EPP-201
Plasma Power Source
Instruction Manual
0558007900 04/2009
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!
TABLE OF CONTENTS
Section / Title Page
1.0 Safety Precautions....................................................................................5
1.1 Safety - English ..................................................................................5
1.2 Safety - Spanish .................................................................................9
1.3 Safety - French .................................................................................13
2.0 Description..........................................................................................17
2.1 Introduction....................................................................................17
2.2 General Specications ..........................................................................17
2.3 Dimensions and Weight.........................................................................18
3.0 Installation ..........................................................................................19
3.1 General ........................................................................................19
3.2 Unpacking .....................................................................................19
3.3 Placement......................................................................................19
3.4 Input Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.5 Output Connections ........................................................................... 22
3.6 Parallel Installation..............................................................................24
3.7 Interface Cable Connectors .................................................................... 26
4.0 Operation .......................................................................................... 29
4.1 EPP-201 Block Diagram......................................................................... 29
4.2 Control Panel.................................................................................. 30
4.3 Modes of Operation ............................................................................32
4.4 Sequence of Operation .........................................................................35
5.0 Maintenance ........................................................................................37
5.1 General ........................................................................................37
5.2 Cleaning .......................................................................................37
6.0 Troubleshooting.................................................................................... 39
6.1 Troubleshooting............................................................................... 39
6.2 Troubleshooting Guide ........................................................................ 40
6.3 Help Code list .................................................................................40
6.4 Fault Isolation ..................................................................................41
7.0 Replacement Parts.................................................................................. 43
7.1 General ....................................................................................... 43
7.2 Ordering ...................................................................................... 43
TABLE OF CONTENTS
4
SECTION 1 SAFETY PRECAUTIONS
1.0 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
ultraviolet (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 tted with the correct lter 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 ameproof gauntlet type gloves, heavy long-
sleeve shirt, cuess 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 ameproof apron may also be desirable as protection against radiated heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cus, 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-ammable partition or
curtains.
6. Use goggles over safety glasses when chipping slag
or grinding. Chipped slag may be hot and can y far.
Bystanders should also wear goggles over safety
glasses.
1.1 Safety - English
FIRES AND EXPLOSIONS -- Heat from
ames and arcs can start res. Hot
slag or sparks can also cause res and
explosions. Therefore:
1. Remove all combustible materials well away from
the work area or cover the materials with a protective non-ammable 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 oors or wall openings and cause a hidden smoldering re or res on the oor 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 ammable or toxic vapors. Do not do hot
work on closed containers. They may explode.
4. Have re extinguishing equipment handy for instant
use, such as a garden hose, water pail, sand bucket,
or portable re 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 re 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 re. Use re watchers when
necessary.
7. For additional information, refer to NFPA Standard
51B, "Fire Prevention in Use of Cutting and Welding
Processes", 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 conned, or if there is
danger of falling.
5
SECTION 1 SAFETY PRECAUTIONS
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.
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.
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in conned spaces. Do
not breathe fumes and gases. Shielding gases can cause asphyxiation.
Therefore:
9. Turn o the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on
next page) for specic grounding recommendations. Do not mistake the work lead for a ground
cable.
ELECTRIC AND MAGNETIC FIELDS
— May be dangerous. Electric current owing 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 eects which
are unknown.
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 specic ventilation recommendations.
6
SECTION 1 SAFETY PRECAUTIONS
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
§25249.5 et seq.)
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 ttings in good
condition. Follow manufacturer's operating instructions for mounting regulator to a compressed gas
cylinder.
1. Always have qualied personnel perform the installation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualied 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.
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 xtures 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 ames.
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 Jeerson Davis Highway,
Arlington, VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
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"
7
SECTION 1 SAFETY PRECAUTIONS
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.
8
SECCION 1 SEGURIDAD
1.2 Safety - Spanish
ADVERTENCIA: Estas Precauciones de Se-
guridad son para su protección. Ellas hacen
resumen de información proveniente de las
referencias listadas 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 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 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:
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 ltro 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 chis-
pas calientes con una cortina adecuada no-amable
como división.
6. Use careta protectora además de sus gafas de segu-
ridad 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.
FUEGO Y EXPLOSIONES -- El calor de
las amas y el arco pueden ocacionar
fuegos. Escoria caliente y las chispas
pueden causar fuegos y explosiones.
Por lo tanto:
1. 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 amables, 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 inamables o vapores tóxicos. No
trabaje dentro o fuera de contenedores o tanques
cerrados. Estos pueden explotar si contienen vapores
inamables.
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 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 corri-
ente alterna (AC) en áreas húmedas,
de movimiento connado en lugares estrechos o
si hay posibilidad de caer al suelo.
9
SECCION 1 SEGURIDAD
1. 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 especícas 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
eléctrica uye 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. Soldadores 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 marca-pasos.
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.
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 sub-
stancias 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 especícas en la ventilación.
10
SECCION 1 SEGURIDAD
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
1. Siempre tenga personal cualicado para efectuar l a instalación, diagnóstico, y mantenimiento
del equipo. No ejecute ningún trabajo eléctrico a
menos que usted esté cualicado 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 modique 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"
MANTENIMIENTO DEL EQUIPO -- Equipo
defectuoso o mal mantenido puede
causar daño o muerte. Por lo tanto:
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
11
SECCION 1 SEGURIDAD
SIGNIFICADO DE LOS SIMBOLOS
-- Según usted avanza en la lectura
de este folleto: Los Símbolos Signican ¡Atención! ¡Esté Alerta! Se
trata de su seguridad.
Signica riesgo inmediato que,
de no ser evadido, puede resultar
inmediatamente en serio daño
personal o la muerte.
Signica el riesgo de un peligro
potencial que puede resultar en
serio daño personal o la muerte.
Signica el posible riesgo que
puede resultar en menores daños
a la persona.
12
SECTION 1 SÉCURITÉ
1.3 Safety - French
AVERTISSEMENT : Ces règles de sécurité
ont pour but d'assurer votre protection. Ils
récapitulent les informations de précaution
provenant des références dans la section
des Informations de sécurité supplémentaires. Avant
de procéder à l'installation ou d'utiliser l'unité, assurezvous de lire et de suivre les précautions de sécurité cidessous, dans les manuels, les ches d'information sur la
sécurité du matériel et sur les étiquettes, etc. Tout défaut
d'observer ces précautions de sécurité peut entraîner
des blessures graves ou mortelles.
