ESAB ESP-400C Instruction manual

Download

Installation, Operation, and Maintenance for the

ESP-400C

Plasma Power Source

F-15-657

Jun, 2005

The equipment described in this manual is potentially hazardous. Use caution when installing, operating and maintaining this equipment.

Purchaser is solely responsible for the safe operation and use of all products purchased, including compliance with OSHA and other government standards. ESAB Cutting Systems has no liability for personal injury or other damage arising out of the use of any product manufactured or sold by ESAB. See standard ESAB terms and conditions of sale for a specific statement of ESAB’s responsibilities and limitations on its liability.

ESAB Cutting Systems first priority is total customer satisfaction. We constantly look for ways to improve our products, service and documentation. As a result, we make enhancements and/or design changes as required. ESAB makes every possible effort to ensure our documentation is current. We cannot guarantee that each piece of documentation received by our customers reflects the latest design enhancements. Therefore, the information contained in this document is subject to change without notice.

This manual is ESAB Part Number F15657

This manual is ESAB Part Number F15657This manual is ESAB Part Number F15657

This manual is for the convenience and use of the cutting machine purchaser. It is not a contract or other obligation on the part of ESAB Cutting Systems.

©©©© ESAB Cutting Systems, 2000

Printed in U.S.A.

ESP-400C Plasma Power Source Table of Contents

Page

Section 1 Safety

1.1 Introduction 1

1.2 Safety Notations And Symbols 1

1.3 General Safety Information 2

1.4 Installation Precautions 3

1.5 Electrical Grounding 4

1.6 Operating A Plasma Cutting Machine 4-7

1.7 Service Precautions 8

1.8 Safety References 9

Section 2 Description

2.1 General 1

2.2 General Specifications 1

2.3 Dimensions and Weight 2

Section 3 Installation

3.1 General 1

3.2 Unpacking 1

3.3 Placement 2

3.4 Input Power Connections 2-5

3.4.1 Primary Power 3

3.4.2 Input Conductors 4

3.4.3 Input Connection Procedure 4-5

3.5 Output Connections 5-6

3.5.1 Output Cables 5

3.5.2 Output Connection Procedure 5

3.6 Parallel Installation 6-7

3.7 System Interconnecting Block Diagram with Smart Flow II 8

3.8 System Interconnecting Block Diagram without Smart Flow II 9

Section 4 Operation

4.1 Introduction 1

4.2 Control Panel 1-3

4.3 Sequence of Operation 4

4.4 Arc Initiation Settings 4-7

4.4.1 Enable/Disable Arc Initiation Timer 6

4.4.2 Adjusting Arc Initiation Timer 6

4.4.3 Arc Initiation Controls 7

4.4.4 Start Current and Up-slope Timer 7

4.5 V-I Curve 8

ESP-400C Plasma Power Source Table of Contents

Section 5 Maintenance

5.1 General 1

5.2 Cleaning 1

5.3 Fan Lubrication 2

Section 6 Troubleshooting

6.1 General 1

6.2 Fault Indicators 1-3

6.3 Fault Isolation (Diagnostics) 4-10

6.3.1 Fans 4

6.3.2 Power not on or Low Voltage 4

6.3.3 Fault Light Illumination 5-8

6.3.4 Torch will not Fire 9

6.3.5 Fuses 1 and 2 Blown 10

6.3.6 Intermittent, interrupted or Partial Operation 10-12

6.4 Testing and Replacing Components 13

6.4.1 Power Rectifiers 14

Negative Plate 14

Positive Plate 15

Electrode Plate 15

6.4.2 Freewheeling Diodes and IGBTs 16-18

6.4.3 Power Shunt Installation 18

6.4.4 Procedure for Verifying Calibration of Digital Meters 19

6.5 ESP-400C Schematic Diagrams 20-27

6.6 Wiring Diagrams 28-35

6.7 PC Controller Board (PCB1 - P/N 38032) Schematics 36-40

6.8 PCB Digital Meter Board (PCB4 – P/N 38139) Schematics 41-43

6.9 IGBT Driver Board (PCB2,3 – P/N 38030) Schematics 44-46

ESP-400C Plasma Power Source Table of Contents

Section 7 Replacement Parts

7.1 General 1

7.2 Ordering 1

7.3 Outside View - Front and Back 2-3

7.4 Front View With PCBs Exposed 4-5

7.5 Right Side View 6-7

7.6 Left Side View 8-9

7.7 Top View 10-11

7.8 Back Inside View 12-13

7.9 Middle Cross Section 14-15

7.10 Front Cross Section – Behind Front Panel 16-17

Customer/Technical Information Back Manual Cover

iii

ESP-400C Plasma Power Source Table of Contents

This page intentionally left blank.

SECTION 1 SAFETY

1.1 Introduction

The process of cutting metals with plasma equipment provides industry with a valuable and versatile tool. ESAB cutting machines are designed to provide both operation safety and efficiency. However, as with any machine tool, sensible attention to operating procedures, precautions, and safe practices is necessary to achieve a full measure of usefulness. Whether an individual is involved with operation, servicing, or as an observer, compliance with established precautions and safe practices must be accomplished. Failure to observe certain precautions could result in serious personnel injury or severe equipment damage. The following precautions are general guidelines applicable when working with cutting machines. More explicit precautions pertaining to the basic machine and accessories are found in the instruction literature. For a wide scope of safety information on the field of cutting and welding apparatus, obtain and read the publications listed in the Recommended References.

1.2 Safety Notations And Symbols

DANGER

WARNING

CAUTION

The following words and symbols are used throughout this manual. They indicate different levels of required safety involvement.

