ESAB EPP-601 Precision Plasma Power Source Instruction manual

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EPP-601

ESAB Precision Plasma Power Source

Instruction Manual

0558007752 06/2012

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

CAUTION

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.

PROTECT YOURSELF AND OTHERS!

TABLE OF CONTENTS

Section / Title Page

1.0 Safety Precautions ....................................................................................5

1.1 Safety - English ..................................................................................5

1.2 Safety - Spanish .................................................................................9

1.3 Safety - French .................................................................................13

2.0 Description ..........................................................................................17

2.1 Introduction....................................................................................17

2.2 General Specications ..........................................................................17

2.3 Dimensions and Weight.........................................................................18

3.0 Installation...........................................................................................19

3.1 General ........................................................................................19

3.2 Unpacking .....................................................................................19

3.3 Placement......................................................................................19

3.4 Input Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.5 Output Connections ........................................................................... 22

3.6 Parallel Installation............................................................................. 23

3.7 Interface Cables ................................................................................27

4.0 Operation .......................................................................................... 29

4.1 Block Diagram Circuit Description .............................................................. 29

4.2 Control Panel...................................................................................32

4.3 Sequence of Operation ........................................................................ 36

4.4 Arc Initiation Settings ...........................................................................37

5.0 Maintenance.........................................................................................41

5.1 General.........................................................................................41

5.2 Cleaning .......................................................................................41

5.3 Lubrication.....................................................................................42

6.0 Troubleshooting .................................................................................... 43

6.1 General ....................................................................................... 43

6.2 Fault Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

6.3 Fault Isolation................................................................................. 46

6.4 Testing and Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

6.5 Control Circuit Interface Using J1, J4 and J6 Connectors ......................................... 60

6.6 Auxiliary Main Contactor (K3 & K33) and Solid State Contactor Circuits ........................... 62

6.7 E-Stop (Emergency Stop) and Main Contactor (K1A, K1B and K1C) Circuits ........................ 63

6.8 Arc Current Detector Circuits................................................................... 65

6.9 Current Control Pot and Remote Vref . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

6.10 High / Low Cut Current Modes and Mark Mode ..................................................67

6.11 Low Current Range ............................................................................68

6.12 Electrode Current Transducer Circuit............................................................68

7.0 Replacement Parts .................................................................................. 69

7.1 General ....................................................................................... 69

7.2 Ordering ...................................................................................... 69

SECTION 1 SAFETY PRECAUTIONS

1.0 Safety Precautions

WARNING: These Safety Precautions are

for your protection. They summarize precautionary information from the references

listed in Additional Safety Information section. Before performing any installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.

PROTECT YOURSELF AND OTHERS -Some welding, cutting, and gouging processes are noisy and require ear protection. The arc, like the sun, e mits

ultraviolet (UV) and other radiation and can injure skin and eyes. Hot metal can cause burns. Training in the proper use of the processes and equipment is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any

work area, even if welding helmets, face shields, and goggles are also required.

2. Use a face shield tted with the correct lter and

cover plates to protect your eyes, face, neck, and ears from sparks and rays of the arc when operating or observing operations. Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric-arc or hot metal.

3. Wear ameproof gauntlet type gloves, heavy long-

sleeve shirt, cuess trousers, high-topped shoes, and a welding helmet or cap for hair protection, to protect against arc rays and hot sparks or hot metal. A ameproof apron may also be desirable as protection against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cus, or pockets. Sleeves and collars should be kept buttoned, and open pockets eliminated from the front of clothing.

5. Protect other personnel from arc rays and hot

sparks with a suitable non-ammable partition or curtains.

6. Use goggles over safety glasses when chipping slag

or grinding. Chipped slag may be hot and can y far. Bystanders should also wear goggles over safety glasses.

1.1 Safety - English

FIRES AND EXPLOSIONS -- Heat from ames and arcs can start res. Hot slag or sparks can also cause res and explosions. Therefore:

1. Remove all combustible materials well away from the work area or cover the materials with a protective non-ammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or crevices in oors or wall openings and cause a hidden smoldering re or res on the oor below. Make certain that such openings are protected from hot sparks and metal.“

3. Do not weld, cut or perform other hot work until the workpiece has been completely cleaned so that there are no substances on the workpiece which might produce ammable or toxic vapors. Do not do hot work on closed containers. They may explode.

4. Have re extinguishing equipment handy for instant use, such as a garden hose, water pail, sand bucket, or portable re extinguisher. Be sure you are trained in its use.

5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and create a re hazard.

6. After completing operations, inspect the work area to make certain there are no hot sparks or hot metal which could cause a later re. Use re watchers when necessary.

7. For additional information, refer to NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", available from the National Fire Protection Association, Batterymarch Park, Quincy, MA

02269.

ELECTRICAL SHOCK -- Contact with live electrical parts and ground can cause severe injury or death. DO NOT use AC welding current in damp areas, if movement is conned, or if there is danger of falling.

SECTION 1 SAFETY PRECAUTIONS

1. Be sure the power source frame (chassis) is connected to the ground system of the input power.

2. Connect the workpiece to a good electrical ground.

3. Connect the work cable to the workpiece. A poor or missing connection can expose you or others to a fatal shock.

4. Use well-maintained equipment. Replace worn or damaged cables.

5. Keep everything dry, including clothing, work area, cables, torch/electrode holder, and power source.

6. Make sure that all parts of your body are insulated from work and from ground.

7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand on dry boards or an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

3. Welders should use the following procedures to minimize exposure to EMF:

A. Route the electrode and work cables together.

Secure them with tape when possible.

B. Never coil the torch or work cable around your

body.

C. Do not place your body between the torch and

work cables. Route cables on the same side of your body.

D. Connect the work cable to the workpiece as close

as possible to the area being welded.

E. Keep welding power source and cables as far

away from your body as possible.

FUMES AND GASES -- Fumes and gases, can cause discomfort or harm, particularly in conned spaces. Do not breathe fumes and gases. Shielding gases can cause asphyxiation.

Therefore:

9. Turn o the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specic grounding recommendations. Do not mistake the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS — May be dangerous. Electric current owing through any conductor causes localized Electric and

Magnetic Fields (EMF). Welding and cutting current creates EMF around welding cables and welding machines. Therefore:

1. Welders having pacemakers should consult their

physician before welding. EMF may interfere with some pacemakers.

2. Exposure to EMF may have other health eects which

are unknown.

1. Always provide adequate ventilation in the work area by natural or mechanical means. Do not weld, cut, or gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead, beryllium, or cadmium unless positive mechanical ventilation is provided. Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat irritation while operating, this is an indication that ventilation is not adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not continue to operate if physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specic ventilation recommendations.

SECTION 1 SAFETY PRECAUTIONS

5. WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code

§25249.5 et seq.)

CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release gas. Sudden rupture of cylinder, valve, or relief device can injure or kill. Therefore:

1. Use the proper gas for the process and use the

proper pressure reducing regulator designed to operate from the compressed gas cylinder. Do not use adaptors. Maintain hoses and ttings in good condition. Follow manufacturer's operating instructions for mounting regulator to a compressed gas cylinder.

1. Always have qualied personnel perform the installation, troubleshooting, and maintenance work. Do not perform any electrical work unless you are qualied to perform such work.

2. Before performing any maintenance work inside a power source, disconnect the power source from the incoming electrical power.

3. Maintain cables, grounding wire, connections, power cord, and power supply in safe working order. Do not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such as furnaces, wet conditions such as water puddles, oil or grease, corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position and in good repair.

6. Use equipment only for its intended purpose. Do not modify it in any manner.

2. Always secure cylinders in an upright position by chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure cylinders to work tables or xtures where they may become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and ames. Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", which is available from Compressed Gas Association, 1235 Jeerson Davis Highway, Arlington, VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death. Therefore:

ADDITIONAL SAFETY INFORMATION -- For more information on safe practices for

electric arc welding and cutting equipment, ask your supplier for a copy of "Precautions and Safe Practices for Arc Welding, Cutting and Gouging", Form 52-529.

The following publications, which are available from the American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon Arc Gouging and Cutting"

SECTION 1 SAFETY PRECAUTIONS

5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal Arc Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.

8. ANSI/AWS F4.1, "Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances."

MEANING OF SYMBOLS - As used throughout this manual: Means Attention! Be Alert! Your safety is involved.

Means immediate hazards which, if not avoided, will result in immediate, serious personal injury or loss of life.

Means potential hazards which could result in personal injury or loss of life.

Means hazards which could result in minor personal injury.

SECCION 1 SEGURIDAD

1.2 Safety - Spanish

ADVERTENCIA: Estas Precauciones de Se-

guridad son para su protección. Ellas hacen

resumen de información proveniente de las referencias listadas en la sección "Información Adicional Sobre La Seguridad". Antes de hacer cualquier instalación o procedimiento de operación , asegúrese de leer y seguir las precauciones de seguridad listadas a continuación así como también todo manual, hoja de datos de seguridad del material, calcomanias, etc. El no observar las Precauciones de Seguridad puede resultar en daño a la persona o muerte.

PROTEJASE USTED Y A LOS DEMAS-Algunos procesos de soldadura, corte y ranurado son ruidosos y requiren protección para los oídos. El arco,

como el sol , emite rayos ultravioleta (UV) y otras radiaciones que pueden dañar la piel y los ojos. El metal caliente causa quemaduras. EL entrenamiento en el uso propio de los equipos y sus procesos es esencial para prevenir accidentes. Por lo tanto:

1. U tilice gafas de seguridad con protección a los lados

siempre que esté en el área de trabajo, aún cuando esté usando careta de soldar, protector para su cara u otro tipo de protección.

2. Use una careta que tenga el ltro correcto y lente

para proteger sus ojos, cara, cuello, y oídos de las chispas y rayos del arco cuando se esté operando y observando las operaciones. Alerte a todas las personas cercanas de no mirar el arco y no exponerse a los rayos del arco eléctrico o el metal fundido.

3. Use guantes de cuero a prueba de fuego, camisa

pesada de mangas largas, pantalón de ruedo liso, zapato alto al tobillo, y careta de soldar con capucha para el pelo, para proteger el cuerpo de los rayos y chispas calientes provenientes del metal fundido. En ocaciones un delantal a prueba de fuego es necesario para protegerse del calor radiado y las chispas.

4. Chispas y partículas de metal caliente puede alojarse

en las mangas enrolladas de la camisa , el ruedo del pantalón o los bolsillos. Mangas y cuellos deberán mantenerse abotonados, bolsillos al frente de la camisa deberán ser cerrados o eliminados.

5. Proteja a otras personas de los rayos del arco y chis-

pas calientes con una cortina adecuada no-amable como división.

6. Use careta protectora además de sus gafas de segu-

ridad cuando esté removiendo escoria o puliendo.

La escoria puede estar caliente y desprenderse con velocidad. Personas cercanas deberán usar gafas de seguridad y careta protectora.

FUEGO Y EXPLOSIONES -- El calor de las amas y el arco pueden ocacionar fuegos. Escoria caliente y las chispas pueden causar fuegos y explosiones. Por lo tanto:

1. Remueva todo material combustible lejos del área de trabajo o cubra los materiales con una cobija a prueba de fuego. Materiales combustibles incluyen madera, ropa, líquidos y gases amables, solventes, pinturas, papel, etc.

2. Chispas y partículas de metal pueden introducirse en las grietas y agujeros de pisos y paredes causando fuegos escondidos en otros niveles o espacios. Asegúrese de que toda grieta y agujero esté cubierto para proteger lugares adyacentes contra fuegos.

3. No corte, suelde o haga cualquier otro trabajo relacionado hasta que la pieza de trabajo esté totalmente limpia y libre de substancias que puedan producir gases inamables o vapores tóxicos. No trabaje dentro o fuera de contenedores o tanques cerrados. Estos pueden explotar si contienen vapores inamables.

4. Tenga siempre a la mano equipo extintor de fuego para uso instantáneo, como por ejemplo una manguera con agua, cubeta con agua, cubeta con arena, o extintor portátil. Asegúrese que usted esta entrenado para su uso.

5. No use el equipo fuera de su rango de operación. Por ejemplo, el calor causado por cable sobrecarga en los cables de soldar pueden ocasionar un fuego.

6. Después de termirar la operación del equipo, inspeccione el área de trabajo para cerciorarse de que las chispas o metal caliente ocasionen un fuego más tarde. Tenga personal asignado para vigilar si es necesario.

7. Para información adicional , haga referencia a la publicación NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", disponible a través de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

CHOQUE ELECTRICO -- El contacto con las partes eléctricas energizadas y tierra puede causar daño severo o muerte. NO use soldadura de corri-

ente alterna (AC) en áreas húmedas, de movimiento connado en lugares estrechos o si hay posibilidad de caer al suelo.

SECCION 1 SEGURIDAD

1. Asegúrese de que el chasis de la fuente de poder esté conectado a tierra através del sistema de electricidad primario.

2. Conecte la pieza de trabajo a un buen sistema de tierra física.

3. Conecte el cable de retorno a la pieza de trabajo. Cables y conductores expuestos o con malas conexiones pueden exponer al operador u otras personas a un choque eléctrico fatal.

4. Use el equipo solamente si está en buenas condiciones. Reemplaze cables rotos, dañados o con conductores expuestos.

5. M antenga todo seco, incluyendo su ropa, el área de trabajo, los cables, antorchas, pinza del electrodo, y la fuente de poder.

6. Asegúrese que todas las partes de su cuerpo están insuladas de ambos, la pieza de trabajo y tierra.

7. No se pare directamente sobre metal o tierra mientras trabaja en lugares estrechos o áreas húmedas; trabaje sobre un pedazo de madera seco o una plataforma insulada y use zapatos con suela de goma.

8. Use guantes secos y sin agujeros antes de energizar el equipo.

9. Apage el equipo antes de quitarse sus guantes.

10. Use como referencia la publicación ANSI/ASC Standard Z49.1 (listado en la próxima página) para recomendaciones especícas de como conectar el equipo a tierra. No confunda el cable de soldar a la pieza de trabajo con el cable a tierra.

CAMPOS ELECTRICOS Y MAGNETICOS - Son peligrosos. La corriente eléctrica uye através de cualquier conductor causando a nivel local

Campos Eléctricos y Magnéticos (EMF). Las corrientes en el área de corte y soldadura, crean EMF alrrededor de los cables de soldar y las maquinas. Por lo tanto:

1. Soldadores u Operadores que use marca-pasos para

el corazón deberán consultar a su médico antes de soldar. El Campo Electromagnético (EMF) puede interferir con algunos marca-pasos.

