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Schematic_Mech_Elec/m3 Plasma EPP-202 Plasma Power Source
Instruction manual
53 pgs6.09 Mb0

ESAB Schematic_Mech_Elec/m3 Plasma EPP-202 Plasma Power Source Instruction manual

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575v
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R
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V
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R
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g
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R
R
0558011313
0558011312
400v CE
0558011311
380-400v
0558011310
ITEM
NO
200/230/460v
PART NO SYMBOL DESCRIPTION
575v
0558011313
0558011312
400v CE
0558011311
380-400v
222210558012490 SKID 4 x 4 1 1 1 - 57 0558010751 88882 36635 CLIP SKID - - - 1 58 0558010713 111130558012483 BASE 2222590558007736 444440558012484 LEG A-FRAME 8888600560947008 111150558012485 SHELF 1111610558010765 111160558011907 SUPPORT SHELF LEFT 2222620558006886 111170558011908 SUPPORT SHELF RIGH 111180558012506 BAFFLE LOWER 111190558010788 BAFFLE UPPER
Base
Shelf
1111100558010731 COVER ACCESS MAIN XFMR TAPS
Shelf
33336317300002 4444640004487048 1111650558000747
11116617280230 1111110558010787 COMPARTMENT INPUT POWER CONNECTION 1111670558000749 1111120558012416 BOX CONTROL 1111680558007484 1111130558012610 COVER CONTROL BOX LOGO SILK SCREENED - - - 1 69 0558010761 1111140558012502 CAP CORNER LEFT FRON 1111150558012503 CAP CORNER RIGHT FRON
1111700558101020
222271 678025
ITEM
NO
0558011310
200/230/460v
PART NO SYMBOL DESCRIPTION
K4,5
RB1-(1-8)
RB1
HS1,2
R1,2,3
R4,5,6,7
R8 R9 M1 M2
TB5
PA
WORK / ETRODE
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 1111160558010728 PANEL OUTPUT CONNECTION - - - 6 72 672065 TERMINAL STRAP 1111170558010738 PANEL CONTROL CONNECTION SILK SCREENED 111173 951814 1111180558010739 PANEL ACCESS FRONT 1111740558007434 1111190558010729 PANEL REAR SILK SCREENED 2222750558008806 111120
0558007264B
PANEL ACCESS INPUT POWER CONNECTION - 2 - - 76 0558011726 1111210558012410 PANEL SIDE LEFT - 1 - - 77 0558011727 1111220558012411 PANEL SIDE RIGHT - 1 - - 78 0558011728 1111230558012409 PANEL TOP 1111790558007895 1111240558012412 PLATE MOUNTING COOLANT PUMP MOTOR 1111800558000423 1111250558012487 PANEL COOLING DUCT LEF 1111260558012419 BRACKET HEAT EXCHANGER RIGH
3333810558007710 3333820558000516 HOLDER FUSE MIDGE
111127 36043 BRACKET FAN GALVANIZED 2222830558004084
- 1 - - 28 0558007870 BRACKET HARMONIC INDUCTO
1111840004487055 1111290558011968 BRACKET IGBT / CAP / COLD PLATE MODULE 1111850558000412 2222300558010784 BRACKET MOUNTING 4x RESISTOR HORIZONTAL
Base
1111860558001010 44443199512069 BRACKET RESISTOR #12 1111870558000600 2222320558006596 BRACKET MOUNTING 4x RESISTOR VERTICAL
Shelf
- - - 1 88 950826 1111330558012413 BRACKET T-STRAINER / FLOW SENSOR ASSY 111189 952026 1111340558012417 BRACKET COOLANT TAN 1111350558012505 SPACER COOLANT TANK GROMME 1111360558010755
- 1 - - 37 0558010782
- 1 - - 38 13732232
- 1 1 - 39 0558012406
- - - 1 40 0558010746 1 - - - 41 0558011717 1111420558012004
L1 L2 L4 T1 T1 T1 T2
INDUCTOR OUTPU REACTOR LINE CE 3 PHASE 1111930558008087 MARKER PLATE (13-24 INDUCTOR HARMONIC CE 111194 952937 TRANSFORMER MAIN 380/400 TRANSFORMER MAIN 200-460 TRANSFORMER MAIN 575 KIT TRANSFORMER CONTROL 200-575V w/ FERRULES 1111980558011703
222290 952073 1111910558000755 222292 952155 MARKER PLATE (1-12
1111950558010758 1111960558011612 1111970558011932
1111430558011930 BUSBAR POSITIVE 2222990558007808 2222440558011931 BUSBAR NEGATIVE / COLLECTO 2222450558007275 PLATE DIODE MOUNTING Pos / Ne
11111000558010255
11111010558011993 222246 34916 BUSSBAR TAB 11111020560986171 1111470558011909 COLD PLATE POWER IGBT 3333103 951005 1111480558008823 HEATSINK PA IGBT 1111104 951007 2222490558006183 1111500558007886 3333510558003658 3333520558003657 1111530558038416 1111540558038382 1111550558007255 1111560558010711
Q1,2
Q5 D2,4,6 D1,3,5
PCB1 PCB2
C1
KIT IGBT CHOPPER 400A 1200V w/ PLUG 11111050560986173 IGBT 50A 1200V 11111060558008954 DIODE FORWARD 300A 1200V 1111107 950640 DIODE REVERSE 300A 1200V 11111080558007485 PUMP COOLANT 225PSI 125GPH PC BOARD - CONTROL 11111090558007501 COUPLING 3-PC - COOLANT PUMP PC BOARD - DRIVER 11111100558007502 ADAPTOR COOLANT PUMP / MOTO CAPACITOR ALUM 6000uF 450VDC 11111110558003078 HEAT EXCHANGE CONTACTOR 3P 40A 24VAC 11111120558012489
PL1
FL1 FN1,2 FN4,5
FN3
L3 D7,8 CB1
F1,2,3
F4,5
TS1 TS2 TB1 TB4 TB6 TB3
TB2,3
TB7
J1
J2 / PCB1-P15
PCB1-P6 / RB1
PCB1-P20 / DB25
PCB1-P12 / PCB2-P2
PCB2-P8,11
PCB1-P8 PCB1-P1 PCB2-P3
PCB1-P2,16 , PCB2-P5
PCB1-P3 PCB1-P9
J3,5
(LS1)
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 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)awg 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 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 CONNECTOR COMBICON 3 PIN CONNECTOR COMBICON 5 PIN CONNECTOR COMBICON 8 PIN HOUSING UNIV CAP 3 POS - Wht HOUSING UNIV PLUG 3 POS - Wht
KIT TANK COOLANT w/ LEVEL SWITCH
Page 1
ITEM
T
(
ydex
ydex
x
ydex
A
A
(Pg9)
K
ARARARA
ARARARA
575v
0558011313
0558011312
400v CE
0558011311
380-400v
NO
0558011310
200/230/460v
1111113
PART NO SYMBOL DESCRIPTION
0558011981
T-STRAINER 100-MESH SCREEN 3/4NPTF 2222169 * SCREW HEX CAP 1/2-13 x 1.50
575v
0558011313
0558011312
400v CE
0558011311
380-400v
ITEM
NO
0558011310
200/230/460v
PART NO SYMBOL DESCRIPTION
111111413735508 SHROUD FAN POLY 14" 11 11 11 11 170 * SCREW HEX CAP 1/4-20 x .50 11111150558101173 BLADE FAN 14" 18 18 18 18 171 * SCREW HEX CAP 1/4-20 x .63 11111160558012488
FS1 / P3
KIT SENSOR TURBINE FLOW w/ PLUG 25 L/MIN 4444172 * SCREW HEX CAP 1/4-20 x .75 11111170558012421 REGULATOR BACK-PRESSURE R-22-175 2222173 * SCREW HEX CAP 1/4-28 x .50 22221180004470818 CHECK VALVE 1/4NPTF 8888174 * SCREW HEX CAP 3/8-16 x 4.00 11111190558000523 ADAPTOR BULKHEAD LH B/A-W*F 1/4NPTM 3333175 * SCREW HEX CAP 3/8-16 x .75 11111200558000421 ADAPTOR BULKHEAD RH B/A-W*M 1/4NPTM 6666176 * SCREW HEX CAP 3/8-16 x 1.00 55551210558000534 ADAPTOR RH B/A-W*M 1/4NPTM 7774177 * SCREW HEX CAP 5/16-18 x 1.00 22221220558004057 ADAPTOR RH B/IG*F 1/4NPTM 92 96 92 94 178 * SCREW HEX WSH TRI 1/4-20 x .50 22221230004494054 BUSHING 1/4NPTF 3/8NPTM 24 24 24 24 179 * SCREW HEX WSH TRI 1/4-20 x .50 Serrated 22221240558101735 BUSHING HEX 3/4NPTM 1/4NPTF 4644180 * SCREW SQ PAN TRI #10-24 x .38 222212544261400 ELBOW PIPE 45° 1/4NPT 33 33 33 33 181 * SCREW SQ PAN TRI #10-24 x .50 22221260558006693 ELBOW STREET 45° 1/4NPT 4444182 * SCREW SQ PAN TRI #10-24 x .63 22221270558000559 ELBOW STREET 90° 1/4NPT - - - 4 183 * SCREW SQ PAN TRI #10-24 x .75 111112867100463 NIPPLE 1/4NPT 3"LG 4444184 * SCREW SQ PAN TRI #10-24 x 1.00 22221292226715 NIPPLE HEX 1/4NPT 1-7/16"LG 6666185 * SCREW SQ PAN TRI #4-40 x .25 22221300558101063 TEE STREET 1/4NP
