ESAB EPP-450 User manual

Brand: ESAB

Model: EPP-450

Category: Welding System

Type: User manual

ESAB EPP-450 is a fan-cooled plasma power source designed for marking and high speed plasma mechanized cutting applications. It provides a cutting range of 10A/84V to 450A/200V, allowing for precise and efficient cutting of various materials. Additionally, it features thermal protection against overload and can be connected in parallel to increase the current range.

Valid for serial no. 015-xxx-xxxx0558 007 946 GB 20110706

EPP-450

Instruction manual

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TOCe

Rights reserved to alter specifications without notice.

1SAFETY 4...........................................................

2 INTRODUCTION 6...................................................

2.1 Equipment 6................................................................

2.2 Features 6.................................................................

3 TECHNICAL DATA 6.................................................

4 INSTALLATION 7....................................................

4.1 Lifting instructions 8.........................................................

4.2 Delivery check 8............................................................

4.3 Location 8..................................................................

4.4 Mains supply 9..............................................................

4.4.1 Recommended fuse sizes and minimum cable area 9.......................

4.4.2 Connecting the incoming mains cable 9....................................

4.4.3 Output cables (customer supplied) 9......................................

4.4.4 Connecting supply and return cables, power source in single operation 9.......

4.5 Parallel installation 11.........................................................

4.5.1 Parallel connection of two power sources 11................................

4.5.2 Marking with two parallel power sources 15.................................

5 OPERATION 17.......................................................

5.1 Connections and control devices 17............................................

5.1.1 Key to symbols 17.......................................................

5.1.2 Control panel 17.........................................................

5.1.3 Operate modes: cutting with high respectively low current and marking mode 19.

5.2 Sequence of operation 20.....................................................

6 MAINTENANCE 21....................................................

6.1 Inspection and cleaning 21....................................................

6.2 Lubrication 22...............................................................

7 FAULT-TRACING 22..................................................

8 ORDERING SPARE PARTS 23.........................................

DIAGRAM 25............................................................

ORDERING NUMBER 38.................................................

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1SAFETY

Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on or

near the equipment observes all the relevant safety precautions. Safety precautions must meet the

requirements that apply to this type of equipment. The following recommendations should be ob-

served in addition to the standard regulations that apply to the workplace.

All work must be carried out by trained personnel well-acquainted with the operation of the equip-

ment. Incorrect operation of the equipment may lead to hazardous situations which can result in in-

jury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:

S its operation

S location of emergency stops

S its function

S relevant safety precautions

S welding and cutting

2. The operator must ensure that:

S no unauthorized person is stationed within the working area of the equipment when it is

started up.

S no-one is unprotected when the arc is struck

3. The workplace must:

S be suitable for the purpose

S be free from drafts

4. Personal safety equipment

S Always wear recommended personal safety equipment, such as safety glasses, flame-proof

clothing, safety gloves.

S Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautions

S Make sure the return cable is connected securely.

S Work on high voltage equipment may only be carried out by a qualified electrician.

S Appropriate fire extinquishing equipment must be clearly marked and close at hand.

S Lubrication and maintenance must not be carried out on the equipment during operation.

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WARNING

Read and understand the instruction manual before installing or operating.

Arc welding and cutting can be injurious to yourself and others. Take precausions when welding and

cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard

data.

ELECTRIC SHOCK - Can kill

S Install and earth the unit in accordance with applicable standards.

S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

S Insulate yourself from earth and the workpiece.

S Ensure your working stance is safe.

FUMES AND GASES - Can be dangerous to health

S Keep your head out of the fumes.

S Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone

and the general area.

ARC RAYS - Can injure eyes and burn skin.

S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.

S Protect bystanders with suitable screens or curtains.

FIRE HAZARD

S Sparks (spatter) can c ause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE - Excessive noise can damage hearing

S Protect your ears. Use earmuffs or other hearing protection.

S Warn bystanders of the risk.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

WARNING

Do not use the power source for thawing frozen pipes.

