ESAB EPP-450 Plasma Power Source User manual

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14

LE SCOSSE ELETTRICHE POSSONO UCCIDERE!

I TERMINALI AD ANELLO DEVONO AVERE UNO SPAZIO TRA IL PAN

NELLO LATERALE ED IL TRASFORMATORE PRINCIPALE. LO SPAZIO

DEVE ESSERE SUFFICIENTE IN CASO DI EVENTUALE CONTATTO

D’ARCO. ACCERTARSI CHE I CAVI NON INTERFERISCANO CON LA

ROTAZIONE DELLA VENTOLA DI RAFFREDDAMENTO.

UNA MESSA A TERRA ERRATA PUÒ RISULTARE IN MORTE O LESIONE.

IL TELAIO DEVE ESSERE COLLEGATO AD UNA MESSA A TERRA ELET

TRICA APPROVATA. ACCERTARSI CHE IL CAVO DI MASSA NON SIA

COLLEGATO AD ALCUN TERMINALE PRIMARIO.

LE SCOSSE ELETTRICHE POSSONO UCCIDER E! TENSIONE E CORRENTE

PERICOLOSI!

QUANDO SI LAVORA INTORNO AD UN GENERATORE DI ENERGIA AL

PLASMA CON I COPERCHI RIMOSSI:

• DISINNESTARE IL GENERATORE DI ENERGIA NEL SEZIONATORE

(A PARETE).

• UN INDIVIDUO QUALIFICATO DOVREBBE CONTROLLARE LE SBAR-

RE COLLETTRICI (POSITIVE E NEGATIVE) CON UN VOLTMETRO.

3.5 Connessioni di uscita

AVVERTIMENTO

3.5.1 Cavi di uscita (forniti dal cliente)

Scegliere i cavi di uscita del taglio a getto di plasma (forniti dal cliente) sulla base di un cavo di rame 4/0 AWG

isolato da 600 volt per 400 ampere di corrente di uscita. Per 450 ampere, devono essere usati cavi a 600 volt,

taglio 100% lavoro, due 2/0 AWG paralleli.

Nota:

Non usare un cavo di saldatura isolato da 100 volt.

SEZIONE 3 INSTALLAZIONE

3.5.2 Procedura di connessione di uscita - Generatore di energia singolo

1. Rimuovere il pannello di accesso sul lato anteriore inferiore del generatore di energia.

2. Inlare i cavi di uscita attraverso le aperture sul fondo del pannello anteriore o sul fondo del generatore di energia subito

dietro il pannello anteriore.

3. Collegare i cavi ai terminali specicati montati all’interno del generatore di energia, usando i connettori del cavo di

pressione classicata UL.

4. Riposizionare il pannello rimosso nel corso del primo procedimento.

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30

SEZIONE 4 FUNZIONAMENTO

1. Applicare l’alimentazione chiudendo il sezionatore (a parete).

(L’EPP-450 non è dotato di un interruttore on / o (acceso/

spento). La luce dell’alimentazione principale si accende e la

luce dei guasti lampeggia e quindi si spegne.

2. Il pulsante E-stop viene estratto.

3. Selezionare l’impostazione Pannello / Remoto.

4. Impostare l’interruttore Alto / Basso dell’arco pilota. Se l’arco

pilota Alto / Basso è selezionato da un telecomando, l’inter-

ruttore deve trovarsi in posizione Basso. (Fare riferimento ai

dati di taglio nel manuale del cannello).

5. Se si utilizza la modalità del pannello, visualizzare gli am-

pere preimpostati con l’interruttore degli AMP EFFETTIVI /

PREIMPOSTATI. Regolare la corrente no a quando il valore

approssimativo desiderato appaia sull’amperometro. Se si

utilizza la modalità remota, il collocamento dell’interrutto-

re degli Amp eettivi / preimpostati nella posizione Amp

preimpostati garantisce la corrente di uscita iniziale richiesta

dal telecomando.

6. Iniziare l’operazione di taglio a getto di plasma. Questa opera-

zione potrebbe includere la congurazione manuale di altre

opzioni, in base al pacchetto del plasma totale.

7. Se si utilizza la modalità del pannello, dopo che il taglio è

iniziato, regolare la corrente sulla quantità desiderata.

8. Se il taglio o la marcatura non iniziano, controllare la luce

dei guasti. Se la luce dei guasti è accesa, fare riferimento alla

sezione sulla risoluzione dei guasti.