2. Exponerse a campos electromagnéticos (EMF) puede

causar otros efectos de salud aún desconocidos.

3. Los soldadores deberán usar los siguientes procedimientos para minimizar exponerse al EMF:

A. Mantenga el electrodo y el cable a la pieza de

trabajo juntos, hasta llegar a la pieza que usted quiere soldar. Asegúrelos uno junto al otro con cinta adhesiva cuando sea posible.

B. Nunca envuelva los cables de soldar alrededor

de su cuerpo.

C. Nunca ubique su cuerpo entre la antorcha y el

cable, a la pieza de trabajo. Mantega los cables a un sólo lado de su cuerpo.

D. Conecte el cable de trabajo a la pieza de trabajo

lo más cercano posible al área de la soldadura.

E. Mantenga la fuente de poder y los cables de soldar

lo más lejos posible de su cuerpo.

HUMO Y GASES -- El humo y los gases, pueden causar malestar o daño, particularmente en espacios

sin ventilación. No inhale el humo

o gases. El gas de protección puede causar falta de oxígeno. Por lo tanto:

1. Siempre provea ventilación adecuada en el área

de trabajo por medio natural o mecánico. No solde, corte, o ranure materiales con hierro galvanizado, acero inoxidable, cobre, zinc, plomo, berílio, o cadmio a menos que provea ventilación mecánica positiva . No respire los gases producidos por estos materiales.

2. No opere cerca de lugares donde se aplique sub-

stancias químicas en aerosol. El calor de los rayos del arco pueden reaccionar con los vapores de hidrocarburo clorinado para formar un fosfógeno, o gas tóxico, y otros irritant es.

3. Si momentáneamente desarrolla inrritación de

ojos, nariz o garganta mientras est á operando, es indicación de que la ventilación no es apropiada. Pare de trabajar y tome las medidas necesarias para mejorar la ventilación en el área de trabajo. No continúe operando si el malestar físico persiste.

4. Haga referencia a la publicación ANSI/ASC Standard

Z49.1 (Vea la lista a continuación) para recomendaciones especícas en la ventilación.

SECCION 1 SEGURIDAD

5. ADVERTENCIA-- Este producto cuando se utiliza para soldaduras o cortes, produce humos o gases, los cuales contienen químicos conocidos por el Estado de California de causar defectos en el nacimiento, o en algunos casos, Cancer. (California Health & Safety Code §25249.5 et seq.)

MANEJO DE CILINDROS-- Los

cilindros, si no son manejados correctamente, pueden romperse y liberar violentamente gases. Rotura repentina del cilindro, válvula, o válvula de escape puede causar daño o muerte. Por lo tanto:

1. Utilize el gas apropiado para el proceso y utilize

un regulador diseñado para operar y reducir la presión del cilindro de gas . No utilice adaptadores. Mantenga las mangueras y las conexiones en buenas condiciones. Observe las instrucciones de operación del manufacturero para montar el regulador en el cilindro de gas comprimido.

2. Asegure siempre los cilindros en posición vertical

y amárrelos con una correa o cadena adecuada para asegurar el cilindro al carro, transportes, tablilleros, paredes, postes, o armazón. Nunca asegure los cilindros a la mesa de trabajo o las piezas que son parte del circuito de soldadura . Este puede ser parte del circuito elélectrico.

3. Cuando el cilindro no está en uso, mantenga la

válvula del cilindro cerrada. Ponga el capote de protección sobre la válvula si el regulador no está conectado. Asegure y mueva los cilindros utilizando un carro o transporte adecuado. Evite el manejo brusco de los

1. Siempre tenga personal cualicado para efectuar l a instalación, diagnóstico, y mantenimiento del equipo. No ejecute ningún trabajo eléctrico a menos que usted esté cualicado para hacer el trabajo.

2. Antes de dar mantenimiento en el interior de la fuente de poder, desconecte la fuente de poder del suministro de electricidad primaria.

3. Mantenga los cables, cable a tierra, conexciones, cable primario, y cualquier otra fuente de poder en buen estado operacional. No opere ningún equipo en malas condiciones.

4. No abuse del equipo y sus accesorios. Mantenga el equipo lejos de cosas que generen calor como hornos, también lugares húmedos como charcos de agua , aceite o grasa, atmósferas corrosivas y las inclemencias del tiempo.

5. Mantenga todos los artículos de seguridad y coverturas del equipo en su posición y en buenas condiciones.

6. Use el equipo sólo para el propósito que fue diseñado. No modique el equipo en ninguna manera.

INFORMACION ADICIONAL DE SEGURIDAD -- Para más información sobre las prácticas de seguridad de los equipos de arco eléctrico para soldar y cortar, pregunte a su suplidor por una copia de "Precautions and Safe Practices for Arc Welding, Cutting and Gouging-Form 52-529.

Las siguientes publicaciones, disponibles através de la American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, son recomendadas para usted:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc Welding"

MANTENIMIENTO DEL EQUIPO -- Equipo defectuoso o mal mantenido puede causar daño o muerte. Por lo tanto:

3. AWS C5.2 - "Recommended Practices for Plasma Arc Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon Arc Gouging and Cutting"

SECCION 1 SEGURIDAD

SIGNIFICADO DE LOS SIMBOLOS

-- Según usted avanza en la lectura de este folleto: Los Símbolos Signican ¡Atención! ¡Esté Alerta! Se trata de su seguridad.

Signica riesgo inmediato que, de no ser evadido, puede resultar inmediatamente en serio daño personal o la muerte.

Signica el riesgo de un peligro potencial que puede resultar en serio daño personal o la muerte.

Signica el posible riesgo que puede resultar en menores daños a la persona.

SECTION 1 SÉCURITÉ

1.3 Safety - French

AVERTISSEMENT : Ces règles de sécurité

ont pour but d'assurer votre protection. Ils récapitulent les informations de précaution

provenant des références dans la section des Informations de sécurité supplémentaires. Avant de procéder à l'inst allation ou d'utiliser l'unité, assurez-vous de lire et de suivre les précautions de sécurité ci-dessous, dans les manuels, les ches d'information sur la sécurité du matériel et sur les étiquettes, etc. Tout défaut d'observer ces précautions de sécurité peut entraîner des blessures graves ou mortelles.

PROTÉGEZ-VOUS -- Les processus de soudage, de coupage et de gougeage

produisent un niveau de bruit élevé et exige l'emploi d'une protection auditive. L'arc, tout comme le soleil, émet des rayons ultraviolets en plus d'autre rayons qui peuvent causer des blessures à la peau et les yeux. Le métal incandescent peut causer des brûlures. Une formation reliée à l'usage des processus et de l'équipement est essentielle pour prévenir les accidents. Par conséquent:

1. Portez des lunettes protectrices munies d'écrans la-

téraux lorsque vous êtes dans l'aire de travail, même si vous devez porter un casque de soudeur, un écran facial ou des lunettes étanches.

2. Portez un écran facial muni de verres ltrants et de

plaques protectrices appropriées an de protéger vos yeux, votre visage, votre cou et vos oreilles des étincelles et des rayons de l'arc lors d'une opération ou lorsque vous observez une opération. Avertissez les personnes se trouvant à proximité de ne pas regarder l'arc et de ne pas s'exposer aux rayons de l'arc électrique ou le métal incandescent.

3. Portez des gants ignifugiés à crispin, une chemise

épaisse à manches longues, des pantalons sans rebord et des chaussures montantes an de vous protéger des rayons de l'arc, des étincelles et du métal incandescent, en plus d'un casque de soudeur ou casquette pour protéger vos cheveux. Il est également recommandé de porter un tablier ininammable an de vous protéger des étincelles et de la chaleur par rayonnement.

4. Les étincelles et les projections de métal incandescent

risquent de se loger dans les manches retroussées, les rebords de pantalons ou les poches. Il est recommandé de garder boutonnés le col et les manches et de porter des vêtements sans poches en avant.

5. Protégez toute personne se trouvant à proximité des

étincelles et des rayons de l'arc à l'aide d'un rideau ou d'une cloison ininammable.

6. Portez des lunettes étanches par dessus vos lunettes

de sécurité lors des opérations d'écaillage ou de meulage du laitier. Les écailles de laitier incandescent peuvent être projetées à des distances considérables. Les personnes se trouvant à proximité doivent également porter des lunettes étanches par dessus leur lunettes de sécurité.

INCENDIES ET EXPLOSIONS -- La chaleur provenant des ammes ou de l'arc peut provoquer un incendie. Le laitier incandescent ou les étincelles

peuvent également provoquer un

incendie ou une explosion. Par conséquent :

1. Éloignez susamment tous les matériaux combustibles de l'aire de travail et recouvrez les matériaux avec un revêtement protecteur ininammable. Les matériaux combustibles incluent le bois, les vêtements, la sciure, le gaz et les liquides combustibles, les solvants, les peintures et les revêtements, le papier, etc.

2. Les étincelles et les projections de métal incandescent peuvent tomber dans les ssures dans les planchers ou dans les ouvertures des murs et déclencher un incendie couvant à l'étage inférieur Assurez-vous que ces ouvertures sont bien protégées des étincelles et du métal incandescent.

3. N'exécutez pas de soudure, de coupe ou autre travail à chaud avant d'avoir complètement nettoyé la surface de la pièce à traiter de façon à ce qu'il n'ait aucune substance présente qui pourrait produire des vapeurs inammables ou toxiques. N'exécutez pas de travail à chaud sur des contenants fermés car ces derniers pourraient exploser.

4. Assurez-vous qu'un équipement d'extinction d'incendie est disponible et prêt à servir, tel qu'un tuyau d'arrosage, un seau d'eau, un seau de sable ou un extincteur portatif. Assurez-vous d'être bien instruit par rapport à l'usage de cet équipement.

5. Assurez-vous de ne pas excéder la capacité de l'équipement. Par exemple, un câble de soudage surchargé peut surchauer et provoquer un incendie.

6. Une fois les opérations terminées, inspectez l'aire de travail pour assurer qu'aucune étincelle ou projection de métal incandescent ne risque de provoquer un incendie ultérieurement. Employez des guetteurs d'incendie au besoin.

7. Pour obtenir des informations supplémentaires, consultez le NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", disponible au National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

CHOC ÉLECTRIQUE -- Le contact avec des pièces électriques ou les pièces de mise à la terre sous tension peut causer des blessures graves ou mor-

telles. NE PAS utiliser un courant de soudage c.a. dans un endroit humide, en espace restreint ou si un danger de chute se pose.

SECTION 1 SÉCURITÉ

1. Assurez-vous que le châssis de la source d'alimentation est branché au système de mise à la terre de l'alimentation d'entrée.

2. Branchez la pièce à traiter à une bonne mise de terre électrique.

3. Branchez le câble de masse à la pièce à traiter et assurez une bonne connexion an d'éviter le risque de choc électrique mortel.

4. Utilisez toujours un équipement correctement entretenu. Remplacez les câbles usés ou endommagés.

5. Veillez à garder votre environnement sec, incluant les vêtements, l'aire de travail, les câbles, le porteélectrode/torche et la source d'alimentation.

6. Assurez-vous que tout votre corps est bien isolé de la pièce à traiter et des pièces de la mise à la terre.

7. Si vous devez eectuer votre travail dans un espace restreint ou humide, ne tenez vous pas directement sur le métal ou sur la terre; tenez-vous sur des planches sèches ou une plate-forme isolée et portez des chaussures à semelles de caoutchouc.

8. Avant de mettre l'équipement sous tension, isolez vos mains avec des gants secs et sans trous.

9. Mettez l'équipement hors tension avant d'enlever vos gants.

10. Consultez ANSI/ASC Standard Z49.1 (listé à la page suivante) pour des recommandations spéciques concernant les procédures de mise à la terre. Ne pas confondre le câble de masse avec le câble de mise à la terre.

CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — comportent un risque de danger. Le courant électrique qui passe dans n'importe quel con-

ducteur produit des champs électriques et magnétiques localisés. Le soudage et le courant de coupage créent des champs électriques et magnétiques autour des câbles de soudage et l'équipement. Par conséquent :

1. Un soudeur ayant un stimulateur cardiaque doit

consulter son médecin avant d'entreprendre une opération de soudage. Les champs électriques et magnétiques peuvent causer des ennuis pour certains stimulateurs cardiaques.

2. L'exposition à des champs électriques et magné-

tiques peut avoir des eets néfastes inconnus pour la santé.

3. Les soudeurs doivent suivre les procédures suivantes pour minimiser l'exposition aux champs électriques et magnétiques :

A. Acheminez l'électrode et les câbles de masse

ensemble. Fixez-les à l'aide d'une bande adhésive lorsque possible.

B. Ne jamais enrouler la torche ou le câble de masse

autour de votre corps.

C. Ne jamais vous placer entre la torche et les câbles

de masse. Acheminez tous les câbles sur le même côté de votre corps.

D. Branchez le câble de masse à la pièce à traiter le

plus près possible de la section à souder.

E. Veillez à garder la source d'alimentation pour le

soudage et les câbles à une distance appropriée de votre corps.

LES VAPEURS ET LES GAZ -- peuvent causer un malaise ou des dommages

corporels, plus particulièrement dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le gaz de protection risque de causer l'asphyxie. Par conséquent :

1. Assurez en permanence une ventilation adéquate dans l'aire de travail en maintenant une ventilation naturelle ou à l'aide de moyens mécanique. N'eectuez jamais de travaux de soudage, de coupage ou de gougeage sur des matériaux tels que l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc, le plomb, le berylliym ou le cadmium en l'absence de moyens mécaniques de ventilation ecaces. Ne respirez pas les vapeurs de ces matériaux.

2. N'eectuez jamais de travaux à proximité d'une opération de dégraissage ou de pulvérisation. Lorsque la chaleur

ou le rayonnement de l'arc entre en contact avec les

vapeurs d'hydrocarbure chloré, ceci peut déclencher la formation de phosgène ou d'autres gaz irritants, tous extrêmement toxiques.

3. Une irritation momentanée des yeux, du nez ou de la gorge au cours d'une opération indique que la ventilation n'est pas adéquate. Cessez votre travail an de prendre les mesures nécessaires pour améliorer la ventilation dans l'aire de travail. Ne poursuivez pas l'opération si le malaise persiste.

