ESP-400C
ESP-400C
Plasma Power Source
Instruction Manual
0558007619
08/2010
Be sure this information reaches the operator.
You can get extra copies through your supplier.
caution
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding and cutting equipment, we urge
you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and
Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain
this equipment. Do NOT attempt to install or operate this equipment until you have read
and fully understand these instructions. If you do not fully understand these instructions,
contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment
should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone
or written request for service advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
table of contents
Section / Title
Page
1.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.0
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3 Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.0
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3 Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.4 Input Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.5 Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.6 Parallel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.7 Interface Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.0
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1 Block Diagram Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.3 Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.4 Arc Initiation Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.5 ESP-400C V-I Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.0
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.3 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.0
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Fault Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 Testing and Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 Control Circuit Interface Using J1 Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6 Auxiliary Main Contactor (K3) and Solid State Contactor Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7 Main Contactor (K1A, K1B and K1C) Activation Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.8 Arc Current Detector Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.9 Current Control Pot and Remote Vref . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
43
43
46
54
60
62
63
64
65
7.0 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.2 Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4
section 1
safety precautions
1.0Safety Precautions
1.1Safety - English
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.
FIRES AND EXPLOSIONS -- Heat from
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 protective 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 example, 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.
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 operating
or observing operations. Warn bystanders not to
watch the arc and not to expose themselves to the
rays of the electric-arc or hot metal.
3. Wear flameproof gauntlet type gloves, heavy longsleeve 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.
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.
5
section 1
safety precautions
1. Be sure the power source frame (chassis) is connected to the ground system of the input power.
3. Welders should use the following procedures to
minimize exposure to EMF:
2. Connect the workpiece to a good electrical
ground.
A.Route the electrode and work cables together.
Secure them with tape when possible.
3. Connect the work cable to the workpiece. A poor
or missing connection can expose you or others
to a fatal shock.
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.
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.
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.
6. Make sure that all parts of your body are insulated
from work and from ground.
7. Do not stand directly on metal or the earth while
working in tight quarters or a damp area; stand
on dry boards or an insulating platform and wear
rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the
power.
Therefore:
9. Turn off the power before removing your gloves.
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shielding gases can cause asphyxiation.
1. Always provide adequate ventilation in the work area
by natural or mechanical means. Do not weld, cut, or
gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead, beryllium, or cadmium
unless positive mechanical ventilation is provided.
Do not breathe fumes from these materials.
10. Refer to ANSI/ASC Standard Z49.1 (listed on
next page) for specific grounding recommendations. Do not mistake the work lead for a ground
cable.
2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly
toxic gas, and other irritant gases.
ELECTRIC AND MAGNETIC FIELDS
— May be dangerous. Electric current flowing through any conductor causes localized Electric and
Magnetic Fields (EMF). Welding and
cutting current creates EMF around welding cables
and welding machines. Therefore:
3. If you develop momentary eye, nose, or throat irritation while operating, this is an indication that
ventilation is not adequate. Stop work and take
necessary steps to improve ventilation in the work
area. Do not continue to operate if physical discomfort persists.
1. Welders having pacemakers should consult their
physician before welding. EMF may interfere with
some pacemakers.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specific ventilation recommendations.
2. Exposure to EMF may have other health effects which
are unknown.
6
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.)
1. Always have qualified personnel perform the installation, 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.
CYLINDER HANDLING -- Cylinders,
if mishandled, can rupture and violently release gas. Sudden rupture
of cylinder, valve, or relief device can
injure or kill. Therefore:
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.
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.
5. Keep all safety devices and cabinet covers in position
and in good repair.
6. Use equipment only for its intended purpose. Do
not modify it in any manner.
2. Always secure cylinders in an upright position by
chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure
cylinders to work tables or fixtures where they may
become part of an electrical circuit.
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for
electric arc welding and cutting equipment, ask your supplier for a copy of
"Precautions and Safe Practices for Arc
Welding, Cutting and Gouging", Form
52-529.
3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder.
The following publications, which are available from
the American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, are recommended to you:
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.
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"
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
7
section 1
safety precautions
5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding“
6. AWS C5.6 - "Recommended Practices for Gas Metal
Arc Welding"“
7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."
Meaning of symbols - As used
throughout this manual: Means Attention! Be Alert! Your safety is involved.
Means immediate hazards which,
if not avoided, will result in immediate, serious personal injury
or loss of life.
Means potential hazards which
could result in personal injury or
loss of life.
Means hazards which could result
in minor personal injury.
8
secCION 1
sEGURIDAD
1.2Safety - Spanish
La escoria puede estar caliente y desprenderse con
velocidad. Personas cercanas deberán usar gafas
de seguridad y careta protectora.
ADVERTENCIA: Estas Precauciones de Seguridad son para su protección. Ellas hacen
resumen de información proveniente de las
referencias listadas en la sección "Información Adicional Sobre La Seguridad". Antes de hacer cualquier
instalación o procedimiento de operación , asegúrese
de leer y seguir las precauciones de seguridad listadas
a continuación así como también todo manual, hoja
de datos de seguridad del material, calcomanias, etc.
El no observar las Precauciones de Seguridad puede
resultar en daño a la persona o muerte.
FUEGO Y EXPLOSIONES -- El calor de
las flamas y el arco pueden ocacionar
fuegos. Escoria caliente y las chispas
pueden causar fuegos y explosiones.
Por lo tanto:
1. Remueva todo material combustible lejos del área
de trabajo o cubra los materiales con una cobija a
prueba de fuego. Materiales combustibles incluyen
madera, ropa, líquidos y gases 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 totalmente 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.
5. No use el equipo fuera de su rango de operación. Por
ejemplo, el calor causado por cable sobrecarga en
los cables de soldar pueden ocasionar un fuego.
6. Después de termirar la operación del equipo, inspeccione el área de trabajo para cerciorarse de que las
chispas o metal caliente ocasionen un fuego más
tarde. Tenga personal asignado para vigilar si es
necesario.
7. Para información adicional , haga referencia a la
publicación NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible
a través de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
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 personas cercanas de no mirar el arco y no exponerse
a los rayos del arco eléctrico o el metal fundido.
3. Use guantes de cuero a prueba de fuego, camisa
pesada de mangas largas, pantalón de ruedo liso,
zapato alto al tobillo, y careta de soldar con capucha
para el pelo, para proteger el cuerpo de los rayos y
chispas calientes provenientes del metal fundido.
En ocaciones un delantal a prueba de fuego es
necesario para protegerse del calor radiado y las
chispas.
4. Chispas y partículas de metal caliente puede alojarse
en las mangas enrolladas de la camisa , el ruedo del
pantalón o los bolsillos. Mangas y cuellos deberán
mantenerse abotonados, bolsillos al frente de la
camisa deberán ser cerrados o eliminados.
5. Proteja a otras personas de los rayos del arco y chispas calientes con una cortina adecuada no-flamable
como división.
6. Use careta protectora además de sus gafas de seguridad cuando esté removiendo escoria o puliendo.
9
CHOQUE ELECTRICO -- El contacto
con las partes eléctricas energizadas
y tierra puede causar daño severo o
muerte. NO use soldadura de corriente alterna (AC) en áreas húmedas,
de movimiento confinado en lugares estrechos o
si hay posibilidad de caer al suelo.
secCion 1
sEGURIDAD
1. Asegúrese de que el chasis de la fuente de poder
esté conectado a tierra através del sistema de
electricidad primario.
2. Conecte la pieza de trabajo a un buen sistema de
tierra física.
3. Conecte el cable de retorno a la pieza de trabajo.
Cables y conductores expuestos o con malas
conexiones pueden exponer al operador u otras
personas a un choque eléctrico fatal.
4. Use el equipo solamente si está en buenas condiciones. Reemplaze cables rotos, dañados o con
conductores expuestos.
5. 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.
3.Los soldadores deberán usar los siguientes procedimientos para minimizar exponerse al EMF:
A.Mantenga el electrodo y el cable a la pieza de
trabajo juntos, hasta llegar a la pieza que usted
quiere soldar. Asegúrelos uno junto al otro con
cinta adhesiva cuando sea posible.
B. Nunca envuelva los cables de soldar alrededor
de su cuerpo.
C.Nunca ubique su cuerpo entre la antorcha y el
cable, a la pieza de trabajo. Mantega los cables a
un sólo lado de su cuerpo.
D.Conecte el cable de trabajo a la pieza de trabajo
lo más cercano posible al área de la soldadura.
E. Mantenga la fuente de poder y los cables de soldar
lo más lejos posible de su cuerpo.
HUMO Y GASES -- El humo y los
gases, pueden causar malestar o
daño, particularmente en espacios
sin ventilación. No inhale el humo
o gases. El gas de protección puede
causar falta de oxígeno. Por lo tanto:
1. Siempre provea ventilación adecuada en el área
de trabajo por medio natural o mecánico. No solde,
corte, o ranure materiales con hierro galvanizado,
acero inoxidable, cobre, zinc, plomo, berílio, o cadmio a menos que provea ventilación mecánica
positiva . No respire los gases producidos por
estos materiales.
2. No opere cerca de lugares donde se aplique substancias 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.
CAMPOS ELECTRICOS Y MAGNETICOS - 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.
10
secCion 1
sEGURIDAD
5.ADVERTENCIA-- Este producto cuando se utiliza para soldaduras o cortes,
produce humos o gases, los
cuales contienen químicos conocidos por el Estado de California de causar defectos en el
nacimiento, o en algunos casos,
Cancer. (California Health &
Safety Code §25249.5 et seq.)
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.
