ESAB | EPP-201 | Instruction manual | ESAB EPP-201 User manual

ESAB EPP-201 User manual
GB
EPP-201
Instruction manual
0558 007 904 GB 20110513
Valid for serial no. 015-xxx-xxxx
DECLARATION OF CONFORMITY
According to
The Low Voltage Directive 2006/95/EC of 12 December 2006, entering into force 16 January 2007
The EMC Directive 2004/108/EC of 15 December 2004, entering into force 20 January 2005
Type of equipment
Plasma Cutting power source
Brand name or trade mark
ESAB
Type designation etc.
EPP-- 201, Valid from serial number 015 xxx xxxx (2010 w.15)
EPP-- 201 is used in installations for mechanized plasma cutting
Manufacturer or his authorised representative established within the EEA
Name, address, telephone number, telefax number:
ESAB AB
Esabvägen, SE-- 695 81 Laxå, Sweden
Phone: +46 586 81000, Fax: +46 584 411 924
The following harmonised standard in force within the EEA has been used in the design:
EN 60974-- 1, Arc welding equipment – Part 1: Welding power sources
EN 60974-- 10, Arc welding equipment – Part 10: Electromagnetic compatibility (EMC) requirements
Additional information: Restrictive use, Class A equipment, intended for use in locations other than residential.
This apparatus EPP-- 201 constitute a part of the electrical installation of a machine
By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorised
representative established within the EEA, that the equipment in question complies with the safety requirements
stated above.
Place and Date:
Laxå 2010-- 09-- 10
Signatur
Position / Befattning
Global Director
Equipment and Automation
Kent Eimbrodt
Clarification
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© ESAB AB 2010
1 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
6
2.1 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Properties and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
6
3 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
7
4.1 Lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Mains supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.1
Connecting the incoming mains cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Supply and return cables (supplied by the customer) . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.1
Connection of supply and return cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6 Parallel installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.1
Parallel connection of two power sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.2
Marking with two parallel connected power sources . . . . . . . . . . . . . . . . . . . . . . . .
4.7 Connections for supply cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
8
8
9
9
10
10
11
11
12
13
5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
5.1 Connections and control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
5.1.1
Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.1.2
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.2 Operate modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
5.2.1
Power source in single operation (used with CNC, there are two basic operating modes)
16
5.2.2
Several power sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.3 Starting cutting and marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
6 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
6.1 Inspection and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
7 FAULT-TRACING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
7.1 List of fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
8 ORDERING SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDERING NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
24
29
Rights reserved to alter specifications without notice.
TOCe
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GB
1
SAFETY
Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on or
near the equipment observes all the relevant safety precautions. Safety precautions must meet the
requirements that apply to this type of equipment. The following recommendations should be observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well-acquainted with the operation of the equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the operator and damage to the equipment.
1.
Anyone who uses the equipment must be familiar with:
S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding and cutting
2.
The operator must ensure that:
S no unauthorized person is stationed within the working area of the equipment when it is
started up.
S no-one is unprotected when the arc is struck
3.
The workplace must:
S be suitable for the purpose
S be free from drafts
4.
Personal safety equipment
S Always wear recommended personal safety equipment, such as safety glasses, flame-proof
clothing, safety gloves.
S Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5.
General precautions
S Make sure the return cable is connected securely.
S Work on high voltage equipment may only be carried out by a qualified electrician.
S Appropriate fire extinquishing equipment must be clearly marked and close at hand.
S Lubrication and maintenance must not be carried out on the equipment during operation.
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WARNING
Arc welding and cutting can be injurious to yourself and others. Take precausions when welding and
cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard
data.
ELECTRIC SHOCK - Can kill
S
Install and earth the unit in accordance with applicable standards.
S
Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
S
Insulate yourself from earth and the workpiece.
S
Ensure your working stance is safe.
FUMES AND GASES - Can be dangerous to health
S
Keep your head out of the fumes.
S
Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone
and the general area.
ARC RAYS - Can injure eyes and burn skin.
S
Protect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
S
Protect bystanders with suitable screens or curtains.
