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ESAB EPP-600 Instruction Manual

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EPP-600
Plasma Power Source
Instruction Manual
0558006514
08/2010

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Summary of Contents for ESAB EPP-600

  • Page 1 EPP-600 Plasma Power Source Instruction Manual 0558006514 08/2010...

  • Page 2: User Responsibility

    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,”...

  • Page 3: Table Of Contents

    4.5 EPP-600 V-I Curves........

  • Page 5: Safety Precautions

    sectIon 1 safetY precautIons safety precautions safety - english WarnIng: These Safety Precautions are fIres anD explosIons -- heat from for your protection. They summarize pre- flames and arcs can start fires. hot cautionary information from the references slag or sparks can also cause fires and listed in Additional Safety Information sec- explosions.
  • Page 6 sectIon 1 safetY precautIons 1. Be sure the power source frame (chassis) is con- 3. Welders should use the following procedures to nected to the ground system of the input power. minimize exposure to EMF: 2. Connect the workpiece to a good electrical A.
  • Page 7 sectIon 1 safetY precautIons 5. WarnIng: this product, when used for welding 1. Always have qualified personnel perform the instal- or cutting, produces fumes or gases lation, troubleshooting, and maintenance work. which contain chemicals known to Do not perform any electrical work unless you are the state of california to cause birth qualified to perform such work.
  • Page 8 sectIon 1 safetY precautIons 5. AWS C5.5 - "Recommended Practices for Gas Tung- sten Arc Welding“ 6. AWS C5.6 - "Recommended Practices for Gas Metal Arc Welding"“ 7. AWS SP - "Safe Practices" - Reprint, Welding Hand- book. 8. ANSI/AWS F4.1, "Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances."...
  • Page 9 seccIon 1 segurIDaD safety - spanish La escoria puede estar caliente y desprenderse con velocidad. Personas cercanas deberán usar gafas aDVertencIa: Estas Precauciones de Se- de seguridad y careta protectora. guridad son para su protección. Ellas hacen resumen de información proveniente de las fuego Y explosIones -- el calor de referencias listadas en la sección "Información Adi- las flamas y el arco pueden ocacionar...
  • Page 10 seccIon 1 segurIDaD 1. Asegúrese de que el chasis de la fuente de poder 3. Los soldadores deberán usar los siguientes proced- esté conectado a tierra através del sistema de imientos para minimizar exponerse al EMF: electricidad primario. 2. Conecte la pieza de trabajo a un buen sistema de A.
  • Page 11 seccIon 1 segurIDaD 5. aDVertencIa-- este producto cuando se uti- 1. Siempre tenga personal cualificado para efec- liza para soldaduras o cortes, tuar l a instalación, diagnóstico, y mantenimiento produce humos o gases, los del equipo. No ejecute ningún trabajo eléctrico a cuales contienen químicos menos que usted esté...
  • Page 12 seccIon 1 segurIDaD sIgnIfIcaDo De los sIMBolos -- según usted avanza en la lectura de este folleto: los símbolos sig- nifican ¡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.
  • Page 13 sectIon 1 sÉcurItÉ safety - french IncenDIes et explosIons -- la chaleur provenant des flammes ou de aVertIsseMent : Ces règles de sécurité l'arc peut provoquer un incendie. le ont pour but d'assurer votre protection. Ils laitier incandescent ou les étincelles récapitulent les informations de précaution provenant des références dans la section peuvent également provoquer un...
  • Page 14 sectIon 1 sÉcurItÉ 1. Assurez-vous que le châssis de la source 3. Les soudeurs doivent suivre les procédures suivantes d'alimentation est branché au système de mise à pour minimiser l'exposition aux champs électriques la terre de l'alimentation d'entrée. et magnétiques : 2.
  • Page 15 sectIon 1 sÉcurItÉ 5. aVertIsseMent : ce produit, lorsqu'il est utilisé entretIen De l'ÉQuIpeMent -- un équipe- dans une opération de soudage ou de ment entretenu de façon défectueuse ou coupage, dégage des vapeurs ou des inadéquate peut causer des blessures gaz contenant des chimiques consi- graves ou mortelles.
  • Page 16 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.

  • Page 17: Description

    The EPP power source is designed for marking and high speed plasma mechanized cutting applications. It can be used with other ESAB products such as the PT-15, Pt-19XLS, PT-600 and PT-36 torches along with the Smart Flow II, a computerized gas regulation and switching system.

  • Page 18: Dimensions And Weight

    sectIon 2 DescrIptIon Dimensions and Weight 114.3 mm 94.6 mm 45.00” 37.25” 102.2 mm 40.25” Weight = 825 kg. (1814 lbs.)

