pantalons sans rebord, des chaussures à embout d’acier et un casque de soudage ou une calotte de protection, afin d’éviter d’exposer la peau au rayonnement de l’arc électrique ou du métal incandescent. ll est également souhaitable d’utiliser un tablier ininflammable de façon à se protéger des étincelles et du rayonnement thermique.

c. Les étincelles ou les projections de métal incandes-

cent risquent de se loger dans des manches retroussées, des bords relevés de pantalons ou dans des poches. Aussi convient-il de garder boutonnés le col et les manches et de porter des vêtements sans poches à l’avant.

d. Protégez des étincelles et du rayonnement de l’arc

électrique les autres personnes travaillant à proximité à l’aide d’un écran ininflammable adéquat.

e. Ne jamais omettre de porter des lunettes de sécurité

lorsque vous vous trouvez dans un secteur où l’on effectue des opérations de soudage ou de coupage à l’arc. Utilisez des lunettes de sécurité à écrans ou verres latéraux pour piquer ou meûler le laitier. Les piquetures incandescentes de laitier peuvent être projetées à des distances considérables. Les personnes se trouvant à proximité doivent également porter des lunettes de protection.

f. Le gougeage à l’arc et le soudage à l’arc au plasma

produisent un niveau de bruit extrêmement élevé (de 100 à 114 dB) et exigent par conséquent l’emploi de dispositifs appropriés de protection auditive.

2 PRÉVENTION DES INCENDES-- Les projections de

laitier incandescent ou d’étincelles peuvent provoquer de graves incendies au contact de matériaux combustibles solides, liquides ou gazeux. Aussi faut-il

observer les précautions suivantes:

a. Éloigner suffisamment tous les matériaux combustibles

du secteur où l’on exécute des soudures ou des coupes à l’arc, à moins de les recouvrir complètement d’une bâche non-inflammable. Ce type de matériaux comprend notamment le bois, les vêtements, la sciure, l’essence, le kérosène, les peintures, les solvants, le gaz naturel, l’acétylène, le propane et autres substances combustibles semblables.

b. Les étincelles ou les projections de métal incandescent

peuvent tomber dans des fissures du plancher ou dans des ouvertures des murs et y déclencher une ignition lente cachée. Veiller à protéger ces ouvertures des étincelles et des projections de métal.

c. N’exécutez pas de soudures, de coupes, d’opérations

de gougeage ou autres travaux à chaud à la surface de barils, bidons, réservoirs ou autres contenants usagés, avant de les avoir nettoyés de toute trace de substance susceptible de produire des vapeurs inflammables ou toxiques.

d. En vue d’assurer la prévention des incendies, il convient

de disposer d’un matériel d’extinction prêt à servir immédiatement, tel qu’un tuyau d’arrosage, un seau à eau, un seau de sable ou un extincteur portatif.

e. Une fois le travail à l’arc terminé, inspectez le secteur de

façon à vous assurer qu’aucune étincelle ou projection de métal incandescent ne risque de provoquer ultérieurement un feu.

3. CHOC ÉLECTRIQUE-- Le gougeage à l’arc et à l’arc au plasma exige l’emploi de tensions à vide relativement importantes; or, celles-ci risquent de causer des dommages corporels graves et même mortels en cas d’utilisation inadéquate. La gravité du choc électrique reçu dépend du chemin suivi par le courant à travers le corps humain et de son intensité.

a. Ne laissez jamais de surfaces métalliques sous tension

venir au contact direct de la peau ou de vêtements humides. Veillez à porter des gants bien secs.

b. Si vous devez effectuer un travail sur une surface

métallique ou dans un secteur humide, veillez à assu-rer votre isolation corporelle en portant des gants secs et des chaussures à semelles de caoutchouc et en vous tenant sur une planche ou une plate-forme sèche.

c. Mettez toujours à la terre le poste de soudage/coupage

en le reliant par un câble à une bonne prise de terre.

d. N’utilisez jamais de câbles usés ou endommagés. Ne

surchargez jamais le câble. Utilisez toujours un équipement correctement entretenu.