CAUTION

Class A equipment is not intended for use in residential locations where

the electrical power is provided by the public low-voltage supply system.

There may be potential difficulties in ensuring electromagnetic

compatibility of class A equipment in those locations, due to conducted

as well as radiated disturbances.

CAUTION

This product is solely intended for plasma cutting.

CAUTION

Read and understand the instruction manual before

installing or operating.

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Dispose of electronic equipment at the recycling facility!

In observance of European Directive 2002/96/EC on Waste Electrical and Electronic

Equipment and its implementation in accordance with national law, electrical and/or

electronic equipment that has reached the end of its life must be disposed of at a

recycling facility.

As the person responsible for the equipment, it is your responsibility to obtain

information on approved collection stations.

For further information contact the nearest ESAB dealer.

2 INTRODUCTION

Plasma power source EPP-450 is designed for marking and high speed plasma

mechanized cutting applications. It can be used with for example PT-15, PT-19XLS,

PT-600 and PT-36 torches along with the Smart Flow II, a computerized gas

regulation and switching system.

2.1 Equipment

The power source is supplied with:

S Instruction manual

2.2 Features

S Fan cooled

S Protection in the event of connecting the incorrect power supply

S Thermal protection in the event of overload

S Can be connected in parallel to increase the current range.

3 TECHNICAL DATA

EPP-450

Mains voltage

3~ 380 V, 400 V, +/–10 %, 50 Hz

Primary current I

max

167 A at 380 V, 159 A at 400 V

Setting range 10 A / 84 V- 450 A / 200

Permitted load, duty cycle 100 % 450 A / 200 V

Output data, duty cycle 100 %

cutting with high current

cutting with low current

marking with low current

50 A at 100 V / 450 A at 200 V

35 A at 94 V / 100 A at 120 V

10 A at 84 V / 100 A at 120 V

Max power consumption

at duty cycle 100 %

90 kW

Open-circuit voltage U

cutting with high current

cutting with low current

marking

406 V at 380 V

427 V at 400 V

430 V vid 380 V

427 V vid 400 V

414 V vid 380 V

413 V vid 400 V

360 V vid 380 V

369 V vid 400 V

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EPP-450

Operating temperature -10to40°C

Transportation temperature -20to55°C

Dimensions, l x w x h 114.3 x 94.6 x 102,2 mm

Weight 850 kg

Enclosure class IP 21

Duty cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or cut at

a certain load without overloading. The duty cycle is valid for 40° C.

Enclosure class

The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid

objects or water. Apparatus marked IP21 are intended for indoor use.

4 INSTALLATION

The installation must be carried ou t by a p rofession al.

WARNING!

ELECTRIC SHOCKS CAN KILL Take precautionary measures against electric

shocks. Ensure that all power supplies are disconnected

– switch off the switch at

the wall socket and pull out the equipment's power cable from the socket before

making any electrical connections in the power source.

WARNING!

It is very important that the chassis is connected to the electric protective earth, to

prevent electric shocks and electrical accidents. Ensure that protective earth is not

connected to any phase conductors by mistake.

CAUTION

This product is intended for industrial use. In a domestic environment this product may

cause radio interference. It is the user's responsibility to take adequate precautions.

CAUTION!

Conducting dust and contaminants inside the power source can cause electrical flashovers.

This can damage the equipment. If dust is allowed to collect inside the power source,

short-circuits can occur (see the chapter regarding maintenance).

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4.1 Lifting instructions

WARNING

The product must be lifted using a fork

lift truck or as follows:

4.2 Delivery check

1. Remove the packaging and inspect the equipment for damage that was not

immediately apparent upon reception of the delivery.

Immediately report any damage to the delivery company.

2. Check that here ar e no loose parts in the packaging before it is r ecycled.

3. Check the cooling air gaps and ensure that any obstructions are removed from

there.

4.3 Location

CAUTION!

Use both lifting eyes when lifting the power source or when lifting with a crane.