  • Page 19: Installation

    Plan for top panel and side panels having to be removed for maintenance, cleaning and inspection. • Locate the EPP-600 relatively close to a properly fused electrical power supply. • Keep area beneath power source clear for cooling air flow.

  • Page 20: Input Power Connection

    Wall DIsconnect sWItch to turn poWer off. 3.4.1 primary power EPP-600 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.
  • Page 21 Input conductors must be terminated with ring terminals. notIce Input conductors must be terminated with ring terminals sized for 12.7 mm (0.50”) hardware before being attached to the epp-600. 3.4.3 Input connection procedure 1. Remove left side panel of the EPP-600 2.

  • Page 22: Output Connection

    sectIon 3 InstallatIon electrIc shocK can KIll! rIng terMInals Must haVe clearance BetWeen sIDe panel WarnIng anD MaIn transforMer. clearance Must Be suffIcIent to preVent possIBle arcIng. MaKe sure caBles Do not Inter- fere WIth coolIng fan rotatIon. IMproper grounDIng can result In Death or InJurY. WarnIng chassIs Must Be connecteD to an approVeD electrIcal grounD.

  • Page 23: Parallel Installation

    4. Replace panel removed during the first step. Access Panel 3.6 parallel Installation Two EPP-600 power sources may be connected together in parallel to extend the output current range. parallel power source minimum output current exceeds recommend- ed amounts when cutting below 100a.
  • Page 24 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 EPP-600 power sources with both power sources in operation. EPP-600...
  • Page 25 3 InstallatIon The EPP-600 does not have an ON/OFF switch. The main power is controlled through the line (wall) disconnect switch. Do not operate the epp-600 WIth coVers reMoVeD. hIgh Voltage coMponents are exposeD IncreasIng shocK WarnIng haZarD. Internal coMponent MaY Be DaMageD Because coolIng fans WIll lose effIcIencY.

  • Page 26: Interface Cables

    3.6.2 Marking with two parallel epp-600’s Two EPP-600’s, connected in parallel, and can be used for marking down to 24A and cutting from 100A up to 1000A. Two simple modifications can be made to the Supplemental Power Source in order to permit marking down to 12A. The modi- fications are necessary only if marking down to 12A is required.
  • Page 27 sectIon 3 InstallatIon 3.7.1 cnc Interface cables with Mating power source connector and unterminated cnc Interface GRN/YEL RED #4 3.7.2 cnc Interface cables with Mating power source connectors at Both ends GRN/YEL RED #4...
  • Page 28 sectIon 3 InstallatIon 3.7.3 Water cooler Interface cables with Mating power source connectors at Both ends...

  • Page 29: Operation

    sectIon 4 operatIon 4.1 Block Diagram circuit Description...
  • Page 30 4.1 Block Diagram circuit Description (con’t.) The power circuit utilized in the EPP-600 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, con- sisting primarily of an inductor (sometimes called a choke), converts the pulses to a relatively constant DC (Direct Current) output.
  • Page 31 Each chopper contains IGBT’s, Free Wheeling Diodes, a Hall Sensor, a Filter Inductor, and Blocking Diodes. The IGBT’s are the electronic switches that, in the EPP-600, turn on and off 10,000 times per second. They provide the pulses of power filtered by the inductor.

  • Page 32: Control Panel

    Indicator illuminates when a serious fault is detected. Input power must be disconnected for at least 5 seconds and then reapplied. F - Current Dial (Potentiometer) EPP-600 dial shown. EPP-600 has a range of 12 to 600 A. Used only in panel mode.
  • Page 33 LOW is used. This can vary depending on gas, material and torch used. High/Low settings are specified in cutting data included in the torch manual. When the EPP-600 is set to marking mode, this switch must be in the low position.
  • Page 34 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.
  • Page 35 7.50VDC. For signals over 8.00V, the power source internally limits the output current to a typical value of 680A. The EPP-600 defaults to the Cutting Mode of operation unless the command signal from a remote control for Marking Mode is supplied.

  • Page 36: Sequence Of Operation

    Operation 4.3 Sequence of Operation 1. Apply power by closing the line (wall) switch. Apply power by closing the line (wall) switch. (The EPP-600 Apply Power (The ESP-400C does not have an on/off does not have an on / off switch). The main power light will switch).

  • Page 37: 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 gradu- ally ramps up to full current. The EPP-600 is factory shipped with soft start enabled. The default settings are: Minimum Start Current .
  • Page 38 sectIon 4 operatIon 4.4.1 enable/Disable arc Initiation conditions Factory default setting shown. 1. Remove access panel on the upper-right corner of the front panel. Be sure to replace this panel after adjustments have been made. 2. Locate SW1 and PCB1 and push both rocker switches down to disable. To enable push both switches up. (If one switch is up and the other is down, arc initiation time is considered on.) Factory default settings shown 4.4.2 adjusting arc Initiation Dwell timer...
  • Page 39 sectIon 4 operatIon 4.4.4 arc Initiation controls Start Current Potentiometer UP-Slope Timer 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..