e. Mettez l’équipement hors tension lorsqu’il n’est pas en

service. une mise à la masse accidentelle peut en effet provoquer une surchauffe de l’équipement et un danger d’incendie. Ne pas enrouler ou passer le câble autour d’une partie quelconque du corps.

f. Vérifiez si le câble de masse est bien relié à la pièce en

un point aussi proche que possible de la zone de travail. Le branchement des câbles de masse à l’ossature du bâtiment ou en un point éloigné de la zone de travail augmente en effet le risque de passage d’un courant de sortie par des chaînes de

Page 10

SECTION 1 PRÉCAUTIONS DE SÉCURITÉ

levage, des câbles de grue ou divers chemins électriques.

g. Empêchez l’apparition de toute humidité, notamment

sur vos vêtements, à la surface de l’emplacement de travail, des câbles, du porte-électrode et du poste de soudage/coupage. Réparez immédiatement toute fuite d’eau.

4. VENTILATION-- La respiration prolongée des fumées résultant des opérations de soudage/coupage, à l’intérieur, d’un local clos, peut provoquer des malaises et des dommages corporels. Aussi convient-il d’observer les précautions suivantes:

a. Assurez en permanence une aération adéquate de

l’emplacement de travail en maintenant une ventilation naturelle ou à l’aide de moyens mécaniques. N’effectuez jamais de travaux de soudage ou de coupage sur des matériaux de zinc, de plomb, de beryllium ou de cadmium en l’absence de moyens mécaniques de ventilation capables d’empêcher l’inhalation des fumées dégagées par ces matériaux.

b. N’effectuez jamais de travaux de soudage ou de

coupage à proximité de vapeurs d’hydrocarbure chloré résultant d’opérations voisines de dégraissage ou de pulvérisation. La chaleur dégagée ou le rayonnement de l’arc peut déclencher la formation de phosgène -- gaz particulièrement toxique -- et d’autres gaz irritants, à partir des vapeurs de solvant.

c. Une irritation momentanée des yeux, du nez ou de la

gorge constatée au cours de l’utilisation de l’équipement dénote un défaut de ventilation. Arrêtezvous de travailler afin de prendre les mesures nécessaires à l’amélioration de la ventilation. Ne poursuivez pas l’opération entreprise si le malaise persiste.

d. Certaines commandes comportent des canalisations

où circule de l’hydrogène. L’armoire de commande est munie d’un ventilateur destiné à empêcher la formation de poches d’hydrogène, lesquelles présentent un danger d’explosion; ce ventilateur ne fonctionne que si l’interrupteur correspondant du panneau avant se trouve placé en position ON (Marche). Veillez à manœuvrer cette commande en vérifiant si le couvercle est bien en place, de façon à assurer l’efficacité de la ventilation ainsi réalisée. Ne jamais débrancher le ventilateur.

e. Les fumées produites par l’opération de soudage ou

de coupage peuvent s’avérer toxiques. Aussi est-il nécessaire de disposer en permanence d’un dispositif adéquat de ventilation de type aspirant, afin d’éliminer du voisinage de l’opérateur tout dégagement de fumée visible.

f. Consultez les recommandations particulières en

matière de ventilation indiquées à l’alinéa 6 de la norme Z49.1 de l’AWS.

5. ENTRETIEN DE L’ÉQUIPEMENT-- Un équipement entretenu de façon défectueuse ou inadéquate risque non seulement de réaliser un travail de mauvaise

qualité mais, chose plus grave encore, d’entraîner des dommages corporels graves, voire mortels en déclenchant des incendies ou des chocs électriques. Observez par conséquent les précautions suivantes:

a. Efforcez-vous de toujours confier à un personnel qua-

lifié l’installation, le dépannage et l’entretien du poste de soudage et de coupage. N’effectuez aucune réparation électrique sur l’équipement à moins d’être qua-lifié à cet effet.