ALERT or ATTENTION. Your safety is involved or potential equipment failure exists. Used with other symbols and information.

Used to call attention to immediate hazards which, if not avoided, will result in serious personal injury or loss of life.

Used to call attention to potential hazards that could result in personal injury or loss of life.

Used to call attention to hazards that could result in minor personal injury or equipment damage.

Used to call attention to minor hazards to equipment.

NOTICE

Used to call attention to important installation, operation or maintenance information not directly related to safety hazards.

ESP-400CPlasma Power Source

ESP-400CPlasma Power SourceESP-400CPlasma Power Source

1-1

SECTION 1 SAFETY

1.3 General Safety Information

Machinery often starts automatically.

WARNING

This equipment moves in various directions and

This equipment moves in various directions andThis equipment moves in various directions and speeds.

speeds.

speeds.speeds.

 Moving machinery can crush.

Moving machinery can crush.

Moving machinery can crush.Moving machinery can crush.

 Only qualified personnel should operate or service

Only qualified personnel should operate or service

Only qualified personnel should operate or serviceOnly qualified personnel should operate or service this power source.

this power source.

this power source.this power source.

 Keep all personnel, materials, and equipment not

Keep all personnel, materials, and equipment not

Keep all personnel, materials, and equipment notKeep all personnel, materials, and equipment not involved in production process clear of entire

involved in production process clear of entire

involved in production process clear of entireinvolved in production process clear of entire system area.

system area.

system area.system area.

 Fence off entire work cell to prevent personnel

Fence off entire work cell to prevent personnel

Fence off entire work cell to prevent personnelFence off entire work cell to prevent personnel from passing through area or standing in the

from passing through area or standing in the

from passing through area or standing in thefrom passing through area or standing in the working envelope of the equipment.

working envelope of the equipment.

working envelope of the equipment.working envelope of the equipment.

 Post appropriate WARNING signs at every work

Post appropriate WARNING signs at every work

Post appropriate WARNING signs at every workPost appropriate WARNING signs at every work cell entrance.

cell entrance.

cell entrance.cell entrance.

WARNING

 Follow lockout procedure before servicing any

Follow lockout procedure before servicing any

Follow lockout procedure before servicing anyFollow lockout procedure before servicing any equipment.

equipment.

equipment.equipment.

Failure to follow operating instructions could result in death or serious injury.

Read and understand this operator’s manual before

Read and understand this operator’s manual beforeRead and understand this operator’s manual before using machine.

using machine.

using machine.using machine.

 Read entire procedure before operating or

Read entire procedure before operating or

Read entire procedure before operating orRead entire procedure before operating or performing any system maintenance.

performing any system maintenance.

performing any system maintenance.performing any system maintenance.

 Special attention must be given to all hazard

Special attention must be given to all hazard

Special attention must be given to all hazardSpecial attention must be given to all hazard warnings that provide essential information

warnings that provide essential information

warnings that provide essential informationwarnings that provide essential information regarding personnel safety and/or possible

regarding personnel safety and/or possible

regarding personnel safety and/or possibleregarding personnel safety and/or possible equipment damage.

equipment damage.

equipment damage.equipment damage.

 All safety precautions relevant to electrical

All safety precautions relevant to electrical

All safety precautions relevant to electricalAll safety precautions relevant to electrical equipment and process operations must be

equipment and process operations must be

equipment and process operations must beequipment and process operations must be strictly observed by all having system

strictly observed by all having system

strictly observed by all having systemstrictly observed by all having system responsibility or access.

responsibility or access.

responsibility or access.responsibility or access.

1-2

 Read all safety publications made available by

Read all safety publications made available by

Read all safety publications made available byRead all safety publications made available by your company.

your company.

your company.your company.

ESP-400CPlasma Power Source

ESP-400CPlasma Power SourceESP-400CPlasma Power Source

SECTION 1 SAFETY

Failure to follow safety warning label

WARNING

1.4 Installation Precautions

instructions could result in death or serious injury.

Read and understand all safety warning labels on

Read and understand all safety warning labels onRead and understand all safety warning labels on machine.

machine.

machine.machine.

Refer to operator’s manual for additional safety

Refer to operator’s manual for additional safetyRefer to operator’s manual for additional safety information.

information.

information.information.

WARNING

Improperly Installed Equipment Can Cause Injury Or Death.

Follow these guidelines while installing machine:

Follow these guidelines while installing machine:Follow these guidelines while installing machine:

 Contact your ESAB representative before

Contact your ESAB representative before

Contact your ESAB representative beforeContact your ESAB representative before installation. He can suggest certain precautions

installation. He can suggest certain precautions

installation. He can suggest certain precautionsinstallation. He can suggest certain precautions regarding piping installation and machine lifting,

regarding piping installation and machine lifting,

regarding piping installation and machine lifting,regarding piping installation and machine lifting, etc. to ensure maximum security.

etc. to ensure maximum security.

etc. to ensure maximum security.etc. to ensure maximum security.

 Never attempt any machine modifications or

Never attempt any machine modifications or

Never attempt any machine modifications orNever attempt any machine modifications or apparatus additions without first consulting a

apparatus additions without first consulting a

apparatus additions without first consulting aapparatus additions without first consulting a qualified ESAB representative.

qualified ESAB representative.

qualified ESAB representative.qualified ESAB representative.

 Observe machine clearance requirements for

Observe machine clearance requirements for

Observe machine clearance requirements forObserve machine clearance requirements for proper operation and personnel safety.

proper operation and personnel safety.

proper operation and personnel safety.proper operation and personnel safety.