  • Page 40: Epp-600 V-I Curves

    4 operatIon 4.5.1 epp-600 V-I curves for 460V and 575V, 60hz Inputs OUTPUT VOLTAGE (Volts) Output Voltage (Volts) = 0.150V MIN MARK RATING = 0.150V Min. Marking Current = 0.625V MIN CUT RATING = 0.625V Min. Cutting Current = 1.000V = 1.000V...
  • Page 41 4 operatIon 4.5.2 epp-600 V-I curves for 380-400V, 50/60hz Inputs OUTPUT VOLTAGE (Volts) Output Voltage (Volts) = 0.150V MIN MARK RATING = 0.150V Min. Marking Current = 0.625V MIN CUT RATING Min. Cutting Current = 0.625V = 1.000V = 1.000V = 2.000V...
  • Page 42 sectIon 4 operatIon...

  • Page 43: Maintenance

    sectIon 5 MaIntenance 5.1 general electrIc shocK can KIll! WarnIng shut off poWer at the lIne (Wall) DIsconnect Before at- teMptIng anY MaIntenance. eYe haZarD When usIng coMpresseD aIr to clean. WarnIng • Wear approved eye protection with side shields when cleaning the power source.

  • Page 44: Lubrication

    5 MaIntenance air restrictions may cause epp-600 to over heat. thermal switches may be activated causing interruption of func- cautIon tion. Do not use air filters on this unit. Keep air passages clear of dust and other obstructions. 5.3 lubrication •...

  • Page 45: Troubleshooting

    sectIon 6 trouBleshootIng 6.1 general electrIc shocK can KIll! WarnIng Do not perMIt untraIneD persons to Inspect or repaIr thIs eQuIpMent. electrIcal WorK Must Be perforMeD BY an expe- rIenceD electrIcIan. stop work immediately if power source does not work properly. cautIon have only trained personnel investigate the cause.
  • Page 46 sectIon 6 trouBleshootIng Fault Indicator (Front Panel) Illuminates when there are abnormalities in the cutting process or when the input voltage falls ±10% outside the normal value. Momentary illumination is normal. If continuously lit, check LEDs 3, 4, 5, 7, and 8 on PCB1 for further diagnosis. LED 3 –...
  • Page 47 sectIon 6 trouBleshootIng Power Reset Fault Indicator (on front panel) Illuminates when a serious fault is detected. Input power must be disconnected for a least 5 seconds to clear this fault. Check PCB1 Red LEDs 6, 9, 10, 11, 12, and 13 if this fault is illuminated for further diagnosis.

  • Page 48: Fault Isolation

    sectIon 6 trouBleshootIng 6.3 fault Isolation Many of the most common problems are listed by symptom. 6.3.1 Fans not working 6.3.2 Power not on 6.3.3 Fault Light Illumination 6.3.4 Torch won’t fire 6.3.5 Fusses Blown F1 and F2 6.3.6 Intermittent, Interrupted or Partial Operation 6.3.1 fans not Working problem possible cause...
  • Page 49 sectIon 6 trouBleshootIng 6.3.3 fault light Illumination problem possible cause action Normal condition caused when ter- Fault light illuminates at the end of Reprogram cutting process to minating the arc by running the torch cut but goes off at the start of the ensure arc is terminated only by off the work or the arc being attached next.
  • Page 50 sectIon 6 trouBleshootIng problem possible cause action Output current of the right side exceeds Turn the output current down to 300A because of operating the power source 400A over 600A. Cutting at over 400A with a faulty left side See faulty left or right side (left side output = 0) Right current transducer connector loose LED 6 –...
  • Page 51 sectIon 6 trouBleshootIng problem possible cause action Shorted IGBT Replace the IGBTs Current pot set too high Lower the current setting Very high Output current ac- companied by either a left or Faulty left PWM / Drive PCB Replace left PWM / Drive PCB right over current (LED 6) High remote current signal Decrease remote current signal...
  • Page 52 sectIon 6 trouBleshootIng problem possible cause action Loose or unplugged P1 connector at Secure P1 connector the left PWM / Drive PCB Loose or unplugged P10 connector LED 12 – (red) Left –12V Missing Secure P10 connector at PCB1 Replace left PWM / Drive PCB Faulty left PWM / Drive PCB 0558038308 Loose or unplugged P1 connector at...
  • Page 53 sectIon 6 trouBleshootIng 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 Check for current reference signal at TB1- short “pop”, placing only a small dimple...
  • Page 54 sectIon 6 trouBleshootIng 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 applica- soon after providing the “Contactor tion of the “Contactor On” signal and On”...
  • Page 55 sectIon 6 trouBleshootIng problem possible cause action Power source is OK. Trouble shoot pro- “Contactor On” signal is removed from unit. cess controller. Restore and maintain input voltage Momentary loss of primary input power. within ±10% of nominal. Remove control PCB (PCB1) access panel Faulty condition, indicated by illumination to determine the fault causing the shut- of the fault lamp.