MANEJO DE CILINDROS-- Los
cilindros, si no son manejados
correctamente, pueden romperse y liberar violentamente
gases. Rotura repentina del
cilindro, válvula, o válvula de
escape puede causar daño o
muerte. Por lo tanto:
1. Utilize el gas apropiado para el proceso y utilize
un regulador diseñado para operar y reducir la
presión del cilindro de gas . No utilice adaptadores. Mantenga las mangueras y las conexiones
en buenas condiciones. Observe las instrucciones
de operación del manufacturero para montar el
regulador en el cilindro de gas comprimido.
INFORMACION ADICIONAL DE SEGURIDAD -- Para más información sobre las
prácticas de seguridad de los equipos de
arco eléctrico para soldar y cortar, pregunte
a su suplidor por una copia de "Precautions
and Safe Practices for Arc Welding, Cutting
and Gouging-Form 52-529.
2. Asegure siempre los cilindros en posición vertical
y amárrelos con una correa o cadena adecuada
para asegurar el cilindro al carro, transportes, tablilleros, paredes, postes, o armazón. Nunca asegure
los cilindros a la mesa de trabajo o las piezas que
son parte del circuito de soldadura . Este puede ser
parte del circuito elélectrico.
Las siguientes publicaciones, disponibles através de
la American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, son recomendadas para usted:
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. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
MANTENIMIENTO DEL EQUIPO -- Equipo
defectuoso o mal mantenido puede
causar daño o muerte. Por lo tanto:
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
11
secCion 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
1.3Safety - French
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 :
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, assurezvous de lire et de suivre les précautions de sécurité cidessous, 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.
1. Éloignez suffisamment tous les matériaux combustibles de l'aire de travail et recouvrez les matériaux
avec un revêtement protecteur ininflammable. Les
matériaux combustibles incluent le bois, les vêtements, la sciure, le gaz et les liquides combustibles,
les solvants, les peintures et les revêtements, le
papier, etc.
2. Les étincelles et les projections de métal incandescent peuvent tomber dans les 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 travail à chaud avant d'avoir complètement nettoyé la
surface de la pièce à traiter de façon à ce qu'il n'ait
aucune substance présente qui pourrait produire
des vapeurs 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 incendie.
6. Une fois les opérations terminées, inspectez l'aire de
travail pour assurer qu'aucune étincelle ou projection de métal incandescent ne risque de provoquer
un incendie ultérieurement. Employez des guetteurs
d'incendie au besoin.
7. Pour obtenir des informations supplémentaires,
consultez le NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible au
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
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 latéraux 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.
CHOC ÉLECTRIQUE -- Le contact avec
des pièces électriques ou les pièces
de mise à la terre sous tension peut
causer des blessures graves ou mortelles. 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
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.
3. Les soudeurs doivent suivre les procédures suivantes
pour minimiser l'exposition aux champs électriques
et magnétiques :
A.Acheminez l'électrode et les câbles de masse
ensemble. Fixez-les à l'aide d'une bande adhésive
lorsque possible.
B. Ne jamais enrouler la torche ou le câble de masse
autour de votre corps.
C.Ne jamais vous placer entre la torche et les câbles
de masse. Acheminez tous les câbles sur le même
côté de votre corps.
D.Branchez le câble de masse à la pièce à traiter le
plus près possible de la section à souder.
E. Veillez à garder la source d'alimentation pour le
soudage et les câbles à une distance appropriée
de votre corps.
LES VAPEURS ET LES GAZ -- peuvent
causer un malaise ou des dommages
corporels, plus particulièrement
dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le
gaz de protection risque de causer
l'asphyxie. Par conséquent :
CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — comportent un risque de
danger. Le courant électrique qui
passe dans n'importe quel conducteur produit des champs électriques
et magnétiques localisés. Le soudage et le courant de coupage créent des champs électriques
et magnétiques autour des câbles de soudage et
l'équipement. Par conséquent :
1. Un soudeur ayant un stimulateur cardiaque doit
consulter son médecin avant d'entreprendre une
opération de soudage. Les champs électriques et
magnétiques peuvent causer des ennuis pour certains stimulateurs cardiaques.
2. L'exposition à des champs électriques et magnétiques peut avoir des effets néfastes inconnus pour
la santé.
14
1. Assurez en permanence une ventilation adéquate
dans l'aire de travail en maintenant une ventilation naturelle ou à l'aide de moyens mécanique.
N'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 ventilation 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.
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.)
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
quelconque.
4. N'utilisez pas l'équipement de façon abusive. Gardez
l'équipement à l'écart de toute source de chaleur,
notamment des fours, de l'humidité, des 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.
MANIPULATION DES CYLINDRES -La manipulation d'un cylindre, sans
observer les précautions nécessaires,
peut produire des fissures et un
échappement dangereux des gaz.
Une brisure soudaine du cylindre, de la soupape ou
du dispositif de surpression peut causer des blessures graves ou mortelles. Par conséquent :
1. Utilisez toujours le gaz prévu pour une opération
et le détendeur approprié conçu pour utilisation
sur les cylindres de gaz comprimé. N'utilisez jamais
d'adaptateur. Maintenez en bon état les tuyaux et
les raccords. Observez les instructions d'opération
du fabricant pour assembler le détendeur sur un
cylindre de gaz comprimé.
2. Fixez les cylindres dans une position verticale, à
l'aide d'une chaîne ou une sangle, sur un chariot
manuel, un châssis de roulement, un banc, un mur,
une colonne ou un support convenable. Ne 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.
INFORMATIONS SUPPLÉMENTAIRES RELATIVES À LA SÉCURITÉ -- Pour obtenir de
l'information supplémentaire sur les règles
de sécurité à observer pour l'équipement
de soudage à l'arc électrique et le coupage,
demandez un exemplaire du livret "Precautions and Safe Practices for Arc Welding,
Cutting and Gouging", Form 52-529.
Les publications suivantes sont également recommandées et mises à votre disposition par l'American Welding
Society, 550 N.W. LeJuene Road, Miami, FL 33126 :
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
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 2description
2.1 Introduction
The ESP-400C power source is designed for high speed plasma mechanized cutting applications. It can be used
with other ESAB products such as the PT-15, Pt-19XLS, PT-600 and PT-36 torches along with the Smart Flow II, a
computerized gas regulation and switching system.
•
•
•
•
•
•
•
•
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
Parallel supplemental power source capabilities to extend current output range.
2.2 General Specifications
ESP-400C 400V,
50 / 60Hz CE
Part Number
0558007615
Voltage
200 VDC
Current range DC (cutting)
Output
(100 % duty cycle) Power
Open Circuit Voltage (OCV)
Input
50A to 400A
80 KW
423 VDC
Voltage (3-phase)
400 V
Current (3- phase)
138A RMS
Frequency
50/60 HZ
KVA
95.6 KVA
Power
87.0 KW
Power Factor
91.0 %
Input Fuse Rec.
200A
17
section 2description
2.3 Dimensions and Weight
114.3 cm
45.00”
94.6 cm
37.25”
102.2 cm
40.25”
Weight = 825 kg. (1814 lbs.)
18
section 3installation
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.
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.
3.3 Placement
Note:
Use both lifting eyes when transporting from overhead.
•
•
•
•
•
A minimum of 1 M (3 ft.) clearance on front and back for cooling air flow.
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.
caution
Conductive dust and dirt inside 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.
19
section 3installation
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.
3.4.1 Primary Power
ESP-400C is a 3-phase unit. Input power must be provided from a line (wall) disconnect switch that contains
fuses or circuit breakers in accordance to local or state regulations.
Recommended input conductor and line fuse sizes:
Input at Rated Load
Volts
Amperes
Input and Ground
conductor* CU/
mm2 (AWG)
400
138
95 (4/0)
Time delay
Fuse size
(amperes)
200
Rated load is output of 400A at 200V
* Sizes per National Electrical Code for a 90° C (194˚ F) rated copper conductors @ 40° C (104˚ F) ambient. Not more
than three conductors in raceway or cable. Local codes should be followed if they specify sizes other than those listed
above.
To estimate the input current for a wide range of output conditions, use the formula below.
Input current =
NOTICE
(V arc) x (I arc) x 0.688
(V line)
Dedicated power line may be necessary.
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.
20
section 3installation
3.4.2 Input Conductors
•
•
•
Customer supplied
May consist either of heavy rubber covered copper conductors (three power and one ground) or run
in solid or 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
12.7 mm (0.50”) hardware before being attached to the ESP-400C.
NOTICE
3.4.3 Input Connection Procedure
1
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.
2
3
1 = Primary Terminals
2 = Chassis Ground
3 = Power Input Cable Access Opening (Rear Panel)
21
section 3installation
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.
WARNING
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
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.
3.5.1 Output Cables (customer supplied)
Choose plasma cutting output cables (customer supplied) on the basis of one 4/0 AWG, 600 volt insulated copper cable for each 400 amps of output current.
Note:
Do not use 100 volt insulated welding cable.
22
section 3installation
3.5.2 Output Connection Procedure
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.
Access Panel
3.6 Parallel Installation
Two ESP-400C power sources may be connected together in parallel to extend the output current range.
caution
Parallel power source minimum output current exceeds recommended amounts when cutting below 100A.
Use only one power source for cutting below 100A.
We recommend disconnecting the negative lead from the supplemental power source when changing to currents below 100A. This
lead should be safely terminated to protect against electric shock.
23
section 3installation
3.6.1 Connections for Two ESP-400C’s in Parallel
Note:
Primary power source has the electrode (-) conductor jumpered. The supplemental power source has the
work (+) jumpered.
1.
2.
3.
4.
Connect the negative (-) output cables to the arc starter box (high frequency generator).
Connect the positive (+) output cables to the workpiece.
