ESAB Precision Plasmarc EPP-600 Manual
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ESAB Precision Plasmarc EPP-600 Manual

ESAB Precision Plasmarc EPP-600 Manual

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Table of Contents
  • Table of Contents

  • 1 Sikkerhedsforanstaltninger

  • 2 Beskrivelse
    • Introduktion
    • Generelle Specifikationer
    • Dimensioner Og Vægt

  • 3 Installation
    • Generelt
    • Udpakning
    • Placering
    • Indgangsstrømtilslutning
    • Udgangsstrømtilslutning
    • Parallel Installation
    • Interface-Kabler

  • 4 Betjening

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EPP-600
Plasmastrømkilde
Instruktionsbog (DA)
0558006942
08/2010

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Summary of Contents for ESAB Precision Plasmarc EPP-600

  • Page 1 EPP-600 Plasmastrømkilde Instruktionsbog (DA) 0558006942 08/2010...
  • Page 2 SØRG FOR AT OPERATØREN FÅR DENNE INFORMATION. DU KAN FÅ EKSTRA KOPIER GENNEM DIN LEVERANDØR. FORSIGTIG Disse INSTRUKTIONER er til brug for erfarne operatører. Hvis du ikke er fuldstændig fortrolig med betjeningsprincipperne og sikkerhedsforskrifterne i forbindelse med lysbuesvejsning og skæreud- styr, beder vi dig indtrængende om at læse vor brochure "Forholdsregler og Sikkerhedsprocedurer i forbindelse med Lysbuesvejsning, Skæring og Fugebrænding".

  • Page 3: Table Of Contents

    INDHOLDSFORTEGNELSE Sektion / Titel Side Sikkerhedsforanstaltninger ................5 Beskrivelse.

  • Page 5: Sikkerhedsforanstaltninger

    SIKKERHEDSFORANSTALTNINGER Sikkerhedsforanstaltninger Brugere af ESAB svejseudstyr og plasmaskæreudstyr har det ultimative ansvar for at tilsikre, at enhver, der arbejder på eller tæt ved udstyret, overholder alle relevante sikkerhedsforanstaltninger. Sikkerhedsforanstaltningerne skal overholde de krav, der gælder for denne type svejseudstyr eller plasmaskæreudstyr. Følgende anbefalinger bør følges udover de standardregulativer, der gælder for arbejdsstedet.
  • Page 6 SEKTION 1 SIKKERHEDSFORANSTALTNINGER SVEJSNING OG PLASMASKÆRING KAN VÆRE SKADELIG FOR DIG SELV ADVARSEL OG ANDRE. TAG DINE FORHOLDSREGLER, NÅR DU SVEJSER ELLER SKÆRER. BED DIN ARBEJDSGIVER OM SIKKERHEDSPROCEDURER, SOM BØR VÆRE BASERET PÅ FABRIKANTENS RISIKODATA. ELEKTRISK STØD - Kan dræbe. - Montér og jordforbind (jord) svejseudstyret eller plasmaskæreudstyret i overensstemmelse med gældende normer.

  • Page 7: Beskrivelse

    BESKRIVELSE 2.1 Introduktion EPP strømkilden er konstrueret til markering og højhastighedsmekaniserede plasmaskæreapplikationer. Den kan anvendes sammen med andre ESAB-produkter så som PT-15, PT-19XLS, PT-600 og PT-36 skærebrændere samt Smart Flow II - et computerstyret gasregulerings- og omskiftersystem. • 12 til 600 Amp til markering •...

  • Page 8: Dimensioner Og Vægt

    SEKTION 2 BESKRIVELSE 2.3 Dimensioner og vægt 114,3 cm 94,6 cm 45.00” 37.25” 102,2 cm 40.25” Vægt = 825 kg (1814 pund)

  • Page 9: Installation

    SEKTION 3 INSTALLATION 3.1 Generelt HVIS MAN UNDLADER AT FØLGE ANVISNINGERNE, KAN DET FØRE ADVARSEL TIL DØD, PERSONSKADE ELLER BESKADIGELSE PÅ EJENDOM. MAN SKAL FØLGE DISSE ANVISNINGER FOR AT UNDGÅ PERSONSKADE ELLER BESKADIGELSE PÅ EJENDOM. MAN SKAL OVERHOLDE DE LO- KALE MYNDIGHEDERS FORSKRIFTER ELLER DE NATIONALE ELEKTRI- CITETS- OG SIKKERHEDSFORSKRIFTER.