Nota:

La luce dei guasti lampeggia quando il contattore

viene inizialmente acceso per indicare che il Bus CC

è alimentato normalmente.

4.3 Sequenza del funzionamento

SECTION 4 Operation

ESP 400C Plasma Power Source

ESP 400C Plasma Power SourceESP 400C Plasma Power Source

ESP 400C Plasma Power Source

4-4

Begin

Cutting

ACTUAL AMPS

PRESET AMPS

HIGH

LOW

PILOT

ARC

PANEL

REMOTE

Apply Power

4.3 Sequence of Operation

1. Apply power by closing the line (wall) switch.

(The ESP-400C does not have an on/off

switch). The main power light will illuminate

and the fault light will flash and then go out.

2. Select the Panel/Remote setting.

3. Set pilot arc High/Low switch. (Refer to cutting

data in the torch manual.)

4. If using panel mode, view preset amps with the

ACTUAL/PRESET AMPS switch. Adjust current

until the approximate desired value is shown on

the ammeter.

5. Begin plasma cutting operation. This may

include manually setting up other options,

depending on the total plasma package.

6. If using panel mode, after cutting has begun,

adjust current to desired amount.

7. Check for fault light. If a fault light illuminates,

refer to troubleshooting section.

Note: The fault light flashes when the contactor is

Note: The fault light flashes when the contactor isNote: The fault light flashes when the contactor is

Note: The fault light flashes when the contactor is

first turned on signifying the DC Bus powered up

first turned on signifying the DC Bus powered upfirst turned on signifying the DC Bus powered up

first turned on signifying the DC Bus powered up

normally.

normally.normally.

normally.

4.4 Arc Initiation Settings

The time to achieve full current can be adjusted to

suit your particular system. This feature uses 50%

of the cutting current to start, dwell and then

gradually (less than a second) achieve full current.

The ESP-400C is factory shipped with this feature

enabled. The default settings are:

Minimum Start Current 40A

Start Current 50% of cut current

Timing to achieve full current 800 msec

Dwell Time 50 msec

SECTION 4 Operation

ESP 400C Plasma Power Source

ESP 400C Plasma Power SourceESP 400C Plasma Power Source

ESP 400C Plasma Power Source

4-4

Begin

Cutting

ACTUAL AMPS

PRESET AMPS

HIGH

LOW

PILOT

ARC

PANEL

REMOTE

Apply Power

4.3 Sequence of Operation

1. Apply power by closing the line (wall) switch.

(The ESP-400C does not have an on/off

switch). The main power light will illuminate

and the fault light will flash and then go out.

2. Select the Panel/Remote setting.

3. Set pilot arc High/Low switch. (Refer to cutting

data in the torch manual.)

4. If using panel mode, view preset amps with the

ACTUAL/PRESET AMPS switch. Adjust current

until the approximate desired value is shown on

the ammeter.

5. Begin plasma cutting operation. This may

include manually setting up other options,

depending on the total plasma package.

6. If using panel mode, after cutting has begun,

adjust current to desired amount.

7. Check for fault light. If a fault light illuminates,

refer to troubleshooting section.

Note: The fault light flashes when the contactor is

Note: The fault light flashes when the contactor isNote: The fault light flashes when the contactor is

Note: The fault light flashes when the contactor is

first turned on signifying the DC Bus powered up

first turned on signifying the DC Bus powered upfirst turned on signifying the DC Bus powered up

first turned on signifying the DC Bus powered up

normally.

normally.normally.

normally.

4.4 Arc Initiation Settings

The time to achieve full current can be adjusted to

suit your particular system. This feature uses 50%

of the cutting current to start, dwell and then

gradually (less than a second) achieve full current.

The ESP-400C is factory shipped with this feature

enabled. The default settings are:

Minimum Start Current 40A

Start Current 50% of cut current

Timing to achieve full current 800 msec

Dwell Time 50 msec

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34

PKH: VI_Curves_EPP-450-600_Bus; EPP-450 VI Curves

EPP-450 V-I CURVES

0

100

200

300

400

0 100 200 300 400 500

OUTPUT CURRENT (Amperes)

OUTPUT VOLTAGE (Volts)