Connect the positive (+) and negative (-) conductors between the power sources.
Connect the pilot arc cable to the pilot arc terminal in the primary power source. The pilot arc connection in the supplemental power source is not used. The pilot arc circuit is not run in parallel.
5. Set the Pilot Arc HIGH / LOW switch on the supplemental power source to “LOW”.
6. Set the Pilot Arc HIGH / LOW switch on the primary power source to “HIGH”.
7. If a remote 0.00 to +10.00 VDC current reference signal is used to set the output current, feed the same signal into both
power sources. Connect J1-B (positive 0.00 to 10.00 VDC) of both power sources together and connect J1-A (negative)
of both power sources together. With both power sources operating, the output current can be predicted using the
following formula: [output current (amps)] = [reference voltage] x [160]
Connections for parallel installation of two ESP-400C power sources with both power sources in operation.
ESP-400C
ESP-400C
Supplemental
Power Source
electrode
work
(-)
(+)
3 - 4/0 600V
positive leads
to workpiece
Primary Power
Source
work
(+)
4/0 600V
cable jumpers
between units
pilot arc
1 - 14 AWG 600V
lead to pilot arc connection in arc starter
box (h.f. generator)
24
electrode
(-)
3 - 4/0 600V
negative leads
in arc starter box
(h.f. generator)
section 3installation
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 Covers Removed.
High voltage components are exposed increasing shock
hazard.
Internal component may be damaged because cooling
fans will lose efficiency.
WARNING
Electric Shock Can Kill!
Exposed Electrical Conductors Can Be Hazardous!
WARNING
Do not leave electrically “hot“ conductors exposed. When
disconnecting the supplemental 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 supplemental power source and the
plumbing box. Failure to do this will leave the supplemental electrically “hot”.
Connections for parallel installation of two ESP-400C power sources with only one power source in operation.
ESP-400C
ESP-400C
Supplemental
Power Source
Primary Power
Source
work
3 - 4/0 600V
positive leads
to workpiece
electrode
work
Disconnect negative connection from
supplemental power
source and insulate to
convert from two to
one power source
25
electrode
3 - 4/0 600V
negative leads
in arc starter box
(h.f. generator)
SECTION 4
Op
4.1 Introduction
section 3installation
The ESP-600C does not have an ON/O
The main power is controlled through th
disconnect switch.
3.7 Interface Cable
! WARNING
Do not operate the ESP-600C
Covers Removed.
High voltage components are exp
increasing shock hazard.
CNC Interface (19 Pin)
Internal component may be dama
because cooling fans will lose ef
4.2 Control Panel
Main Power
Indicator illuminates when input power i
the power source.
Over Temp
Indicator illuminates when power source
overheated.
Contactor On
Indicator illuminates when the main con
energized.
ESP-600C Plasma Power Source
26
section 3installation
3.7.1CNC Interface Cable with 19-Pin Mating Power Source Connector
27
section 3installation
28
(Slave)
T1 Main
Transformer
29
CNC Common
(Floating)
S
T
Galvanic
Isolator
See
Note
Twisted Pair
See Note
T
Right
IGBT Modules
Left
IGBT Modules
See Note
T
L1
Note
Both the IGBT’s and Free Wheeling Diodes are
contained in the same module.
WORK
NOZZLE
ELECTRODE
Precision
Shunt
Pilot Arc
Circuit
R (snub)
Biased Snubber
250V Peak
T1
Blocking Diodes
R (boost)
Boost Starting
Circuit
425V Peak
T1
Blocking Diodes
Contact on Pilot
Arc Contactor
Right Hall
Sensor
L2
Free Wheeling
Diodes - See Note
Left Hall
Sensor
ESP-400C
BLOCK DIAGRAM
“T” Common Connected to Earth Grounded Work Through the “+” Output
Error Amplifiers
Feedback For Fast Inner Servos
Control Circuit
Bus Rectifiers
300U120’s
Cap.
Bank
Feedback for Constant
Current Servo
Gate
Drive
Sync Signal
For Alternate
Switching
Gate
Drive
-300V-375V
DC Bus
PWM
PWM
4.1 Block Diagram Circuit Description
0.0 - 10.0V DC Vref
Iout = (Vref) x (50)
3 Phase
Input
H
Galvanic
Isolator
Right PWM / Gate Drive Board
2
(Master)
Galvanic
Isolator
Left PWM / Gate Drive Board
section 4
operation
section 4
operation
4.1 Block Diagram Circuit Description (con’t.)
The power circuit utilized in the ESP-400C is commonly referred to as a Buck Converter or a Chopper. High speed electronic
switches turn on and off several thousand times per second providing pulses of power to the output. A filter circuit, consisting primarily of an inductor (sometimes called a choke), converts the pulses to a relatively constant DC (Direct Current)
output.
Although the filter inductor removes most of the fluctuations from the “chopped” output of the electronic switches, some
small fluctuations of output, called ripple, remain. The ESP-400C utilizes a patented power circuit combining the output
of two choppers, each providing approximately half the total output, in a manner that reduces ripple. The choppers are
synchronized so that when the ripple from the first chopper is increasing output, the second chopper is decreasing output.
The result is the ripple from each chopper partially cancels the ripple from the other. The result is ultra low ripple with a
very smooth and stable output. Low ripple is highly desirable because torch consumable life is often improved with low
ripple.
The graph below shows the effect of ESAB’s patented ripple reduction using two choppers synchronized and switching
alternately. Compared to two choppers switching in unison, the alternate switching typically reduces ripple a factor of 4
to 10.
ESP-400C
10/20
KHz Output
RMSRipple
RippleCurrent
Current
Versus
Output
Voltage
EPP-600
10/20KHz
Output RMS
Versus
Output
Voltage
9.0
Choppers Synchronized
andand
Switching
in Unison
(10KHz Ripple)
Choppers
Synchronized
Switchng
in Unison
(10KHz Ripple)
RMS
Ripple
Current
RMS
Ripple
Current(Amperes)
(Amperes)
8.0
7.0
6.0
5.0
4.0
Choppers
Synchronizedand
and Switching
in Alternately
(20KHz
Ripple)
Choppers
Synchronized
Switching
Alternately
(20KHz
Ripple)
3.0
2.0
1.0
0.0
0
50
100
150
200
Output
Voltage
(Volts)
Output
Voltage
(Volts)
P. K. Higgins: Current_Ripple_ESP-600C; RMS CURRENT RIPPLE Chart 17
30
250
300
350
section 4
operation
4.1 Block Diagram Circuit Description (con’t.)
The ESP-400C Block Diagram (after Subsection 6.4.4) shows the main functional elements of the power source. T1, the
Main Transformer, provides isolation from the primary power line as well as the proper voltage for the *375V DC Bus. The
Bus Rectifiers convert the three phase output of T1 to the *375V bus voltage. A capacitor bank provides filtering and energy storage that supplies power to the high speed electronic switches. The switches are IGBT’s (Insulated Gate Bipolar
Transistors). The *375V bus provides power for both the Left (Master) Chopper and the Right (Slave) Chopper.
Each chopper contains IGBT’s, Free Wheeling Diodes, a Hall Sensor, a Filter Inductor, and Blocking Diodes. The IGBT’s are
the electronic switches that, in the ESP-400C, turn on and off 10,000 times per second. They provide the pulses of power
filtered by the inductor. The Free Wheeling Diodes provide the path for current to flow when the IGBT’s are off. The Hall
Sensor is a current transducer that monitors the output current and provides the feedback signal for the control circuit.
The Blocking Diodes provide two functions. First, they prevent the 425V DC from the Boost Starting Circuit from feeding
back to the IGBT’s and the *375V Bus. Second, they provide isolation of the two choppers from one another. This permits
independent operation of each chopper without the other chopper functioning.
The Control Circuit contains regulating servos for both choppers. It also contains a third servo that monitors the total
output current signal fed back from the Precision Shunt. This third servo adjusts the two chopper servos to maintain an
accurately controlled output current commanded by the Vref signal.
The Vref circuitry is galvanically isolated from the rest of the power source. The isolation prevents problems that can arise
from “ground” loops.
Each chopper, the Left Master, and the Right Slave, contain their own PWM / Gate Drive PC Boards mounted next to the
IGBT’s. This circuitry provides the on / off PWM (Pulse Width Modulation) signals to drive the IGBT’s. The Left (Master) PWM
provides a synchronized clock signal to its own Gate Drive circuitry as well as to the Right (Slave) Gate Drive circuitry. It is
through this synchronized signal that the IGBT’s from the two sides switch alternately reducing output ripple.
The ESP-400C contains a Boost Supply for providing approximately 425V DC for arc starting. After the cutting arc is established, the Boost Supply is turned off with a contact on the Pilot Arc Contactor (K4).
A Biased Snubber reduces the voltage transients created during cutting arc termination. It also reduces the transient voltages from a parallel power source thus preventing damage to the power source.
The Pilot Arc Circuit consists of the necessary components for establishing a pilot arc. This circuit disengages when the
cutting arc is established.
* The Bus voltage for the 400V, 50Hz model is approximately 320V DC.
31
! WARNING
Covers Removed.
section 4
High voltage compon
operationshock haz
increasing
4.2 Control Panel
Internal component m
because cooling fans
J
H
I
F
4.2 Control Panel
G
A
C
B
D
E
K
A - Main Power
Mainsource.
Power
Indicator illuminates when input power is applied to the power
B - Contactor On
Indicator illuminates when
the power source.
Indicator illuminates when the main contactor is energized.
C - Over Temp
Indicator illuminates when power source has overheated.Over
Temp
D - Fault
Indicator illuminates when
Indicator illuminates when there are abnormalities in the overheated.
cutting process or
when the input line voltage falls outside of the required nominal value by
±10%.