S Minimum permitted distance to walls or other cold air obstructions in front of and

behind the power source is 1 m.

S Place the power source so that the top and side panels can b e removed for

maintenance, cleaning and inspection.

S Place the power source relatively close to a fused mains socket.

S Keep the surface under the power source clean, so that the cold air does not

bring any contaminants in with it.

S The area around the equipment must be as free of dust and vapour as possible

and also be as cool as possible. These factors affect the cooling capacity.

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4.4 Mains supply

The power source is 3-phase driven. Th e mains power is taken from a socket with a

switch, anti-surges or MCBs, in accordance with local regulations.

4.4.1 Recommended fuse sizes and minimum cable area

EPP-450 50 Hz

Mains voltage 380 V 400 V

Mains cable area mm

4 G 90*) 4 G 90*)

Phase current I

1eff

167 A 159 A

Fuse, anti-surge 200 A 200 A

*) Supplied by the customer.

NOTE! The mains cable areas and fuse sizes as shown above are in accordance with Swedish

regulations. Use the power source in accordance with the relevant national regulations.

4.4.2 Connecting the incoming mains cable

1. Remove the left-hand side panel

2. Insert the mains cable through the opening (1) in the rear panel

3. Secure the cable with the strain relief at the opening

4. Connect the protective earth to the main earth terminal.

5. Connect the phase conductors to the phase terminals

1 Opening for mains cable in the rear panel 2 Main earth

terminal

3 Phase terminals

4.4.3 Output cables (cu sto mer supplied)

Choose p lasma cutting output cables (customer supplied) on the basis of one 105

, 600 volt insulated copper cable for each 400 amps of output current. For 450

amps, 100% duty cutting, two parallel 70 mm

600 insulated volt cables should be

used.

(+)

(--)

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4.4.4 Connecting supply and return cables, power source in single operation

1. Remove the safety plate from the front of the power source.

2. Insert the output cables through the openings at the bottom of the front panel or

at the bottom of the power source immediately behind the front panel.

3. Connect the cables to the output terminals in the power source.

4. Reinstall the safety plate on the front of the power source.

Safety plate removed

EPP-450

Power source

return electrode *Two parallel 70 mm

leads are

recommended for 450A 100% duty

operation. For operation at or below

400A 100% duty, one 105 mm

lead

may be used. Also, for 450A operation

at or below 80% duty, one 105 mm

lead may be used. 80% maximum duty

means operation for no more than 8

minutes in any 10 minute time interval.

pilot arc

* 2 - 105 mm

600V

positive leads to workpiece

* 2 - 105 mm

600V

negative leads in

arc starter box (h.f.

generator

1-2,5mm

600V

lead to pilot arc connection

in arc starter box (h.f.

generator)

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4.5 Parallel installation

Two power sources may be connected together in parallel to extend the output

current range.

CAUTION!

When cutting below 100 A only use one power source. We recommend removing the

negative conductor from the auxiliary power source prior to work with current less than 100

A. The disconnected conductor must be isolated safely to prevent the risk of electric shock.

4.5.1 Parallel connection of two power sources

CAUTION!

The main power source has the electrode conductor (negative conductor) jumpered. The

auxiliary power source has the return conductor (positive conductor) jumpered.

1. Connect outgoing negative cables to the arc start box (high frequency

generator).

2. Connect the outgoing positive cables to the workpiece.

3. Connect positive and negative cables between the power sources.

4. Connect the pilot arc cable to the pilot arc terminal in the power source. The

auxiliary power sour ce pilot arc connection is not used. The pilot arc cir cuit is not

connected in parallel.

5. Set the pilot arc switch (marked HIGH/LOW) on the auxiliary power source to

LOW.

6. Set the pilot arc switch (marked HIGH/LOW) on the main power source to HIGH.

7. If the output current is remotely controlled by direct current reference signal

0.00–10.00 V, the same reference signal must be connected to both power

sources. Connect both power sources' J1-G (direct current positive 0.00 to 10.00

V) and connect both power sources' J1-P (negative). When both power sources

are in operation, the output current can be calculated according to the following

formula: (output current) = (reference voltage) x 160 in the high current area.

