ESAB m3 Plasma EPP-202 Instruction Manual
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ESAB m3 Plasma EPP-202 Instruction Manual

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EPP-202
Plasma Power Source
Instruction Manual
For equipment starting with Serial Number PG-xxxxxxxx .
0558012601
10/2015

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Summary of Contents for ESAB m3 Plasma EPP-202

  • Page 1 EPP-202 Plasma Power Source Instruction Manual For equipment starting with Serial Number PG-xxxxxxxx . 0558012601 10/2015...
  • Page 2 EPP-202 Plasma Power Source...
  • Page 3 EPP-202 Plasma Power Source 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,”...
  • Page 4 EPP-202 Plasma Power Source...

  • Page 5: Table Of Contents

    EPP-202 Plasma Power Source contents safetY safety - english ................. . 9 Safety - Spanish .
  • Page 6 EPP-202 Plasma Power Source trouBleshooting troubleshooting ................59 Troubleshooting Guide .
  • Page 7 safetY...
  • Page 8 SAFETY...

  • Page 9: Safety - English

    SAFETY safety - english Warning: these safety precautions are fires anD explosions -- heat from for your protection. they summarize flames and arcs can start fires. hot precautionary information from the slag or sparks can also cause fires and references listed in additional safety explosions.
  • Page 10 SAFETY 1. Be sure the power source frame (chassis) is con- 3. Welders should use the following procedures to nected to the ground system of the input power. minimize exposure to EMF: 2. Connect the work piece to a good electrical ground. A.
  • Page 11 SAFETY 2. Before performing any maintenance work inside a 5. Warning: this product, when used for welding power source, disconnect the power source from or cutting, produces fumes or gases which con- the incoming electrical power. tain chemicals known to the state of california to cause birth defects and, in some cases, can- 3.
  • Page 12 SAFETY meaning of sYmBols - as used throughout this manual: means attention! Be alert! Your safety is involved. Danger means immediate hazards which, if not avoided, will result in immediate, serious personal injury or loss of life. caution means potential hazards which could result in personal injury or loss of life. Warning means hazards which could result in minor personal injury.

  • Page 13: Safety - Spanish

    SAFETY safety - spanish la escoria puede estar caliente y desprenderse con velocidad. personas cercanas deberán usar aDVertencia: estas precauciones de gafas de seguridad y careta protectora. seguridad son para su protección. ellas hacen resumen de información prove- fuego Y explosiones -- el calor de niente de las referencias listadas en la sección las flamas y el arco pueden ocacionar "información adicional sobre la seguridad".
  • Page 14 SAFETY 3. Los soldadores deberán usar los siguientes proced- 1. Asegúrese de que el chasis de la fuente de poder imientos para minimizar exponerse al EMF: esté conectado a tierra através del sistema de electricidad primario. A. Mantenga el electrodo y el cable a la pieza de 2.
  • Page 15 SAFETY 2. Antes de dar mantenimiento en el interior de la 5. aDVertencia-- este producto cuando se utiliza fuente de poder, desconecte la fuente de poder para soldaduras o cortes, produce humos o del suministro de electricidad primaria. gases, los cuales contienen químicos cono- 3.
  • Page 16 SAFETY significaDo De los simBolos -- según usted avanza en la lectura de este folleto: los símbolos significan ¡atención! ¡esté alerta! se trata de su seguridad. significa riesgo inmediato que, de no ser evadido, puede resultar inmediata- peligro mente en serio daño personal o la muerte. significa el riesgo de un peligro potencial que puede resultar en serio daño aDVertencia personal o la muerte.