b. Ne procédez jamais à une tâche d’entretien quelconque

à l’intérieur du poste de soudage/coupage, avant d’avoir débranché l’alimentation électrique.

c . Maintenez en bon état de fonctionnement les câbles,

le câble de masse, les branchements, le cordon d’alimentation et le poste de soudage/coupage. N’utilisez jamais le poste ou l’équipement s’il présente une défectuosité quelconque.

d. Prenez soin du poste de soudage et de coupage et

des équipements accessoires. Gardez-les à l’écart des sources de charleur, notamment des fours, de l’humidité, des flaques d’eau maintenez-les à l’abri des traces d’huile ou de graisse, des atmosphères corrosives et des intempéries.

e. Laissez en place tous les dispositifs de sécurité et

tous les panneaux de l’armoire de commande en veillant à les garder en bon état.

f. Utilisez le poste de soudage/coupage conformément

à son usage prévu et n’effectuez aucune modification.

6. INFORMATIONS COMPLÉMENTAIRES RELATIVES À LA SÉCURITÉ--

Pour obtenir des informations complémentaires sur

les règles de sécurité à observer pour le montage et l’utilisation d’équipements de soudage et de coupage électriques et sur les méthodes de travail recommandées, demandez un exemplaire du livret N° 52529 “Precautions and Safe Practices for Arc Welding, Cutting and Gouging” publié par ESAB. Nous conseillons également de consulter les publications sui-vantes, tenues à votre disposition par l’American Welding Society, 550 N.W. LeJuene Road, Miami, FL 32126:

a. “Safety in Welding and Cutting” AWS Z49.1 b. “Recommended Safe Practices for Gas-Shielded Arc

Welding “AWS A6. 1.

c. “Safe Practices for Welding and Cutting Containers

That Have Held Combustibles” AWS-A6.0.

d. “Recommended Safe Practices for Plasma Arc

Cutting” AWS-A6. 3.

e. “Recommended Safe Practices for Plasma Arc

Welding” AWS-C5. 1.

f. “Recommended Safe Practices for Air Carbon Arc

Gouging and Cutting” AWS-C5. 3.

g. “Code For Safety in Welding and Cutting” CSA-St andard

W117. 2.

Page 11

SECTION 2SECTION 2

SECTION 2

SECTION 2SECTION 2

2.1 Introduction

DESCRIPTIONDESCRIPTION

DESCRIPTION

DESCRIPTIONDESCRIPTION

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.

• 50 to 200 Amperes cutting current range

• Forced air cooled

• Solid state DC power

• Integral water cooler

• Input voltage protection

• Local or remote front panel control

• Thermal switch protection for main transformer and power semiconductor components

• LED status troubleshooting

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

Frequency........................................................................ 50/60Hz

KVA................................................................................. 39.8 kW

Power .............................................................................. 37.8 kW

Power Factor ...................................................................... 95%

Input Fuse ...........................................................See Section 3, Installation

Page 12

SECTION 2 DESCRIPTION

Electric Shock Can Kill!

WARNINGWARNING

WARNING

WARNINGWARNING

2.3 Dimensions and Weight

Use of torches not designed for this console could result in a hazardous electric shock.

Use only torches designed for the EPP-200 Console.

22in. (550mm)

42in. (1050mm)

44 in. (1100mm)

Weight = 725 lbs. (330 kg)

Page 13

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

0558003979

0558003980 0558003981

33132 0558003982 0558003983

33133

33134

33135

33136 0558003984

Control Cable

Plumbing Box to Console

N / A

N / A N / A

0558004651

N / A

N / A 0558004652 0558004653 0558004654 0558003978 0558004655

* Use with one adaptor fitting (41V12) included with unit.