12 12 12 12 186 * SCREW SQ PAN TRI #6-32 x .38 222213168100175 BUSHING HEX 1/2NPTM 1/4NPTF 2222187 * SCREW SQ PAN TRI #6-32 x .63 11111320558006271 BUSHING 1/4NPTM 1/8NPTF 8888188 * SCREW SQ PAN TRI #6-32 x .75 222213368121050 COUPLING 1/2NPT 7/8"LG - - - 2 189 * SCREW SQ PAN TRI #6-32 x 1.00 22221340558101279 CLAMP END DIN 35 RAIL 22 22 22 22 190 * SCREW SQ PAN TRI #8-32 x .38 11111350558012427 RAIL MOUNTING 3.5" DIN 11111360558011992 BAFFLE IGBT K 11111370558007276 INSULATOR DIODE BRIDGE K
- 1 - - 138 680398 INSULATOR LINE REACTOR Nome
11111390558007288 INSULATOR TERMINAL BLOCK K
35/7.5) PERFORATED 6666191 * SCREW SQ PAN TRI #8-32 x .50
2222192 * SCREW SQ PAN TRI #8-32 x .63 8888193 * SCREW LAG 1/4 x 2.00
18 18 18 22 194 * WASHER FLAT #10
6666195 * WASHER FLAT #6 11111400558001018 STANDOFF GLASTIC FEMALE 1/4-20 HEX 1" LG 21 21 21 18 196 * WASHER FLAT #8 4444141 672225 STANDOFF GLASTIC FEMALE 1/4-20 HEX 1.25" LG 6666197 * WASHER FLAT 1/2 22221422235785 CLAMP CABLE STEEL .312 DI 11111430558012504 CLAMP TUBE .625 DI
51 51 51 51 198 * WASHER FLAT 1/4
25 25 25 25 199 * WASHER FLAT 3/8 11111440558004079 STRAIN RELIEF 2" STEEL 10 10 10 4 200 * WASHER FLAT 5/16 3333145 950823 BUSHING SNAP .56ID .69MH 1111201 * WASHER FLAT NYLON 19/32
Blk 8888146 639533 BUSHING SNAP .88ID 1.09MH 4444202 * SCREW SKT HEX M6-1.0 x 12 Blk 5555147 647345 BUSHING SNAP 1.31ID 1.50MH 12 12 12 12 203 * SCREW SKT HEX M6-1.0 x 20 Blk 11111480558012420 GROMMET RUBBER 4.19ID COOLANT TAN
- - - 18 204 * WASHER FLAT BRASS 1/4 11111490558010733 PANEL DISPLAY SILK SCREENED 12 12 12 12 205 * WASHER FLAT M6 11111500558004053 GROMMET RUBBER 2.12ID 2.50GD .06W 1111206 * WASHER FLAT M16
R 151 90861100 TUBING PVC, 600V 105C, 1" BLACK 23 23 23 27 207 * WASHER LOCK #10 R 152
90862010
TUBING PVC, 600V 105C, 1.25" BLACK 7777208 * WASHER LOCK #6 11111530558010374 JUMPER 2 POS Red 25 25 25 22 209 * WASHER LOCK #8 33331540558007179 TERM LUG, MECHANICAL 17/32" 6-1/0 AWG 3333210 * WASHER LOCK 1/2 1111155 647361 1111156 98W68
GND2 GND1
LUG, MECHANICAL (2-8)AWG 39 39 39 39 211 * WASHER LOCK 1/4
LUG, MECHANICAL (4-3/0)AWG 16 16 16 16 212 * WASHER LOCK 3/8 33331570558009292 FERRULE NON-INSULATED 1/0 7774213 * WASHER LOCK 5/16
- - - 6 158 0558011877 FERRULE NON-INSULATED 2 AWG - - - 18 214 * WASHER LOCK BRONZE 1/4
- 6 6 - 159 0558011878 FERRULE NON-INSULATED 6 AWG 1111215 * WASHER LOCK EXT #6 6 - - - 160 0558011879 FERRULE NON-INSULATED 8 AWG 3333216 * WASHER LOCK EXT #8 7777161 46n08 ROD THREADED #8-32 x 9.75" LG 1111217 * WASHER LOCK INT 1/2
14 14 14 14 162 91w19 WASHER CENTERING 1111218 * WASHER LOCK EXT 3/8 14 14 14 14 163 647182 WASHER INSULATING MICA 1111219 * WASHER LOCK EXT 5/8
66661640558101654 CLAMP WORM GEAR .250-.625 16 16 16 16 220 * WASHER LOCK M6
16 16 16 16 165 0558006557 SCREW PHL HEX #10-32 x .50 w/ FLW Blk 27 27 27 27 221 * NUT #10-24
22221660558002087 SCREW PHL HEX w/ FLW M5 x 12 7777222 * NUT #6-32 66661670558006737 SCREW PHL HEX w/ FLW M6 x 12 4444223 * NUT LOCK #8-32 2222168 * JACK SCREW #4-40 HEX 5/16" LG 21 21 21 18 224 * NUT #8-32
Page 2
575v
R
(
)
A
A
A
A
A
Y
E
L
A
A
T
A
E
ARARARA
ARARARA
A
T
ARARARA
K
ARARARA
ARARARA
ARARARA
A
P
A
R
A
R
A
A
T
T
Y
T
T
0558011313
0558011312
400v CE
0558011311
380-400v
0558011310
200/230/460v
ITEM
NO
PART NO SYMBOL DESCRIPTION
575v
0558011313
0558011312
400v CE
0558011311
380-400v
ITEM
NO
0558011310
200/230/460v
PART NO SYMBOL DESCRIPTION
3333225 * NUT 1/2-13
23 23 23 23 226 * NUT 1/4-20 0558010798 Kit IGBT / Cap / Heatsink Module EPP-202
- - - 18 227 * NUT BRASS 1/4-20
(Includes) Includes the Following Items:
12 12 12 12 228 * NUT 3/8-16 1111430558011930 BUSBAR POSITIVE
3 3 3 - 229 * NUT 5/16-18 2222440558011931 BUSBAR NEGATIVE / COLLECTO 3333230 * NUT LOCK NYLON #8-32 1111470558011909 COLD PLATE POWER IGBT 6666231 * NUT 3/4-16 JAM 2222490558006183 1111232 * BOLT CARRIAGE 1/2-13 x 1.75 1111540558038382 4444233 * RIVET 1/8
- - - 1 234 N
- - 1 - 235 N
- 1 - - 236 N 1 - - - 237 N 1111238 N
LABEL RATING EPP-202 200/230/460V 1111840004487055 LABEL RATING EPP-202 380-400V CCC 2222990558007808 LABEL RATING EPP-202 400V CE 11111400558001018 STANDOFF GLASTIC FEMALE 1/4-20 HEX 1" LG LABEL RATING EPP-202 575V 1111290558011968 BRACKET IGBT / CAP / COLD PLATE MODULE LABEL NAMEPLATE Stock / Serial No 66661670558006737 SCREW PHL HEX w/ FLW M6 x 12
.126-.187
1111550558007255
Q1,2
PCB2
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
11112392091514 LABEL WARNING GENERAL ARC WELD & CUT 1111170 * SCREW HEX CAP 1/4-20 x .50
- - 1 - 240 0558954289 LABEL WARNING GENERAL ARC WELD & CUT Chinese 2222173 * SCREW HEX CAP 1/4-28 x .50 1111241 995110 LABEL WARNING EXPOSED VOLTAGE INSIDE 12 12 12 12 203 * SCREW SKT HEX M6-1.0 x 20 Blk 1111242 954291 LABEL WARNING COOLANT GENERAL 2222186 * SCREW SQ PAN TRI #6-32 x .38 11112430558954172
LABEL CAUTION GROUNDED PNL / REMOVE CAREFULL
3333198 *
WASHER FLAT 1/4 11112442091558 LABEL PE GROUND 3333211 * WASHER LOCK 1/4 1111245 954509 LABEL SYMBOL CAUTION HIGH VOLTAG 1111246 955269 LABEL SYMBOL CAUTION READ MANUA
12 12 12 12 220 * WASHER LOCK M6
22222550558000525 PAD THERMAL POWER IGBT MODULE 111124713732733 LABEL COPPER WIRE ONLY Wht/Clr 1111248 954507 LABEL WORK/ PILOT ARC/ ELECTRODE Wht/Clr 0558012477 KIT COOLANT PUMP EPP-202 11112490558954244 LABEL COOLANT FILL Blk/Wht
- 1 - - 250 N
- - 1 - 251 N
LABEL CE - Plain 11111080558007485 PUMP COOLANT 225PSI 125GPH LABEL CCC 22221210558000534 ADAPTOR RH B/A-W*M 1/4NPTM
(Includes) Includes the Following Items:
11112520558954292 LABEL SET EPP-202/362 22221230004494054 BUSHING 1/4NPTF 3/8NPTM 22222530558954334 LABEL ESAB DIE CUT 16.0 x 9.0 Blk 11111300558101063 TEE STREET 1/4NP 1111254 N
LABEL ISO 9001 11111270558000559 ELBOW STREET 90° 1/4NPT 22222550558000525 PAD THERMAL POWER IGBT MODULE 11111220558004057 ADAPTOR RH B/IG*F 1/4NPTM 11112560004492035 PAD THERMAL PA IGBT MODUL 11112570558954328 LABEL PC BOARD LAYOUT m2/m3-202 112 0558012489 KIT TANK COOLANT EPP-202
R 258 * ADHESIVE THREADLOCKER LOCTITE 242 - Blue R 259 * SEALANT THREAD LOCTITE PST 592 - White 1111301 N
(Includes) Includes the Following Items:
TANK COOLAN R 260 * ADHESIVE SILICON RUBBER DOW 732 - Clear 11113020558010759 CAP COOLANT TAN R 261 * COMPOUND ELECTRICAL JOINT ALCOA #2 11113030558011991
LS1
SWITCH COOLANT LEVEL w/ LEADS R 262 * TYWRAP LG 7.25" 22223040558011884 NIPPLE COOLANT TANK 3/8 HOSE R 263 * TYWRAP MED 5.5" 22223050558011883 WASHER RUBBER 0.516 ID x 0.781 OD x .063 NBR
