ESP ULTRA-LIFE 300
Cutting Power Source
Instruction Manual
F-15-141-A 03/2005
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 ser
vice facility designated by the manufacturer.
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
2.2 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
2.3 Cool-Down Periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
2.4 Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
2.5 Parallel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.0 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.3 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.4 Testing and Replacing Bridge Assembly Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.0 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.3 Recommended Fuse and Input Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.0 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.2 Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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TABLE OF CONTENTS
4
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, emits
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 fitted with the correct filter and
cover plates to protect your eyes, face, neck, and
ears from sparks and rays of the arc when operat
ing 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 flameproof gauntlet type gloves, heavy long-
sleeve shirt, cuffless 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 flameproof apron may also be desirable as protection against radiated heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cuffs, 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-flammable partition or
curtains.
6. Use goggles over safety glasses when chipping slag
or grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety
glasses.
1.1 Safety - English
FIRES AND EXPLOSIONS -flames and arcs can start fires. Hot
slag or sparks can also cause fires and
explosions. Therefore:
1. Remove all combustible materials well away from
the work area or cover the materials with a protec
tive non-flammable 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 floors or wall openings and cause a hidden smoldering fire or fires on the floor 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 flammable or toxic vapors. Do not do hot
work on closed containers. They may explode.
4. Have fire extinguishing equipment handy for instant
use, such as a garden hose, water pail, sand bucket,
or portable fire extinguisher. Be sure you are trained
in its use.
5. Do not use equipment beyond its ratings. For ex-
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ample, overloaded welding cable can overheat and
create a fire 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 fire. Use fire 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 confined, or if there is
danger of falling.
Heat from
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5
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
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.
and from ground.
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 confined spaces. Do
not breathe fumes and gases. Shield
ing gases can cause asphyxiation.
Therefore:
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9. Turn off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on
next page) for specific grounding recommenda
tions. Do not mistake the work lead for a ground
cable.
ELECTRIC AND MAGNETIC FIELDS
— May be dangerous. Electric cur
rent flowing 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 effects 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, stain
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less 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 opera
tions. 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 ir
ritation 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 specific ventilation recommendations.
6
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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 fittings in good
condition. Follow manufacturer's operating instructions for mounting regulator to a compressed gas
cylinder.
1. Always have qualified personnel perform the instal
lation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualified 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.
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2. Always secure cylinders in an upright position by
chain or strap to suitable hand trucks, undercar
riages, benches, walls, post, or racks. Never secure
cylinders to work tables or fixtures 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 con
nected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames.
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 Jefferson Davis Highway,
Arlington, VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
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ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for
electric arc welding and cutting equip
ment, ask your supplier for a copy of
"Precautions and Safe Practices for Arc
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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"
Welding, Cutting and Gouging", Form
52-529.
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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 Hand
book.
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 Atten
tion! 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.
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Means hazards which could result
in minor personal injury.
8
SECTION 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 Adi
cional 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. Utilice 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 filtro 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 per
sonas 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-flamable
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
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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 flamables, 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 to
talmente limpia y libre de substancias que puedan
producir gases inflamables o vapores tóxicos. No
trabaje dentro o fuera de contenedores o tanques
cerrados. Estos pueden explotar si contienen vapores
inflamables.
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.
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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, inspec
cione 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.
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de movimiento confinado en lugares estrechos o
si hay posibilidad de caer al suelo.
9
las flamas y el arco pueden ocacionar
fuegos. Escoria caliente y las chispas
pueden causar fuegos y explosiones.
Por lo tanto:
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,
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SECTION 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. Mantenga 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 específicas 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 MAGNETI
COS - Son peligrosos. La corriente
eléctrica fluye 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 proced
imientos 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 cad
mio a menos que provea ventilación mecánica
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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 específicas en la ventilación.
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-
10
SECTION 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 romp
erse 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, tab
lilleros, 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 cualificado para efectuar l a instalación, diagnóstico, y mantenimiento
del equipo. No ejecute ningún trabajo eléctrico a
menos que usted esté cualificado 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 modifique el equipo en ninguna
manera.
INFORMACION ADICIONAL DE SEGU
RIDAD -- Para más información sobre las
prácticas de seguridad de los equipos de
arco eléctrico para soldar y cortar, pregunte
-
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
a su suplidor por una copia de "Precautions
and Safe Practices for Arc Welding, Cutting
and Gouging-Form 52-529.
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"
11
SECTION 1 SEGURIDAD
SIGNIFICADO DE LOS SIMBOLOS
-- Según usted avanza en la lectura
de este folleto: Los Símbolos Significan ¡Atención! ¡Esté Alerta! Se
trata de su seguridad.
