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Schematic_Mech_Elec/m2 Plasma Smart Plasmarc 200 Cutting System
Instruction manual
48 pgs5.68 Mb0
Instruction manual
64 pgs7.41 Mb0

ESAB Schematic_Mech_Elec/m2 Plasma Smart Plasmarc 200 Cutting System Instruction manual

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575v
y
T
(
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(
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A
)
A
T
T
V
c
)
R
T
g)
T
g)
)
R
(
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(
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T
T
T
L
K
g
T
T
g
g
V
V
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V
Y
)
R
S
g
S
S
0558012393
0558012392
400v CE
0558012391
380v CCC
0558012390
ITEM
NO
230/460v
PART NO SYMBOL DESCRIPTION
575v
0558012393
0558012392
400v CE
0558012391
380v CCC
222210558012490 SKID 4 x 4 1111570558038416 88882 36635 CLIP SKID 1111580558038382 111130558012483 BASE 1111590558038419 444440558012484 LEG A-FRAME 1111600558012288 111150558012485 SHELF 1111610558007255 111160558011907 SUPPORT SHELF LEFT 1111620558010711 111170558011908 SUPPORT SHELF RIGH 111180558012506 BAFFLE LOWER 111190558010788 BAFFLE UPPER
Base
Shelf
1111100558010731 COVER ACCESS MAIN XFMR TAPS (Shelf
1 1 1 - 63 0558010751
- - - 1 64 0558010713 2222650558007736 8888660560947008
1111110558010787 COMPARTMENT INPUT POWER CONNECTION 1111670558010765 1111120558012416 BOX CONTROL 2222680558006886 1111130558012496 COVER CONTROL BOX SILK SCREENED 33336917300002 1111140558012502 CAP CORNER LEFT FRON 1111150558012503 CAP CORNER RIGHT FRON
44447017300008 11117117280215
1111160558010728 PANEL OUTPUT CONNECTION 11117217280230 1111170558010738 PANEL CONTROL CONNECTION SILK SCREENED 1111730558000749 1111180558010739 PANEL ACCESS FRONT 1111740558007484 1111190558010729 PANEL REAR SILK SCREENED - - - 1 75 0558010761 1111200558007264B PANEL ACCESS INPUT POWER CONNECTION 111176 35908 1111210558012410 PANEL SIDE LEFT 222277 678025
ITEM
NO
230/460v
0558012390
PART NO SYMBOL DESCRIPTION
C1 K2 K1 K1
K4,5
RB1-(1-8)
RB1
HS1,2
R1,2,3
R4,5,6,7
R8 R9 M1 M2
TB5
PA
WORK / ETRODE
PC BOARD - CONTROL PC BOARD - DRIVER PCB INTERFACE CONTROL w/ Displa PWR SUPPLY 24VDC 5A PCB CAPACITOR ALUM 6000uF 450VDC CONTACTOR 3P 40A 24VAC CONTACTOR 3P 75A 115VAC CONTACTOR 3P 150A 115VAC RELAY 3PDT 24VAC 10 RELAY ASSY SPDT 24VDC 6A w/ BASE ADAPTOR 8 x RELAY ASSY SPDT / RIBBON 14 PIN TRANSDUCER CURRENT 300 RESISTOR 2 OHM 300W RESISTOR 8 OHM 300W RESISTOR 1.5K OHM 100W RESISTOR 3K OHM 100W MOTOR FAN 1/3 HP 230V MOTOR COOLANT PUMP 1/2 HP 115/230 TERMINAL BOARD INPUT (200)230V / (400)460V TERMINAL BOARD ASSY - Pilot Ar
TERMINAL OUTPUT ASSY (Bussbar 1111220558012411 PANEL SIDE RIGHT - - - 6 78 672065 TERMINAL STRAP 1111230558012409 PANEL TOP 111179 951814 111124
0558012412
PLATE MOUNTING COOLANT PUMP MOTO 1111250558012487 PANEL COOLING DUCT LEF 1111260558012419 BRACKET HEAT EXCHANGER RIGH
111180 951815 2222810558008806
- 2 - - 82 0558011726
111127 36043 BRACKET FAN GALVANIZED - 1 - - 83 0558011727
- 1 - - 28 0558007870 BRACKET HARMONIC INDUCTO
- 1 - - 84 0558011728 1111290558011968 BRACKET IGBT / CAP / COLD PLATE MODULE 1111850558007895 2222300558010784 BRACKET MOUNTING 4x RESISTOR HORIZONTAL
Base