  • Page 17: Safety - French

    SAFETY safety - french incenDies et explosions -- la aVertissement : ces règles de sécurité chaleur provenant des flammes ou de ont pour but d'assurer votre protection. l'arc peut provoquer un incendie. le ils récapitulent les informations de pré- laitier incandescent ou les étincelles caution provenant des références dans peuvent également provoquer un la section des informations de sécurité...
  • Page 18 SAFETY 1. Assurez-vous que le châssis de la source 3. Les soudeurs doivent suivre les procédures suivantes d'alimentation est branché au système de mise à pour minimiser l'exposition aux champs électriques la terre de l'alimentation d'entrée. et magnétiques : 2. Branchez la pièce à traiter à une bonne mise de A.
  • Page 19 SAFETY 5. aVertissement : ce produit, lorsqu'il est utilisé 1. Efforcez-vous de toujours confier les tâches d'installation, dans une opération de soudage ou de coupage, de dépannage et d'entretien à un personnel qualifié. dégage des vapeurs ou des gaz contenant des N'effectuez aucune réparation électrique à...
  • Page 20 SAFETY signification Des sYmBoles ce symbole, utilisé partout dans ce manuel, signifie "attention" ! soyez vigilant ! Votre sécurité est en jeu. signifie un danger immédiat. la situation peut Danger entraîner des blessures graves ou mortelles. signifie un danger potentiel qui peut entraîner des aVertissement blessures graves ou mortelles.
  • Page 21 Description...
  • Page 22 description...

  • Page 23: Description

    The EPP-202 power source is designed for mechanized plasma cutting and marking applications. It can be used with other ESAB products such as the PT-36 torch along with the m3 gas interface, a computerized gas regulation and switching system. features •...

  • Page 24: Dimensions

    description Dimensions 23.75” 47.25” (603.25 mm) (1200 mm) 40.75” (1035 mm) optional accessories Interface Adaptor - allows the EPP-202/362 to be used in place of the EPP-201/360. For installation see help code section........... p/n 0558011592...
  • Page 25 installation...
  • Page 26 installation...

  • Page 27: Installation

    installation installation general failure to folloW instructions coulD leaD to Death, in- JurY or DamageD propertY. folloW these instructions Warning to preVent inJurY or propertY Damage. You must com- plY With local, state anD national electrical anD safetY coDes. unpacking •...

  • Page 28: Input Power Connection

    installation input power connection electric shocK can Kill! Warning proViDe maximum protection against electrical shocK. Before anY connections are maDe insiDe the machine, open the line Wall Disconnect sWitch to turn poWer off. primary power Three-phase input power must be provided from a line (wall) disconnect switch that contains fuses or circuit breakers in accordance to local or state regulations.

  • Page 29: Input Conductors

    installation input conductors • Customer supplied • May consist either of heavy rubber covered copper conductors (three power and one ground) or run in solid or flexible conduit. • Sized according to the chart. input connection procedure improper grounDing can result in Death or inJurY. Warning chassis must Be connecteD to an approVeD electrical grounD.
  • Page 30 installation input Voltage configuration and changeover 200/230/460 Vac models - As shipped from the factory, this model of EPP-202 is configured for the highest connectable voltage. If using other input voltages, the links on the terminal board (TB) inside the unit must be repositioned for the appropriate input voltage.
  • Page 31 installation JUMPER POSITIONS FOR 230/460 VAC note: TB2 wires connected on 230/460 must be re- connected to 200/400. JUMPER POSITIONS FOR 200/400 VAC note: Wires connected on 230/460 main transformer tap must be re-connected to 200/400 main transformer tap on all 3 coils.
  • Page 32 installation 380 Vac and 400 Vac models - As shipped from the factory, these models of EPP-202 are configured for the single input voltage listed on the rating plate. If using other input voltages, it is possible to configure these units for either 380 VAC or 400 VAC input.
  • Page 33 installation 380 Vac and 400 Vac models (continued) - 2. Reconfigure TB2 terminal strip for proper voltage. JUMPER POSITIONS FOR 400 VAC JUMPER POSITIONS FOR 380 VAC 380 tap note: Wires connected on main transformer tap must be re-connected to 400 or 380 main transformer taps on all 3 coils.

