ESAB EPP-200 Precision Plasmarc Cutting Console User manual

EPP-200

Precision Plasmarc Cutting Console

0558004676 10 / 2007

Instruction ManualInstruction Manual

Instruction Manual

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!

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4

TABLE OF CONTENTSTABLE OF CONTENTS

TABLE OF CONTENTS

5

WARNING: These Safety Precautions are for

your protection. They summarize precaution-

ary information from the references listed in

Additional Safety Information section. Before

performing any installation or operating procedures, be

sure to read and follow the safety precautions listed below

as well as all other manuals, material safety data sheets,

labels, etc. Failure to observe Safety Precautions can result

in injury or death.

PROTECT YOURSELF AND OTHERS

--

Some welding, cutting, and gouging pro-

cesses are noisy and require ear pro-

tection. The arc, like the sun, emits ul-

traviolet (UV) and other radiation and

can injure skin and eyes. Hot metal can cause burns.

Training in the proper use of the processes and equip-

ment is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any work

area, even if welding helmets, face shields, and goggles

are also required.

2. Use a face shield fitted with the correct filter and cover

plates to protect your eyes, face, neck, and ears from

sparks and rays of the arc when operating or observing

operations. Warn bystanders not to watch the arc and not

to expose themselves to the rays of the electric-arc or hot

metal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeve

shirt, cuffless trousers, high-topped shoes, and a weld-

ing helmet or cap for hair protection, to protect against

arc rays and hot sparks or hot metal. A flameproof apron

may also be desirable as protection against radiated

heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cuffs, or pockets. Sleeves and collars should be

kept buttoned, and open pockets eliminated from the

front of clothing

5. Protect other personnel from arc rays and hot sparks with

a suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag or

grinding. Chipped slag may be hot and can fly far.

Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS -- Heat from

flames and arcs can start fires. Hot slag

or sparks can also cause fires and ex-

plosions. Therefore:

1. Remove all combustible materials well away from the

work area or cover the materials with a protective non-

flammable covering. Combustible materials include

wood, cloth, sawdust, liquid and gas fuels, solvents,

paints and coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or

crevices in floors or wall openings and cause a hidden

smoldering fire or fires on the floor below. Make certain

that such openings are protected from hot sparks and

metal.“

3. Do not weld, cut or perform other hot work until the

workpiece has been completely cleaned so that there

are no substances on the workpiece which might pro-

duce flammable or toxic vapors. Do not do hot work on

closed containers. They may explode.

4. Have fire extinguishing equipment handy for instant use,

such as a garden hose, water pail, sand bucket, or

portable fire extinguisher. Be sure you are trained in its

use.

5. Do not use equipment beyond its ratings. For example,

overloaded welding cable can overheat and create a fire

hazard.

6. After completing operations, inspect the work area to

make certain there are no hot sparks or hot metal which

could cause a later fire. Use fire watchers when neces-

sary.

7. For additional information, refer to NFPA Standard 51B,

"Fire Prevention in Use of Cutting and Welding Pro-

cesses", available from the National Fire Protection Asso-

ciation, Batterymarch Park, Quincy, MA 02269.

ELECTRICAL SHOCK -- Contact with live

electrical parts and ground can cause

severe injury or death. DO NOT use AC

welding current in damp areas, if move-

ment is confined, or if there is danger of

falling.

1. Be sure the power source frame (chassis) is connected

to the ground system of the input power.

2. Connect the workpiece to a good electrical ground.

3. Connect the work cable to the workpiece. A poor or

missing connection can expose you or others to a fatal

shock.

4. Use well-maintained equipment. Replace worn or dam-

aged cables.

5. Keep everything dry, including clothing, work area,

cables, torch/electrode holder, and power source.

6. Make sure that all parts of your body are insulated from

work

and from ground.

7. Do not stand directly on metal or the earth while working

in tight quarters or a damp area; stand on dry boards or

an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

9. Turn off the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)

for specific grounding recommendations. Do not mis-

take the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS — May

be dangerous. Electric current flowing

through any conductor causes local-

ized Electric and Magnetic Fields (EMF).

Welding and cutting current creates EMF

around welding cables and welding ma-

chines. Therefore:

1. Welders having pacemakers should consult their physi-

cian before welding. EMF may interfere with some pace-

makers.

2. Exposure to EMF may have other health effects which are

unknown.