431V Open Circuit

INTERNAL CURRENT LIMIT

DATA PLATE

MAX RATING

VREF = 8.000

VREF = 6.000

VREF = 4.000

VREF = 2.000 HIGH RANGE

VREF = 1.000 MIN HIGH RANGE

Output of Boost/Start Circuit

Max Output Voltage

@

Nominal Line

I

OUT

= (50) x (V

REF

) High Range

VREF = 9.000

VREF = 10.00 MAX LOW RANGE

I

OUT

= (10) x (V

REF

) Low Range

VREF = 5.00 HIGH RANGE

VREF = 1.00 MIN LOW RANGE MARKING*

SEZIONE 4 FUNZIONAMENTO

4.5.1 Curve approssimative V-I EPP-450 per tutti i modelli

Tensione di uscita (Volt)

Corrente di uscita (Ampere)

Circuito aperto 431 V

Uscita del circuito di spinta / avviamento

I

OUT

= (50) x (V

REF

) Gamma alta

I

OUT

= (10) x (V

REF

) Gamma bassa

Tensione di uscita massima

sulla linea nominale

Limite della corrente interno

V

REF

= 8,000

V

REF

= 6,000

V

REF

= 5,00 Gamma alta

V

REF

= 1,00 Min. Marcatura a gamma bassa *

V

REF

= 4,000

V

REF

= 1,00 Min. Gamma alta

PIASTRA DEI DATI

CLASSIFICAZIONE

MASSIMA

V

REF

= 10,00 Max. Gamma bassa

V

REF

= 2,00 Gamma alta

V

REF

= 9,000

35

SECTION 5 MAINTENANCE

5.1 General

ELECTRIC SHOCK CAN KILL!

SHUT OFF POWER AT THE LINE WALL DISCONNECT BEFORE AT

TEMPTING ANY MAINTENANCE.

WARNING

EYE HAZARD WHEN USING COMPRESSED AIR TO CLEAN.

• Wear approved eye protection with side shields when cleaning the

powersource.

• Useonlylowpressureair.

CAUTION

Maintenance On This Equipment Should Only Be Performed By

Trained Personnel.

5.2 Cleaning

Regularlyscheduledcleaningofthepowersourceisrequiredtohelpkeeptheunitrunningtroublefree.Thefrequencyof

cleaningdependsonenvironmentanduse.

1. Turnpoweroatwalldisconnect.

2. Removesidepanels.

3. Uselowpressurecompresseddryair,removedustfromallairpassagesandcomponents.Payparticularattentionto

heatsinksinthefrontoftheunit.Dustinsulates,reducingheatdissipation.Besuretoweareyeprotection.

36

SECTION 5 MAINTENANCE

Air restrictions may cause EPP-450 to over heat.

Thermal Switches may be activated causing interruption of func-

tion.

Do not use air lters on this unit.

Keep air passages clear of dust and other obstructions.

WARNING

CAUTION

5.3 Lubrication

• Someunitsareequippedwithoiltubesonthefans.Thesefansshouldbeoiledafter1yearofser-

vice.

• AllotherEPP-450shavefanmotorsthatarepermanentlylubricatedandrequirenoregularmainte-

nance.

ELECTRIC SHOCK HAZARD!

BE SURE TO REPLACE ANY COVERS REMOVED DURING CLEANING

BEFORE TURNING POWER BACK ON.

37

SECTION 6 TROUBLESHOOTING

6.1 General

ELECTRIC SHOCK CAN KILL!

DO NOT PERMIT UNTRAINED PERSONS TO INSPECT OR REPAIR THIS

EQUIPMENT. ELECTRICAL WORK MUST BE PERFORMED BY AN EXPE

RIENCED ELECTRICIAN.

WARNING

Stop work immediately if power source does not work properly.

Have only trained personnel investigate the cause.

Use only recommended replacement parts.

CAUTION

6.2 Fault Indicators

FaultindicatorsarefoundonthefrontpanelUsedwith

theLEDsonPCB1(locatedbehindthecoverwiththe

EPPlabel)problemscanbediagnosed.

NOTE:

Itisnormal for momentarylight-

ing(ashing)ofthefaultindicator

andLED3whena“contactoron”

signalisappliedatthebeginning

ofeachcutstart.

FaultIndicatorusedwith:

LED3-BusRipple

LED4-HighBus

LED5-LowBus

LED7-ArcVoltageSaturation

LED8-ArcVoltageCuto

PowerResetFaultIndicatorusedwith:

LED6-RightOvercurrent

LED9-LeftOvercurrent

LED10-LeftIGBTUnsaturated

LED11-RightIGBTUnsaturated

LED12-Left-12VBiasSupply

LED13-Right-12VBiasSupply

PCB1 Located behind

thispanel.