Significa riesgo inmediato que,
de no ser evadido, puede resultar
inmediatamente en serio daño
personal o la muerte.
Significa el riesgo de un peligro
potencial que puede resultar en
serio daño personal o la muerte.
Significa el posible riesgo que
puede resultar en menores daños
a la persona.
12
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'installation ou d'utiliser l'unité, assurez-vous
de lire et de suivre les précautions de sécurité ci-des
sous, dans les manuels, les fiches 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 filtrants et de
plaques protectrices appropriées afin 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 afin 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 ininflammable afin
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 ininflammable.
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 flammes 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 suffisamment tous les matériaux combus
tibles de l'aire de travail et recouvrez les matériaux
avec un revêtement protecteur ininflammable. Les
matériaux combustibles incluent le bois, les vête
ments, 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 incan
descent peuvent tomber dans les fissures 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 tra
vail 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 inflammables 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 surchauffer et provoquer un in
cendie.
6. Une fois les opérations terminées, inspectez l'aire de
travail pour assurer qu'aucune étincelle ou projec
tion 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.
13
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-
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-
-
-
-
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 afin 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 effectuer 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
spécifiques 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 MAGNÉ
TIQUES — 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 cer
tains stimulateurs cardiaques.
2. L'exposition à des champs électriques et magné-
tiques peut avoir des effets 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 re
spirez 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 ventila
tion naturelle ou à l'aide de moyens mécanique.
N'effectuez 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 efficaces. Ne
respirez pas les vapeurs de ces matériaux.
2. N'effectuez 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 ven
tilation n'est pas adéquate. Cessez votre travail afin
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 spécifiques
concernant la ventilation.
14
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-
-
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 bles
sures 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 fixez
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
flammes. 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
Jefferson 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 qualifié. N'effectuez aucune réparation
électrique à moins d'être qualifié à cet effet.
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 fils 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 quel-
-
conque.
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 flaques
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'effectuez aucune modification.
INFORMATIONS SUPPLÉMENTAIRES RELA
TIVES 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 recomman
dées 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"
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-
15
SECTION 1 SÉCURITÉ
SIGNIFICATION DES SYMBOLES
Ce symbole, utilisé partout dans ce manuel,
signifie "Attention" ! Soyez vigilant ! Votre
sécurité est en jeu.
DANGER
Signifie un danger immédiat. La situation peut
entraîner des blessures graves ou mortelles.
AVERTISSEMENT
Signifie un danger potentiel qui peut entraîner des
blessures graves ou mortelles.
ATTENTION
Signifie un danger qui peut entraîner des blessures
corporelles mineures.
16
SECTION 2 DESCRIPTION
2.1 Introduction
The ESP ULTRA-LIFE 300 Plasma Power Source is designed for high speed plasma cutting applications. It is normally used
with equipment such as the ESAB Smart Plasma 1000 System (ESP). For additional operating data and electrical characteristics of this machine, refer below to Table 2-1, ESP ULTRA-LIFE 300 Specifications.
TABLE 2-1. SPECIFICATIONS
Rated Output Duty Cycles Power Factor THD* Input**
300 A @ 130 V 100% DUTY 0.81 0.52 460 V @ 80 A
575 V @ 64 A
300 A @ 200 V 60% DUTY 0.88 0.45 575 V @ 86 A
460 V @ 108 A
Output Current Range 50 to 300 Amperes***
Open Circuit Voltage 375 V dc
Dimensions Width
Depth
Height
Weight
*Total Harmonic Distortion
**60 Hz, 3-phase
***Units manufactured before S/N C94B-46623 have output current range
of 100 to 300 amperes.
44.50 in. (1130.30 mm)
32.00 in. (812.80 mm)
33.00 in. (838.20 mm)
1636 lbs (742.08 kg)
2.2 Description
The ESP ULTRA-LIFE 300 Plasma Power Source is a silicon controlled rectifier (SCR), three-phase transformer/rectifier type dc
unit with solid state circuitry. The unit can be operated from 50 to 300 amperes at duty cycles shown in Table 2-1 above. A
current control Panel-Remote Switch determines the location from which the output current will be regulated: either locally
from the Power Source front panel ("Panel" position) or remotely ("Remote" position) from a precision 0-10 volt reference
(V ref ) signal.
The Power Source circuitry receiving the V ref signal is electrically (galvanically) isolated. This means that the common for
this signal may be tied to any voltage less than 150 V ac or dc with respect to earth ground.