3. Welders should use the following procedures to minimize

exposure to EMF:

A. Route the electrode and work cables together. Secure

them with tape when possible.

B. Never coil the torch or work cable around your body.

C. Do not place your body between the torch and work

cables. Route cables on the same side of your body.

D. Connect the work cable to the workpiece as close as

possible to the area being welded.

E. Keep welding power source and cables as far away

from your body as possible.

SECTION 1 SAFETY PRECAUTIONS

6

FUMES AND GASES -- Fumes and

gases, can cause discomfort or harm,

particularly in confined spaces. Do

not breathe fumes and gases. Shield-

ing gases can cause asphyxiation.

Therefore:

1. Always provide adequate ventilation in the work area by

natural or mechanical means. Do not weld, cut, or gouge

on materials such as galvanized steel, stainless steel,

copper, zinc, lead, beryllium, or cadmium unless posi-

tive mechanical ventilation is provided. Do not breathe

fumes from these materials.

2. Do not operate near degreasing and spraying opera-

tions. The heat or arc rays can react with chlorinated

hydrocarbon vapors to form phosgene, a highly toxic

gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat irritation

while operating, this is an indication that ventilation is not

adequate. Stop work and take necessary steps to im-

prove ventilation in the work area. Do not continue to

operate if physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)

for specific ventilation recommendations.

5. WARNING: This product, when used for welding or

cutting, produces fumes or gases which

contain chemicals known to the State of

California to cause birth defects and, in

some cases, cancer. (California Health &

Safety Code

§25249.5 et seq.)

CYLINDER HANDLING -- Cylinders, if mis-

handled, can rupture and violently re-

lease gas. Sudden rupture of cylinder,

valve, or relief device can injure or kill.

Therefore:

1. Use the proper gas for the process and use the proper

pressure reducing regulator designed to operate from

the compressed gas cylinder. Do not use adaptors.

Maintain hoses and fittings in good condition. Follow

manufacturer's operating instructions for mounting regu-

lator to a compressed gas cylinder.

2. Always secure cylinders in an upright position by chain

or strap to suitable hand trucks, undercarriages, benches,

walls, post, or racks. Never secure cylinders to work

tables or fixtures where they may become part of an

electrical circuit.

3. When not in use, keep cylinder valves closed. Have

valve protection cap in place if regulator is not con-

nected. Secure and move cylinders by using suitable

hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and flames.

Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,

"Precautions for Safe Handling of Compressed Gases in

Cylinders", which is available from Compressed Gas

Association, 1235 Jefferson Davis Highway, Arlington,

VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or im-

properly maintained equipment can cause

injury or death. Therefore:

1. Always have qualified personnel perform the installa-

tion, troubleshooting, and maintenance work. Do not

perform any electrical work unless you are qualified to

perform such work.

2. Before performing any maintenance work inside a power

source, disconnect the power source from the incoming

electrical power.

3. Maintain cables, grounding wire, connections, power

cord, and power supply in safe working order. Do not

operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep

equipment away from heat sources such as furnaces,

wet conditions such as water puddles, oil or grease,

corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position

and in good repair.

6. Use equipment only for its intended purpose. Do not

modify it in any manner.

ADDITIONAL SAFETY INFORMATION -- For more

information on safe practices for electric arc

welding and cutting equipment, ask your sup-

plier for a copy of "Precautions and Safe Prac-

tices for Arc Welding, Cutting and Gouging",

Form 52-529.

The following publications, which are available from the

American Welding Society, 550 N.W. LeJuene Road, Mi-

ami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc

Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc

Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon Arc

Gouging and Cutting"

5. AWS C5.5 - "Recommended Practices for Gas Tungsten

Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal Arc

Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.

8. ANSI/AWS F4.1, "Recommended Safe Practices for

Welding and Cutting of Containers That Have Held

Hazardous Substances."

MEANING OF SYMBOLS - As used throughout

this manual: Means Attention! Be Alert! Your

safety is involved.

Means immediate hazards which, if not

avoided, will result in immediate, seri-

ous personal injury or loss of life.

Means potential hazards which could

result in personal injury or loss of life.

Means hazards which could result in

minor personal injury.

SECTION 1 SAFETY PRECAUTIONS

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11

SECTION 2SECTION 2

SECTION 2

DESCRIPTIONDESCRIPTION

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.

