ESAB PLASMAWELD 202 User manual

Brand: ESAB

Model: PLASMAWELD 202

Category: Welding System

Type: User manual

This manual is also suitable for

ESAB PLASMAWELD 202 is a versatile welding machine designed for both manual and automatic plasma welding applications. It offers a wide range of features and capabilities that make it suitable for a variety of welding tasks.

The PLASMAWELD 202 can be used for welding high-, low- and unalloyed steel, nickel, copper, titanium, zirconium, and their alloys. It has a built-in water cooler for the torch, making it easy to transport and use in confined spaces.

The machine features a constant current control, ensuring that the welding current remains stable even when the mains voltage or arc length varies. This results in high-quality welds with minimal distortion.

0457 974 074

Plasmaweld 202,

Plasmaweld 402

Instruction manual

INDEX Page

Safety advice 3

Technical data PLW 202 4

Technical data PLW 402 5

Technical description 6

Installation 7

Welding 9

Data sheet plasma welding 13

Accessories 14

Maintenance 14

Trouble shooting 15

Spare parts 16

!WARNING!

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND

OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR

EMPLOYER'S SAFETY PRACTICES WHICH SHOULD BE BASED ON

MANUFACTURER'S HAZARD DATA .

!ELECTRIC SHOCK - CAN KILL!

* Install and earth the welding or cutting equipment 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 workpiece.

* Ensure that your working place is safe.

!FUMES AND GASES - CAN BE DANGEROUS TO HEALTH!

* Keep your head out of the fumes.

* Use ventilation, extraction of fumes at the arc or both to keep fumes and gases out of your

breathing zone and the general area.

!ARC RAYS - CAN INJURE EYES AND BURN SKIN!

* Protect your eyes and body. Use the correct welding screen and filter lens and wear

protective, insulating and non-flammable clothing.

* Protect bystanders with suitable screens or curtains.

!FIRE HAZARD!

* Sparks and spatters can cause fire. Make sure, that there is no inflammable material in the

surrounding of welding and cutting works.

!MALFUNCTION!

* Call for expert assistance in the event of malfunction.

Read and understand the instruction manual before installation and operation

!Protect yourself and others!

WARNING.doc

Plasmaweld 202

Technical Data

TDE202.doc * = option

Mains voltage (V) 3-phase 230 400 *460 500

M Permanent power (kVA) 9,7 9,7 9,7

Permanent current (A) 24,4 14,0 12,2 11,2

I Max. current (A) 31,4 18,0 15,8 14,5

Power factor cos phi 0,85 0,84 0.85 0,85

Efficiency 0,80

S Frequency (Hz) 50/60

Fuses, slow blow (A) 35 20 16 16

______________________________________________________________________

W Current range DC 5 - 220 A

E Duty cycle Plasma, 60% at 220 A

(10 min cycle) TIG 100% at 170 A

L MMA

Open circuit voltage DC 98V DC

______________________________________________________________________

O Dimensions (mm) L/W/H 1040/570/940

S Weight (kg) 150

R Protection class IP 23 M

U Cooling F

C Insulation class F

T Standards EN 60974-1

I VDE 0544-1

O EN 50199

N S-Mark Yes

CE-mark Yes

Plasmaweld 402

Technical Data

TDE402.doc * = option

Mains voltage (V) 3-phase 230 400 *460 500

M Permanent power (kVA) 19,4 19,4 19,4 19,4

Permanent current (A) 49 28 24 22

I Max. current (A) 61353028

Power factor cos phi 0,85 0,85 0.85 0.85

Efficiency 0,80

S Frequency (Hz) 50/60

Fuses, slow blow (A) 63 35 35 35

______________________________________________________________________

W Current range DC 6 - 400 A

E Duty cycle Plasma, 60% at 400 A

(10 min cycle) TIG 100% at 310 A

L MMA

Open circuit voltage DC 98V DC

______________________________________________________________________

O Dimensions (mm) L/W/H 1060/620/885

S Weight (kg) 290

R Protection class IP 23 M

U Cooling F

C Insulation class F

T Standards EN 60974-1

I VDE 0544-1

O EN 50199

N S-Mark Yes

CE-mark Yes

Technical description

The plasma arc welding machines PLASMAWELD 202 and 402 have been developed for welding

with transferred arc, i. e. the main arc transfers from the tungsten to the work piece.