PROTÉGEZ-VOUS -- Les processus de
soudage, de coupage et de gougeage
produisent un niveau de bruit élevé et
exige l'emploi d'une protection auditive. L'arc, tout
comme le soleil, émet des rayons ultraviolets en plus
d'autre rayons qui peuvent causer des blessures à la
peau et les yeux. Le métal incandescent peut causer
des brûlures. Une formation reliée à l'usage des
processus et de l'équipement est essentielle pour
prévenir les accidents. Par conséquent:
1. Portez des lunettes protectrices munies d'écrans la-
téraux lorsque vous êtes dans l'aire de travail, même
si vous devez porter un casque de soudeur, un écran
facial ou des lunettes étanches.
2. Portez un écran facial muni de verres ltrants et de
plaques protectrices appropriées an de protéger
vos yeux, votre visage, votre cou et vos oreilles des
étincelles et des rayons de l'arc lors d'une opération
ou lorsque vous observez une opération. Avertissez
les personnes se trouvant à proximité de ne pas regarder l'arc et de ne pas s'exposer aux rayons de l'arc
électrique ou le métal incandescent.
3. Portez des gants ignifugiés à crispin, une chemise
épaisse à manches longues, des pantalons sans rebord
et des chaussures montantes an de vous protéger des
rayons de l'arc, des étincelles et du métal incandescent,
en plus d'un casque de soudeur ou casquette pour
protéger vos cheveux. Il est également recommandé
de porter un tablier ininammable an de vous protéger des étincelles et de la chaleur par rayonnement.
4. Les étincelles et les projections de métal incandescent
risquent de se loger dans les manches retroussées,
les rebords de pantalons ou les poches. Il est recommandé de garder boutonnés le col et les manches et
de porter des vêtements sans poches en avant.
5. Protégez toute personne se trouvant à proximité des
étincelles et des rayons de l'arc à l'aide d'un rideau ou
d'une cloison ininammable.
6. Portez des lunettes étanches par dessus vos lunettes
de sécurité lors des opérations d'écaillage ou de
meulage du laitier. Les écailles de laitier incandescent
peuvent être projetées à des distances considérables.
L es p er so n ne s se tr o uv an t à p r ox im it é do ive n t é ga l e ment porter des lunettes étanches par dessus leur
lunettes de sécurité.
INCENDIES ET EXPLOSIONS -- La
chaleur provenant des ammes ou de
l'arc peut provoquer un incendie. Le
laitier incandescent ou les étincelles
peuvent également provoquer un
incendie ou une explosion. Par conséquent :
1. Éloignez susamment tous les matériaux combustibles de l'aire de travail et recouvrez les matériaux
avec un revêtement protecteur ininammable. Les
matériaux combustibles incluent le bois, les vêtements, la sciure, le gaz et les liquides combustibles,
les solvants, les peintures et les revêtements, le
papier, etc.
2. Les étincelles et les projections de métal incandescent peuvent tomber dans les ssures dans
les planchers ou dans les ouvertures des murs et
déclencher un incendie couvant à l'étage inférieur
Assurez-vous que ces ouvertures sont bien protégées
des étincelles et du métal incandescent.
3. N'exécutez pas de soudure, de coupe ou autre travail à chaud avant d'avoir complètement nettoyé la
surface de la pièce à traiter de façon à ce qu'il n'ait
aucune substance présente qui pourrait produire
des vapeurs inammables ou toxiques. N'exécutez
pas de travail à chaud sur des contenants fermés
car ces derniers pourraient exploser.
4. Assurez-vous qu'un équipement d'extinction
d'incendie est disponible et prêt à servir, tel qu'un
tuyau d'arrosage, un seau d'eau, un seau de sable
ou un extincteur portatif. Assurez-vous d'être bien
instruit par rapport à l'usage de cet équipement.
5. Assurez-vous de ne pas excéder la capacité de
l'équipement. Par exemple, un câble de soudage
surchargé peut surchauer et provoquer un incendie.
6. Une fois les opérations terminées, inspectez l'aire de
travail pour assurer qu'aucune étincelle ou projection de métal incandescent ne risque de provoquer
un incendie ultérieurement. Employez des guetteurs
d'incendie au besoin.
7. Pour obtenir des informations supplémentaires,
consultez le NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible au
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
CHOC ÉLECTRIQUE -- Le contact avec
des pièces électriques ou les pièces
de mise à la terre sous tension peut
causer des blessures graves ou mor-
telles. NE PAS utiliser un courant de
soudage c.a. dans un endroit humide, en espace
restreint ou si un danger de chute se pose.
13
SECTION 1 SÉCURITÉ
1. Assurez-vous que le châssis de la source
d'alimentation est branché au système de mise à
la terre de l'alimentation d'entrée.
2. Branchez la pièce à traiter à une bonne mise de
terre électrique.
3. Branchez le câble de masse à la pièce à traiter et
assurez une bonne connexion an d'éviter le risque
de choc électrique mortel.
4. Utilisez toujours un équipement correctement
entretenu. Remplacez les câbles usés ou endommagés.
5. Veillez à garder votre environnement sec, incluant
les vêtements, l'aire de travail, les câbles, le porteélectrode/torche et la source d'alimentation.
6. Assurez-vous que tout votre corps est bien isolé
de la pièce à traiter et des pièces de la mise à la
terre.
7. Si vous devez eectuer votre travail dans un espace
restreint ou humide, ne tenez vous pas directement sur le métal ou sur la terre; tenez-vous sur
des planches sèches ou une plate-forme isolée et
portez des chaussures à semelles de caoutchouc.
8. Avant de mettre l'équipement sous tension, isolez
vos mains avec des gants secs et sans trous.
9. Mettez l'équipement hors tension avant d'enlever
vos gants.
10. Consultez ANSI/ASC Standard Z49.1 (listé à
la page suivante) pour des recommandations
spéciques concernant les procédures de mise à
la terre. Ne pas confondre le câble de masse avec
le câble de mise à la terre.
CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — comportent un risque de
danger. Le courant électrique qui
passe dans n'importe quel conduc-
teur produit des champs électriques
et magnétiques localisés. Le soudage et le courant de coupage créent des champs électriques
et magnétiques autour des câbles de soudage et
l'équipement. Par conséquent :
1. Un soudeur ayant un stimulateur cardiaque doit
consulter son médecin avant d'entreprendre une
opération de soudage. Les champs électriques et
magnétiques peuvent causer des ennuis pour certains stimulateurs cardiaques.