2522264 * TYWRAP X-LG 14.5" 2222306 * WASHER FLAT 1/2 111126513730801 PLUG HOLE .438 DIA 2222307 * NUT 1/2-20 JAM 1111266 * BAG CLOTH 4" x 6" 1111267 NA WIRE KIT EPP-202/362 ADDITIONAL SPARES 1111268 N
- - - 1 269 N
- - 1 - 270 N
- 1 - - 271 N
CABLE KIT m2/m3-202 COMMON 11113080558006580 STRAINER - COOLANT PUM CABLE KIT m2/m3-202 200/230/460V 11113090558011982 O-RING 1" 100-MESH T-STRAINE CABLE KIT m2/m3-202 380V CCC 11113100558011983 SCREEN 100-MESH T-STRAINE
CABLE KIT m2/m3-202 400V CE 1 - - - 272 NA CABLE KIT m2/m3-202 575V COOLANT HOSE SPARES 1111273 N 11112740558038423
PCB3
HOSE KIT m2/m3-202 1111-0558011605 HOSE 28.00" TANK OUTLET to PUMP INLE
PC BOARD - FILTER 1111-0558011603 HOSE 13.00" PUMP OUTLET to REGULATOR INLE 1111275 995204 LABEL TEXT WARNING HAZARD COVER 1111-0558011601 HOSE 16.50" PUMP OUTLET to TORCH SUPPL 11112760558012565
R10 / C3
KIT RC-SNUBBER PA IGB
1111-0558011606 HOSE 20.00" RADIATOR OUTLET to FILTER INLET 4444277 * WASHER LOCK #4 1111-0558011599 HOSE 34.00" FLOW SENSOR OUTLET to COLD PLATE INLET 4444278 * WASHER FLAT #4 1111-0558011602 HOSE 31.00" TORCH RETURN to RADIATOR INLE
Page 3
T1
T1
2X 30
65
H
OR
575V only
41
4X
4X
39
4
CCC & CE Units only
OR
X
147
T1
40
4X
64
200/230/460V Only
145
4X
1.5k ohms
3.00kohm
178
4X
180
66
4X 31
12X 179
8X
2X
2X 2X
2X
193
207
181 221
194
2
2242X161
(TYP 4 PLCS)
2X
8X
2X
209
DETAIL X
2X
196
162 163
64
2X 2X
8 181
2X 2X
2X
6X
190 209
224
31
DETAIL H
SCALE 2 : 1 (TYP 2 PLCS)
217
197
210
225
4X 4X 4X
A
199 212 228
206
232
4X 4X
199 174
G
228 212 199
NOTE:
4 Quantity of Foot should be supplied with ITEM NO: 3
199
174
DETAIL G
SCALE 2 : 3
TYP 4 PLCS
DETAIL A
SCALE 1 : 1
FAMILYEPP-202 TOP ASSEMBLY
0558011309-G
SHEET 4
146
2X 45
83
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
152
4X
137 178
262
V
T
151 263
NOTE: APPLY EJC ESAB P/N 73585980 TO ALL CONNECTIONS
4X
179
36 L1
W
146
146
DETAIL V
SCALE 1 : 1
2X
171 198 211 226
2X
171 198 211 226
DETAIL U
SCALE 1 : 1
75
FN1
264
TYPICAL CONNECTION, 6 PLCS, COVER WITH 4 INCHES OF TUBING, SECURE WITH TYWRAP
D2
51 231
NOTE: APPLY EJC ESAB P/N 73585980 TO ALL CONNECTIONS
151 263
U
2X
TS2 85 186
D1
1721982X226
211
52 231
F4,F5
2X
83
2X
171 198
4X
211
2X 2X
226
REMOVE SECTION OF BUSBAR
AND INSTALL F4 AND F5 AS SHOWN
(TYPICAL 2 PLCS)
DETAIL T
SCALE 1 : 1
152 262
DETAIL W
SCALE 1 : 2
171 226 198
2X
211
(TYP 3 PLCS)
(TYP 2 PLCS)
TYPICAL CONNECTION, 2 PLCS, COVER WITH 4 INCHES OF TUBING AND SECURE WITH TYWRAP
2X
AA
177
200 213
229
146
DETAIL AA
SCALE 1 : 1
152
D4
51
231
4X
141
(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
170 198 211
(TYP 4 PLCS)
51 231
D6
52 231
D5
0558011309-G
52
231
75
264
D3
FN2
FAMILYEPP-202 TOP ASSEMBLY
SHEET 5
228212175
(TYP 2 PLCS)
Q5
2X
2X
4X
2X
50 184
221
25648
207
194
2X
79 166
276 186
150
2X
4X
(TYP 3 PLCS)
2X
181
2X
194
2X
207
2X
221
DETAIL AB
SCALE 1 : 1
2X 2X 3X
(TYP 3 PLCS)
224 209 196
2X 2X 2X
92
145
(TYP 3 PLCS)
162 163
5
2X 32
10178
AB
3X 63
145
161
(CE UNIT ONLY)
76
FN4
264
115
M1
(CE UNIT ONLY)
FN5
76
264
170 211 198
(TYP 4 PLCS)
28
L4
38
4X
178
(CE UNIT ONLY)
2X
178
77
FN3
(CE UNIT ONLY)
78
L3
(CE UNIT ONLY)
42
T2
178
3X
90
188
3X
92
TB3
93
89
188
TB3
2X
146
90
188
9
178
146
3X
2X
4X 4X
67 196 223
2X
27
179
FAMILYEPP-202 TOP ASSEMBLY
0558011309-G
SHEET 6
2X
164
Q1, Q2
2X
49
TO TANK INLET
140
170 211 198
NOTE: FOLLOW TORQUE SPECS LISTED ON IGBT DRAWING
4X
205
4X
220
TYP 2 PLCS
4X
203
55 1982X2112X173
C1
2X
47
2054X2204X203
4X
44 44
43
TS1
84
255
2X
2X
186
29
HS1
6262190
HS2
2X
190
2X
FROM FLOW SENSOR TEE
2X
99
PCB2-P8,11
USE EJC (ITEM ) ON ALL BUS BAR BOLTED CONNECTIONS
167
261
NOTE: FOLLOW TORQUE SPECS LISTED ON IGBT DRAWING
6X
TYP CONNECTION,
3 PLCS,
COVER EACH W/4 INCHES OF VINYL TUBE
151
3X
Ref.
44 198 211 226 171
(TYP 3 PLCS)
0558011309-G
FAMILYEPP-202 TOP ASSEMBLY
SHEET 7
NOTE: ORIENTATION OF
CHECK VALVES
TO RADIATOR INLET TEE
16
PCB3
274
2X
185
46 1761992X212228
(TYPICAL 2 PLCS)
FROM PUMP OUTLET
121 122
2X
125
2X
129
2X
118
2X
126
2X
2X
191
209
209
191
2X
2X
119
120
70
PA
192
2X
221
4X
71
182
4X
2X
154 169
2X
197 210 225
(TYPICAL 2 PLCS)
REF
119
120
REF
248
155
FAMILYEPP-202 TOP ASSEMBLY
0558011309-G
SHEET 8
198
2X
211
2X
170
2X
130
121
123
117
132
33
TO PUMP OUTLET
130 131 133 116 133 131 128 124 113 124 127 121
121
TO RADIATOR OUTLET TEE
TO COLD PLATE INLET
NOTE ORIENTATION OF FILTER
NOTE ORIENTATION OF PUMP
TO Back Pressure REGULATOR INLET
GROUND TETHER POINT FOR SIDE AND TOP PANEL
TO TANK OUTLET
181
178
24
5
4X
Ref.
Ref.
181
11
5X
127
123
108110122
308
177 213 200
4X 4X 4X
24
M2
68
109
121
176 212
4X 4X
172 211
3X
178
190
2X
6
TO TORCH OUTLET
3X 3X
2X
179
3X
178
8X
178
178
4X
7
199
(TYP 4 PLCS)
4X
198
3X
FAMILYEPP-202 TOP ASSEMBLY
0558011309-G
SHEET 9
NOTE: ORIENT FLAT SURFACE OF STEM FACING UPWARD. SUPPLIED WASHER LOCATED INSIDE TANK.
303
302
301
Ref.
305304 307306
2X 2X 2X 2X
(TO TORCH INLET)
(TO FILTER INLET)
(TO PUMP INLET)
(FROM IGBT OUTLET)
25
4X 4X
1X
26
221 207
111
(TO PUMP INLET)
(FROM IGBT OUTLET)
12
Ref.
2X
164
2X
164
178
2X
34
221
2X
207
2X
FAMILYEPP-202 TOP ASSEMBLY
0558011309-G
SHEET 10
TB6
2X
TB5
6X
2X
189
2X
69
200/230/460V Unit Only
72
88
2X
190
K2
56
(TYP 9 PLCS)
(200/230/460V UNIT)
4X 4X 4X 6X
(CE UNITS ONLY)
L2
37
180
K1
58 183 207 194 158
204
214
227
178
(CE ONLY)
138
OR
159
160
(575V)
57
K1
(CE, CCC, AND 575V UNITS ONLY)
196 209
3X 3X
156175199218
GND1
139
244
86 TB1
184
2X
147
Ref.
11
Ref.
25
(TYP 2 PLCS)
211
226
2X
2X
112
26
Ref.
224
3X
FAMILYEPP-202 TOP ASSEMBLY
0558011309-G
SHEET 11
61
RB1
2X
134
2X
2X
J3
106
Y
12
PCB1-P3
104
TB7
91
Z
2X 59
4X
4X
4X
8X 60
SECTION Y-Y
SCALE 1 : 2
222
2082X195
135
2X
2X
278
277
153 INSTALL JUMPER PER
WIRING SCHEMATIC/DIAGRAM
Connect to RB1
CONNECT TO PCB1 J12
2X
185
96
PCB1-P6
103
PCB1-P16
Y
53
PCB1
101
PCB1-P1
103
100
105
K4K5
PCB1-P2
PCB1-P8
PCB1-P9
222
TB4
87
GROUND
195
2X
187
208
215208222
SECTION Z-Z
SCALE 1 : 2
Z
107
P5
PCB2-P5
185
103
PCB2-P2
98
54
PCB2
185
102
PCB2-P3
FAMILYEPP-202 TOP ASSEMBLY
0558011309-G
SHEET 12
148
35
2X
20
165
19
F3
82
F1
82
F2
82
2X
186
2X
186
2X
186
81
81
81
149
Connect to PCB1-P20
PCB1-P20 / DB25
277
278
168
2X
J2
2X
95
207
219
2X
201
142221
4X
178
17
97
1X
17
REF
4X
144
247 265
241
114 181
CB1
80
2X
233
238233
2X
J1
94
Ref.
12
275
2X
190
6X
190
136 191
2X
236
237
235 251
234
230/
460V
UNIT
CCC
UNIT
575V
UNIT
CE
UNIT
250
CE
UNIT
OR
CCC
UNIT
FAMILYEPP-202 TOP ASSEMBLY
0558011309-G
SHEET 13
(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
190230216
4X
5X
179
178
Ref.
149
6X
4X
165
13165
9X
GROUND TETHER ATTACH POINT
190 230 216
21178
9X
22
178
ATTACH FRONT PANEL GROUND WIRE AT UPPER LEFT MOUNTING
.
