ESAB ESP 200 Calibration Procedure Troubleshooting instruction

Brand: ESAB

Model: ESP 200 Calibration Procedure

Type: Troubleshooting instruction

www.esabna.com

DATE: December 17, 2004 BULLETIN NO: P_04_019

Revised – January 4, 2005

TITLE/ PRODUCT NAME: ESP 200 Calibration Procedure

RATING:

_ DIRECTIVE _ _ ALERT

(Action is Required) (Potential Problem)

X_ INFORMATION _ _ PRODUCT IMPROVEMENT

(Action is Optional) (Enhanced Product)

X_ General Distribution _ _ Business Confidential

(Unrestricted) (Restricted Distribution)

PRODUCT SERIES/ MODEL:

ESP-200 Series A PN-36324 and 36974

SERIAL NO:

All serial numbers

SUMMARY:

This procedure allows for field calibration of the ESP-200 voltmeter and ammeter when the

isolation amplifier PCB is replaced

OPERATIONAL IMPACT:

Improves the accuracy of the voltmeter and ammeter compared to actual cutting conditions

ACTION:

Perform the following procedure when replacing the 38094 Isolation Amplifier Printed Circuit

Board assembly. Perform Section 1 to calibrate the voltmeter. Perform Section 2 if using a

DMM to calibrate the ammeter. Perform section 3 using a clamp on ammeter (preferred

method).

CALIBRATION PROCEDURE

for the

38094 ISOLATION AMPLIFIER

Section 1 - Voltmeter Calibration

A hand held digital voltmeter (FLUKE model 77 or equivalent) capable of reading 400V DC is

required to perform this test. This meter will be referred to as the DMM. Set the meter function switch to

Volts DC

Remove the two mounting screws that hold the ESP-200 front meter panel in place. This allows

access to the POT1 and POT2 potentiometers on the isolation amplifier PCB.

View from Front of Power Source Console

Viewed from Rear of Power Source Console

Note

Turning POT1 on the isolation amplifier PCB counter

clockwise increases voltage reading.

1.1 Disable the HF starting circuit to protect the DMM by disconnecting the wire to the HF transformer at

TB5-1. (right front bottom of console )

HF Wire

1.2 Connect the DMM to the console output (torch) connections, Positive (red) lead on torch electrode

terminal, Negative (black).lead on the work connection. The DMM will display a negative output

voltage reading when the main contactor is energized.

1.3 Turn the power switch on the console to ON and press the torch trigger switch with the torch in the

air AWAY FROM any metallic surfaces and the operator. The DMM should display approximately –

330V DC.

1.4 Adjust POT1 on PCB to adjust the front panel voltmeter (V) to agree with this reading on the DMM

within +/- 1 volt.

1.5 Turn the power switch on the console to OFF.

1.6 Remove DMM leads and reconnect the wire at TB5-1.

CALIBRATION PROCEDURE

for the

38094 ISOLATION AMPLIFIER

Section 2 - Ammeter Calibration – Using a DMM

NOTE

During his test the console will be set to operate at a

200 amp output. MAKE SURE that the torch has a

200 amp nozzle

2.1 Set the DMM to read millivolts DC

2.2 Turning POT2 on the PCB clockwise will increase amp reading.

2.3 Remove the left and right side panels.

2.4 Connect the DMM to P6-10 (black) and 11 (red) of the MASTER module control PCB

P6-10 & 11

2.5 Turn the power switch on the console to ON.

2.6 Follow all safety precautions and make a cut. While cutting, have a second operator set the front

panel CCP control for a reading of 100 mv on the DMM.

2.7 Tell the cutting operator to stop cutting.

2.8 Connect the DMM to P6-10 (black) and 11 (red) of the SLAVE module control PCB

P6-10 & 11

2.9 Follow all safety precautions and make a cut. While cutting, have a second operator read the

DMM.

2.10 Add the two DMM readings from step 2.5 and 2.8. The total should be between 195 and 206.

2.11 Adjust POT2 on isolation amplifier PCB until the front panel ammeter (A) reads the total number

from step 2.10.

2.12 Turn the power switch on the console to OFF.

2.13 Replace the two panel mounting screws that hold the meter panel in place.

2.14 Remove DMM leads.

2.15 Replace the left and right side panels.

2.16 Calibration complete.

CALIBRATION PROCEDURE

for the

38094 ISOLATION AMPLIFIER

Section 3 - Ammeter Calibration – Using an Clamp-on Ammeter

NOTE

During his test the console will be set to operate at a 200 amp

output. MAKE SURE that the torch has a 200 amp nozzle

A clamp-on DC ammeter capable of reading 250 AMPS DC is

required for this test. (YOKOGAWA model CL-250 or equivalent.)

Turning POT2 on the PCB clockwise will increase amp reading.

3.1 Place the Amp Clamp around the WORK lead.

3.2 Turn the power switch on the console to ON.

3.3 Follow all safety precautions and make a cut. While cutting, have a second operator set the front

panel CCP control for a reading of 200 amps on the amp clamp.

3.4 Tell the cutting operator to stop cutting.

3.5 Follow all safety precautions and make a cut. While cutting, have a second operator adjust POT2

on the isolation amplifier PCB so that the front panel ammeter (A) reads the same as the amp

clamp.

3.6 Turn the power switch on the console to OFF.

3.7 Replace the two panel mounting screws that hold the meter panel in place.

3.8 Remove the amp clamp from the work lead.

3.9 Calibration complete.

CONTACT:

ESAB Welding & Cutting Products

Product & Service Information Group

843-664-4416 Phone

843-664-5539 FAX

ESAB ESP 200 Calibration Procedure Troubleshooting instruction

ESAB ESP 200 Calibration Procedure Troubleshooting instruction

ESAB ESP 200 Calibration Procedure Troubleshooting instruction

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