FIRE HAZARD
S
Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE - Excessive noise can damage hearing
S
Protect your ears. Use earmuffs or other hearing protection.
S
Warn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
Read and understand the instruction manual before installing or operating.
PROTECT YOURSELF AND OTHERS!
WARNING
Do not use the power source for thawing frozen pipes.
CAUTION
Class A equipment is not intended for use in residential locations where
the electrical power is provided by the public low-voltage supply system.
There may be potential difficulties in ensuring electromagnetic
compatibility of class A equipment in those locations, due to conducted
as well as radiated disturbances.
CAUTION
This product is solely intended for plasma cutting.
CAUTION
Read and understand the instruction manual before
installing or operating.
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© ESAB AB 2010
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Dispose of electronic equipment at the recycling facility!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation in accordance with national law, electrical and/or
electronic equipment that has reached the end of its life must be disposed of at a
recycling facility.
As the person responsible for the equipment, it is your responsibility to obtain
information on approved collection stations.
For further information contact the nearest ESAB dealer.
2
INTRODUCTION
Plasma power source EPP 201 is designed for marking and mechanical high speed
plasma cutting. It can be used with, for example, torches PT-15, PT-19XLS, PT-600
and PT-36 together with Smart Flow II, a computer controlled system for gas control
and reconnection.
2.1
Equipment
The power source is supplied with:
S
Instruction manual
2.2
Properties and function
S
Fan cooled
S
Protection in the event of connecting the incorrect power supply
S
Thermal protection in the event of overload
S
Can be connected in parallel to increase the current range.
3
TECHNICAL DATA
EPP201
Mains voltage
3~ 380 V, 400 V +/–10 %, 50 Hz
Mains supply
Ssc min. 7.2 MVA
Zmax. 0.020 Ω
Primary current lmax
64 A at 380 V, 59 A at 400 V
Setting range
marking
cutting
5 A - 200 A
10 A - 36 A
30 A - 200 A
Permissible load
duty cycle 100 %
200 A / 160 V
Efficiency at maximum current
90 %
Power factor at maximum current
0,90
Open-circuit voltage U0
342 V at 380 V
360 V at 400 V
Operating temperature
-10 to 40 °C
Transportation temperature
-20 to 55 °C
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EPP201
Dimensions, l x w x h
1200 x 603 x 1035 mm
Weight
475 kg
Enclosure class
IP21
Mains supply, Ssc min
Minimum short circuit power on the network in accordance with IEC 61000-3-12
Mains supply, Zmax
Maximum permissible line impedance of the network in accordance with IEC 61000-3-11.
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or cut at
a certain load without overloading. The duty cycle is valid for 40° C.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Apparatus marked IP21 are intended for indoor use.
4
INSTALLATION
The installation must be executed by a professional.
WARNING!
ELECTRIC SHOCKS CAN KILL
Take precautionary measures against electric shocks. Ensure that all power
supplies are disconnected – switch off the switch at the wall socket and pull out
the equipment's power cable from the socket before making any electrical
connections in the power source.
WARNING!
Failure to follow these instructions can lead to serious personal injury, death or
property damage. Follow the instructions to prevent accidents and injuries.
Observe local and national electrical safety regulations.
WARNING!
Incorrect earthing can result in personal injury or death. The chassis must be
connected to approved protective earth. Ensure that protective earth is not
connected to any phase terminals by mistake.
CAUTION
This product is intended for industrial use. In a domestic environment this product may
cause radio interference. It is the user's responsibility to take adequate precautions.
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CAUTION!
Conducting dust and contaminants inside the power source can cause electrical flashovers.
This can damage the equipment. If dust is allowed to collect inside to the power source,
short-circuits can occur (see the chapter regarding maintenance).
4.1
Lifting instructions
WARNING
The product must be lifted using a fork
lift truck or as follows:
4.2
Delivery check
1. Remove the packaging and inspect the equipment for damage that was not
immediately apparent upon reception of the delivery.
Immediately report any damage to the delivery company.