The ESP ULTRA-LIFE 300 is powered by two 3-phase main transformers which combine with solid state control to provide
volt-amperes curve output characteristics required for plasma cutting (see Figure 2-1). Two 3-phase full wave SCRs and
two diode bridge rectifiers are used to convert the ac output current from the transformers to dc cutting current, and also
control the output current through the SCRs. A network of integrally-mounted capacitors and resistors provide transient
and high frequency voltage protection to the rectifier SCRs and diodes. Protection for main transformer bridge rectifiers
and inductors is provided by over-temperature thermal switches which interrupt power in the event of an overheating
condition and automatically reset when the components have cooled to their normal operating temperature. Filtering of
the dc output current is provided by an inductor.
The solid state circuitry of the ESP ULTRA-LIFE 300 produces stable cutting current and eliminates changes in output cur
rent as components heat up and/or if input line voltage changes within ±10% of nominal. This feature ensures consistency
in cutting conditions. The oxygen consumable life is extended by using a ripple cancellation technique. This technique is
achieved by connecting two power sources in parallel in a manner whereby the ripple from one
-
17
SECTION 2 DESCRIPTION
power source cancels the ripple from the other. Actual load current and voltage are indicated by an ammeter and voltmeter
mounted on the front panel.
Connections for control functions from the Flow Control assembly are made from a 19-pin plug receptacle on the front
panel. This receptacle provides connection for auxiliary 115 volts out, remote current control.
The Power Source is designed for ease in moving and handling. Sufficient clearance and reinforcement at its base permits
lifting with a fork lift truck; or raising with a crane or hoist using the lifting rings in the top cover.
When moving the Power Source, always use both lifting rings in order to keep the
Power Source level, otherwise serious internal damage may occur.
2.3 Cool-Down Periods
There is no cool-down period required for the 130 V/300 A output rating (100% duty). However, the 200 V/300 A output
rating requires a 4-minute cool-down period with fan motor running for every 6-minute application (60% duty).
Output ratings are designed and based on an unobstructed supply of cooling air
flow over internal components. DO NOT USE FILTERS ON THIS UNIT. Periodically
blow out dirt accumulations, using low pressure air.
2.4 Volt-Ampere Curves
The volt-ampere curves show the output voltage available at any given output current for the various current control (or V
ref signals from CNC control) settings. Values for settings other than those shown in figure 2-1, fall between the Minimum
and Maximum curves shown.
2.5 Parallel Operation
Parallel operation is the use of two Power Sources connected in parallel to provide an extended output current range. In
the case of the Ultra-Life 300, parallel connection provides an output current range from 50-600 A.
In order to avoid confusion between the two Power Sources being connected, the terms Master and Slave will be used.
The Master Power Source is the Ultra-Life 300 to which the Pilot Arc Wire is connected. It is also connected to the front of
the Flow Control by a 19-conductor cable. The Slave Power Source is connected to the back of the Flow Control with a 19conductor cable.
A. Parallel Operation for S/Ns before C94B-46623 (100 A Minimum Output)
1. For operation from 100-200 A, use the Master Power Source only. "Pilot Arc Current" switches on both Power Sources
may be in either "LOW" or "HIGH" positions.
2. For operation from 200-600 A, use both Power Sources. The "Pilot Arc Current" switch on the Master Power Source
should be in the "HIGH" position. The Slave Unit's "Pilot Arc Current" switch may be in either position.
18
SECTION 2 DESCRIPTION
B. Parallel Operation for S/N's after C94B-46623 (50 A Minimum Output)
1. For operation from 50-200 A, use the Master Power Source only. The Master's "Output Current Range" switch must
be in the "LOW" position for 50-100 A or the "HIGH" position for the 100-200 A.
2. For operation from 200-600 A, use both Power Sources. The "Output Current Range" switch on both Master and
Slave Power Sources must be in the "HIGH" position.
WHENEVER THE MASTER POWER SOURCE IS USED BY ITSELF IN A PARALLEL INSTALLATION,
THE NEGATIVE OUTPUT FROM THE SLAVE UNIT SHOULD BE DISCONNECTED FROM THE
MASTER. FAILURE TO DISCONNECT WILL MAKE THE SLAVE POWER SOURCE ELECTRICALLY
"HOT" WHEN THE MASTER POWER SOURCE IS ENERGIZED.
Ensure that there is a safe means of disconnecting the Slave Power Source without exposing any electrically "hot" conduc
tors. This can usually be accomplished by disconnecting the negative output cable of the Slave Unit at both ends (at the
Slave Power Source and at the Plumbing Box). Insulate both ends with electrical tape.
-
THE V
VOLTAGE REFERENCE SIGNAL (0 TO 10 VOLTS RANGE) FROM THE CNC (CUTTING) CONTROL THAT ESTABLISHES THE PRECISE OUTPUT ARC CURRENT OF THE POWER SOURCE. THESE CURVES ARE DERIVED FROM
THE FORMULA I
BECOMES I
DESIGNATION SHOWN ON THE TYPICAL V/A CURVES (ABOVE) CORRESPONDS TO AN ABSOLUTE
REF
ARC
ARC
= 60V
= 30V
. WHEN OPERATING TWO POWER SOURCES IN PARALLEL, THE RELATIONSHIP
REF
.