  • Page 10: Indgangsstrømtilslutning

    SEKTION 3 INSTALLATION 3.4 Indgangsstrømtilslutning ELEKTRISK STØD KAN DRÆBE! ADVARSEL MAN SKAL SØRGE FOR MAKSIMAL BESKYTTELSE MOD ELEKTRISK STØD. FØREND MAN TILSLUTTER NOGET SOM HELST INDENI MASKINEN, SKAL MAN ÅBNE LEDNINGSAFBRYDERKONTAKTEN PÅ VÆGGEN FOR AT SLUKKE FOR STRØMMEN. 3.4.1 Primærstrøm EPP-600 er en 3-faset enhed.
  • Page 11 SEKTION 3 INSTALLATION 3.4.2 Indgangsstrømledere • Leveret af kunden • Kan bestå af enten kraftigt gummibelagte kobberstrømledere (tre strøm og én jord), eller de kan være ført gennem en fast eller bøjelig ledningskanal. • Størrelse i henhold til diagrammet. Indgangsstrømledere skal være afsluttet med ringterminaler. BEMÆRK Indgangsstrømledere skal være afsluttet med ringterminaler til ma- terialestørrelser på...

  • Page 12: Udgangsstrømtilslutning

    SEKTION 3 INSTALLATION ELEKTRISK STØD KAN DRÆBE! DER SKAL VÆRE AFSTAND FRA RINGTERMINALER TIL SIDEPANEL ADVARSEL OG HOVEDTRANSFORMER. AFSTANDEN SKAL VÆRE SÅ STOR, AT MAN UNDGÅR MULIG GNISTDANNELSE. SØRG FOR AT KABLERNE IKKE KOMMER I VEJEN FOR DEN ROTERENDE AFKØLINGSVENTILA- TOR.

  • Page 13: Parallel Installation

    SEKTION 3 INSTALLATION 3.5.2 Procedure for udgangsstrømtilslutning 1. Fjern adgangsdækslet på den nederste, forreste del af strømkilden. 2. Træk udgangskablerne igennem åbningerne nederst på det forreste panel eller nederst på strømkilden umiddelbart bagved det forreste panel. 3. Tilslut kablerne til de tilhørende terminaler, der er monteret inde i strømkilden ved brug af UL-godkendte tryklednings- konnektorer.
  • Page 14 SEKTION 3 INSTALLATION 3.6.1 Tilslutninger til to parallelle EPP-600'ere Bemærk: Elektrode (-) strømlederen er jumpered på primærstrømkilden. Den supplerende strømkilde er jumpe- red på arbejdet (+). 1. Tilslut de negative (-) udgangskabler til lysbuens startanordning (høj-frekvens generator). 2. Tilslut de positive (+) udgangskabler til arbejdsstykket. 3.
  • Page 15 SEKTION 3 INSTALLATION EPP-600 har ikke en TÆND/SLUK (ON/OFF) knap. Netstrømmen kontrolleres via ledningsafbryderkontakten (væg). EPP-600 MÅ IKKE BETJENES, NÅR DÆKSLERNE ER TAGET AF. KOMPONENTER MED HØJ SPÆNDING ER SYNLIGGJORTE OG ØGER ADVARSEL FAREN FOR STØD. INTERNE KOMPONENTER KAN BESKADIGES, FORDI AFKØLINGS- VENTILATORERNE MISTER VIRKNINGSGRADEN.

  • Page 16: Interface-Kabler

    SEKTION 3 INSTALLATION 3.6.2 Markering med to parallelle EPP-600'ere To EPP-600'ere, tilsluttet parallelt, kan anvendes til markering ned til 24A og skæring fra 100A op til 1.000A. Der kan foreta- ges to enkle ændringer på den supplerende strømkilde, så man kan markere ned til 12A. Det er kun nødvendigt at foretage disse ændringer, hvis man skal markere ned til 12A.
  • Page 17 SEKTION 3 INSTALLATION 3.7.1 CNC interface-kabler med matchende strømkildekonnektor og uafsluttet CNC-interface GRN/GUL RØD #4 3.7.2 CNC interface-kabler med matchende strømkildekonnektorer i begge ender GRN/GUL RØD #4...
  • Page 18 SEKTION 3 INSTALLATION 3.7.3 Interface-kabler til vandafkøler med matchende strømkildekonnektorer i begge ender...