4. Consultez ANSI/ASC Standard Z49.1 (à la page suivante) pour des recommandations spéciques concernant la ventilation.

SECTION 1 SÉCURITÉ

5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé dans une opération de soudage ou de coupage, dégage des vapeurs ou des gaz contenant des chimiques considéres par l'état de la Californie comme étant une cause des malformations congénitales et dans certains cas, du cancer. (California Health & Safety Code §25249.5 et seq.)

MANIPULATION DES CYLINDRES -La manipulation d'un cylindre, sans observer les précautions nécessaires, peut produire des fissures et un

échappement dangereux des gaz. Une brisure soudaine du cylindre, de la soupape ou du dispositif de surpression peut causer des blessures graves ou mortelles. Par conséquent :

1. Utilisez toujours le gaz prévu pour une opération

et le détendeur approprié conçu pour utilisation sur les cylindres de gaz comprimé. N'utilisez jamais d'adaptateur. Maintenez en bon état les tuyaux et les raccords. Observez les instructions d'opération du fabricant pour assembler le détendeur sur un cylindre de gaz comprimé.

2. Fixez les cylindres dans une position verticale, à

l'aide d'une chaîne ou une sangle, sur un chariot manuel, un châssis de roulement, un banc, un mur, une colonne ou un support convenable. Ne xez jamais un cylindre à un poste de travail ou toute autre dispositif faisant partie d'un circuit électrique.

3. Lorsque les cylindres ne servent pas, gardez les

soupapes fermées. Si le détendeur n'est pas branché, assurez-vous que le bouchon de protection de la soupape est bien en place. Fixez et déplacez les cylindres à l'aide d'un chariot manuel approprié. Toujours manipuler les cylindres avec soin.

4. Placez les cylindres à une distance appropriée

de toute source de chaleur, des étincelles et des ammes. Ne jamais amorcer l'arc sur un cylindre.

5. Pour de l'information supplémentaire, consultez

CGA Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", mis à votre disposition par le Compressed Gas Association, 1235 Jeerson Davis Highway, Arlington, VA 22202.

ENTRETIEN DE L'ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou inadéquate peut causer des blessures graves ou mortelles. Par conséquent :

1. Efforcez-vous de toujours confier les tâches d'installation, de dépannage et d'entretien à un personnel qualié. N'eectuez aucune réparation électrique à moins d'être qualié à cet eet.

2. Avant de procéder à une tâche d'entretien à l'intérieur de la source d'alimentation, débranchez l'alimentation électrique.

3. Maintenez les câbles, les ls de mise à la terre, les branchements, le cordon d'alimentation et la source d'alimentation en bon état. N'utilisez jamais un équipement s'il présente une défectuosité quelconque.

4. N'utilisez pas l'équipement de façon abusive. Gardez l'équipement à l'écart de toute source de chaleur, notamment des fours, de l'humidité, des aques d'eau, de l'huile ou de la graisse, des atmosphères corrosives et des intempéries.

5. Laissez en place tous les dispositifs de sécurité et tous les panneaux de la console et maintenez-les en bon état.

6. Utilisez l'équipement conformément à son usage prévu et n'eectuez aucune modication.

INFORMATIONS SUPPLÉMENTAIRES RELATIVES À LA SÉCURITÉ -- Pour obtenir de l'information supplémentaire sur les règles de sécurité à observer pour l'équipement de soudage à l'arc électrique et le coupage, demandez un exemplaire du livret "Precautions and Safe Practices for Arc Welding, Cutting and Gouging", Form 52-529.

Les publications suivantes sont également recommandées et mises à votre disposition par l'American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126 :

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon Arc Gouging and Cutting"

SECTION 1 SÉCURITÉ

SIGNIFICATION DES SYMBOLES Ce symbole, utilisé partout dans ce manuel, signie "Attention" ! Soyez vigilant ! Votre sécurité est en jeu.

DANGER

Signie un danger immédiat. La situation peut entraîner des blessures graves ou mortelles.

AVERTISSEMENT

Signie un danger potentiel qui peut entraîner des blessures graves ou mortelles.

ATTENTION

Signie un danger qui peut entraîner des blessures corporelles mineures.

SECTION 2 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-19XLS, PT-600 and PT-36 torches along with the numerous computerized gas regulation and switching systems.

• 10 to 100 amperes for marking in low current range

• 50 to 600 amperes cutting in high current range

• 35 to 100 amperes cutting in low 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 rings or base forklift clearance for transport

• Parallel supplemental power source capabilities to extend current output range.

2.2 General Specications

EPP-601 Input/Output Information

EPP-601

380V 50/60HZ

380V TAPS

Part Number Input Voltage (3-Phase) 380VAC 380VAC 400VAC 460VAC 575VAC Input Current (3-Phase) 217A RMS 217A RMS 206A RMS 179A RMS 143A RMS Input Frequency 50 HZ 50 HZ 50 HZ 60 HZ 60 HZ Input KVA 142.8 KVA 142.8 K VA 142.7 KVA 142.6 KVA 142.4 K VA Input Power 128 .5 KW 128 .5 KW 128 .4 KW 128 .4 KW 128 .2 KW Input Power Factor 90% 90% 90% 90% 90% Recommended Input

Power Cable Input Fuse (Recommended) 250A 250A 250A 250A 200A Output Open Circuit Voltage

(OCV) (High Range Cutting) Output Open Circuit Voltage

(OCV) (Low Range Cutting) Output Open Circuit Voltage

(OCV) (Marking) Output Cutting High Range

(100% Duty) Output Cutting Low Range

(100% Duty) Output Marking Low Range

(100% Duty) Output Power (100% Duty) 120 KW

*4/0 AWG *4/0 AWG *4/0 AWG *3/0 AWG *1/0 AWG

430VDC 406VDC 427VDC 431VDC 431VDC

414VDC 393VDC 413VD C 415VDC 415V DC

360VDC 342VDC 369VDC 360VDC 360VDC

EPP-601

380V 50/60HZ

40 0V TAPS

0558007733 0558007734 0558007735

50A @ 100V TO 600A @ 200V

35A @ 94V TO 100A @ 120V

10A @ 84V TO 100A @ 120V

EPP-601

400V 50/60HZ

EPP-601

460V 60HZ

EPP-601

575V 60HZ

* Fuse 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.

SECTION 2 DESCRIPTION

2.3 Dimensions and Weight

1143 m m

45.00”

946 mm

37. 25”

1022 mm

40.25”

Weight = 850 kg. (1870 lbs.)

SECTION 3 INSTALLATION

3.1 General

FAILURE TO FOLLOW INSTRUCTION S COULD LEAD TO DEATH, INJURY OR DAMAGED PROPERTY. FOLLOW THESE INSTRUCTIONS TO PRE

WARNING

3.2 Unpacking

CAUTIONCAUTION

• 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.

Using one lifting eye will damage sheet metal and frame. Use both lifting eyes when transporting with overhead method.

3.3 Placement

Note:

Use both lifting eyes when transporting from overhead.

• A minimum of 1 M (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-601 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 aect cool-

ing eciency.

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.

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-601 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 regulations.

Please refer to table under “General Specications” in Subsection 2.2 for recommended cable and input fuse sizes.

BEFORE ANY CON NECTIONS ARE MADE I NSIDE THE MACHINE, OPEN THE LINE WALL DISCONNECT SWITCH TO TURN POWER OFF.

Note:

To estimate the input current for a wide range of output conditions, use the formula below.

(V arc) x (I arc) x 0.688

(V line)

NOTICE

Input current =

Dedicated power line may be necessary. EPP-601 is equipped with line voltage compensation but to avoid impaired performance due to an overloaded circuit, a dedicated power line may be required.

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 table under “General Specications” in Subsection 2.2.

Input conductors must be terminated with ring terminals.

NOTICE

CAUTION

Input conductors must be terminated with ring terminals sized for

12.7 mm (0.50”) hardware before being attached to the EPP-601.

Inspect the clearance between the power lead ring terminals and the side panel. The barrels of some large terminals can come very close to or touch the side panel if the terminal is mounted incorrectly. The barrels of the terminals mounted on TB4 and TB6 should be rotated to face away from the side panel.

3.4.3 Input Connection Procedure

1. Remove left side panel of the EPP-601

2. Thread cables through the access opening in the rear panel.

3. Secure cables with a strain relief at the access opening.

4. Connect the ground lead to the stud on the chassis base.

5. Connect the power lead ring terminals to the primary terminals with supplied bolts, washers and nuts.

6. Connect the input conductors to the line (wall) disconnect.

1 = Primary Terminals 2 = Chassis Ground 3 = Power Input Cable Access Opening (Rear Panel)

SECTION 3 INSTALLATION

ELECTRIC SHOCK CAN KILL!

RING TERMINALS MUST HAVE CLEARANCE BETWEEN SIDE PANEL

WARNING

3.5 Output Connections

AND MAIN TRANSFORMER. CLEARANCE MUST BE SUFFICIENT TO PREVENT POSSIBLE ARCING. MAKE SURE CABLES DO NOT INTER FERE WITH COOLING FAN ROTATION.

IMPROPER GROUNDING CAN RESULT IN DEATH OR INJURY. CHASSIS MUST BE CONNECTED TO AN APPROVED ELECTRICAL GROUND. BE SURE GROUND LEAD IS NOT CONNECTED TO ANY PRI MARY TERMINAL.

ELECTRIC SHOCK CAN KILL! DANGEROUS VOLTAGE AND CURRENT! ANY TIME WORK ING AROUND A PLA SMA POWER SOURCE WITH COV ERS REMOVED:

WARNING

• DISCONNECT POWER SOURCE AT THE LINE (WALL) DISCONNECT.

• HAVE A QUALIFIED PERSON CHECK THE OUTPUT BUS BARS (POSI-

TIVE 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. For 600 amps, 100% duty cutting, two parallel 4/0 AWG, 600 volt cables should be used.

Note:

Do not use 100 volt insulated welding cable.

3.5.2 Output Connection Procedure - Single Power Source

1. Remove access panel on the lower front of the power source.

2. Thread output cables through the openings at the bottom of the front panel or 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. Replace panel removed during the rst step.

SECTION 3 INSTALLATION

Open Access Panel

EPP-601

Power Source

work

(+)

* 2 - 4/0 AWG 600V

positive leads

to workpiece

pilot arc

1 - 14 AWG 600V lead to pilot arc connection in arc starter

box (h.f. generator)

electrode

(-)

* Two parallel 4/0 AWG leads are recommended for 600A 100% duty operation.

* 2 - 4/0 AWG 600V

negative leads in

arc starter box (h.f.

generator)

3.6 Parallel Installation

Two EPP-601 power sources may be connected together in parallel to extend the output current range.

CAUTION

Use only one power source for cutting below 100A. We recommend disconnecting the negative lead from the supplemental power source when changing to currents below 100A. This lead should be safely insulated to protect against electric shock.

SECTION 3 INSTALLATION

3.6.1 Connections for Two EPP-601’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. Set the Pilot Arc HIGH / LOW switch on the supplemental power source to “LOW”.

6. Set the Pilot Arc HIGH / LOW switch on the primary power source to “HIGH”.

7. If a remote 0.00 to +10.00 VDC current reference signal is used to set the output current, feed the same signal into both power sources. Connect J1-G (positive 0.00 to 10.00 VDC) of both power sources together and connect J1-P (negative) of both power sources together. With both power sources operating, the output current can be predicted using the following formula: [output current (amps)] = [reference voltage] x [160] in the high current range

The EPP-601 does not have an ON/OFF switch. The main power is controlled through the line (wall) disconnect switch.

DO NOT OPERATE THE EPP601 WITH COVERS REMOVED. HIGH VOLTAGE COMPONENTS ARE EXPOSED INCREASING SHOCK HAZARD. INTERNAL COM PONENT MAY BE DAMAGED BECAUSE COOLING FANS WILL LOSE EFFICIENCY.

ELECTRIC SHOCK CAN KILL!

EXPOSED ELECTRICAL CONDUCTORS CAN BE HAZARDOUS!

WARNING

DO NOT LEAVE ELECTR ICALLY “HOT“ CONDUCTOR S EXPOSE D. WHEN DISCONNECTING THE SUPPLEMENTAL POWER SOURCE FROM THE PRIMARY, VERIFY THE CORRECT CABLES WERE DISCONNECTED. IN SULATE THE DISCONNECTED ENDS.

WHEN USING ONLY ONE POWER SOURCE IN A PARALLEL CONFIGU RATION, THE NEGATIVE ELECTRODE CONDUCTOR MUST BE DIS CONNECTED FROM THE SUPPLEMENTAL POWER SOURCE AND THE PLUMBING BOX. FAILURE TO DO THIS WILL LEAVE THE SUPPLEMEN  TAL ELECTRICALLY “HOT”.

SECTION 3 INSTALLATION

work

3.6.1 Connections for Two EPP-601’s in Parallel (continued)

Connections for parallel installation of two EPP-601 power sources with both power sources in operation.

EPP-601 EPP-601

Supplemental

Power Source

(+)

3 - 4/0 600V

positive leads

to workpiece

electrode

(-)

4/0 600V cable jumpers between units

(+)

1 - 14 AWG 600V lead to pilot arc connection in arc starter

box (h.f. generator)

Primary Power

Source

pilot arc

electrode

(-)

3 - 4/0 600V

negative leads

in arc starter box

(h.f. generator)

Connections for parallel installation of two EPP-601 power sources with only one power source in operation.

The connections below are suitable for single power supply operation up to 600A up to 100% duty.

EPP-601 EPP-601

Supplemental

Power Source

3 - 4/0 AWG 600V

positive leads

to workpiece

electrode

Disconnect negative connection from supplemental power source and insulate to convert from two to one power source

Primary Power

work

Source

electrode

3 - 4/0 AWG 600V

negative leads in arc

starter box (h.f. generator)

SECTION 3 INSTALLATION

3.6.2 Marking with Two Parallel EPP-601’s

Two EPP-601’s, connected in parallel, and can be used for marking down to 20A and cutting from 100A up to 1000A. Two simple modications can be made to the Supplemental Power Source in order to permit marking down to 10A. The modications are necessary only if marking below 20A is required.