2. Check that here are no loose parts in the packaging before it is recycled.
3. Check the cooling air gaps and ensure that any obstacles are removed from
there.
4.3
Location
S
Minimum permitted distance to walls or other cold air obstructions in front of and
behind the power source is 1 m.
S
Place the power source so that the top and side panels can be removed for
maintenance, cleaning and inspection.
S
Place the power source relatively close to a correctly fused mains socket.
S
Keep the surface under the power source clean, so that the cold air does not
bring any contaminants in with it.
S
The area around the equipment must be as free of dust and vapour as possible
and also be as cool as possible. These factors affect the cooling capacity.
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© ESAB AB 2010
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4.4
Mains supply
The power source is 3-phase driven. The power supply must be taken from a socket
equipped with a switch, anti-surges or MCBs, in accordance with local regulations.
Recommended fuse sizes and minimum cable area
ESP 150
50 Hz
380 V
400 V
4 G 35*)
4 G 35*)
Phase current I1eff
64 A
59 A
Fuse, anti-surge
100 A
100 A
Mains voltage
Mains cable area mm 2
*) Supplied by the customer.
NOTE! The mains cable areas and fuse sizes as shown above are in accordance with Swedish
regulations. Use the power source in accordance with the relevant national regulations.
4.4.1
1
Connecting the incoming mains cable
Opening for mains cable in
the rear panel
2
Main earth terminal
3
Phase terminals
1. Remove the small panel from the reverse of the power source.
2. Insert the mains cable through the opening in the rear panel.
3. Secure the cable with the strain relief at the opening.
4. Connect the protective earth to the chassis's main earth terminal.
5. Connect the phase conductors to the phase terminals.
6. Reinstall the panel on the reverse before powering the equipment.
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4.5
Supply and return cables (supplied by the customer)
Supply and return cables for plasma cutting must have a copper conductor with
cross section of 105 mm2 per 400 A and be rated for at least 600 V.
4.5.1
Connection of supply and return cables
1. Open the safety plate from the front of the power source.
2. Insert the cables through the openings at the bottom of the power source
immediately behind the front panel.
3. Connect the cables to the output terminals in the power source.
4. Close the front panel.
Closed front protective panel
Open front protective panel
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4.6
Parallel installation
Two power sources can be connected in parallel for higher current.
4.6.1
Parallel connection of two power sources
CAUTION!
The main power source has the electrode conductor (negative conductor) jumpered. The
auxiliary power source has the return conductor (positive conductor) jumpered.
1. Connect outgoing negative cables to the arc start box (high frequency
generator).
2. Connect the outgoing positive cables to the workpiece.
3. Connect positive and negative cables between the power sources.
4. Connect the pilot arc cable to the pilot arc terminal in the power source. The
auxiliary power source pilot arc connection is not used. The pilot arc circuit is not
connected in parallel.
5. Connect a parallel control cable between both power sources.
6. Connect the CNC control cable to the main power source.
The power source does not have a mains voltage switch. Then mains voltage is
switched off using the switch at the power socket.
Parallel connection of two power sources when both power sources are used.
EPP-201
EPP-201
Auxiliary power source
Main power source
Return cable
(+)
Electrode
(-)
Return cable
(+)
Pilot arc
Parallel control cable for power
sources
Electrode
(-)
Control
cable to
cooling unit
CNC
control
cable
2 pcs positive
cables
600 V 105 mm2
to the workpiece
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1 pcs 600 V conductor
2.5 mm2 to
arc start box (high frequency
generator)
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2 pcs negative cables
600 V 105 mm2
in arc start box
(high frequency
generator)
© ESAB AB 2010
GB
Parallel connection of two power sources when only one power source is
used.
EPP-201
EPP-201
Auxiliary power source
Main power source
Return
cable
Electrode
Return
cable
Electrode
(+)
(-)
(+)
(-)
Parallel control
cable for power sources
2 pcs positive
cables
600 V 105 mm2
to the workpiece
4.6.2
To reset from parallel operation to
single operation, disconnect the
negative cables from the auxiliary
power source and isolate the cable
ends.