REF
Figure 2-1. Volt-Ampere Curves
19
SECTION 2 DESCRIPTION
20
SECTION 3 INSTALLATION
3.1 General
If this equipment does not operate properly, stop work immediately and investigate the cause of the malfunction. Maintenance work must be performed by an experienced person, and electrical work by a trained electrician. Do not permit
untrained persons to inspect, clean, or repair this equipment. Use only recommended replacement parts.
TO PREVENT ACCIDENTAL ELECTRIC SHOCK, BE SURE THAT THE WALL DISCONNECT
SWITCH OR CIRCUIT BREAKER IS OPEN BEFORE ATTEMPTING ANY INSPECTION OR
WORK INSIDE THE POWER SOURCE.
3.2 Cleaning
Since there are no moving parts (other than the fan) in the Power Source, maintenance consists mainly of keeping the interior
of the cabinet clean. Periodically, remove the cover from the cabinet and blow accumulated dust and dirt from the air passages and the interior components, using clean, dry low pressure air. It is imperative that the air passages to the interior of
the unit be kept free of dirt accumulation to ensure adequate circulation of cooling air, especially over the extrusion fins of
bridge rectifier. This unit is NOT designed to be used with air filters of any kind. Any obstruction to the free flow of cooling
air may damage the machine and void the warranty. The frequency of cleaning needed depends upon the amount of dirt
that is drawn into the unit.
3.3 Lubrication
Fan motors with oil tubes located on the side of the motor require lubrication after one year of service. Motors without oil
tubes are permanently lubricated and should not require any attention.
3.4 Testing and Replacing Bridge Assembly Components
The silicon diodes and SCRs used in the Power Source are devices which allow current to flow in only one direction. They
block current flow in the other direction. The diodes and SCRs used in this Power Source are designed to provide long
trouble-free operation; however, should a failure occur, they require replacement. The location and replacement parts data
for the diodes and SCRs are shown in figures 5-1 through 5-4.
If after troubleshooting (see Section 4), the "trouble symptom" appears to be in a bridge network, the following three-part
procedure can be used to determine the faulty component(s): Visual Analysis, Component Group Testing, and Individual
Component/Isolation Testing.
If repair or replacement of bridge components is necessary, removing the bridge assembly is recommended.
Before removing a bridge assembly for servicing, carefully tag (identify) all interconnecting wires and bus connections to facilitate proper reinstallation. Also, refer to
the diagrams and illustrations in the back of this book.
21
SECTION 3 INSTALLATION
A. Visual Analysis For Defective Bridge Components.
1. Remove top, left side, and right side panels of Power Source. Inspect the 150 A bridge fuse links (F1/F2 on the left
- F3/F4 on the right) mounted on the phenolic plates in front of Main Transformers to see if they have blown.
2. If either or both of the fuses protecting its respective bridge assembly are open, it's a sign that one or more of the
diodes or SCRs in that particular bridge may be shorted.
3. Check for cracked or broken ceramic around each diode pigtail of SCR body. If cracked, it's a sign of a shorted diode
or SCR. When the larger diodes or SCRs fail, they most commonly fail shorted.
B. Testing Left and Right Bridge Assemblies.
Each bridge assembly essentially contains three groups of components to be tested. The left side bridge contains Power
Diodes D1, D2, and D3; Freewheeling Diodes D4 and D5; and SCRs 1, 2, and 3. The right side bridge contains Power
Diodes D6, D7, and D8; Freewheeling Diodes D9 and D10; and SCRs 4, 5, and 6. The group testing sequence does not
require electrical isolation; however, to determine the specific faulty component in a group, some form of isolation may
be required as follows:
1. Checking Power Diode Groups.
(a) If fuse links are not blown, use an ohmmeter set at its lowest resistance scale and check the diode group as
described in step 1.(c). Checking any one diode within the group will determine if the group is good or if a
shorted condition exists. If there is a short, you must electrically isolate to determine the specific component.
Electrical isolation is accomplished by unbolting the pigtail of the diode being tested.
(b) If one or more fuse links are blown, the diodes must be isolated and checked individually.
(c) Ohmmeter check of diodes (group or individual).
NOTE
Some analog meters and most digital meters will read similarly high both before and
after reversing the meter leads when testing good diodes and SCRs.
1 Place one test probe on NEG heatsink (diode stud) and the other probe to each diode pigtail's SCR
heatsink. Note the resistance readings obtained. All three readings should be similar (high or low).