FIELD MODIFICATIONS TO PERMIT MARKING DOWN TO 10A:

1. CHANGES TO THE PRIMARY POWER SOURCE: None

2. CHANGES TO THE SUPPLEMENTAL POWER SOURCE: A. Unplug the WHT wire from the coil of K12 B. Remove the jumper between TB7-7 and TB7-8. The jumper is a link built into the terminal strip.

NOTE:

These modications disable the current output of the secondary power supply only in the marking mode. The modications have no eect on the output current of the secondary power supply while cutting in either HI or LOW current cutting modes.

OPERATION OF TWO PARALLEL EPP-601’S:

1. Provide Contactor On/O, Cut/Mark, Current Range High/Low signals to both the Primary and Supplemental power sources. Feed the same V

signal into both power sources.

REF

2. When marking with parallel power sources, and the Secondary power source is not modied, the output current transfer function is the sum of the transfer functions for each power source: I

= 20 x V

OUT

. Each power source will provide

REF

the same output current.

When marking with parallel power sources, and the Secondary power source is modied, the current transfer function

is that of the Primary power source: I

= 10 x V

OUT

. Both power sources will turn on when the Contactor signal is pres-

REF

ent, but the output current of a modied Secondary power source is disabled in the marking mode.

3. When cutting in the Low current mode, the current transfer function is the sum of the transfer functions for each power source: I

= 20 x V

OUT

. For cutting at currents below 100A, disconnect the negative cable(s) from the secondary

REF

power source, and insure their terminations are insulated to protect against electric shock. With the secondary power source disconnected, the current transfer function is that of the Primary power source: I

= 10 x V

OUT

REF

4. When cutting in the High current mode, the current transfer function is the sum of the transfer functions for each power source: I

= 160 x V

OUT

. For cutting at currents below 100A, disconnect the negative cable(s) from the second-

REF

ary power source, and insure their terminations are insulated to protect against electric shock. Use the Low current cutting mode.

SECTION 3 INSTALLATION

3.7 Interface Cables

CNC Interface (24 Conductors)Water Cooler Interface (8 Conductors)

3.7.1 CNC Interface Cables with Mating Power Source Connector and Unterminated CNC Interface

Male Connector

P/N: 647032

GRN/YEL

RED #4

SECTION 3 INSTALLATION

3.7.2 CNC Interface Cables with Mating Power Source Connectors and Mating CNC Connector

CNC Connector

P/N: 2010549

Male Connector

P/N: 647032

GRN/YEL

RED #4

3.7.3 Water Cooler Interface Cables with Mating Power Source Connectors at Both Ends

Female Connector

P/N: 2062105

Male Connector

P/N: 647257

SECTION 4 OPERATION

4.1 Block Diagram Circuit Description

Blocking Diodes

Sensor

EPP-601

Left Hall

BLOCK DIAGRAM

NOZZLE

ELECTRODE

Circuit

Pilot Arc

R (snub)

250V Peak

R (boost)

Blocking Diodes

Right Hall

Free Wheeling

Diodes - See Note

425V Peak

Sensor

WORK

Shunt

Precision

Note

Biased Snubber

Circuit

Boost Starting

Arc Contactor

Contact on Pilot

contained in the same module.

Both the IGBT’s and Free Wheeling Diodes are

Left

See Note

IGBT Modules

Cap.

Bank

Gate

Drive

Sync Signal

For Alternate

PWM

(Master)

Galvanic

Isolator

Left PWM / Gate Drive Board

Gate

Drive

Switching

PWM

(Slave)

Galvanic

Isolator

Right PWM / Gate Drive Board

DC Bus

-300V-375V

Right

30 0U120’s

Bus Rectiers

T1 Main

Transformer

See Note

IGBT Modules

See

Note

Current Servo

Twisted Pair

Feedback for Constant

“T” Common Connected to Earth Grounded Work Through the “+” Output

Control Circuit

Error Ampliers

Feedback For Fast Inner Servos

Galvanic

Isolator

Input

3 Phase

Iout = (Vref ) x (80)

0.0 - 10.0V DC Vref

(Floating)

CNC Common

(High Current Range)

EPP-600 10/20KHz Output RMS Ripple Current Versus Output Voltage

9.0

SECTION 4 OPERATION

4.1 Block Diagram Circuit Description (con’t.)

The power circuit utilized in the EPP-601 is commonly referred to as a Buck Converter or a Chopper. High speed electronic switches turn on and o several thousand times per second providing pulses of power to the output. A lter circuit, consisting primarily of an inductor (sometimes called a choke), converts the pulses to a relatively constant DC (Direct Current) output.

Although the lter inductor removes most of the uctuations from the “chopped” output of the electronic switches, some small uctuations of output, called ripple, remain. The EPP-601 utilizes a patented power circuit combining the output of two choppers, each providing approximately half the total output, in a manner that reduces ripple. The choppers are synchronized so that when the ripple from the rst chopper is increasing output, the second chopper is decreasing output. The result is the ripple from each chopper partially cancels the ripple from the other. The result is ultra low ripple with a very smooth and stable output. Low ripple is highly desirable because torch consumable life is often improved with low ripple.

The graph below shows the eect of ESAB’s patented ripple reduction using two choppers synchronized and switching alternately. Compared to two choppers switching in unison, the alternate switching typically reduces ripple a factor of 4 to 10.

EPP-601 10/20 KHz Output RMS Ripple Current Versus Output Voltage

Choppers Synchronized and Switching in Unison (10KHz Ripple)

Choppers Synchronized and Switchng in Unison (10KHz Ripple)

8.0

7.0

6.0

5.0

4.0

Choppers Synchronized and Switching Alternately (20KHz Ripple)

3.0

2.0

RMS Ripple Current (Amperes)

1.0

0.0 0 50 100 150 200 250 300 350

Output Voltage (Volts)

SECTION 4 OPERATION

4.1 Block Diagram Circuit Description (con’t.)

The EPP-601 Block Diagram (after Subsection 4.1) shows the main functional elements of the power source. T1, the Main Transformer, provides isolation from the primary power line as well as the proper voltage for the *375V DC Bus. The Bus Rectiers convert the three phase output of T1 to the *375V bus voltage. A capacitor bank provides ltering and energy storage that supplies power to the high speed electronic switches. The switches are IGBT’s (Insulated Gate Bipolar Transistors). The *375V bus provides power for both the Left (Master) Chopper and the Right (Slave) Chopper.

Each chopper contains IGBT’s, Free Wheeling Diodes, a Hall Sensor, a Filter Inductor, and Blocking Diodes. The IGBT’s are the electronic switches that, in the EPP-601, turn on and o 10,000 times per second (25,000 times per second in low current and marking mode). They provide the pulses of power ltered by the inductor. The Free Wheeling Diodes provide the path for current to ow when the IGBT’s are o. The Hall Sensors are current transducers that monitor the output currents and provide the feedback signals for the control circuit.

The Blocking Diodes provide two functions. First, they prevent the 430V DC from the Boost Starting Circuit from feeding back to the IGBT’s and the *375V Bus. Second, they provide isolation of the two choppers from one another. This permits independent operation of each chopper without the other chopper functioning.

The Control Circuit contains regulating servos for both choppers. It also contains a third servo that monitors the total output current signal fed back from the Precision Shunt. This third servo adjusts the two chopper servos to maintain an accurately controlled output current commanded by the V

signal.

REF

The V from “ground” loops.

Each chopper, the Left Master, and the Right Slave, contain their own PWM / Gate Drive PC Boards mounted next to the IGBT’s. This circuitry provides the on / o PWM (Pulse Width Modulation) signals to drive the IGBT’s. The Left (Master) PWM provides a synchronized clock signal to its own Gate Drive circuitry as well as to the Right (Slave) Gate Drive circuitry. It is through this synchronized signal that the IGBT’s from the two sides switch alternately reducing output ripple.

The EPP-601 contains a Boost Supply for providing approximately 430V DC for arc starting. After the cutting arc is established, the Boost Supply is turned o with contacts on the Contactor (K10).

A Biased Snubber reduces the voltage transients created during cutting arc termination. It also reduces the transient voltages from a parallel power source thus preventing damage to the power source.

The Pilot Arc Circuit consists of the necessary components for establishing a pilot arc. This circuit disengages when the cutting or marking arc is established.

* The buss voltage for the 380/400V, 50Hz model is approximately 360V DC when operating with 380V input.

circuitry is galvanically isolated from the rest of the power source. The isolation prevents problems that can arise

REF

SECTION 4 OPERATION

4.2 Control Panel

L MN

A - Main Power

Indicator illuminates when input power is applied to the power source.

B - Contactor On

Indicator illuminates when the main contactor is energized.

C - Over Temp

Indicator illuminates when power source has overheated.

D - Fault

Indicator illuminates when there are abnormalities in the cutting process or when the input line voltage falls outside of the required nominal value by more than ±10%.

E - Power Reset Fault

Indicator illuminates when a serious fault is detected. Input power must be disconnected for at least 5 seconds and then reapplied.

F - Current Dial (Potentiometer)

EPP-601 dial shown. EPP-601 has a range of 10 to 100A in low current range and 50 to 600A in high current range. The potentiometer is used only in panel mode.

G - 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).

SECTION 4 OPERATION

4.2 Control Panel (con’t.)

H and L - Remote Connections

H - 24 pin plug for connecting the power source to CNC (remote control)

L - 8 pin plug for connecting the power source to the coolant circulator

I - Pilot Arc HIGH / LOW Switch

Used to select amount of pilot arc current desired. As a general rule, for 100 amperes and below, a setting of LOW is used. This can vary depending on gas, material and torch used. High/Low settings are specied in cutting data included in the torch manual. When the EPP-601 is set to marking mode, this switch must be in the low position.

M - E-Stop Connector

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.

N - 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.

NOTE:

The EPP-601 power supply is normally in “Low Current Range”, 100A maximum. The external control must supply a connection (contact closure) between J1-R and J1-T to place the power supply in “High Current Range”, 600A maximum. If the EPP-601 will be permanently connected in “High Current Range”, move the red wire from TB8-1 to TB8-2. TB8 is located near the top of the power supply on the back of the sheet metal box containing the control PC board.

L MN

SECTION 4 OPERATION

DANGEROUS VOLTAGES AND CURRENT! ELECTRIC SHOCK CAN KILL!

WARNING

4.2 Control Panel (con’t.)

J - Meters

Displays voltage and amperage when cutting. The ammeter can be activated with the Actual / Preset switch when not cutting to view an estimation of the cutting current before cutting begins.

K - Actual/Preset Switch

The ACTUAL AMPS / PRESET AMPS spring return toggle switch, S4, defaults to the ACTUAL (UP) position. In the ACTUAL position, the OUTPUT AMMETER displays the output cutting current.

BEFORE O PERATION, ENSUR E INSTALLATION AND GROUNDI NG PRO  CEDURES HAVE BEEN FOLLOWED. DO NOT OPERATE THIS EQUIP MENT WITH COVERS REMOVED.

In the PRESET (DOWN) position, the OUTPUT AMMETER displays an estimate of the output cutting current by monitoring the 0.00 to 10.00 VDC cutting or marking current reference signal (Vref). The reference signal comes from the CURRENT POTENTIOMETER with the PANEL/REMOTE switch in the PANEL (UP) position and from a remote reference signal (J1-J / J1L(+)) with the PANEL/REMOTE switch in the REMOTE (DOWN) position. The value displayed on the OUTPUT AMMETER will be the value of estimated actual output current for both the Hi and Lo current modes.

The switch may be changed to and from the ACTUAL and PRESET positions at any time without aecting the cutting process.

SECTION 4 OPERATION

4.2.1 Modes of Operation: High and Low Cutting Modes and Marking Mode

1. The EPP-601 operates in the Cutting Mode in two current ranges. The low current range is 35-100A corresponding to a V

signal of 3.50-10.00V. In the high current range, the current output is continuously adjustable from 50A through

REF

600A using either the Current Potentiometer, on the front panel, or a remote current reference signal fed into connector, J1. The EPP-601 defaults to low cutting mode. To operate in the high cutting current mode, provide 115VAC to J1-T by connecting J1-T to J1-R with an isolated contact.

When using a remote signal, 50A corresponds to a current reference signal of 0.625VDC, and 600A corresponds to a signal of 7.50VDC. For signals over 7.50V, the power source internally limits the output current to a typical value of 680A.

The EPP-601 defaults to the Cutting Mode of operation unless the command signal from a remote control for Marking Mode is supplied.

2. The power source is placed in Marking Mode with an external isolated relay or switch contact connecting J1-R (115VAC) to J1-M. See Schematic Diagram included inside back cover. This contact closure must be made before (50mS or longer) issuing a Start (Contactor On) command.

In the Marking Mode, the output current is adjusted through a single continuously adjustable range from 10A through 100A using either the Current Potentiometer, on the front panel, or a remote current reference signal fed into connector, J1. The EPP-601 automatically switches to the low current range in marking mode.

In the low current range, when using a remote signal, 10A corresponds to a current reference signal of 1.00VDC, and 100A corresponds to a signal of 10.00VDC. In the high current range, when using the remote current reference signal (V

), the output current of 50 to 600A corresponds to a reference signal of 0.625 to 7.50VDC. For reference signals over

REF

7.50V the power source limits the output current to a typical value of 680A.

In the Marking Mode, the Boost Supply, used for arc starting in the Cutting Mode, is de-activated. The resulting Open Circuit Voltage is approximately 360V at nominal input line voltage*. Additionally, K12 closes connecting R60 through R67 into the output circuit. These resistors help stabilize the output for the low marking currents. The power source is capable of 10-100A at 100% duty output in the marking mode.

10 Amp output is provided by resistors R60-R67. The factory set Minimum Starting Current (SW2) is 5 Amps. The default settings of Switch Two (SW2) on the Control PC Board mounted behind the access cover on the upper right of the front panel is positions 5, 6, 7 and 8 are o (down).

* Approximately 345V for the 380/400V model operating on 380V.

SECTION 4 OPERATION

1. Apply power by closing the line (wall) switch. (The ESP-400C does not have an on/off switch). The main power light will illuminate and the fault light will flash and then go out.

Apply Power

1. Apply power by closing the line (wall) switch. (The ESP-400C does not have an on/off switch). The main power light will illuminate and the fault light will flash and then go out.

2. Select the Panel/Remote setting.

3. Set pilot arc High/Low switch. (Refer to cutting data in the torch manual.)

4. If using panel mode, view preset amps with the ACTUAL/PRESET AMPS switch. Adjust current until the approximate desired value is shown on the ammeter.