Control cable to
cooling unit
2 pcs negative cables 600 V 105 mm2
in arc start box
(high frequency generator)
Marking with two parallel connected power sources
Two parallel connected EPP-201s can be used for marking down to 10 A and for
cutting from 30 A to 400 A.
Operation with two parallel connected power sources
1. The signal supply main power source with digital logic signals for start/stop,
marking/cutting and current range high, and either digital logic input signals or
analogue input signals for controlling pilot current signals to the main power
source for both marking and cutting. Both power sources switch on during
marking, but the auxiliary power source's current output switches off when
marking signals are given.
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4.7
Connections for supply cables
1
Remote operation (CNC)
2
Parallel connected power source
3
Cooling unit
4
Emergency stop connection
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5
OPERATION
General safety regulations for the handling of the equipment can be found on
page 4. Read through before you start using the equipment!
5.1
Connections and control devices
1
Connection for cooling unit
9
2
Connection for parallel connected power
source
10 Switch for control panel or remote control
unit
3
Connection for remote control unit, CNC unit 11 Switch for actual and setpoint value display
4
MCB for CNC unit.
12 Controls for current settings
5
Emergency stop
13 Connection for emergency stop
6
Ammeter
14 Connecting mains cable (supplied by the
customer)
7
Red indicating lamp, restart error
15 Fuse 15 A
8
Orange indicating lamp - Overheating
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Voltmeter
© ESAB AB 2010
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5.1.1
5.1.2
Key to symbols
Over heating (8)
Fault indication (7)
Emergency stop (5)
Emergency stop
connection (13)
Local operation (10)
Remote control unit (10)
Pilot arc current (11)
Current (12)
Control panel
Switch actual value/setpoint value display (11)
Middle position: the cutting parameters; actual value is displayed.
Up mode: setpoint value for pilot arc current during local operation or remote
operation is displayed.
S Mode down: setpoint value for cutting current during local operation or remote
operation is displayed.
Overheating protection (8)
S
S
Lights when the power source has overheated.
Fault indication (7)
Lights in the event of a fault that requires the power source to be restarted.
Current control potentiometer (12)
The range for the power source is 30 to 200 A. Only used in “PANEL” mode.
Switch control panel / remote operation (10)
This switch is used to select where the current is controlled from.
With the switch in the local control mode, PANEL, use the current potentiometer.
With the switch in the remote control mode, REMOTE, the current is controlled
by external signal (CNC).
Display window (6, 9)
S
S
Displays voltage and current during cutting. The ammeter can be activated before
cutting is started, to give an indication of how high the cutting or marking current or
pilot arc current will be, see A above. The display window also shows any fault
codes.
Emergency stop connection (13)
The emergency stop connection gives access to the emergency stop's breaking
contact. The contact is connected to J4-A and J4-B and breaks when the emergency
stop button is pressed. This gives a signal to the plasma cutting equipment stating
that the power source is in emergency stop mode.
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Emergency stop button (5)
The emergency stop button affects the emergency stop switch. When the button is
pressed, emergency stop status is active. The power source cannot provide any
power, even if a start signal is given.
Miniature circuit breaker (MCB) CB1 - 3 A (4)
Switch for 115 VAC to CNC unit.
5.2
Operate modes
In cutting mode, the outgoing current on the power source can be regulated
steplessly from 30 to 200 A using the current potentiometer on the control panel or
with a remote reference signal connected to J1.
When remote reference signals are used, 1 V corresponds to 36 A and 200
corresponds to signal voltage of 5.55 VDC.
The power source has cutting as standard setting. To switch to marking mode, the
control signal for this must be supplied from a remote control unit.
The switch is set to marking mode with an external, isolated relay or external,
isolated switch that connects J1-R (115 VAC) with J1-C. The electrical circuit
diagram is in the inside of the rear panel. Contact closure for marking mode must
occur at least 50 ms before command for start or contact on is given.