 Always have qualified personnel

Always have qualified personnel perform

Always have qualified personnel Always have qualified personnel installation, troubleshooting and maintenance of

installation, troubleshooting and maintenance of

installation, troubleshooting and maintenance ofinstallation, troubleshooting and maintenance of this equipment.

this equipment.

this equipment.this equipment.

 Provide a wall mounted disconnect switch with

Provide a wall mounted disconnect switch with

Provide a wall mounted disconnect switch withProvide a wall mounted disconnect switch with proper fuse sizes close to the power supply.

proper fuse sizes close to the power supply.

proper fuse sizes close to the power supply.proper fuse sizes close to the power supply.

perform

performperform

ESP-400CPlasma Power Source

ESP-400CPlasma Power SourceESP-400CPlasma Power Source

1-3

SECTION 1 SAFETY

1.5 Electrical Grounding

Electrical grounding is imperative for proper machine operation and SAFETY. Refer to this manual’s Installation section for detailed grounding instructions.

Electric shock hazard.

WARNING

Improper grounding can cause severe injury or death.

Improper grounding can cause severe injury or death.Improper grounding can cause severe injury or death.

Machine must be properly grounded before put into

Machine must be properly grounded before put intoMachine must be properly grounded before put into service.

service.

service.service.

1.6 Operating A Plasma Cutting Machine

WARNING

Flying debris and loud noise hazards.

 Hot spatter can burn and injure eyes. Wear

Hot spatter can burn and injure eyes. Wear

Hot spatter can burn and injure eyes. WearHot spatter can burn and injure eyes. Wear goggles to protect eyes from burns and flying

goggles to protect eyes from burns and flying

goggles to protect eyes from burns and flyinggoggles to protect eyes from burns and flying debris generated during operation.

debris generated during operation.

debris generated during operation.debris generated during operation.

 Chipped slag may be hot and fly far. Bystanders

Chipped slag may be hot and fly far. Bystanders

Chipped slag may be hot and fly far. BystandersChipped slag may be hot and fly far. Bystanders should also wear goggles and safety glasses.

should also wear goggles and safety glasses.

should also wear goggles and safety glasses.should also wear goggles and safety glasses.

 Noise from plasma arc can damage hearing. Wear

Noise from plasma arc can damage hearing. Wear

Noise from plasma arc can damage hearing. WearNoise from plasma arc can damage hearing. Wear correct ear protection when cutting above water.

correct ear protection when cutting above water.

correct ear protection when cutting above water.correct ear protection when cutting above water.

Burn hazard.

Hot metal can burn.

Hot metal can burn.Hot metal can burn.

 Do not touch metal plate or parts immediately after

Do not touch metal plate or parts immediately after

Do not touch metal plate or parts immediately afterDo not touch metal plate or parts immediately after cutting. Allow metal time to cool, or douse with

cutting. Allow metal time to cool, or douse with

cutting. Allow metal time to cool, or douse withcutting. Allow metal time to cool, or douse with water.

water.

water.water.

 Do not touch plasma torch immediately after

Do not touch plasma torch immediately after

Do not touch plasma torch immediately afterDo not touch plasma torch immediately after cutting. Allow torch time to cool.

cutting. Allow torch time to cool.

cutting. Allow torch time to cool.cutting. Allow torch time to cool.

1-4

ESP-400CPlasma Power Source

ESP-400CPlasma Power SourceESP-400CPlasma Power Source

SECTION 1 SAFETY

WARNING

Hazardous voltages. Electric shock can kill.

 Do NOT touch plasma torch, cutting table or cable

Do NOT touch plasma torch, cutting table or cable

Do NOT touch plasma torch, cutting table or cableDo NOT touch plasma torch, cutting table or cable connections during plasma cutting process.

connections during plasma cutting process.

connections during plasma cutting process.connections during plasma cutting process.

 Always turn power off to plasma power supplies

Always turn power off to plasma power supplies

Always turn power off to plasma power suppliesAlways turn power off to plasma power supplies before touching or servicing plasma torch.

before touching or servicing plasma torch.

before touching or servicing plasma torch.before touching or servicing plasma torch.

 Always turn power off to plasma power supplies

Always turn power off to plasma power supplies

Always turn power off to plasma power suppliesAlways turn power off to plasma power supplies before servicing any system component.

before servicing any system component.

before servicing any system component.before servicing any system component.

 Do not touch live electrical parts.

Do not touch live electrical parts.

Do not touch live electrical parts.Do not touch live electrical parts.

 Keep all panels and covers in place when machine

Keep all panels and covers in place when machine

Keep all panels and covers in place when machineKeep all panels and covers in place when machine is connected to power source.

is connected to power source.

is connected to power source.is connected to power source.

 Wear insulating gloves, shoes and clothing to

Wear insulating gloves, shoes and clothing to

Wear insulating gloves, shoes and clothing toWear insulating gloves, shoes and clothing to insulate yourself from

insulate yourself from workpiece and electrical

insulate yourself from insulate yourself from ground.

ground.

ground.ground.

 Keep gloves, shoes, clothing, work area, and

Keep gloves, shoes, clothing, work area, and

Keep gloves, shoes, clothing, work area, andKeep gloves, shoes, clothing, work area, and equipment dry.

equipment dry.

equipment dry.equipment dry.

 Replace worn or damaged cables.

Replace worn or damaged cables.