SCREW
181
181
142
143
FAMILYEPP-202 TOP ASSEMBLY
0558011309-G
SHEET 14
GROUND TETHER ATTACH POINT
230216
LABEL CONFIGURATION FOR: 0558012390, 0558012392 (CE), AND 0558012393 (575V) UNITS
6X
23 178
DETAIL AD
SCALE 1 : 1
4X
AD
PLACE LABLE BEHIND PANEL
257
73
74
245
18
PL1
FL1
254
249
242
239 246
243
LABEL CONFIGURATION FOR: 0558012391 (CCC) UNITS
178
14
(2 Each CAP)
6X
178
15
(3 Each CAP)
( Place in center of side
253
panel 1 on Each Side)
2X
165
4X
ATTACH GROUND WIRE TO REAR OF ACCESS PANEL (#6 STUD)
254 249
242
239
246
243
240
FAMILYEPP-202 TOP ASSEMBLY
0558011309-G
SHEET 15
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
11
(TYP. 4 PLCS)
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
0558012495-A
0558012495-A
0558012498-A
0558012498-A
P1 1 TB7-1 BLU 2 J1-J RED 3 4 TB4-2 ORN 5 TS2-1 WHT
1 TB3-13 BLU 2 TB3-14 YEL 3 TB3-15 BRN 4 TB3-4 ORN 5 TB3-5 VIO
6 K5-7 VIO
1 2 PCB1 P8-4 BLK 3 4 PCB1 P8-2 BLK PCB1 P16-2 BLK
P2
1 TB3-9 WHT 2 3 TB3-10 GRY
1 HS1/HS2 SHIELD 2 HS1-1/HS2-1 BLK 3 HS1-3/HS2-3 RED PCB1 P9-5 RED 4 HS1-2 WHT 5 PCB1 P9-3 RED 6 7 8 HS2-2 ORN
PCB1
P3
P8
P9
P6
RIBBON CABLE
TO
RB1 (RELAY TERM BLK)
P12
RIBBON CABLE
TO
PCB2 J2 (DRIVER PCB)
P15
1 J2 -1 WHT
2 J2-2 BRN
3 J2-3 GRN
P16 1 J3-1 RED 2 J3-2
BLK PCB1 P8-4 BLK 3 J3-3 BRN
RIBBON CABLE TO PCB1 P6
J3 (FS1 CONNECTION)
RB1
PCB1
(CONTROL)
PCB2 (DRIVER)
TB7
K4 (FRONT) K5 (REAR)
TB4
K4-8 BLK
J1-G GRY
PL1-2 VIO
TB2-7 BLU
K4-4 ORN
TB3-9 WHT
JUMPER (11-5 TO 11-6)
K2-B WHT
GND-3
K1-B ORN
M1-2 BLU
FL1-2 RED
J1-D YEL J1-C BLK
RB1
1 2 3 4 5 6 7
8
TS1-1 (SP) ORN
PCB1 P1-4 ORN
K5-4 ORN
J1-L ORN
TB7-2 ORN
(11)
TB4
(14)
(12)
P5-2 WHT
12
TB3-12 WHT
J1-K G/Y
J1-H WHT
GND-3 G/Y
RB1-2 (11) ORN
TB2-3 BRN
K5-A WHT J1-E BLU
TB4-2 ORN
PCB1 P1-6 VIO K4-A WHT
PCB4 X3-3 GRN
PCB4 X3-2 WHT
PCB4 X3-1 ORN
PCB4 X3-4 BLK
PCB4 X3-5 RED
CB1-2 RED
K4
2
1 4
7
3
5
6
8
9 BA
P5-1 RED
TB3-10 GRY
K2-A VIO
K5-B YEL TB3-6 YEL
J2
J1
Connect J6 with P6
J6
J1
J5
P5
P5
RB1-6 (11) BLK
J2
5
5
4
K5
2
1
4
7
3
5
6
8
9 BA
K4-B YEL
4
3
3
1
PCB1 P15-1 WHT
2
PCB1 P15-2 BRN
3
PCB1 P15-3 GRN
4
P6-1 YEL
5
P6-2 GRY
6
P6-3 PNK
7
P6-4 BLU
8
P6-5 RED
J6
6
6
8
8
7
7
2
1
2
1
F
G
H
M
I
N
E
D
C
J
K
L
B
A
A B
RB1-6 (14) BLK
C
RB1-5 (14) YEL
D
K4-A BLU
E
TB3-8 BRN
F
RB1-5 (11) GRY
G
TB4-1 WHT
H I J
PCB1 P1-2 RED
K
TB4-1 G/Y TB4-2 ORN
L
J5
TB3-1 BLK TB3-2 RED
1 2 3
Q1-6 (SPLICE) RED Q1-7 (SPLICE) WHT Q2-7 (SPLICE) WHT
K4-5 RED
TB4-1 WHT
GND-3 G/Y
RIBBON CABLE TO PCB1 J12
PCB2 (DRIVER PCB)
J8
2
1
J9
2
1
Q2-6 (SPLICE) RED
J2
J10
2
1
PCB1 P1-1 BLU
LS1-1 WHT*
1
TB7
J5
PCB5 P1-1 RED
PCB5 P1-3 WHT
J3
2 1
J4
J6
J11
2
1
J7
TB4-2 ORN
LS1-2 WHT*
2
PCB5 GND G/Y
Q5-7 RED Q5-6 BLK
PCB3 J4 BLU
A
WORK WHT NEG(-) BUS BRN
GND-3
PL1
1
2
ORN
TB3-16 ORN
1
2
FL1
Note: * Indicates Self-lead
TB4-1 G/Y P5-3 G/Y
TB3-17 VIO
RB1-4 (11) VIO
RB1-4 (14) RED
M N
WIRING DIA EPP-202
230-460V
0558012499-A
SHEET 1 OF 6
PCB5
J5-3 G/Y J5-1 RED
J5-2 WHT
3 2 1
GND
P1
1 2 3 4 5 6
P2
J6-3 GRN J6-2 WHT
J6-1 ORN
X3
1 2 3 4 5
J3
PCB4
ENC1
PL1
Ribbon cable to DB37
PCB4 X3-4 BLK
X1
FL1
CB2
1
2
PCB5 P2-6 BLK
TB1
F1
CB1
F2F3
PCB4 X3-5 RED
CB2-2 BLK
Used on M2 Versions Only
TS1
A
PCB2 J8-1 (SPLICE) RED
PCB2 J8-2 (SPLICE) WHT
PCB5 P2-1 RED
Ribbon cable connect to ENC1
J6-5 RED CB2-1 BLK
J6-4 BLK
Q1
PCB2 J11-1 (SPLICE) RED
TOP VIEW
Q2
PCB2 J11-2 (SPLICE) WHT
L1-X1 (+)
COLLECTOR BUS
NEG (-) BUS
DIODE PLATE (-)
PCB2 J7 BRN
POS (+) BUS
DIODE PLATE (+)
TB4-2 ORN
1
TB3-11 BLK
K4-5 RED
Used on M2 Versions Only
TS1
TS2-2 VIO
2
CB1
1
2
TB1
BLK K1-L1
1
BLK K1-L2
2
BLK K1-L3
3
GND-1
F1
K2-L1 BLK
F3-2 BLK
BLU K1-L1
12
Q5-1 RED
WORK (4GA)
HS1
HS2
F2
K2-L2 RED
A
TB6-3 (SPLICE) RED
GRY K1-L2
12
M2-1 BRN
F1-1 BLK
F3
12
T2-H1(SPLICE)BLK
REAR WIRING VIEW
PCB1 P9-3 RED PCB1 P9-4 WHT PCB1 P9-2 BLK
PCB1 P9-3 RED PCB1 P9-8 ORN
PCB1 P9-2 BLK
3 2 1
3 2 1
HS1
HS2
WIRING DIA EPP-202
230-460V
0558012499-A
SHEET 2 OF 6
TB3
T2 BLU *
T2 BLU *
T2 BRN *
T2 BRN *
PCB2 J5-3 RED
PCB2 J5-1 BLK
PCB1 P3-5 VIO
PCB1 P3-4 ORN
T2 BLK *
T2 YEL *
T2 YEL *
T2 ORN (TOP) *
T2 ORN (BOT) *
1110987654321
J1-F BRN
K4-B YEL
PCB1 P2-1 WHT
CB1-1 BLK
K4-6 GRY
RB1-1 (11) WHT
PCB1 P2-3 GRY
T2 RED/YEL *
T2 VIO *
T2 RED *
T2 RED *
T2 BLK *
12
PCB1 P3-3 BRN
PL1-1 ORN
PCB1 P3-2 YEL
PCB1 P3-1 BLU
TB4-1 WHT
T2 VIO *
181716151413
PL1-2 VIO
FS1
R14
K1
T2
K2
TB3
TB6-4 ORN
TB6-1 BLU
M2-4 BLU
TB6-5 WHT
TB6-2 GRY
F3-2 (SPLICE) BLK
H4
H7
H3
H6
H2
H5
H1
T2
TOP VIEW
TOP
BOT
TB3-11 BLK * TB3-12 BLK * TB3-1 BRN * TB3-2 BRN * TB3-8 ORN * TB3-15 RED *
TB3-14 RED/YEL * TB3-13 RED *
TB3-6 ORN * TB3-9 YEL * TB3-10 YEL * TB3-5 BLU * TB3-4 BLU * TB3-17 VIO * TB3-16 VIO *
FLOW
FS1
WORK (OUT) WHT
ELECTRODE (OUT) YEL
J3-1 RED* J3-2 BLK* J3-3 BRN*
TB7-1 WHT
TB7-2 WHT
J4
PCB2 J4 BLU
ELECTRODE OUT BLK
PA Stud - BLK
A
LS1
M2
K1-L3 WHT
F2-1 RED F1-1 BLK
TB1-1 BLK
F1-2 BLU
RB1-2(14) ORN
B
RB1-1 (14) WHT
B
L3
L2
L1
K2
T3
T2 T1
A
K4-9 VIO
F2-2 GRY
TB1-2 BLK
L1 L2 L3
R3-2 WHT
R2-2 RED
R1-2 BLK
K2-L3 WHT
TB1-3 BLK
TB2-1 BRN
A
COLLECTOR BUS BLK
X1
X2
L1
FRONT VIEW
A
(ELECTRODE)
L1-X2 BLK
R9-2 YEL
PCB3 J1 YEL
L1
T1
T1 T2 T3
R1-1 BLK
TB5-7 BLK TB5-4 BLK
R2-1 RED
K1
TB5-1 BLK
R3-1 WHT
WIRING DIA EPP-202
230-460V
0558012499-A
SHEET 3 OF 6
T1-BH4* T1-CH1* K1-T1
TB5
Q5
7
8
T1-CH3*
PCB2 J3-2 RED
PCB2 J3-1 BLK
T1-BH2*
T1-BH3*
T1-AH4* T1-BH1* K1-T2
T1-AH2*
T2-H3 BLU
T2-H2 GRY
F2-1 (SPLICE) RED
T2-H4 ORN
T2-H6 WHT
6
5
4
3
REAR WIRING VIEW
9
1
2
1
2
3
4
5
T1-CH2*
T1-AH1* T1-CH4* K1-T3
T1-AH3*
TB6
BLK
BLK
(230V)
(460V)
TB6
TB5
1 R1 2
1 R2 2
1 R3 2
R4-1 YEL
Q5
A
D7
D8
POS BUS RED
A
C3
R10
A
76
3
2
1
BLK
RESISTOR ASSY
Note
: See literature for Tap changes for
dierent voltage congurations.