111186 950829 44443199512069 BRACKET RESISTOR #12 1111870558000433 2222320558006596 BRACKET MOUNTING 4x RESISTOR VERTICAL 1111330558012422 PANEL CONTROL BOX LEF 1111340558012423 PANEL CONTROL BOX RIGH
Shelf
1111880558011503
3333890558007710
333390 952136 HOLDER FUSE MIDGE 1111350558012413 BRACKET T-STRAINER / FLOW SENSOR ASSY 222291 673905 1111360558012424 PANEL MOUNTING INTERFACE CONTRO 2222370558012425 BRACKET RAS-2 111193 1111380558012417 BRACKET COOLANT TAN 1111390558012505 SPACER COOLANT TANK GROMME 1111400558010755
- 1 - - 41 0558010782
- 1 - - 42 13732232
- 1 1 - 43 0558012406
- - - 1 44 0558010746 1 - - - 45 0558011717 1111460558012004
L1 L2 L4 T1 T1 T1 T2
INDUCTOR OUTPU REACTOR LINE CE 3 PHASE 111197 952026 INDUCTOR HARMONIC CE 222298 952073 TRANSFORMER MAIN 380/400 TRANSFORMER MAIN 200-460 TRANSFORMER MAIN 575 KIT TRANSFORMER CONTROL 200-575V w/ FERRULES 11111020558008087 MARKER PLATE (13-24
111192 951085
950711 1111940558001010 111195 950487
- - - 1 96 950826
11119913730583 2222100 952155 MARKER PLATE (1-12 11111010558954324 OVERLA
1111470558011930 BUSBAR POSITIVE 1111103 952937 2222480558011931 BUSBAR NEGATIVE / COLLECTO 2222490558007275 PLATE DIODE MOUNTING Pos / Ne
11111040558010758 11111050558011612
222250 34916 BUSSBAR TAB 11111060558011932 1111510558011909 COLD PLATE POWER IGBT 11111070558012053 1111520558008823 HEATSINK PA IGBT 11111080558011703 2222530558006183 1111540558007886 3333550558003658 3333560558003657
Q1,2
Q5 D2,4,6 D1,3,5
KIT IGBT CHOPPER 400A 1200V w/ PLUG 22221090558007808 IGBT 50A 1200V 11111100558010255 DIODE FORWARD 300A 1200V 1111111
0558011993
DIODE REVERSE 300A 1200V 11111120560986171
PL1
FL1 FN1,2 FN4,5
FN3
L3
D7,8
CB1
CB2 ENC1
F1,2,3
F4,5
TS1
TS2
TB1
TB4
TB6
TB3 TB2,3
TB7
J1
J2 / PCB1-P15
PCB1-P6 / RB1
PCB1-P20 / DB25
PCB4-X1 / DB37
PCB1-P12 / PCB2-P2
PCB2-P8,11
PCB1-P8 PCB1-P1 PCB2-P3
LAMP WHITE 14V PANEL LAMP AMBER 12V PANEL FILTER MODULE (Rin FILTER MODULE CE (Rin FILTER MODULE CE (Faston FILTER INDUCTOR CE 1 PHASE KIT MOV 275VAC 140J CIRCUIT BREAKER 3A 32VDC 250VAC CIRCUIT BREAKER 2A 32VDC 250VAC THUMB WHEEL POT w/ KNOB ICH FUSE MIDGET SLO-BLO 15A 600V
FUSE LINK 150A 250V SWITCH THERMAL N/C 80°C 176°F SWITCH THERMAL N/C 90°C 194°F BLOCK TERMINAL 3P (14-2/0)aw BLOCK TERMINAL 2-POS x 4 FASTON BLOCK TERMINAL 5-POS x 4 FASTON BLOCK TERMINAL 7-POS (12-18)aw BLOCK TERMINAL 12-POS (12-18)aw BUSHING TERMINAL FAST 1/4" MALE .687MH
RECEPTACLE PNL MT HOUSING FEMALE 14 POS X-Rotation KIT RCPT PNL MT (M12) 8 SOCKET w/ 3 & 6 POS PLUG RIBBON CABLE ASSY 14 SKT 18" RIBBON CABLE ASSY (DB25 SKT - 26 SKT) 20" RIBBON CABLE ASSY (DB37 SKT - 40 SKT) 20" RIBBON CABLE TWISTED PAIR ASSY 26 SKT 20" LEAD ASSY DRIVER PC BOARD CONNECTOR MINI-COMBICON 4 PO CONNECTOR MINI-COMBICON 6 PO CONNECTOR COMBICON 2 PIN
Page 1
ITEM
575v
0558012393
0558012392
400v CE
0558012391
380v CCC
NO
230/460v
0558012390
3333113
PART NO SYMBOL DESCRIPTION
951005 1111114 951007 11111150560986173 111111656995342 22221170558008954 1111118 950640 11111190558012290 11111200558011836 11111210558012289
PCB1-P2,16 , PCB2-P5
PCB1-P3 PCB1-P9 PCB4-X3
J3,5
P5
PCB5-P1
J6
PCB5-P2
575v
400v CE
0558012393
0558012392
380v CCC
0558012391