2. L'exposition à des champs électriques et magné-
tiques peut avoir des eets néfastes inconnus pour
la santé.
3. Les soudeurs doivent suivre les procédures suivantes
pour minimiser l'exposition aux champs électriques
et magnétiques :
A. Acheminez l'électrode et les câbles de masse
ensemble. Fixez-les à l'aide d'une bande adhésive
lorsque possible.
B. Ne jamais enrouler la torche ou le câble de masse
autour de votre corps.
C. Ne jamais vous placer entre la torche et les câbles
de masse. Acheminez tous les câbles sur le même
côté de votre corps.
D. Branchez le câble de masse à la pièce à traiter le
plus près possible de la section à souder.
E. Veillez à garder la source d'alimentation pour le
soudage et les câbles à une distance appropriée
de votre corps.
LES VAPEURS ET LES GAZ -- peuvent
causer un malaise ou des dommages
corporels, plus particulièrement
dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le
gaz de protection risque de causer
l'asphyxie. Par conséquent :
1. Assurez en permanence une ventilation adéquate
dans l'aire de travail en maintenant une ventilation naturelle ou à l'aide de moyens mécanique.
N'effectuez jamais de travaux de soudage, de
coupage ou de gougeage sur des matériaux tels que
l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc,
le plomb, le berylliym ou le cadmium en l'absence
de moyens mécaniques de ventilation ecaces. Ne
respirez pas les vapeurs de ces matériaux.
2. N'eectuez jamais de travaux à proximité d'une
opération de dégraissage ou de pulvérisation. Lorsque la chaleur
ou le rayonnement de l'arc entre en contact avec les
vapeurs d'hydrocarbure chloré, ceci peut déclencher
la formation de phosgène ou d'autres gaz irritants,
tous extrêmement toxiques.
3. Une irritation momentanée des yeux, du nez ou de la
gorge au cours d'une opération indique que la ventilation n'est pas adéquate. Cessez votre travail an
de prendre les mesures nécessaires pour améliorer
la ventilation dans l'aire de travail. Ne poursuivez
pas l'opération si le malaise persiste.
4. Consultez ANSI/ASC Standard Z49.1 (à la page
suivante) pour des recommandations spéciques
concernant la ventilation.
14
SECTION 1 SÉCURITÉ
5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé
dans une opération de soudage ou de
coupage, dégage des vapeurs ou des
gaz contenant des chimiques considéres par l'état de la Californie comme
étant une cause des malformations
congénitales et dans certains cas, du
cancer. (California Health & Safety
Code §25249.5 et seq.)
MANIPULATION DES CYLINDRES -La manipulation d'un cylindre, sans
observer les précautions nécessaires,
peut produire des fissures et un
échappement dangereux des gaz.
Une brisure soudaine du cylindre, de la soupape ou
du dispositif de surpression peut causer des blessures graves ou mortelles. Par conséquent :
1. Utilisez toujours le gaz prévu pour une opération
et le détendeur approprié conçu pour utilisation
sur les cylindres de gaz comprimé. N'utilisez jamais
d'adaptateur. Maintenez en bon état les tuyaux et
les raccords. Observez les instructions d'opération
du fabricant pour assembler le détendeur sur un
cylindre de gaz comprimé.
2. Fixez les cylindres dans une position verticale, à
l'aide d'une chaîne ou une sangle, sur un chariot
manuel, un châssis de roulement, un banc, un mur,
une colonne ou un support convenable. Ne xez
jamais un cylindre à un poste de travail ou toute autre
dispositif faisant partie d'un circuit électrique.
3. Lorsque les cylindres ne servent pas, gardez les
soupapes fermées. Si le détendeur n'est pas branché, assurez-vous que le bouchon de protection de
la soupape est bien en place. Fixez et déplacez les
cylindres à l'aide d'un chariot manuel approprié.
Toujours manipuler les cylindres avec soin.
4. Placez les cylindres à une distance appropriée
de toute source de chaleur, des étincelles et des
ammes. Ne jamais amorcer l'arc sur un cylindre.
5. Pour de l'information supplémentaire, consultez
CGA Standard P-1, "Precautions for Safe Handling
of Compressed Gases in Cylinders", mis à votre disposition par le Compressed Gas Association, 1235
Jeerson Davis Highway, Arlington, VA 22202.
ENTRETIEN DE L'ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou
inadéquate peut causer des blessures
graves ou mortelles. Par conséquent :
1. Efforcez-vous de toujours confier les tâches
d'installation, de dépannage et d'entretien à un
personnel qualié. N'eectuez aucune réparation
électrique à moins d'être qualié à cet eet.
2. Avant de procéder à une tâche d'entretien à
l'intérieur de la source d'alimentation, débranchez
l'alimentation électrique.
3. Maintenez les câbles, les ls de mise à la terre,
les branchements, le cordon d'alimentation et la
source d'alimentation en bon état. N'utilisez jamais un équipement s'il présente une défectuosité
quelconque.
4. N'utilisez pas l'équipement de façon abusive. Gardez
l'équipement à l'écart de toute source de chaleur,
notamment des fours, de l'humidité, des aques
d'eau, de l'huile ou de la graisse, des atmosphères
corrosives et des intempéries.
5. Laissez en place tous les dispositifs de sécurité et
tous les panneaux de la console et maintenez-les
en bon état.
6. Utilisez l'équipement conformément à son usage
prévu et n'eectuez aucune modication.
INFORMATIONS SUPPLÉMENTAIRES RELATIVES À LA SÉCURITÉ -- Pour obtenir de
l'information supplémentaire sur les règles
de sécurité à observer pour l'équipement
de soudage à l'arc électrique et le coupage,
demandez un exemplaire du livret "Precautions and Safe Practices for Arc Welding,
Cutting and Gouging", Form 52-529.
Les publications suivantes sont également recommandées et mises à votre disposition par l'American Welding
Society, 550 N.W. LeJuene Road, Miami, FL 33126 :
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"
15
SECTION 1 SÉCURITÉ
SIGNIFICATION DES SYMBOLES
Ce symbole, utilisé partout dans ce manuel,
signie "Attention" ! Soyez vigilant ! Votre
sécurité est en jeu.
DANGER
Signie un danger immédiat. La situation peut
entraîner des blessures graves ou mortelles.
