ESAB PLASMAWELD 402 User manual

ESAB
Brand
ESAB
Model
PLASMAWELD 402
Category
Welding System
Type
User manual

This manual is also suitable for

0457 974 074
Plasmaweld 202,
Plasmaweld 402
Instruction manual
2
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
3
!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
4
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
A
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
N
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
D
I
Open circuit voltage DC 98V DC
N
G
______________________________________________________________________
C
O Dimensions (mm) L/W/H 1040/570/940
N
S Weight (kg) 150
T
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
5
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
A
Permanent current (A) 49 28 24 22
I Max. current (A) 61353028
Power factor cos phi 0,85 0,85 0.85 0.85
N
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
D
I
Open circuit voltage DC 98V DC
N
G
______________________________________________________________________
C
O Dimensions (mm) L/W/H 1060/620/885
N
S Weight (kg) 290
T
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
6
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.
7
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
2
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
C.
8
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
9
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
10
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.
11
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
a
in diagram).
2. Position of poti
h defines duration of current up-slope (see t
r
in diagram), whereas time of
down-slope t
f
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.
12
B. TIG Welding
1. Position of poti h defines the duration of up-slope, while time of down-slope is set at
poti
m.
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.
13
Data for plasma welding (Recommended values)
Material Material-
thickness
(mm)
Edge-
preparati
on
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
II
II
II
16
45
90
80
Ar
Ar
Ar
Ar
0,3
0,3
0,5
0,7
1%H
2
+Ar
5%H
2
+Ar
5%H
2
+Ar
5%H
2
+Ar
7
12
12
10
25
25
30
15
Carbon-
Steel
1,5
3,0
II
80
100
Ar
Ar
0,7
0,7
Ar
Ar
10
10
20
20
Titanium 0,6
1,2
II
II
13
60
Ar
Ar
0,3
2,0
Ar
Ar
8
12
17
50
For torches PT-8 and PT-300
Stainless
Steel
0,5
1,5
2,4
4,5
9,5
3,0
II
II
II
II
Y
Root-
pass
Coverpass
16
45
170
260
245
220
80
Ar
Ar
Ar
Ar
Ar
Ar
Ar
0,3
0,5
2,4
6,0
4,0
6,0
0,7
1%H
2
+Ar
5%H
2
+Ar
5%H
2
+Ar
5%H
2
+Ar
5%H
2
+Ar
5%H
2
+Ar
5%H
2
+Ar
7
12
12
12
12
12
10
25
25
50
35
25
20
15
Carbon-
Steel
1,5
3,2
3,0
II
II
80
185
100
Ar
Ar
Ar
0,7
5,0
0,7
Ar
5%H
2
+Ar
Ar
10
12
10
20
30
20
14
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.
15
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.
16
Spare parts list for power source PLW 202/402
Item: Designation: PLW 202
P
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
2
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
1
2
3
4
5
6
7
17
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
16
17 18 17 19 18
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
22
26
26.1
25
25
27
28
20
21
22 23 24
19
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
29
30
31 32 33 34
35
36
20
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
37
38
39
40
41
Page is loading ...
Page is loading ...
  • Page 1 1
  • Page 2 2
  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
  • Page 7 7
  • Page 8 8
  • Page 9 9
  • Page 10 10
  • Page 11 11
  • Page 12 12
  • Page 13 13
  • Page 14 14
  • Page 15 15
  • Page 16 16
  • Page 17 17
  • Page 18 18
  • Page 19 19
  • Page 20 20
  • Page 21 21
  • Page 22 22

ESAB PLASMAWELD 402 User manual

ESAB
Brand
ESAB
Model
PLASMAWELD 402
Category
Welding System
Type
User manual
This manual is also suitable for
Download PDF
report

Ask a question and I''ll find the answer in the document

Finding information in a document is now easier with AI

Related papers

Other documents