CONNECTOR COMBICON 3 PIN 33331690558007179 TERM LUG, MECHANICAL 17/32" 6-1/0 AWG CONNECTOR COMBICON 5 PIN 2222170 647361 CONNECTOR COMBICON 8 PIN 1111171 98W68 CONNECTOR BL 5 POS 33331720558009292 FERRULE NON-INSULATED 1/0 HOUSING UNIV CAP 3 POS - Wht - - - 6 173 0558011877 FERRULE NON-INSULATED 2 AWG HOUSING UNIV PLUG 3 POS - Wht - 6 6 - 174 0558011878 FERRULE NON-INSULATED 6 AWG HOUSING CONTACT 3 POS - Molex 6 - - - 175 0558011879 FERRULE NON-INSULATED 8 AWG HOUSING UNIV CAP 6 POS - Wht 7777176 46n08 ROD THREADED #8-32 x 9.75" LG HOUSING CONTACT 6 POS - Molex 14 14 14 14 177 91w19 WASHER CENTERING
ITEM
NO
230/460v
0558012390
PART NO SYMBOL DESCRIPTION
GND2 GND1
LUG, MECHANICAL (2-8)AWG LUG, MECHANICAL (4-3/0)AWG
11111220558007485 PUMP COOLANT 225PSI 125GPH 14 14 14 14 178 647182 WASHER INSULATING MICA 11111230558007501 COUPLING 3-PC - COOLANT PUMP 666617913734871 CLAMP WORM GEAR .250-.625 11111240558007502 ADAPTOR COOLANT PUMP / MOTOR 16 16 16 16 180 0558006557 SCREW PHL HEX #10-32 x .50 w/ FLW Blk 11111250558003078 HEAT EXCHANGER 22221810558002087 SCREW PHL HEX w/ FLW M5 x 12 11111260558012489
(LS1)
KIT TANK COOLANT w/ LEVEL SWITCH 66661820558006737 SCREW PHL HEX w/ FLW M6 x 12 11111270558011981 T-STRAINER 100-MESH SCREEN 3/4NPTF 4444183 * JACK SCREW #4-40 HEX 5/16" LG 111112813735508 SHROUD FAN POLY 14" 2222184 * SCREW HEX CAP 1/2-13 x 1.50 1111129 36173 BLADE FAN 14" 11 11 11 11 185 * SCREW HEX CAP 1/4-20 x .50 11111300558012488
FS1 / P3
KIT SENSOR TURBINE FLOW w/ PLUG 25 L/MIN 18 18 18 18 186 * SCREW HEX CAP 1/4-20 x .63 11111310558012421 REGULATOR BACK-PRESSURE R-22-175 4444187 * SCREW HEX CAP 1/4-20 x .75 2222132 21124 CHECK VALVE 1/4NPTF 2222188 * SCREW HEX CAP 1/4-28 x .50 1111133 58v75 ADAPTOR BULKHEAD LH B/A-W*F 1/4NPTM 8888189 * SCREW HEX CAP 3/8-16 x 4.00 1111134 33033 ADAPTOR BULKHEAD RH B/A-W*M 1/4NPTM 3333190 * SCREW HEX CAP 3/8-16 x .75 5555135 10Z30 ADAPTOR RH B/A-W*M 1/4NPTM 6666191 * SCREW HEX CAP 3/8-16 x 1.00 2222136 74S76 ADAPTOR RH B/IG*F 1/4NPTM 7774192 * SCREW HEX CAP 5/16-18 x 1.00 222213768100126 BUSHING 1/4NPTF 3/8NPTM 93 97 93 95 193 * SCREW HEX WSH TRI 1/4-20 x .50 222213868100276 BUSHING HEX 3/4NPTM 1/4NPTF 24 24 24 24 194 * SCREW HEX WSH TRI 1/4-20 x .50 Serrated 222213944261400 ELBOW PIPE 45° 1/4NPT 4644195 * SCREW SQ PAN TRI #10-24 x .38 22221400558006693 ELBOW STREET 45° 1/4NPT 33 33 33 33 196 * SCREW SQ PAN TRI #10-24 x .50 2222141 182w82 ELBOW STREET 90° 1/4NPT 4444197 * SCREW SQ PAN TRI #10-24 x .63 111114267100463 NIPPLE 1/4NPT 3"LG - - - 4 198 * SCREW SQ PAN TRI #10-24 x .75 22221432226715 NIPPLE HEX 1/4NPT 1-7/16"LG 4444199 * SCREW SQ PAN TRI #10-24 x 1.00 2222144 461107 TEE STREET 1/4NPT 10 10 10 10 200 * SCREW SQ PAN TRI #4-40 x .25 222214568100175 BUSHING HEX 1/2NPTM 1/4NPTF 4444201 * SCREW SQ PAN TRI #6-32 x .25 11111460558006271 BUSHING 1/4NPTM 1/8NPTF 12 12 12 12 202 * SCREW SQ PAN TRI #6-32 x .38 222214768121050 COUPLING 1/2NPT 7/8"LG 2222203 * SCREW SQ PAN TRI #6-32 x .63 22221482234485 CLAMP END DIN 35 RAIL 8888204 * SCREW SQ PAN TRI #6-32 x .75 11111490558012427 RAIL MOUNTING 3.5" DIN (35/7.5) PERFORATED - - - 2 205 * SCREW SQ PAN TRI #6-32 x 1.00 11111500558011992 BAFFLE IGBT Kydex 22 22 22 22 206 * SCREW SQ PAN TRI #8-32 x .38 11111510558007276 INSULATOR DIODE BRIDGE Kydex 6666207 * SCREW SQ PAN TRI #8-32 x .50