AVERTISSEMENT
Signie un danger potentiel qui peut entraîner des
blessures graves ou mortelles.
ATTENTION
Signie un danger qui peut entraîner des blessures
corporelles mineures.
16
SECTION 2 DESCRIPTION
2.1 Introduction
The EPP power source is designed for marking and high speed plasma mechanized cutting applications. It can
be used with other ESAB products such as the PT-15, PT-19XLS, PT-600 and PT-36 torches along with the Smart
Flow II, a computerized gas regulation and switching system.
10 to 36 amperes for marking•
30 to 200 amperes cutting current range•
Forced air cooled •
Solid state DC power•
Input voltage protection•
Local or remote front panel control•
Thermal switch protection for main transformer and power semiconductor components•
Top lifting eyes or base forklift clearance for transport•
Parallel supplemental power source capabilities to extend current output range.•
2.2 General Specications
Part Number 0558007801 0558007802
Output
(100 % duty cycle)
Input
EPP-201 460V,
60Hz
Voltage 160 VDC
Current range DC (marking) 10A to 36A
Current range DC (cutting) 30A to 200A
Power 32 KW
* Open Circuit Voltage (OCV) 360 VDC
Voltage (3-phase) 460V 575V
Current (3- phase) 51A RMS 41A RMS
Frequency 60 HZ 60 HZ
KVA 40.6 KVA 40.6 KVA
Power 35.5 KW 35.5 KW
Power Factor 90.0 % 90.0 %
Input Fuse Rec. 100A 60A
EPP-201 575V,
CSA, 60Hz
17
SECTION 2 DESCRIPTION
2.3 Dimensions and Weight
40.75”
(1035 mm)
23.75”
(603.25 mm)
47. 2 5 ”
(1200 mm)
Weight = 1085 lb
18
SECTION 3 INSTALLATION
3.1 General
FAILURE TO FOLLOW INSTRUCTIONS COULD LEAD TO DEATH, INJURY
OR DAMAGED PROPERTY. FOLLOW THESE INSTRUCTIONS TO PRE
WARNING
3.2 Unpacking
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.•
VENT INJURY OR PROPERTY DAMAGE. YOU MUST COMPLY WITH LO
CAL, STATE AND NATIONAL ELECTRICAL AND SAFETY CODES.
3.3 Placement
A minimum of 1 meter (3 ft.) clearance on front and back for cooling air ow.•
Plan for top panel and side panels having to be removed for maintenance, cleaning and inspection. •
Locate the EPP-201 relatively close to a properly fused electrical power supply.•
Keep area beneath power source clear for cooling air ow.•
Environment should be relatively free of dust, fumes and excessive heat. These factors will aect cool-•
ing eciency.
CAUTION
Conductive dust and dirt inside power source may cause arc ashover. Equipment damage may occur. Electrical shorting may occur if
dust is allowed to build-up inside power source.
See maintenance section.
19
SECTION 3 INSTALLATION
3.4 Input Power Connection
ELECTRIC SHOCK CAN KILL!
PROVIDE MAXIMUM PROTECTION AGAINST ELECTRICAL SHOCK.
WARNING
3.4.1 Primary Power
EPP-201 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.
BEFORE ANY CONNECTIONS ARE MADE INSIDE THE MACHINE, OPEN
THE LINE WALL DISCONNECT SWITCH TO TURN POWER OFF.
Recommended input conductor and line fuse sizes:
Input at Rated Load Input and Ground
Volts Amperes
460 51 35 (2)* 100
575 41 35 (2)* 60
Rated load is output of 200A at 160V
* Sizes per National Electrical Code for a 90° C (194˚ F) rated copper conductors @ 40° C (104˚ F) ambient. Not
more than three conductors in raceway or cable. Local codes should be followed if they specify sizes other
than those listed above.
To estimate the input current for a wide range of output conditions, use the formula below.
Input current =
(V arc) x (I arc) x 0.73
(V line)
conductor* CU/
mm2 (AWG)
Time delay
Fuse size
(amperes)
Dedicated power line may be necessary.
EPP-201 is equipped with line voltage compensation but to avoid
NOTICE
impaired performance due to an overloaded circuit, a dedicated
power line may be required.
20
SECTION 3 INSTALLATION
3.4.2 Input Conductors
Customer supplied•
May consist either of heavy rubber covered copper conductors (three power and one ground) or run •
in solid or exible conduit.
Sized according to the chart. •
3.4.3 Input Connection Procedure
IMPROPER GROUNDING CAN RESULT IN DEATH OR INJURY.
WARNING
CHASSIS MUST BE CONNECTED TO AN APPROVED ELECTRICAL
GROUND. BE SURE GROUND LEAD IS NOT CONNECTED TO ANY PRI
MARY TERMINAL.
Chassis Ground
Power Input Cable Access Opening (Rear Panel)
Remove small rear panel of the EPP-201.1.
Thread cables through the access opening in the rear panel.2.
Secure cables with strain relief at the access opening.3.
Connect the ground lead to the stud on the chassis.4.
Connect the power leads to the primary terminals.5.
Connect the input conductors to the line (wall) disconnect.6.
Before applying power, replace the rear cover panel.7.
Primary Terminals
21
SECTION 3 INSTALLATION
3.5 Output Connections
ELECTRIC SHOCK CAN KILL! DANGEROUS VOLTAGE AND CURRENT!
ANY TIME WORKING AROUND A PLASMA POWER SOURCE WITH COV
ERS REMOVED:
WARNING
DISCONNECT POWER SOURCE AT THE LINE (WALL) DISCONNECT.•
HAVE A QUALIFIED PERSON CHECK THE OUTPUT BUS BARS (POSI-•
TIVE AND NEGATIVE) WITH A VOLTMETER.
3.5.1 Output Cables (customer supplied)
Choose plasma cutting output cables (customer supplied) on the basis of one 4/0 AWG, 600 volt insulated copper cable for each 400 amps of output current.
Note:
Do not use 100 volt insulated welding cable.
22
SECTION 3 INSTALLATION
3.5.2 Output Connection Procedure
1. Open access panel on the lower front of the power source.
2. Thread output cables through the openings at the bottom of the power source 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 Closed
23
Front Access
Panel Opened
SECTION 3 INSTALLATION
work
(+)
work
(+)
3.6 Parallel Installation
Two EPP-201 power sources may be connected together in parallel to extend the output current range.