E - Power Reset Fault
Contactor On
Indicator illuminates when a serious fault is detected. Input
power must
be
Indicator
illuminates
disconnected for at least 5 seconds and then reapplied.
energized.
F - Current Dial (Potentiometer)
ESP-400C dial shown. ESP-400C has a range of 50 to 400 A. Used only in
panel mode.
ESP-600C Plasma Power Source
32
when
section 4
operation
4.2 Control Panel (con’t.)
G - Panel Remote Switch
the location of current control.
SECTION 4Controls
• Place in the PANEL position for control using the current po-
4.1
tentiometer.
Place in REMOTE position for control from an external signal
(CNC).
Introduction•
The ESP-600C does
The main power is co
disconnect switch.
H - 19 pin plug for connecting the power source to CNC (remote control)
H and L - Remote Connections
Do not operate
!UsedWARNING
Covers Remove
to select amount of pilot arc current desired. As a general rule, for 100
I - Pilot Arc HIGH / LOW Switch
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
High
voltage
included in the torch manual.
com
increasing shock
Internal compone
because cooling f
J
I
H
F
4.2 Control Panel
G
A
C
B
D
E
K
Main Power
33
Indicator illuminates w
the power source.
section 4
operation
4.2 Control Panel (con’t.)
J - Meters
Displays voltage and amperage when cutting. The ammeter can be activated
when not cutting to view an estimation of the cutting current before cutting
begins.
K - Actual/Preset Switch
The ACTUAL AMPS / PRESET AMPS spring return toggle switch, S42, defaults
to the ACTUAL (UP) position. In the ACTUAL position, the OUTPUT AMMETER
displays the output cutting current.
In the PRESET (DOWN) position, the OUTPUT AMMETER displays an estimate
of the output cutting current by monitoring the 0.00 to 10.00 VDC cutting
current reference signal (Vref ). The reference signal comes from the CURRENT
POTENTIOMETER with the PANEL/REMOTE switch in the PANEL (UP) position
and from a remote reference signal (J1-D / J1-C(+)) with the PANEL/REMOTE
switch in the REMOTE (DOWN) position. The value displayed on the OUTPUT
AMMETER will be the value of Vref (volts) times 80. For example, a reference
signal of 5.00V will result in a preset reading of 400 Amps on the meter.
The switch may be changed to and from the ACTUAL and PRESET positions
at any time without affecting the cutting process.
WARNING
Dangerous Voltages and Current!
Electric Shock Can Kill!
Before operation, ensure installation and grounding procedures have been followed. Do not operate this equipment with covers removed.
34
section 4
operation
4.3 Sequence of Operation
SECTION 4
Operation
4.3 Sequence of Operation
Apply Power
1. Apply power by closing the line (wall) switch.
1. Apply power by closing the line (wall) switch. (The ESP-400C
ESP-400C
does
not The
have
an power
on/off light will
does(The
not have
an on / off
switch).
main
switch).
The
main
power
light
will
illuminate
illuminate and the fault light will flash and then
go out.
and the fault light will flash and then go out.
PANEL
REMOTE
PILOT
ARC
HIGH
LOW
ACTUAL AMPS
PRESET AMPS
Begin
Cutting
2. Select the Panel / Remote setting.
2. pilot
Select
the Panel/Remote
setting.
3. Set
arc High
/ Low switch. (Refer
to cutting data in the
torch manual.)
3. Set pilot arc High/Low switch. (Refer to cutting
4. If using
panel
mode,
view
preset amps with the ACTUAL /
data
in the
torch
manual.)
PRESET AMPS switch. Adjust current until the approximate
4. If using
mode,
presetIf using
ampsthe
with
the
desired
value panel
is shown
on theview
ammeter.
remote
mode,
placing the actual Amps
/ Preset
Amps
switch
in the
ACTUAL/PRESET
AMPS
switch.
Adjust
current
Preset
Amps
providesdesired
the initialvalue
outputiscurrent
until
theposition
approximate
showncomon
manded
by
the
remote
control.
the ammeter.
5. Begin plasma cutting operation. This may include manually
5. Begin
plasma
cutting
operation.
Thistotal
mayplasma
setting
up other
options,
depending
on the
include
manually
setting
up
other
options,
package.
depending on the total plasma package.
6. If using panel mode, after cutting has begun, adjust current
to
amount.
6.desired
If using
panel mode, after cutting has begun,
adjust
current
to desired
7. If cutting
fails
to initiate,
check foramount.
fault light. If a fault light
illuminates, refer to troubleshooting section.
7. Check for fault light. If a fault light illuminates,
refer to troubleshooting section.
Note: The fault lightNote:
flashes when the contactor is
The
lighton
flashes
whenthe
theDC
contactor
is first up
firstfault
turned
signifying
Bus powered
turned
on
signifying
the
DC
Bus
powered
up
nornormally.
mally.
4.4 Arc Initiation Settings
The time to achieve full current can be adjusted to
suit your particular system. This feature uses 50%
of the cutting current to start, dwell and then
gradually (less than a second) achieve full current.
The ESP-400C is factory shipped with this feature
enabled. The default settings are:
35
Minimum Start Current
40A
Start Current
50% of cut current
Timing to achieve full current
800 msec
section 4
operation
4.4 Arc Initiation Settings
The time to achieve full current can be adjusted for a soft start. This feature uses a reduced current to start and then gradually ramps up to full current. The ESP-400C is factory shipped with soft start enabled. The default settings are:
Minimum Start Current . . . . . . . . . . . . . 43A
Start Current . . . . . . . . . . . . . . . . . . . . . . . 50% of cut current
Timing to achieve full current . . . . . . . 800 msec
Dwell Time . . . . . . . . . . . . . . . . . . . . . . . . . 50 msec
These timing functions can be disabled or adjusted to suit individual system requirements.
Start Current Wave Form With Soft Start ON
Cut Current
1OUT = 50 VREF
DC Output Current
DC Output Current
Start Current Wave Form With Soft Start OFF
Approx. 2 msec time to full current
Time
WARNING
Cut Current
1OUT = 50 VREF
Start Current
Dwell
Time
Time to full current
800 msec
Time
Electric Shock Can Kill!
Shut off power at the line (wall) disconnect before removing any covers or making any adjustments to the
power source.
36
section 4
operation
4.4.1 Enable/Disable Arc Initiation Conditions
Factory default setting shown.
SW2
1
2
3
4
5
6
7
on
off
1
2
3
4
5
6
SW1
7
8
1. Remove access panel on the upper-right corner of the front panel. Be sure to replace this
panel after adjustments have
SW2
been made.
2. Locate SW1 and PCB1 and push both rocker switches down to disable. To enable push both switches up. (If one switch
is up and the other is down, arc initiation time is considered on.)
Factory default settings shown
1
2
3
14
25
3
6
4
7
58
6
7
8
on
off
SW2
SW2
4.4.2 Adjusting Arc Initiation Dwell Timer
Dwell Time is controlled by selections of positions 1 through 4 of SW2 on PCB1. When a switch is pushed on, its value is
added to the minimum dwell time of 10 msec.
Switch #1 = 10 msec dwell time
Switch #2 = 20 msec dwell time
Switch #3 = 40 msec dwell time
Switch #4 = 80 msec dwell time
The default setting is with switch #3 on. 40 msec + 10 msec (minimum) = 50 msec
4.4.3 Adjusting the Minimum Start Current
Minimum Start Current is controlled by selection of positions 5 through 8 of SW2. When a switch is pushed on, its value is
added to the factory set minimum value of 3A.
Switch #5 = 25A min. start current
Switch #6 = 12A min. start current
Switch #7 = 6A min. start current
Switch #8 = 3A min. start current
Default setting is with 5, 6 and 8 on 3A + 25A + 12A + 3A = 43A
37
8
section 4
operation
4.4.4 Arc Initiation Controls
Start Current Potentiometer
UP-Slope Timer
SW1
SW2
4.4.5 Start Current and Up-Slope Timer
Starting Current (%) and Pot Setting Relationship
Start Current
Set using potentiometer located above and to the left of center
of PCB1. Factory default setting of 7 results in a starting current
that is 50% of the cutting current..
Percentage (%) of Cutting Current
90%
80%
70%
60%
Up-Slope Timer
Three position switch located next to the start current potentiometer. Time is from start current (after dwell ends) to full
current. Factory default = 800 msec.
50%
40%
30%
Left position = 250 msec
Center position = 800 msec
Right Position = 1200 msec
20%
10%
0%
0
1
2
3
4
5
6
Start Current Pot Setting
7
8
9
10
MAX
38
38
operation
section 4
Output Voltage (Volts)
300
300
= 6.000
VREF
= 6.000
V REF =VREF
6.000V
I OUT = (50) x ( V REF )
IOUT
OUT = (50) x (VREF
REF)
INTERNAL
CURRENT
INTERNAL
CURRENT
LIMIT
Internal Current
LimitLIMIT
Output Voltage
MaxMax.
Output
Voltage
@Nominal Line
@ Nominal
Line
DATAPLATE
PLATE
DATA
MAXRATING
RATING
MAX
400400
500 500
39
EPP-400
CURVES FOR
400V
INPUT
EPP-400
V-IV-I
CURVES
FOR
460V
& 575V INPUTS
200
200
VREF
= 4.000
VREF
= 4.000
V REF = 4.000V
OutputCURRENT
Current (Amperes)
OUTPUT
(Amperes)
VREF=V=8.000
8.000
VREF
= 8.000V
REF
423V
Open
Circuit (400V
Inputs)
423V
Open
Circuit
(400V
427V
Open
Circuit
(460V
& Input)
575V Inputs)
100
100
= 2.000
2.000V
V REF = VREF
VREF = 2.000
Output of Boost / Start Circuit
Output
of Boost/Start Circuit
MIN CURRENT
CUT CURRENT
RATING
VREF
=V 1.000
MIN
CUT
RATING
VREF
= 1.000
Rating
= 1.000V Min.