- 1 - - 152 680398 INSULATOR LINE REACTOR Nomex 2222208 * SCREW SQ PAN TRI #8-32 x .63 11111530558007288 INSULATOR TERMINAL BLOCK Kydex 8888209 * SCREW LAG 1/4 x 2.00 44441540558012054 STANDOFF STEEL FEMALE #6-32 HEX 3/4" LG 19 19 19 23 210 * WASHER FLAT #10 11111550558001018 STANDOFF GLASTIC FEMALE 1/4-20 HEX 1" LG 6666211 * WASHER FLAT #6 4444156 672225 STANDOFF GLASTIC FEMALE 1/4-20 HEX 1.25" LG 21 21 21 18 212 * WASHER FLAT #8 22221572235785 CLAMP CABLE STEEL .312 DIA 6666213 * WASHER FLAT 1/2 11111580558012504 CLAMP TUBE .625 DIA 51 51 51 51 214 * WASHER FLAT 1/4 11111590558004079 STRAIN RELIEF 2" STEEL 25 25 25 25 215 * WASHER FLAT 3/8 3333160 950823 BUSHING SNAP .56ID .69MH 10 10 10 4 216 * WASHER FLAT 5/16 8888161 639533 BUSHING SNAP .88ID 1.09MH 1111217 * WASHER FLAT NYLON 19/32 (Pg9) Blk 5555162 647345 BUSHING SNAP 1.31ID 1.50MH 4444218 * SCREW SKT HEX M6-1.0 x 12 Blk 11111630558012420 GROMMET RUBBER 4.19ID COOLANT TANK 12 12 12 12 219 * SCREW SKT HEX M6-1.0 x 20 Blk 1111164 647270 BUSHING SNAP .31ID .44MH - - - 18 220 * WASHER FLAT BRASS 1/4 11111650558004053 GROMMET RUBBER 2.12ID 2.50GD .06W 12 12 12 12 221 * WASHER FLAT M6
AR AR AR AR 166 90861100 TUBING PVC, 600V 105C, 1" BLACK 1111222 * WASHER FLAT M16 AR AR AR AR 167 90862010 TUBING PVC, 600V 105C, 1.25" BLACK 28 28 28 32 223 * WASHER LOCK #10
11111680558010374 JUMPER 2 POS Red 7777224 * WASHER LOCK #6
Page 2
575v
A
A
A
A
A
A
A
A
T
)
(
)
A
A
A
A
A
Y
E
L
A
A
A
E
ARARARA
ARARARA
ARARARA
ARARARA
ARARARA
ARARARA
0558012393
0558012392
400v CE
0558012391
380v CCC
0558012390
230/460v
ITEM
NO
PART NO SYMBOL DESCRIPTION
575v
0558012393
0558012392
400v CE
0558012391
380v CCC
ITEM
NO
230/460v
0558012390
PART NO SYMBOL DESCRIPTION
25 25 25 22 225 * WASHER LOCK #8 2522281 * TYWRAP X-LG 14.5"
3333226 * WASHER LOCK 1/2 1111282 * TYWRAP SCREW MOUNT LG 7.25"
39 39 39 39 227 * WASHER LOCK 1/4 1111283 * BAG CLOTH 4" x 6" 16 16 16 16 228 * WASHER LOCK 3/8 1111284 N
7774229 * WASHER LOCK 5/16 1111285 N
- - - 18 230 * WASHER LOCK BRONZE 1/4 1111286 N 1111231 * WASHER LOCK EXT #6 - - - 1 287 N 3333232 * WASHER LOCK EXT #8 - - 1 - 288 N 1111233 * WASHER LOCK INT 1/2 - 1 - - 289 N 1111234 * WASHER LOCK EXT 3/8 1 - - - 290 N 1111235 * WASHER LOCK EXT 5/8 1111291 N
16 16 16 16 236 * WASHER LOCK M6 11112920558038423
WIRE KIT EPP-202/362 WIRE KIT INTFC CTRL m2-200 CABLE KIT m2/m3-202 COMMON CABLE KIT m2/m3-202 200/230/460V CABLE KIT m2/m3-202 380V CCC CABLE KIT m2/m3-202 400V CE CABLE KIT m2/m3-202 575V HOSE KIT m2/m3-202 PC BOARD - FILTER
32 32 32 32 237 * NUT #10-24 1111293 995204 LABEL TEXT WARNING HAZARD COVER
7777238 * NUT #6-32 11112940558012565
R10 / C3
KIT RC-SNUBBER PA IGB
4444239 * NUT LOCK #8-32 1111295 952157 FERRITE CORE / CUBE (Supplied for System CAN Cable
21 21 21 18 240 * NUT #8-32 11112960558954341 LABEL FERRITE CORE / CAN CABLE
3333241 * NUT 1/2-13 6666297 * WASHER LOCK #4
23 23 23 23 242 * NUT 1/4-20 6666298 * WASHER FLAT #4
- - - 18 243 * NUT BRASS 1/4-20
12 12 12 12 244 * NUT 3/8-16
3 3 3 - 245 *
NUT 5/16-18 3333246 * NUT LOCK NYLON #8-32 6666247 * NUT 3/4-16 JAM 1111248 * BOLT CARRIAGE 1/2-13 x 1.75 4444249 * RIVET 1/8
- - - 1 250 N
- - 1 - 251 N
- 1 - - 252 N 1 - - - 253 N 1111254 N
LABEL RATING EPP-202 200/230/460V LABEL RATING EPP-202 380-400V CCC LABEL RATING EPP-202 400V CE LABEL RATING EPP-202 575V LABEL NAMEPLATE Stock / Serial No