D2 BLK SPLICE
FN2
D4 BLU SPLICE D6 BRN SPLICE
D2, D4, D6 COMMON GRN/YEL
* * * *
POS (+) BUS BLK
FN2
D4
BLK NEG BUS
D2 D1
T1-AX2 SPLICE
T1-BX2 SPLICE
T1-CX2 SPLICE
T1-CX2 SPLICE
T1-BX2 SPLICE
T1-AX2 SPLICE
D5D6
D3
FN1
K1-T1 BLK
K1-T2 RED
K1-T3 WHT
D1, D3, D5 COMMON GRN/YEL
1
1
1
D1 BLK SPLICE D3 BLU SPLICE D5 BRN SPLICE
R1
R2
R3
* * * *
FN1
2
2
2
BLK K2-T1
RED K2-T2
WHT K2-T3
R8-2 YEL
WIRING DIA EPP-202
230-460V
0558012499-A
SHEET 4 OF 6
T2-H3 BLU
F3-1 BRN
GRN/YEL GND-4
TYP. M2 Versions Only
ENC1
PL1
FL1
CB2
M1-1 BLK
K1-A BRN
M1-1 BLK
K1-A BRN
1 2 3 4 5 6 7 8 9 10 11 12
T1-AX6
T1-AX5
BLK
1 2 3 4 5 6 7 8 9 10 11 12
T1-AX5
T1-AX6
K4-7 BRN
T1-AX7
BLK (200V)
T1-AX9
T1-AX8
T1-AX7
K4-7 BRN
BLK
T1-AX9
T1-AX8
RB1-3(11) BLU
OPTIONAL TB2 WIRING FOR 200V INPUT
BLK (200V)
T1-AX11
T1-AX10
RB1-3(11) BLU
T1-AX10
TB2
T1-AX11
TB2
M2
4
1
M1
TS2
C C
(WORK)
BLK POS(+) BUS
BLK R9-1
WHT PCB3 J2
WHT PCB2 J6
1
TB2-1 BLK
RB1-3(14) BLU
PCB1 P1-5 WHT
1
M1
2
TS2
TS1-2 VIO
2
Q5-2 YEL
A
YEL NEG (-) DIODE PLATE
YEL ELECTRODE (OUT)
BLK BLK BLK
22
2
R4
1
21
2
2
R5
R6
R7
1
1
YEL
R8
R9
1
YEL
YEL
BLK
1
A
PA STUD BLK
WORK (+) BLK
SECTION C-C
SCALE 1 : 4
PA STUD
A
R7-2 BLK
PCB3 J3 BLK
PL1
FL1
(CONNECTION MADE ON
REAR SIDE OF BOARD)
(CONNECTION MADE ON
REAR SIDE OF BOARD)
TYP. M3 Versions Only
WIRING DIA EPP-202
0558012499-A
SHEET 5 OF 6
230-460V
TB5-1 SPLICE *
TB5-6 SPLICE *
TB5-3 SPLICE *TB5-7 SPLICE *
D4,D3 SPLICE BLK*
D1,D6 SPLICE BLK*
TB5-9 SPLICE *
CH2
CX1
CX2
CH4
CX3
CX4
BX1
BH2
BX2
F4F5
BX3
BH4
BX4
AX1
AH2
AX2
AH4
TB5-4 SPLICE *
TB2-1 * TB2-2 * TB2-4 *
TB2-5 * TB2-6 *
TB2-8 * TB2-9 *
BX3
AX5 AX6
AX7 AX8
AX9 AX10 AX11
AX4
TB5-7 SPLICE *
TB5-8 SPLICE *
CH1
CH3
TB5-4 SPLICE *
BH1
MAIN TRANSFORMER
T1
BH3
AH1
TB5-5 SPLICE *
AH3
TB5-1 SPLICE *
D2,D5 SPLICE BLK
TB5-2 SPLICE *
WIRING DIA EPP-202
230-460V
0558012499-A
SHEET 6 OF 6
P1 1 TB7-1 BLU 2 J1-J RED 3 4 TB4-2 ORN 5 TS2-1 WHT
1 TB3-13 BLU 2 TB3-14 YEL 3 TB3-15 BRN 4 TB3-4 ORN 5 TB3-5 VIO
6 K5-7 VIO
1 2 PCB1 P8-4 BLK 3 4 PCB1 P8-2 BLK PCB1 P16-2 BLK
P2
1 TB3-9 WHT 2 3 TB3-10 GRY
1 HS1/HS2 SHIELD 2 HS1-1/HS2-1 BLK 3 HS1-3/HS2-3 RED PCB1 P9-5 RED 4 HS1-2 WHT 5 PCB1 P9-3 RED 6 7 8 HS2-2 ORN
1
RB1-2 (11) ORN
TB2-3 BRN
4
7
K5-A WHT J1-E BLU
1
TB4-2 ORN
4
PCB1
P3
P8
P9
K4
2
3
5
6
8
9 BA
RB1-6 (11) BLK
K5
2
3
5
6
P6
RIBBON CABLE
TO
RB1 (RELAY TERM BLK)
P12
RIBBON CABLE
TO
PCB2 J2 (DRIVER PCB)
P15
1 J2 -1 WHT
2 J2-2 BRN
3 J2-3 GRN
P16 1 J3-1 RED 2 J3-2
BLK PCB1 P8-4 BLK 3 J3-3 BRN
CB1-2 RED P5-1 RED
TB3-10 GRY
K2-A VIO
K5-B YEL TB3-6 YEL
3
3
RIBBON CABLE TO PCB1 P6
J3 (FS1 CONNECTION)
TB7
K4 (FRONT) K5 (REAR)
TB4
RB1
1 2 3 4 5 6 7
K4-8 BLK
J1-G GRY
RB1
PCB1
JUMPER (11-5 TO 11-6)
PL1-2 VIO
TB2-7 BLU
K4-4 ORN
TB3-9 WHT
(CONTROL)
K2-B WHT
K1-B ORN
GND-3
M1-2 BLU
FL1-2 RED
J1-D YEL J1-C BLK
PCB2 (DRIVER)
PCB1 P1-1 BLU
LS1-1 WHT*
1
Connect J6 with P6
J6
J1
J2
F
G
5
5
4
4
6
6
8
8
7
7
2
1
2
1
E
H
M
I
N
J
K
L
D
C
B
A
J1 J2
J5
P5
P5
K4-5 RED
TB4-1 WHT
GND-3 G/Y
RIBBON CABLE TO PCB1 J12
PCB5 P1-1 RED
PCB5 P1-3 WHT
TB7
J5
TB4-2 ORN
LS1-2 WHT*
2
PCB5 GND G/Y
TB3-16 ORN
8
(11)
(14)
(12)
GND-3
ORN
PL1
1
2
1
2
FL1
J1-L ORN
TB7-2 ORN
TS1-1 (SP) ORN
PCB1 P1-4 ORN
K5-4 ORN
TB4
12
P5-2 WHT
TB3-17 VIO
RB1-4 (11) VIO
RB1-4 (14) RED
J1-K G/Y
J1-H WHT
TB3-12 WHT
GND-3 G/Y
TB4-1 G/Y P5-3 G/Y
PCB1 P1-6 VIO K4-A WHT
PCB4 X3-3 GRN
PCB4 X3-2 WHT
PCB4 X3-1 ORN
PCB4 X3-4 BLK
PCB4 X3-5 RED
8
7
J6
9
1
BA
K4-B YEL
PCB1 P15-1 WHT
2
PCB1 P15-2 BRN
3
PCB1 P15-3 GRN
4
P6-1 YEL
5
P6-2 GRY
6
P6-3 PNK
7
P6-4 BLU
8
P6-5 RED
A B
RB1-6 (14) BLK
C
RB1-5 (14) YEL
D
K4-A BLU
E
TB3-8 BRN
F
RB1-5 (11) GRY
G
TB4-1 WHT
H I J
PCB1 P1-2 RED
K
TB4-1 G/Y TB4-2 ORN
L M
N
TB3-1 BLK TB3-2 RED
J2
J5
1 2 3
PCB2 (DRIVER PCB)
J9J8 J11J10
2
2
1
1
2
2
1
1
J3
2 1
J4
J6
J7
Q1-6 (SPLICE) RED Q1-7 (SPLICE) WHT Q2-7 (SPLICE) WHT
Q2-6 (SPLICE) RED
Q5-7 RED Q5-6 BLK
PCB3 J4 BLU WORK WHT NEG(-) BUS BRN
A
Note: * Indicates Self-lead
WIRING DIA EPP-202
380V CCC
0558012500-B
SHEET 1 OF 6
PCB5
J5-3 G/Y J5-1 RED
J5-2 WHT
3 2 1
GND
P1
J6-3 GRN J6-2 WHT
J6-1 ORN
X3
1 2 3 4 5
J3
ENC1
PL1
Ribbon cable to DB37
PCB4 X3-4 BLK
X1
FL1
CB2
1
2
PCB5 P2-6 BLK
TB1
PCB4 X3-5 RED
CB2-2 BLK
TS1
A
PCB2 J8-1 (SPLICE) RED
PCB2 J8-2 (SPLICE) WHT
1 2 3 4 5 6
P2
PCB5 P2-1 RED
J6-5 RED CB2-1 BLK
J6-4 BLK
Used on M2 Versions Only
Q1
PCB2 J11-1 (SPLICE) RED
TOP VIEW
PCB4
Ribbon cable connect to ENC1
Q2
PCB2 J11-2 (SPLICE) WHT
L1-X1 (+)
COLLECTOR BUS
NEG (-) BUS
DIODE PLATE (-)
PCB2 J7 BRN
POS (+) BUS
DIODE PLATE (+)
Used on M2 Versions Only
TB4-2 ORN
1
TS1
TS2-2 VIO
2
TB1
GND-1
BLK K1-L1
1
BLK K1-L2
2
BLK K1-L3
3
F1
CB1
F2F3
Q5-1 RED
WORK (4GA)
HS1
HS2
CB1
TB3-11 BLK
K4-5 RED
A
1 2
F3-2 BLK
K2-L1 BLK
K2-L2 RED
T2-H4 (SPLICE) RED
F1
BLU K1-L1
21
F2
GRY K1-L2
21
M2-1 BRN
F1-1 BLK
21
F3
T2-H1(SPLICE)BLK
REAR WIRING VIEW
PCB1 P9-3 RED PCB1 P9-4 WHT PCB1 P9-2 BLK
PCB1 P9-3 RED PCB1 P9-8 ORN
PCB1 P9-2 BLK
3 2 1
3 2 1
HS1
HS2
WIRING DIA EPP-202
380V CCC
0558012500-B
SHEET 2 OF 6
T2 BLU *
T2 BLU *
T2 BRN *
T2 BRN *
PCB2 J5-3 RED
PCB2 J5-1 BLK
PCB1 P3-5 VIO
PCB1 P3-4 ORN
T2 BLK *
T2 YEL *
T2 YEL *
T2 ORN (TOP) *
T2 ORN (BOT) *
1110987654321
K4-B YEL
J1-F BRN
PCB1 P2-1 WHT
CB1-1 BLK
PCB1 P2-3 GRY
K4-6 GRY
RB1-1 (11) WHT
T2 RED *
T2 RED/YEL *
T2 BLK *
12
PCB1 P3-2 YEL
PCB1 P3-1 BLU
TB4-1 WHT
T2 VIO *
T2 VIO *
T2 RED *
PCB1 P3-3 BRN
PL1-2 VIO
PL1-1 ORN
FS1
TB3
TB3-11 BLK * TB3-12 BLK * TB3-1 BRN *
TB3-2 BRN *
R14
181716151413
T2
F2-1 (SPLICE) RED
M2-4 BLU
H4
H7
H3
H6
H2
F3-2 (SPLICE) BLK
H5
H1
T2
TOP VIEW
TOP
BOT
TB3-8 ORN *
TB3-15 RED * TB3-14 RED/YEL * TB3-13 RED *
TB3-6 ORN *
TB3-9 YEL * TB3-10 YEL * TB3-5 BLU *
TB3-4 BLU *
TB3-17 VIO *
K1
K2
TB3-16 VIO *
FLOW
FS1
A
J3-1 RED* J3-2 BLK* J3-3 BRN*
TB7-1 WHT
TB7-2 WHT
WORK (OUT) WHT
J4
