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 before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions 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 immediately. 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 service facility designated by the manufacturer.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
according to the Low Voltage Directive 2006/95/EC, according to the EMC Directive 2004/108/EC
FÖRSÄKRAN OM ÖVERENSSTÄMMELSE
enligt Lågspänningsdirektivet 2006/95/EG, enligt EMC-Direktivet 2004/108/EG
Type of equipment Materialslag
Plasma Cutting Console
Brand name or trade mark Fabrikatnamn eller varumärke
ESAB
Type designation etc. Typbeteckning etc.
EPP-201, (0558007800) & EPP-360 (0558007831)
Manufacturer or his authorised representative established within the EEA
Name, address, telephone No, telefax No: Tillverkarens namn, adress, telefon, telefax:
ESAB AB
Esabvägen, SE-695 81 Laxå, Sweden
Phone: +46 586 81000, Fax: +46 584 411 924
The following harmonised standard in force within the EEA has been used in the design:
Följande harmoniserande standarder har använts i konstruktionen:
EN 60974-1, Arc welding equipment – Part 1: Welding power sources
EN 60974-10, Arc welding equipment – Part 10: Electromagnetic compatibility (EMC) requirements
Additional information: / Tilläggsinformation: Restrictive use, Class A equipment, intended for use in locations other than
residential
By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorised
representative established within the EEA, that the equipment in question complies with the safety requirements
stated above.
Genom att underteckna detta dokument försäkrar undertecknad såsom tillverkare, eller tillverkarens representant inom
EES, att angiven materiel uppfyller säkerhetskraven angivna ovan.
Signature / Underskrift Position / Befattning
Global Director
Equipment and Automation
Kent Eimbrodt
Clarification
Date / Datum
Laxå 2007-12-20
4
SECTION 1 SAFETY PRECAUTIONS
1.0 Safety Precautions
Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that anyone
who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet
the requirements that apply to this type of welding or plasma cutting equipment. The following recommendations
should be observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well acquainted with the operation of the welding or plasma
cutting equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in
injury to the operator and damage to the equipment.
1. Anyone who uses welding or plasma cutting equipment must be familiar with:
- its operation
- location of emergency stops
- its function
- relevant safety precautions
- welding and / or plasma cutting
2. The operator must ensure that:
- no unauthorized person stationed within the working area of the equipment when it is started up.
- no one is unprotected when the arc is struck.
3. The workplace must:
- be suitable for the purpose
- be free from drafts
4. Personal safety equipment:
- Always wear recommended personal safety equipment, such as safety glasses, ame proof
clothing, safety gloves.
- Do not wear loose tting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions:
- Make sure the return cable is connected securely.
- Work on high voltage equipment may only be carried out by a qualied electrician.
- Appropriate re extinquishing equipment must be clearly marked and close at hand.
- Lubrication and maintenance must not be carried out on the equipment during operation.
5
SECTION 1 SAFETY PRECAUTIONS
WELDING AND PLASMA CUTTING CAN BE INJURIOUS TO YOURSELF AND
OTHERS. TAKE PRECAUTIONS WHEN WELDING OR CUTTING. ASK FOR
WARNING
ELECTRIC SHOCK - Can kill.
- Install and earth (ground) the welding or plasma cutting unit 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 the workpiece.
- Ensure your working stance is safe.
FUMES AND GASES - Can be dangerous to health.
- Keep your head out of the fumes.
- Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone
and the general area.
YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE BASED ON
MANUFACTURERS’ HAZARD DATA.
ARC RAYS - Can injure eyes and burn skin.
- Protect your eyes and body. Use the correct welding / plasma cutting screen and lter lens and wear
protective clothing.
- Protect bystanders with suitable screens or curtains.
FIRE HAZARD
- Sparks (spatter) can cause re. Make sure therefore that there are no inammable materials nearby.
NOISE - Excessive noise can damage hearing.
- Protect your ears. Use earmus or other hearing protection.
- Warn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
6
SECTION 2 DESCRIPTION
2.0 Description
2.1 Introduction
The EPP power source is designed for marking and high speed plasma mechanized cutting applications. It can
be used with other ESAB products such as the PT-15, PT-19XLS, PT-600 and PT-36 torches along with the Smart
Flow II, a computerized gas regulation and switching system.
• 10 to 36 amperes for marking
• 30 to 360 amperes cutting current range
• Forced air cooled
• Solid state DC power
• Input voltage protection
• Local or remote front panel control
• Thermal switch protection for main transformer and power semiconductor components
• Top lifting eyes or base forklift clearance for transport
• Parallel supplemental power source capabilities to extend current output range.