.126-.187
11112552091514 LABEL WARNING GENERAL ARC WELD & CUT
- - 1 - 256 0558954289 LABEL WARNING GENERAL ARC WELD & CUT Chinese 1111257 995110 LABEL WARNING EXPOSED VOLTAGE INSIDE 1111258 954291 LABEL WARNING COOLANT GENERAL 11112590558954172 LABEL CAUTION GROUNDED PNL / REMOVE CAREFULL 11112602091558 LABEL PE GROUND 1111261 954509 LABEL SYMBOL CAUTION HIGH VOLTAG 1111262 955269 LABEL SYMBOL CAUTION READ MANUA 111126313732733 LABEL COPPER WIRE ONLY Wht/Clr 1111264 954507 LABEL WORK/ PILOT ARC/ ELECTRODE Wht/Clr 11112650558954244 LABEL COOLANT FILL Blk/Wht
- 1 - - 266 N
- - 1 - 267 N
LABEL CE - Plain
LABEL CCC 11112680558954292 LABEL SET EPP-202/362 22222690558954334 LABEL ESAB DIE CUT 16.0 x 9.0 Blk 1111270 N
LABEL ISO 9001 11112710558008436 LABEL CHASSIS GROUND 2222272 951833 PAD THERMAL POWER IGBT MODULE 1111273 951191 PAD THERMAL PA IGBT MODUL 11112740558954328 LABEL PC BOARD LAYOUT m2/m3-202
R 275 * ADHESIVE THREADLOCKER LOCTITE 242 - Blue R 276 * SEALANT THREAD LOCTITE PST 592 - White R 277 * ADHESIVE SILICON RUBBER DOW 732 - Clear R 278 * COMPOUND ELECTRICAL JOINT ALCOA #2 R 279 * TYWRAP LG 7.25" R 280 * TYWRAP MED 5.5"
Page 3
575v
0558012393
0558012392
400v CE
0558012391
380v CCC
0558012390
ITEM
NO
230/460v
PART NO SYMBOL DESCRIPTION
0558010798 Kit IGBT / Cap / Heatsink Module m2-200
(Includes) Includes the Following Items:
1111470558011930 BUSBAR POSITIVE 2222480558011931 BUSBAR NEGATIVE / COLLECTOR 1111510558011909 COLD PLATE POWER IGBT 2222530558006183 1111580558038382 1111610558007255 111192 951085 22221090558007808
Q1,2
C1
TS1
PCB2-P8,11
KIT IGBT CHOPPER 400A 1200V w/ PLUG
PC BOARD - DRIVER
CAPACITOR ALUM 6000uF 450VDC
SWITCH THERMAL N/C 80°C 176°F
LEAD ASSY DRIVER PC BOARD 11111550558001018 STANDOFF GLASTIC FEMALE 1/4-20 HEX 1" LG 1111290558011968 BRACKET IGBT / CAP / COLD PLATE MODULE 66661820558006737 SCREW PHL HEX w/ FLW M6 x 12 1111185 * SCREW HEX CAP 1/4-20 x .50 2222188 * SCREW HEX CAP 1/4-28 x .50
12 12 12 12 219 * SCREW SKT HEX M6-1.0 x 20 Blk
2222202 * SCREW SQ PAN TRI #6-32 x .38 3333214 * WASHER FLAT 1/4 3333227 * WASHER LOCK 1/4
12 12 12 12 236 * WASHER LOCK M6
2222272 951833 PAD THERMAL POWER IGBT MODULE
575v
0558012393
0558012392
400v CE
0558012391
380v CCC
0558012390
230/460v
ITEM
NO
PART NO SYMBOL DESCRIPTION
0558012477 KIT COOLANT PUMP m2-200
(Includes) Includes the Following Items:
11111220558007485 PUMP COOLANT 225PSI 125GPH 2222135 10Z30 ADAPTOR RH B/A-W*M 1/4NPTM 222213768100126 BUSHING 1/4NPTF 3/8NPTM 1111144 461107 TEE STREET 1/4NPT 1111141182W82 ELBOW STREET 90° 1/4NPT 1111136 74S76 ADAPTOR RH B/IG*F 1/4NPTM
126 0558012489 KIT TANK COOLANT m2-200
(Includes) Includes the Following Items:
1111301 NA TANK COOLANT 11113020558010759 CAP COOLANT TANK 11113030558011991
LS1
SWITCH COOLANT LEVEL w/ LEADS 22223040558011884 NIPPLE COOLANT TANK 3/8 HOSE 22223050558011883 WASHER RUBBER 0.516 ID x 0.781 OD x .063 NBR 2222306 * WASHER FLAT 1/2 2222307 * NUT 1/2-20 JAM
ADDITIONAL SPARES
1111308 19972 STRAINER - COOLANT PUMP 11113090558011982 O-RING 1" 100-MESH T-STRAINER 11113100558011983 SCREEN 100-MESH T-STRAINER
COOLANT HOSE SPARES