In CNC marking mode, the outgoing current can be regulated steplessly from 0 to 36
A using a remote reference signal connected to J1. In local operated marking mode,
the outgoing current can be regulated steplessly from 0 to 18 A using the current
potentiometer on the control panel (standard setting upon delivery). If SW1-1, which
is open on the control panel, closes, the range becomes 0 to 18 A.
When remote reference signals are used, 1 V corresponds to 3.6 A and 36 A
corresponds to signal voltage of 10.00 VDC.
5.2.1
Power source in single operation (used with CNC, there are two basic
operating modes)
1. Local operation from control panel – (switch on the power source) Switch for
local/remote operation in local control mode, PANEL. Used with limited CNC
unit, which only provides start/stop signals to the power source. The
micro-control unit in the power source uses the control panel potentiometer's
analogue setting as setpoint signal for cutting current. From these values, the
micro control unit calculates initial current, pilot arc current and ramp up time.
The current values for cutting and pilot arc can be displayed before cutting, by
moving the return sprung switch to the position for display of the setpoint value
for cutting current respectively pilot arc current. If the pilot arc current seems to
be insufficient the CNC unit can increase it by sending out output signals on
inputs PA0 and PA1. The current increases as follows.
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PAO
PA1
no signal
no signal
no change
signal
no signal
the current increases by 12.5 %
no signal
signal
the current increases by 2,5 %
signal
signal
the current increases by 37,5 %
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© ESAB AB 2010
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See diagram on page24.
The table below, which is used to calculate starting current, pilot arc current and
ramp up time, is stored in the micro control unit.
Cutting current
(A)
Start current
(A)
Pilot arc current
(A)
Ramp up time
(ms)
30
20
15
200
50
25
20
250
100
50
25
500
200
100
30
800
If other values than the table values used for the cutting current, the corresponding
values are calculated assuming a linear ramp for all required parameters.
2. Remote control mode
a. Partial CNC operation – (CNC cable pin V open, open for internal control).
The switch for local/remote operation must be in the REMOTE mode. The
CNC unit must supply setpoint values for cutting current and start/stop
signals to the power source. The micro-control unit in the power source
calculates initial current, pilot arc current and ramp up time from the setpoint
value for cutting current.
b. Remote control mode with full CNC operation – (CNC cable pin V closed,
closed for internal control). The switch for local/remote operation must be in
the REMOTE mode. The CNC unit must activate the input for full CNC
control on pin V in the connection cable. In this mode, all parameters are
controlled by the CNC unit, including initial current, pilot arc current and
ramp times. The pilot arc current can be controlled using a digital logic input
signals or analogue input signals. If the analogue input signal is less than 0.5
V, the power source uses the digital logic signals on the inputs PA0 and PA1
to supply the required pilot arc current, based on the following combination.
PAO
PA1
Pilot arc current (A)
no signal
no signal
10
signal
no signal
20
no signal
signal
30
signal
signal
40
If analogue reference signals are used, 10 VDC gives 45 A and 1 VDC 4.5 A.
Marking – Can be carried out in local operating mode remote control mode. The
input for marking mode must be closed in the CNC unit. In local operating mode,
the marking current is set using the potentiometer on the control panel.
Maximum marking current is 36 A. If SW1-1, which is open on the control panel,
closes, the range becomes max. 0 to 18 A. In remote control mode, the marking
current is regulated by a remote reference signal, 10 VDC gives 36 A and 1 VDC
gives 3.6 A marking current.
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5.2.2
Several power sources
1. Parallel connected operation – Connect the power sources according to section
3.6. Set the switch for local/remote operation in REMOTE mode, on both power
sources. If the units are used for cutting and both power sources are to supply
cutting current, activate the logic input HI CURRENT (pin T) in the CNC cable.
With this setting, the maximum current is 400 A at analogue input signal 10 VDC
from CNC. If the input HI CURRENT is deactivated, the auxiliary source's current
outout switches off, despite it being connected to the main power source. Only
the main power source produces current in marking mode. If marking and cutting
are carried alternately the input HI CURRENT can be left active, whereupon the
input for marking is controlled if both the power sources' current outputs or only
the main power source's is to be active. The current range when marking is 10 to
36 A and when cutting 30 to 400 A.
5.3
Starting cutting and marking
1. Power the equipment by switching on the switch at the power socket (the power
source does not have its own mains power switch). When the current source is
powered, the display window briefly shows EPP-201 and then Pr x.xx, (the
program version number) and then 0 A and 0 V.