  • Page 34: Coolant Connection Procedure

    With the torch connected, fill the reservoir with the specially formulated torch coolant (approx 4 gallons). Do not use regular anti-freeze solutions, such as for an automobile, as the additives will harm the pump and torch. ESAB P/N 0558004297 is recommended for service down to 12° F (-11° C). ESAB P/N 156F05 is recommended for service below 12°...

  • Page 35: Delivery Pressure Adjustment

    installation Delivery pressure adjustment Delivery pressure is controlled by the relief valve mounted next to the pump in the tank compartment. Turn- ing the pressure adjustment screw clockwise increases pressure on the spring and raises the delivery pressure. Turning it counterclockwise reduces pressure on the spring and reduces the delivery pressure. The pressure is adjusted at the factory to deliver approxomately 175 psig (12 bar) at 1.5 gallons per minute (5.7 l/min).

  • Page 36: Output Connections

    installation output connections electric shocK can Kill! Dangerous Voltage anD current! anY time WorKing arounD a plasma poWer source With coVers remoVeD: Warning • Disconnect poWer source at the line (Wall) Disconnect. • haVe a QualifieD person checK the output Bus Bars (positiVe anD negatiVe) With a Voltmeter.
  • Page 37 installation output connection procedure 1. Open access panel on the lower front of the power source by removing four M6 screws. 2. Thread output cables through the openings at the bottom of the power source immediately behind the front panel. 3.

  • Page 38: Interface Cable Connectors

    installation interface cable connectors can connector This is the CAN communication bus connector. The cable from this connector is tied to the CNC/process controller. J1 (ras) This is a connector for interfacing with Remote Arc Starter (RAS) unit. The cable from this connector carries signals such as: Mark Mode and Hi-Frequency ON.
  • Page 39 installation J1 (ras) interface cable can cables...
  • Page 40 installation...
  • Page 41 operation...
  • Page 42 OPERATION...

  • Page 43: Operation

    OPERATION operation Dangerous Voltages anD current! electric shocK can Kill! Warning Before operation, ensure installation anD grounDing pro- ceDures haVe Been folloWeD. Do not operate this eQuip- ment With coVers remoVeD. epp-202 Block Diagram 1 ~ T2 200/230/380/ Input Fuse 400/460/575V Fuses Control...
  • Page 44 OPERATION epp-202 coolant flow Diagram As soon as the power source is supplied with input power, the coolant pump motor turns ON. Coolant pumps out to the torch and returns back to the coolant tank through the radiators, filter, flow sensor, and IGBTs cold plate respectively.

  • Page 45: Display Panel

    OPERATION Display panel a - power light This indicator illuminates when input power is applied to the power supply. B - fault light Whenever there is a fault, this indicator illuminates. This may stay ON continuously or flash with 50% ON/OFF intervals depending on the type of fault.

  • Page 46: Modes Of Operation

    OPERATION modes of operation Plasma unit can be operated in Cutting Mode or Marking Mode. The command to operate the machine in Cut- ting or Marking mode can be received from the CNC or Process controller through CAN (digital) communication or through analog communication.

  • Page 47: Epp-202 J1 (Ras) - Interface Diagram

    OPERATION epp-202 J1 (ras) - interface Diagram...

  • Page 48: Sequence Of Operation

    OPERATION sequence of operation The EPP-202 has no power switch installed in the unit. The wall breaker is the power disconnect for this power supply. Once the wall breaker is closed, the following events occur: 1. Power is applied to the control transformer T2. This supplies power to the circuit boards - PCB1 the Con- trol board and PCB2 the Driver board.

  • Page 49: Machine Operation Flow Diagram

    OPERATION 5. Once the Pilot Arc is established, if the torch is close enough to the work, and the work piece is grounded, Main Arc will transfer to work. Once main arc is established, which will be verified by sensing the work current through HS2 (work current greater than 5A), power supply will send the Arc ON signal to CNC/ Process Controller via CAN and begins to ramp up current in accordance with the TDF file or the internal matrix.
  • Page 50 OPERATION...
  • Page 51 maintenance...
  • Page 52 Maintenance...