1111-0558011605 HOSE 28.00" TANK OUTLET to PUMP INLET 1111-0558011603 HOSE 13.00" PUMP OUTLET to REGULATOR INLET 1111-0558011601 HOSE 16.50" PUMP OUTLET to TORCH SUPPLY 1111-0558011606 HOSE 20.00" RADIATOR OUTLET to FILTER INLET 1111-0558011599 HOSE 34.00" FLOW SENSOR OUTLET to COLD PLATE INLET 1111-0558011602 HOSE 31.00" TORCH RETURN to RADIATOR INLET
Page 4
T1
T1
2X 30
71
H
OR
575V only
45
4X
4X
43
4
CCC & CE Units only
OR
X
162
T1
44
4X
70
200/230/460V Only
160
4X
1.5k ohms
3.00kohm
193
4X
195
72
4X 31
12X 194
8X
2X
2X 2X
2X
209
223
196 237
210
2
1
2402X176
(TYP 4 PLCS)
2X
8X
2X
225
212
DETAIL X
SCALE 2 : 1
2X
177 178
70
2X 2X
8 196
2X 2X
2X
6X
206 225
240
3
DETAIL H
SCALE 2 : 1 (TYP 2 PLCS)
233
213
226
241
4X 4X 4X
A
215 228 244
222
248
4X 4X
215 189
G
NOTE:
4 Quantity of Foot should be supplied with ITEM NO: 3
244 228 215
215
189
DETAIL G
SCALE 2 : 3
TYP 4 PLCS
DETAIL A
SCALE 1 : 1
EPP-202-M2 TOP
ASSEMBLY FAMILY
0558012389-C
SHEET 5
161
2X 49
91
F5
ORIENT BUSBAR VERTICALLY, 3 PLCS, FOLD 6 INCHES OF TUBING IN HALF TO CREATE COVER FOR BUSBAR, SECURE WITH TYWRAP
TYPICAL CONNECTION, 3 PLCS,
COVER CONNECTION WITH 4
INCHES OF TUBINGAND SECURE
WITH TYWRAP
167
4X
151 193
279
V
T
166 280
NOTE: APPLY EJC ESAB P/N 73585980 TO ALL CONNECTIONS
4X
194
40 L1
W
161
161
DETAIL V
SCALE 1 : 1
2X
186 214 227 242
2X
186 214 227 242
DETAIL U
SCALE 1 : 1
81
FN1
281
TYPICAL CONNECTION, 6 PLCS, COVER WITH 4 INCHES OF TUBING, SECURE WITH TYWRAP
D2
55 247
NOTE: APPLY EJC ESAB P/N 73585980 TO ALL CONNECTIONS
166 280
U
2X
TS2 93 202
D1
1872142X242
227
56 247
F4,F5
2X
91
2X
186 214
4X
227
2X 2X
242
REMOVE SECTION OF BUSBAR
AND INSTALL F4 AND F5 AS SHOWN
(TYPICAL 2 PLCS)
DETAIL T
SCALE 1 : 1
167 279
DETAIL W
SCALE 1 : 2
186 242 214
2X
227
(TYP 3 PLCS)
(TYP 2 PLCS)
TYPICAL CONNECTION, 2 PLCS, COVER WITH 4 INCHES OF TUBING AND SECURE WITH TYWRAP
2X
AA
192
216 229
245
161
DETAIL AA SCALE 1 : 1
167
D4
55
247
4X
156
(Input connection of Transformer of CE, CCC, AND 575V UNITS ONLY)
TYPICAL CONNECTION,
3 PLCS, COVER
CONNECTION WITH 4
INCHES OF TUBINGAND
SECURE WITH TYWRAP
185 214 227
(TYP 4 PLCS)
55 247
D6
56 247
D5
D3
56
247
FN2
81
281
EPP-202-M2 TOP
ASSEMBLY FAMILY
0558012389-C
SHEET 6
244228190
(TYP 2 PLCS)
Q5
2X
2X
4X
2X
193 170
271
54 199
237
27352
223
210
2X
85 181
294 202
165
2X
4X
(TYP 3 PLCS)
2X
196
2X
210
2X
223
2X
237
DETAIL AB
SCALE 1 : 1
2X 2X 3X
(TYP 3 PLCS)
240 225 212
2X 2X 2X
100
160
(TYP 3 PLCS)
177 178
5
2X 32
10193
AB
3X 69
160
176
(CE UNIT ONLY)
82
FN4
281
129
M1
(CE UNIT ONLY)
FN5
82
281
185 227 214
(TYP 4 PLCS)
28
L4
42
4X
193
(CE UNIT ONLY)
2X
193
281
83
FN3
(CE UNIT ONLY)
84
L3
(CE UNIT ONLY)
46
T2
193
3X
98
204
3X
100
TB3
102
97
204
TB3
2X
161
98
204
9
193
161
3X
2X
4X 4X
73 212 239
2X
27
194
EPP-202-M2 TOP
ASSEMBLY FAMILY
0558012389-C
SHEET 7
CONNECT TO PCB1 J12
PCB2-P2
PCB2-P5
200
113
108
58
PCB2
200
2X
112
179
PCB2-P3
155
185 227 214
NOTE: FOLLOW TORQUE SPECS LISTED ON IGBT DRAWING
4X
221
TYP 2 PLCS
4X
236
4X
219
61 2142X2272X188
C1
2X
51
2214X2364X219
4X
48
Q1, Q2 53
272
TS1
92
2X 2X
2X
202
29
TO TANK INLET
HS1
6868206
HS2
2X
206
2X
FROM FLOW SENSOR TEE
2X
109
PCB2-P8,11
USE EJC (ITEM ) ON ALL BUS BAR BOLTED CONNECTIONS
182
278
NOTE: FOLLOW TORQUE SPECS LISTED ON IGBT DRAWING
6X
48
47
TYP CONNECTION,
3 PLCS,
COVER EACH W/4 INCHES OF VINYL TUBE
166
3X
Ref.