2 Reverse the test probes and recheck the diodes. Note each resistance reading. All three readings
should be similar; but, opposite of those noted in the first reading.
3 Diodes are good if they test high in one direction and low in the opposite direction. Diodes are
bad if the resistance readings are low in both directions. High readings in both directions when using
a digital ohmmeter indicates a good diode.
4 Diodes are bad when they show no, or very low, resistance in both directions indicating they are shorted.
Although it is possible for power rectifier diodes to fail "open", such failures are rare, particularly for
the larger diodes. In the vast majority of cases, a high resistance reading in either or both directions
indicate a good diode.
22
SECTION 3 INSTALLATION
Table 3-1. Recommended Torques
Diodes
Min., 20 in-lbs (1.7 ft•lbs)
Max., 30 in-lbs (2.5 ft•lbs)
SCRs
Min., 125 in-lbs (10.4 ft•lbs)
Max., 150 in-lbs (12.5 ft•lbs)
2. Checking Freewheeling Diodes.
These diodes must be checked in the circuit using the same procedures outlined in steps 1.(a), 1.(b), and 1.(c). If
each diode tests "good", nothing else need be done; however, if a diode tests "bad", you must disconnect its pigtail
and retest it for verification.
3. Checking SCR Groups.
NOTE
Before proceeding with the following SCR tests, all diodes should have been checked
and defective (shorted) diodes electrically isolated.
(a) If fuse links are not blown and are still connected to the bridge heatsink, used an ohmmeter set to its lowest
resistance scale and check the SCR group as described in step 3.(c). Checking any one SCR within the group
will determine if the group is good or if a shorted condition exists. If there is a short, you must electrically
isolate to determine the specific faulty component, see step 3.(d).
(b) If one or more fuse links are blown, the SCRs must be isolated and checked individually. Refer to step 3.(d).
(c) Ohmmeter check of SCRs (group or individual).
1 Place one test probe on the POS heatsink (same as the shunt) and touch the other test probe to each
of the SCR's anode heatsinks. The resistance reading across each SCR should be 1000 (1K) ohms or
higher.
2 Reverse the test probes and repeat the check. Again, the resistance reading across each SCR should
be 1000 (1K) ohms or higher.
3 SCRs are bad if they show no or very low resistance reading in either direction.
(d) If the diagnosis indicates a defective SCR within the group, you must disconnect the fuses to electrically isolate
the SCRs (assuming all diodes have checked good, or defective diodes previously isolated), and repeat the
ohmmeter tests in steps
D. Replacing Faulty SCRs and Diodes.
1. Make sure that heatsink mounting surfaces are cleaned before replacing faulty components.
2. For diodes and SCRs, coat mounting surfaces with Alcoa No. 2 EJC Electrical Joint Compound.
3. Torque procedure for SCRs and diodes.
Use a torque wrench to tighten stud mounted SCRs and diodes. Recommended torques are listed in table 3-1.
1, 2, and 3 above for each SCR.
23
SECTION 3 INSTALLATION
24
SECTION 4 OPERATION
4.1 General
DISCONNECT PRIMARY POWER AT WALL SWITCH, OR CIRCUIT BREAKER, BEFORE
ATTEMPTING INSPECTION OR WORK INSIDE OF THE POWER SOURCE.
If the Power Source is operating improperly, the following troubleshooting information may be used to locate the source
of the trouble.
Check the problem against the symptoms in the following troubleshooting guide. The remedy for the problem may be quite
simple. If the cause cannot be quickly located, open up the unit and perform a simple visual inspection of all the components
and wiring. Check for proper terminal connections, loose or burned wiring or components, blown fuses, bulged or leaking
capacitors, or any other sign of damage or discoloration.
4.2 Troubleshooting Guide
A. Fan Not Running.
1. No input power. Check main line (customer's) switch fuses.
2. Defective control transformer. Check for continuity.
3. Fan motor defective. Check motor and leads, and replace if necessary.
B. No Output.
1. No incoming three-phase power. Wall disconnect switch may be open, or fuse(s) blown.
2. Poor connections at output terminals. Tighten or replace connections.
3. Main contactor (K1) will not energize.
a. Thermal overload device(s) tripped. Check left and right thermal overload lights on front panel.
b. Missing "start" signal.
c. Defective AMC or Main Contactor (K1).
C. No Current Control or Erratic Output Current.
1. No current control.
a. Missing power or blown fuse links in bridge assemblies.
b. Defective SCR board (PCB1 - left side, PCB3 - right side).
c. Defective constant current (CC) board (PCB2).
2. Pilot arc without transfer (pops then goes out).
25
SECTION 4 OPERATION
a. Missing Vref signal from remote source. Check voltage from pins P1-2 to P1-1 on CC board for Vref signal.