  • Page 19: Betjening

    SEKTION 4 BETJENING 4.1 Blokdiagram kredsløbsbeskrivelse...
  • Page 20 Lav rippel er langt at foretrække, fordi levetiden på brænderens forbrugsdele forbedres med lav rippel. Grafen herunder viser effekten af ESAB's patenterede rippel-reduktion ved brug af to synkroniserede choppere, der skifte- vis tænder og slukker. Sammenlignet med to choppere, der tænder og slukker på samme tid, så reducerer den skiftevise tænd- og slukfunktion typisk rippelet med en faktor på...
  • Page 21 SEKTION 4 BETJENING 4.1 Blokdiagram kredsløbsbeskrivelse (fortsat) Blokdiagrammet for EPP-600 (efter delafsnit 6.4.4) viser strømkildens funktionelle hovedelementer. T1, hovedtransforme- ren, yder isolation fra den primære netstrøm og korrekt spænding til *375 V jævnstrøms-bus. Bus-ensretterne konverterer den trefasede udgang fra T1 til *375 V bus-spændingen. En kondensatorbank yder filtrering og energilagring, der giver strøm til de højhastigheds elektroniske afbrydere.

  • Page 22: Kontrolpanel

    SEKTION 4 BETJENING 4.2 Kontrolpanel A - Netstrøm En indikator lyser, når der tændes for indgangsstrømmen til strømkilden. B - Kontaktor tændt (on) En indikator lyser, når der tændes for hovedkontaktoren. C - Overtemperatur En indikator lyser, når strømkilden er overophedet. D - Fejl En indikator lyser, når der er uregelmæssigheder i skæreprocessen, eller når spændingen i indgangsledningen falder udenfor den krævede nominelle værdi på...
  • Page 23 SEKTION 4 BETJENING 4.2 Kontrolpanel (fortsat) G - Fjernstyret panel vælgerkontakt Styrer placeringen af strømkontrollen. • Sæt den i positionen PANEL til kontrol ved brug af strøm-potentiometeret. • Sæt den i positionen REMOTE til kontrol fra et eksternt signal (CNC). H og L - Fjernstyrede forbindelser H - 24-bens stik til forbindelse af strømkilden til CNC (fjernstyring) L - 8-bens stik til forbindelse af strømkilden til vandafkøleren...
  • Page 24 SEKTION 4 BETJENING 4.2 Kontrolpanel (fortsat) J - Målere Viser spænding og Amp under skæring. Amperemeteret kan aktiveres, når der ikke skæres, så man får vist en beregning af skærestrømmen, inden man begynder at skære. K - Faktisk/forudindstillet vælgerkontakt Standardindstillingen for FAKTISK AMP/FORUDINDSTILLET AMP returfjeder vippekontakten, S42, er i position ACTUAL (UP) (faktisk (op)).
  • Page 25 SEKTION 4 BETJENING 4.2.1 Betjeningsarbejdsmåder: Skære- og markeringsmåde EPP-600 betjenes i skærearbejdsmåden via et enkelt kontinuert justérbar udgangsstrømområde fra 50A til 600A ved brug af enten strømpotentiometeret på det forreste panel eller et fjernstyret strømreferencesignal, der føres ind i kon- nektor J1.

  • Page 26: Betjeningsrækkefølge

    SEKTION 4 BETJENING 4.3 Betjeningsrækkefølge ON 4 Operation quence of Operation Tænd for strømmen på netafbryderkontakten (væg). (EPP-600 har ikke en tænd/ sluk (on/off ) vælgerkontakt). Lampen for hovedstrøm vil lyse, og fejllampen vil blinke og herefter slukkes. Vælg indstillingen for panel/fjernstyring. Indstilling af pilotlysbue høj/lav vælgerkontakt.