3.6.1 Connections for Two EPP-201’s in Parallel
Note:
Primary power source has the electrode (-) conductor jumpered. The supplemental power
source has the work (+) jumpered.
1. Connect the negative (-) output cables to the arc starter box (high frequency generator).
2. Connect the positive (+) output cables to the workpiece.
3. Connect the positive (+) and negative (-) conductors between the power sources.
4. Connect the pilot arc cable to the pilot arc terminal in the primary power source. The pilot arc connection in
the supplemental power source is not used. The pilot arc circuit is not run in parallel.
5. Connect a power source paralleling control cable between the two power sources.
6. Connect the CNC control cable to the primary power source.
Connections for parallel installation of two EPP-201 power sources with both power sources in operation.
EPP-201 EPP-201
S u p p l em e nt a l
Power Source
2 - 4/0 600V
positive leads
to workpiece
electrode
(-)
P/S Parallel Control Cable
lead to pilot arc connection in arc starter
box (h.f. generator)
Primary Power
Source
pilot arc
1 - 14 AWG 600V
electrode
(-)
Control cable to
water cooler
CNC
Control
Cable
2 - 4/0 600V
negative leads
in arc starter box
(h.f. generator)
24
SECTION 3 INSTALLATION
work
The EPP-201 does not have an ON/OFF switch. The main power is controlled through the line (wall) disconnect switch.
DO NOT OPERATE THE EPP201 WITH COVERS REMOVED. HIGH
VOLTAGE COMPONENTS ARE EXPOSED INCREASING SHOCK HAZ
WARNING
WARNING
ARD. INTERNAL COMPONENTS MAY BE DAMAGED BECAUSE COOL
ING FANS WILL LOSE EFFICIENCY.
ELECTRIC SHOCK CAN KILL!
EXPOSED ELECTRICAL CONDUCTORS CAN BE HAZARDOUS!
DO NOT LEAVE ELECTRICALLY “HOT“ CONDUCTORS EXPOSED. WHEN
DISCONNECTING THE SUPPLEMENTAL POWER SOURCE FROM THE
PRIMARY, VERIFY THE CORRECT CABLES WERE DISCONNECTED. IN
SULATE THE DISCONNECTED ENDS.
WHEN TWO POWER SOURCES ARE CONNECTED IN PARALLEL AND
ONE OF THE TWO IS NOT POWERED, OR IF THE PARALLELING CABLE
DOES NOT CONNECT THE TWO, THE NEGATIVE ELECTRODE CONDUC
TOR MUST BE DISCONNECTED FROM THE SUPPLEMENTAL POWER
SOURCE AND THE PLUMBING BOX. FAILURE TO DO THIS WILL LEAVE
THE SUPPLEMENTAL ELECTRICALLY “HOT”, UNSAFE, AS WELL AS IN
OPERATIVE.
Connections for parallel installation of two EPP-201 power sources with only one power source in operation.
EPP-201 EPP-201
S u p p l em e nt a l
Power Source
2 - 4/0 600V
positive leads
to workpiece
electrode
P/S Parallel Control
Cable
Disconnect negative
connection from secondary power source
and insulate to convert from two to one
power source
25
Primary Power
work
Source
electrode
Control cable to
water cooler
2 - 4/0 600V
negative leads
in arc starter box
(h.f. generator)
SECTION 3 INSTALLATION
3.6.2 Marking with Two Parallel EPP-201’s
Two EPP-201’s, connected in parallel, and can be used for marking down to 10A and cutting from 30A up to
400A.
OPERATION OF TWO PARALLEL EPP-201’S:
Provide start/stop, Cut/Mark, “HI CURRENT” logic signals and either logic or analog inputs to control the pilot 1.
current signals to primary unit for both cutting and marking. When marking, both power sources are powered up, but the mark signal disables the output of the supplemental power source.
3.7 Interface Cable Connectors
E-Stop Connector
Remote Control (CNC)
Parallel Power Source
Coolant Circulator
26
SECTION 3 INSTALLATION
3.7.1 CNC Interface Cables with Mating Power Source Connector and
Unterminated CNC Interface
GRN/YEL
RED #4
3.7.2 CNC Interface Cables with Mating Power Source Connectors at Both Ends
GRN/YEL
27
RED #4
SECTION 3 INSTALLATION
3.7.3 Water Cooler Interface Cables with Mating Power Source Connectors at Both Ends
3.7.4 Power Source Parallel Control Cable
28
SECTION 4 OPERATION
DANGEROUS VOLTAGES AND CURRENT! ELECTRIC SHOCK CAN KILL!
WARNING
4.1 EPP-201 Block Diagram
BEFORE OPERATION, ENSURE INSTALLATION AND GROUNDING PRO
CEDURES HAVE BEEN FOLLOWED. DO NOT OPERATE THIS EQUIP
MENT WITH COVERS REMOVED.
Main
Contactor
Main
Transformer
3 ~
Rectier
2 x 6000uf
450V
Capacitors
400 / 460V 3 ~
Input
3 x 2 Ohm
300 Watt
Resistors
Soft
Start
Relay
IGBT Driver
Board
4 x 400 Amp
IGBT’s
Control
Power
Fuses
1 ~
Control
Transformer
Relay / Interface
Board
Main Control
Board
CNC
Interface
&
Isolation
Inductor
Output
Front Panel
Display
29
SECTION 4 OPERATION
4.2 Control Panel
E
F
B
H
A
C
D
J
30
SECTION 4 OPERATION
4.2 Control Panel (con’t.)
A - Preset / Operate Switch
“Center” position = will show actual cut parameters
“Up” position = Pilot Arc Current Preset for either the Panel or Remote mode
“Down” position = Cut Current Preset for either the Panel or Remote mode
B - Over Temp
Indicator illuminates when power source has overheated.
C - Fault
Indicator illuminates when errors have occurred which require a main power reset of the unit.
D - Current Dial (Potentiometer)
EPP-201 dial shown. EPP-201 has a range of 10 to 200 amps. Used only in panel mode.
E - Panel Remote Switch
Controls the location of current control.
Place in the PANEL position for control using the current potentiometer.•
Place in REMOTE position for control from an external signal (CNC).•
F - Meters
Displays voltage and amperage when cutting. The ammeter can be activated when not cutting to view an estimation of the cutting/marking current or pilot arc current before cutting begins. See “A” above. Also displays
various error codes that may occur.