2.2 General Specications
Part Number0558007831
Voltage200 VDC
Output
(100 % duty cycle)
Input
Current range DC (marking)10A to 36A
Current range DC (cutting)30A to 360A
Power72 KW
* Open Circuit Voltage (OCV)360 VDC
Voltage (3-phase)380 / 400V
Current (3- phase)140 / 132A RMS
Frequency50 / 60 HZ
KVA91.6 KVA
Power82.5 KW
Power Factor90.0 %
Input Fuse Rec.200A
EPP-360, CCC/CE, 380 / 400V,
50 / 60Hz
7
SECTION 2 DESCRIPTION
2.3 Dimensions and Weight
40.75”
(1035 mm)
23.75”
(603.25 mm)
47.25”
(1200 mm)
Weight = 1085 lb
8
SECTION 3 INSTALLATION
3.0 Installation
3.1 General
FAILURE TO FOLLOW INSTRUCTIONS COULD LEAD TO DEATH, INJURY
OR DAMAGED PROPERTY. FOLLOW THESE INSTRUCTIONS TO PRE
WARNING
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.
VENT INJURY OR PROPERTY DAMAGE. YOU MUST COMPLY WITH LO
CAL, STATE AND NATIONAL ELECTRICAL AND SAFETY CODES.
3.3 Placement
• A minimum of 1 meter (3 ft.) clearance on front and back for cooling air ow.
• Plan for top panel and side panels having to be removed for maintenance, cleaning and inspection.
• Locate the EPP-360 relatively close to a properly fused electrical power supply.
• Keep area beneath power source clear for cooling air ow.
• Environment should be relatively free of dust, fumes and excessive heat. These factors will aect cooling eciency.
Conductive dust and dirt inside power source may cause arc ash-
CAUTION
over. Equipment damage may occur. Electrical shorting may occur if
dust is allowed to build-up inside power source.
See maintenance section.
9
SECTION 3 INSTALLATION
3.4 Input Power Connection
ELECTRIC SHOCK CAN KILL!
PROVIDE MAXIMUM PROTECTION AGAINST ELECTRICAL SHOCK.
WARNING
3.4.1 Primary Power
EPP-360 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.
BEFORE ANY CONNECTIONS ARE MADE INSIDE THE MACHINE, OPEN
THE LINE WALL DISCONNECT SWITCH TO TURN POWER OFF.
*** Recommended input conductor and line fuse sizes:** *
Input at Rated LoadInput and Ground
VoltsAmperes
38014050 (1)200
40013235 (2)150 slo-blo +10%/-0
Rated load is output of 360A at 200V
* Sizes per National Electrical Code for a 90° C (194˚ F) rated copper conductors @ 40° C (104˚ F) ambient. Not
more than three conductors in raceway or cable. Local codes should be followed if they specify sizes other
than those listed above.
To estimate the input current for a wide range of output conditions, use the formula below.
Input current =
NOTICE
Dedicated power line may be necessary.
EPP-360 is equipped with line voltage compensation but to avoid
impaired performance due to an overloaded circuit, a dedicated
power line may be required.
(V arc) x (I arc) x 0.73
conductor* CU/
mm2 (AWG)
(V line)
Time delay Fuse size
(amperes)
10
SECTION 3 INSTALLATION
3.4.2 Input Conductors
• Customer supplied
• May consist either of heavy rubber covered copper conductors (three power and one ground) or run
in solid or exible conduit.
• Sized according to the chart.
3.4.3 Input Connection Procedure
IMPROPER GROUNDING CAN RESULT IN DEATH OR INJURY.
WARNING
CHASSIS MUST BE CONNECTED TO AN APPROVED ELECTRICAL
GROUND. BE SURE GROUND LEAD IS NOT CONNECTED TO ANY PRI
MARY TERMINAL.
Chassis Ground
Power Input Cable Access Opening (Rear Panel)
1. Remove small rear panel of the EPP-360.
2. Thread cables through the access opening in the rear panel.
3. Secure cables with strain relief at the access opening.
4. Connect the ground lead to the stud on the chassis.
5. Connect the power leads to the primary terminals.
6. Connect the input conductors to the line (wall) disconnect.
7. Before applying power, replace the rear cover panel.
Primary Terminals
11
SECTION 3 INSTALLATION
3.5 Output Connections
ELECTRIC SHOCK CAN KILL! DANGEROUS VOLTAGE AND CURRENT!
