ESAB PLASMAWELD 202, PLASMAWELD 402 Instruction Manual

0457 974 074

Plasmaweld 202,
Plasmaweld 402

Instruction manual

2

INDEX Page

Safety advice 3

Technical data PLW 202 4

Technical data PLW 402 5

Technical description 6

Installation 7

Welding 9

Data sheet plasma welding 13

Accessories 14

Maintenance 14

Trouble shooting 15

Spare parts 16

3

!WARNING!

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND
OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR
EMPLOYER'S SAFETY PRACTICES WHICH SHOULD BE BASED ON
MANUFACTURER'S HAZARD DATA .

!ELECTRIC SHOCK - CAN KILL!

* Install and earth the welding or cutting equipment in accordance with applicable standards.
* Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
* Insulate yourself from earth and workpiece.
* Ensure that your working place is safe.

!FUMES AND GASES - CAN BE DANGEROUS TO HEALTH!

* Keep your head out of the fumes.
* Use ventilation, extraction of fumes at the arc or both to keep fumes and gases out of your
breathing zone and the general area.

!ARC RAYS - CAN INJURE EYES AND BURN SKIN!

* Protect your eyes and body. Use the correct welding screen and filter lens and wear
protective, insulating and non-flammable clothing.
* Protect bystanders with suitable screens or curtains.

!FIRE HAZARD!

* Sparks and spatters can cause fire. Make sure, that there is no inflammable material in the
surrounding of welding and cutting works.

!MALFUNCTION!

* Call for expert assistance in the event of malfunction.

Read and understand the instruction manual before installation and operation

!Protect yourself and others!

WARNING.doc

4

Plasmaweld 202

Technical Data

TDE202.doc * = option

Mains voltage (V) 3-phase 230 400 *460 500

M Permanent power (kVA) 9,7 9,7 9,7

A

Permanent current (A) 24,4 14,0 12,2 11,2

I Max. current (A) 31,4 18,0 15,8 14,5

Power factor cos phi 0,85 0,84 0.85 0,85

N

Efficiency 0,80

S Frequency (Hz) 50/60

Fuses, slow blow (A) 35 20 16 16
______________________________________________________________________
W Current range DC 5 - 220 A

E Duty cycle Plasma, 60% at 220 A

(10 min cycle) TIG 100% at 170 A
L MMA

D

I

Open circuit voltage DC 98V DC
N

G
______________________________________________________________________
C
O Dimensions (mm) L/W/H 1040/570/940
N
S Weight (kg) 150
T
R Protection class IP 23 M
U Cooling F
C Insulation class F
T Standards EN 60974-1
I VDE 0544-1
O EN 50199
N S-Mark Yes

CE-mark Yes

5

Plasmaweld 402

Technical Data

TDE402.doc * = option

Mains voltage (V) 3-phase 230 400 *460 500

M Permanent power (kVA) 19,4 19,4 19,4 19,4

A

Permanent current (A) 49 28 24 22

I Max. current (A) 61353028

Power factor cos phi 0,85 0,85 0.85 0.85
N

Efficiency 0,80

S Frequency (Hz) 50/60

Fuses, slow blow (A) 63 35 35 35
______________________________________________________________________
W Current range DC 6 - 400 A

E Duty cycle Plasma, 60% at 400 A

(10 min cycle) TIG 100% at 310 A
L MMA

D

I

Open circuit voltage DC 98V DC
N

G
______________________________________________________________________
C
O Dimensions (mm) L/W/H 1060/620/885
N
S Weight (kg) 290
T
R Protection class IP 23 M
U Cooling F
C Insulation class F
T Standards EN 60974-1
I VDE 0544-1
O EN 50199
N S-Mark Yes

CE-mark Yes

6

Technical description

The plasma arc welding machines PLASMAWELD 202 and 402 have been developed for welding
with transferred arc, i. e. the main arc transfers from the tungsten to the work piece.
These units can also be used for TIG, TIG pilot arc and manual metal arc (MMA) welding.

The power supplies can be used in confined spaces and are labelled with the S-mark according to EN
60 974-1.
Infinitely variable adjustment of the welding current makes the units suitable for micro-plasma and
high current plasma as well as for plasma key hole welding.
The pilot arc , started by HF, remains ignited and permits safe and touch-free starting of the main
arc.
By means of rh 19“ rack control system, the units can be used for all manual and automatic plasma
welding applications.
The required welding current and gas flow can be preset before starting the welding operation.
The power supplies are equipped with a constant current control so variations of the mains voltage or
different arc length do not effect the current of the main arc.
The following materials can be welded:
high-, low- and unalloyed steel; nickel, copper, titanium , zirconium and their alloys.
The compact construction with built in water cooler for the torch enables easy transportation of the
machines.

WARNING

This product is intended for industrial use (Class A). In a domestic environment this product may
cause radio interference. It is the users responsibility to take adequate precautions.

The welding equipment creates a noise level of < 70 dB(A) at idle.
An emission level related to the work-place cannot be stated, because this value is depending on the
method and the surroundings. It is conditioned by a variety of parameters e.g. the welding or cutting
process, the kind of current, the power, the kind of material, resonance’s of the workpiece, the
surroundings and more.

7

Installation

On the last page of these instruction manual a picture of the unit marked with symbols is located.
Please unfold and refer to this page in conjunction with the following instructions.

1. Mains connection

The units are factory connected to 400 V 50/60 Hz. They also can be used on 230 V 50/60 Hz and
500 V 50/60 Hz mains. The wiring instruction for reconnection is located inside of the machines
near the input terminal (460V 50/60Hz option).

Important! In case the machines are used with 230 V mains voltage, the mains

cable delivered must be replaced by one with a bigger cross section.

230 V 400/460/500 V
PLW 202 4 x 4 mm² 4 x 2,5 mm²
PLW 402 4 x 10 mm² 4 x 4 mm²

The mains plug must comply to country regulations and must be connected by an electrician. Check
the mains voltage before the machine is switched on.

2. Coolant

Pull the plastic plug of the cooling unit and check the water level. Liquid level should be about 3 cm
(1“) below the filling hole. If not, top up the tank using LoDuct cooling fluid.

Caution! Electrolytic corrosion may shorten the live time of the torch, when normal mains

water is used
Lo Duct contains glycol. Do not give access to children. Injurious to health

when drunk.

3. Gas connection

At the rear of the machine a cylinder mounting position is provided. The cylinders must always be
secured with the chains. Fit the regulators and the gas hoses for Ar/H

2

and Ar to the cylinders.
Connect the other ends of the hoses to the corresponding connections clearly marked on the back
side of the machines. Open the valve of the bottle slowly and adjust the gas pressure to 6 bar.

Optional two different flow meter slide-in modules are available. It depends on the welding
application which type of flow meter slide-in module is required.

Welding gas: Pilot gas: Slide-in module: Standard at:

0 - 20 l/min 0 - 1 l/min 1 261 046 PLW 202
0 - 12 l/min 0 - 7 l/min 1 261 035 PLW 402

4. Torch connection

The manual welding torches PT 75 and PT-150 as well as the machine torches PT-8 and PT 300 can
be connected with the central connector easily and without tools. Make sure, that the water in- and
outlet hoses are connected to the corresponding colour coded quick connections.

At socket

A the control plug is connected, when manual torches are fitted, whereas a foot switch has

to be fitted to this socket, when machine torches are used.
The pilot circuit is connected to the torch via socket

C.