5. Begin plasma cutting operation. This may include manually setting up other options, depending on the total plasma package.

6. If using panel mode, after cutting has begun, adjust current to desired amount.

7. Check for fault light. If a fault light illuminates, refer to troubleshooting section.

Note: The fault light flashes when the contactor is

Note: The fault light flashes when the contactor isNote: The fault light flashes when the contactor is

Note: The fault light flashes when the contactor is first turned on signifying the DC Bus powered up

first turned on signifying the DC Bus powered upfirst turned on signifying the DC Bus powered up

first turned on signifying the DC Bus powered up normally.

normally.normally.

normally.

4.3 Sequence of Operation

1. Apply power by closing the line (wall) switch. (The EPP-601 does not have an on / o switch). The main power light will illuminate and the fault light will ash and then go out.

2. E-stop button is pulled out.

PILOT

ARC

Apply Power

PANEL

REMOTE

HIGH

LOW

3. Select the Panel / Remote setting.

4. Set pilot arc High / Low switch. If pilot arc High / Low is selected from a remote control, the switch must be in the Low position. (Refer to cutting data in the torch manual.)

5. If using panel mode, view preset amps with the ACTUAL / PRESET AMPS switch. Adjust current until the approximate desired value is shown on the ammeter. If using the remote mode, placing the actual Amps / Preset Amps switch in the Preset Amps position provides the initial output current commanded by the remote control.

6. Begin plasma cutting operation. This may include manually setting up other options, depending on the total plasma package.

7. If using panel mode, after cutting has begun, adjust current to desired amount.

8. If cutting or marking fails to initiate, check for fault light. If a fault light illuminates, refer to troubleshooting section.

Note:

The fault light ashes when the contactor is rst turned on signifying the

DC Bus powered up normally.

ACTUAL AMPS

PRESET AMPS

Begin

Cutting

SECTION 4 OPERATION

ELECTRIC SHOCK CAN KILL! SHUT OFF POWER AT THE LINE WALL DISCONNECT BEFORE RE

WARNING

4.4 Arc Initiation Settings

The time to achieve full current can be adjusted for a soft start. This feature uses a reduced current to start and then gradually ramps up to full current. The EPP-601 is factory shipped with soft start enabled. The default settings are:

MOVING ANY COVERS OR MAKING ANY ADJUSTMENTS TO THE POWER SOURCE.

Minimum Start Current . . . . . . . . . . . . . 5A

Start Current . . . . . . . . . . . . . . . . . . . . . . . 50% of cut current

Timing to achieve full current . . . . . . . 800 msec

Dwell Time . . . . . . . . . . . . . . . . . . . . . . . . . 2 msec

These timing functions can be disabled or adjusted to suit individual system requirements.

Start Current Wave Form With Soft Start OFF

Approx. 2 msec time to full current

DC Output Current

Time

Cut Current

= 80 V

OUT

= 10 V

OUT

REF

(High) (Low)

Start Current Wave Form With Soft Start ON

Start Current

DC Output Current

Dwell

Time

Time to full cu rrent

800 msec

Time

Cut Current

= 80 V

OUT

= 10 V

OUT

REF

(High)

(Low)

SECTION 4 OPERATION

1 2 3 4 5 6 7 8

4.4.1 Enable/Disable Arc Initiation Conditions

Factory default setting shown.

o

SW1

1. Remove access panel on the upper-right corner of the front panel. Be sure to replace this panel after adjustments have been made.

2. Locate SW1 and PCB1 and push both rocker switches down to disable. To enable push both switches up. (If one switch is up and the other is down, arc initiation time is considered on.)

Factory default settings shown

1 2 3 4 5 6 7 8

o

SW2

4.4.2 Adjusting Arc Initiation Dwell Timer

Dwell Time is controlled by selections of positions 1 through 4 of SW2 on PCB1. When a switch is pushed on, its value is added to the minimum dwell time of 2 msec.

Switch #1 = 2 msec dwell time Switch #2 = 4 msec dwell time Switch #3 = 8 msec dwell time Switch #4 = 16 msec dwell time All switches o. 2 msec is the factory default dwell time.

4.4.3 Adjusting the Minimum Start Current

Minimum Start Current is controlled by selection of positions 5 through 8 of SW2. When a switch is pushed on, its value is added to the factory set minimum value of 5A.

Switch #5 = 40A min. start current Switch #6 = 20A min. start current Switch #7 = 10A min. start current Switch #8 = 5A min. start current Default setting is with 5, 6, 7 and 8 o (down) 0A + 0A + 0A + 0A + 5A = 5A

SECTION 4 OPERATION

90%

80%

70%

60%

50%

40%

30%

20%

10%

0 1 2 3 4 5 6 7

8 9 10

4.4.4 Arc Initiation Controls

Start Current Potentiometer

UP-Slope Timer

SW1

SW2

4.4.5 Start Current and Up-Slope Timer

Starting Current (%) and Pot Setting Relationship

Start Current Set using potentiometer located above and to the left of center of PCB1. Factory default setting of 7 results in a starting current that is 50% of the cutting current..

Up-Slope Timer Three position switch located next to the start current potentiometer. Time is from start current (after dwell ends) to full current. Factory default = 800 msec.

Left position = 250 msec Center position = 800 msec Right Position = 1200 msec

Percentage (%) of Cutting Current

MAX

Start Current Pot Setting

SECTION 4 OPERATION

4.4.6 Approximate EPP-601 V-I Curves for all models

Output Voltage (Volts)

0 100 200 300 400 500 600 700

REF

100

= 3.50V Min. Cutting Low Range

REF

= 5.00V Low Range

150

REF

= 0.625V High Range Min. Current

REF

= 10.00V Max. Low Range

REF

= 2.000V

REF

= 3.000V

REF

200

250

= 1.00V Min. Marking Low Range

= 1.000V High Range

REF

300

350

400

Output of Boost / Start Circuit (O in Marking Mode)

450

431V Open Circuit

Output Current (Amperes)

= 4.000V

REF

= 5.000V

REF

= 6.000V

REF

= 7.000V

REF

= 7.50 0 V

REF

Max Rating

Internal Current Limit

MAX RATING

DATA PL ATE

Max. Output Voltage

@Nominal Line

OUT

= (80) x (V

REF

)

SECTION 5 MAINTENANCE

ELECTRIC SHOCK CAN KILL!

WARNING

CAUTION

5.1 General

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.

SECTION 5 MAINTENANCE

Air restrictions may cause EPP-601 to over heat. Thermal Switches may be activated causing interruption of func-

CAUTION

5.3 Lubrication

• Some units are equipped with oil tubes on the fans. These fans should be oiled after 1 year of service.

• All other EPP-601s have fan motors that are permanently lubricated and require no regular maintenance.

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.

SECTION 6 TROUBLESHOOTING

ELECTRIC SHOCK CAN KILL! DO NOT PERMIT UNTRAINE D PERSONS TO INSPECT OR REPAI R THIS

WARNING

CAUTION

6.1 General

6.2 Fault Indicators

EQUIPMENT. ELECTRIC AL WORK MUST BE PERFORM ED 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.

Front Panel Fault

Indicators

Fault indicators are found on the front panel Used with the LEDs on PCB1 (located behind the cover with the EPP label) problems can be diagnosed.

PCB1 Located behind

this panel.

NOTE:

It is normal for momentary lighting (ashing) of the fault indicator and LED 3 when a “contactor on” signal is applied at the beginning

of each cut start.

Fault Indicator used with: LED 3 - Bus Ripple LED 4 - High Bus LED 5 - Low Bus LED 7 - Arc Voltage Saturation LED 8 - Arc Voltage Cuto

Power Reset Fault Indicator used with: LED 6 - Right Overcurrent LED 9 - Left Overcurrent LED 10 - Left IGBT Unsaturated LED 11 - Right IGBT Unsaturated LED 12 - Left -12V Bias Supply LED 13 - Right -12V Bias Supply

SECTION 6 TROUBLESHOOTING

Fault Indicator (Front Panel)

Illuminates when there are abnormalities in the cutting process or when the input voltage falls ±10% outside the normal value. Momentary illumination is normal. If continuously lit, check LEDs 3, 4, 5, 7, and 8 on PCB1 for further diagnosis.

LED 3 – (yellow) Bus Ripple Fault - Momentarily illuminates at the beginning of each cut. Continuously lit during single-phasing or imbalanced line-to-line voltages of the three phase input line (Excessive Ripple). Power Source is shut down.

LED 4 – (yellow) High Bus Fault – Illuminates when input line voltage is too high for proper operation (approximately 20% above nominal line voltage rating). Power source is shut down.

LED 5 – (yellow) Low Bus Fault – Illuminates when input line voltage is lower than 10% below nominal line voltage rating. Power Source is shut down.

LED 7 – (yellow) Arc Voltage Saturation Fault – Illuminates when the cutting arc voltage is too high and cutting current drops below preset level. LED will extinguish after voltage decreases and current rises.

LED 8 – (yellow) Arc Voltage Cuto Fault – Illuminates when arc voltage increases over the preset value. PS is shut down.

SECTION 6 TROUBLESHOOTING

Power Reset Fault Indicator (on front panel)

Illuminates when a serious fault is detected. Input power must be disconnected for a least 5 seconds to clear this fault. Check PCB1 Red LEDs 6, 9, 10, 11, 12, and 13 if this fault is illuminated for further diagnosis.

LED 6 – (red) Right Overcurrent Fault – Illuminates when the current out of the right side chopper is too high (400 amps). This current is measured by the right-side hall sensor. The power source is shut down.

LED 9 – (red) Left Overcurrent Fault – Illuminates when the current from the left side chopper is too high (400 amps). Measured by the left hall sensor. Power source is shut down.

LED 10 _ (red) Left IGBT Unsaturated Fault – Illuminates when left IGBT is not fully conducting. PS (PS) is shut down.

LED 11 – (red) Right IGBT Unsaturated Fault – Illuminates when right IGBT is not fully conducting. Power Source (PS) is shut down.

LED 12 – (red) Left -(neg) 12V Bias Supply Fault – Illuminates when negative 12 V bias supply to the left side IGBT gate drive circuit (located on PWM-drive board PCB2) is missing. PS is shut down.

LED 13 – (red) Right –(neg) 12V Bias Supply Fault - Illuminates when negative 12 V bias supply to the right side IGBT gate drive circuit (located on PWM drive board PCB3) is missing. PS is shut down.

SECTION 6 TROUBLESHOOTING

6.3 Fault Isolation

Many of the most common problems are listed by symptom.

6.3.1 No output with contactor signal applied

6.3.2 Output limited to 100A

6.3.3 Fans not working

6.3.4 Power not on or low voltage

6.3.5 Fault light illumination

6.3.6 Torch won’t re

6.3.7 Fusses blown - F1 and F2

6.3.8 Intermittent, interrupted or partial operation

6.3.1 No output with contactor signal applied

Problem Possible Cause Action

External emergency stop (E-stop) is Contactor signal is applied, contactor lamp on front panel is illuminated, K2 and K3 contactors do not close and low bus fault light, LED 5 illuminates.

open.

E-stop button on front panel is pushed

in.

Power reset lamp on front panel indi-

cates a serious fault condition.

6.3.2 Output limited to 100A

Problem Possible Cause Action

Power source will not go over 100A.

High current range signal missing.

6.3.3 Fans Not Working

Problem Possible Cause Action

Connect isolated contact of E-stop switch to provide connection between J1-E and J1-F.

Twist and pull out to reset E-stop condition.

Refer to section under fault light illumination.

External control should connect J1-R to J1-T. As an alternative, in the power source, move the red wire on TB8-1 to TB8-2.

All 4 fans do not run

1, 2 or 3 fans do not run.

This is normal when not cutting.

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.

SECTION 6 TROUBLESHOOTING

6.3.4 Power Not On or LOW Voltage

Problem Possible Cause Action

Power source inoperable: Main power lamp is o.

Low open circuit voltage

Missing 3-phase input voltage

Missing 1 of 3-phase input voltage

Fuse F3/F4 blown Replace F3/F4 Pilot arc Contactor (K4) faulty Replace K4 Faulty Control PCB1 Replace Control PCB1 (P/N

6.3.5 Fault Light Illumination

Problem Possible Cause Action

Fault light illuminates at the end of cut but goes o at the start of the next.

LED 3 – (amber) Bus Ripple

LED 4 – (amber) High Bus

LED 5 – (amber) Low Bus

Restore all 3 phases of input voltage to within ±10% of nominal line.

0558038313

Normal condition caused when terminating the arc by running the torch o the work or the arc being attached to a part that falls away.

Imbalance of 3-phase input power

Momentary loss of one phase of input power

Faulty control PCB1 Replace PCB1 P/N One or more phases of input voltage

exceed nominal line voltage by more than 15%.

Faulty control PCB1 Replace PCB1 P/N One or more shorted diode rectiers

(D25-D28) on the “Electrode Plate” One or more phases of input volt-

age are lower than nominal by more than 15%.

Blown F1 and F2 fuses

Over temp Light comes on. See over temp in Fault Light Section Imbalanced 3-phase input

power Momentary loss of one phase of

input power Faulty Main Contactor (K1) Replace K1 FAULTY Control PCB1 Replace PCB1 P/N

Reprogram cutting process to ensure arc is terminated only by removing the “Contactor On” signal.

Maintain phase voltage imbalance of less than 5%.

Restore and maintain input power within ±10% nominal

0558038313

Restore and maintain line voltage within ±10%

0558038313

Replace shorted diode rectiers

Restore and maintain within ±10% of nominal

See F1 and F2 in Blown Fuses Section

Maintain phase voltage imbalance of less than 5%

Restore and maintain within ±10% of nominal

0558038313

)

SECTION 6 TROUBLESHOOTING

Problem Possible Cause Action

LED 6 – (red) Right Over Current

Note:

If operation at 400A or less is

possible, then the LEFT side is

not working.

LED 9 – (red) Left Over Current

Note:

If operation at 400A or less is

possible, then the Right side is

not working.

Cutting at over 400A with a faulty left side (left side output = 0)

Right current transducer connector loose or unplugged. PCB loose.

Loose or unplugged connector at right PWM/Drive Printed circuit board.

P2 at left of PWM / Drive PCB loose or unplugged.