  • Page 56: Testing And Replacing 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 distribu- tor for a replacement. Provide the distributor with the part number of the board as well as the serial number of the power source.
  • Page 57 sectIon 6 trouBleshootIng 6.4.1 power rectifiers Power Rectifiers – Procedure to access behind the front panel Remove top cover and side panels Locate and disconnect plug in rear of ammeter (at- tached tone red and one black wire) Remove pilot arc switch Disconnect voltmeter Disconnect orange and yellow wires from relay K4.
  • Page 58 sectIon 6 trouBleshootIng NEG Plate Diode Rectifier 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. If fuses F8 and/or F9 were open in the first step, make two more ohmmeter readings.
  • Page 59 sectIon 6 trouBleshootIng 6.4.2 IgBt / freewheeling Diode (fWD) replacement the emitter and the gate of each affected IgBt must be jum- cautIon pered together to prevent electrostatic damage. each power source is supplied with six jumper plugs that mate to the IgBt gate / emitter plug.
  • Page 60 sectIon 6 trouBleshootIng replaceMent: A. Thoroughly clean any thermal compound from the heat sink and the modules. Any foreign material trapped between the module and heat sink, other than an appropriate thermal interface, can cause module damage due to over heat- ing.
  • Page 61 sectIon 6 trouBleshootIng 6.4.3 power shunt Installation Instability or oscillation in cutting current can be caused by im- cautIon proper 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).

  • Page 62: Control Circuit Interface Using J1 And J6 Connectors

    0.75%. 6.5 control circuit Interface using J1 and J6 connectors Interface to the EPP-600 control circuitry is made with connectors J1 and J6 on the front panel. J1 has 24 conductors, and J6 has 8.
  • Page 63 sectIon 6 trouBleshootIng (80)

  • Page 64: Auxiliary Main Contactor (K3) And Solid State Contactor Circuits

    sectIon 6 trouBleshootIng 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.

  • Page 65: Main Contactor (K1A, K1B And K1C) Activation Circuit

    sectIon 6 trouBleshootIng 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.

  • Page 66: Arc Current Detector Circuits

    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 EPP-600 is off. It opens whenever primary power is supplied to the power source, and it closes when main arc current is established.

  • Page 67: Current Control Pot And Remote Vref

    High Speed input (P8-3), the EPP-600 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 EPP-600 will respond to a change in Vref within 50 mS. The slower...

  • Page 68: Pilot Arc Hi / Lo And Cut / Mark Circuits

    Pilot Arc Hi/Lo switch on the front panel must be in the “LO” position. The EPP-600 is placed in the Marking mode when a remote contact connecting 115V AC from J1-R to J1-C operates K11. In the Marking mode, a normally closed contact on K11 opens turning off K10.

  • Page 69: Replacement Parts

    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.
  • Page 70 sectIon 7 replaceMent parts...
  • Page 71 sectIon 7 replaceMent parts...
  • Page 72 sectIon 7 replaceMent parts...
  • Page 73 sectIon 7 replaceMent parts...
  • Page 74 sectIon 7 replaceMent parts...
  • Page 75 7 replaceMent parts EPP-400 Only - 2 Places EPP-600 Only - 2 Places...
  • Page 76 sectIon 7 replaceMent parts...
  • Page 77 sectIon 7 replaceMent parts...
  • Page 78 sectIon 7 replaceMent parts...
  • Page 79 sectIon 7 replaceMent parts...
  • Page 80 sectIon 7 replaceMent parts...
  • Page 81 sectIon 7 replaceMent parts 35751Y 35752Y 0558006169...
  • Page 82 sectIon 7 replaceMent parts 17280215 R10, 11 Resistor 1.5K OHMS 100W R28-31 951198 FERRITE CORE...
  • Page 83 sectIon 7 replaceMent parts...
  • Page 84 sectIon 7 replaceMent parts...
  • Page 85 sectIon 7 replaceMent parts...
  • Page 86 sectIon 7 replaceMent parts 0558954035...
  • Page 87 sectIon 7 replaceMent parts 3.62 W 4600610...
  • Page 88 notes...

  • Page 89: Revision History

    reVIsIon hIstorY 1. Original release - 08 / 2006 2. Changed 400V callout to 380-400V. 3. Revision 08/2010 - Updated with new DOC form.
  • Page 90 Welding & cutting products, florence, sc coMMunIcatIon guIDe - custoMer serVIces 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 ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693...

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