ELECTRODE (OUT) - YEL
ELECTRODE OUT BLK
PCB2 J4 BLU
PA Stud - BLK
LS1
M2
K1-L3 WHT
F2-1 RED
F1-1 BLK
TB1-1 BLK
F1-2 BLU
RB1-2(14) ORN
B
RB1-1 (14) WHT
B
L3
L2
L1
K2
T3
T2
T1
A
K4-9 VIO
F2-2 GRY
TB1-2 BLK
L1 L2 L3
R3-2 WHT
R2-2 RED
R1-2 BLK
K2-L3 WHT
TB1-3 BLK
TB2-1 BRN
A
COLLECTOR BUS BLK
X1
X2
L1
FRONT VIEW
A
(ELECTRODE)
L1-X2 BLK
R9-2 YEL
PCB3 J1 YEL
L1
T1
R1-1 BLK
T1-CH1 BLK
K1
T1 T2 T3
R2-1 RED
T1-BH1 BLK
T1-AH1 BLK
R3-1 WHT
WIRING DIA EPP-202
380V CCC
0558012500-B
SHEET 3 OF 6
A
TB5
1 R1 2
1 R2 2
1 R3 2
PCB2 J3-2 RED
Q5
PCB2 J3-1 BLK
R4-1 YEL
Q5
A
K1-T2 RED
D7
D8
POS BUS RED
C3
A
R10
A
K1-T1 BLK
76
3
2
1
BLK
A
RESISTOR ASSY
1
1
R1
R2
A
2
2
BLK K2-T1
RED K2-T2
D2 BLK SPLICE
FN2
D2, D4, D6 COMMON GRN/YEL
D4 BLU SPLICE D6 BRN SPLICE
* * * *
POS (+) BUS BLK
FN2
D4
BLK NEG BUS
D2 D1
T1-AX3 SPLICE
T1-BX3 SPLICE
T1-CX3 SPLICE
T1-CX3 SPLICE
T1-BX3 SPLICE
T1-AX3 SPLICE
D5D6
D3
FN1
K1-T3 WHT
D1, D3, D5 COMMON GRN/YEL
1
D1 BLK SPLICE D3 BLU SPLICE D5 BRN SPLICE
R3
* * * *
FN1
2
WHT K2-T3
R8-2 YEL
WIRING DIA EPP-202
380V CCC
0558012500-B
SHEET 4 OF 6
M1-1 BLK
K1-A BRN
( 380V CCC Only)
BLK
( 380V CCC Only)
BLK
TB2
1 2 3 4 5 6 7 8 9 10 11 12
T1-AX4
T1-AX5
K4-7 BRN
T1-AX6
T1-AX8
T1-AX7
RB1-3(11) BLU
M1
TS2
TB2
T2-H3 BLU
F3-1 BRN
GRN/YEL GND-4
M2
TYP. M2 Versions Only
ENC1
4
1
(WORK)
BLK POS(+) BUS
BLK R9-1
WHT PCB3 J2
WHT PCB2 J6
PL1
FL1
CB2
1
TB2-1 BLK
RB1-3(14) BLU
PCB1 P1-5 WHT
1
M1
2
TS2
TS1-2 VIO
2
C C
Q5-2 YEL
A
YEL NEG (-) DIODE PLATE
YEL ELECTRODE (OUT)
BLK BLK
BLK
22
2
R4
1
21
2
2
R5
R6
R7
1
1
YEL
1
YEL
YEL
R8
R9
BLK
1
PA STUD BLK
WORK (+) BLK
PA STUD
A
R7-2 BLK
PCB3 J3 BLK
TYP. M3 Versions Only
(CONNECTION MADE ON
REAR SIDE OF BOARD)
(CONNECTION MADE ON
REAR SIDE OF BOARD)
PL1
FL1
SECTION C-C
A
SCALE 1 : 4
WIRING DIA EPP-202
380V CCC
0558012500-B
SHEET 5 OF 6
T1-BH1 BLK
T1-CH1 BLK
K1-T3 BLK * T1-CH2 BLK
K1-T2 BLK * T1-AH2 BLK
T1-AH1 BLK
K1-T1 BLK * T1-BH2 BLK
AH2
D2,D5 SPLICE BLK
*
AX3
TB2-1 * TB2-4 * TB2-5 * TB2-8 * TB2-9 *
AX4 AX5
AX6 AX7 AX8
AH1
AX2 BX2
BX3
BH1BH2
AX1 BX1
CX3
CH2 CH1
CX2
CX1
D1,D6 SPLICE BLK
D4,D3 SPLICE BLK
*
*
MAIN TRANSFORMER T1
WIRING DIA EPP-202
380V CCC
0558012500-B
SHEET 6 OF 6
P1 1 TB7-1 BLU 2 J1-J RED 3 4 TB4-2 ORN 5 TS2-1 WHT
1 TB3-13 BLU 2 TB3-14 YEL 3 TB3-15 BRN 4 TB3-4 ORN 5 TB3-5 VIO
6 K5-7 VIO
1 2 PCB1 P8-4 BLK 3 4 PCB1 P8-2 BLK PCB1 P16-2 BLK
P2
1 TB3-9 WHT 2 3 TB3-10 GRY
1 HS1/HS2 SHIELD 2 HS1-1/HS2-1 BLK 3 HS1-3/HS2-3 RED PCB1 P9-5 RED 4 HS1-2 WHT 5 PCB1 P9-3 RED 6 7 8 HS2-2 ORN
1
RB1-2 (11) ORN
4
PCB1
P3
P8
P9
K4
2
3
5
6
P6
RIBBON CABLE
TO
RB1 (RELAY TERM BLK)
P12
RIBBON CABLE
TO
PCB2 J2 (DRIVER PCB)
P15
1 J2 -1 WHT
2 J2-2 BRN
3 J2-3 GRN
P16 1 J3-1 RED 2 J3-2
BLK PCB1 P8-4 BLK 3 J3-3 BRN
CB1-2 RED P5-1 RED
TB3-10 GRY
RIBBON CABLE TO PCB1 P6
J3 (FS1 CONNECTION)
RB1
PCB1
(CONTROL)
PCB2 (DRIVER)
TB7
K4 (FRONT) K5 (REAR)
TB4
K4-8 BLK
J1-G GRY
PL1-2 VIO
TB2-7 BLU
K4-4 ORN
TB3-9 WHT
JUMPER (11-5 TO 11-6)
K2-B WHT
K1-B ORN
M1-2 BLU
FL1-2 RED
J1-D YEL J1-C BLK
GND-3
PCB1 P1-1 BLU
LS1-1 WHT*
RB1
1 2 3 4 5 6 7
TB4-2 ORN
LS1-2 WHT*
2
1
8
(11)
(14)
(12)
GND-3
PL1
J1-L ORN
PCB1 P1-4 ORN
TB7-2 ORN
K5-4 ORN
TB4
12
P5-2 WHT
TB3-12 WHT
J1-K G/Y
J1-H WHT
TB4-1 G/Y P5-3 G/Y
TS1-1 (SP) ORN
GND-3 G/Y
TB2-3 BRN
K5-A WHT J1-E BLU
TB4-2 ORN
PCB1 P1-6 VIO K4-A WHT
PCB4 X3-3 GRN
PCB4 X3-2 WHT
PCB4 X3-1 ORN
PCB4 X3-4 BLK
PCB4 X3-5 RED
8
7
9 BA
K2-A VIO
K5-B YEL
Connect J6 with P6
J6
J1 J2
J5
P5
TB7
1
TB3-17 VIO
2
RB1-4 (11) VIO
TB3-6 YEL
RB1-6 (11) BLK
J2
K5
5
2
1 4
7
J6
3
5
6
8
9 BA
K4-B YEL
1
PCB1 P15-1 WHT
2
PCB1 P15-2 BRN
3
PCB1 P15-3 GRN
4
P6-1 YEL
5
P6-2 GRY
6
P6-3 PNK
7
P6-4 BLU
8
P6-5 RED
5
4
4
3
3
6
6
8
8
7
7
2
1
2
1
A B C
D E F G H I J K L
J1
F
G
H
M
I
N
E
D
C
J
K
L
B
A
RB1-6 (14) BLK RB1-5 (14) YEL K4-A BLU TB3-8 BRN
RB1-5 (11) GRY TB4-1 WHT
PCB1 P1-2 RED TB4-1 G/Y TB4-2 ORN
K4-5 RED
TB4-1 WHT
RIBBON CABLE TO PCB1 J12
J5
TB3-1 BLK TB3-2 RED
1 2 3
PCB2 (DRIVER PCB)
2
1
Q1-6 (SPLICE) RED Q1-7 (SPLICE) WHT Q2-7 (SPLICE) WHT
P5
GND-3 G/Y
J9J8 J11J10
2
1
Q2-6 (SPLICE) RED
PCB5 P1-1 RED
PCB5 P1-3 WHT
J2
2
2
1
1
J5
TB3-16 ORN
PCB5 GND G/Y
J3
2 1
J4
J6
J7
Q5-7 RED Q5-6 BLK
PCB3 J4 BLU WORK WHT NEG(-) BUS BRN
A
Note: * Indicates Self-lead
M N
ORN
1
2
FL1
RB1-4 (14) RED
WIRING DIA EPP-202
400V CE
0558012501-A
SHEET 1 OF 6
PCB5
J5-3 G/Y J5-1 RED
J5-2 WHT
3 2 1
GND
P1
J6-3 GRN J6-2 WHT
J6-1 ORN
X3
1 2 3 4 5
J3
ENC1
PL1
Ribbon cable to DB37
PCB4 X3-4 BLK
X1
FL1
CB2
1
2
PCB5 P2-6 BLK
TB1
PCB4 X3-5 RED
CB2-2 BLK
TS1
A
PCB2 J8-1 (SPLICE) RED
PCB2 J8-2 (SPLICE) WHT
1 2 3 4 5 6
P2
PCB4
PCB5 P2-1 RED
J6-5 RED CB2-1 BLK
J6-4 BLK
Used on M2 Versions Only
Q1
PCB2 J11-1 (SPLICE) RED
TOP VIEW
Ribbon cable connect to ENC1
PCB2 J11-2 (SPLICE) WHT
Q2
L1-X1 (+)
COLLECTOR BUS
NEG (-) BUS
DIODE PLATE (-)
PCB2 J7 BRN
POS (+) BUS
L4-X1 BLK
Used on M2 Versions Only
TB4-2 ORN
1
TS1
TS2-2 VIO
2
TB1
GND-1
BLK L2-AH1
1
BLK L2-BH1
2
BLK L2-CH1
3
F1
CB1
F2F3
* * *
Q5-1 RED
WORK (4GA)
HS1
HS2
CB1
TB3-11 BLK
K4-5 RED
A
1 2
F3-2 BLK
K2-L1 BLK
K2-L2 RED
L3-X2 (SPLICE) RED
F1
BLU K1-L1
21
F2
GRY K1-L2
21
M2-1 BRN
F1-1 BLK
21
F3
L3-X1(SPLICE)BLK
REAR WIRING VIEW
PCB1 P9-3 RED PCB1 P9-4 WHT PCB1 P9-2 BLK
PCB1 P9-3 RED PCB1 P9-8 ORN
PCB1 P9-2 BLK
3 2 1
3 2 1
HS1
HS2
WIRING DIA EPP-202
400V CE
0558012501-A
SHEET 2 OF 6
TB3
T2 BRN *
T2 BRN *
PCB2 J5-3 RED
PCB2 J5-1 BLK
FLOW
T2 BLU *
T2 BLU *
PCB1 P3-5 VIO
PCB1 P3-4 ORN
J3-1 RED* J3-2 BLK* J3-3 BRN*
FS1
WORK (OUT) WHT
T2 YEL *
T2 ORN (TOP) *
T2 ORN (BOT) *
J1-F BRN
K4-B YEL
PCB1 P2-1 WHT
T2 BLK *
T2 YEL *
1110987654321
PCB1 P2-3 GRY
RB1-1 (11) WHT
K4-6 GRY
TB7-1 WHT
TB7-2 WHT
T2 RED *
T2 RED/YEL *
T2 RED *
T2 BLK *
12
PCB1 P3-1 BLU
TB4-1 WHT
CB1-1 BLK
T2 VIO *
PL1-1 ORN
PCB1 P3-2 YEL
PCB1 P3-3 BRN
T2 VIO *
181716151413