Check voltage between P7-6 and P7-7. A voltage in either polarity of greater than

0.01 V indicates a faulty right current transducer (TD2).

Faulty PCB1 Replace PCB1 P/N

Faulty right PWM / Drive PCB

Cutting at over 400A with a faulty right side (right side output = 0)

Left current transducer connector loose or unplugged. PCB loose.

Loose or unplugged connector at left PWM / Drive Printed circuit board.

P2 at right of PWM / Drive PCB loose or unplugged.

Check voltage between P7-2 and P7-3. A voltage in either polarity of greater than

0.01 V indicates a faulty left current transducer (TD1).

Faulty PCB1 Replace PCB1 P/N

Faulty left PWM / Drive PCB

See faulty left or right side

Secure connections

Secure connection

Replace right current transducer (TD2)

Replace right PWM / Drive PCB P/N 0558038324

See faulty right side

Secure connections

Secure connection

Replace left current transducer (TD1)

Replace left PWM / Drive PCB P/N 0558038324

0558038313

CAUTION

NEVER attempt to power-up or operate the power source with any Gate / Emitter IGBT Plug disconnected from it’s PWM / Gate Drive Board. Attempting to operate the power source with any open (unplugged) IGBT Gate / Emitter Connector may damage the IGBT and the plasma cutting torch.

SECTION 6 TROUBLESHOOTING

Problem Possible Cause Action

Shorted IGBT Replace the IGBTs

Very high Output current accompanied by either a left or right over current (LED 6)

LED 10 - (red) Left IGBT Unsaturated

LED 11 - (red) Right IGBT Unsaturated

Current pot set too high Lower the current setting Faulty left PWM / Drive PCB Replace left PWM / Drive PCB High remote current signal Decrease remote current signal Faulty PCB1 Replace PCB1 P/N 0558038313 Black wire connecting IGBT (Q2) collector to P3 of the

left PWM / Drive PCB (PCB2) is disconnected. Shorted Freewheeling Diode(s) Replace freewheeling diode(s) Loose or unplugged P1 connector at the left PWM /

Drive PCB Loose or unplugged P10 connector at PCB1 Secure P10 Faulty PCB1 Replace PCB1 P/N 0558038313 Faulty left PWM / Drive PCB Replace PCB2 P/N 0558038324 Black wire connecting IGBT (Q5) collector to P3 of the

right PWM / Drive PCB (PCB3) is disconnected. Shorted Freewheeling Diode(s) Replace freewheeling diode(s) Loose or unplugged P1 connector at the left PWM /

Drive PCB Loose or unplugged P10 connector at PCB1 Secure P11 Faulty PCB1 Replace PCB1 P/N 0558038313 Faulty right PWM / Drive PCB Replace PCB3 P/N 0558038324

Secure connector

Secure P1

Secure connector

Secure P1

SECTION 6 TROUBLESHOOTING

Problem Possible Cause Action

LED 12 – (red) Left –12V Missing

LED 13 – (red) Right –12V Missing

Very high Output current accompanied by either a left or right over current (LED 9 or LED 6 respectively)

Over Temp Lamp illuminates

Loose or unplugged P1 connector at the left PWM / Drive PCB

Loose or unplugged P10 connector at PCB1

Faulty left PWM / Drive PCB

Loose or unplugged P1 connector at the right PWM / Drive PCB

Loose or unplugged P11 connector at PCB1

Faulty right PWM / Drive PCB

Shorted IGBT Replace the IGBTs Current pot set too high Lower the current setting

Faulty left PWM / Drive PCB

High remote current signal Decrease remote current signal Faulty PCB1 Replace PCB1 P/N 0558038313 One or more fans inoperable Repair or replace fan(s) Broken wire or unplugged connector

at thermal switch.

Obstruction to air ow closer than 3 feet (1 m) to rear of power source.

Excessive dirt restricting cooling air ow

Obstructed air intake

Secure P1 connector

Secure P10 connector

Replace left PWM / Drive PCB P/N 0558038324

Secure P1 connector

Secure P11 connector

Replace right PWM / Drive PCB P/N 0558038324

Replace left PWM / Drive PCB P/N 0558038324

Repair broken wires and unplugged connector

Allow 3 ft. (1 m) minimum between the rear of the power source and any object that may restrict air ow.

Clean out excessive dirt, especially in the extrusions for the IGBTs and freewheeling diodes, the POS, NEG and Electrode Plates, the main transformer (T1) and the lter inductors (L1 and L2).

Check and clear any obstructions from the bottom, front, and top rear of the Power Source.

SECTION 6 TROUBLESHOOTING

6.3.6 Torch Will Not Fire

Problem Possible Cause Action

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

Place Panel/Remote switch in “Panel” position

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 current control present but signal missing.

Current pot set too low. Increase current pot setting. Start current pot, located behind the

cover for the control PCB is set too low. Current up-slope controlled by external

control and power source is set for soft start.

Open connection between the power source positive output and the work.

Fuse F6 in the Pilot arc circuit is blown. Replace F6 Fuse F7 in the pilot arc circuit is blown. Replace F7 Pilot arc High/Low switch is in the ”LOW”

position when using consumables for 100A or higher (Refer to process data included in torch manuals)

Pilot arc contactor (K4) faulty. Replace K4 Faulty PCB1

Check for current reference signal at TB14(+) and TB1-5(-). See Signal vs. Output Current Curve this section.

Increase the start current post setting to “7”.

Set power source for start by placing SW1, positions 1 & 2, on control board in o position. See section 4.4.

Repair connection

Change Pilot arc to “High” position. (Refer to process data included in torch manuals)

Replace PCB1 P/N

0558038312

SECTION 6 TROUBLESHOOTING

6.3.7 Fuses F1 and F2 Blown

Problem Possible Cause Action

Process controller must allow at least

Fuses F1 and F2 blown.

Process controller ignites pilot arc too soon after providing the “Contactor On” signal

Faulty negative (Electrode) output cable shorting to earth ground.

Shorted freewheeling diode.

One or more shorted diode rectiers (D13-D18) on “POS Plate”.

One or more shorted diode rectiers (D7-D12) on “NEG Plate”.

300MS to lapse between the application of the “Contactor On” signal and the ignition of the pilot arc. Fix process controller logic and replace diodes.

Repair cable

Replace shorted freewheeling diode and F1-F2

Replace all diode rectiers on the “POS P la te”.

Replace all diode rectiers on the “NEG P la te”.

6.3.8 Intermittent, Interrupted or Partial Operation

Problem Possible Cause Action

Loose or unplugged connector at left PWM / Drive PCB (PCB2)

Works OK at 400A or less - Over current right side when cutting over 400A. LED 6 on control board illuminated.

Works OK at 400A or less - Over current left side when cutting over 400A. LED 9 on control board illuminated.

Faulty left PWM / Drive PCB

Check voltage between P5-1 and P5-2 at the left PWM / Drive PCB (PCB2). Should be 20V AC. Between P5-1 and P5-3 should be 40V AC. If not the control transformer (T5) is faulty.

Loose or unplugged connector at Right PWM / Drive PCB (PCB3)

Faulty Right PWM / Drive PCB

Check voltage between P5-1 and P5-2 at the right PWM / Drive PCB (PCB3). Should be 20V AC. Between P5-1 and P5-3 should be 40V AC. If not the control transformer (T7) is faulty.

Secure connector

Replace right PWM / Drive PCB P/N 0558038324

Replace control transformer T5

Secure connector

Replace right PWM / Drive PCB P/N 0558038324

Replace control transformer T7

CAUTION

SECTION 6 TROUBLESHOOTING

Problem Possible Cause Action

Power Supply turns o prematurely in the middle of the cut.

Problem Possible Cause Action

Output current is unstable and drifts above or below the setting.

“Contactor On” signal is removed from unit.

Momentary loss of primary input power.

Faulty condition, indicated by illumination of the fault lamp.

Faulty condition, indicated by the illumination of the power reset fault lamp.

Current setting too low. Increase current setting Remote current signal removed during cut. Fix remote current signal

Place the PANEL / REMOTE switch in the “PANEL” position. Adjust current control pot. If current no longer drifts, the remote current control signal is faulty.

Select “PANEL” on the PANEL / REMOTE switch and adjust the current control pot. The current still drifts, measure the current reference signal at TB1-4 (+) and TB1-5 (-). If the signal drifts, the current control pot is faulty. If the signal does not drift, the Control PCB (PCB1) is faulty.

Power source is OK. Trouble shoot process controller.

Restore and maintain input voltage within ±10% of nominal.

Remove control PCB (PCB1) access panel to determine the fault causing the shutdown. Refer to fault light illumination section.

Fix the remote current control signal.

Replace the current control pot.

Replace the control PCB (PCB1) P/N 0558038313

SECTION 6 TROUBLESHOOTING

6.4 Testing and Replacing Components

• Replace a PC board only when a problem is isolated to that board.

• Always disconnect power before removing or installing a PC board.

• Do not grasp or pull on board components.

• Always place a removed board on a static free surface.

NOTICE

Power Semiconductor Components

Categories of power semiconductors include;

• If a PC board is found to be a problem, check with your ESAB distributor for a replacement. Provide the distributor with the part number of the board as well as the serial number of the power source.

• Do not attempt to repair the board yourself. Warranty will be voided if repaired by the customer or an unauthorized repair shop.

• Power Rectiers

• Modules containing the free wheeling diodes and IGBTs

SECTION 6 TROUBLESHOOTING

6.4.1 Power Rectiers and Blocking Diodes

Power Rectiers

Procedure to access behind the front panel

1. Remove top cover and side panels

2. Locate and disconnect plug in rear of ammeter (attached tone red and one black wire)

3. Remove pilot arc switch

4. Disconnect voltmeter

5. Disconnect orange and yellow wires from relay K4.

6. Remove two bolts holding the left side of the front panel to the base.

7. Remove three bolts holding across the center base of the front panel. These are accessed from underneath.

8. Remove one of the bolts holding the right side of the front panel to the base. Loosen the second bolt. Of these two bolts, remove the bolt on the left and loosen the bold on the right.

9. Swing the front panel out to gain access to power recti-

Blocking Diodes

er components.

Troubleshooting Procedures –Negative Plate

Location of Neg. Plate

Location of fuses F8 and F9

1. Visually inspect fuses F8 and F9. Replace if they show signs

of being blown or melted. Inspect diodes. If ruptured or burned, replace all diodes on the NEG Plate. If diodes appear to be OK, proceed to next step.

SECTION 6 TROUBLESHOOTING

Diode RectierNEG Plate

1. Check ohms between NEG Plate and BR “A” Bus. A reading of 2 ohms or less indicates one or more shorted diodes. Replace all Diodes on NEG Plate.

2. If fuses F8 and/or F9 were open in the rst step, make two more ohmmeter readings.

A. Measure resistance between the NEG Plate and

BR “B” bus.

Troubleshooting POS Plate

Location of Pos. Plate

Location of fuses F8 and F9

POS PlateElectrode Plate

B. Measure between NEG Plate and BR “C” bus.

If resistance is 2 ohms or less in either case, replace all the diodes on the NEG Plate.

1. Check ohms between POS Plate and BR “A” Bus. A reading

of 2 ohms or less indicates one or more shorted diodes. Replace all Diodes on POS Plate.

2. If fuses F8 and/or F9 were open in the rst step, make two

Troubleshooting Electrode Plate

Bus

Cathode Leads

Blocking Diodes D25, D26, D27 and D-28

1. Visually inspect for ruptured or burned diodes. Replace

only those damaged.

2. Check resistance between Electrode Plate and the parallel

pig tails (cathode leads) of D25 and D26. If reading is 2 ohms or less, disconnect leads from bus and check each diode. Replace only shorted diodes.

Repeat procedure for D27 and D28. Replace only shorted diodes.

SECTION 6 TROUBLESHOOTING

6.4.2 IGBT / Freewheeling Diode (FWD) Replacement

The emitter and the gate of each aected IGBT must be jum-

CAUTION

pered together to prevent electrostatic damage. Each power source is supplied with six jumper plugs that mate to the IGBT Gate / Emitter Plug.

Electrostatic Discharge Hazard Electrostatic discharge may damage these components.

• Damage is accumulative and may only appear as shortened component life and not as a catastrophic failure.

• Wear a protective ground strap when handling to prevent damage to PCB components.

• Always place a pc board in a static-free bag when not installed.

REMOVAL:

A. Insure that input power is removed by two actions such as a disconnect switch and removal of fuses. Tag and lock any

disconnect switch to prevent accidental activation. B. Remove the top panel to gain access to the modules located in the top rear of the power source. C. Clean the compartment containing the modules with dry, oil-free compressed air. D. Unplug the gate drive leads connecting the IGBT Gates to the PWM/Gate Drive PC Board. In order to prevent damage

to the IGBT, install jumper plugs into the IGBT Gate Drive Connector. See Caution below. Jumper plugs are supplied

with each power source. E. Remove the copper buss plates and bars connected to the IGBT’s. Save the M6 hardware connecting the bus structure

to the module terminals. You may need to re-use the hardware. Longer hardware can damage the module by contact-

ing the circuitry directly below the terminals. F. Remove the M6 hardware mounting the modules to the heat sink. Save the hardware because you may need to re-use

it. Hardware too short can strip the threads in the Aluminum heat sink. Hardware too long can hit the bottom of the

holes causing the modules to have insucient thermal contact to the heat sink. Hardware too long or too short can

cause module damage due to over heating.

The module gate plugs must be plugged into the PWM/Gate

CAUTION

Drive PC Board whenever the power source is in operation. Failure to plug them in will result in damage to the module and possible damage to the torch.

SECTION 6 TROUBLESHOOTING

REPLACEMENT:

A. Thoroughly clean any thermal compound from the heat sink and the modules. Any foreign material trapped between

the module and heat sink, other than an appropriate thermal interface, can cause module damage due to over heating.

B. Inspect the thermal (interface) pad, P/N 951833, for damage. A crease or deformity can prevent the module from seat-

ing properly, impeding the heat transfer from the module to the heat sink. The result can be module damage due to over heating.

If a thermal pad is not available, a heat sink compound such as Dow Corning® 340 Heat Sink Compound may be used. It’s a good idea to mount all paralleled modules located on the same heat sink using the same thermal interface. Dierent interfaces can cause the modules to operate at dierent temperatures resulting in un-equal current sharing. The imbalance can shorten module life.