ANY TIME WORKING AROUND A PLASMA POWER SOURCE WITH COV
ERS REMOVED:
WARNING
• DISCONNECT POWER SOURCE AT THE LINE (WALL) DISCONNECT.
• HAVE A QUALIFIED PERSON CHECK THE OUTPUT BUS BARS (POSITIVE AND NEGATIVE) WITH A VOLTMETER.
3.5.1 Output Cables (customer supplied)
Choose plasma cutting output cables (customer supplied) on the basis of one 4/0 AWG, 600 volt insulated copper cable for each 400 amps of output current.
Note:
Do not use 100 volt insulated welding cable.
12
SECTION 3 INSTALLATION
3.5.2 Output Connection Procedure
1. Open access panel on the lower front of the power source.
2. Thread output cables through the openings at the bottom of the power source immediately behind the front
panel.
3. Connect cables to designated terminals mounted inside the power source using UL listed pressure wire connectors.
4. Close front access panel.
Front Access
Panel Closed
13
Front Access
Panel Opened
SECTION 3 INSTALLATION
3.6 Parallel Installation
Two EPP-360 power sources may be connected together in parallel to extend the output current range.
3.6.1 Connections for Two EPP-360’s in Parallel
Note:
Primary power source has the electrode (-) conductor jumpered. The supplemental power
source has the work (+) jumpered.
1. Connect the negative (-) output cables to the arc starter box (high frequency generator).
2. Connect the positive (+) output cables to the workpiece.
3. Connect the positive (+) and negative (-) conductors between the power sources.
4. Connect the pilot arc cable to the pilot arc terminal in the primary power source. The pilot arc connection in
the supplemental power source is not used. The pilot arc circuit is not run in parallel.
5. Connect a power source paralleling control cable between the two power sources.
6. Connect the CNC control cable to the primary power source.
Connections for parallel installation of two EPP-360 power sources with both power sources in operation.
EPP-360EPP-360
S u p p l e m e n t a l
Power Source
work
(+)
2 - 4/0 600V
positive leads
to workpiece
electrode
(-)
P/S Parallel Control Cable
work
(+)
lead to pilot arc connection in arc starter
box (h.f. generator)
Primary Power
Source
pilot arc
1 - 14 AWG 600V
electrode
(-)
Control cable to water cooler
CNC
Control
Cable
2 - 4/0 600V
negative leads
in arc starter box
(h.f. generator)
14
SECTION 3 INSTALLATION
work
The EPP-360 does not have an ON/OFF switch. The main power is controlled through the line (wall) disconnect switch.
DO NOT OPERATE THE EPP360 WITH COVERS REMOVED. HIGH
VOLTAGE COMPONENTS ARE EXPOSED INCREASING SHOCK HAZ
WARNING
WARNING
ARD. INTERNAL COMPONENTS MAY BE DAMAGED BECAUSE COOL
ING FANS WILL LOSE EFFICIENCY.
ELECTRIC SHOCK CAN KILL!
EXPOSED ELECTRICAL CONDUCTORS CAN BE HAZARDOUS!
DO NOT LEAVE ELECTRICALLY “HOT“ CONDUCTORS EXPOSED. WHEN
DISCONNECTING THE SUPPLEMENTAL POWER SOURCE FROM THE
PRIMARY, VERIFY THE CORRECT CABLES WERE DISCONNECTED. IN
SULATE THE DISCONNECTED ENDS.
WHEN TWO POWER SOURCES ARE CONNECTED IN PARALLEL AND
ONE OF THE TWO IS NOT POWERED, OR IF THE PARALLELING CABLE
DOES NOT CONNECT THE TWO, THE NEGATIVE ELECTRODE CONDUC
TOR MUST BE DISCONNECTED FROM THE SUPPLEMENTAL POWER
SOURCE AND THE PLUMBING BOX. FAILURE TO DO THIS WILL LEAVE
THE SUPPLEMENTAL ELECTRICALLY “HOT”, UNSAFE, AS WELL AS IN
OPERATIVE.
Connections for parallel installation of two EPP-360 power sources with only one power source in operation.
EPP-360EPP-360
S u p p l e m e n t a l
Power Source
2 - 4/0 600V
positive leads
to workpiece
electrode
P/S Parallel Control
Cable
Disconnect negative
connection from secondary power source
and insulate to convert from two to one
power source
15
Primary Power
Source
work
electrode
Control cable to
water cooler
2 - 4/0 600V
negative leads
in arc starter box
(h.f. generator)
SECTION 3 INSTALLATION
3.6.2 Marking with Two Parallel EPP-360’s
Two EPP-360’s, connected in parallel, and can be used for marking down to 10A and cutting from 30A up to
720A.