Replace worn or damaged cables.Replace worn or damaged cables.

workpiece and electrical

workpiece and electricalworkpiece and electrical

WARNING

Fume hazard.

Fumes and gases generated by the plasma cutting

Fumes and gases generated by the plasma cuttingFumes and gases generated by the plasma cutting process can be hazardous to your health.

process can be hazardous to your health.

process can be hazardous to your health.process can be hazardous to your health.

 Do NOT breathe fumes.

Do NOT breathe fumes.

Do NOT breathe fumes.Do NOT breathe fumes.

 Do not operate plasma torch without fume removal

Do not operate plasma torch without fume removal

Do not operate plasma torch without fume removalDo not operate plasma torch without fume removal system operating properly.

system operating properly.

system operating properly.system operating properly.

 Use additional ventilation to remove fumes if

Use additional ventilation to remove fumes if

Use additional ventilation to remove fumes ifUse additional ventilation to remove fumes if necessary.

necessary.

necessary.necessary.

 Use approved respirator if ventilation is not

Use approved respirator if ventilation is not

Use approved respirator if ventilation is notUse approved respirator if ventilation is not adequate.

adequate.

adequate.adequate.

 Provide positive mechanical ventilation when

Provide positive mechanical ventilation when

Provide positive mechanical ventilation whenProvide positive mechanical ventilation when cutting galvanized steel, stainless steel, copper,

cutting galvanized steel, stainless steel, copper,

cutting galvanized steel, stainless steel, copper,cutting galvanized steel, stainless steel, copper, zinc, beryllium, or cadmium. Do not breathe these

zinc, beryllium, or cadmium. Do not breathe these

zinc, beryllium, or cadmium. Do not breathe thesezinc, beryllium, or cadmium. Do not breathe these fumes.

fumes.

fumes.fumes.

 Do not operate near degreasing and spraying

Do not operate near degreasing and spraying

Do not operate near degreasing and sprayingDo not operate near degreasing and spraying operations. Heat or arc rays can react with

operations. Heat or arc rays can react with

operations. Heat or arc rays can react withoperations. Heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene,

chlorinated hydrocarbon vapors to form phosgene,

chlorinated hydrocarbon vapors to form phosgene,chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas and other irritant gases.

a highly toxic gas and other irritant gases.

a highly toxic gas and other irritant gases.a highly toxic gas and other irritant gases.

ESP-400CPlasma Power Source

ESP-400CPlasma Power SourceESP-400CPlasma Power Source

1-5

SECTION 1 SAFETY

WARNING

Radiation hazard.

Arc rays can injure eyes and burn

Arc rays can injure eyes and burn skin.

Arc rays can injure eyes and burn Arc rays can injure eyes and burn  Wear correct eye and body protection.

Wear correct eye and body protection.

Wear correct eye and body protection.Wear correct eye and body protection.

 Wear dark safety glasses or goggles with

Wear dark safety glasses or goggles with side

Wear dark safety glasses or goggles with Wear dark safety glasses or goggles with shields. Refer to following chart for recommended

shields. Refer to following chart for recommended

shields. Refer to following chart for recommendedshields. Refer to following chart for recommended lens shades for plasma cutting:

lens shades for plasma cutting:

lens shades for plasma cutting:lens shades for plasma cutting:

Arc Current

Arc Current Lens Shade

Arc CurrentArc Current Up to 100 Amps

Up to 100 Amps Shade No. 8

Up to 100 AmpsUp to 100 Amps 100-200 Amps

100-200 AmpsShade No. 10

100-200 Amps100-200 Amps 200-400 Amps

200-400 AmpsShade No. 12

200-400 Amps200-400 Amps Over 400 Amps

Over 400 Amps Shade No. 14

Over 400 AmpsOver 400 Amps

 Replace glasses/goggles when lenses are pitted or

Replace glasses/goggles when lenses are pitted or

Replace glasses/goggles when lenses are pitted orReplace glasses/goggles when lenses are pitted or broken

broken

brokenbroken

 Warn others in area not to look directly at the arc

Warn others in area not to look directly at the arc

Warn others in area not to look directly at the arcWarn others in area not to look directly at the arc unless wearing appropriate safety glasses.

unless wearing appropriate safety glasses.

unless wearing appropriate safety glasses.unless wearing appropriate safety glasses.

 Prepare cutting area to reduce reflection and

Prepare cutting area to reduce reflection and

Prepare cutting area to reduce reflection andPrepare cutting area to reduce reflection and transmission of ultraviolet light.

transmission of ultraviolet light.

transmission of ultraviolet light.transmission of ultraviolet light.

§ Use special paint on walls to absorb UV

Use special paint on walls to absorb UV

Use special paint on walls to absorb UVUse special paint on walls to absorb UV

light.

light.light.

Lens Shade

Lens Shade Lens Shade

Shade No. 10

Shade No. 10Shade No. 10 Shade No. 12

Shade No. 12Shade No. 12

skin.

skin.skin.

Shade No. 8

Shade No. 8Shade No. 8

Shade No. 14

Shade No. 14Shade No. 14

side

sideside

WARNING

§ Install protective screens or curtains to

Install protective screens or curtains to

Install protective screens or curtains toInstall protective screens or curtains to

reduce ultraviolet transmission.

reduce ultraviolet transmission.reduce ultraviolet transmission.

Burn Hazard.

Heat, spatter, and sparks cause fire and burns.

Heat, spatter, and sparks cause fire and burns.Heat, spatter, and sparks cause fire and burns.  Do not cut near combustible material.

Do not cut near combustible material.

Do not cut near combustible material.Do not cut near combustible material.