• 50 to 200 Amperes cutting current range

• Forced air cooled

• Solid state DC power

• Integral water cooler

• Input voltage protection

• Local or remote front panel control

• Thermal switch protection for main transformer and

power semiconductor components

• LED status troubleshooting

2.1 Introduction

2.2 General Specifications

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

Frequency........................................................................ 50/60Hz

KVA................................................................................. 39.8 kW

Power .............................................................................. 37.8 kW

Power Factor ...................................................................... 95%

Input Fuse ...........................................................See Section 3, Installation

12

SECTION 2 DESCRIPTION

Electric Shock Can Kill!

Use of torches not designed for this console could result in

a hazardous electric shock.

Use only torches designed for the EPP-200 Console.

WARNINGWARNING

WARNING

2.3 Dimensions and Weight

44 in. (1100mm)

42in. (1050mm)

22in. (550mm)

Weight = 725 lbs. (330 kg)

13

SECTION 2 DESCRIPTION

2.4 EPP-200 Options and Accessories

Torch Coolant – 1gallon (3.8 L) - (4 required) = 156F05

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)

* Cooling Water 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

33134

33135

33136

0558003984

N / A

0558004651

N / A

0558004652

0558004653

0558004654

0558003978

0558004655

0558003985

0558003986

0558003987

33303

0558003988

0558003989

33304

33305

33306

33307

0558003990

0558003991

0558003992

0558003993

22001

0558003994

0558003995

22002

22003

22004

22005

0558003996

* Use with one adaptor fitting (41V12) included with unit.

14

SECTION 2 DESCRIPTION

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 (order separately)

** = Requires adapter P/N 74S76 (order separately)

2.6 Gas Regulators

Station Regulator Cylinder Regulator

Nitrogen .......................................19155 ...............................998343

Oxygen.........................................19151 ...............................998336

Argon/Hydrogen (H-35) ................19153 ...............................998341

Air................................................30338 ............................... N/A

A separate start gas regulator is always required:

• For air plasma use air start gas.

• For oxygen or nitrogen use nitrogen start gas.

• For H-35 (argon/hydrogen) H-35 or nitrogen start gas.

A total of 3 regulators will be required (plasma, start and

secondary).

When using a plumbing box:

• Gas hoses from supply cylinders go directly to the

plumbing box.

• Console gas manifold is not used.

NONO

NO

TICETICE

TICE

NONO

NO

TICETICE

TICE

15

SECTION 2 DESCRIPTION

2.7 Basic Packages

The EPP-200 system is available as a pre-engineered package

or can be ordered as individual parts as listed.

Basic Packages include:

• EPP-200 Console

• Plasma Torch

• Appropriate regulators for the gases indicated

• Gas hoses from regulators to console

• Torch coolant

Torch Coolant – 1 gallon (3.8 L) P/N 0558004297

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17

SECTION 3SECTION 3

SECTION 3

INSTALLATIONINSTALLATION

INSTALLATION

3.1 General

Failure To Follow Instructions Could Lead

To Death, Injury Or Damaged Property

Follow these instructions to prevent injury or property

damage.

You must comply with local, state and national electrical and

safety codes.

WARNINGWARNING

WARNING

Use Lifting Eye When Hoisting From

Overhead

Use safe practices when transporting with overhead method.

Unit weighs over 700 lbs (318 kg). Use approved straps or

cables in good condition.

CACA

CA

UTIONUTION

UTION

3.2 Unpacking

• Inspect for transit damage immediately upon receipt.

• Remove all components from shipping container and

check for loose parts in container.

• Inspect louvers for air obstructions.

18

SECTION 3SECTION 3

SECTION 3

INSTALLATIONINSTALLATION

INSTALLATION

WARNINGWARNING

WARNING

CACA

CA

UTIONUTION

UTION

CACA

CA

UTIONUTION

UTION

Do Not Restrict Air Flow

Restricting intake air with any type of filter on or around the

Plasma console will result in overheating and may void the

warranty.

3.3 Placement

• A minimum of 2 ft. (0.61m) clearance for cooling air flow.

• Plan for top panel and side panels having to be removed

for maintenance, cleaning and inspection.

• Locate the EPP-200 relatively close to a properly fused

electrical power supply.

• Keep area beneath power source clear for cooling air

flow.

• Environment should be relatively free of dust, fumes and

excessive heat. These factors will affect cooling

efficiency.

Conductive Dust And Dirt Inside Power

Source May Cause Arc Flash Over

Equipment damage may occur. Electrical shorting may

occur if dust is allowed to buildup inside power source.