The power source does not have a mains voltage switch. T hen mains voltage is

switched off using the switch at the power socket.

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Parallel connection of two power sources when both power sources are used.

The connections below are suitable for parallel operation up to 800A at 100% duty or

900A at or below 80% duty. 80% duty means 8 minutes of arc “on” time in any 10

minute period.

EPP-450 EPP-450

Auxiliary power source Main power source

return electrode return electrode

(+) (-) (+) pilot arc (-)

1-2.5mm

600V

lead to pilot arc

connection in arc starter

box (h.f. generator)

2 - 105 mm

600V

negative leads

in arc starter box

(h.f. generator)

2-105 mm

600 V

positive leads

to workpiece

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For 100% duty operation above 800A refer to the connection diagram below.

EPP-450 EPP-450

Auxiliary power source Main power source

return electrode return electrode

(+) (-) (+) pilot arc (-)

70 mm

600 V

cable jumpers

between units

1-2.5mm

600V

lead to pilot arc

connection in arc starter

box (h.f. generator)

3-70mm

600V

negative leads

in arc starter box

(h.f. generator)

3-70 mm

600 V

positive leads

to workpiece

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Connections for parallel installation of two power sources with only one power

source in operation.

Connections for single power source operation up to 400A, 100% duty or 450A up to

a maximum of 80% duty. Maximum 80% duty means operation for no more than 8

minutes in any 10 minute time interval.

EPP-450 EPP-450

Auxiliary power source Main power source

return electrode return electrode

(+) (-) (+) (-)

Disconnect negative connection from

auxiliary power source and insulate to

convert from two to one power source

3-70mm

600 V

positive leads

to workpiece

3-70mm

600V

negative leads in arc starter box

(h.f. generator)

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Connections for parallel installation of two power sources with only one power

source in operation.

The connections below are suitable for single power supply operation up to 450A up

to 100% duty.

EPP-450 EPP-450

Auxiliary power source Main power source

return electrode return electrode

(+) (-) (+) (-)

Disconnect negative connection from

supplemental power source and insulate to

convert from two to one power source

3- 70 mm

600 V

positive leads

to workpiece

3-70mm

600V

negative leads in arc starter box

(h.f. generator)

4.5.2 Marking with two parallel power sources

Two power sourcess, connected in parallel, and can be used for marking down to

20A and cutting from 100A up to 1000A. Two simple modifications can be made to

the supplemental power source in order to permit marking down to 10A. T he

modifications are necessary only if marking below 20A is required.

Field modifications to permit marking down to 10 A:

1. Changes to the primary power source: None

2. Changes to the supplement power source:

a. Unplug the WHT wire from the coil of K12

b. Remove the jumper between TB7-7 and TB7-8. The jumper is a link built into

the terminal strip.

NOTE:

These modifications disable the current output of the secondary power supply

only in the marking m ode. The modifications have no effect on the output current

of the secondary power supply while cuttingin either HI or LOW current cutting

modes.

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Operation with two parallel connected power sources

1. Signal supply main and auxiliary power sour ce with signals for switching on and

off contactors, marking/cutting and current range high/low. Same V

ref-

signal must

supply both power sources.

2. When marking with parallel connected power sources when the auxiliary power

source is not modified, the power control's transfer function is equal to the sum

of each power source transfer function: I

out

=20xV

ref

. Each power source will

be supplied with the same amount of power.

When marking with parallel connected power sources when the auxiliary power

source is not modified, the power control's transfer function is equal to the main

power source's control transfer function: I

out

=10xV

ref

. Both power sources

switch on when ther e is a contactor signal, but the auxiliary power source's

power output is off when working in marking mode.