  • Page 27: Opstartsindstillinger For Lysbue

    SEKTION 4 BETJENING 4.4 Opstartsindstillinger for lysbue Tidspunktet for opnåelse af fuld strøm kan justeres, således at man får en blød start. Denne funktion anvender en reduceret strøm til start og kører så gradvis op til fuld strøm. EPP-600 er fra fabrikkens side indstillet til blød start. Standardindstil- lingerne er: Minimum startstrøm.
  • Page 28 SEKTION 4 BETJENING 4.4.1 Tilkoble/afkoble opstartsforhold for lysbue sECtIon 4 opErAtIon Standardindstillinger fra fabrikken er vist. 4.4.1 Enable/Disable Arc Initiation Conditions Factory default setting shown. tændt (on) slukket (off ) 1. Fjern adgangsdækslet i øverste højre hjørne på det forreste panel. Husk at sætte dækslet tilbage, efter at justeringerne 1. Remove access panel on the upper-right corner of the front panel. Be sure to replace this panel after adjustments have er blevet foretaget.
  • Page 29 SEKTION 4 BETJENING 4.4.4 Styringselementer til opstartsindstillinger til lysbue Startstrøms-potentiometer UP-Slope tidsindstilling 4.4.5 Startstrøm og Up-Slope tidsindstilling Startstrøm (%) og Pot indstilling Startstrøm Indstil ved brug af potentiometer placeret over og til venstre for midten af PCB1. Fabriksindstillet standardindstilling på 7 resulterer i en startstrøm, som er 50% af skærestrømmen.

  • Page 30: Epp-600 V-I Kurver

    SEKTION 4 BETJENING 4.5.1 EPP-600 V-I kurver til 460 V og 575 V, 60 Hz indgange OUTPUT VOLTAGE (Volts) Udgangsspænding (volt) = 0.150V MIN MARK RATING = 0,150V Min. markeringsstrøm = 0.625V MIN CUT RATING = 0,625V Min. skærestrøm = 1.000V = 1.000V = 2.000V = 2.000V...
  • Page 31 SEKTION 4 BETJENING 4.5.2 EPP-600 V-I kurver til 400 V og 50/60 Hz indgange OUTPUT VOLTAGE (Volts) Udgangsspænding (volt) = 0.150V MIN MARK RATING = 0,150V Min. markeringsstrøm = 0.625V MIN CUT RATING = 0,625V Min. skærestrøm = 1.000V = 1.000V = 2.000V = 2.000V = 3.000V...
  • Page 32 SEKTION 4 BETJENING...
  • Page 33 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 34: Section 5 Maintenance