Front Panel Fault

Indicators

38

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.

38

LED3–(yellow)BusRippleFault-Momentarilyilluminatesatthebeginningof

eachcut.Continuouslylitduringsingle-phasingorimbalancedline-to-linevolt-

agesofthethreephaseinputline(ExcessiveRipple).PowerSourceisshutdown.

LED4–(yellow)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–(yellow)LowBusFault–Illuminateswheninputline

voltageislowerthan10%belownominallinevoltagerating.

PowerSourceisshutdown.

LED7–(yellow)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–(yellow)ArcVoltageCutoFault–Illuminateswhen

arcvoltageincreasesoverthepresetvalue.PSisshutdown.

39

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(300amps).Thiscurrentismeasuredbytheright-sidehall

sensor.Thepowersourceisshutdown.

38

LED9–(red)LeftOvercurrentFault–Illuminateswhenthecurrentfromtheleftside

chopperistoohigh(300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.

40

SECTION 6 TROUBLESHOOTING

6.3 Fault Isolation

Manyofthemostcommonproblemsarelistedbysymptom.

6.3.1 Nooutputwithcontactorsignalapplied

6.3.2 Outputlimitedto100A

6.3.3 Fansnotworking

6.3.4 Powernotonorlowvoltage

6.3.5 Faultlightillumination

6.3.6 Torchwon’tre

6.3.7 Fussesblown-F1andF2

6.3.8 Intermittent,interruptedorpartialoperation

6.3.3 Fans Not Working

Problem Possible Cause Action

All4fansdonotrun

Thisisnormalwhennotcutting.

Fans run only when “Contactor On”

signalisreceived.

None

1,2or3fansdonotrun.

Broken or disconnected wire in fan

motorcircuit.

Repairwire.

Faultyfan(s) Replacefans

6.3.1 No output with contactor signal applied

Problem Possible Cause Action

Contactor signal is applied,

contactor lamp on front

panelis illuminated,K2 and

K3 contactors do not close

andlowbusfault light,LED

5illuminates.

External emergency stop (E-stop) is

open.

ConnectisolatedcontactofE-stopswitchtopro-

videconnectionbetweenJ1-EandJ1-F.

E-stopbuttononfrontpanelispushed

in.

TwistandpullouttoresetE-stopcondition.

Powerresetlamponfrontpanelindi-

catesaseriousfaultcondition.

Refertosectionunderfaultlightillumination.

6.3.2 Output limited to 100A

Problem Possible Cause Action

Powersourcewillnotgoover

100A.

Highcurrentrangesignalmissing.

ExternalcontrolshouldconnectJ1-RtoJ1-T.As

analternative,inthepowersource,movethered

wireonTB8-1toTB8-2.

41

6.3.4 Power Not On or LOW Voltage

Problem Possible Cause Action

Powersourceinoperable:

Mainpowerlampiso.

Missing3-phaseinputvoltage

Restoreall 3 phases of input voltageto within

±10%ofnominalline.

Missing1of3-phaseinputvoltage

Restoreall 3 phases of input voltageto within

±10%ofnominalline.

Lowopencircuitvoltage

FuseF3/F4blown ReplaceF3/F4

PilotarcContactor(K4)faulty ReplaceK4

FaultyControlPCB1 ReplaceControlPCB1(P/N

0558038312

)



Problem Possible Cause Action

Faultlightilluminatesattheendof

cutbutgoesoatthestartofthe

next.

Normalconditioncausedwhenter-

minatingthearcbyrunningthetorch

otheworkorthearcbeingattached

toapartthatfallsaway.

Reprogramcuttingprocessto

ensurearcisterminatedonlyby

removingthe“ContactorOn”signal.

LED3–(amber)BusRipple

Imbalanceof3-phaseinputpower

Maintainphasevoltageimbalance

oflessthan5%.

Momentary loss of one phase of

inputpower

Restoreandmaintaininputpower

within±10%nominal

FaultycontrolPCB1 ReplacePCB1P/N

0558038312

LED4–(amber)HighBus

Oneormorephasesofinputvoltage

exceednominallinevoltagebymore

than15%.

Restoreandmaintainlinevoltage

within±10%

FaultycontrolPCB1 ReplacePCB1P/N

0558038312

Oneormoreshorteddioderectiers

(D25-D28)onthe“ElectrodePlate”

Replaceshorteddioderectiers

LED5–(amber)LowBus

One or more phases of input volt-

agearelowerthannominalbymore

than15%.