  • Page 53: Maintenance

    Maintenance maintenance general electric shocK can Kill! Warning shut off poWer at the line (Wall) Disconnect Before at- tempting anY maintenance. eYe haZarD When using compresseD air to clean. Warning • Wear approved eye protection with side shields when cleaning the power source.

  • Page 54: Flow Sensors

    Maintenance flow sensors Turbine Flow Sensor features : Small and compact dimension Easy connection, 1/2” BSP thread High reliability and durability Installation flexibility : vertical or horizontal Wide rated voltage : 2.4 to 26 VDC Hall effect sensor, digital output electrical : Supply voltage : 2.4 –...
  • Page 55 Maintenance RotorFlow Sensor RotorFlow Sensor is used to monitor the flow rate of the coolant. Operation: The rotor reacts to turbulence, pulsation, entrained air, and other flow anomalies induced in the flow stream by other process hardware. For optimum performance, install RotorFlow units where nominal flow condi- tions exist, with ports located at the top.

  • Page 56: Level Switch

    CNC/Process controller by the power supply through CAN communication. THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY 411 S. Ebenezer Rd OF ESAB WELDING & CUTTING. ANY REPRODUCTION IN PART OR AS A Florence, SC 29501 WHOLE WITHOUT THE WRITTEN PERMISSION OF ESAB WELDING & CUTTING IS PROHIBITED.
  • Page 57 trouBleshooting...
  • Page 58 TROUBLESHOOTING...

  • Page 59: Troubleshooting

    TROUBLESHOOTING troubleshooting electric shocK can Kill! Warning Do not permit untraineD persons to inspect or repair this eQuipment. electrical WorK must Be performeD BY an experienceD electrician. stop work immediately if power source does not work properly. caution have only trained personnel investigate the cause. use only recommended replacement parts.

  • Page 60: Help Codes

    TROUBLESHOOTING help codes When fault light is in either one of the above-mentioned states, check the CNC/Process Controller screen for the complete description of the error. The list of errors with detail description for the power source are shown in the table below. Error code problem Solution...
  • Page 61 TROUBLESHOOTING Output voltage fell below 70 volts 1. Check for short in the torch cable. during cutting or below 40 volts during 2. Check cutting or marking height is too low. marking. 3. Check for short between electrode and nozzle. 4.

  • Page 62: Interface Adaptor Box

    TROUBLESHOOTING interface adaptor Box The Interface Adaptor Box is required when using a EPP-202/362 in place of a EPP-201/360. The box has 2 LED indicators. The indicator on the left represents the “10s” digits, the indicator on the right rep- resents the “1s”...
  • Page 63 TROUBLESHOOTING electric shocK can Kill! Warning shut off poWer at the line (Wall) Disconnect Before at- tempting anY maintenance. electric shocK can Kill! Warning Do not permit untraineD persons to inspect or repair this eQuipment. electrical WorK must Be performeD BY an experienceD electrician.

  • Page 64: Fault Isolation

    TROUBLESHOOTING fault isolation fan not Working problem possible cause action This is normal when unit is in idle None mode for more than 5 minutes. Broken or disconnected wire in fan Repair wire. motor circuit. Fan does not turn ON Faulty fan(s) Replace fans Check relay connection and/or replace...
  • Page 65 replacement parts...
  • Page 66 Replacement paRts...

  • Page 67: Replacement Parts

    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.
  • Page 68 Replacement paRts...
  • Page 69 reVision historY 1. Originally released - 01/2015 2. Revision 10/2015 - added RotorFlow Sensor.
  • Page 70 Welding & cutting products, florence, sc communication guiDe - customer serVices 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 ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693...

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