 Do not have on your person any combustibles (e.g.

Do not have on your person any combustibles (e.g.

Do not have on your person any combustibles (e.g.Do not have on your person any combustibles (e.g. butane lighter).

butane lighter).

butane lighter).butane lighter).

 Pilot arc can cause burns. Keep torch nozzle

Pilot arc can cause burns. Keep torch nozzle

Pilot arc can cause burns. Keep torch nozzlePilot arc can cause burns. Keep torch nozzle away from yourself and others when activating

away from yourself and others when activating

away from yourself and others when activatingaway from yourself and others when activating plasma process.

plasma process.

plasma process.plasma process.

 Wear correct eye and body protection.

Wear correct eye and body protection.

Wear correct eye and body protection.Wear correct eye and body protection.

 Wear gauntlet gloves, safety shoes and hat.

Wear gauntlet gloves, safety shoes and hat.

Wear gauntlet gloves, safety shoes and hat.Wear gauntlet gloves, safety shoes and hat.

 Wear flame-retardant clothing covering all exposed

Wear flame-retardant clothing covering all exposed

Wear flame-retardant clothing covering all exposedWear flame-retardant clothing covering all exposed areas.

areas.

areas.areas.

 Wear

Wear cuffless trousers to prevent entry of sparks

cuffless trousers to prevent entry of sparks

Wear Wear

cuffless trousers to prevent entry of sparkscuffless trousers to prevent entry of sparks

and slag.

and slag.and slag.

1-6

 Have

Have fire extinguishing equipment available for use.

fire extinguishing equipment available for use.

Have Have

fire extinguishing equipment available for use.fire extinguishing equipment available for use.

ESP-400CPlasma Power Source

ESP-400CPlasma Power SourceESP-400CPlasma Power Source

SECTION 1 SAFETY

WARNING

Explosion hazard.

 Certain molten aluminum-lithium (Al-

Certain molten aluminum-lithium (Al-Li) alloys can

Certain molten aluminum-lithium (Al-Certain molten aluminum-lithium (Alcause explosions when plasma cut OVER water.

cause explosions when plasma cut OVER water.

cause explosions when plasma cut OVER water.cause explosions when plasma cut OVER water.

§ These alloys should only be dry cut on a dry

These alloys should only be dry cut on a dry

These alloys should only be dry cut on a dryThese alloys should only be dry cut on a dry table.

table.

table.table.

§ DO NOT dry cut over water.

DO NOT dry cut over water.

DO NOT dry cut over water.DO NOT dry cut over water.

§ Contact your aluminum supplier for

Contact your aluminum supplier for

Contact your aluminum supplier forContact your aluminum supplier for additional safety information regarding

additional safety information regarding

additional safety information regardingadditional safety information regarding hazards associated with these alloys

hazards associated with these alloys

hazards associated with these alloyshazards associated with these alloys

 Do not cut in atmospheres containing explosive

Do not cut in atmospheres containing explosive

Do not cut in atmospheres containing explosiveDo not cut in atmospheres containing explosive dust or vapors.

dust or vapors.

dust or vapors.dust or vapors.

 Do not carry any combustibles on your person

Do not carry any combustibles on your person

Do not carry any combustibles on your personDo not carry any combustibles on your person (e.g. butane lighter)

(e.g. butane lighter)

(e.g. butane lighter)(e.g. butane lighter)

 Do not cut containers that have held combustibles.

Do not cut containers that have held combustibles.

Do not cut containers that have held combustibles.Do not cut containers that have held combustibles.

Li) alloys can

Li) alloys canLi) alloys can

ESP-400CPlasma Power Source

ESP-400CPlasma Power SourceESP-400CPlasma Power Source

1-7

SECTION 1 SAFETY

1.7 Service Precautions

WARNING

Hazardous voltages. Electric shock can kill.

 Do NOT touch plasma torch, cutting table or cable

Do NOT touch plasma torch, cutting table or cable

Do NOT touch plasma torch, cutting table or cableDo NOT touch plasma torch, cutting table or cable connections during plasma cutting process.

connections during plasma cutting process.

connections during plasma cutting process.connections during plasma cutting process.

 Always turn power off to plasma power supplies

Always turn power off to plasma power supplies

Always turn power off to plasma power suppliesAlways turn power off to plasma power supplies before touching or servicing plasma torch.

before touching or servicing plasma torch.

before touching or servicing plasma torch.before touching or servicing plasma torch.

 Always turn power off to plasma power supplies

Always turn power off to plasma power supplies

Always turn power off to plasma power suppliesAlways turn power off to plasma power supplies before removing covers or panels to service any

before removing covers or panels to service any

before removing covers or panels to service anybefore removing covers or panels to service any system component.

system component.

system component.system component.

 Do not touch live electrical parts.

Do not touch live electrical parts.

Do not touch live electrical parts.Do not touch live electrical parts.

 Keep all panels and covers in place when machine

Keep all panels and covers in place when machine

Keep all panels and covers in place when machineKeep all panels and covers in place when machine is connected to power source.

is connected to power source.

is connected to power source.is connected to power source.

 Keep gloves, shoes, clothing, work area, and

Keep gloves, shoes, clothing, work area, and

Keep gloves, shoes, clothing, work area, andKeep gloves, shoes, clothing, work area, and equipment dry.

equipment dry.

equipment dry.equipment dry.