OPERATION OF TWO PARALLEL EPP-360’S:
1. Provide start/stop, Cut/Mark, “HI CURRENT” logic signals and either logic or analog inputs to control the pilot
current signals to primary unit for both cutting and marking. When marking, both power sources are powered up, but the mark signal disables the output of the supplemental power source.
3.7 Interface Cable Connectors
E-Stop Connector
Remote Control (CNC)
Parallel Power Source
Coolant Circulator
16
SECTION 3 INSTALLATION
3.7.1 CNC Interface Cables with Mating Power Source Connector and Unterminated CNC Interface
GRN/YEL
RED #4
3.7.2 CNC Interface Cables with Mating Power Source Connectors at Both Ends
GRN/YEL
17
RED #4
SECTION 3 INSTALLATION
3.7.3 Water Cooler Interface Cables with Mating Power Source Connectors at Both Ends
3.7.4 Power Source Parallel Control Cable
18
SECTION 4 OPERATION
DANGEROUS VOLTAGES AND CURRENT! ELECTRIC SHOCK CAN KILL!
WARNING
4.0 Operation
4.1 EPP-360 Block Diagram
BEFORE OPERATION, ENSURE INSTALLATION AND GROUNDING PRO
CEDURES HAVE BEEN FOLLOWED. DO NOT OPERATE THIS EQUIP
MENT WITH COVERS REMOVED.
Main
Contactor
Main
Transformer
3 ~
Rectier
2 x 6000uf
450V
Capacitors
380/400V 3 ~
Input
3 x 2 Ohm
300 Watt
Resistors
Soft
Start
Relay
IGBT Driver
Board
4 x 400 Amp
IGBT’s
Control
Power
Fuses
1 ~
Control
Transformer
Relay / Interface
Board
Main Control
Board
CNC
Interface
&
Isolation
Inductor
Output
Front Panel
Display
19
SECTION 4 OPERATION
4.2 Control Panel
E
F
B
H
A
C
D
J
20
SECTION 4 OPERATION
4.2 Control Panel (con’t.)
A - Preset / Operate Switch
“Center” position = will show actual cut parameters
“Up” position = Pilot Arc Current Preset for either the Panel or Remote mode
“Down” position = Cut Current Preset for either the Panel or Remote mode
B - Over Temp
Indicator illuminates when power source has overheated.
C - Fault
Indicator illuminates when errors have occurred which require a main power reset of the unit.
D - Current Dial (Potentiometer)
EPP-360 dial shown. EPP-360 has a range of 10 to 360 A. Used only in panel mode.
E - Panel Remote Switch
Controls the location of current control.
• Place in the PANEL position for control using the current potentiometer.
• Place in REMOTE position for control from an external signal (CNC).
F - Meters
Displays voltage and amperage when cutting. The ammeter can be activated when not cutting to view an estimation of the cutting/marking current or pilot arc current before cutting begins. See “A” above. Also displays
various error codes that may occur.
G - E-Stop Connector (not shown)
The E-stop connector provides a normally closed contact of the E-stop switch. The contact is connected to J4-A
and J4-B. The contact opens after the E-stop button is pushed. This provides a signal to the plasma control that
the power source is in an E-stop condition.
H - E-Stop Button
The E-stop button operates the E-stop switch. When the button is pushed in an E-stop condition exists which
prevents the power source from providing output even when a start signal is provided.
J - CB1 - 3 amp
Circuit breaker for 115 vac to CNC.
21
SECTION 4 OPERATION
4.3 Modes of Operation
The EPP-360 operates in the Cutting Mode through a single continuously adjustable output current range from
30 amps through 360 amps using either the Current Potentiometer on the front panel, or a remote current reference signal fed into connector J1.
When using a remote signal, 1 volt corresponds to 36 amps, and 360 amps corresponds to a signal of 10.00
VDC.
The EPP-360 defaults to the Cutting Mode of operation unless the command signal from a remote control for
Marking Mode is supplied.
The power source is placed in Marking Mode with an external isolated relay or switch contact connecting J1-R
(115VAC) to J1-C. See Schematic Diagram included inside back cover. This contact closure must be made before
(50 mS or longer) issuing a Start or Contactor On command.