REF
400
400
200
200
100
100
0
0
0
0
MINCURRENT
MARK CURRENT
MIN MARK
RATINGRATING
VREF
= 0.240
VREF
= 0.240
300
300
OUTPUT
OUTPUT VOLTAGE
VOLTAGE (Volts)
(Volts)
PKH: VI_Curves_370V_Bus.xls;
VI_Curves_370V_Bus.xls; EPP-400
EPP-400 (460&575V)
(400V) VI Curves
PKH:
VI Curves
4.5.1 ESP-400C V-I Curves for 400V, 50/60Hz Inputs
section 4
operation
40
section 5maintenance
5.1 General
WARNING
WARNING
caution
Electric Shock Can Kill!
Shut off power at the line (wall) disconnect before attempting any maintenance.
Eye Hazard When Using Compressed Air To Clean.
•
•
Wear approved eye protection with side shields when cleaning the
power source.
Use only low pressure air.
Maintenance On This Equipment Should Only Be Performed By
Trained Personnel.
5.2 Cleaning
Regularly scheduled cleaning of the power source is required to help keep the unit running trouble free. The frequency of
cleaning depends on environment and use.
1. Turn power off at wall disconnect.
2. Remove side panels.
3. Use low pressure compressed dry air, remove dust from all air passages and components. Pay particular attention to
heat sinks in the front of the unit. Dust insulates, reducing heat dissipation. Be sure to wear eye protection.
41
section 5maintenance
caution
Air restrictions may cause ESP-400C to over heat.
Thermal Switches may be activated causing interruption of function.
Do not use air filters on this unit.
Keep air passages clear of dust and other obstructions.
5.3 Lubrication
•
•
Some units are equipped with oil tubes on the fans. These fans should be oiled after 1 year of service.
All other ESP-400Cs have fan motors that are permanently lubricated and require no regular maintenance.
WARNING
Electric Shock Hazard!
Be sure to replace any covers removed during cleaning
before turning power back on.
42
section 6TROUBLESHOOTING
6.1 General
WARNING
caution
Electric Shock Can Kill!
Do not permit untrained persons to inspect or repair this
equipment. Electrical work must be performed by an experienced electrician.
Stop work immediately if power source does not work properly.
Have only trained personnel investigate the cause.
Use only recommended replacement parts.
SECTION 4
Operation
4.1 Introduction
The ESP-600C does not have an ON/OFF switch.
The main power is controlled through the line(wall)
disconnect switch.
not operate the ESP-600C with
6.2 Fault
Indicators Do
! WARNING
Covers Removed.
High voltage components are exposed
Front
Fault
increasingPanel
shock hazard.
InternalIndicators
component may be damaged
Fault indicators are found on the front panel Used with
the LEDs on PCB1 (located behind the cover with the
ESP label) problems can be diagnosed.
because cooling fans will lose efficiency.
4.2 Control Panel
NOTE:
It is normal for momentary lighting (flashing) of the fault indicator
and LED 3 when a “contactor on”
signal is applied at the beginning
of each cut start.
Main Power
Indicator illuminates when input power is applied to
the power source.
PCB1 Located behind
this panel.
Over Temp
Indicator illuminates when power source has
overheated.
Contactor On
Indicator illuminates when the main contactor is
energized.
ESP-600C Plasma Power Source
Fault Indicator used with:
LED 3 - Bus Ripple
LED 4 - High Bus
LED 5 - Low Bus
LED 7 - Arc Voltage Saturation
LED 8 - Arc Voltage Cutoff
Power Reset Fault Indicator used with:
LED 6 - Right Overcurrent
LED 9 - Left Overcurrent
LED 10 - Left IGBT Unsaturated
LED 11 - Right IGBT Unsaturated
LED 12 - Left -12V Bias Supply
LED 13 - Right -12V Bias Supply
4-1
43
section 6TROUBLESHOOTING
Fault Indicator (Front Panel)
Illuminates when there are abnormalities in the cutting process or when the input
voltage falls ±10% outside the normal value. Momentary illumination is normal. If
continuously lit, check LEDs 3, 4, 5, 7, and 8 on PCB1 for further diagnosis.
LED 3 – (amber) Bus Ripple Fault - Momentarily illuminates at the beginning
of each cut. Continuously lit during single-phasing or imbalanced line-to-line
voltages of the three phase input line (Excessive Ripple). Power Source is shut
down.
LED 4 – (amber) High Bus Fault – Illuminates when input line voltage is too high
for proper operation (approximately 20% above nominal line voltage rating).
Power source is shut down.
LED 5 – (amber) Low Bus Fault – Illuminates when input line
voltage is approximately 20% below nominal line voltage
rating. Power Source is shut down.
38
LED 7 – (amber) Arc Voltage Saturation Fault – Illuminates
when the cutting arc voltage is too high and cutting current
drops below preset level. LED will extinguish after voltage
decreases and current rises.
LED 8 – (amber) Arc Voltage Cutoff Fault – Illuminates when arc
voltage increases over the preset value. PS is shut down.
44
section 6TROUBLESHOOTING
Power Reset Fault Indicator (on front panel)
Illuminates when a serious fault is detected. Input power must be disconnected for a
least 5 seconds to clear this fault. Check PCB1 Red LEDs 6, 9, 10, 11, 12, and 13 if this
fault is illuminated for further diagnosis.
LED 6 – (red) Right Overcurrent Fault – Illuminates when the current out of the right
side chopper is too high (200 amps). This current is measured by the right-side hall
sensor. The power source is shut down.
LED 9 – (red) Left Overcurrent Fault – Illuminates when the current from the left side
chopper is too high (200 amps). Measured by the left hall sensor. Power source is
shut down.
LED 10 _ (red) Left IGBT Unsaturated Fault – Illuminates when left IGBT is not fully
conducting. PS (PS) is shut down.
LED 11 – (red) Right IGBT Unsaturated Fault – Illuminates
when right IGBT is not fully conducting. Power Source (PS)
is shut down.
LED 12 – (red) Left -(neg) 12V Bias Supply Fault – Illuminates
when negative 12 V bias supply to the left side IGBT gate
drive circuit (located on PWM-drive board PCB2) is missing.
PS is shut down.
LED 13 – (red) Right –(neg) 12V Bias Supply Fault - Illuminates when negative 12 V bias
supply to the right side IGBT gate drive circuit (located on PWM drive board PCB3) is
missing. PS is shut down.
45
section 6TROUBLESHOOTING
6.3 Fault Isolation
Many of the most common problems are listed by symptom.
6.3.1
6.3.2
6.3.3
6.3.4
6.3.5
6.3.6
Fans not working
Power not on
Fault Light Illumination
Torch won’t fire
Fusses Blown F1 and F2
Intermittent, Interrupted or Partial Operation
6.3.1 Fans Not Working
Problem
All 4 fans do not run
1, 2 or 3 fans do not run.
Possible Cause
Action
This is normal when not cutting.
Fans run only when “Contactor On” None
signal is received.
Broken or disconnected wire in fan
Repair wire.
motor circuit.
Faulty fan(s)
Replace fans
6.3.2 Power Not On or LOW Voltage
Problem
Power source inoperable:
Main power lamp is off.
Low open circuit voltage
Possible Cause
Action
Missing 3-phase input voltage
Restore all 3 phases of input voltage to within
±10% of nominal line.
Missing 1 of 3-phase input voltage
Restore all 3 phases of input voltage to within
±10% of nominal line.
Fuse F3 blown
Replace F3
Pilot arc Contactor (K4) faulty
Replace K4
Faulty Control PCB1
Replace Control PCB1 (P/N 0558038287)
46
section 6TROUBLESHOOTING
6.3.3 Fault Light Illumination
Problem
Fault light illuminates at the end of
cut but goes off at the start of the
next.
LED 3 – (amber) Bus Ripple
LED 4 – (amber) High Bus
LED 5 – (amber) Low Bus
Possible Cause
Action
Normal condition caused when terminating the arc by running the torch
off the work or the arc being attached
to a part that falls away.
Reprogram cutting process to
ensure arc is terminated only by
removing the “Contactor On” signal.
Imbalance of 3-phase input power
Maintain phase voltage imbalance
of less than 5%.
Momentary loss of one phase of
input power
Restore and maintain input power
within ±10% nominal
Faulty control PCB1
Replace PCB1 P/N 0558038287
One or more phases of input voltage
exceed nominal line voltage by more
than 15%.
Restore and maintain line voltage
within ±10%
Faulty control PCB1
Replace PCB1 P/N 0558038287
One or more shorted diode rectifiers
(D25-D28) on the “Electrode Plate”
Replace shorted diode rectifiers
One or more phases of input voltage are lower than nominal by more
than 15%.
Restore and maintain within
±10% of nominal
Blown F1 and F2 fuses
See F1 and F2 in Blown
Fuses Section
Over temp Light comes on.
See over temp in Fault Light Section
Imbalanced 3-phase input
power
Maintain phase voltage imbalance
of less than 5%
Momentary loss of one phase of
input power
Restore and maintain within
±10% of nominal
Faulty Main Contactor (K1)
Replace K1
FAULTY Control PCB1
Replace PCB1 P/N 0558038287
47
section 6TROUBLESHOOTING
Problem
Possible Cause
Action
Output current of the right side exceeds
Turn the output current down to
200A because of operating the power source
400A
over 400A.