2. Set the switch for local/remote operation in the desired mode, depending on
whether the CNC unit can be remotely controlled.
a. During local operation (PANEL mode) you can display the set setpoint value
for cutting current by keeping the switch on the control panel in the position
for display of setpoint for cutting current. In PANEL mode, the power source
calculates pilot arc current, initial current and ramp up time from the set
cutting current setpoint value. You can display the set setpoint value for pilot
arc current by keeping the switch on the control panel in the position for
display of setpoint for pilot arc current. See section 5.1.2 Control panel.
b. In remote control mode, there are two possible operating modes.
1 The standard mode is similar to local operating mode, but the cutting
current signal comes from the CNC unit instead of from the control
panel's potentiometer. The scale for the current signal during remote
control operation is 1.0 VDC = 36 A. This mode can be used if the CNC
unit does not have functions for controlling initial current and ramp times.
Connections for remote control are based on the schedule for the CNC
interface.
2 If the CNC unit has functions for controlling the initial current and ramp
times, set the switch for local/remote control in REMOTE mode, and
connects the pins R and V in the CNC contact. In this mode, the CNC
unit supplies analogue signals for controlling the values for initial current,
ramp up time and cutting current. The scale is the same as in the
standard mode. The pilot arc current is regulated by another analogue
signal, 0–10 VDC, if applicable, or using a binary signal according to the
schedule for the CNC unit's interface. The scale for the pilot arc current
signal is 10 VDC = 45 A.
3. Start plasma cutting. Variables such as gas pressure, flow, torch height etc. may
need to be set.
4. If cutting/marking, for any reason, cannot be initiated, the power source displays
a fault code that indicates the cause of the fault, see Fault codes in the fault
tracing section.
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© ESAB AB 2010
GB
6
MAINTENANCE
CAUTION
All guarantee undertakings from the supplier cease to apply if the customer himself
attempts any work in the product during the guarantee period in order to rectify any faults.
WARNING!
ELECTRIC SHOCKS CAN KILL
Switch off the switch at the power socket before starting maintenance work.
WARNING!
Risk of eye injuries when blow cleaning with compressed air.
S Use approved eye protection with side guards when cleaning the power
source.
S Only use low pressure air.
WARNING!
Risk of electric shock!
Always reinstall all covers that were removed when cleaning, before switching the
power back on.
CAUTION!
The maintenance may only carried out by persons with the appropriate training.
CAUTION!
If the cold air flow is blocked for any reason, EPP-201 can overheat.
The thermo switches can then deploy and prevent continued operation.
Do not use air filters on this power source.
Keep cold air passages clear of dust and obstructions.
Regular maintenance is important for safe, reliable operation.
Only those persons who have appropriate electrical knowledge (authorized
personnel) may remove the safety plates.
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© ESAB AB 2010
GB
6.1
Inspection and cleaning
The following points on the power source should be checked and/or cleaned
regularly.
1. Check the return cable connection to the workpiece.
2. Check that the protective earth from the work piece is securely connected to the
power source chassis earth.
3. Check the torch heat shield. Replace it if it is damaged.
4. Check the electrode and the nozzle for wear daily. Remove any splash, replace
the electrode and nozzle as necessary.
5. Check that the cables or hoses are not damaged or bent.
6. Check that all plugs and connections and ground terminal are firmly connected.
7. Using dry, clean, low pressure compressed air, blow clean any dust from all air
ducts from all components, especially from cooling fins in the front part of the
power source. Dust is a heat insulator and reduces the cooling capacity. Use eye
protection.
8. Ensure that all incoming power supplies are disconnected. Use goggles and face
mask and blow clean the power source internally using dry compressed air at
low pressure .
7
FAULT-TRACING
WARNING!