These units can also be used for TIG, TIG pilot arc and manual metal arc (MMA) welding.

The power supplies can be used in confined spaces and are labelled with the S-mark according to EN

60 974-1.

Infinitely variable adjustment of the welding current makes the units suitable for micro-plasma and

high current plasma as well as for plasma key hole welding.

The pilot arc , started by HF, remains ignited and permits safe and touch-free starting of the main

arc.

By means of rh 19“ rack control system, the units can be used for all manual and automatic plasma

welding applications.

The required welding current and gas flow can be preset before starting the welding operation.

The power supplies are equipped with a constant current control so variations of the mains voltage or

different arc length do not effect the current of the main arc.

The following materials can be welded:

high-, low- and unalloyed steel; nickel, copper, titanium , zirconium and their alloys.

The compact construction with built in water cooler for the torch enables easy transportation of the

machines.

WARNING

This product is intended for industrial use (Class A). In a domestic environment this product may

cause radio interference. It is the users responsibility to take adequate precautions.

The welding equipment creates a noise level of < 70 dB(A) at idle.

An emission level related to the work-place cannot be stated, because this value is depending on the

method and the surroundings. It is conditioned by a variety of parameters e.g. the welding or cutting

process, the kind of current, the power, the kind of material, resonance’s of the workpiece, the

surroundings and more.

Installation

On the last page of these instruction manual a picture of the unit marked with symbols is located.

Please unfold and refer to this page in conjunction with the following instructions.

1. Mains connection

The units are factory connected to 400 V 50/60 Hz. They also can be used on 230 V 50/60 Hz and

500 V 50/60 Hz mains. The wiring instruction for reconnection is located inside of the machines

near the input terminal (460V 50/60Hz option).

Important! In case the machines are used with 230 V mains voltage, the mains

cable delivered must be replaced by one with a bigger cross section.

230 V 400/460/500 V

PLW 202 4 x 4 mm² 4 x 2,5 mm²

PLW 402 4 x 10 mm² 4 x 4 mm²

The mains plug must comply to country regulations and must be connected by an electrician. Check

the mains voltage before the machine is switched on.

2. Coolant

Pull the plastic plug of the cooling unit and check the water level. Liquid level should be about 3 cm

(1“) below the filling hole. If not, top up the tank using LoDuct cooling fluid.

Caution! Electrolytic corrosion may shorten the live time of the torch, when normal mains

water is used

Lo Duct contains glycol. Do not give access to children. Injurious to health

when drunk.

3. Gas connection

At the rear of the machine a cylinder mounting position is provided. The cylinders must always be

secured with the chains. Fit the regulators and the gas hoses for Ar/H

and Ar to the cylinders.

Connect the other ends of the hoses to the corresponding connections clearly marked on the back

side of the machines. Open the valve of the bottle slowly and adjust the gas pressure to 6 bar.

Optional two different flow meter slide-in modules are available. It depends on the welding

application which type of flow meter slide-in module is required.

Welding gas: Pilot gas: Slide-in module: Standard at:

0 - 20 l/min 0 - 1 l/min 1 261 046 PLW 202

0 - 12 l/min 0 - 7 l/min 1 261 035 PLW 402

4. Torch connection

The manual welding torches PT 75 and PT-150 as well as the machine torches PT-8 and PT 300 can

be connected with the central connector easily and without tools. Make sure, that the water in- and

outlet hoses are connected to the corresponding colour coded quick connections.

At socket

A the control plug is connected, when manual torches are fitted, whereas a foot switch has

to be fitted to this socket, when machine torches are used.

