ESAB EPP-200 User manual

EPP-200
Precision Plasmarc Cutting System
0558007005 10 / 2007
Instruction Manual

2
This equipment will perform in conformity with the description thereof contained in this manual and accompa-
nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-
tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment
should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme-
diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone
or written request for service advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a ser-
vice facility designated by the manufacturer.
BE SURE THIS INFORMATION REACHES THE OPERATOR.
YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding and cutting equipment, we urge
you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and
Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain
this equipment. Do NOT attempt to install or operate this equipment until you have read
and fully understand these instructions. If you do not fully understand these instructions,
contact your supplier for further information. Be sure to read the Safety Precautions be-
fore installing or operating this equipment.
CAUTION
USER RESPONSIBILITY
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!

3
SECTION TITLE PAGE
SECTION 1 SAFETY .................................................................................................................................... 5
SECTION 2 DESCRIPTION.......................................................................................................................................................... 7
SECTION 3 INSTALLATION......................................................................................................................................................13
SECTION 4 OPERATION............................................................................................................................................................21
TABLE OF CONTENTS

DECLARATION OF CONFORMITY
According to
The Low Voltage Directive 2006/95/EC of 12 December 2006, entering into force 16 January 2007
The EMC Directive 2004/108/EC
FÖRSÄKRAN OM ÖVERENSSTÄMMELSE
Lågspänningsdirektivet 2006/95/EG från 12 december 2006, ikrafsat 16 januari 2007
EMC-Direktivet 2004/108/EG
Type of equipment Materialslag
Plasma Cutting Console
Brand name or trade mark Fabrikatnamn eller varumärke
ESAB
Type designation etc. Typbeteckning etc.
EPP-200, (0558004315)
Manufacturer or his authorised representative established within the EEA
Name, address, telephone No, telefax No: Tillverkarens namn, adress, telefon, telefax:
ESAB AB
Esabvägen, SE-695 81 Laxå, Sweden
Phone: [phone], Fax: [phone]
The following harmonised standard in force within the EEA has been used in the design:
Följande harmoniserande standarder har använts i konstruktionen:
EN 60974-1, Arc welding equipment – Part 1: Welding power sources
EN 60974-10, Arc welding equipment – Part 10: Electromagnetic compatibility (EMC) requirements
Additional information: / Tilläggsinformation: Restrictive use, Class A equipment, intended for use in locations other than
residential
By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorised
representative established within the EEA, that the equipment in question complies with the safety requirements
stated above.
Genom att underteckna detta dokument försäkrar undertecknad såsom tillverkare, eller tillverkarens representant inom
EES, att angiven materiel uppfyller säkerhetskraven angivna ovan.
Date / Datum
Laxå 2009-02-18
Signature / Underskrift Position / Befattning
Global Director
Equipment and Automation
Kent Eimbrodt
Clarification

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SECTION 1 SAFETY PRECAUTIONS
1.0 Safety Precautions
Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that anyone
who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet
therequirements thatapplytothistypeof welding orplasmacuttingequipment. The followingrecommendations
should be observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well acquainted with the operation of the welding or plasma
cutting equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in
injury to the operator and damage to the equipment.
1. Anyone who uses welding or plasma cutting equipment must be familiar with:
- its operation
- location of emergency stops
- its function
- relevant safety precautions
- welding and / or plasma cutting
2. The operator must ensure that:
- no unauthorized person stationed within the working area of the equipment when it is started up.
- no one is unprotected when the arc is struck.
3. The workplace must:
- be suitable for the purpose
- be free from drafts
4. Personal safety equipment:
- Always wear recommended personal safety equipment, such as safety glasses, ame proof
clothing, safety gloves.
- Do not wear loose tting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions:
- Make sure the return cable is connected securely.
- Work on high voltage equipment may only be carried out by a qualied electrician.
- Appropriate re extinquishing equipment must be clearly marked and close at hand.
- Lubrication and maintenance must not be carried out on the equipment during operation.