See maintenance section.

Electric Shock Can Kill!

Provide maximum protection against electrical shock.

Before any connections are made inside the machine,

open the line wall disconnect switch to turn power off.

3.4 Input Connections to Console

Plasma

Console

19

SECTION 3SECTION 3

SECTION 3

INSTALLATIONINSTALLATION

INSTALLATION

NONO

NO

TICETICE

TICE

3.4.1 Primary Power Specifications

EPP-200 is a 3-phase unit. Input power must be provided from

a line (wall) disconnect switch that contains fuses or circuit

breakers in accordance to local or state regulations.

Recommended input conductor and line fuse sizes:

Dedicated power line may be necessary.

EPP-200 is equipped with line voltage compensation but to

avoid impaired performance due to an overloaded circuit,

a dedicated power line may be required.

* Sizes per National Electrical Code for a 75° C (165° F) rated

copper conductors @ 40° C (104° F) ambient. Not more than

four conductors in raceway or cable. Local codes should be

followed if they specify sizes other than those listed above.

Input current values given in this table are at maximum output

power (32kW) 200 amps at 160VDC.

Rated Load Input and Time delay

Ground Fuse size

Volts Amperes conductor* (amperes)

CU/AWG

200/208 115 1 150

230 100 2 125

380 60 4 80

415 55 6 70

460 50 6 70

575 40 8 60

20

SECTION 3SECTION 3

SECTION 3

INSTALLATIONINSTALLATION

INSTALLATION

3.4.2 Primary Power Hookup Procedure

The following procedure explains the proper installation steps

for connecting primary electrical power to the plasma console.

NOTE: Safety codes specify the power ground wire be

the last connection to break should the cable be pulled

out of the unit. When preparing the cable for connection,

make the ground wire 6 inches (152mm) longer than the

three pr primary wires.

1. Ensure input power cable is disconnected from all electrical

sources.

2. Remove right side panel (as viewed from front of console).

3. Route input power cable through the strain relief located at

the rear panel.

4. Pull input power cable through the strain relief to allow cable

wires sufficient length to connect to main contactor. Tighten

strain relief to ensure input power cable is secured.

5. Connect input power cable ground wire to the ground lug

provided above TB2 (7 position terminal block).

6. Connect three power leads of input power cable to terminals

located atop the main contactor. Secure the leads by tightening

each screw.

7. Connect jumper power cables from bottom of the main

contactor to proper input voltage marked on auto transformer.

Unit is factory set for 575V as shown at the left.

8. Connect jumper on TB2 to proper input voltage. This 7

position terminal block jumper is factory set to 575V.

Input Power Jumper Connection

Ensure each input power jumper cable is connected to

correct input voltage on autotransformer and on TB2.

Factory wired for 575 Volts

CACA

CA

UTIONUTION

UTION

Input Power Cable

Strain Relief

Main

Contactor

Ground

Connection

7 Position

Terminal

Block

Auto

Transformer

Factory wired

for 575 volts

21

SECTION 3SECTION 3

SECTION 3

INSTALLATIONINSTALLATION

INSTALLATION

9. Connect input conductors to line (wall) disconnect.

10. Replace side panel. Replace only if all connections have

made. Output connections require this panel to be removed.

11. Connect the other end of work cable to workpiece or

cutting table. Connection must be made to a clean, exposed

metal surface, free of paint, rust, mill scale, etc.

Electric Current Is Hazardous.

It is important to have a good earth ground connected to

the workpiece or cutting table.

WARNINGWARNING

WARNING

Work ground to work piece

Work ground to cutting table

22

SECTION 3SECTION 3

SECTION 3

INSTALLATIONINSTALLATION

INSTALLATION

3.5 Connecting Plasma Torches to EPP-200 Console and Options

3.5.1 EPP-200 Output Cables, Hoses and Adapters (customer supplied)

EPP-200:

Lengths vary depending on system.

• Coolant Return

• Coolant Supply

• Pilot Arc Cable

• Electrode Cable

• Shield Gas (directly to the Plumbing Box)

• Start Gas (directly to the Plumbing Box)

• Cut Gas (directly to the Plumbing Box)

• Work Cable

• Pendant Cable (if pendant option is ordered)

See Description, Section 2 for part numbers.

A remote SETUP Panel option (P/N 22000) is available on

Avenger 1 and larger ESAB cut cutting machines. This panel

operates the same as the pendant. Refer to your machine

manual for replacement parts.