The pilot circuit is connected to the torch via socket

5.Pilot arc current adjustment

The PLW 402 pilot arc current is factory set for PT-300 and PT-8 to 10 A. If PT-75 or PT-150 resp.

PTM-150 are used, pilot current must be reduced to 5A. This is performed by eliminating jumper at

resistor R105.

The PLW 202 pilot arc current is factory set to 5A and can be increased to 10A by connecting

jumper at resistor R105.

Disconnect machine from mains before opening the machine!

6. Connection of work return lead and electrode holder lead

a) The work return lead is connected to socket

H marked with symbol work clamp.

b) When MMA-welding the electrode holder has to be connected either to plus (+) or

minus (-) at socket

H depending on the kind of electrode to be welded.

7. Connection of remote controls

At the 5-pole socket

G the following remote controls may be connected:

a) Foot remote control FC 4

b) Manual remote control

c) Pulse unit

Article numbers see accessories

8. Connection for automatic welding

With socket

b the machine can be connected to an automatic control (see wiring diagram)

Wiring diagram of 5-pole socket on adjusting board

Welding

A. Plasma Welding

1. Open cylinder valves and handwheels for gas flow rate at regulators.

2. Switch main switch

F on. Fan and water pump will start, lamp d will light.

3. Keep torch away from work

4. Set switch

i to symbol

5. set switch k to symbol

6. Push test button for plasma gas and adjust flow rate acc. to data sheet plasma welding

7. set switch

f to symbol (Pilot arc will ignite after a gas pre-flow time of

about 5 sec. and lamp

e will light up.

8. Keep button E depressed and adjust welding current. Amperage is preset at potentiometer a

and can be read from ammeter D.

9. Actuate torch switch or foot switch and adjust flow rate of shielding gas at the other

regulator.

Adjustment of tungsten with torch PT-8

Set switch f to mid position and operate torch switch or foot switch. HF will start. Check whether HF

sparks over to nozzle on all sides. If not, readjust tungsten electrode of torch

This adjustment is very important and should be repeated regularly

The electrodes of all other torches are centred by the insulation tube inside the torches automatically.

B. TIG - Welding

1. Substitute the plasma-torch by an appropriate TIG-torch.

2. Open cylinder valve and adjust gas flow rate to the value desired.

3. Switch main switch

F on. (Fan and water pump will start. Lamp d will light.

4. Set switch i to (4-stroke) or (2-stroke)

5. Set switch k to

6. Set switch

f to

7. Turn potentiometer

c counterclockwise to 0

8. Keep button

E depressed and adjust welding current. Amperage is preset at potentiometer a

and can be read from ammeter D.

C. TIG - Pilot - Welding

Connection of the plasma torch and adjustment of power supply is done as described under

paragraph A. Only the plasma torch has to be modified as follows:

Redrill the aperture of the torch tip to a diameter of 5,5 - 6,0 mm and slide out the electrode until it

protrudes about 1,5 mm beyond the tip face. Potentiometer

c must be turned to 0 during this welding

procedure.

D. Switching off Plasma- and TIG-Pilot-Welding

To switch off the pilot arc, set switch

f to mid position.

Wait about 15 sec. until the post flow time for the pilot gas has passed, before switching off the

machine with the main switch. During this time the electrode can cool down protected against

oxidation by the pilot gas.

Even in case of an emergency stop command by a automatic control the post flow process will be

initiated.

E. Manual Metal Arc Welding

1. Remove TIG- or plasma-torch control cable plug (Water pump is now out of

operation).

2. Connect electrode holder

3. Set switch k to symbol

4. Set switch f to mid position

5. Keep button E depressed and adjust welding current. Amperage is preset at potentiometer a

and can be read from ammeter D.

Welding

A. Plasma welding

1. Current down slope time can be adjusted at poti c to give a delay time of 0,5 to 5,0 s.

after the third operation in the 4-stroke mode has been activated (see t

in diagram).

