ESAB EPP-450 Plasma Power Source User manual

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14

TOUTE DÉCHARGE ÉLECTRIQUE PEUT ÊTRE MORTELLE !

VÉRIFIEZ DE LAISSER UN ESPACE ENTRE LES BORNES À BAGUE, LE

PANNEAU LATÉRAL ET LE TRANSFORMATEUR PRINCIPAL. CET ESPA

CE DOIT ÊTRE SUFFISANT POUR ÉVITER TOUT ARC ÉLECTRIQUE ÉVEN

TUEL. VÉRIFIEZ QUE LES CÂBLES NE GÊNENT PAS LA ROTATION DU

VENTILATEUR DE REFROIDISSEMENT.

UNE PRISE DE TERRE INCORRECTE PEUT ENTRAÎNER DE GRAVES BLES

SURES POUVANT MÊME ÊTRE MORTELLES.

LE CHÂSSIS DOIT ÊTRE CONNECTÉ À UNE PRISE DE TERRE HOMOLO

GUÉE. ASSUREZVOUS QUE LE FIL DE TERRE N’EST PAS BRANCHÉ À

UNE BORNE PRINCIPALE.

TOUTE DÉCHARGE ÉLECTRIQUE PEUT ÊTRE MORTELLE ! TENSION ET

COURANT DANGEREUX !

AVANT DE TRAVAILLER SUR UNE SOURCE D’ÉNERGIE POUR DÉCOUPE

AU PLASMA AVEC LES COUVERCLES RETIRÉS :

• DÉBRANCHEZ L’ALIMENTATION AU NIVEAU DE L’INTERRUPTEUR

MURAL.

• DEMANDEZ À UN TECHNICIEN QUALIFIÉ DE VÉRIFIER LES BARRES

OMNIBUS DE SORTIE (POSITIVES ET NÉGATIVES) AVEC UN VOLT-

MÈTRE.

3.5 Branchements de sortie

DANGER

3.5.1 Câbles de sortie (fournis par le client)

Sélectionnez les câbles de sortie de découpe au plasma (fournis par le client) sur la base d’un câble en cuivre

isolé de 4/0 AWG, 600 V pour chaque 400 A de courant en sortie. Pour 450 ampères à 100 % de la capacité de

découpe, deux cables en parallèle de taille 2/0 AWG de 600 volts devraient être utilisés.

Remarque :

N’utilisez aucun câble de soudure isolé de 100 V.

SECTION 3 INSTALLATION

3.5.2 Procédure de branchements de sortie - Alimentation simple

1. Retirez le panneau d’accès sur la partie inférieure avant de la source d’énergie.

2. Faites passer les câbles de sortie par les ouvertures situées sur la partie inférieure du panneau avant ou à la base de la

source d’alimentation située directement derrière le panneau avant.

3. Branchez les câbles aux bornes appropriées situées à l’intérieur de la source d’alimentation à l’aide de connecteurs à

pression pour câbles portants le label UL.

4. Remettez en place le panneau retiré dans la première étape.

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30

SECTION 4 FONCTIONNEMENT

1. Mettez sous tension en fermant l’interrupteur mural de la ligne.

(L’EPP-401/450 n’est pas équipé d’un interrupteur de marche/

arrêt). Le témoin d’alimentation principale va s’éclairer et le

témoin de défaillance va clignoter avant de s’éteindre.

2. Le bouton d’arrêt d’urgence est tiré.

3. Positionner l’interrupteur Panel / Remote (panneau / à dis-

tance).

4. Positonner le commutateur HIGH / LOW (Haute / Basse) de l’arc

pilote. Si ce dernier est sélectionné par commande à distance,

il doit se trouver en position basse. (Consultez les données

de découpe présentées dans le manuel de la torche.)

5. En mode de panneau, contrôlez la tension préétablie par l’in-

termédiaire du commutateur ACTUAL / PRESET AMPS. Réglez

l’intensité jusqu’à ce que la valeur désirée approximative soit

visible sur l’ampèremètre. En mode de commande à distance,

le positionnement du commutateur à bascule ACTUAL AMPS

/ PRESET AMPS sur la position PRESET AMPS fournira la sortie

initiale de courant commandée à distance.

6. Commencez la découpe au plasma. Cette opération peut

inclure le paramétrage manuel d’autres options en fonction

de l’ensemble du kit plasma.

7. En mode de panneau, réglez l’intensité du courant désirée

après le démarrage du processus de découpe.

8. En cas de panne de démarrage de la découpe ou du mar-

quage, vériez le témoin de défaillance. Si l’un d’eux s’allume,

consultez la section relative au dépannage.

Remarque :

Le témoin de défaillance clignote lors de la première

mise sous tension du contacteur signiant que le

bus c.c. a été normalement alimenté.

4.3 Séquence du fonctionnement

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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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.

52

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.Dierent

interfacescancausethemodulestooperateatdierent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ngertightintheorder:A-B-C-D.Seegurebelow.

F. Fullytighten,inthesameorderabove,toatorqueof35–44in-lbs(4.0–5.0N-M).Seegure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.

I. Replacethetoppanel.

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

Four-PointMountingType

 Partialtightening-A

-B-C-D

 Fullytightening-A

-B-C-D

A

D

C

B

1

2

3

6 (RED)

7 (WHT)

Key Plug

Position 1 (RED)

1-IBGTCollector,FreeWheeling

Diode(FWD)Anode

2-IGBTEmitter

3-FWDCathode

6-IGBTGate

7-IGBTEmitter

threeleads

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ESAB EPP-450 Plasma Power Source User manual

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