Cutting at over 250A with a faulty left side
See faulty left or right side
(left side output = 0)
Right current transducer connector loose
LED 6 – (red) Right Over Curor unplugged. PCB loose.
rent
Loose or unplugged connector at right
PWM/Drive Printed circuit board.
Note:
P2 at left of PWM / Drive PCB loose or unIf operation at 400A or less is plugged.
possible, then the LEFT side is
Check voltage between P7-6 and P7-7. A
not working.
voltage in either polarity of greater than
0.01 V indicates a faulty right current transducer (TD2).
Secure connections
Secure connection
Secure connection
Replace right current transducer
(TD2)
Faulty PCB1
Replace PCB1 P/N 0558038287
Faulty right PWM / Drive PCB
Replace right PWM / Drive PCB P/N
0558038308
Output current of the left side exceeds 200A
Turn the output current down to
because of operating the power source
400A
over 400A.
Cutting at over 250A with a faulty right side
See faulty right side
(right side output = 0)
Left current transducer connector loose or
Secure connections
LED 9 – (red) Left Over Current unplugged. PCB loose.
Note:
If operation at 400A or less is
possible, then the Right side is
not working.
caution
Loose or unplugged connector at left PWM
Secure connection
/ Drive Printed circuit board.
P2 at right of PWM / Drive PCB loose or
Secure connection
unplugged.
Check voltage between P7-2 and P7-3. A
voltage in either polarity of greater than
Replace left current transducer (TD1)
0.01 V indicates a faulty left current transducer (TD1).
Faulty PCB1
Replace PCB1 P/N 0558038287
Faulty left PWM / Drive PCB
Replace left PWM / Drive PCB P/N
0558038308
NEVER attempt to power-up or operate the power source with any
Gate / Emitter IGBT Plug disconnected from it’s PWM / Gate Drive
Board. Attempting to operate the power source with any open (unplugged) IGBT Gate / Emitter Connector may damage the IGBT and
the plasma cutting torch.
48
section 6TROUBLESHOOTING
Problem
Possible Cause
Shorted IGBT
Action
Replace the IGBTs
Very high Output current ac- Current pot set too high
companied by either a left or Faulty left PWM / Drive PCB
right over current (LED 6)
High remote current signal
Lower the current setting
Replace left PWM / Drive PCB
Decrease remote current signal
Faulty PCB1
Replace PCB1 P/N 0558038287
Black wire connecting IGBT (Q2) collector to P3 of the
Secure connector
left PWM / Drive PCB (PCB2) is disconnected.
Shorted Freewheeling Diode(s)
Replace freewheeling diode(s)
LED 10 - (red) Left IGBT Un- Loose or unplugged P1 connector at the left PWM / Secure P1
Drive PCB
saturated
Loose or unplugged P10 connector at PCB1
Secure P10
Faulty PCB1
Replace PCB1 P/N 0558038287
Faulty left PWM / Drive PCB
Replace PCB2 P/N 0558038308
Black wire connecting IGBT (Q5) collector to P3 of the
Secure connector
right PWM / Drive PCB (PCB3) is disconnected.
Shorted Freewheeling Diode(s)
Replace freewheeling diode(s)
LED 11 - (red) Right IGBT Loose or unplugged P1 connector at the left PWM / Secure P1
Drive PCB
Unsaturated
Loose or unplugged P10 connector at PCB1
Secure P11
Faulty PCB1
Replace PCB1 P/N 0558038287
Faulty right PWM / Drive PCB
Replace PCB3 P/N 0558038308
49
section 6TROUBLESHOOTING
Problem
Possible Cause
Action
Loose or unplugged P1 connector at
Secure P1 connector
the left PWM / Drive PCB
LED 12 – (red) Left –12V Missing
Loose or unplugged P10 connector
Secure P10 connector
at PCB1
Faulty left PWM / Drive PCB
Replace left PWM / Drive PCB
0558038308
P/N
Loose or unplugged P1 connector at
Secure P1 connector
the right PWM / Drive PCB
LED 12 – (red) Right –12V Missing
Loose or unplugged P11 connector
Secure P11 connector
at PCB1
Faulty right PWM / Drive PCB
Replace right PWM / Drive PCB P/N
0558038308
Shorted IGBT
Replace the IGBTs
Current pot set too high
Very high Output current accompanied by either a left or right over cur- Faulty left PWM / Drive PCB
rent (LED 9 or LED 6 respectively)
High remote current signal
Lower the current setting
Replace left PWM / Drive PCB P/N
0558038308
Decrease remote current signal
Faulty PCB1
Replace PCB1 P/N 0558038287
One or more fans inoperable
Repair or replace fan(s)
Broken wire or unplugged connector Repair broken wires and unplugged conat thermal switch.
nector
Allow 3 ft. (1 m) minimum between the rear
Obstruction to air flow closer than 3 feet
of the power source and any object that may
(1 m) to rear of power source.
restrict air flow.
Over Temp Lamp illuminates
Clean out excessive dirt, especially in the
extrusions for the IGBTs and freewheeling
Excessive dirt restricting cooling air
diodes, the POS, NEG and Electrode Plates,
flow
the main transformer (T1) and the filter
inductors (L1 and L2).
Obstructed air intake
50
Check and clear any obstructions from the
bottom, front, and top rear of the Power
Source.
section 6TROUBLESHOOTING
6.3.4 Torch Will Not Fire
Problem
Possible Cause
Action
Remote control removes the start
signal when the main arc transfers to
the work.
Place Panel/Remote switch in “Panel”
position
Panel/Remote switch in “Remote” with
no remote control of the current
Main Arc Transfers to the work with a
short “pop”, placing only a small dimple Remote current control present but Check for current reference signal at
TB1-4(+) and TB1-5(-). See Signal vs.
in the work.
signal missing.
Output Current Curve this section.
Current pot set too low.
Increase current pot setting.
Start current pot, located behind the
Increase the start current post setting
cover for the control PCB is set too
to “7”.
low.
Open connection between the power
Repair connection
source positive output and the work.
Fuse F6 in the Pilot arc circuit is blown. Replace F6
Fuse F7 in the pilot arc circuit is blown. Replace F7
Arc does not start. There is no arc at the Pilot arc High/Low switch is in the ”LOW”
Change Pilot arc to “High” position.
torch. Open circuit voltage is OK.
position when using consumables for
(Refer to process data included in torch
100A or higher (Refer to process data
manuals)
included in torch manuals)
Pilot arc contactor (K4) faulty.
Replace K4
Faulty PCB1
Replace PCB1 P/N 0558038287
51
section 6TROUBLESHOOTING
6.3.5 Fuses F1 and F2 Blown
Problem
Possible Cause
Action
Process controller must allow at least
Process controller ignites pilot arc too 300MS to lapse between the applicasoon after providing the “Contactor tion of the “Contactor On” signal and
On” signal
the ignition of the pilot arc. Fix process
controller logic and replace diodes.
Fuses F1 and F2 blown.
Faulty negative (Electrode) output cable
Repair cable
shorting to earth ground.
Shorted freewheeling diode.
Replace shorted freewheeling diode
and F1-F2
One or more shorted diode rectifiers Replace all diode rectifiers on the “POS
(D13-D18) on “POS Plate”.
Plate”.
One or more shorted diode rectifiers Replace all diode rectifiers on the “NEG
(D7-D12) on “NEG Plate”.
Plate”.
6.3.6 Intermittent, Interrupted or Partial Operation
Problem
Possible Cause
Action
Loose or unplugged connector at left PWM /
Secure connector
Drive PCB (PCB2)
Works OK at 400A or less - Over
Replace right PWM / Drive PCB P/N
Faulty left PWM / Drive PCB
current right side when cutting
0558038308
over 400A. LED 6 on control board Check voltage between P5-1 and P5-2 at the
illuminated.
left PWM / Drive PCB (PCB2). Should be 20V
Replace control transformer T5
AC. Between P5-1 and P5-3 should be 40V AC.
If not the control transformer (T5) is faulty.
Loose or unplugged connector at Right PWM
Secure connector
/ Drive PCB (PCB3)
Works OK at 400A or less - Over
Replace right PWM / Drive PCB P/N
Faulty Right PWM / Drive PCB
current left side when cutting
0558038308
over 400A. LED 9 on control board Check voltage between P5-1 and P5-2 at the
illuminated.
right PWM / Drive PCB (PCB3). Should be 20V
Replace control transformer T7
AC. Between P5-1 and P5-3 should be 40V AC.
If not the control transformer (T7) is faulty.
caution
NEVER attempt to power-up or operate the power source with any
Gate / Emitter IGBT Plug disconnected from it’s PWM / Gate Drive
Board. Attempting to operate the power source with any open (unplugged) IGBT Gate / Emitter Connector may damage the IGBT and
the plasma cutting torch.
52
section 6TROUBLESHOOTING
Problem
Possible Cause
Action
“Contactor On” signal is removed from unit.
Power source is OK. Trouble shoot process controller.
Momentary loss of primary input power.
Restore and maintain input voltage
within ±10% of nominal.
Remove control PCB (PCB1) access panel
Faulty condition, indicated by illumination to determine the fault causing the shutdown. Refer to fault light illumination
Power Supply turns off prema- of the fault lamp.
section.
turely in the middle of the cut.
Remove control PCB (PCB1) access panel
Faulty condition, indicated by the illumination to determine the fault causing the shutof the power reset fault lamp.
down. Refer to fault light illumination
section.
Problem
Current setting too low.
Increase current setting
Remote current signal removed during cut.