Pilot Arc Lead

Plumbing Box to Console

0558003985

0558003986 0558003987

33303 0558003988 0558003989

33304

33305

33306

33307 0558003990

Power Lead

Console to Plumbing Box

0558003991

0558003992 0558003993

22001 0558003994 0558003995

22002

22003

22004

22005 0558003996

Torch Coolant – 1gallon (3.8 L) - (4 required) = 156F05

Page 14

SECTION 2 DESCRIPTION

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)

Note: * = Requires adapter P/N 19X54 (order separately)

** = Requires adapter P/N 74S76 (order separately)

2.6 Gas Regulators

Nitrogen ....................................... 19155 ............................... 998343

Oxygen.........................................19151 ............................... 998336

Argon/Hydrogen (H-35) ................19153 ...............................998341

Air................................................ 30338 ............................... N/A

NONO

TICETICE

TICE

TICETICE

0558002978** 0558002979** 0558002980** 0558002981** 0558002982**

Station Regulator Cylinder Regulator

A separate start gas regulator is always required:

• For air plasma use air start gas.

• For oxygen or nitrogen use nitrogen start gas.

• For H-35 (argon/hydrogen) H-35 or nitrogen start gas.

NONO

TICETICE

TICE

TICETICE

A total of 3 regulators will be required (plasma, start and secondary).

When using a plumbing box:

• Gas hoses from supply cylinders go directly to the plumbing box.

• Console gas manifold is not used.

Page 15

SECTION 2 DESCRIPTION

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:

• EPP-200 Console

• Plasma Torch

• Appropriate regulators for the gases indicated

• Gas hoses from regulators to console

• Torch coolant

Torch Coolant – 1 gallon (3.8 L) P/N 0558004297

Page 16

SECTION 2 DESCRIPTION

Page 17

SECTION 3SECTION 3

SECTION 3

SECTION 3SECTION 3

3.1 General

WARNINGWARNING

WARNING

WARNINGWARNING

3.2 Unpacking

INSTALLATIONINSTALLATION

INSTALLATION

INSTALLATIONINSTALLATION

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.

CACA

UTIONUTION

UTION

UTIONUTION

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.

• Inspect for transit damage immediately upon receipt.

• Remove all components from shipping container and

check for loose parts in container.

• Inspect louvers for air obstructions.

Page 18

SECTION 3SECTION 3

SECTION 3

SECTION 3SECTION 3

CACA

3.3 Placement

UTIONUTION

UTION

UTIONUTION

Plasma

Console

INSTALLATIONINSTALLATION

INSTALLATION

INSTALLATIONINSTALLATION

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.

• 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 excessive heat. These factors will affect cooling efficiency.

Conductive Dust And Dirt Inside Power

CACA

3.4 Input Connections to Console

WARNINGWARNING

WARNING

WARNINGWARNING

UTIONUTION

UTION

UTIONUTION

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.

Page 19

SECTION 3SECTION 3

SECTION 3

SECTION 3SECTION 3

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 Volts Amperes conductor* (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

INSTALLATIONINSTALLATION

INSTALLATION

INSTALLATIONINSTALLATION

Ground Fuse size

CU/AWG

NONO

TICETICE

TICE

TICETICE

* 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 circuit, a dedicated power line may be required.

Page 20

SECTION 3SECTION 3

SECTION 3

SECTION 3SECTION 3

3.4.2 Primary Power Hookup Procedure

The following procedure explains the proper installation steps

Input Power Cable

Strain Relief

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).

INSTALLATIONINSTALLATION

INSTALLATION

INSTALLATIONINSTALLATION

Ground

Connection

Factory wired

for 575 volts

Main Contactor

7 Position Terminal Block

Auto Transformer

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.

CACA

UTIONUTION

UTION

UTIONUTION

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

Page 21

SECTION 3SECTION 3

SECTION 3

SECTION 3SECTION 3

Work ground to work piece

INSTALLATIONINSTALLATION

INSTALLATION

INSTALLATIONINSTALLATION

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.

Work ground to cutting table

WARNINGWARNING

WARNING

WARNINGWARNING

Electric Current Is Hazardous.

It is important to have a good earth ground connected to the workpiece or cutting table.

Page 22

SECTION 3SECTION 3

SECTION 3

SECTION 3SECTION 3

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.