    section 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 35 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 36 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 – (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. 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 V oltage Cutoff Fault – Illuminates when arc voltage increases over the preset value. PS is shut down.
  • Page 37 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. LED 6 – (red) Right Overcurrent Fault – Illuminates when the current out of the right side chopper is too high (400 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 (400 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.
  • Page 38 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 action This is normal when not cutting. All 4 fans do not run Fans run only when “Contactor On” None signal is received. Broken or disconnected wire in fan Repair wire.
  • Page 39 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 t he a rc b y r unning t he t orch cut but goes off at the start of the ensure arc is terminated only by off the work or the arc being attached next. removing the “Contactor On” signal. to a part that falls away. Maintain phase voltage imbalance Imbalance of 3-phase input power of less than 5%. LED 3 – (amber) Bus Ripple Momentary loss of one phase of Restore and maintain input power input power within ±10% nominal...
  • Page 40 section 6 troubleshootinG problem possible cause action Output current of the right side exceeds Turn the output current down to 300A b ecause o f o perating t he p ower s ource 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 – (red) Right Over Cur- Secure connections or unplugged. PCB loose.
  • Page 41 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 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) Loose or unplugged P1 connector at the left PWM / LED 10 - (red) Left IGBT Un- 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) Loose or unplugged P1 connector at the left PWM / LED 11 - (red) Right IGBT...
  • Page 42 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 P/N Faulty left PWM / Drive PCB 0558038308 Loose or unplugged P1 connector at Secure P1 connector the right PWM / Drive PCB Loose or unplugged P11 connector LED 12 – (red) Right –12V Missing Secure P11 connector at PCB1 Replace right PWM / Drive PCB P/N Faulty right PWM / Drive PCB 0558038308 Shorted IGBT...
  • Page 43 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 f or c urrent r eference s ignal a t T B1- short “...
  • Page 44 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” signal the ignition of the pilot arc. Fix process controller logic and replace diodes. Faulty negative (Electrode) output cable Repair cable shorting to earth ground.
  • Page 45 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. down. Refer to fault light illumination Power Supply turns off prema- section. turely in the middle of the cut. Remove control PCB (PCB1) access panel Faulty c ondition, i ndicated b y t he i llumination to determine the fault causing the shut- of the power reset fault lamp.
  • Page 46 6 troubleshootinG 6.4 testing and replacing components • 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. notice • 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. • 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...
  • Page 47 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. 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 under- neath. 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...
  • Page 48 section 6 troubleshootinG 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 1. Check ohms between POS Plate and BR “ A” Bus. A reading Location of Pos. Plate of 2 ohms or less indicates one or more shorted diodes.
  • Page 49 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 50 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. B. Inspect the thermal (interface) pad, P/N 951833, for damage. A crease or deformity can prevent the module from seat- ing 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 imbal- ance 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 heat- sink 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 com- pound 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. Replace the top panel. the module gate plugs must be plugged into the pwm/Gate caution drive pc board whenever the power source is in operation.
  • Page 51 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). 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.
  • Page 52 section 6 troubleshootinG 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 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.
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  • Page 54 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. The Contactor Signal is supplied through a remote contact connecting 115VAC from J1-R to J1-M. 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 /...
  • Page 55 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. 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.
  • Page 56 section 6 troubleshootinG arc current detector circuits There are three Arc Current Detector circuits in the EPP-600. 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-G (-) and J1-P (+). J1 is the 24 conductor con- nector on the EPP-600 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 EPP-600 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. J6-D J6-E J1-G J1-P...
  • Page 57 section 6 troubleshootinG current control pot and remote vref A Reference Voltage, Vref, is used to command the output current of the EPP-600. 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-L (+) and J1-J (-). The EPP-600 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 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 response of the “Normal” input helps filter electrical noise sometimes encountered in industrial environments.
  • Page 58 section 6 troubleshootinG 6.10 pilot arc hi / lo and cut / mark circuits A remote contact connecting 115V AC from J1-F to J1-L places the Pilot Arc in High by operating K8. Note, that for this func- tion to operate, the 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. When K10 turns off, the Boost supply is discon- nected lowering the normal Cutting Mode 425V DC Open Circuit Voltage to 360V* DC for Marking. A normally open con- tact on K11 activates K12. K12 connects the I (min) resistors necessary for stabilizing the low currents required for marking. In the Cutting mode, the minimum stable output current is 50A, and in the marking mode, it’s 12A. * 310V for 400V, 50/60Hz model J1-D J1-S J1-C J1-Z J6-B J6-A...
  • Page 59 7 replacement parts replacement parts General 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. ordering To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this equipment. The use of non-ESAB parts may void your warranty. Replacement parts may be ordered from your ESAB Distributor. Be sure to indicate any special shipping instructions when ordering replacement parts. Refer to the Communications Guide located on the back page of this manual for a list of customer service phone numbers. note Bill of material items that have blank part numbers are provided for customer information only. Hardware items should be available through local sources. NOTE: Schematics on 279.4mm x 431.8mm (11” x 17”) paper are included inside the back cover of this manual.
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  • Page 65 section 7 replacement parts EPP-400 Only - 2 Places EPP-600 Only - 2 Places...
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  • Page 72 section 7 replacement parts R10, 11 Resistor 1.5K OHMS 100W 17280215 R28-31 951198 FERRITE CORE...
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  • Page 78 notes...

  • Page 79: Revision History

    revision history 1. Original release - 11 / 2006 2. Revision 08/2010 - Updated with new DOC form.
  • Page 80 ESAB Saldatura S.p.A. ESAB (Malaysia) Snd Bhd ESAB Ges.m.b.H Mesero (Mi) CONARCO Shah Alam Selangor Vienna-Liesing Tel: +39 02 97 96 81 Buenos Aires Tel: +60 3 5511 3615 Tel: +43 1 888 25 11 Fax: +39 02 97 28 91 81 Tel: +54 11 4 753 4039 Fax: +60 3 5512 3552 Fax: +43 1 888 25 11 85 Fax: +54 11 4 753 6313 the netherlands sinGapore belGium brazil ESAB Nederland B.V. ESAB Asia/Pacific Pte Ltd S.A. ESAB N.V. Utrecht ESAB S.A.

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