Restoreandmaintainwithin

±10%ofnominal

BlownF1andF2fuses

SeeF1andF2inBlown

FusesSection

OvertempLightcomeson. SeeovertempinFaultLightSection

Imbalanced3-phaseinput

power

Maintainphasevoltageimbalance

oflessthan5%

Momentary loss of one phase of

inputpower

Restoreandmaintainwithin

±10%ofnominal

FaultyMainContactor(K1) ReplaceK1

FAULTYControlPCB1 ReplacePCB1P/N

0558038312

SECTION 6 TROUBLESHOOTING

6.3.5 Fault Light Illumination

42

SECTION 6 TROUBLESHOOTING

Problem Possible Cause Action

LED 6 – (red) Right Over Cur-

rent

Note:

Ifoperationat275Aorlessis

possible,thentheLEFTsideis

notworking.

Cuttingatover275Awithafaultyleftside

(leftsideoutput=0)

Seefaultyleftorrightside

Rightcurrenttransducerconnectorloose

orunplugged.PCBloose.

Secureconnections

Loose or unplugged connector at right

PWM/DrivePrintedcircuitboard.

Secureconnection

P2atleftofPWM/DrivePCBlooseorun-

plugged.

Secureconnection

CheckvoltagebetweenP7-6andP7-7.A

voltage in either polarity of greater than

0.01Vindicatesafaultyrightcurrenttrans-

ducer(TD2).

Replace right current transducer

(TD2)

FaultyPCB1 ReplacePCB1P/N

0558038312

FaultyrightPWM/DrivePCB

Replace right PWM / Drive PCB  P/N

0558038324

LED9–(red)LeftOverCurrent

Note:

Ifoperationat275Aorlessis

possible,thentheRightsideis

notworking.

Cuttingatover275Awithafaultyrightside

(rightsideoutput=0)

Seefaultyrightside

Leftcurrenttransducerconnectorlooseor

unplugged.PCBloose.

Secureconnections

LooseorunpluggedconnectoratleftPWM

/DrivePrintedcircuitboard.

Secureconnection

P2 at right of PWM / Drive PCB loose or

unplugged.

Secureconnection

CheckvoltagebetweenP7-2andP7-3.A

voltage in either polarity of greater than

0.01Vindicatesafaultyleftcurrenttrans-

ducer(TD1).

Replaceleftcurrenttransducer(TD1)

FaultyPCB1 ReplacePCB1P/N

0558038312

FaultyleftPWM/DrivePCB

Replace left PWM / Drive PCB  P/N

0558038324

NEVER attempt to power-up or operate the power source with any

Gate / Emitter IGBT Plug disconnected from it’s PWM / Gate Drive

Board. Attempting to operate the power source with any open (un-

plugged) IGBT Gate / Emitter Connector may damage the IGBT and

the plasma cutting torch.

CAUTION

43

SECTION 6 TROUBLESHOOTING

Problem Possible Cause Action

VeryhighOutputcurrentac-

companiedbyeitheraleftor

rightovercurrent(LED6)

ShortedIGBT ReplacetheIGBTs

Currentpotsettoohigh Lowerthecurrentsetting

FaultyleftPWM/DrivePCB ReplaceleftPWM/DrivePCB

Highremotecurrentsignal Decreaseremotecurrentsignal

FaultyPCB1 ReplacePCB1P/N0558038312

LED10-(red)LeftIGBTUn-

saturated

BlackwireconnectingIGBT(Q2)collectortoP3ofthe

leftPWM/DrivePCB(PCB2)isdisconnected.

Secureconnector

ShortedFreewheelingDiode(s) Replacefreewheelingdiode(s)

LooseorunpluggedP1connectorattheleftPWM/

DrivePCB

SecureP1

LooseorunpluggedP10connectoratPCB1 SecureP10

FaultyPCB1 ReplacePCB1P/N0558038312

FaultyleftPWM/DrivePCB ReplacePCB2P/N0558038324

LED 11 - (red)  Right IGBT

Unsaturated

BlackwireconnectingIGBT(Q5)collectortoP3ofthe

rightPWM/DrivePCB(PCB3)isdisconnected.