In the CNC Marking mode, the output current is adjusted through a single continuously adjustable range from
0 amps through 36 amps using the remote current reference signal fed into connector J1. In the Panel Marking mode, the output current can be adjusted from 0 - 36 amps using the panel potentiometer, as the unit is
shipped. If SW1-1 (which is open on the control board) is closed, the range becomes 0 -18 amps max.
When using a remote signal, 1 volt corresponds to 3.6 amps, and 36A corresponds to a signal of 10.00 VDC.
4.3.1. Single Power Source (used with the CNC, two basic modes of operation are possible)
1. Panel Mode - (switch is provided on the power source) Put Panel/Remote switch to Panel position. Used with
a limited capability CNC that can only provide a start/stop signal to the power source. The microcontroller in
the power source will accept the analog setting from the panel potentiometer as the cut current information.
Based on this value it will calculate the initial current value, the pilot arc and the upslope time. The cut value
and P.A. value can be displayed prior to cutting by moving the spring return switch on the power source to
the cut current preset, and the pilot arc preset positions. If the pilot arc current is deemed insucient, the
CNC can increase it by providing inputs on the PA0 and PA1 control leads. The increased values are as follows:
PA0PA1
oono change
onovalue increased by 12.5%
oonvalue increased by 25%
ononvalue increased by 37.5%
22
SECTION 4 OPERATION
24 CONDUCTOR CABLE
Plasma System Control
EPP-360
PA ON
WC FLOW FAULT: OFF WITH LO FLOW
MARK MODE SELECT
CLOSED FOR MARKING
I mark = (3.6) X (Vcut cur ref)
E-STOP: ISOLATED CONTACT
CLOSED TO RUN
MASTER SELECT - CONNECT H TO R (ALWAYS PRESENT)
+
CNC
15V15V
WC LEVEL: OFF
WITH FAULT
0 TO 10V0 TO 10V
15V CNC
COMMON
PLASMA START
PA CURRENT SELECT
PA CURRENT SELECT
CURRENT HI/LO
CLOSED FOR 720A; OPEN FOR 360A
(PARALLEL OPERATION ONLY)
not used
OPEN FOR INTERNAL CONTROL
CLOSED FOR EXTERNAL CONTROL
POWER SOURCE FAULT
MASTER CURRENT
CNC ANALOG COMMON
0 TO 10V0 TO 10V
CUT CURRENT REF
+
+
Icut = (36) X (Vcut cur ref)
Ipa = (4.5) X (Vpa cur ref)
ARC ON
PA CURRENT REF
FOR LO: Icut = (36) X (Vcut cur ref)
FOR HI: Icut = (72) X (Vcut cur ref)
CABLE
WIRE ID
RED 01
RED 02
RED 03
RED 04
RED 05
RED 06
RED 07
RED 08
RED 09
RED 10
RED 11
RED 12
RED 13
RED 14
RED 15
RED 16
RED 17
RED 18
RED 19
RED 20
RED 21
RED 22
RED 23
GRN/YEL
24-
CONDUCTOR
CONNECTOR
PA ON
A
WC FLOW FAULT: ON WITH FLOW OK
B
C
Z
E
F
G
H
K
L
+
M
N
+
P
Q
R
S
T
U
V
W
X
Y
D
MARK MODE SELECT
115V AC NEUTRAL
E-STOP
E-STOP
CNC +15V DC
MASTER SELECT
CURRENT REF COMJ
WC LEVEL (ON W/ LEVEL OK)
CUT CURRENT REF
PLASMA START
PA CURRENT REF
ARC ON
PA0
115V AC H
PA1
HI RANGE (720A)
not used
PROCESS CONTROL SELECTION
POWER SOURCE FAULT
ON WITH FAULT
HALL TRANSDUCER
PA CURRENT SELECT
PA CURRENT SELECT
PS 24V DC COMMON
MASTER OUTPUT CURRENT
SIGNAL 1.0V = 100A
CHASSIS
10K
K4
10K
20K
10K
10K
10K
10K
10K
10K
+
24V AC
20K
CNC +15V DC
24V24V
24V DC
COMMON
115V AC NEUTRAL
3A
FUSE
115V AC
+
23
SECTION 4 OPERATION
The table used to calculate the initial current, pilot current and upslope values are stored in the micro and contains the following information:
Cut Current
(amps)
302015200
502520250
1005025500
20010030800
30015035900
36018040950
Start Current
(amps)
Pilot Arc Current
Command (amps)
Upslope Time
(msec)
If values other than the table values are used for the cut current, the corresponding values are calculated assuming a linear slope for all the required parameters.