Fix remote current signal
Possible Cause
Action
Place the PANEL / REMOTE switch in the“PANEL”
Fix the remote current control signal to
position. Adjust current control pot. If current
operate the PANEL / REMOTE switch in
no longer drifts, the remote current control
the “PANEL” position.
signal is faulty.
Output current is unstable and Select “PANEL” on the PANEL / REMOTE switch
drifts above or below the set- and adjust the current control pot. The cur- Replace the current control pot.
ting.
rent still drifts, measure the current reference
signal at TB1-4 (+) and TB1-5 (-). If the signal
drifts, the current control pot is faulty. If the
Replace the control PCB (PCB1) P/N
signal does not drift, the Control PCB (PCB1)
0558038287
is faulty.
53
section 6TROUBLESHOOTING
6.4 Testing and Replacing Components
NOTICE
•
•
•
•
•
•
Replace a PC board only when a problem is isolated to that board.
Always disconnect power before removing or installing a PC board.
Do not grasp or pull on board components.
Always place a removed board on a static free surface.
If a PC board is found to be a problem, check with your ESAB distributor
for a replacement. Provide the distributor with the part number of the
board as well as the serial number of the power source.
Do not attempt to repair the board yourself. Warranty will be voided if
repaired by the customer or an unauthorized repair shop.
Power Semiconductor Components
Categories of power semiconductors include;
•
•
Power Rectifiers
Modules containing the free wheeling diodes and IGBTs
54
section 6TROUBLESHOOTING
6.4.1 Power Rectifiers
Power Rectifiers – Procedure to access behind the front panel
1.
2.
3.
4.
5.
6.
7.
8.
9.
Remove top cover and side panels
Locate and disconnect plug in rear of ammeter (attached tone red and one black wire)
Remove pilot arc switch
Disconnect voltmeter
Disconnect orange and yellow wires from relay K4.
Remove two bolts holding the left side of the front
panel to the base.
Remove three bolts holding across the center base
of the front panel. These are accessed from underneath.
Remove one of the bolts holding the right side of the
front panel to the base. Loosen the second bolt. Of
these two bolts, remove the bolt on the left and loosen
the bold on the right.
Swing the front panel out to gain access to power
rectifier components.
Power Rectifiers located behind the
front panel.
Troubleshooting Procedures –Negative Plate
Location of Neg. Plate
1. Visually inspect fuses F8 and F9. Replace if they show signs
of being blown or melted. Inspect diodes. If ruptured
or burned, replace all diodes on the NEG Plate. If diodes
appear to be OK, proceed to next step.
Location of fuses F8 and F9
55
section 6TROUBLESHOOTING
NEG Plate
Diode Rectifier
1. Check ohms between NEG Plate and BR “A” Bus. A reading
of 2 ohms or less indicates one or more shorted diodes.
Replace all Diodes on NEG Plate.
2. If fuses F8 and/or F9 were open in the first step, make two
more ohmmeter readings.
A. Measure resistance between the NEG Plate and BR “B” bus.
Electrode Plate
POS Plate
B. Measure between NEG Plate and BR “C” bus.
If resistance is 2 ohms or less in either case, replace all the
diodes on the NEG Plate.
Troubleshooting POS Plate
Location of Pos. Plate
1. Check ohms between POS Plate and BR “A” Bus. A reading
of 2 ohms or less indicates one or more shorted diodes.
Replace all Diodes on POS Plate.
2. If fuses F8 and/or F9 were open in the first step, make two
more ohmmeter readings.
A. Measure resistance between the POS Plate and BR
“B” bus.
Location of fuses F8 and F9
B. Measure between POS Plate and BR “C” bus.
If resistance is 2 ohms or less in either case, replace all the
diodes on the POS Plate.
D25,26
Bus
D27,28
Cathode
Leads
1. Visually inspect for ruptured or burned diodes. Replace
only those damaged.
2. Check resistance between Electrode Plate and the parallel
pig tails (cathode leads) of D25 and D26. If reading is 2
ohms or less, disconnect leads from bus and check each
diode. Replace only shorted diodes.
Repeat procedure for D27 and D28. Replace only shorted
diodes.
56
section 6TROUBLESHOOTING
6.4.2 IGBT / Freewheeling Diode (FWD) Replacement
caution
caution
The emitter and the gate of each affected IGBT must be jumpered together to prevent electrostatic damage. Each power
source is supplied with six jumper plugs that mate to the IGBT
Gate / Emitter Plug.
Electrostatic Discharge Hazard
Electrostatic discharge may damage these components.
•
•
•
Damage is accumulative and may only appear as shortened component life and not as a catastrophic failure.
Wear a protective ground strap when handling to prevent damage to
PCB components.
Always place a pc board in a static-free bag when not installed.
Removal:
A. Insure that input power is removed by two actions such as a disconnect switch and removal of fuses. Tag and lock any
disconnect switch to prevent accidental activation.
B. Remove the top panel to gain access to the modules located in the top rear of the power source.
C. Clean the compartment containing the modules with dry, oil-free compressed air.
D. Unplug the gate drive leads connecting the IGBT Gates to the PWM/Gate Drive PC Board. In order to prevent damage
to the IGBT, install jumper plugs into the IGBT Gate Drive Connector. See Caution below. Jumper plugs are supplied
with each power source.
E. Remove the copper buss plates and bars connected to the IGBT’s. Save the M6 hardware connecting the bus structure
to the module terminals. You may need to re-use the hardware. Longer hardware can damage the module by contacting the circuitry directly below the terminals.
F. Remove the M6 hardware mounting the modules to the heat sink. Save the hardware because you may need to re-use
it. Hardware too short can strip the threads in the Aluminum heat sink. Hardware too long can hit the bottom of the
holes causing the modules to have insufficient thermal contact to the heat sink. Hardware too long or too short can
cause module damage due to over heating.
caution
The module gate plugs must be plugged into the PWM/Gate
Drive PC Board whenever the power source is in operation.
Failure to plug them in will result in damage to the module and
possible damage to the torch.
57
section 6TROUBLESHOOTING
Replacement:
A. Thoroughly clean any thermal compound from the heat sink and the modules. Any foreign material trapped between
the module and heat sink, other than an appropriate thermal interface, can cause module damage due to over heating.
B. Inspect the thermal (interface) pad, P/N 951833, for damage. A crease or deformity can prevent the module from seating properly, impeding the heat transfer from the module to the heat sink. The result can be module damage due to
over heating.
If a thermal pad is not available, a heat sink compound such as Dow Corning® 340 Heat Sink Compound may be used. It’s
a good idea to mount all paralleled modules located on the same heat sink using the same thermal interface. Different interfaces can cause the modules to operate at different temperatures resulting in un-equal current sharing. The imbalance
can shorten module life.
C. Place a thermal pad, and an IGBT module on the heat sink. Carefully align the holes in the thermal pad with the heatsink and module holes. If heat sink compound is used in place of a thermal pad, apply a thin coat of even thickness to
the metal bottom of the module. A thickness of 0.002” – 0.003” (0.050mm – 0.075mm) is optimum. Too much compound impedes heat transfer from the module to the heat sink resulting in short module life due to over heating.
D. Insert the four M6 mounting bolts, but do not tighten. Leave them loose a few turns. Be certain that the threads from
the mounting bolts do not bend the edges of the thermal pad clearance holes. A bent thermal pad can prevent the
module from seating properly, impeding the heat transfer from the module to the heat sink. The result can be module
damage due to over heating.
E. Partially tighten the four mounting bolts a little more than finger tight in the order: A-B-C-D. See figure below.
F. Fully tighten, in the same order above, to a torque of 35 – 44 in-lbs (4.0 – 5.0 N-M). See figure below.
G. Install the bus plates and bus bars. Be careful that the sheets of insulation separating the bus plates are still in their
original positions. It’s a good idea to tighten the mounting hardware only after getting it all started. Torque the M6
module terminal hardware to 35 – 44 in-lbs (4.0 – 5.0 N-M).
H. Remove the jumper plugs from the module gate lead plugs, and plug into the appropriate plugs from the PWM/Gate
Drive PC Board. See Caution below.
I. Replace the top panel.
caution
The module gate plugs must be plugged into the PWM/Gate
Drive PC Board whenever the power source is in operation.
Failure to plug them in will result in damage to the module and
possible damage to the torch.
A
1 - IBGT Collector, Free Wheeling
Diode (FWD) Anode
2 - IGBT Emitter
3 - FWD Cathode
6 - IGBT Gate
Four-Point Mounting Type
Partial tightening - A B C D
Fully tightening - A B C D
C
D
Key Plug
Position 1 (RED)
B
1
2
7 - IGBT Emitter
3
7 (RED)
6 (WHT)
58
section 6TROUBLESHOOTING
6.4.3 Power Shunt Installation
caution
Instability or oscillation in cutting current can be caused by improper dressing of shunt pick-up leads.
Poor torch consumable life will be the result.
There are two cables that attach to the shunt pick-up points:
a two conductor cable drives the ammeter
a three conductor which provides the current feedback signal to PCB1 (control PCB).
Dressing of the 2 conductor cable is not critical.
The following is the dressing procedure for the 3 conductor cable.
•
•
•
The breakout point should be physically at the middle of the shunt. The breakout point is the place
where the conductors exit from the outer insulation jacket.
The black and clear insulated wires must be kept next to the shunt and under the cable ties.
The wire terminals for the black and clear insulated wires should be oriented in parallel with bus bars
as shown.
Terminals parallel
to bus bars
clear insulation
three leads
two leads
59
•
It is important to have the barrels of the black
and clear insulated wires, from the three lead
cable, be pointing in opposite directions.