Secureconnector

ShortedFreewheelingDiode(s) Replacefreewheelingdiode(s)

LooseorunpluggedP1connectorattheleftPWM/

DrivePCB

SecureP1

LooseorunpluggedP10connectoratPCB1 SecureP11

FaultyPCB1 ReplacePCB1P/N0558038312

FaultyrightPWM/DrivePCB ReplacePCB3P/N0558038324

44

SECTION 6 TROUBLESHOOTING

Problem Possible Cause Action

LED12–(red)Left–12VMissing

LooseorunpluggedP1connectorat

theleftPWM/DrivePCB

SecureP1connector

Loose or unplugged P10 connector

atPCB1

SecureP10connector

FaultyleftPWM/DrivePCB

Replace left PWM / Drive PCB  P/N

0558038324

LED12–(red)Right–12VMissing

LooseorunpluggedP1connectorat

therightPWM/DrivePCB

SecureP1connector

Loose or unplugged P11 connector

atPCB1

SecureP11connector

FaultyrightPWM/DrivePCB

Replace right PWM / Drive PCB  P/N

0558038324

VeryhighOutputcurrentaccompa-

niedbyeitheraleftorrightovercur-

rent(LED9orLED6respectively)

ShortedIGBT ReplacetheIGBTs

Currentpotsettoohigh Lowerthecurrentsetting

FaultyleftPWM/DrivePCB

Replace left PWM / Drive PCB P/N

0558038324

Highremotecurrentsignal Decreaseremotecurrentsignal

FaultyPCB1 ReplacePCB1P/N0558038312

OverTempLampilluminates

Oneormorefansinoperable Repairorreplacefan(s)

Brokenwireorunpluggedconnector

atthermalswitch.

Repair brokenwires and unplugged con-

nector

Obstructiontoairowcloserthan3feet

(1m)torearofpowersource.

Allow3ft.(1m)minimumbetweentherear

ofthepowersourceandanyobjectthatmay

restrictairow.

Excessive dirt restricting cooling air

ow

Cleanout excessivedirt, especially in the

extrusionsfortheIGBTsandfreewheeling

diodes,thePOS,NEGandElectrodePlates,

the main transformer (T1) and the lter

inductors(L1andL2).

Obstructedairintake

Checkandclearanyobstructionsfromthe

bottom, front, and toprear of the Power

Source.

45

SECTION 6 TROUBLESHOOTING

6.3.6 Torch Will Not Fire

Problem Possible Cause Action

MainArcTransfersto the workwitha

short“pop”,placingonlyasmalldimple

inthework.

Remote control removes the start

signalwhen the main arc transfersto

thework.

Panel/Remoteswitchin“Remote”with

noremotecontrolofthecurrent

Place Panel/Remote switch in“Panel”

position

Remote current control present but

signalmissing.

CheckforcurrentreferencesignalatTB1-

4(+)andTB1-5(-).SeeSignalvs.Output

CurrentCurvethissection.

Currentpotsettoolow. Increasecurrentpotsetting.

Start current pot, located behind the

cover for the control PCB is set too

low.

Increasethestartcurrentpostsetting

to“7”.

Arcdoesnotstart.Thereisnoarcatthe

torch.OpencircuitvoltageisOK.

Openconnectionbetweenthepower

sourcepositiveoutputandthework.

Repairconnection

FuseF6inthePilotarccircuitisblown. ReplaceF6

FuseF7inthepilotarccircuitisblown. ReplaceF7

PilotarcHigh/Lowswitchisinthe”LOW”

positionwhen using consumablesfor

100Aorhigher(Refertoprocessdata

includedintorchmanuals)

Change Pilot arc to “High” position.

(Refertoprocessdataincludedintorch

manuals)

Pilotarccontactor(K4)faulty. ReplaceK4

FaultyPCB1

ReplacePCB1P/N

0558038312

46

Problem Possible Cause Action

FusesF1andF2blown.

Processcontrollerignitespilotarctoo

soon after providing the “Contactor

On”signal

Process controller must allow at least

300MS to lapse between the applica-

tion of the“Contactor On” signal and

theignitionofthepilotarc.Fixprocess

controllerlogicandreplacediodes.

Faultynegative(Electrode)outputcable

shortingtoearthground.

Repaircable

Shortedfreewheelingdiode.

Replace shorted freewheeling diode

andF1-F2

One or more shorted diode rectiers

(D13-D18)on“POSPlate”.

Replacealldioderectiersonthe“POS

P l a t e ”.