• Coolant Return

• Coolant Supply

• Pilot Arc Cable

• Electrode Cable

• Shield Gas (directly to the Plumbing Box)

INSTALLATIONINSTALLATION

INSTALLATION

INSTALLATIONINSTALLATION

• 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 22000) 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.

Page 23

SECTION 3SECTION 3

SECTION 3

SECTION 3SECTION 3

3.6 Coolant Installation

WARNINGWARNING

WARNING

WARNINGWARNING

CACA

UTIONUTION

UTION

UTIONUTION

INSTALLATIONINSTALLATION

INSTALLATION

INSTALLATIONINSTALLATION

Electric Current Is Hazardous.

It is important to have a good earth ground connected to the workpiece or cutting table.

Commercial Antifreeze Will Cause Torch To 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).

• Do not fill above indicated maximum level.

• Reinstall cap.

Coolant Fill Cap

Page 24

SECTION 3SECTION 3

SECTION 3

SECTION 3SECTION 3

INSTALLATIONINSTALLATION

INSTALLATION

INSTALLATIONINSTALLATION

Page 25

SECTION 4SECTION 4

SECTION 4

SECTION 4SECTION 4

4.1 Introduction – Operational Safety

Electric Shock Can Kill!

ANGERANGER

ANGER

ANGERANGER

Disconnect current supply at wall disconnect before servicing console, torch or plumbing box.

• Do not operate 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 any portion of this plasma

system unless power has been disconnected at the wall disconnect.

OPERATIONOPERATION

OPERATION

OPERATIONOPERATION

WARNINGWARNING

WARNING

WARNINGWARNING

WARNING

WARNINGWARNING

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 Eyes And Ears.

• Wear hearing protection.

• Wear eye protection specifically designed for arc

welding and cutting. Lenses should be at least a No. 6 or No. 7 lens shade.

• Wear protective clothing to avoid skin burns.

Page 26

SECTION 4SECTION 4

SECTION 4

SECTION 4SECTION 4

4.2 Operating the EPP-200 Console

4.2.1 Console Controls

OPERATIONOPERATION

OPERATION

OPERATIONOPERATION

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 6 Fault Lights 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.

Page 27

SECTION 4SECTION 4

SECTION 4

SECTION 4SECTION 4

OPERATIONOPERATION

OPERATION

OPERATIONOPERATION

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 in 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.

Page 28

SECTION 4SECTION 4

SECTION 4

SECTION 4SECTION 4

4.3 Sequence of Operation

OPERATIONOPERATION

OPERATION

OPERATIONOPERATION

1. Apply power by closing the line (wall) switch. Main power

light will not illuminate until console power switch is turned ON. Fault light 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. 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.

Page 29

SECTION 5 MAINTENANCE

5.1 General

Electric Shock Can Kill!

WARNING

Open wall disconnect switch before attempting any maintenance on:

• plasmaconsole

• interconnectingcables

Only trained personnel should perform maintenance or repairs

CAUTION

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:

• 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,ttings,andgroundconnectionsare

tight.

• Checkscreenlterincoolantpump(locatedinside

console) periodically and ush as required.

Page 30

SECTION 5 MAINTENANCE

Flying Debris Hazard.

WARNING

Flying Debris Can Seriously Injure Eyes

Wear protective eyewear when cleaning with compressed air.

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rstairblastawayfromequipmenttoavoid

damaging the junction box or ow control box.

• Withallinputpowerdisconnectedandwithpropereye  andfaceprotection,blowouttheinsideofthepower  source,owcontrol,andjunctionboxusinglow-pressure,

clean dry compressed air.

• Periodicallybleedallwaterfromtheairlter/regulator

trap.

Page 31

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:

• 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)

Page 32

SECTION 5 MAINTENANCE

Page 33

SECTION 6 TROUBLESHOOTING

6.1 Introduction

Electric Shock Can Kill!

WARNING

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.

WARNING

Disconnecting plasma console does not ensure capacitors are deenergized.

Ensure console capacitors are grounded after removing power and prior to performing maintenance.