Put switch in "Panel" position and use panel control.
b. Missing "current control" signal to SCR boards (defective CC board). Check "current control" signal at pins
P1-2 and P2-8 on SCR boards.
c. Pilot arc fuse(s) (F5/F6) blown.
3. If current remains fixed at approximately 300 amperes (in Panel position), the bottom of the current control poten
tiometer (R50) may not be connected. This applies +10 volts straight into CC board. Check remote control switch
(SW1) for continuity and proper common connection.
4. Current control to 175 A only.
a. Current Range Switch in "LOW" position. Put switch in "HIGH" position.
b. Left or right side power source not operating. Measure signal (mV) from left and right SCR boards at P1-10
and P1-11.
c. Defective left or right side bridge assemblies or bridge fuses.
d. Defective SCR board (PCB1 - left side, PCB3 - right side).
5. Erratic current control.
a. Defective current control potentiometer (R50) (panel and/or remote location).
b. Defective remote control switch (SW1). Check continuity.
c. Defective SCR board (PCB1 - left side, PCB3 - right side).
d. Defective CC board (PCB2).
-
D. Short (Torch) Tip Life -- Double Arcing.
1. Defective SCR board (PCB1 - left side, PCB3 - right side).
2. Defective CC board (PCB2).
3. Defective SCR in bridge assemblies.
4. Excessive ripple voltage. Measure ripple voltage with a true RMS AC voltmeter at output of machine. It should
read less than 2 V ac RMS with system operating at 260 A/130 V with 0.5 ohm resistive load. Actual waveform can
be measured with an oscilloscope on the CC board (refer to Figures 4-1 and 4-2).
5. Faulty Pilot Arc Connection at Power Source (refer to Figure 5-2).
6. Faulty Pilot Arc Connection at plumbing box (refer to ESP manual).
26
SECTION 4 OPERATION
TEST POINT
(NEG)
Figure 4-1. ESP ULTRA-LIFE 300 CC Board Test Points
for Measuring Output Current
TEST POINT
(POS)
Oscilloscope must be isolated from ground when taking measurement.
27
SECTION 4 OPERATION
Rated Output
Rated Input
Input &
Ground
Conductor*
CU/AWG
Time-Delay
or Slow Blow
Fuse Size
Amps**
Voltage Frequency Amperes
300 A @ 200 V 460 V 60 Hz 108 2 125
300 A @ 200 V 575 V 60 Hz 86 3 100
* Sized per National Electric code for 75 °C rated copper conductors @ 30 °C ambient. Not more than three
conductors in raceway or cable. Local codes should be followed if they specify sizes others than those listed
above.
** Selection of adequate fuses or circuit breakers for this unit is critical because the in-rush current for large
magnetic components like the main transformers is several times greater than its steady state full load
current draw. We therefore recommend using only slow blowing or time-delay fuses that are sized in
accordance with the table recommendations. If a breaker is used, it should be of the slow tripping variety.
Thermally activated breakers are preferable to magnetically activated breakers.
Must not overshoot output current
NOTE: Oscilloscope set at 2 V/DIV (60 A/DIV).
4.3 Recommended Fuse and Input Cable Sizes
Figure 4-2. ESP ULTRA-LIFE 300 Load Bank Start and Output
80 ms/DIV
Current Waveform
28
SECTION 4 OPERATION
Figure 4-5. SCR Board (PCB1, 3) Component Layout
29
SECTION 4 OPERATION
Figure 4-6. Constant Current Board (PCB2) Component Layout
30
SECTION 4 OPERATION
Figure 4-7. Filter Board (PCB4, 5) Component Layout
31
SECTION 4 OPERATION
Figure 4-8. ESP ULTRA-LIFE 300 Left Terminal Board (TB1)
32
SECTION 4 OPERATION
TB2 IS NOT MODIFIED FOR VOLTAGE CHANGEOVER
Figure 4-9. ESP ULTRA-LIFE 300 Right Terminal Board (TB2)
33
SECTION 4 OPERATION
NOTE:
Schematics and Wiring Diagrams on 11” x 17”
paper are included
inside the back cover of this manual.
34
SECTION 5 REPLACEMENT PARTS
5.0 Replacement Parts
5.1 General
Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on
the unit nameplate.
5.2 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.
Note
Bill of material items that have blank part numbers are provided for customer information only.
Hardware items should be available through local sources.