23

SECTION 3SECTION 3

SECTION 3

INSTALLATIONINSTALLATION

INSTALLATION

Commercial Antifreeze Will Cause Torch To

Malfunction.

Use special torch coolant. P/N 156F05

Due to high electrical conductivity, DO NOT use tap water

or commercial automotive type antifreeze for torch cooling.

A specially formulated torch coolant is REQUIRED. This

coolant also protects from freezing to -34° C (-29° F).

Operating the unit without coolant will cause permanent

damage to the coolant pump.

Check coolant level frequently.

Remove coolant fill cap at front console and fill coolant tank

with 4 gallons (15 liters) of plasma torch coolant, P/N 156F05

(one gallon / 3.8 liters).

• Do not fill above indicated maximum level.

• Reinstall cap.

CACA

CA

UTIONUTION

UTION

Electric Current Is Hazardous.

It is important to have a good earth ground connected to

the workpiece or cutting table.

WARNINGWARNING

WARNING

3.6 Coolant Installation

Coolant Fill Cap

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SECTION 4SECTION 4

SECTION 4

OPERATIONOPERATION

OPERATION

DD

D

ANGERANGER

ANGER

4.1 Introduction – Operational Safety

Electric Shock Can Kill!

Disconnect current supply at wall disconnect before

servicing console, torch or plumbing box.

• Do not operate console or plumbing box with any covers

removed/open.

• Do not touch any torch front-end parts with power on.

• Do not attempt to service any portion of this plasma

system unless power has been disconnected at the wall

disconnect.

WARNINGWARNING

WARNING

This equipment can be hazardous if not

properly operated and maintained.

Read and understand all equipment literature and warning

labels before operating this equipment.

WARNINGWARNING

WARNING

Plasma Arc Cutting Can Be Hazardous To

Eyes And Ears.

• Wear hearing protection.

• Wear eye protection specifically designed for arc

welding and cutting. Lenses should be at least a No. 6

or No. 7 lens shade.

• Wear protective clothing to avoid skin burns.

26

SECTION 4SECTION 4

SECTION 4

OPERATIONOPERATION

OPERATION

4.2 Operating the EPP-200 Console

4.2.1 Console Controls

1 Pilot Arc High/Low Switch

2 Cutting Voltage and Cutting Current Meters

3 Output Current Control

4 Remote/Panel Selection Switch

5 Gas Test Switch

6 Fault Lights

7 Main Power Switch

Pilot Arc Switch

Used to select pilot arc current range when Remote / Panel

Switch is in the Panel position. HIGH position is used for most

cutting applications. Electrode life is adversely affected when

used in high position when low is suitable. Starting may be

difficult if set on low when high is required. Related to the initial

torch standoff height.

Cutting Voltage and Current Meters

“A” meter indicates actual cutting current, 0-200 amperes

“V” meter indicates actual output voltage, 0-160 VDC

Output Current Control

Sets the cutting current when current settings are made from

the power console front panel. (The Remote/Panel switch must

be in the Panel position.)

Remote/Panel Switch

Panel position – Output current is set by the output current

control on the console front panel as described above.

Remote position – Output current is set by the CNC with an

analog dc signal.

1

2

3

4

5

6

7

27

SECTION 4SECTION 4

SECTION 4

OPERATIONOPERATION

OPERATION

Gas Test Switch

Cut – Allows for setup of cut gas pressure and flow. Start/

Shield – Setup of gas pressures and flows.

Operate – Default position – Must be in this position for

cutting.

Fault Indicator Lights

• Coolant Flow – Will show low coolant flow. Light will

briefly show a fault when console is turned on and then

go out.

• Plasma Gas Pressure — fault indicator – low plasma

gas pressure. Torch will not fire when illuminated.

• Interlock Fault – Indicates Remote Plumbing box door

is not properly closed.

• P/S Temp – fault indicator – over temperature condition

in the inverter power source.

• P/S Fault – fault indicator – Not used.

• Over/Under Voltage – fault indicator – input voltage is

above or below tolerances of the power source console.

Will stay shut down console until main power switch is

recycled and fault is corrected.

Main Power Switch

Controls the input power to the fan, water cooler, inverter and

interface circuitry. Light illuminates to indicate power is on.

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ESAB EPP-200 Precision Plasmarc Cutting Console User manual

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