G - E-Stop Connector (not shown)
The E-stop connector provides a normally closed contact of the E-stop switch. The contact is connected to J4-A
and J4-B. The contact opens after the E-stop button is pushed. This provides a signal to the plasma control that
the power source is in an E-stop condition.
H - E-Stop Button
The E-stop button operates the E-stop switch. When the button is pushed in an E-stop condition exists which
prevents the power source from providing output even when a start signal is provided.
J - CB1 - 3 amp
Circuit breaker for 115 vac to CNC.
31
SECTION 4 OPERATION
4.3 Modes of Operation
The EPP-201 operates in the Cutting Mode through a single continuously adjustable output current range from
25A through 200A using either the Current Potentiometer on the front panel, or a remote current reference signal fed into connector J1.
When using a remote signal, 1 volt corresponds to 36 amps, and 200A corresponds to a signal of 5.55 VDC.
The EPP-201 defaults to the Cutting Mode of operation unless the command signal from a remote control for
Marking Mode is supplied.
The power source is placed in Marking Mode with an external isolated relay or switch contact connecting J1-R
(115VAC) to J1-C. See Schematic Diagram included inside back cover. This contact closure must be made before
(50 mS or longer) issuing a Start or Contactor On command.
In the CNC Marking mode, the output current is adjusted through a single continuously adjustable range from
0 amps through 36 amps using the remote current reference signal fed into connector J1. In the Panel Marking
mode, the output current can be adjusted from 0 - 18 amps using the panel potentiometer, as the unit is shipped.
If SW1-1 (which is open on the control board) is closed, the range becomes 0 -18 amps max.
When using a remote signal, 1 volt corresponds to 3.6 amps, and 36A corresponds to a signal of 10.00 VDC.
4.3.1. Single Power Source (used with the CNC, two basic modes of operation are possible)
1. Panel Mode - (switch is provided on the power source) Put Panel/Remote switch to Panel position. Used with
a limited capability CNC that can only provide a start/stop signal to the power source. The microcontroller in
the power source will accept the analog setting from the panel potentiometer as the cut current information.
Based on this value it will calculate the initial current value, the pilot arc and the upslope time. The cut value
and P.A. value can be displayed prior to cutting by moving the spring return switch on the power source to
the cut current preset, and the pilot arc preset positions. If the pilot arc current is deemed insucient, the
CNC can increase it by providing inputs on the PA0 and PA1 control leads. The increased values are as follows:
PA0 PA1
o o no change
on o value increased by 12.5%
o on value increased by 2.5%
on on value increased by 37.5%
32
3A
not used
10K
24 CONDUCTOR CABLE
+
E-STOP: ISOLATED CONTACT
CLOSED TO RUN
MARK MODE SELECT
CUT CURRENT REF
CURRENT REF COMJ
L
A
G
Z
M
T
Q
Y
S
N
C
D
E
F
H
K
R
U
V
W
X
B
P
CUT CURRENT REF
+
MARK MODE SELECT
I mark = (3.6) X (Vcut cur ref)
CLOSED FOR MARKING
POWER SOURCE FAULT
RED 09
MASTER SELECT - CONNECT H TO R (ALWAYS PRESENT)
RED 22
RED 01
RED 18
RED 13
RED 12
RED 15
RED 23
RED 17
RED 07
RED 11
RED 04
RED 02
RED 14
RED 03
RED 05
RED 08
RED 06
RED 10
RED 16
RED 20
RED 19
RED 21
115V AC NEUTRAL
WC LEVEL (ON W/ LEVEL OK)
ON WITH FAULT
+
K4
WC LEVEL: OFF
WITH FAULT
PA CURRENT SELECT
E-STOP
PA CURRENT SELECT
E-STOP
PA CURRENT SELECT
CNC
(PARALLEL OPERATION ONLY)
Icut = (36) X (Vcut cur ref)
CURRENT HI/LO
CLOSED FOR 400A; OPEN FOR 200A
Ipa = (4.5) X (Vpa cur ref)
+
FOR HI: Icut = (40) X (Vcut cur ref)
PLASMA START
PS 24V DC COMMON
HI RANGE (400A)
PLASMA START
FOR LO: Icut = (20) X (Vcut cur ref)
15V CNC
COMMON
PA CURRENT SELECT
24V DC
COMMON
PA ON
CNC +15V DC
WC FLOW FAULT: ON WITH FLOW OK
CABLE
WIRE ID
ARC ON
+
MASTER SELECT
115V AC NEUTRAL
+
Plasma System Control
POWER SOURCE FAULT
20K
115V AC H
24V AC
PA ON
PA CURRENT REF
CNC +15V DC
20K
PA CURRENT REF
ARC ON
not used
GRN/YEL
PROCESS CONTROL SELECTION
24-
CONDUCTOR
CONNECTOR
CNC ANALOG COMMON
CHASSIS
WC FLOW FAULT: OFF WITH LO FLOW
PA1
HALL TRANSDUCER
OPEN FOR INTERNAL CONTROL
+
MASTER CURRENT
115V AC
CLOSED FOR EXTERNAL CONTROL
10K
10K
10K
10K
10K
10K
MASTER OUTPUT CURRENT
SIGNAL 1.0V = 100A
10K
PA0
FUSE
24V24V
15V15V
0 TO 10V0 TO 10V
0 TO 10V0 TO 10V
SECTION 4 OPERATION
EPP-201
33
SECTION 4 OPERATION
The table used to calculate the initial current, pilot current and upslope values are stored in the micro and contains the following information:
Cut Current
(amps)
30 20 15 200
50 25 20 250
100 50 25 500
200 100 30 800
Start Current
(amps)
Pilot Arc Current
(amps)
Upslope Time
(msec)
If values other than the table values are used for the cut current, the corresponding values are calculated assuming a linear slope for all the required parameters.
2. Remote Mode -
a. Partial CNC operation - (CNC cable pin “V” open, open for internal control) In this mode of operation the
panel/remote switch needs to be in the REMOTE position. The CNC should be providing the cut current reference and start/stop signal to the power source. Based on the cut reference the micro in the power source will
compute the initial current, pilot current and upslope time.
b. Remote with Full CNC Mode - (CNC cable pin “V” closed, closed for external control) Panel/remote switch
on the power source is set to REMOTE. The CNC should activate the input labeled “full CNC control” on pin
“V” of the interconnect cable. In this mode all parameters are controlled by the CNC, including start current,
pilot current and sloping times. The control of the pilot current can be done either by logic inputs or by an
analog input. If the analog input is less than 0.5 volts the power source will use the logic inputs PA0 and PA1
to provide the requested pilot arc current, based on the following combination:
PA0 PA1 Pilot current in amp
open open 10
closed open 20
open closed 30
closed closed 40
If the analog reference is used, 10 VDC will provide 45 amps or 1 V = 4.5 amps.