 Inspect power and ground leads cables for wear or

Inspect power and ground leads cables for wear or

Inspect power and ground leads cables for wear orInspect power and ground leads cables for wear or cracking. Replace worn or damaged cables. Do

cracking. Replace worn or damaged cables. Do

cracking. Replace worn or damaged cables. Docracking. Replace worn or damaged cables. Do not use if damaged.

not use if damaged.

not use if damaged.not use if damaged.

 Never bypass safety interlocks.

Never bypass safety interlocks.

Never bypass safety interlocks.Never bypass safety interlocks.

CAUTION

 Follow

Follow lock-out procedures.

Follow Follow

Establish and adhere to preventive maintenance. A

Establish and adhere to preventive maintenance. AEstablish and adhere to preventive maintenance. A composite program can be established from

composite program can be established from

composite program can be established fromcomposite program can be established from recommended schedules.

recommended schedules.

recommended schedules.recommended schedules.

Avoid leaving test equipment or hand tools on

Avoid leaving test equipment or hand tools onAvoid leaving test equipment or hand tools on machine. Severe electrical or mechanical damage

machine. Severe electrical or mechanical damage

machine. Severe electrical or mechanical damagemachine. Severe electrical or mechanical damage could occur to equipment or machine.

could occur to equipment or machine.

could occur to equipment or machine.could occur to equipment or machine.

Extreme caution should be used when probing

Extreme caution should be used when probingExtreme caution should be used when probing circuitry with an oscilloscope or voltmeter. Integrated

circuitry with an oscilloscope or voltmeter. Integrated

circuitry with an oscilloscope or voltmeter. Integratedcircuitry with an oscilloscope or voltmeter. Integrated circuits are susceptible to over voltage damage.

circuits are susceptible to over voltage damage.

circuits are susceptible to over voltage damage.circuits are susceptible to over voltage damage. Power off before using test probes to prevent

Power off before using test probes to prevent

Power off before using test probes to preventPower off before using test probes to prevent accidental shorting of components.

accidental shorting of components.

accidental shorting of components.accidental shorting of components.

All circuit boards securely seated in sockets, all cables

All circuit boards securely seated in sockets, all cablesAll circuit boards securely seated in sockets, all cables properly connected, all cabinets closed and locked, all

properly connected, all cabinets closed and locked, all

properly connected, all cabinets closed and locked, allproperly connected, all cabinets closed and locked, all guards and covers replaced before power is turned

guards and covers replaced before power is turned

guards and covers replaced before power is turnedguards and covers replaced before power is turned on.

on.

on.on.

lock-out procedures.

lock-out procedures.lock-out procedures.

1-8

ESP-400CPlasma Power Source

ESP-400CPlasma Power SourceESP-400CPlasma Power Source

SECTION 1 SAFETY

1.8 Safety References

The following nationally recognized publications on safety in welding and cutting operations are recommended. These publications have been prepared to protect persons from injury or illness and to protect property from damage, which could result from unsafe practices. Although some of these publications are not related specifically to this type of industrial cutting apparatus, the principles of safety apply equally.

 “Precautions and Safe Practices in Welding and Cutting with

Oxygen-Fuel Gas Equipment,” Form 2035. ESAB Cutting

Systems.

 “Precautions and Safe Practices for Electric Welding and Cutting,”

Form 52-529. ESAB Cutting Systems.

 “Safety in Welding and Cutting” - ANSI Z 49.1, American Welding

Society, 2501 NW 7th Street, Miami, Florida, 33125.

 “Recommended Safe Practices for Shielded Gases for Welding and

Plasma Arc Cutting” - AWS C5.10-94, American Welding Society.

 “Recommended Practices for Plasma Arc Welding” - AWS C5.1,

American Welding Society.

 “Recommended Practices for Arc Cutting” - AWS C5.2, American

Welding Society.

 “Safe Practices” - AWS SP, American Welding Society.  “Standard for Fire Protection in Use of Cutting and Welding

Procedures” - NFPA 51B, National Fire Protection Association, 60

Batterymarch Street, Boston, Massachusetts, 02110.

 “Standard for Installation and Operation of Oxygen - Fuel Gas

Systems for Welding and Cutting” - NFPA 51, National Fire

Protection Association.

 “Safety Precautions for Oxygen, Nitrogen, Argon, Helium, Carbon

Dioxide, Hydrogen, and Acetylene,” Form 3499. ESAB Cutting

Systems. Obtainable through your ESAB representative or local distributor.

 "Design and Installation of Oxygen Piping Systems," Form 5110.

ESAB Cutting Systems.

 “Precautions for Safe Handling of Compressed Gases in

Cylinders”, CGA Standard P-1, Compressed Gas Association.

Literature applicable to safe practices in welding and cutting with gaseous materials is also available from the Compressed Gas Association, Inc., 500 Fifth Ave., New York, NY 10036.

ESP-400CPlasma Power Source

ESP-400CPlasma Power SourceESP-400CPlasma Power Source

1-9

SECTION 1 SAFETY

This page intentionally left blank.

1-10

ESP-400CPlasma Power Source

ESP-400CPlasma Power SourceESP-400CPlasma Power Source

SECTION 2 Description

2.1 Introduction

The ESP power Source is designed for high speed plasma mechanized cutting applications. It can be used with other ESAB products such as the PT-15 and PT-600 torches along with the Smart Flow II, a computerized gas regulation and switching system.