2. Remote Mode -
a. Partial CNC operation - (CNC cable pin “V” open, open for internal control) In this mode of operation the
panel/remote switch needs to be in the REMOTE position. The CNC should be providing the cut current reference and start/stop signal to the power source. Based on the cut reference the micro in the power source will
compute the initial current, pilot current and upslope time.
b. Remote with Full CNC Mode - (CNC cable pin “V” closed, closed for external control) Panel/remote switch
on the power source is set to REMOTE. The CNC should activate the input labeled “full CNC control” on pin
“V” of the interconnect cable. In this mode all parameters are controlled by the CNC, including start current,
pilot current and sloping times. The control of the pilot current can be done either by logic inputs or by an
analog input. If the analog input is less than 0.5 volts the power source will use the logic inputs PA0 and PA1
to provide the requested pilot arc current, based on the following combination:
PA0PA1Pilot current in amp
openopen10
closedopen20
openclosed30
closedclosed40
If the analog reference is used, 10 VDC will provide 45 amps or 1 V = 4.5 amps.
Marking - Can be done in both panel and remote mode and requires the mark mode select input to be closed
by the CNC. In the panel mode the maximum marking current (set by the panel potentiometer) is 36 amps.
If SW1-1 (which is open on the control board) is closed, the range becomes 0 -18 amps max. In the remote
mode the marking current is set by the main reference input and 10 VDC will provide 36 amps or 1 V = 3.6
amps of marking current.
24
SECTION 4 OPERATION
4.3.2 Multiple Power Sources
1. Parallel Mode of operation - Connect power sources together as shown in section 3.6. Set the panel/remote
switches on both power sources to remote. If the units will be used for cutting and both power sources are to
contribute to the cut current value, activate the logic input labeled “HI CURRENT” (pin “T”) on the CNC cable. In
this manner a maximum current of 720 amps can be provided for an analog input of 10 VDC from the CNC. If the
“HI CURRENT” input is deactivated the supplemental power source will not provide any output even though it is
connected to the primary power source. In marking mode only the primary power source will supply the marking current. If alternating marking and cutting operations are done, the “HI CURRENT” input can be maintained
and the mark input will control whether both or only one power source will provide output current. The marking
current range is from 10 to 36 amps and the cut current range is from 30 to 720 amps.
4.4 Sequence of Operation
A. Apply power by closing the line (wall) switch. The EPP-360 does not contain its own power On/O switch.
Once power is supplied, the EPP-360 display board will display “EPP-360” briey, followed by the display “Pr
x.xx”, indicating the software program revision number, then “0 amps” and “0 volts”.
B. Select Panel / Remote setting for current control depending on whether your CNC has remote current con-
trol capability.
1. If using the “Panel” mode, the selected cutting current may be viewed by holding the front panel switch
in the “Cut Current Preset” position. In the “Panel” mode, the Pilot Arc Current, Initial Current, and Upslope Time are determined by the power source based on the selected cutting current. The selected
Pilot Arc Current can be viewed by holding the front panel switch in the “PA Current Preset” position. See
section 4.2 Control Panel.
2. If using the “Remote” mode, there are two possible modes of operation.
a. The default mode is similar to the “Panel” mode with the exception that the cutting current com-
mand is supplied by the CNC instead of the front panel potentiometer. Scaling of the remote current command is 1.0 V DC = 36 amps. This mode is useful if the CNC does not have the capability
of controlling the initial current and sloping of the output. For remote control connections see the
CNC interface diagram.
b. If your CNC has the capability of controlling Initial Current and Slopes, place the Panel/Remote switch
in “Remote” and supply a contact closure between pins “R” and “V” of the CNC interface connector.
In this mode the CNC must supply the analog signal to control Initial Current, Upslope, and Cut Current level. Scaling is the same as default mode. Pilot Arc current will be controlled by a second 0 – 10
V DC analog signal, if available, or by supplying a binary coded signal as dened in the CNC interface
diagram. Scaling of the pilot arc signal is 10 V DC = 45 amps.
C. Begin plasma cutting operation. This may require setting of other variables such as gas pressures, ow rates,
and torch height etc.
D. If for any reason cutting or marking fails to initiate, the EPP-360 should display an error code indicating the
reason for the shutdown. See “Help Codes” in the troubleshooting section.
25
SECTION 4 OPERATION
26
SECTION 5 MAINTENANCE
5.0 Maintenance
5.1 General
ELECTRIC SHOCK CAN KILL!
WARNING
WARNING
CAUTION
5.2 Cleaning
SHUT OFF POWER AT THE LINE WALL DISCONNECT BEFORE AT
TEMPTING ANY MAINTENANCE.