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SECTION 1 SAFETY PRECAUTIONS
WELDING AND PLASMA CUTTING CAN BEINJURIOUS TO YOURSELF AND
OTHERS. TAKE PRECAUTIONS WHEN WELDING OR CUTTING. ASK FOR
YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE BASED ON
MANUFACTURERS’ HAZARD DATA.
ELECTRIC SHOCK - Can kill.
- Install and earth (ground) the welding or plasma cutting unit in accordance with applicable standards.
- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
- Insulate yourself from earth and the workpiece.
- Ensure your working stance is safe.
FUMES AND GASES - Can be dangerous to health.
- Keep your head out of the fumes.
- Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone
and the general area.
ARC RAYS - Can injure eyes and burn skin.
- Protect your eyes and body. Use the correct welding / plasma cutting screen and lter lens and wear
protective clothing.
- Protect bystanders with suitable screens or curtains.
FIRE HAZARD
- Sparks (spatter) can cause re. Make sure therefore that there are no inammable materials nearby.
NOISE - Excessive noise can damage hearing.
- Protect your ears. Use earmus or other hearing protection.
- Warn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
WARNING

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SECTION 2 DESCRIPTION
The EPP-200 Power Console is designed for mechanized plasma
applications. It can be used with other ESAB products such as the
PT-24 and PT-600 torches, an optional plumbing box and a remote
set-up pendant.
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power semiconductor components
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2.1 Introduction
2.2 General Specications
EPP-200 Power Console (0558004315):
OUTPUT (100% duty cycle)
Voltage......................................................................................................... 160VDC
Current range DC................................................................................. 50A to 200A
Power................................................................................................. 8000 W to 32000 W
Open Circuit Voltage (OCV) .................................................................. 325VDC
INPUT
Voltage (3-phase) ..............................................................200/230/380/415/460/575 Volts
Current (3-phase) ...............................................................115/100/60/55/50/40 Amperes
 ....................................................................................................50/60Hz
KVA .................................................................................................................39.8 kW
Power.............................................................................................................37.8 kW
 ...................................................................................................95%
 .................................................................................. See Section 3, Installation

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Electric Shock Can Kill!
Use of torches not designed for this console could result in a haz-
ardous electric shock.
Use only torches designed for the EPP-200 Console.
WARNING
2.3 Dimensions and Weight
44 in. (1100mm)
42in. (1050mm)
22in. (550mm)
Weight = 725 lbs. (330 kg)
SECTION 2 DESCRIPTION

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2.4 EPP-200 Options and Accessories
Options
5 ft. (1.5m)
10 ft. (3.0m)
20 ft. (6.1m)
25 ft. (7.6m)
30 ft. (9.1m)
40 ft. (12.2m)
50 ft. (15.2m)
75 ft. (22.9m)
100 ft. (30.5m)
125 ft. (38.1m)
150 ft. (45.7m)
* CoolingWater Hoses (2)
Console to Plumbing Box Control Cable Plumbing Box to Console Pilot Arc Lead Plumbing Box to Console Power Lead Console to Plumbing Box
0558003979
0558003980
0558003981
33132
0558003982
0558003983
33133 (4495019)
33134 (4495020)
33135 (4495021)
33136 (4495022)
0558003984
N / A
N / A
N / A
0558004651
N / A
N / A
0558004652
0558004653
0558004654
0558003978
0558004655
0558003985
0558003986
0558003987
33303
0558003988
0558003989
33304 (4495034)
33305 (4495035)
33306 (4495036)
33307 (4495037)
0558003990
0558003991
0558003992
0558003993
22001 (4495038)
0558003994
0558003995
22002 (4495039)
22003 (4495040)
22004 (4495041)
22005 (4495042)
0558003996
SECTION 2 DESCRIPTION
NOTE:
Part Numbers in parenthesis apply to "CE"/European units only.
* Use with one adaptor fitting (41V12) included with unit.

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2.5 Gas Hoses
Gas Type 25 ft. 50 ft. 75 ft. 100 ft. 125 ft.
(7.6m) (15.2m) (22.8m) (30.4m) (38.1m)
Nitrogen (clear) 33122 33123 33124 33125 33126
Oxygen (clear - USA) 33117 33118 33119 33120 33121
Oxygen (blue - Euro) 0558002973 0558002974 0558002975 0558002976 0558002977
Argon/Hydrogen (H-35) (1) 33122* 33123* 33124* 33125* 33126*
Air (clear - USA) 33122** 33123** 33124** 33125** 33126**
Air (black - Euro) (2) 0558002978** 0558002979** 0558002980** 0558002981** 0558002982**
Note: * = Requires adapter P/N 19X54 (4494001) (order separately)
** = Requires adapter P/N 74S76 (0558004057) (order separately)
2.6 Gas Regulators
Station Regulator Cylinder Regulator
Nitrogen .....................................................19155 ............................................998343
Oxygen .......................................................19151.............................................998336
Argon/Hydrogen (H-35) .......................19153.............................................998341
Air .................................................................30338 (4492008) .......................N/A
A separate start gas regulator is always required:
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A total of 3 regulators will be required (plasma, start and
secondary).
When using a plumbing box:
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plumbing box.
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NOTICE
NOTICE
SECTION 2 DESCRIPTION
NOTE:
Part Numbers in parenthesis apply to "CE"/European units only.