Marking - Can be done in both panel and remote mode and requires the mark mode select input to be closed
by the CNC. In the panel mode the maximum marking current (set by the panel potentiometer) is 36 amps.
If SW1-1 (which is open on the control board) is closed, the range becomes 0 -18 amps max. In the remote
mode the marking current is set by the main reference input and 10 VDC will provide 36 amps or 1 V = 3.6
amps of marking current.
34
SECTION 4 OPERATION
4.3.2. Multiple Power Sources
1. Parallel Mode of operation - Connect power sources together as shown in section 3.6. Set the panel/remote
switches on both power sources to remote. If the units will be used for cutting and both power sources are to
contribute to the cut current value, activate the logic input labeled “HI CURRENT” (pin “T”) on the CNC cable. In
this manner a maximum current of 400 amps can be provided for an analog input of 10 VDC from the CNC. If the
“HI CURRENT” input is deactivated the supplemental power source will not provide any output even though it is
connected to the primary power source. In marking mode only the primary power source will supply the marking current. If alternating marking and cutting operations are done, the “HI CURRENT” input can be maintained
and the mark input will control whether both or only one power source will provide output current. The marking
current range is from 10 to 36 amps and the cut current range is from 30 to 400 amps.
4.4 Sequence of Operation
A. Apply power by closing the line (wall) switch. The EPP-201 does not contain its own power On/O switch.
Once power is supplied, the EPP-201 display board will display “EPP-201” briey, followed by the display “Pr
x.xx”, indicating the software program revision number, then “0 amps” and “0 volts”.
B. Select Panel / Remote setting for current control depending on whether your CNC has remote current con-
trol capability.
1. If using the “Panel” mode, the selected cutting current may be viewed by holding the front panel switch
in the “Cut Current Preset” position. In the “Panel” mode, the Pilot Arc Current, Initial Current, and Upslope Time are determined by the power source based on the selected cutting current. The selected
Pilot Arc Current can be viewed by holding the front panel switch in the “PA Current Preset” position. See
section 4.2 Control Panel.
2. If using the “Remote” mode, there are two possible modes of operation.
a. The default mode is similar to the “Panel” mode with the exception that the cutting current com-
mand is supplied by the CNC instead of the front panel potentiometer. Scaling of the remote current command is 1.0 V DC = 36 amps. This mode is useful if the CNC does not have the capability
of controlling the initial current and sloping of the output. For remote control connections see the
CNC interface diagram.
b. If your CNC has the capability of controlling Initial Current and Slopes, place the Panel/Remote switch
in “”Remote” and supply a contact closure between pins “R” and “V” of the CNC interface connector. In this mode the CNC must supply the analog signal to control Initial Current, Upslope, and Cut
Current level. Scaling is the same as default mode. Pilot Arc current will be controlled by a second
0 – 10 V DC analog signal, if available, or by supplying a binary coded signal as dened in the CNC
interface diagram. Scaling of the pilot arc signal is 10 V DC = 45 amps.
C. Begin plasma cutting operation. This may require setting of other variables such as gas pressures, ow rates,
and torch height etc.
D. If for any reason cutting or marking fails to initiate, the EPP-201 should display an error code indicating the
reason for the shutdown. See “Help Codes” in the troubleshooting section.
35
SECTION 4 OPERATION
36
SECTION 5 MAINTENANCE
5.1 General
ELECTRIC SHOCK CAN KILL!
WARNING
WARNING
CAUTION
5.2 Cleaning
SHUT OFF POWER AT THE LINE WALL DISCONNECT BEFORE AT
TEMPTING ANY MAINTENANCE.
EYE HAZARD WHEN USING COMPRESSED AIR TO CLEAN.
Wear approved eye protection with side shields when cleaning the •
power source.
Use only low pressure air.•
Maintenance On This Equipment Should Only Be Performed By
Trained Personnel.
Regularly scheduled cleaning of the power source is required to help keep the unit running trouble free. The
frequency of cleaning depends on environment and use.
1. Turn power o at wall disconnect.
2. Remove side panels.
3. Use low pressure compressed dry air, remove dust from all air passages and components. Pay particular
attention to heat sinks in the front of the unit. Dust insulates, reducing heat dissipation. Be sure to wear
eye protection.
Air restrictions may cause EPP-201 to over heat.
Thermal Switches may be activated causing interruption of func-
CAUTION
WARNING
tion.
Do not use air lters on this unit.
Keep air passages clear of dust and other obstructions.
ELECTRIC SHOCK HAZARD!
BE SURE TO REPLACE ANY COVERS REMOVED DURING CLEANING
BEFORE TURNING POWER BACK ON.
37
SECTION 5 MAINTENANCE
38
SECTION 6 TROUBLESHOOTING
ELECTRIC SHOCK CAN KILL!
DO NOT PERMIT UNTRAINED PERSONS TO INSPECT OR REPAIR THIS
WARNING
CAUTION
6.1 Troubleshooting
Check the problem against the symptoms in the following troubleshooting guide. The remedy may be quite
simple. If the cause cannot be quickly located, shut o the input power, open up the unit, and perform a simple
visual inspection of all the components and wiring. Check for secure terminal connections, loose or burned wiring or components, bulged or leaking capacitors, or any other sign of damage or discoloration.
EQUIPMENT. ELECTRICAL WORK MUST BE PERFORMED BY AN EXPE
RIENCED ELECTRICIAN.
Stop work immediately if power source does not work properly.
Have only trained personnel investigate the cause.
Use only recommended replacement parts.
The cause of control malfunctions can be found by referring to the sequence of operations, electrical schematics
and checking the various components. A volt-ohmmeter will be necessary for some of these checks.
6.2 Troubleshooting Guide
As the unit is powered up, the display should show EPP-201 for one second and then show the program number
such as: Pr 2.01 or higher. If the display remains blank, look for the following:
a. loose or missing display cable between the main control board and the display board
b. lack of +15 volt bias supply which could be caused by blown fuses F1 or F2
c. an open circuit breaker CB1 on the front panel.