 50 to 400 Amperes cutting current range  Forced air cooled  Solid state DC power  Input voltage protection  Local or remote front panel control  Thermal switch protection for main transformer

and power semiconductor components

 Top lifting rings or base forklift clearance for

transport

2.2 General Specifications

Part Number

Part Number 0558001730

Part NumberPart Number

Voltage

VoltageVoltage

Current range

Current rangeCurrent range DC

OUTPUT (100

OUTPUT (100OUTPUT (100

% duty cycle)

% duty cycle)% duty cycle)

INPUT

INPUTINPUT

DCDC

Power

PowerPower

Open Circuit

Open CircuitOpen Circuit Voltage (OCV)

Voltage (OCV)

Voltage (OCV)Voltage (OCV) Voltage

Voltage

VoltageVoltage (3-phase)

(3-phase)

(3-phase)(3-phase) Current

Current

CurrentCurrent (3- phase)

(3- phase)

(3- phase)(3- phase)

Frequency

FrequencyFrequency

KVA

KVAKVA

 Parallel secondary power source capabilities to

extend current output range.

ESP-400C 400V,

ESP-400C 400V,ESP-400C 400V,

50Hz

50Hz 50Hz

CECE

0558001730 0558001729

05580017300558001730

410 V dc 427 V dc 427 V dc

400 V 460 V 575 V

138 A RMS 120 A RMS 96 A RMS

50/60 HZ 60 Hz 60 Hz

95.6 KVA 95.6 KVA 95.6 KVA

ESP-400C 460V,

ESP-400C 460V,ESP-400C 460V,

60Hz

60Hz60Hz

0558001729 0558001731

05580017290558001729

ESP-400C 575V,

ESP-400C 575V,ESP-400C 575V,

60Hz

60Hz60Hz

0558001731

05580017310558001731

200 V dc

50A to 400A

80 KW

Power

PowerPower

Power Factor

Power FactorPower Factor

Input Fuse

Input FuseInput Fuse Rec.

Rec.

Rec.Rec.

87 KW 87 KW 87 KW

91.0 %

200A 150A 125A

ESP 400C Plasma Power Source

ESP 400C Plasma Power SourceESP 400C Plasma Power Source

2-1

SECTION 2 Description

2.3 Dimensions and Weight

40.25 inches

102.2 mm

45 inches

114.

37.25 inches

94.6 mm

Weight = 2040 lbs.

(925.34 kg.)

2-2

ESP 400C Plasma Power Source

ESP 400C Plasma Power SourceESP 400C Plasma Power Source

SECTION 3 Installation

3.1 General

WARNING

Failure To Follow Instructions Could Lead To Death, Injury Or Damaged Property

Follow these instructions to prevent injury or property damage.

You must comply with local, state and national electrical and safety codes.

3.2 Unpacking

CAUTION

Using One Lifting Eye Will Damage Sheet Metal And Frame

Use both lifting eyes when transporting with overhead method.

600C

Unit weighs over 2000 lbs. Use approved straps or cables in good condition.

• 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.

ESP-400C Plasma Power Source

3-1

SECTION 3 Installation

3.3 Placement

Note: Use both lifting eyes when transporting

from overhead.

• A minimum of 2 ft. clearance on front and back

for cooling air flow.

Power

Source

• Plan for top panel and side panels having to be

removed for maintenance, cleaning and inspection.

• Locate the ESP-400C relatively close to a

properly fused electrical power supply.

• Keep area beneath power source clear for

cooling air flow.

• Environment should be relatively free of dust,

fumes and excessive heat. These factors will affect cooling efficiency.

Conductive Dust And Dirt Inside

CAUTION

Power Source May Cause Arc FlashOver

Equipment damage may occur. Electrical shorting may occur if dust is allowed to build-up inside power source. See maintenance section.

3.4 Input Power Connection

WARNING

Electric Shock Can Kill!

Provide maximum protection against electrical shock.

Before any connections are made inside the machine, open the line wall disconnect switch to turn power off.

3-2

ESP-400C Plasma Power Source

SECTION 3 Installation

3.4.1 Primary Power

ESP-400C is a 3-phase unit. Input power must be

Rated Load

Volts Amperes

400

*Sizes per National Electrical Code for a 90 °C rated

provided from a line (wall) disconnect switch that contains fuses or circuit breakers in accordance to local or state regulations.

Recommended input conductor and line fuse sizes:

Input and

Ground

conductor*

CU/AWG

138 460 575

copper conductors @ 40 °C ambient. Not more than

three conductors in raceway or cable. Local codes

should be followed if they specify sizes other than those

120

listed above.

4/0 3/0 1/0

Time delay

Fuse size

(amperes)

200 150 125

Input current =

(V arc) x (I arc) x 0.688

(V line)

Dedicated power line may be necessary.

NOTICE

ESP-400C is equipped with line voltage compensation but to avoid impaired performance due to an overloaded circuit, a dedicated power line may be required.

ESP-400C Plasma Power Source

3-3

SECTION 3 Installation

3.4.2 Input Conductors

NOTICE

3.4.3 Input Connection Procedure

• Customer supplied

• May consist either of heavy rubber covered

copper conductors (three power and one ground) or run in solid or flexible conduit.

• Sized according to the chart.

Input conductors must be terminated with ring terminals.

Input conductors must be terminated with ring terminals sized for ½" hardware before being attached to the ESP-400C.

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

1. Remove left side panel of the ESP-400C

2. Thread cables through the access opening in

the rear panel.

3. Secure cables with a strain relief or conduit

coupling (not supplied) 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.

3-4

ESP-400C Plasma Power Source

SECTION 3 Installation

WARNING

Electric Shock Can Kill!

Ring terminals must have clearance between side panel and main transformer. Clearance must be sufficient to prevent possible arcing

Make sure cables do not interfere 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 primary terminal.