35
SECTION 5 REPLACEMENT PARTS
14
5743
2
1
118,9,106
12
13
Figure 5-1. ESP ULTRA-LIFE 300 Power Source (Front View)
Item No. Qty Req. Part No. Description Circuit Symbol
1 1 2062290 VOLTMETER, DC, 500 V VM
2 1 647288 AMMETER, DC, 300 A AM
3 1 33997 PANE, TOP
4 1 672508 SWITCH, TOGGLE, 3PST S1
5 1 598227 LIGHT, PILOT PL2, 3
6 1 634716 LIGHT, PILOT PL1
7 1 950122 CIRCUIT BREAKER, 10 A CB1
8 1 2062170 KNOB
9 1 673999 SHAFT, LOCK
10 1 950715 POTENTIOMETER, CURRENT CONT. R50
11 1 634518 SWITCH, TOGGLE, DPDT S5
12 1 1006733 CONNECTOR, 19-PIN, AMPHENOL J1
13 1 33995 PANEL, SIDE, RIGHT
14 1 33996 PANEL, SIDE, LEFT
36
SECTION 5 REPLACEMENT PARTS
Item
No.
Qty
Req.
Part
No.
Description
Ckt.
Symbol
1
2
3
4
5
6
7
8
9
10
11
12
1
2
2
2
1
1
1
1
1
1
1
33993
674970
17300016
17300008
677329
30833
33998
32091
33994
951491
672772
30855
PANEL, FRONT
P.C. BD. ASSEMBLY, FILTER
RESISTOR, 16 OHM, 300 W
RESISTOR, 8 OHM, 300 W
BOARD, TERMINAL
TRANSFORMER, MAIN (LEFT)
BAIL ASSEMBLY
BOARD, TERMINAL (LEFT)
PANEL, REAR
CONTACTOR, MAIN, 120 V, 90 A
CAPACITOR, 10 µF @ 370 WVDC
INDUCTOR
PCB4, 5
R38
R39-41
TB3
T1
TB1
K1
L1
11
10
9
8
12
1
2
REF: PILOT ARC
CONNECTION
3
4
6
Figure 5-2. ESP ULTRA-LIFE 300 Power Source (Left Side View)
37
57
SECTION 5 REPLACEMENT PARTS
1
2
1
4
Figure 5-3. ESP ULTRA-LIFE 300 Power Source (Left Side Top View)
Item No. Qty Req. Part No. Description Circuit Symbol
1 8 17280010 RESISTOR, 10 OHM, 100 W R19-24, R33-34
2 8 672772 CAPACITOR, 10 µF @ 370 WVDC C25-32
3 1 950826 BLOCK, TERMINAL (5 POINT) TB6
4 1 17280010 RESISTOR, 10 OHM, 100 W R35
3
2
38
SECTION 5 REPLACEMENT PARTS
1
2
3
4
Figure 5-4. ESP ULTRA-LIFE 300 Power Source (Right Side View)
Item No. Qty Req. Part No. Description Circuit Symbol
1 1 30855 INDUCTOR L2
2 1 34005 TRANSFORMER, MAIN (RIGHT) T2
3 1 677384 TRANSFORMER, CONTROL T3
4 4 17300008 RESISTOR, 8 OHM, 300 W R42-45
39
SECTION 5 REPLACEMENT PARTS
Item
No.
Qty
Req.
Part
No.
Description
Ckt.
Symbol
1
2
3
4
5
6
7
8
9
10
11
12
13
14
2
2
2
2
1
1
1
1
1
1
1
2
2
1
676453
672330
673676
2062334
680912
635568
2080196
635568
672772
950116
951275
31444
993539
31492
SEAL, WEATHERSTRIP
SHROUD, FAN
BLADE, FAN
MOTOR, FAN
BOARD, TERMINAL (RIGHT)
BLOCK, TERMINAL
CONTACTOR (AUX) RELAY, 3PDT
BLOCK, TERMINAL (8 POINT)
CAPACITOR, 10 µF @ 370 WVDC
FILTER, 2 A
FILTER, 10 A
P.C. BD. ASSEMBLY, S.C.R.
CAPACITOR, ALLUM., 1500 µF, 50 V
P.C. BD. ASSEMBLY, CONST.
