ESAB PLASMAWELD 202 Instruction Manual Download

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0457 974 074

Plasmaweld 202,

Plasmaweld 402

Instruction manual

Summary of Contents for PLASMAWELD 202

Page 1: ...0457 974 074 Plasmaweld 202 Plasmaweld 402 Instruction manual ...

Page 2: ...ge 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 ...

Page 3: ...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 HA...

Page 4: ... 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 I...

Page 5: ...w 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 Insul...

Page 6: ...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 ...

Page 7: ...ns 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 H2 and Ar to the cylinders Connect the other ends of the hoses to the corresponding connections clearly marked on t...

Page 8: ...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 re...

Page 9: ...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 Weldi...

Page 10: ...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 contr...

Page 11: ...tion of poti h defines duration of current up slope see tr in diagram whereas time of down slope tf 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 ...

Page 12: ... 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...

Page 13: ...H2 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 H2 Ar 5 H2 Ar 5 H2 Ar 5 H2 Ar 5 H2 Ar 5 H2 Ar 5 H2 Ar 7 12 12 12 12 12...

Page 14: ... 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 i...

Page 15: ...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 ...

Page 16: ...rol 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 702 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 ...

Page 17: ...lator 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 ...

Page 18: ... 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 ...

Page 19: ...06 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 ...

Page 20: ... 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 21: ...21 Reference pictures for the installation instruction on page 7 G C H A F B b G a l d e f g h i E m k D ...

Page 22: ...RLAND ESAB AG Dietikon Tel 41 1 741 25 25 Fax 41 1 740 30 55 North and South America ARGENTINA CONARCO Buenos Aires Tel 54 11 4 753 4039 Fax 54 11 4 753 6313 BRAZIL ESAB S A Contagem MG Tel 55 31 333 43 33 Fax 55 31 361 31 51 CANADA ESAB Group Canada Inc Missisauga Ontario Tel 1 905 670 02 20 Fax 1 905 670 48 79 MEXICO ESAB Mexico S A Monterrey Tel 52 8 350 5959 Fax 52 8 350 7554 USA ESAB Welding ...

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