EYE HAZARD WHEN USING COMPRESSED AIR TO CLEAN.
• Wear approved eye protection with side shields when cleaning the
power source.
• Use only low pressure air.
Maintenance On This Equipment Should Only Be Performed By
Trained Personnel.
Regularly scheduled cleaning of the power source is required to help keep the unit running trouble free. The
frequency of cleaning depends on environment and use.
1. Turn power o at wall disconnect.
2. Remove side panels.
3. Use low pressure compressed dry air, remove dust from all air passages and components. Pay particular
attention to heat sinks in the front of the unit. Dust insulates, reducing heat dissipation. Be sure to wear
eye protection.
Air restrictions may cause EPP-360 to over heat.
Thermal Switches may be activated causing interruption of func-
CAUTION
WARNING
tion.
Do not use air lters on this unit.
Keep air passages clear of dust and other obstructions.
ELECTRIC SHOCK HAZARD!
BE SURE TO REPLACE ANY COVERS REMOVED DURING CLEANING
BEFORE TURNING POWER BACK ON.
27
SECTION 5 MAINTENANCE
28
SECTION 6 TROUBLESHOOTING
ELECTRIC SHOCK CAN KILL!
DO NOT PERMIT UNTRAINED PERSONS TO INSPECT OR REPAIR THIS
WARNING
CAUTION
6.0 Troubleshooting
6.1 Troubleshooting Introduction
Check the problem against the symptoms in the following troubleshooting guide. The remedy may be quite
simple. If the cause cannot be quickly located, shut o the input power, open up the unit, and perform a simple
visual inspection of all the components and wiring. Check for secure terminal connections, loose or burned wiring or components, bulged or leaking capacitors, or any other sign of damage or discoloration.
EQUIPMENT. ELECTRICAL WORK MUST BE PERFORMED BY AN EXPE
RIENCED ELECTRICIAN.
Stop work immediately if power source does not work properly.
Have only trained personnel investigate the cause.
Use only recommended replacement parts.
The cause of control malfunctions can be found by referring to the sequence of operations, electrical schematics
and checking the various components. A volt-ohmmeter will be necessary for some of these checks.
6.2 Troubleshooting Guide
As the unit is powered up, the display should show EPP-360 for one second and then show the program number
such as: Pr 3.01 or higher. If the display remains blank, look for the following:
a. loose or missing display cable between the main control board and the display board
b. lack of +15 volt bias supply which could be caused by blown fuses F1 or F2
c. an open circuit breaker CB1 on the front panel.
If the unit shows Error 5 after the program number display times out, look for a closed start switch. To reset the
unit simply open the start switch. At this point the display should show 0’s in both windows. If the power source
is not connected to a CNC at power up, the emergency stop relay (K4) in the power source is not energized, preventing any relay operation in the power source itself.
If the CNC has been booted up the display should read 0 for both the volts and amps. The unit will not respond
to a start signal until it’s master select input (pin H on J1) is connected to the “HOT“ side of 115 input (master
select input). This connection is handled in the CNC to primary supply cable. Note all inputs from the CNC are
relay closures, providing 115 V AC inputs to the isolation board (PCB4 in the power source). The isolation board
converts these inputs to open collector type outputs. The control will monitor various signals in the idle mode
and will shut down with an error indication if the condition is not satisfactory: Errors 1, 3, 4, 5, 9 or 12 (See 6.3
Help code list).
As the start switch is activated and the unit is being prepared for cutting, additional conditions are being monitored. The resulting error conditions are as follows: Error 2, 6, 8, 12, 13, 14, 15, 17, 18, 19 or 113 (See 6.3 Help code
list).
29
SECTION 6 TROUBLESHOOTING
6.3 Help Code list
HELP CODES
01 LINE VOLT, IDLE08 TORCH ERROR15 BUS CHARGER FAILURE
02 LINE VOLT, CUTTING09 OCV OVER 40V, IDLE17 IGBT DRIVER ERROR
03 CONTROL BIAS10 OCV OVER 70V, STARTUP18 CUT/MARK VOLTAGE TOO LOW
05 START ON POWER UP13 OCV FAILURE20 SHORTED IGBT, BUS CHARGED
06 FAIL TO FIRE14 AMBIENT TEMP113 SLAVE P/S ERROR
Error number displays and their meaning for the EPP-360 power supply.
Error 1 +/- 15% deviation in the idle mode is exceeded.
Error 2 Line voltage during cut drops by more than 20 %.
