ESAB PLASMAWELD 202 User manual

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/H2and 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 Athe 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.

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 Hmarked 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 Gthe 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 bthe 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 Fon. Fan and water pump will start, lamp dwill light.

3. Keep torch away from work

4. Set switch ito symbol

5. set switch kto symbol

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

7. set switch fto symbol (Pilot arc will ignite after a gas pre-flow time of

about 5 sec. and lamp ewill light up.

8. Keep button Edepressed 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 fto 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 dwill light.

4. Set switch ito (4-stroke) or (2-stroke)

5. Set switch kto

6. Set switch fto

7. Turn potentiometer ccounterclockwise to 0

8. Keep button Edepressed 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 cmust be turned to 0 during this welding

procedure.

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

To switch off the pilot arc, set switch fto 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 kto symbol

4. Set switch fto mid position

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

and can be read from ammeter D.

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