48 214 227 242 186
(TYP 3 PLCS)
EPP-202-M2 TOP
ASSEMBLY FAMILY
0558012389-C
SHEET 8
NOTE: ORIENTATION OF
CHECK VALVES
TO RADIATOR INLET TEE
16
PCB3
292
2X
200
50 1912152X228244
(TYPICAL 2 PLCS)
FROM PUMP OUTLET
135 136
2X
139
2X
143
2X
132
2X
140
2X
2X
207
225
225
207
2X
2X
133
134
76
PA
208
2X
237
4X
77
197
4X
2X
169 184
2X
213 226 241
(TYPICAL 2 PLCS)
REF
133
134
REF
264
170
EPP-202-M2 TOP
ASSEMBLY FAMILY
0558012389-C
SHEET 9
214
2X
227
2X
185
2X
193
24
5
4X
Ref.
Ref.
144
135
137
131
146
35
TO PUMP OUTLET
144 145 147 130 147 145 142 138 127 138 141 135
135
TO COLD PLATE INLET
NOTE ORIENTATION
TO RADIATOR OUTLET TEE
NOTE ORIENTATION OF FILTER
TO Back Pressure REGULATOR INLET
OF PUMP
135
123
GROUND TETHER POINT FOR SIDE AND TOP PANEL
TO TANK OUTLET
3X
2X
193
206
196
196
11
5X
141
137
122124136
308
192 229 216
4X 4X 4X
24
74
M2
191 228 215
(TYP 4 PLCS)
4X 4X 4X
187 227 214
6
TO TORCH OUTLET
3X 3X 3X
2X
194
3X
193
8X
193
193
4X
7
EPP-202-M2 TOP
ASSEMBLY FAMILY
0558012389-C
SHEET 10
302
NOTE: ORIENT FLAT SURFACE OF STEM FACING UPWARD. SUPPLIED WASHER LOCATED INSIDE TANK.
25
303
(TO PUMP INLET)
301
Ref.
305304 307306
2X 2X 2X 2X
(FROM IGBT OUTLET)
(TO TORCH INLET)
(TO FILTER INLET)
(TO PUMP INLET)
2X
179
(FROM IGBT OUTLET)
4X 4X
1X
2X
26
237 223
125
179
193
2X
38
12
237
2X
Ref.
223
2X
EPP-202-M2 TOP
ASSEMBLY FAMILY
0558012389-C
SHEET 11
(TYP 9 PLCS)
TB6
2X
220
TB5
6X
2X
205
2X
230
75
200/230/460V Unit Only
78
96
2X
243
(200/230/460V UNIT)
4X 4X 4X 6X
K2 62
206
K1
64 198 223 210 173
193
41
L2
195
(CE UNITS ONLY)
(CE ONLY)
152
Ref.
OR
174
63
K1
(CE, CCC, AND 575V UNITS ONLY)
212 225 240
175
(575V)
3X 3X 3X
171190215234
GND1
153
260
94 TB1
199
2X
162
Ref.
11
25
(TYP 2 PLCS)
242
227
2X
2X
126
26
Ref.
EPP-202-M2 TOP
ASSEMBLY FAMILY
0558012389-C
SHEET 12
67
RB1
2X
148
2X
2X
J3
117
Y
12
PCB1-P3
114
TB7
99
Z
2X 65
4X
4X
4X
8X 66
SECTION Y-Y
SCALE 1 : 2
238
2242X211
149
2X
2X
298
297
168 INSTALL JUMPER PER
WIRING SCHEMATIC/DIAGRAM
Connect to RB1
2X
200
105
PCB1-P6
113
PCB1-P16
Y
57
PCB1
111
PCB1-P1
120
PCB1-P2
113
PCB1-P8
110
PCB1-P9
115
Z
J5J6
118117
P5
Note: Connect to P6(Ref. drawing of J2)
K4K5
SECTION Z-Z
SCALE 1 : 2
238
TB4
95
203
GROUND
211
2X
224
231224238
Ref.
34
4X
2234X237
Ref.
33
PCB5
4X
PCB5-P2
60
200
121
Ref.
36
282 237 210
PCB5-P1
119
4X
116154
PCB4-X3
PCB4
59
4X
201
Ref. PCB4-X1
ENC1
101
88
36
223
EPP-202-M2 TOP
ASSEMBLY FAMILY
0558012389-C
SHEET 13
163
F3
19
2X
CB2
Connect to PCB1-P20
PCB1-P20 / DB25
298
297
2X
Connect to PCB4-X1
PCB4-X1 / DB37
297
2X
2X
298
2X
183
2X
183
2X
39
33
87
34
106
1X
107
1X
2X
4X
20
180
159
263 164
257
128 196
90
202
F1
2X
90
202
2X
F2
90
202
CB1
86
249
2X
254 249
2X
89
89
89
J2
104
223
J1
235
193
4X
103
217
157237
17
296
293
206
2X
12
Ref.