If the unit shows Error 5 after the program number display times out, look for a closed start switch. To reset the
unit simply open the start switch. At this point the display should show 0’s in both windows. If the power source
is not connected to a CNC at power up, the emergency stop relay (K4) in the power source is not energized, preventing any relay operation in the power source itself.
If the CNC has been booted up the display should read 0 for both the volts and amps. The unit will
not respond to a start signal until it’s master select input (pin H on J1) is connected to the “HOT
“ side of 115 input (master select input). This connection is handled in the CNC to primary supply cable. Note
all inputs from the CNC are relay closures, providing 115 V AC inputs to the isolation board (PCB4 in the power
source). The isolation board converts these inputs to open collector type outputs. The control will monitor various signals in the idle mode and will shut down with an error indication if the condition is not satisfactory: Error
1, 3, 4, 5, 9 or 12 (See 6.4 Help code list).
As the start switch is activated and the unit is being prepared for cutting, additional conditions are being monitored. The resulting error conditions are as follows: Error 2, 6, 8, 12, 13, 15, 17, 18, 19 or 113 (See 6.4 Help code
list).
39
SECTION 6 TROUBLESHOOTING
6.3 Help Code list
HELP CODES
01 LINE VOLT, IDLE 08 TORCH ERROR 15 BUS CHARGER FAILURE
02 LINE VOLT, CUTTING 09 OCV OVER 40V, IDLE 17 IGBT DRIVER ERROR
03 CONTROL BIAS 10 OCV OVER 70V, STARTUP 18 CUT/MARK VOLTAGE TOO LOW
04 THERMAL (SWITCH OPEN) 12 1Ф OPERATION, SHUTDOWN 19 SLAVE P/S NOT DETECTED
05 START ON POWER UP 13 OCV FAILURE 20 SHORTED IGBT, BUS CHARGED
06 FAIL TO FIRE 14 AMBIENT TEMP 113 SLAVE P/S ERROR
Error number displays and their meaning for the EPP-360 power supply.
Error 1 +/- 15% deviation in the idle mode is exceeded.
Error 2 Line voltage during cut drops by more than 20 %.
Error 3 Problem with the bias supplies on the control board. The +15 and -15 volt supplies are not balanced, board
should be replaced.
Error 4 Thermal switch has opened. Unit is disabled until overheated component cools down. Look for fans not
working or restrictions on input or output louvers.
Error 5 The start switch from the CNC was already on when the power source was powered up. Unit will not be
functional until start signal is removed and then reapplied.
Error 6 Ignition did not take place during the 10 seconds allowed for arc ignition.
Note: This should rarely occur since the CNC has a much shorter time allowed for the ignition time and
will reset the power source to idle.
Error 7 Not used.
Error 8 Electrode current was present before the PWM was enabled. Most likely caused by an electrode to nozzle
short on the torch.
Error 9 Open circuit voltage in idle mode was over 40 volts. Possible cause leaky IGBTs, faulty PWM drive.
Error 10 Open circuit voltage is over 70 volts when unit is powered up. Possible cause leaky IGBT’s, faulty PWM.
Error 11 Not used.
Error 12 Shut down due to single phasing. Fuse blown in supply line circuit.
Error 13 Open circuit voltage did not reach 300 volts in the allowed time. Check PWM circuit & E-Stop on J1.
Error 14 Ambient temperature exceeded 55 C in control enclosure.
Error 15 Bus voltage did not reach 100 volts during the allowed time. Bus charge relay or surge limiting resistors
defective
Error 16 Not used
Error 17 IGBT driver board error.
Error 18 Cutting voltage fell below 70 volts during cutting or below 40 volts during marking.
Error 19 Master is requested to engage slave power supply but slave is not present.
Error 20 Open circuit voltage detected before PWM was engaged.
Error 113 Error detected in slave power supply.
40
SECTION 6 TROUBLESHOOTING
6.4 Fault Isolation
6.4.1 Fans Not Working
Problem Possible Cause Action
This is normal when not cutting.
All 3 fans do not run
1 or 2 fans do not run.
6.4.2 Torch Will Not Fire
Problem Possible Cause Action
Fans run only when “Contactor On”
signal is received.
Broken or disconnected wire in fan
motor circuit.
Faulty fan(s) Replace fans
None
Repair wire.
Main Arc Transfers to the work with a
short “pop”, placing only a small dimple
in the work.
Arc does not start. There is no arc at the
torch. Open circuit voltage is OK.
Remote control removes the start
signal when the main arc transfers to
the work.
Panel/Remote switch in “Remote” with
no remote control of the current
Remote current control present but
signal missing.
Current pot set too low. Increase current pot setting.
Open connection between the power
source positive output and the work.
Pilot current and/or start current should
be increased for better starts when
using consumables for 100A or higher
(Refer to process data included in torch
manuals)
Faulty PCB1 Replace PCB1
Place Panel/Remote switch in “Panel”
position
Check for current reference signal
between J and L on 24 pin receptacle should be between 0.5 - 10 volts
(5.55 volts = 200 amps)
Repair connection
Increase pilot current. (Refer to process
data included in torch manuals)
41
SECTION 6 TROUBLESHOOTING
42
SECTION 7 REPLACEMENT PARTS
7.0 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 serial number plate.
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.
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.
EPP-201 Information
Part Number
EPP-201 460V,
60Hz
0558007801 0558007802
EPP-201 575V,
CSA, 60Hz
Note
Items listed in the following Bill of Materials that do not have a part number
shown are not available from ESAB as a replaceable item and cannot be
ordered. Descriptions are shown for reference only. Please use local retail
hardware outlets as a source for these items.
Note
Replacement Parts, Schematics and Wiring Diagrams are
printed on 279.4mm x 431.8mm (11” x 17”) paper and are
included inside the back cover of this manual.
43
NOTES
44
Original release - 06/2008.
Revision 09/2008 - Updated replacement parts and BOM.1.
Revision 04/2009 - Updated replacement parts and BOM.2.
REVISION HISTORY
45
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 Specications 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
or
visit us on the web at http://www.esabna.com
The ESAB web site oers
Comprehensive Product Information
Material Safety Data Sheets
Warranty Registration
Instruction Literature Download Library
Distributor Locator
Global Company Information
Press Releases
Customer Feedback & Support
0558007900 04/2009
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