3.5 Output Connections

WARNING

3.5.1 Output Cables (customer supplied)

Electric Shock Can Kill! Dangerous Voltage And Current!

Any time working around a plasma power source with covers removed:

• Disconnect power source at the line(wall)

disconnect.

• Have a qualified person check the output

bus bars (positive and negative) with a voltmeter.

Choose plasma cutting output cables (customer supplied) on the basis of one 4/0 AWG, 600 volt insulated copper cable for each 400 amps of output current.

Note: Do not use 100 volt insulated welding cable.

ESP-400C Plasma Power Source

3-5

SECTION 3 Installation

3.5.2 Output Connection Procedure

Access Panel

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 first step.

3.6 Parallel Installation

Two 400A power sources may be connected

together to extend the output current range.

Parallel power source start currents

CAUTION

exceed recommended amounts when cutting below 100A.

Use Only One Power Source For Currents Below 100A.

We recommend disconnecting the negative lead from the secondary power source when changing to currents below 100 amperes. This lead should be safely terminated to protect against electric shock.

3-6

ESP-400C Plasma Power Source

SECTION 3 Installation

)

Connections for Parallel Installation

of 2 Power sources

Secondary Power

Source

work

(+)

3 - 4/0 600V

positive leads to workpiece

electrode

(-)

4/0 600V Cable jumpers between units

Primary Power

work

(+)

1 - 14 AWG 600V lead to pilot arc connection in plumbing box (h.f. generator)

Source

pilot arc

electrode

3 - 4/0 600V

negative leads in plumbing box (h.f.

(-)

enerator

WARNING

Secondary Power

Source

work

(+)

3 - 4/0 600V

positive leads to

workpiece

electrode

(-)

Disconnect

negative

connection from

secondary power source

and insulate to

convert from two

to one power

sources

Primary Power

Source

work

(+)

negative leads

to plumbing bo

electrode

(-)

3 - 4/0 600V

(high freq. generator)

ESP-400C Plasma Power Source

Note: Primary power source has the electrode (-) conductor jumpered. The secondary power source has the work (+) jumpered.

1. Connect the negative (-) output cables to the

plumbing 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 secondary power source is not used. The pilot arc circuit is not run in parallel.

5. Set the Pilot Arc HIGH/LOW switch on the

secondary power source to “LOW”.

6. Set the Pilot Arc HIGH/LOW switch on the

primary power source to “HIGH”.

Electric Shock Can Kill! Exposed Electrical Conductors Can

Be Hazardous!

Do not leave electrically “hot “ conductors exposed. When disconnecting the secondary power source from the primary, verify the correct cables were disconnected. Insulate the disconnected ends.

When using only one power source in a parallel configuration, the negative electrode conductor must be disconnected from the secondary power source and the plumbing box. Failure to do this will leave the secondary electrically “hot”.

3-7

SECTION 3 Installation

3.7 System Interconnecting Block Diagram with Smart Flow II

Air

H-35

3-8

ESP-400C Plasma Power Source

SECTION 3 Installation

System Interconnecting Block Diagram with Smart Flow II

3 phase with ground (wall disconnect)

Front view

Rear view

Remote to CNC

CNC

CNC Input/Output to Smart Flow II

Torch Lead (-)

Pilot Arc Lead

Work Lead (+)

10 11 12 13 14 15 16 17 18

SmartFlow II

Cut Water Pump (required for PT-15)

Cooling Water to Torch

Cooling Water from Torch

Voltage Height Control

Plasma Torch Lead Bundle and Torch

Earth Ground

On/Off Control

WC-7C Water Cooling

ESP-400C Plasma Power Source

3-9

SECTION 3 Installation

3.8 System Interconnecting Block Diagram with Manual Flow Control

3-10

ESP-400C Plasma Power Source

SECTION 4 Operation

4.1 Introduction

The ESP-400C does not have an ON/OFF switch. The main power is controlled through the line(wall) disconnect switch.

Do not operate the ESP-400C with

WARNING

4.2 Control Panel

Covers Removed.

High voltage components are exposed increasing shock hazard.

Internal component may be damaged because cooling fans will lose efficiency.

Main Power

Main PowerMain Power

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

Over Temp

Over TempOver Temp

Indicator illuminates when power source has overheated.

Contactor On

Contactor OnContactor On

Indicator illuminates when the main contactor is energized.

ESP 400C Plasma Power Source

ESP 400C Plasma Power SourceESP 400C Plasma Power Source

4-1

SECTION 4 Operation

Fault

FaultFault

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

Power Reset Fault

Power Reset FaultPower Reset Fault

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

Current Dial (Potentiometer)

Current Dial (Potentiometer)Current Dial (Potentiometer)

ESP-400C dial shown. ESP-400C has a range of 50 to 600 A. Used only in panel mode.

Panel Remote Switch

Panel Remote SwitchPanel 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).

Remote Connection

Remote ConnectionRemote Connection

Amphenol 19 pin plug for connecting power source to CNC.

Pilot Arc HIGH/LOW Switch

Pilot Arc HIGH/LOW SwitchPilot 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 specified in cutting data included in the torch manual.

4-2

ESP 400C Plasma Power Source

ESP 400C Plasma Power SourceESP 400C Plasma Power Source

+ 90 hidden pages

ESAB ESP-400C Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.1 Introduction

1.2 Safety Notations And Symbols

1.5 Electrical Grounding

1.6 Operating A Plasma Cutting Machine

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

3.5.2 Output Connection Procedure

3.6 Parallel Installation

4.1 Introduction

4.2 Control Panel