One or more shorted diode rectiers

(D7-D12)on“NEGPlate”.

Replacealldioderectiersonthe“NEG

P l a t e ”.

SECTION 6 TROUBLESHOOTING

6.3.7 Fuses F1 and F2 Blown

Problem Possible Cause Action

WorksOKat275Aorless-Over

current right side when cutting

over275A.LED6oncontrolboard

illuminated.

LooseorunpluggedconnectoratleftPWM/

DrivePCB(PCB2)

Secureconnector

FaultyleftPWM/DrivePCB

Replace right PWM / Drive PCB  P/N

0558038324

CheckvoltagebetweenP5-1andP5-2atthe

leftPWM/DrivePCB(PCB2).Shouldbe20V

AC.BetweenP5-1andP5-3shouldbe40VAC.

Ifnotthecontroltransformer(T5)isfaulty.

ReplacecontroltransformerT5

6.3.8 Intermittent, Interrupted or Partial Operation

NEVER attempt to power-up or operate the power source with any

Gate / Emitter IGBT Plug disconnected from it’s PWM / Gate Drive

Board. Attempting to operate the power source with any open (un-

plugged) IGBT Gate / Emitter Connector may damage the IGBT and

the plasma cutting torch.

CAUTION

WorksOKat275Aorless-Over

current left side when cutting

over275A.LED9oncontrolboard

illuminated.

LooseorunpluggedconnectoratRightPWM

/DrivePCB(PCB3)

Secureconnector

FaultyRightPWM/DrivePCB

Replace right PWM / Drive PCB  P/N

0558038324

CheckvoltagebetweenP5-1andP5-2atthe

rightPWM/DrivePCB(PCB3).Shouldbe20V

AC.BetweenP5-1andP5-3shouldbe40VAC.

Ifnotthecontroltransformer(T7)isfaulty.

ReplacecontroltransformerT7

47

SECTION 6 TROUBLESHOOTING

Problem Possible Cause Action

Power Supply turns o prema-

turelyinthemiddleofthecut.

“ContactorOn”signalisremovedfromunit.

PowersourceisOK.Troubleshootpro-

cesscontroller.

Momentarylossofprimaryinputpower.

Restore and maintain input voltage

within±10%ofnominal.

Faulty condition, indicated by illumination

ofthefaultlamp.

RemovecontrolPCB(PCB1)accesspanel

todeterminethefaultcausingtheshut-

down.Refertofaultlightillumination

section.

Faultycondition,indicatedbytheillumination

ofthepowerresetfaultlamp.

RemovecontrolPCB(PCB1)accesspanel

todeterminethefaultcausingtheshut-

down.Refertofaultlightillumination

section.

Currentsettingtoolow. Increasecurrentsetting

Remotecurrentsignalremovedduringcut. Fixremotecurrentsignal

Problem Possible Cause Action

Output current is unstable and

drifts above or below the set-

ting.

PlacethePANEL/REMOTEswitchinthe“PANEL”

position.Adjustcurrentcontrolpot.Ifcurrent

nolongerdrifts,theremotecurrentcontrol

signalisfaulty.

Fixtheremotecurrentcontrolsignalto

operatethePANEL/REMOTEswitchin

the“PANEL”position.

Select“PANEL”onthePANEL/REMOTEswitch

andadjustthecurrentcontrolpot.Thecur-

rentstilldrifts,measurethecurrentreference

signalatTB1-4(+)andTB1-5(-).Ifthesignal

drifts,thecurrentcontrolpotisfaulty.Ifthe

signaldoesnotdrift,theControlPCB(PCB1)

isfaulty.

Replacethecurrentcontrolpot.

Replace the control PCB (PCB1)  P/N

0558038312

48

SECTION 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.

• 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.

NOTICE

Power Semiconductor Components

Categoriesofpowersemiconductorsinclude;

• PowerRectiers

• ModulescontainingthefreewheelingdiodesandIGBTs

49

SECTION 6 TROUBLESHOOTING

6.4.1 Power Rectiers and Blocking Diodes

1. Removetopcoverandsidepanels

2. Locateanddisconnectpluginrearofammeter(attached

toneredandoneblackwire)

3. Removepilotarcswitch

4. Disconnectvoltmeter

5. DisconnectorangeandyellowwiresfromrelayK4.

6. Removetwoboltsholdingtheleftsideofthefrontpanel

tothebase.