PL1-2 VIO
LS1
FS1
M2
T2
FN3
K1
TB3
TB3-11 BLK * TB3-12 BLK * TB3-1 BRN *
L3
L2
L3-X4 (SPLICE) RED
M2-4 BLU
L3-X3 (SPLICE) BLK
H7
H6
H5
H4
H3
H2
H1
T2
TOP VIEW
TOP
BOT
TB3-2 BRN * TB3-8 ORN * TB3-15 RED * TB3-14 RED/YEL *
TB3-13 RED *
TB3-6 ORN * TB3-9 YEL * TB3-10 YEL * TB3-5 BLU * TB3-4 BLU * TB3-17 VIO * TB3-16 VIO *
K2
TB1-1 * TB1-2 * TB1-3 *
AH1 BH1
CH1
L2
AH2 BH2
CH2
K1-L3 WHT
F2-1 RED F1-1 BLK
K1-L1 * K1-L2 * K1-L3 *
F2-1 SPLICE RED X2
RB1-1 (14) WHT
B
L3
L2
L1
K2
T3
T2
T1
A
K4-9 VIO
X4 T2-H4 RED
R3-2 WHT
R2-2 RED R1-2 BLK
A
PA STUD BLK
F3-2 SPLICE BLK X1
X3 T2-H1 BLK
L3
J4
ELECTRODE (OUT) YEL
PCB2 J4 BLU
ELECTRODE OUT BLK
COLLECTOR BUS BLK
X1
X2
L1
FRONT VIEW
A
(ELECTRODE)
L1-X2 BLK
R9-2 YEL
PCB3 J1 YEL
L1
T1
L2-AH2 BLK*
F1-2 BLU
RB1-2(14) ORN
L4
B
L1 L2 L3
T1 T2 T3
R1-1 BLK
T1-CH1 BLK
R2-1 RED
T1-BH1 BLK
F2-2 GRY
L2-BH2 BLK* L2-CH2 BLK*
A
K1
T1-AH1 BLK
R3-1 WHT
K2-L3 WHT
TB2-1 BRN
BRN*
BLU*
BLK*
FN3
GRN/YEL*
WIRING DIA EPP-202
400V CE
0558012501-A
SHEET 3 OF 6
PCB2 J3-2 RED
Q5
PCB2 J3-1 BLK
L4
POS (+) BUS BLK
X1
X2
DIODE PLATE (+) *
TB5
1 R1 2
1 R2 2
1 R3 2
R4-1 YEL
Q5
A
A
D7
D8
POS BUS RED
C3
R10
A
76
3
2
1
BLK
A
A
RESISTOR ASSY
FN2
FN5
D2 BLK SPLICE D4 BLU SPLICE D6 BRN SPLICE
D2, D4, D6 COMMON GRN/YEL
D2 BLK SPLICE D4 BLU SPLICE D6 BRN SPLICE
GND GRN/YEL
* * * *
* * * *
L4
FN5
FN2
L4- X2 *
D2 D1
T1-AX2 SPLICE
T1-BX2 SPLICE
D4
T1-CX2 SPLICE
T1-CX2 SPLICE
T1-BX2 SPLICE
T1-AX2 SPLICE
BLK NEG BUS
D5D6
D3
FN1
K1-T1 BLK
K1-T2 RED
K1-T3 WHT
FN4
1
1
1
D1 BLK SPLICE D3 BLU SPLICE D5 BRN SPLICE
D1, D3, D5 COMMON GRN/YEL
R1
R2
R3
* * *
2
2
2
FN1
*
FN4
D1 BLK SPLICE D3 BLU SPLICE D5 BRN SPLICE
GRND GRN/YEL
* * * *
BLK K2-T1
RED K2-T2
WHT K2-T3
R8-2 YEL
WIRING DIA EPP-202
400V CE
0558012501-A
SHEET 4 OF 6
M1-1 BLK
K1-A BRN
( 400V CE Unit)
BLK
( 400V CE Unit)
BLK
TB2
1 2 3 4 5 6 7 8 9 10 11 12
T1-AX4
T1-AX5
K4-7 BRN
T1-AX6
T1-AX8
T1-AX7
RB1-3(11) BLU
M1
TS2
TB2
T2-H3 BLU
F3-1 BRN
GRN/YEL GND-4
M2
TYP. M2 Versions Only
ENC1
PL1
FL1
CB2
4
1
(WORK)
BLK POS(+) BUS
BLK R9-1
WHT PCB3 J2
WHT PCB2 J6
M1
1
TB2-1 BLK
RB1-3(14) BLU
PCB1 P1-5 WHT
1
2
TS2
TS1-2 VIO
2
C C
Q5-2 YEL
A
YEL NEG (-) DIODE PLATE
YEL ELECTRODE (OUT)
BLK BLK
BLK
22
2
R4
1
21
2
2
R5
R6
R7
1
1
R8
R9
1
YELYEL
YEL
BLK
1
WORK (+) BLK
PA STUD BLK
PA STUD BLK
PA STUD
(CONNECTION MADE ON
R7-2 BLK
PCB3 J3 BLK
REAR SIDE OF BOARD)
(CONNECTION MADE ON
REAR SIDE OF BOARD)
PL1
FL1
TYP. M3 Versions Only
A
SECTION C-C
A
SCALE 1 : 4
WIRING DIA EPP-202
400V CE
0558012501-A
SHEET 5 OF 6
T1-BH1 BLK
T1-CH1 BLK
K1-T3 BLK * T1-CH2 BLK
K1-T2 BLK * T1-AH2 BLK
T1-AH1 BLK
K1-T1 BLK * T1-BH2 BLK
AH2
D2,D5 SPLICE BLK
*
AX3
TB2-1 * TB2-4 * TB2-5 * TB2-8 * TB2-9 *
AX4 AX5
AX6 AX7 AX8
AH1
AX2 BX2
BX3
BH1BH2
AX1 BX1
CX3
CH2 CH1
CX2
CX1
D1,D6 SPLICE BLK
D4,D3 SPLICE BLK
*
*
MAIN TRANSFORMER T1
WIRING DIA EPP-202
400V CE
0558012501-A
SHEET 6 OF 6
P1 1 TB7-1 BLU 2 J1-J RED 3 4 TB4-2 ORN 5 TS2-1 WHT
1 TB3-13 BLU 2 TB3-14 YEL 3 TB3-15 BRN 4 TB3-4 ORN 5 TB3-5 VIO
6 K5-7 VIO
1 2 PCB1 P8-4 BLK 3 4 PCB1 P8-2 BLK PCB1 P16-2 BLK
P2
1 TB3-9 WHT 2 3 TB3-10 GRY
1 HS1/HS2 SHIELD 2 HS1-1/HS2-1 BLK 3 HS1-3/HS2-3 RED PCB1 P9-5 RED 4 HS1-2 WHT 5 PCB1 P9-3 RED 6 7 8 HS2-2 ORN
1
RB1-2 (11) ORN
4
PCB1
P3
P8
P9
K4
2
3
5
6
P6
RIBBON CABLE
TO
RB1 (RELAY TERM BLK)
P12
RIBBON CABLE
TO
PCB2 J2 (DRIVER PCB)
P15
1 J2 -1 WHT
2 J2-2 BRN
3 J2-3 GRN
P16 1 J3-1 RED 2 J3-2
BLK PCB1 P8-4 BLK 3 J3-3 BRN
CB1-2 RED P5-1 RED
TB3-10 GRY
RIBBON CABLE TO PCB1 P6
J3 (FS1 CONNECTION)
RB1
PCB1
(CONTROL)
PCB2 (DRIVER)
TB7
K4 (FRONT) K5 (REAR)
TB4
K4-8 BLK
J1-G GRY
PL1-2 VIO
TB2-7 BLU
K4-4 ORN
TB3-9 WHT
JUMPER (11-5 TO 11-6)
K2-B WHT
K1-B ORN
M1-2 BLU
FL1-2 RED
J1-D YEL J1-C BLK
GND-3
PCB1 P1-1 BLU
LS1-1 WHT*
RB1
1 2 3 4 5 6 7
TB4-2 ORN
LS1-2 WHT*
2
1
8
GND-3
(11)
(14)
(12)
PL1
K5-4 ORN
J1-L ORN
PCB1 P1-4 ORN
TB7-2 ORN
TB4
12
P5-2 WHT
TB3-12 WHT
J1-K G/Y
J1-H WHT
TB4-1 G/Y P5-3 G/Y
TS1-1 (SP) ORN
GND-3 G/Y
TB2-3 BRN
K5-A WHT J1-E BLU
TB4-2 ORN
PCB1 P1-6 VIO
K4-A WHT
PCB4 X3-3 GRN
PCB4 X3-2 WHT
PCB4 X3-1 ORN
PCB4 X3-4 BLK
PCB4 X3-5 RED
8
7
9 BA
K2-A VIO
K5-B YEL
Connect J6 with P6
J6
J1 J2
J5
P5
TB7
1
TB3-17 VIO
2
RB1-4 (11) VIO
TB3-6 YEL
RB1-6 (11) BLK
J2
K5
2
1
4
7
J6
3
5
6
8
9 BA
K4-B YEL
1 2 3 4 5 6 7 8
5
5
4
4
3
3
2
2
PCB1 P15-1 WHT PCB1 P15-2 BRN PCB1 P15-3 GRN P6-1 YEL P6-2 GRY P6-3 PNK P6-4 BLU P6-5 RED
6
6
8
8
7
7
1
1
A B C
D E F G H I J K L
J1
F
G
H
M
I
N
E
D
C
J
K
L
B
A
RB1-6 (14) BLK RB1-5 (14) YEL K4-A BLU TB3-8 BRN
RB1-5 (11) GRY TB4-1 WHT
PCB1 P1-2 RED TB4-1 G/Y TB4-2 ORN
K4-5 RED
TB4-1 WHT
RIBBON CABLE TO PCB1 J12
J5
TB3-1 BLK TB3-2 RED
1 2 3
PCB2 (DRIVER PCB)
2
1
Q1-6 (SPLICE) RED Q1-7 (SPLICE) WHT Q2-7 (SPLICE) WHT
P5
GND-3 G/Y
J9J8 J11J10
2
1
Q2-6 (SPLICE) RED
PCB5 P1-1 RED
PCB5 P1-3 WHT
J2
2
2
1
1
J5
TB3-16 ORN
PCB5 GND G/Y
J3
2 1
J4
J6
J7
Q5-7 RED Q5-6 BLK
PCB3 J4 BLU WORK WHT NEG(-) BUS BRN
A
Note: * Indicates Self-lead
M N
ORN
1
2
FL1
RB1-4 (14) RED
WIRING DIA EPP-202
575V
0558012517
SHEET 1 OF 6
ENC1
J5-3 G/Y J5-1 RED
J5-2 WHT
3 2 1
P1
PCB5
1 2 3 4 5 6
PCB4 X3-5 RED
CB2-2 BLK
A
J6-3 GRN J6-2 WHT
J6-1 ORN
GND
X3
1 2 3 4 5
J3
P2
PCB5 P2-1 RED
J6-5 RED CB2-1 BLK
J6-4 BLK
TS1
PCB4
Ribbon cable connect to ENC1
Q1
Ribbon cable to DB37
X1
Used on M2 Versions Only
Q2
PL1
FL1
CB2
1
PCB4 X3-4 BLK
2
PCB5 P2-6 BLK
L1-X1 (+)
COLLECTOR BUS
NEG (-) BUS
DIODE PLATE (-)
PCB2 J7 BRN
Used on M2 Versions Only
TB4-2 ORN
1
TS1
TS2-2 VIO
2
TB1
GND-1
TB1
F1
CB1
F2F3
1
2
3
BLK K1-L1
BLK K1-L2
BLK K1-L3
Q5-1 RED
WORK (4GA)
PCB2 J8-1 (SPLICE) RED
PCB2 J8-2 (SPLICE) WHT
A
HS1
HS2
PCB2 J11-1 (SPLICE) RED
TOP VIEW
PCB2 J11-2 (SPLICE) WHT
POS (+) BUS
DIODE PLATE (+)
CB1
TB3-11 BLK
K4-5 RED
PCB1 P9-3 RED PCB1 P9-4 WHT PCB1 P9-2 BLK
1 2
3 2 1
HS1
F1
K2-L1 BLK
F3-2 BLK