C. Place a thermal pad, and an IGBT module on the heat sink. Carefully align the holes in the thermal pad with the heat-

sink and module holes. If heat sink compound is used in place of a thermal pad, apply a thin coat of even thickness to the metal bottom of the module. A thickness of 0.002” – 0.003” (0.050mm – 0.075mm) is optimum. Too much compound impedes heat transfer from the module to the heat sink resulting in short module life due to over heating.

D. Insert the four M6 mounting bolts, but do not tighten. Leave them loose a few turns. Be certain that the threads from

the mounting bolts do not bend the edges of the thermal pad clearance holes. A bent thermal pad can prevent the module from seating properly, impeding the heat transfer from the module to the heat sink. The result can be module

damage due to over heating. E. Partially tighten the four mounting bolts a little more than nger tight in the order: A-B-C-D. See gure below. F. Fully tighten, in the same order above, to a torque of 35 – 44 in-lbs (4.0 – 5.0 N-M). See gure below. G. Install the bus plates and bus bars. Be careful that the sheets of insulation separating the bus plates are still in their

original positions. It’s a good idea to tighten the mounting hardware only after getting it all started. Torque the M6

module terminal hardware to 35 – 44 in-lbs (4.0 – 5.0 N-M). H. Remove the jumper plugs from the module gate lead plugs, and plug into the appropriate plugs from the PWM/Gate

Drive PC Board. See Caution below. I. Replace the top panel.

CAUTION

1 - IBGT Collector, Free Wheeling

Diode (FWD) Anode

2 - IGBT Emitter

3 - FWD Cathode

6 - IGBT Gate

7 - IGBT Emitter

The module gate plugs must be plugged into the PWM/Gate Drive PC Board whenever the power source is in operation. Failure to plug them in will result in damage to the module and possible damage to the torch.

Four-Point Mounting Type Partial tightening - A

Fully tightening - A

-B-C-D

Key Plug

6 (RED)

7 (WHT)

Position 1 (RED)

SECTION 6 TROUBLESHOOTING

6.4.3 Power Shunt Installation

Instability or oscillation in cutting current can be caused by improper dressing of shunt pick-up leads.

CAUTION

Poor torch consumable life will be the result.

There are two cables that attach to the shunt pick-up points:

a two conductor cable drives the ammeter a three conductor which provides the current feedback signal to PCB1 (control PCB).

Dressing of the 2 conductor cable is not critical.

The following is the dressing procedure for the 3 conductor cable.

• The breakout point should be physically at the middle of the shunt. The breakout point is the place where the conductors exit from the outer insulation jacket.

• The black and clear insulated wires must be kept next to the shunt and under the cable ties.

• The wire terminals for the black and clear insulated wires should be oriented in parallel with bus bars

as shown.

three leads

Terminals parallel

to bus bars

clear insulation

• It is important to have the barrels of the black and clear insulated wires, from the three lead cable, be pointing in opposite directions.

• The third wire attaches to the bus bar on the left with the shunt mounting hardware. Orientation of this wire is not critical.

two leads

SECTION 6 TROUBLESHOOTING

6.4.4 Procedure For Verifying Calibration Of Digital Meters.

Voltmeter

1. Connect a digital meter known to be calibrated to the positive and negative output bus bars.

2. Compare the power source voltmeter reading to the calibrated meter reading. Readings should match within ±0.75%.

Ammeter

1. External to the power source, connect a precision shunt in series with the work lead(s). The best shunt is one with a

value of 100 micro-ohms (50mV / 500A or 100mV / 1000A) and a calibrated tolerance of 0.25%.

2. Use a calibrated 4 ½ digit meter to measure the output of the shunt. The amperage indicated with the external shunt

and meter should match power source ammeter to within 0.75%.

6.5 Control Circuit Interface Using J1, J4 and J6 Connectors

Interface to the EPP-601 control circuitry is made with connectors J1, J4 and J6 on the front panel. J1 has 24 conductors, J4 has 2 and J6 has 10.

J1-P and J1-G provide access to the galvanically isolated transistor output signal indicating an “Arc On” condition. See Subsection 6.8, Arc Current Detector Circuits. J1-L and J1-J are the inputs for the remote Voltage Reference Signal that commands the EPP-601 output current Subsection 6.9, Current Control Pot & Remote Vref. J1-R and J1-Z supply 115V AC for remote controls. See Subsection 6.6, Auxiliary Main Contactor (K3 and K33) & Solid State Contactor Circuits and Subsection

6.10, Pilot Arc Hi/lo & Cut/mark Circuits.

J1-E and J1-F are the input connections for the Emergency Stop function. For Emergency Stop to operate, the Jumper between TB8-18 and TB8-19 must be removed.

J1-S is the input to K8 that parallels S1 switch contact. When 115V AC from J1-R is fed into J1-S, K8 activates placing the Pilot Arc in High.

J4-A and J4-B are from an isolated contact on the emergency stop (E-stop) switch. This signal can be used by the plasma control to indicate the state of the E-stop switch on the power source.

Cut / Mark selection: The power source defaults to Cutting mode when there is no signal fed into J1-C. When 115V AC from J1-R is fed into J1-C, K11 is activated placing the EPP-601 in the Marking mode. For more details concerning the operation of K11 and the Cut / Mark modes, refer to Subsection 6.10, High / Low Cut Current Modes and Mark Mode.

High / Low current ranges: The power source defaults to low cutting current range (35-100A) when no signal is fed into J1-T. High range (50A to maximum current rating) is selected whenever 115VAC is fed into J1-T by connecting J1-R to J1-T.

J6 connects to the water cooler. J6-A and J6-B are 115VAC hot and neutral respectively. This 115VAC activates the contactor for the pump. J6-C and J6-D connect to the ow switch. The ow switch is closed when coolant is owing. J6-E and J6-H connect to the coolant level switch. The switch is closed when the coolant reservoir contains sucient coolant and it is open when the reservoir is low.

SECTION 6 TROUBLESHOOTING

CONTROL CIRCUIT INTERFACE USING J1, J4, & J6 CONNECTORS

EPP-450 POWER SOURCE

CONTROL

REMOTE EMERGENCY STOP

ISOLATED CONTACT

E-STOP LOOP MUST BE CLOSED FOR POWER SOURCE TO FUNCTION

PILOT ARC HI/LO

PLASMA START

CUT/MARK MODE SELECT

HI/LO CURRENT RANGE

CUT/MARK CURRENT DETECT

REMOTE 0 - 10V Vref

CUT

MARK

COOLANT LEVEL

COOLANT FLOW

15 - 50 VDC

J4-A

J4-B

J1-F

RED 06

J1-E

RED 05

J1-D

GRN/YEL

J1-Z

RED 04

J1-R

RED 16

J1-S

RED 17

J1-M

RED 12

J1-C

RED 03

J1-T

RED 18

J1-K

RED 10

J1-B

RED 02

J1-G

RED 07

J1-P

RED 14

J1-Y

RED 23

J1-L

RED 11

J1-J

RED 09

TB8-19

TB8-18

K11

115 VAC HI RANGE INPUT

EPP-601 POWER SOURCE

ISOLATED CONTACT

E-STOP RELAY

K15

115V AC NEUTRAL

115V AC HOT

115V AC CONTACTOR INPUT

115V AC MARK MODE INPUT

K13 K14

100V 50mA MAX

10 OHMS

100 OHMS

ELECTRODE CURRENT SIGNAL 1.0V = 100A

24 VAC

CHASSIS

OFF: PILOT ARC LOW ON: PILOT ARC HIGH

IN MARK MODE, K11 FORCES THE LO CURRENT RANGE

115 VAC

CURRENT DETECTOR

200K Ohms

E-STOP BUTTON

1112

CB2

115 VAC

NOTE: Panel S1 MUST BE in LOW position for remote contact to function

K33

K11

J6-B

J1-B

CONTACTOR FOR

J6-A

J1-A

J6-H

J1-H

J6-C

J1-C

J6-D

J1-D

J6-E

J1-E

REMOTE CUTTING CURRENT REFERENCE VOLTAGE (Vref) Icut = (Vref) x (80)

PUMP & FAN

FLOW SWITCH

COOLANT CIRCULATOR

LEVEL SWITCH

SECTION 6 TROUBLESHOOTING

115V

J6-BJ1-ZJ1-R

TB1-7

TB8-7

J1-D

TB1-8

115V AC

TB9-18

TB9-13

TB9-16

K33 K15

6 69

R45B

TB7-8

TB7-9

P6-1

TB1-9

P2-5 P2-6

K33

P1-9 P1-10

680

P6-2

K3 K7

6 699

ON/OFF

IGBT DRIVE

ON/OFF

LED3 LED3

LEFT PWM/GATE DRIVE PC BOARD

RIGHT PWM/GATE DRIVE PC BOARD

+15V

CONTROL PC BOARD

Solid State Contactor

(AMC)

NEUTRAL

HOT

FN4

J1-E

STARTING CONTACTOR

PILOT ARC CONTACTOR

Current Detector Contact on Control PCB

Fault Relay

IGBT DRIVE

AUXILLARY MAIN CONTACTOR (K3 & K33) & SOLID STATE CONTACTOR CIRCUITS

Open with fault and main line power off

Over Heat Relay - Closed during normal operation

R45A

10K

P1-9 P1-10

TB7-8

P10-5

P10-6

P11-5

P11-6

10K

K15

E-STOP RELAY

J6-A

6.6 Auxiliary Main Contactor (K3 & K33) and Solid State Contactor Circuits

K3 and K33, activated by supplying a Contactor Signal, initiate and controls the operation of K2 (Starting Contactor) and K4 (Pilot Arc Contactor). K3/K33 are called the Auxiliary Main Contactors because they must be activated before the Main Contactor (K1) power-up sequence can occur. The Contactor Signal is supplied through a remote contact connecting 115VAC from J1-R to J1-M. If K6 is closed (no fault), K3 will activate. The closing of K3(6, 9) activates K2, the Starting Contactor, and K4, the Pilot Arc Contactor, provided the power source is not over heated. See Subsection 6.7, E-stop and Main Contactor Circuits for more information on the operation of K2. K4 is turned o when the Current Detector senses arc current and opens the contact connecting P2-5 to P2-6 on the Control PC Board.

In addition to operating K3/K33, the Contactor Signal also activates the Solid State Contactor. The Solid State Contactor is a logic and interlock circuit permitting the IGBT’s to conduct whenever the remote Contactor Signal is present. The 115V AC Contactor Signal is fed to TB1-9, TB7-8, and resistors R45 and R45-A. These resistors reduce the 115V to approximately 16V AC fed into the Control PC Board at P6-1 and P6-2. The Control PC Board sends a signal to both the Left and Right PWM / Gate Drive PC Boards. Illumination of LED3 on both of the PWM / Gate Drive PC Boards is indication that the Solid State Contactor is functioning.

SECTION 6 TROUBLESHOOTING

6.7 E-Stop (Emergency Stop) and Main Contactor (K1A, K1B and K1C) Circuits

A power-up sequence takes place before the Main Contactor (K1) activates. K1 is actually three separate contactors – one for each primary input phase. Thus, K1A, K1B, and K1C switch phases A, B, and C respectively to the Main Transformer, T1.

The power-up sequence begins with a remote Contactor Signal activating K3 and K33. Refer to the description entitled, Section 6.6, Auxiliary Main Contactor (K3 and K33) & Solid State Contactor Circuits for more information. K3 and K33 activates K2 closing the three contacts of K2. K2 bypasses K1 contacts providing primary input power to the Main Transformer, T1. This current is limited by three one Ohm resistors, R1, R2, and R3. The resistors eliminate the high surge currents typical of the turn-on inrush transients associated with large transformers. The high current surge of charging the Bus Capacitor Bank is also eliminated by initially powering the Main Transformer through K2 and the resistors.

The discharged Bus Capacitor Bank initially prevents the output of the Main transformer from reaching its normal value. As the Bus Capacitor Bank charges, the Main Transformer output voltage rises and becomes high enough for K1A, K1B, and K1C to close. Once the K1’s are closed, the contacts of the Starting Contactor, K2, are bypassed, and full primary line power is supplied to the Main Transformer through the contacts of the K1’s.

Because the starting sequence takes time, it is important at least 300 mS lapse between applying the Contactor Signal and applying load to the power source. Applying load too soon will prevent the K1’s from closing and fuses F1 and F2 will open.

K15, the E-Stop relay must be closed for the power-up sequence to take place. K15 contains one contact in the K2 coil circuit and another contact in the K1A, K1B, & K1C circuits. There is no power supplied to the Main Transformer, T1, until K15 is activated. For K15 to activate, S5, the E-Stop switch on the front panel must be closed. Also, the Plasma Control must complete the E-stop loop by closing an isolated contact between J1-E and J1-F.

The E-Stop switch is closed whenever the E-Stop button, on the front panel, is pulled out. For troubleshooting purposes only, a jumper can be connected between TB8-18 and TB8-19. If a jumper is installed, it MUST be removed before placing the power source back into service. If the jumper is not removed, the power source E-Stop condition will not function when the E-Stop button for the Plasma Control is pushed.

J4-A and J4-B are connected together whenever the E-Stop button on the power source is pulled out. This signal can be sent to the Plasma Control so that the control senses the state of the power source E-Stop switch.

SECTION 6 TROUBLESHOOTING

E-STOP (EMERGENCY STOP) CIRCUIT

3 PHASE INPUT POWER

6.7 E-Stop (Emergency Stop) and Main Contactor (K1A, K1B and K1C) Circuits (continued)

TB4

K1A

L1 L2 L3

T1 T2 T3

300W

TB5

15A

K1B K1C

L1 L2 L3

T1 T2 T3

300W

MAIN TRANSFORMER

TB6

15A

(MC)(MC)(MC)

L1 L2 L3

T1 T2 T3

115 VAC WINDING ON "A" COIL OF MAIN TRANSFORMER

(T1) ASSY

7 4

K15

K1A

J6-A

J1-R

K15

115 VAC

STARTING CONTACTOR

K33

K15

300W

K2K2K2

7 4

K33

J4-A

J4-B

E-STOP RELAY

J1-E

TB8-19

TB8-18

J1-F

E-STOP

E-STOP LOOP MUST BE CLOSED FOR POWER SOURCE TO FUNCTION

K15

TO T2-X3 TO CB2-2

E-STOP BUTTON

12 11

24 VAC

K1B

K1C

SECTION 6 TROUBLESHOOTING

6.8 Arc Current Detector Circuits

There are three Arc Current Detector circuits in the EPP-601. One is used internally to control the Pilot Arc Contactor, K4. The other two are available for remote use.