ELECTRIC SHOCKS CAN KILL
Never allow persons other than those with the applicable knowledge to check or
repair the equipment. Electrical work must always be carried out by authorised
electricians.
CAUTION!
Stop all work immediately if the power source does not work correctly.
Only allow qualified people to fault trace the equipment.
Only use recommended spare parts.
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© ESAB AB 2010
GB
Try these recommended checks and inspections before sending for an authorized
service technician.
Type of fault
Corrective action
No arc.
S
S
S
The current is interrupted during welding.
S
S
Check that the mains power supply switch is
turned on.
Check that the return cables are correctly
connected.
Check that the correct current value is set.
Check whether the thermal overload trips
have operated (indicated by the lamp on the
front panel).
Check the mains power supply fuses.
The thermal cut-out trips frequently.
S
Make sure that you are not exceeding the
rated data for the power source (i.e. that the
unit is not being overloaded).
Poor cutting performance.
S
Check that the return cables are correctly
connected.
Check that the correct current value is set.
Check that the correct electrode is being
used.
Check the mains power supply fuses.
S
S
S
7.1
List of fault codes
01
LINE VOLT, IDLE
08
TORCH ERROR
15
BUS CHARGER FAILURE
02
LINE VOLT, CUTTING
09
OCV OVER 40V, IDLE
17
IGBT DRIVER ERROR
03
CONTROL BIAS
10
OCV OVER 70V,
STARTUP
18
CUT/MARK VOLTAGE
TOO LOW
04
THERMAL (SWITCH
OPEN)
12
1Ф OPERATION,
SHUTDOWN
19
SLAVE P/S NOT
DETECTED
05
START ON POWER UP
13
OCV FAILURE
20
SHORTED IGBT, BUS
CHARGED
06
FAIL TO FIRE
14
AMBIENT TEMP
113 SLAVE P/S ERROR
Code
The fault code's content for power source EPP-201.
01
Deviation greater than +/- 15 % in idle mode.
02
Mains voltage drops more than 20 % while cutting.
03
Problem with pre-voltage supply on the control card. Supplies +15 respectively -15 V are not
balanced, the card must be replaced.
04
A thermal overload has tripped. The power source cannot be activated until the overheated
components have cooled. Check that all fans work and that no ventilation openings are
blocked.
05
The start switch on the CNC unit was switched on when the power source was powered.
Switch the switch off and on to commission the power source.
06
The arc is not lit within 10 seconds.
NOTE! The CNC unit has a shorter permitted waiting time for arc lighting and therefore
normally resets the power source to idle mode before this fault can occur.
08
The electrode current occurred before pulse width modulation was activated. Probably
caused by the electrode lying against the nozzle in the torch.
09
Open-circuit voltage in idle mode greater than 40 V. May be caused by leaking IGBT or
defective pulse with modulating card.
bp06de2
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© ESAB AB 2010
GB
Code
The fault code's content for power source EPP-201.
10
Open-circuit voltage greater than 70 V when voltage is switched on. May be caused by
leaking IGBT or defective pulse with modulating card.
12
Shutdown due to phase drop. The fuse has tripped in the power supply circuit.
13
Open-circuit voltage did not reach 300 V within the permitted time. Check the pulse width
modulated circuit and emergency stop on J1.
14
Temperature in control and regulation cabinet greater than 55 °C.
15
Bus voltage did not reach 100 V within the permitted time. Bus charging relay or transient
protection resistor defective.
17
Fault on IGBT control card.
18
Cutting voltage fell below 70 V during cutting or below 40 V during marking.
19
The main power source receives signals to power the auxiliary power source, but there is no
auxiliary power source.
20
Open-circuit voltage detected before pulse width modulation was activated.
113
Fault in auxiliary power source.
8
ORDERING SPARE PARTS
EPP-201 is designed and tested in accordance with the international and European
standards EN 60974-1 and EN 60974-10. It is the obligation of the service unit which
has carried out the service or repair work to make sure that the product still conforms
to the said standard.
Repair and electrical work should be performed by an authorized ESAB serviceman.
Use only ESAB original spare and wear parts.