7. Removethreeboltsholdingacrossthecenterbaseofthe

frontpanel.Theseareaccessedfromunderneath.

8. 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.

9. Swingthefrontpanelouttogainaccesstopowerrecti-

ercomponents.

Troubleshooting Procedures –Negative Plate

1. VisuallyinspectfusesF8andF9.Replaceiftheyshowsigns

ofbeingblownormelted.Inspectdiodes.Ifruptured

orburned,replacealldiodesontheNEGPlate.Ifdiodes

appeartobeOK,proceedtonextstep.

LocationofNeg.Plate

LocationoffusesF8andF9

PowerRectiers

Proceduretoaccessbehindthefrontpanel

BlockingDiodes

PowerRectiers

50

SECTION 6 TROUBLESHOOTING

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rststep,maketwo

moreohmmeterreadings.

 A.MeasureresistancebetweentheNEGPlateand

BR“B”bus.

 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.

POSPlateElectrodePlate

DiodeRectierNEGPlate

LocationofPos.Plate

LocationoffusesF8andF9

Troubleshooting POS Plate

1. CheckohmsbetweenPOSPlateandBR“A”Bus.Areading

of2ohmsorlessindicatesoneormoreshorteddiodes.

ReplaceallDiodesonPOSPlate.

2. IffusesF8and/orF9wereopenintherststep,maketwo

moreohmmeterreadings.

A.MeasureresistancebetweenthePOSPlateandBR

“B”bus.

B.MeasurebetweenPOSPlateandBR“C”bus.

If resistanceis 2ohms or less in either case, replace allthe

diodesonthePOSPlate.

CathodeLeads

Bus

1. Visuallyinspectforrupturedorburneddiodes.Replace

onlythosedamaged.

2. CheckresistancebetweenElectrodePlateandtheparallel

pigtails(cathodeleads)ofD25andD26.Ifreadingis2

ohmsorless,disconnectleadsfrombusandcheckeach

diode.Replaceonlyshorteddiodes.

Repeat procedure for D27 and D28.  Replace only shorted

diodes.

Blocking Diodes D25, D26, D27 and D-28

Troubleshooting Electrode Plate

51

SECTION 6 TROUBLESHOOTING

6.4.2 IGBT / Freewheeling Diode (FWD) Replacement

The emitter and the gate of each aected IGBT must be jum-

pered together to prevent electrostatic damage. Each power

source is supplied with six jumper plugs that mate to the IGBT

Gate / Emitter Plug.

CAUTION

Electrostatic Discharge Hazard

Electrostatic discharge may damage these components.

• Damageisaccumulativeandmayonlyappearasshortenedcompo-

nentlifeandnotasacatastrophicfailure.

• Wearaprotectivegroundstrapwhenhandlingtopreventdamage

toPCBcomponents.

• Alwaysplaceapcboardinastatic-freebagwhennotinstalled.

CAUTION

The module gate plugs must be plugged into the PWM/Gate

Drive PC Board whenever the power source is in operation.

Failure to plug them in will result in damage to the module and

possible damage to the torch.

CAUTION

REMOVAL:

A. Insurethatinputpowerisremovedbytwoactionssuchasadisconnectswitchandremovaloffuses.Tagandlockany

disconnectswitchtopreventaccidentalactivation.

B. Removethetoppaneltogainaccesstothemoduleslocatedinthetoprearofthepowersource.

C. Cleanthecompartmentcontainingthemoduleswithdry,oil-freecompressedair.

D. UnplugthegatedriveleadsconnectingtheIGBTGatestothePWM/GateDrivePCBoard.Inordertopreventdamage

totheIGBT,installjumperplugsintotheIGBTGateDriveConnector.SeeCautionbelow.Jumperplugsaresupplied

witheachpowersource.

E. RemovethecopperbussplatesandbarsconnectedtotheIGBT’s.SavetheM6hardwareconnectingthebusstructure

tothemoduleterminals.Youmayneedtore-usethehardware.Longerhardwarecandamagethemodulebycontact-

ingthecircuitrydirectlybelowtheterminals.

F. RemovetheM6hardwaremountingthemodulestotheheatsink.Savethehardwarebecauseyoumayneedtore-use

it.HardwaretooshortcanstripthethreadsintheAluminumheatsink.Hardwaretoolongcanhitthebottomofthe

holescausingthemodulestohaveinsucientthermalcontacttotheheatsink.Hardwaretoolongortooshortcan

causemoduledamageduetooverheating.

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