•
The third wire attaches to the bus bar on the left
with the shunt mounting hardware. Orientation
of this wire is not critical.
section 6TROUBLESHOOTING
6.4.4 Procedure For Verifying Calibration Of Digital Meters.
Voltmeter
1. Connect a digital meter known to be calibrated to the positive and negative output bus bars.
2. Compare the power source voltmeter reading to the calibrated meter reading. Readings should match within
±0.75%.
Ammeter
1. External to the power source, connect a precision shunt in series with the work lead(s). The best shunt is one with a
value of 100 micro-ohms (50mV / 500A or 100mV / 1000A) and a calibrated tolerance of 0.25%.
2. Use a calibrated 4 ½ digit meter to measure the output of the shunt. The amperage indicated with the external shunt
and meter should match power source ammeter to within 0.75%.
6.5 Control Circuit Interface Using J1 Connector
Interface to the ESP-400C control circuitry is made with connector J1 on the front panel. J1 has 19 conductors.
J1-A and J1-B provide access to the galvanically isolated transistor output signal indicating an “Arc On” condition. See
Subsection 6.8, Arc Current Detector Circuits. J1-C and J1-D are the inputs for the remote Voltage Reference Signal that
commands the ESP-400C output current Subsection 6.9, Current Control Pot & Remote Vref. J1-F and J1-G supply 115V AC
for remote controls. See Subsection 6.6, Auxiliary Main Contactor (K3) & Solid State Contactor Circuits and Subsection 6.6,
Pilot Arc Hi/lo Circuit.
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section 6TROUBLESHOOTING
J1-J
J1-K
TB1-13
SPARE
TB1-14
J1-H
J1-G
J1-F
J1-E
J1-C
+
J1-D
J1-B
-
J1-A
(80)
61
section 6TROUBLESHOOTING
6.6 Auxiliary Main Contactor (K3) and Solid State Contactor Circuits
K3, activated by supplying a Contactor Signal, initiates and controls the operation of K2 (Starting Contactor) and K4 (Pilot
Arc Contactor). K3 is called the Auxiliary Main Contactor because it must be activated before the Main Contactor (K1)
power-up sequence can occur. The Contactor Signal is supplied through a remote contact connecting 115VAC from J1-F
to J1-E. If K6-2 is closed (no fault) and the Emergency Stop loop is closed, K3 will activate. The closing of K3-3 activates K2,
the Starting Contactor, and K4, the Pilot Arc Contactor, provided the power source is not over heated. See Subsection 6.7,
Main Contactor (K1A, K1B and K1C) Activation Circuit for more information on the operation of K2. K4 is turned off when the
Current Detector senses arc current and opens the contact connecting P2-5 to P2-6 on the Control PC Board.
In addition to operating K3, the Contactor Signal also activates the Solid State Contactor. The Solid State Contactor is a
logic and interlock circuit permitting the IGBT’s to conduct whenever the remote Contactor Signal is present. The 115V AC
Contactor Signal is fed to TB1-9, TB7-8, and resistors R45 and R45A. These resistors reduce the 115V to approximately 16V
AC fed into the Control PC Board at P6-1 and P6-2. The Control PC Board sends a signal to both the Left and Right PWM /
Gate Drive PC Boards mounted directly on the IGBT’s. Illumination of LED3 on both of the PWM / Gate Drive PC Boards is
indication that the Solid State Contactor is functioning.
J1-H
J1-F
R45A
10K - 8W
J1-G
J1-E
TB7-11
TB7-10
62
section 6TROUBLESHOOTING
6.7 Main Contactor (K1A, K1B and K1C) Activation Circuit
A power-up sequence takes place before the Main Contactor (K1) activates. K1 is actually three separate contactors – one
for each primary input phase. Thus, K1A, K1B, and K1C switch phases A, B, and C respectively to the Main Transformer, T1.
The power-up sequence begins with a remote Contactor Signal activating K3. Refer to the description entitled, “Auxiliary
Main Contactor (K3) & Solid State Contactor Circuits” for more information. K3 activates K2 closing the three contacts of
K2. K2 bypasses K1 contacts providing primary input power to the Main Transformer, T1. This current is limited by three
one Ohm resistors, R1, R2, and R3. The resistors eliminate the high surge currents typical of the turn-on inrush transients
associated with large transformers. The high current surge of charging the Bus Capacitor Bank is also eliminated by initially
powering the Main Transformer through K2 and the resistors.
The discharged Bus Capacitor Bank initially prevents the output of the Main transformer from reaching its normal value.
As the Bus Capacitor Bank charges, the Main Transformer output voltage rises and becomes high enough for K1A, K1B, and
K1C to close. Once the K1’s are closed, the contacts of the Starting Contactor, K2, are bypassed, and full primary line power
is supplied to the Main Transformer.
Because the starting sequence takes time, it is important at least 300 mS lapse between applying the Contactor Signal and
applying load to the power source. Applying load too soon will prevent K1 from closing, and fuses F1 and F2 will open.
63
section 6TROUBLESHOOTING
6.8 Arc Current Detector Circuits
There are three Arc Current Detector circuits in the ESP-400C. One is used internally to control the Pilot Arc Contactor, K4.
The other two are available for remote use.
A galvanically isolated transistor Current Detector Output is accessible at J1-A (-) and J1-B (+). J1 is the 19 conductor connector on the ESP-400C front panel. The transistor is best suited for switching small relays or low current logic signals like
those utilized by PLC’s (Programmable Logic Controllers). The transistor can withstand a maximum peak voltage of 150V.
It can switch a maximum of 50 mA. The transistor turns on whenever the arc current through the Work Lead exceeds 5A.
Pilot arcs not establishing main arcs will not turn on the transistor.
A second current detector output is available at TB8-3 and TB8-4. This output is supplied by an isolated relay contact rated
for 150V, 3 Amperes. This contact is closed when the primary input power to the ESP-400C is off. It opens whenever primary power is supplied to the power source, and it closes when main arc current is established. Like the transistor output,
the relay contact closes whenever the arc current through the Work Lead exceeds 5A. Pilot arcs not establishing main arcs
will not close the contact.
J1-A
J1-B
64
section 6TROUBLESHOOTING
6.9 Current Control Pot and Remote Vref
The ESP-400C operates through a single continuously adjustable output current range from 50A through 400A using either
the Current Potentiometer, on the front panel, or a remote current reference signal, Vref, fed into connector, J1.
The reference voltage, Vref, is used to command the output current of the ESP-400C. Vref is a DC voltage that can come from
either the Current Control Potentiometer on the front panel or from a remote source. In the “Panel” position, S2, the Panel
/ Remote switch selects the Current Control Potentiometer. In the “Remote” position, the Panel/Remote switch selects the
Vref fed into J1-C (+) and J1-D (-). The ESP-400C Output Current, I (out), will follow Vref with the following relationship:
I(out) = (80) x (Vref)
The Control PC Board contains two inputs for Vref: High Speed; and Normal. When the negative of the Vref signal is fed
into the High Speed input (P8-3), the ESP-400C will respond to a change in Vref within 10 mS. When the negative of the
Vref signal is fed into the Low Speed input (P8-1), the ESP-400C will respond to a change in Vref within 50 mS. The slower
response of the “Normal” input helps filter electrical noise sometimes encountered in industrial environments.
J1-D
J1-C
65
section 6TROUBLESHOOTING
66
section 7
replacement parts
7.0Replacement Parts
7.1General
Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on
the unit serial number plate.
7.2Ordering
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.
NOTE:
Schematics on 279.4mm x 431.8mm
(11” x 17”) paper are included
inside the back cover of this manual.
67
section 7
replacement parts
68
section 7
replacement parts
69
section 7
replacement parts
70
section 7
replacement parts
71
section 7
replacement parts
72
section 7
replacement parts
73
section 7
replacement parts
49
74
section 7
replacement parts
75
section 7
replacement parts
76
section 7
replacement parts
77
section 7
replacement parts
78
section 7
replacement parts
0558006170M
0558005712M
0558005705Y
0558007606M
PLATE COVER - 400C
0558007605M
PANEL CONTROL
79
section 7
replacement parts
17280215
951198
R10-11 RESISTOR 1.5K OHMS 100W
R28-31
L3
FERRITE CORE
80
section 7
replacement parts
951223
0558002348
SHUNT, 100mV, 500A
81
section 7
replacement parts
82
section 7
replacement parts
142
954932
83
section 7
replacement parts
0558954035
84
section 7
replacement parts
85
section 7
replacement parts
3.62 W
4600610
86
revision history
1.
2.
3.
4.
Original release - 06 / 2007
03 / 2008 - Made changes per CN# 083032.
05 / 2008 - Made changes per P. Higgins to parallel connection diagrams.
Revision 08/2010 - Updated with new DOC form.
87
ESAB Welding & Cutting Products, Florence, SC
COMMUNICATION GUIDE - CUSTOMER SERVICES
A.
CUSTOMER SERVICE QUESTIONS:
Telephone: (800)362-7080 / Fax: (800) 634-7548
Hours: 8:00 AM to 7:00 PM EST
Order Entry
Product Availability
Pricing Order Information Returns
B.
ENGINEERING SERVICE:
Telephone: (843) 664-4416 / Fax : (800) 446-5693
Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting
C.
TECHNICAL SERVICE:
Telephone: (800) ESAB-123/ Fax: (843) 664-4452
Part Numbers
Technical Applications
Specifications
Hours: 8:00 AM to 5:00 PM EST
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
Repair Estimates Repair Status
Hours: 7:30 AM to 3:30 PM EST
F.
WELDING EQUIPMENT TRAINING
Telephone: (843)664-4428 / Fax: (843) 679-5864
Training School Information and Registrations
Hours: 7:30 AM to 4:00 PM EST
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
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