2. Position of poti

h defines duration of current up-slope (see t

in diagram), whereas time of

down-slope t

is set at poti m.

3. Activate torch- or foot switch (lamp g will light) 1. and 2. stroke.

4. To finish the welding operation, down-slope is initiated by actuating torch- or foot- switch.

3. stroke (closing of keyhole)

5. After the time set at poti

c has passed, down-slope starts. When down-slope is over,

switch can be released.

B. TIG Welding

1. Position of poti h defines the duration of up-slope, while time of down-slope is set at

poti

2. Depending on the position of switch i, the machine can be operated in 2- or 4-stroke

mode:

2-stroke mode Symbol

1. Press torch- or foot-switch = Welding

2. Release torch- or foot-switch = End of welding and gas post-flow

4-stroke mode Symbol

1. Press torch- or foot-switch = Gas pre-flow and HF

2. Release torch- or foot-switch = Welding with current up-slope

3. Press torch or foot-switch = Current down-slope

4.Release torch- or foot-switch = End of welding and gas post-flow

C. TIG pilot arc welding

Welding process runs as with Plasma welding

D. MMA Welding

1. Hot-Start

When switch-potentiometer

h is in position 0, current drops down immediately from

maximum value of power supply to preset value.

2. Soft-Start

When switch-potentiometer

h is turned clockwise, soft-start function is switched on.

Up-slope time from basic current to preset welding current is infinitely variable.

Data for plasma welding (Recommended values)

Material Material-

thickness

(mm)

Edge-

preparati

Welding

current

(A)

Pilot gas

Gas Flow-

rate

(l/min)

Welding gas

Gas Flow-

rate

(l/min)

Travelspeed

(cm/min)

For torch PT-150

Stainless

Steel

0,5

1,5

2,0

3,0



0,3

0,5

0,7

1%H

+Ar

5%H

+Ar

5%H

+Ar

5%H

+Ar

Carbon-

Steel

1,5

3,0



100

0,7

Titanium 0,6

1,2

0,3

2,0

For torches PT-8 and PT-300

Stainless

Steel

0,5

1,5

2,4

4,5

9,5

3,0

Root-

pass

Coverpass



170

260

245

220

0,3

0,5

2,4

6,0

4,0

6,0

0,7

1%H

+Ar

5%H

+Ar

5%H

+Ar

5%H

+Ar

5%H

+Ar

5%H

+Ar

5%H

+Ar

Carbon-

Steel

1,5

3,2

3,0



185

100

0,7

5,0

0,7

5%H

+Ar

Accessories

A. For Plasma Welding

1. Pulse unit p/n: 1 090 123

2. Manual remote control 8 m cable p/n: 1 090 124

16 m cable p/n: 1 090 125

25 m cable p/n: 1 090 126

3. Foot remote control FC 4 p/n: 1 090 130

ATTENTION: If foot remote control is used, switch-

i must be in pos.

and poti

c set to 0.

B. for TIG welding only

Combined pulse-/dual current-control p/n: 1 270 253

Maintenance

REMARK

This plasma welding unit is designed, manufactured and tested for

highest quality standards in order to ensure long trouble-free service

life. Regular maintenance is, however, of utmost importance for reliable

and safe operation of the unit. Your attention is therefore drawn to all

maintenance instructions included in this operating manual.

As a general rule each welding unit should be thoroughly inspected,

tested and serviced at least once a year. In the case of high loading

of the units, maintenance should be performed more frequently.

Wear is a slow process in the case of electro-mechanical and moving

components in particular. If wear is detected in good time, repair

costs are kept low and advantages are significant as regards performance,

reliability and safety. Unnoticed wear can become dangerous both for the

equipment and the user.

Have this unit inspected and maintained by authorised dealers at

regular intervals.

Note: Use original ESAB parts throughout; otherwise the warranty will

rendered null and void.