6.2 Procedure

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connections

• Bulgedorleakingcapacitors

• Othersignsofdiscoloration

Refer to the troubleshooting guide for identication of many

problems, possible causes and remedies.

Reference wiring diagrams and schematics are found in the last part of this section

Page 34

SECTION 6 TROUBLESHOOTING

6.3 Front Panel Fault Lights

Fault Indicator Lights

• Coolant Flow – Will show low coolant ow. The light will briey show a fault when console is turned on and then go out.

• Plasma Gas Pressure — fault indicator – low plasma  gaspressure.Torchwillnotre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 is

above or below the tolerances of the power source console. Will stay shut down console until main power switch is recycled.

Page 35

SECTION 6 Troubleshooting

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

ProblemProblem

Problem Possi

PossiPossi

Possible Cause

ble Causeble Cause

ble Cause Corrective Action

Corrective ActionCorrective 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 OFFmodules 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 ONPlasma 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

6.4 Troubleshooting Guide

High Voltages Can Cause Serious Injury or Death!

WARNING

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.

Page 36

SECTION 6 Troubleshooting

Problem

ProblemProblem

Problem Possible Cause

Possible CausePossible Cause

Possible Cause Corrective Action

Corrective ActionCorrective 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 ONis 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

Page 37

SECTION 6 Troubleshooting

Problem

ProblemProblem

Problem Possible Cause

Possible CausePossible Cause

Possible Cause Corrective Action

Corrective ActionCorrective Action

Corrective Action

LEDX on MOD1 not ON

LEDX on MOD1 not ONLEDX on MOD1 not ON

LEDX on MOD1 not ON

LEDX on MOD2 not ON

LEDX on MOD2 not ONLEDX 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 sentsignal 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 doArc 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

SchematicsandWiringDiagramson11"x17"paperareincluded

NOTE:

insidethebackcoverofthismanual.

Page 38

SECTION 6 TROUBLESHOOTING

Page 39

SECTION 7 REPLACEMENT PARTS

7.1 General

Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on the unit nameplate.

7.2 Ordering

Toensureproperoperation,itisrecommendedthatonly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.

Note:

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.

Page 40

SECTION 7 REPLACEMENT PARTS

Page 41

SECTION 7 REPLACEMENT PARTS

Page 42

SECTION 7 REPLACEMENT PARTS

Page 43

SECTION 7 REPLACEMENT PARTS

Page 44

SECTION 7 REPLACEMENT PARTS

Page 45

SECTION 7 REPLACEMENT PARTS

Page 46

SECTION 7 REPLACEMENT PARTS

Page 47

SECTION 7 REPLACEMENT PARTS

Page 48

SECTION 7 REPLACEMENT PARTS

Page 49

SECTION 7 REPLACEMENT PARTS

Page 50

SECTION 7 REPLACEMENT PARTS

Page 51

SECTION 7 REPLACEMENT PARTS

Page 52

SECTION 7 REPLACEMENT PARTS

Page 53

SECTION 7 REPLACEMENT PARTS

Page 54

SECTION 7 REPLACEMENT PARTS

Page 55

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 - .88d qty: 6.

February,2006-UpdatedSchematicandReplacementPartsperECN#053186.

November,2006-UpdatedReplacementParts

December,2006-UpdatedReplacementParts

October,2007-Updatedconductor/fusetableinSubsection3.4.1.Updateddisclaimerpage.

Page 56

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ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

A. 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

B. 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

C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Hours: 8:00 AM to 5:00 PM EST Part Numbers Technical Applications Specications Equipment Recommendations

D. LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4487 / Fax: (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 and Registrations

G. WELDING PROCESS ASSISTANCE: Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES: Telephone : (800) 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

visit us on the web at http://www.esabna.com

The ESAB web site oers

Comprehensive Product Information

Material Safety Data Sheets

Warranty Registration

Instruction Literature Download Library

Distributor Locator

Global Company Information

Press Releases

Customer Feedback & Support

0558004676 10 / 2007