A galvanically isolated transistor Current Detector Output is accessible at J1-G (-) and J1-P (+). J1 is the 24 conductor connector on the EPP-601 front panel. The transistor is best suited for switching small relays or low current logic signals like those utilized by PLC’s (Programmable Logic Controllers). The transistor can withstand a maximum peak voltage of 150V. It can switch a maximum of 50 mA. The transistor turns on whenever the arc current through the Work Lead exceeds 5A. Pilot arcs not establishing main arcs will not turn on the transistor.

A second current detector output is available at TB8-3 and TB8-4. This output is supplied by an isolated relay contact rated for 150V, 5 Amperes. This contact is closed when the primary input power to the EPP-601 is o. It opens whenever primary power is supplied to the power source, and it closes when main arc current is established. Like the transistor output, the relay contact closes whenever the arc current through the Work Lead exceeds 5A. Pilot arcs not establishing main arcs will not close the contact.

J6-D J6-E J1-G J1-P

SECTION 6 TROUBLESHOOTING

6.9 Current Control Pot and Remote Vref

A Reference Voltage, V

, is used to command the output current of the EPP-601. V

REF

is a DC voltage that can come from

REF

either the Current Control Potentiometer on the front panel or from a remote source. In the “Panel” position, S2, the Panel / Remote switch selects the Current Control Potentiometer. In the “Remote” position, the Panel/Remote switch selects the V

fed into J1-L (+) and J1-J (-). The EPP-601 Output Current, I

REF

= (80) x (V

OUT

) in the high output current mode and I

REF

OUT

, will follow V

OUT

= (10) x (V

with the following relationship:

REF

) in the low output current mode.

REF

PCB10 is the analog signal scaling board. If 115VAC is fed into P1-2 and P1-3 the output current range is in the high mode used for cutting from 50 to 600A. With the 115VAC absent, the output current range is in the low mode used for marking between 10 and 100A and cutting between 35 and 100A.

The Control PC Board contains two inputs for V the High Speed input (P8-3), the EPP-601 will respond to a change in V is fed into the Low Speed input (P8-1), the EPP-601 will respond to a change in V

: High Speed; and Normal. When the negative of the V

REF

within 10 mS. When the negative of the V

REF

within 50 mS. The slower response of

REF

signal is fed into

REF

signal

REF

the “Normal” input helps lter electrical noise sometimes encountered in industrial environments.

0.00-10.00V

CONTROL BOARD 0558038313

JUMPER

CURRENT REFERENCE

EPP-600: I(out) = (80) X Vref

200K

HIGH SPEED

P8-3

200K

NRM

P8-1

+10T

P8-2

PRECISION REFERENCE

JUMPER FOR EPP-600

P5-8 TB1-3

P4-10

P4-11

220

P4-12

S BIAS

P3-3 P3-5P3-4

PRI: 120V SEC: 40VCT

H1 H2

H N

T10

120V

P4-9

220

+15S

20V20V

TB8-11

TB1-4

J1-L

REMOTE

C46

.01

P4-8

SIGNAL:

LO: 10V = 100A

HI EPP-600: 1V = 80A

P4-2

C45

0-10V

200K

.01

P4-7

NRM SPEED

P4-1

PANEL

TB1-5

J1-J

66 TB1-6

TB8-12

J1-J, DC SIGNAL COMMON (NEG) ALSO SHOWN ON PAGE 1

P2-1 P2-2

PCB10

ANALOG SCALING BOARD 0558038326

HIGH

P4-3

115VAC = HIGH RANGE

P1-3 P1-2

CURRENT

CURRENT CONTROL

CONTROL POT

POT R50 10K

SEE PAGE 1, K13-6

SECTION 6 TROUBLESHOOTING

HIGH/LOW CUT CURRENT MODES & MARK MODE

6.10 High / Low Cut Current Modes and Mark Mode

A remote contact connecting 115V AC from J1-R to J1-S places the Pilot Arc in High by operating K8. Note, that for this function to operate, the Pilot Arc Hi/Lo switch on the front panel must be in the “LO” position.

The EPP-601 is placed in the Marking mode when a remote contact connecting 115V AC from J1-R to J1-C operates K11. In the Marking mode, a normally closed contact on K11 opens turning o K10. When K10 turns o, the Boost supply is disconnected lowering the normal Cutting Mode 430V DC Open Circuit Voltage to 360VDC for Marking. A normally open contact on K11 activates K12. K12 connects the I (min) resistors necessary for stabilizing the low currents required for marking. In the Cutting mode, the minimum stable output current is 50A in the high current range, 35A in the low current range and 10A in the marking mode. In the marking mode, the normally closed contacts K11(3, 9) and K11(1, 7) open. This deactivates K13 and K14 placing the power source in the low current range.

115 VAC

K15

SEE PAGE 2 PCB10 P1-2

J6-A

E-STOP RELAY

K13

Z BIAS

SEC 40VCT

K11

P5-2P5-3

20V20V

PRI 120V

PILOT ARC HI/LO

P5-1

PCB3 Right PWM/Gate Drive

10 2W

K12

K13

FAN

R70

I(min) RESISTORS

1µF

600V

WHT

K10

BOOST

TB9-18

TB9-13

FN4

115V

J1-M

TB1-7

TB8-7

J1-R

TB1-7

CONTACTOR SIGNAL

J1-Z

TB1-8

J6-B

PILOT ARC MARK

J1-S

CUT/

CUT

K11

J1-C

MARK

CUT CURRENT RANGE

K14

TB8-2

TB8-1

J1-T

K13

K11

RED

MOVE RED WIRE FROM TB8-1 TO TB8-2 FOR FOR HI CURRENT RANGE

SECTION 6 TROUBLESHOOTING

ELECTRODE CURRENT TRANSDUCER CIRCUIT

6.11 Low Current Range

The EPP-601 operates in either LOW or HIGH current output ranges. The LOW range is used for marking from 10 to 100 amperes and cutting from 35 to 100 amperes. The HIGH range is used for cutting from 50 to 600 amperes.

In the HIGH range, both the left and right power sources are used. Each side contributes 50% of the total output current. The left side acts as a master power source by synchronizing the switching of the right side to its own switching frequency of 10 KHz.

In the LOW range, only the left power source is used. The normally open contact, K13(6, 9) prevents T7 from supplying bias supply power to PCB-3, the right PWM / IGBT Gate Drive PC Board. This disables the right side.

The same K13 contact (square labeled “D” on the schematic diagrams) places the EPP-601 in the HIGH current mode. In addition to providing bias power to PCB-3 in the HIGH current mode, this 115 VAC is fed into PCB-10 P1-2.

PCB-10 performs two functions. With no input on PCB-10 P1-2, PCB-10 scales the 0 to 10 VDC current reference signal for 0 to 100 amperes (LOW range). In the LOW range, PCB-10 P4-11 / P4-12 provides a signal to PCB-2 P4-1 / P4-2. This signal commands PCB-2, the left (master) PWM / IGBT Gate Drive PC Board to change the switching frequency from 10 KHz to 25 KHz.

The higher switching frequency results in the more power dissipation by the heat sinks on PCB-3. Therefore, in the LOW current mode, a small fan, M5, turns on to provide additional cooling. M5 does not operate in the HIGH current mode.

6.12 Electrode Current Transducer Circuit

The Electrode Current Transducer Circuit provides a galvanically isolated signal to the plasma control indicating the power source output current. The scaling of the signal is: VOUT = IELECTRODE/100. For example, 200A results in 2.0V output. The scaling is the same for both high and low current ranges. The output signal resistance is 100 Ohms.

PCB11 receives the signal from the Hall Eect Transducer and sends the signal through FN5 to J1-Y (+) and J1-J (-). PCB11 supplies +15V and -15V to operate the transducer. It also buers the signal to prevent damage to the transducer from voltage transients generated outside the power source.

J1-J

TB9-1

Vref COMMON

NOZZLE

(TB10)

JUMPER CONNECTS Vref (-) AND OUTPUT CURRENT SIGNAL (-) TOGETHER (POSITION FOR PLASMA CUTTING)

TO SHUNT NEG.

TO PILOT ARC CONTACTOR, K4-T1

ELECTRODE CURRENT TRANSDUCER

TD3

HALL

ARROW

OUTPUT CURRENT SIGNAL COMMON

TB9-3

TB9-2

MOVING JUMPER SEPARATES Vref COMMON & OUTPUT CURRENT SIGNAL COMMON

P1-2 P1-4

P1-3

P1-1

J1-X

1.00V SIGNAL = 100A OUTPUT

P4-6

P4-5

P4-1

P4-2

J1-Y

-15V

COMMON

SIGNAL -

SIGNAL +

FN5

PCB11

P4-7

OUTPUT CURRENT SIGNAL

ANALOG SCALING BOARD

P4-8

ELECTRODE

FN1

WORK

FN2

P4-4

+15V

P3-2

P3-1P1-2 P1-1

PRI: 120V SEC: 40VCT

P3-3

P3-4

20V 20V

T11

P3-5

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-601 Input/Output Information

Part Number

EPP-601

380V 50/60HZ

380V TAPS

EPP-601

380V 50/60HZ

40 0V TAPS

0558007733 0558007734 0558007735

EPP-601

400V 50/60HZ

EPP-601

460V 60HZ

EPP-601

575V 60HZ

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.

NOTES

REVISION HISTORY

1. Original release - 12/2007

2. Revision 05/2008 - added E-stop information throughout manual. Included Replacement Parts section in Schematic / Wiring Diagram package. Changed power supply name from EPP-600 to EPP-601.

3. Revision 07/2010 - made various per P. Higgins in accordance with GE manual.

4. Revision 08/2010 - Updated with new DOC form.

5. Revision 05/2012 - minor editorial changes.

6. Revision 06/2012 - dimensions changes section 2.3.

ESAB Welding & Cutting Products, Florence, SC

COMMUNICATION GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS: Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST Order Entry Product Availability Pricing Order Information Returns

B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting

C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Hours: 8:00 AM to 5:00 PM EST Part Numbers Technical Applications Specications Equipment Recommendations

D. LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4487 / Fax: (843) 664-5557 Hours: 7:30 AM to 3:30 PM EST Repair Estimates Repair Status

F. WELDING EQUIPMENT TRAINING Telephone: (843)664-4428 / Fax: (843) 679-5864 Hours: 7:30 AM to 4:00 PM EST Training School Information and Registrations

G. WELDING PROCESS ASSISTANCE: Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES: Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123

Fax: (843) 664-4462

Hours: 7:30 AM to 5:00 PM EST

visit us on the web at http://www.esabna.com

The ESAB web site oers

Comprehensive Product Information

Material Safety Data Sheets

Warranty Registration

Instruction Literature Download Library

Distributor Locator

Global Company Information

Press Releases

Customer Feedback & Support

ESAB EPP-601 Precision Plasma Power Source Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SECTION 1 SAFETY PRECAUTIONS

1.0 Safety Precautions

1.1 Safety - English

1.2 Safety - Spanish

1.3 Safety - French

2.1 Introduction

2.3 Dimensions and Weight

3.1 General

3.2 Unpacking

3.3 Placement

3.4 Input Power Connection

3.4.1 Primary Power

3.4.2 Input Conductors

3.4.3 Input Connection Procedure

3.5 Output Connections

3.5.1 Output Cables (customer supplied)

3.5.2 Output Connection Procedure - Single Power Source

3.6 Parallel Installation

3.6.1 Connections for Two EPP-601’s in Parallel

3.6.1 Connections for Two EPP-601’s in Parallel (continued)

3.6.2 Marking with Two Parallel EPP-601’s

3.7 Interface Cables

3.7.1 CNC Interface Cables with Mating Power Source Connector and Unterminated CNC Interface

3.7.2 CNC Interface Cables with Mating Power Source Connectors and Mating CNC Connector

3.7.3 Water Cooler Interface Cables with Mating Power Source Connectors at Both Ends

4.1 Block Diagram Circuit Description

4.1 Block Diagram Circuit Description (con’t.)

4.1 Block Diagram Circuit Description (con’t.)

4.2 Control Panel

4.2 Control Panel (con’t.)

4.2 Control Panel (con’t.)

4.2.1 Modes of Operation: High and Low Cutting Modes and Marking Mode

4.3 Sequence of Operation

4.4 Arc Initiation Settings

4.4.1 Enable/Disable Arc Initiation Conditions

4.4.2 Adjusting Arc Initiation Dwell Timer

4.4.3 Adjusting the Minimum Start Current

4.4.4 Arc Initiation Controls

4.4.5 Start Current and Up-Slope Timer

4.4.6 Approximate EPP-601 V-I Curves for all models

5.1 General

5.2 Cleaning

5.3 Lubrication

6.1 General

6.2 Fault Indicators

6.3 Fault Isolation

6.3.1 No output with contactor signal applied

6.3.2 Output limited to 100A

6.3.3 Fans Not Working

6.3.4 Power Not On or LOW Voltage

6.3.5 Fault Light Illumination

6.3.6 Torch Will Not Fire

6.3.7 Fuses F1 and F2 Blown

6.3.8 Intermittent, Interrupted or Partial Operation

6.4 Testing and Replacing Components

Power Semiconductor Components

Troubleshooting Procedures –Negative Plate

Troubleshooting POS Plate

Troubleshooting Electrode Plate

6.4.2 IGBT / Freewheeling Diode (FWD) Replacement

6.4.3 Power Shunt Installation

6.4.4 Procedure For Verifying Calibration Of Digital Meters.

6.5 Control Circuit Interface Using J1, J4 and J6 Connectors

6.6 Auxiliary Main Contactor (K3 & K33) and Solid State Contactor Circuits

6.7 E-Stop (Emergency Stop) and Main Contactor (K1A, K1B and K1C) Circuits

6.7 E-Stop (Emergency Stop) and Main Contactor (K1A, K1B and K1C) Circuits (continued)

6.8 Arc Current Detector Circuits

6.9 Current Control Pot and Remote Vref

6.10 High / Low Cut Current Modes and Mark Mode

ELECTRODE CURRENT TRANSDUCER CIRCUIT

6.11 Low Current Range

6.12 Electrode Current Transducer Circuit

SECTION 7 REPLACEMENT PARTS

7.0 Replacement Parts

7.1 General

7.2 Ordering