BLU K1-L1
21
F2
K2-L2 RED
T2-H7 (SPLICE) RED
GRY K1-L2
21
REAR WIRING VIEW
M2-1 BRN
F1-1 BLK
21
T2-H1(SPLICE)BLK
F3
PCB1 P9-3 RED PCB1 P9-8 ORN
PCB1 P9-2 BLK
3 2 1
HS2
WIRING DIA EPP-202
575V
0558012517
SHEET 2 OF 6
TB3
T2 BLU *
T2 BRN *
T2 BRN *
PCB2 J5-3 RED
PCB2 J5-1 BLK
T2 BLU *
PCB1 P3-4 ORN
PCB1 P3-5 VIO
T2 YEL *
T2 ORN (TOP) *
T2 ORN (BOT) *
K4-B YEL
J1-F BRN
PCB1 P2-1 WHT
T2 BLK *
T2 YEL *
1110987654321
CB1-1 BLK
K4-6 GRY
PCB1 P2-3 GRY
RB1-1 (11) WHT
T2 RED/YEL *
T2 RED *
T2 BLK *
12
PCB1 P3-1 BLU
PCB1 P3-2 YEL
TB4-1 WHT
T2 VIO *
T2 VIO *
T2 RED *
PCB1 P3-3 BRN
PL1-2 VIO
PL1-1 ORN
FS1
TB3
TB3-11 BLK * TB3-12 BLK * TB3-1 BRN *
TB3-2 BRN *
R14
181716151413
T2
F2-1 (SPLICE) RED
M2-4 BLU
H4
H7
H3
H6
H2
F3-2 (SPLICE) BLK
H5
H1
T2
TOP VIEW
TOP
BOT
TB3-8 ORN *
TB3-15 RED * TB3-14 RED/YEL * TB3-13 RED *
TB3-6 ORN *
TB3-9 YEL * TB3-10 YEL * TB3-5 BLU *
TB3-4 BLU *
TB3-17 VIO *
K1
K2
TB3-16 VIO *
FS1
A
FLOW
WORK (OUT) WHT
ELECTRODE (OUT) - YEL
J3-1 RED* J3-2 BLK* J3-3 BRN*
TB7-1 WHT
TB7-2 WHT
J4
PCB2 J4 BLU
ELECTRODE OUT BLK
PA Stud - BLK
A
LS1
M2
K1-L3 WHT
F2-1 RED
F1-1 BLK
TB1-1 BLK
F1-2 BLU
RB1-2(14) ORN
B
RB1-1 (14) WHT
B
L3
L2
L1
K2
T3
T2
T1
A
K4-9 VIO
F2-2 GRY
TB1-2 BLK
L1 L2 L3
R3-2 WHT
R2-2 RED
R1-2 BLK
K2-L3 WHT
TB1-3 BLK
TB2-1 BRN
A
COLLECTOR BUS BLK
X1
X2
L1
FRONT VIEW
A
(ELECTRODE)
L1-X2 BLK
R9-2 YEL
PCB3 J1 YEL
L1
T1
R1-1 BLK
T1-CH1 BLK
K1
T1 T2 T3
R2-1 RED
T1-BH1 BLK
T1-AH1 BLK
R3-1 WHT
WIRING DIA EPP-202
575V
0558012517
SHEET 3 OF 6
5
TB5
1 R1 2
1 R2 2
1 R3 2
PCB2 J3-2 RED
PCB2 J3-1 BLK
C14 (+) RED
Q5
D7
D8
POS BUS RED
C3
A
A
A
R10
76
3
2
1
BLK
A
A
Q5
D2 BLK SPLICE
FN2
D2, D4, D6 COMMON GRN/YEL
D4 BLU SPLICE D6 BRN SPLICE
* * * *
POS (+) BUS BLK
FN2
D4
BLK NEG BUS
D2 D1
T1-AX2 SPLICE
T1-BX2 SPLICE
T1-CX2 SPLICE
T1-CX2 SPLICE
T1-BX2 SPLICE
T1-AX2 SPLICE
D5D6
D3
FN1
K1-T1 BLK
K1-T2 RED
K1-T3 WHT
D1 BLK SPLICE D3 BLU SPLICE D5 BRN SPLICE
D1, D3, D5 COMMON GRN/YEL
RESISTOR ASSY
1
1
1
R1
R2
R3
* *
FN1
* *
2
2
2
BLK K2-T1
RED K2-T2
WHT K2-T3
R8-2 YEL
WIRING DIA EPP-202
575V
0558012517
SHEET 4 OF 6
M1-1 BLK
K1-A BRN
( 575V Unit)
BLK
( 575V Unit)
BLK
TB2
1 2 3 4 5 6 7 8 9 10 11 12
T1-AX3
T1-AX4
K4-7 BRN
T1-AX5
RB1-3(11) BLU
M1
TS2
TB2
T2-H3 BLU
F3-1 BRN
GRN/YEL GND-4
M2
TYP. M2 Versions Only
ENC1
4
1
(WORK)
BLK POS(+) BUS
BLK R9-1
WHT PCB3 J2
WHT PCB2 J6
PL1
FL1
CB2
M1
1
TB2-1 BLK
RB1-3(14) BLU
PCB1 P1-5 WHT
1
2
TS2
TS1-2 VIO
2
C C
Q5-2 YEL
A
YEL NEG (-) DIODE PLATE
YEL ELECTRODE (OUT)
YEL YEL
YEL
22
2
R4
1
21
2
2
R5
R6
R7
1
1
YEL
R8
R9
1
YELYEL
1
PA STUD BLK
WORK (+) BLK
BLK
PA STUD
R7-2 BLK
PCB3 J3 BLK
TYP. M3 Versions Only
(CONNECTION MADE ON
REAR SIDE OF BOARD)
(CONNECTION MADE ON
REAR SIDE OF BOARD)
PL1
FL1
A
SECTION C-C
SCALE 1 : 4
A
WIRING DIA EPP-202
575V
0558012517
SHEET 5 OF 6
T1-BH1 BLK
T1-CH1 BLK
K1-T3 BLK * T1-CH2 BLK
K1-T2 BLK * T1-AH2 BLK
T1-AH1 BLK
K1-T1 BLK * T1-BH2 BLK
AH2
D2,D5 SPLICE BLK
TB2-1 * TB2-2 * TB2-6 *
*
AX3 AX4
AX5
AH1
BH1BH2
AX2 BX2
AX1 BX1
CH2 CH1
CX2
CX1
D1,D6 SPLICE BLK
D4,D3 SPLICE BLK
*
*
MAIN TRANSFORMER T1
WIRING DIA EPP-202
575V
0558012517
SHEET 6 OF 6
LABEL PCB LAYOUT
0558954317
EPP CAN2 Second Station Kit
P/N 0558011641
To enable the EPP power source to accomodate two torch stations, the EPP CAN Second Station Kit must be installed. Do so as follows. Before installation:
1. Disconnect input power to machine.
2. Remove covers as shown.
3. Route Braided Connector assembly as shown below.
4. Use supplied clamp to ground the braid to machine cabinet. Install on ground stud opposite existing clamp by removing and re-install nut.
5. Insert Plug into J17 header on PCB board. Ensure connection is completely inserted into terminal.
6. Slide SW5 position from CLOSE to OPEN position only on station #1 power supply.
7. Insert 8 pin receptacle into access hole in sheetmetal. Use kit at washer inside cabinet, use external tooth lock washer outside of cabinet, and secure with supplied receptacle nut.
SW5 position
Ensure fully inserted connections
as shown here
Station #1: OPEN Station #2: CLOSE
Kit plugs into J17 header
(***shown NOT fully inserted***)
J14 not used
J15 CAN1 station
J17 CAN2 station
Use at washer on inside of cabinet.
Add supplied clamp to existing clamp, attach to existing ground stud.
Secure 8 pin recetacle in existing access hole, use supplied external tooth lock washer on outside of cabinet .
0558008950 12/2013
ITEM
)
A
T
T
A
T
(
A
A
A
QTY
NO
PART NO SYMBOL DESCRIPTION
1 1 0558012332 CHASSIS BASE 1 2 0558012333 COVER TOP 1 3 0558012334 1 4 0558012335 15 N
J1 J2
(J5)
CABLE / CONNECTOR ASSY - 14 PIN X-Rotation CABLE / CONNECTOR ASSY - DB25 (25 PIN
WIRE KIT CONTROL 2 6 0558003353 STRAIN RELIEF SEALED 3/4" NYLON Black 1 7 599800 1 8 673213
J3
SW1
RECEPTACLE PNL MT 24 SOCKE
SWITCH TOGGLE SPST 15A 125V 1 9 680088 GUARD TOGGLE SWITCH - Plated 1 10 0558011837 1 11 23210751 3 12 0560938881
J4 J6
K5,6,7
RECEPTACLE PNL MT 4 PIN
RECEPTACLE PNL MT 2 SOCKE
RELAY MINI DPDT 115VAC 8 3 13 0560996139 SOCKET RELAY MINI - DIN M 4 14 0558009383
K1,2,3,4
RELAY ASSY SPDT 24V AC/DC 6A w/ BASE 2 15 2234485 CLAMP END DIN 35 RAIL 1 16 57002499
ISO
1 17 0558009578 RAIL MOUNTING 4.5" DIN
ANALOG SIGNAL ISOLATOR DC Voltage Input
35/7.5) PERFORATED 3 18 * NUT LOCK NYLON #6-32 2 19 * WASHER FLAT #6 2 20 * WASHER LOCK EXT #6 4 21 * SCREW HEX WSH TRI 1/4-20 x .50 4 22 * SCREW SQ PAN TRI #8-32 x .38 8 23 * SCREW SQ PAN TRI #6-32 x .38
R 24 * SOLDER .062 DIA
16 25 * TUBING PVC, 300V 105C, #8 x 0.75L Black
R 26 * TYWRAP MED 5.5"
R 27 * TYWRAP SM 4" 2 28 * WASHER FLAT 1/4 2 29 0560949593
FL1,2
LAMP LED GREEN 24VDC PANEL
Page 1
Rev B
-
-
ONES
FL1
FL2
TENS
+
+
Rev B
Rev B
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