CURRENT
M1, M2
TB2
TB4
K3
TB5
C46
FN2
FN4
PCB1, 3
C36, 37
PCB 2
1
2
3
4
12
13
14
13
12
11
10
9
8
Figure 5-5. ESP ULTRA-LIFE 300 Power Source (Top View)
6
7
5
2
3
4
40
SECTION 5 REPLACEMENT PARTS
1
2
3
3
11, 12
4
3
5
10
6
8, 9
Figure 5-6. ESP ULTRA-LIFE 300 Power Source (Top View Cutaway)
Item No. Qty Req. Part No. Description Circuit Symbol
1 2 674969 FILTER, P.C. BD. ASSEMBLY FN1, 2
2 1 17280110 RESISTOR, 100K OHM, 110 W R49
3 5 951312 CAPACITOR, ALUM., 1300 µF, 450 V C33,34,47-49
4 2 17280210 RESISTOR, 1K OHM, 100 W R57,58
5 1 950255 CAPACITOR, 60 µF, 370 V AC C35
6 1 673458 CONTACTOR, PILOT ARC K2
7 1 672772 CAPACITOR, 10 µF @ 370 WVDC C44
8 2 639514 FUSE BLOCK
9 2 951527 FUSE, 15 A F5, 6
10 1 17250230 RESISTOR, 3K OHM, 50 W R46
11 1 950627 CAPACITOR, 4200 µF, 350 V C50
12 1 17315247 RESISTOR, 4.7K OHMS, 12 W R59
7
41
NOTES
LEFT SIDE (except where noted)
Figure 4-3. ESP ULTRA-LIFE
300 Power Source Schematic
Diagram (Sheet 1 of 8)
APPLIES TO S/N's BEFORE C94B-46623
ESP ULTRA-LIFE 300 Power Source
LEFT SIDE (except where noted)
Figure 4-3. ESP ULTRA-LIFE
300 Power Source Schematic
Diagram (Sheet 2 of 8)
APPLIES TO S/N's AFTER C94B-46623
ESP ULTRA-LIFE 300 Power Source
RIGHT SIDE
Figure 4-3. ESP ULTRA-LIFE
300 Power Source Schematic
Diagram (Sheet 3 of 8)
APPLIES TO S/N's BEFORE C94B-46623
ESP ULTRA-LIFE 300 Power Source
RIGHT SIDE
Figure 4-3. ESP ULTRA-LIFE
300 Power Source Schematic
Diagram (Sheet 4 of 8)
APPLIES TO S/N's AFTER C94B-46623
LEFT MAIN TRANSFORMER (T1)
ESP ULTRA-LIFE 300 Power Source
Figure 4-3. ESP ULTRA-LIFE
300 Power Source Schematic
Diagram (Sheet 5 of 8)
RIGHT MAIN TRANSFORMER (T2)
ESP ULTRA-LIFE 300 Power Source
Figure 4-3. ESP ULTRA-LIFE
300 Power Source Schematic
Diagram (Sheet 6 of 8)
ESP ULTRA-LIFE 300 Power Source
SCR BOARD (PCB1, 3)
Figure 4-3. ESP ULTRA-LIFE
300 Power Source Schematic
Diagram (Sheet 7 of 8)
ESP ULTRA-LIFE 300 Power Source
CONSTANT CURRENT BOARD (PCB2)
Figure 4-3. ESP ULTRA-LIFE
300 Power Source Schematic
Diagram (Sheet 8 of 8)
ESP ULTRA-LIFE 300 Power Source
Figure 4-4. ESP ULTRA-LIFE
300 Power Source Wiring
Diagram (Sheet 1 of 6)
APPLIES TO S/N's BEFORE C94B-46623
ESP ULTRA-LIFE 300 Power Source
Figure 4-4. ESP ULTRA-LIFE
300 Power Source Wiring
Diagram (Sheet 2 of 6)
APPLIES TO S/N's AFTER C94B-46623
ESP ULTRA-LIFE 300 Power Source
Figure 4-4. ESP ULTRA-LIFE
300 Power Source Wiring
Diagram (Sheet 3 of 6)
APPLIES TO S/N's BEFORE C94B-46623
ESP ULTRA-LIFE 300 Power Source
Figure 4-4. ESP ULTRA-LIFE
300 Power Source Wiring
Diagram (Sheet 4 of 6)
APPLIES TO S/N's AFTER C94B-46623
ESP ULTRA-LIFE 300 Power Source
Figure 4-4. ESP ULTRA-LIFE
300 Power Source Wiring
Diagram (Sheet 5 of 6)
APPLIES TO S/N's BEFORE C94B-46623
ESP ULTRA-LIFE 300 Power Source
FILTER BOARD DETAIL
Figure 4-4. ESP ULTRA-LIFE
300 Power Source Wiring
Diagram (Sheet 6 of 6)
APPLIES TO S/N's AFTER C94B-46623
REVISION HISTORY
Revision 09/2004 - Updated Figure 5-6, Section 5 - Replacement Parts, item 4 deleted “DC” & reformat-
1.
ted descriptions.
Revision 03/2005 - updated format with TOC, correct page # layout, and moved schematics to 11 x 17
2.
format.
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
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 Specifications 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
or
visit us on the web at http://www.esabna.com
The ESAB web site offers
Comprehensive Product Information
Material Safety Data Sheets
Warranty Registration
Instruction Literature Download Library
Distributor Locator
Global Company Information
Press Releases
Customer Feedback & Support
F15-141-A 03/2005
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