Error 3Problem with the bias supplies on the control board. The +15 and -15 volt supplies are not balanced, board
should be replaced.
Error 4Thermal switch has opened. Unit is disabled until overheated component cools down. Look for fans not
working or restrictions on input or output louvers.
Error 5The start switch from the CNC was already on when the power source was powered up. Unit will not be
functional until start signal is removed and then reapplied.
Error 6Ignition did not take place during the 10 seconds allowed for arc ignition.
Note: This should rarely occur since the CNC has a much shorter time allowed for the ignition time and
will reset the power source to idle.
Error 7Not used.
Error 8Electrode current was present before the PWM was enabled. Most likely caused by an electrode to nozzle
short on the torch.
Error 9Open circuit voltage in idle mode was over 40 volts. Possible cause leaky IGBTs, faulty PWM drive.
Error 10Open circuit voltage is over 70 volts when unit is powered up. Possible cause leaky IGBT’s, faulty PWM.
Error 11Not used.
Error 12Shut down due to single phasing. Fuse blown in supply line circuit.
Error 13Open circuit voltage did not reach 300 volts in the allowed time. Check PWM circuit & E-Stop on J1.
Error 14Ambient temperature exceeded 55 C in control enclosure.
Error 15Bus voltage did not reach 100 volts during the allowed time. Bus charge relay or surge limiting resistors
defective
Error 16Not used
Error 17IGBT driver board error.
Error 18Cutting voltage fell below 70 volts during cutting or below 40 volts during marking.
Error 19Master is requested to engage slave power supply but slave is not present.
Error 20Open circuit voltage detected before PWM was engaged.
Error 113Error detected in slave power supply.
30
SECTION 6 TROUBLESHOOTING
6.4 Fault Isolation
6.4.1 Fans Not Working
ProblemPossible CauseAction
This is normal when not cutting.
All 3 fans do not run
1 or 2 fans do not run.
6.4.2 Torch Will Not Fire
ProblemPossible CauseAction
Fans run only when “Contactor On”
signal is received.
Broken or disconnected wire in fan
motor circuit.
Faulty fan(s)Replace fans
None
Repair wire.
Main Arc Transfers to the work with a
short “pop”, placing only a small dimple
in the work.
Arc does not start. There is no arc at the
torch. Open circuit voltage is OK.
Remote control removes the start
signal when the main arc transfers to
the work.
Panel/Remote switch in “Remote” with
no remote control of the current
Remote current control present but
signal missing.
Current pot set too low.Increase current pot setting.
Open connection between the power
source positive output and the work.
Pilot current and/or start current should
be increased for better starts when
using consumables for 100A or higher
(Refer to process data included in torch
manuals)
Faulty PCB1Replace PCB1
Place Panel/Remote switch in “Panel”
position
Check for current reference signal
between J and L on 24 pin receptacle should be between 0.5 - 10 volts
(10 volts = 360 amps)
Repair connection
Increase pilot current. (Refer to process
data included in torch manuals)
31
SECTION 6 TROUBLESHOOTING
32
SECTION 7 REPLACEMENT PARTS
7.0 Replacement Parts
7.1 General
Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on
the unit serial number plate.
7.2 Ordering
To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this
equipment. The use of non-ESAB parts may void your warranty.
Replacement parts may be ordered from your ESAB Distributor.
Be sure to indicate any special shipping instructions when ordering replacement parts.
Refer to the Communications Guide located on the back page of this manual for a list of customer service phone
numbers.
EPP-360 Information
EPP-360, CCC/CE, 380 / 400V,
Part Number
50 / 60Hz
0558007831
Note
Items listed in the following Bill of Materials that do not have a part number
shown are not available from ESAB as a replaceable item and cannot be
ordered. Descriptions are shown for reference only. Please use local retail
hardware outlets as a source for these items.
Note
Replacement Parts, Schematics and Wiring Diagrams are
printed on 279.4mm x 431.8mm (11” x 17”) paper and are
included inside the back cover of this manual.
33
NOTES
34
REVISION HISTORY
1. Original release - 02/2008.
2. Revision 07/2008 - Updated with E-stop info.
3. Revision 09/2008 - Updated replacement parts and BOM.
4. Revision 04/2009 - Updated replacement parts and BOM.
5. Revision 06/2010 - Updated Recommended input conductor and line fuse sizes, section 3.4.1.
6. Revision 01/2011 - Updated Recommended input conductor and line fuse sizes, section 3.4.1.
7. Revision 09/2011 - updates per M. Wright’s mark-up.