206
6X
17
REF
150 207
2X
252
253
251 267
250
230/
460V
UNIT
CCC
UNIT
575V
UNIT
CE
UNIT
266
CE
UNIT
OR
CCC
UNIT
0558012389-C
EPP-202-M2 TOP
ASSEMBLY FAMILY
SHEET 14
(REF)
19
THERE MUST BE A MINIMUM OF .630 INCHES (16MM) CLEARANCE BETWEEN THE FAN BLADE AND THE INSIDE SURFACE OF THE REAR PANEL AFTER INSTALLATION. ADJUST THE POSITION OF THE FAN BLADE ON THE MOTOR SHAFT AS NECESSARY TO MAINTAIN THIS CLEARANCE.
GROUND TETHER ATTACH POINT
206246232
4X
5X
194
193
Ref.
33
6X
180
Ref.
2X
180
13
2X
9X
GROUND TETHER ATTACH POINT
206 246 232
21193
9X
22
193
180
34
ATTACH FRONT PANEL GROUND WIRE AT UPPER LEFT MOUNTING
.
SCREW
196
196
157
158
EPP-202-M2 TOP
ASSEMBLY FAMILY
0558012389-C
SHEET 15
GROUND TETHER ATTACH POINT
246232
LABEL CONFIGURATION FOR: 0558012390, 0558012392 (CE), AND 0558012393 (575V) UNITS
6X
23 193
DETAIL AD SCALE 1 : 1
4X
AD
PLACE LABLE BEHIND PANEL
274
79
80
261
18
PL1
FL1
270
265
258
255 262
259
LABEL CONFIGURATION FOR: 0558012391 (CCC) UNITS
193
14
(2 Each CAP)
6X
193
15
(3 Each CAP)
( Place in center of side
269
panel 1 on Each Side)
2X
180
4X
ATTACH GROUND WIRE TO REAR OF ACCESS PANEL (#6 STUD)
270 265
258
255
262
259
256
EPP-202-M2 TOP
ASSEMBLY FAMILY
0558012389-C
SHEET 16
2 X
PART #
0558010798
0558010799
KIT IGBT/CAP/HEATSINK MODULE EPP-202
KIT IGBT/CAP/HEATSINK MODULE EPP-362
18
C1
Front View Scale 1:2
4 X
2 X
TS1
1
18
6
13
2
2 X 2 X 2 X
9 15 19 18
0558010798 ASSY
DESCRIPTION
PCB2
5
4 X
17
4 X
16
REV
A
A
ITEM
Symbol
NO.
1 0558011968
2 0558011909
3 0558011930
4 0558011931
5
PCB2
6
TS1
7
D9
8 0558001018 STANDOFF GLASTIC 1/4-20 1.0" 1 1
9
C1, C2
10
PCB2- P8-P11
11 951833
Q1, Q2 , Q3,
12
Q4
13
14
15
16
17
18
19
20 SCREW M6X12 CAPTIVE WSHRS 6 12
PART NUMBER
0558038382
951085
0558012002
0558007255
0558007808
0558006183
BOM Table
DESCRIPTION
BRACKET IGBT MODULE
COLD PLATE 4MODULE
BUS BAR POS
BUSBAR NEG/COL
PCB DRIVER
SWITCH THERMAL 176F
KIT DIODE REVERSING 85A 1200A
CAP ELECT ALUM 6000UF 450V
DRIVER BOARD LEAD ASSEMBLY
PAD THERMAL IGBT
IGBT MODULE 400A 1200V
#6-32 X .38 PAN SCREW QUADREX
1/4-20 X .5 HEX CAP SCREW
1/4-28 X .5 SCR STLZPC
SCREW SKT HEX M6-1.0 x 20
LOCKWASHER M6
1/4 FLAT WASHER
1/4 LOCK WASHER
0558011310/QTY.
0558011314/QTY.
11
11
11
22
11
11
11
12
24
24
24
22
11
24
12 20
12 20
35
35
Q1 Q2
Bottom View Scale 1:2
4 X174 X203 X
12 16
(TYP. 2 PLCS)
11
D9
7
3
A
8 14 18
C1 C2
19
(TYP. 2 PLCS)
9 15 19 18
2 X 2 X 2 X
Front View Scale 1:2
0558010799 ASSY
4 X174 X203 X
Q1
Q3 Q4 Q2
12 16
3
4
(TYP. 4 PLCS)
11
4
Replacement Kit IGBT
0558011771
rev
A
SHEET 1 OF 1
ITEM NO.
PART NUMBER
DESCRIPTION
QTY.
A
30°
A A
1 0558007485 2 68100126 3 4 461107 5 6
NOTE:
1. APPLY PIPE SEALANT TO MALE PIPE THREAD USING LOCTITE #242
10Z30
182W82
74S76
PUMP COOLANT 250PSI 125GPH
BUSHING PIPE HEX 3/8 X 1/4 BRS
ADAPT B/A-W*M 1/4NPT OLD
TEE PIPE STREET 1/4 BRS
ELBOW PIPE ST 90 1/4 BRS
ADAPT B/I-G*F 1/4NPTM
1 2 2 1 1 1
(ESAB P/N 74585435) ON HARD PLUMBING CONNECTIONS UNLESS OTHERWISE SPECIFIED.
6
5
A
3
3
4
A
2
1
2
KIT COOLANT PUMP EPP-202-M2
0558012477
SHEET 1 OF 1
A
0558012575-OR
0558012575-OR
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