Always state the manufacturer number of the unit that the spare part order refers to.
The manufacturing number is on the rating plate of the unit.
Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication.
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© ESAB AB 2010
p
- 23 -
Diagram
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© ESAB AB 2010
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© ESAB AB 2010
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© ESAB AB 2010
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© ESAB AB 2010
CABLE
WIRE ID
PA ON
24-CONDUCTOR
CONNECTOR
24 CONDUCTOR CABLE
Plasma System Control
A
PA ON
B
WC FLOW FAULT: ON WITH FLOW OK
RED 01
WC FLOW FAULT: OFF WITH LO FLOW
RED 02
MARK MODE SELECT
CLOSED FOR MARKING
I mark = (3.6) X (Vcut cur ref)
MARK MODE SELECT
C
RED 03
Z
10K
115V AC NEUTRAL
RED 04
E-- STOP: ISOLATED CONTACT
CLOSED TO RUN
24V AC
E
RED 05
F
K4
E-- STOP
E-- STOP
RED 06
15V
15V CNC
COMMON
0 TO 10V
0 TO 10V
+
PLASMA START
+
CNC +15V DC
H
MASTER SELECT
J
CURRENT REF COM
K
WC LEVEL (ON W/ LEVEL OK)
L
+
CUT CURRENT REF
M
PLASMA START
N
+
PA CURRENT REF
P
ARC ON
10K
RED 10
20K
CUT CURRENT REF
Icut = (36) X (Vcut cur ref)
RED 11
20K
RED 12
ARC ON
10K
CNC +15V DC
PA CURRENT REF
Ipa = (4.5) X (Vpa cur ref)
RED 13
RED 14
RED 15
R
RED 16
RED 17
FOR LO: Icut = (20) X (Vcut cur ref)
CURRENT HI/LO
FOR HI: Icut = (40) X (Vcut cur ref)
CLOSED FOR 400A; OPEN FOR 200A
RED 18
(PARALLEL OPERATION ONLY)
RED 19
OPEN FOR INTERNAL CONTROL
CLOSED FOR EXTERNAL CONTROL
S
10K
115V AC H
PA1
PA CURRENT SELECT
10K
T
HI RANGE (400A)
10K
U
not used (reserved for P/A continuous)
V
PROCESS CONTROL SELECTION
W
POWER SOURCE FAULT
ON WITH FAULT
10K
RED 20
POWER SOURCE FAULT
FUSE
PA CURRENT SELECT
not used
PA CURRENT SELECT
Q PA0
PA CURRENT SELECT
115V AC
+
G
115V AC NEUTRAL
CNC
RED 07
MASTER SELECT - CONNECT H TO R (ALWAYS PRESENT)
RED 08
CNC ANALOG COMMON
WC LEVEL: OFF
RED 09
WITH FAULT
10K
RED 21
X
+
24V
PS 24V DC COMMON
RED 22
MASTER CURRENT
Y
RED 23
GRN/YEL
D
HALL TRANSDUCER
+
MASTER OUTPUT CURRENT
SIGNAL 1.0V = 100A
24V DC
COMMON
CHASSIS
bp06e
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© ESAB AB 2010
3A
EPP-201
Ordering number
Ordering no.
Denomination
Type
0558 007 800 Plasma cutting
EPP-201
0463 148 086 Instruction manual RU
EPP-201
Notes
380 V / 400 V, 50 Hz
Instruction manuals are available on the Internet at www.esab.com
bp06o
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© ESAB AB 2010
NOTES
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notes
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© ESAB AB 2010
NOTES
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notes
- 31 -
© ESAB AB 2010
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna-Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
BELGIUM
S.A. ESAB N.V.
Brussels
Tel: +32 2 745 11 00
Fax: +32 2 745 11 28
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AS ESAB
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Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
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Tel: +1 905 670 02 20
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Tel: +20 2 390 96 69
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Tel: +27 (0)21 975 8924
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 2326 3000
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Amersfoort
Tel: +31 33 422 35 55
Fax: +31 33 422 35 44
www.esab.com
© ESAB AB
110426
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