Trouble shooting

All ESAB units are subjected to a thorough quality control check and final inspection. Nevertheless,

if there is a malfunction, please make a first check for general faults as follow:

• Main input voltage

• Fuses

• Gas supply

• Electrical connections

• Fault indications

• Digital readout

• Are fans and water pump running

• Unusual noise

• Mistake in operation

• Torch problems

• HF

• Open circuit voltage (Set switch

k to symbol and measure between output)

• Check logic functions of power source

If you can’t solve the problem, please get in contact with our service department.

Spare parts list for power source PLW 202/402

Item: Designation: PLW 202

art No.:

PLW 402

Part No.:

Designation

on circuit

diagram:

1 Control panel PLW 202/402 kpl. 1 170 168 1 170 168 A101

2 Pilot receptacle 1 441 834 1 441 834 X107

3 Receptacle for welding cable 70

1 440 698 1 440 698

4 Central connection 1 260 795 1 260 795 ZA

5 Receptacle 5-pol. 1 440 162 1 440 162 X101

6 Main switch 1 441 317 1 442 523 Q101

7 Water connection 1 260 983/984 1 260 983/984

Item: Designation: PLW 202/402

Part No.:

Designation on

circuit diagram:

8 Display board 1 270 363 A107

9 Gas test push bottom 1 442 005

10 Adjusting board PLW 1 270 295 A102

11 Rotating knob 1 440 214

12 Regulator board 1 270 254 A103

13 Logic board 1 270 447 A104

14 Flowmeter pilot gas 0-7 l/min 1 431 846

14.1 Flowmeter pilot gas 0-1 l/min 1 431 473

15 Flowmeter welding gas 0-12 l/min 1 431 845

15.1 Flowmeter welding gas 0-20 l/min 1 431 472

16 Signallamp green 1 440 901

16.1 Lamp 60V 1 440 902

17 Signallamp whit 1 441 523

18 Switch 1 441 381

19 Rotating knob 1 430 941

8 9 10 11 12 13 14 15

17 18 17 19 18

Item: Designation: PLW 202/402

Part No.:

Designation

on circuit

diagram:

20 HF-Generator SIG 3.1 1 170 100 G101

21 Resistor 330R/55W 1 440 979 R106

22 Contactor 42V 1 442 708 K101-K103,

K105, K106

23 Capacitor fan 3µF/400V 1 441 785 C103

24 Water pump incl. capacitor 1 431 679 M105, C105

25 Fan 150mmØ 1 441 550 M106, M107

26 Relays board 1 270 517 A110

26.1 Water flow switch 1 431 657 F106

27 Gas solenoid valve 42VAC 1 440 327 Y103

28 Relays Pilot 1 440 377 K104

26.1

22 23 24

Item: Designation: PLW 202

Part No.:

PLW 402

Part No.:

Designation on

circuit

diagram:

29 Filter board 1 270 614 1 270 614 A106

30 Thyristorbridge 1 443 024 1 441 530 A108

31 Steering roller 1 430 640 1 430 640

32 Main inductor 1 130 061 1 130 059 L101

33 HF- inductor 1 130 037 1 130 080 L102

34 Pedestal mounted roller 1 430 639 1 430 639

35 Fan 300mm Ø 1 442 707 1 442 707 M103

36 Main transformer 1 120 266 1 120 256 T101

31 32 33 34

Item: Designation: PLW 202/402

Part No.:

Designation

on circuit

diagram:

37 Fuse 4A slow blow (5x20mm) 1 440 459 F101, F102

38 Fuse1,6A slow blow (5x20mm) 1 440 769 F103, F104

Fuse holder 1 440 016

Screw cap 1 440 017

39 Pilot- and base current rectifier 1 441 529 V102

40 Gas solenoid valve 1 440 327 Y101, Y102

41 Pilot- u. base current resistor 5R6/12R/1000W 1 441 581 R101, R105

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ESAB PLASMAWELD 202 User manual

Brand: ESAB

Model: PLASMAWELD 202

Category: Welding System

Type: User manual

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ESAB PLASMAWELD 202 User manual

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