3. When cutting in the low current range, current control's transfer function is equal

to the sum of both power sources' current regulation's transfer function: I

out

=20

ref

. For current currents less than 100 A, disconnect the negative cable(s)

from the auxiliary power source and isolate the cable ends to prevent the risk of

electric shock. When the auxiliary power sour ce is disconnected, the curr ent

regulation's transfer function is equal to the m ain power source's current

regulation transfer function: I

out

=10xV

ref.

4. When cutting in the high current range, current control's transfer function is equal

to the sum of both power sources' current regulation's transfer function: I

out

160 x V

ref

. For current currents less than 100 A, disconnect the negative cable(s)

from the auxiliary power source and isolate the cable ends to prevent the risk of

electric shock. Use the low current operating mode.

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5OPERATION

General safety regulations for handling of the equipment can be found on

page 4. Read through before you start using the equipment!

5.1 Connections and control devices

1 Connection for cooling unit 9 Controls for current settings

2 Switch for actual and setpoint value display 10 Switch for control panel or remote control

unit

3 Ammeter 11 White indicating lamp, mains power supply

4 Voltmeter 12 White indicating lamp, contactor on

5 Emergency stop 13 Orange indicating lamp, overheating

6 Connection emergency stop 14 Red indicating lamp, fault

7 Switch for high or low pilot arc current 15 Red indicating lamp, restart error

8 Connection for remote control unit, CNC unit

5.1.1 Key to symbols

Emergency stop (5) Pilot arc current (7)

Remote control unit (8) Current (9)

Mains voltage (11) Contactor on (12)

Over heating (13) Fault indication (14, 15)

5.1.2 Control panel

Mains voltage indicator (11)

Lights when the m ains voltage is connected to the power source.

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Contactor on (12)

Lights when the mains voltage contactor is on

Overheating protection ( 13)

Lights when the power source has overheated.

Fault indication (14)

Lights when the cutting process does not work normally or when incoming mains

voltage deviates more than ±10 % from the nominal value.

Fault indication that requires restart (15)

Lights in the event of serious fault. Incoming mains voltage must be switched off and

stay off for at least 5 seconds before switching back on.

Current control potentiometer (9)

The power source can be set from 10 to 100 A in the low current range and from 50

to 600 A in the high current range. Only used in “PANEL” mode.

Switch co n t rol pan el / remote operation (10)

This switch is used to select where the current is controlled from.

S With the switch in the local control mode, PANEL mode, use the potentiometer

on the control panel.

S With the switch in the remote control mode, REMOTE mode, the current is

controlled by e xternal signal (CNC).

Switch HIGH/LOW for the p ilo t arc (7)

Used for setting desired pilot arc current. LOW mode usually works best for cutting

currents up to 100 A, but this can vary depending on the type of gas and torch type

used and the material. How to set high/low is given in the cutting data included in the

user instructions for the burner. When the power source is set for marking, this

switch must be set to LOW.

Emergency stop connection (6)

The emergency stop connection gives access to the emergency stop's breaking

contact. The contact is connected to J4- A and J4-B and breaks when the emergency

stop button is pressed. This gives a signal to the plasma cutting equipment stating

that the power source is in emergency stop mode.

Emergency stop button (5)

The emergency stop button affects the emergency stop switch. When the button is

pressed, emergency stop status is active. T he power source cannot provide any

power, even if a start signal is given.

Display window (3, 4)

Voltage and current are shown in these display windows during cutting and marking.

The ammeter can be switched from displaying the actual value of the set setpoint

value before cutting starts, to give a n indication of how high the cutting cu rrent will

be.

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Switch actual valu e/setp o in t value display (2)

Switch for switching between display of cutting current's actual value, ACTUAL

AMPS, and setpoint value, PRESET AMPS. The switch spring returns upwards, to

ACTUAL AMPS mode. In ACTUAL AMPS mode, the cutting current's actual value is

shown in the ammeter' s display window.

in PRESET AMPS mode (down) an approximate value for the cutting current' s

setpoint value is shown. The value is obtained by measuring the voltage reference

signal Vref 0 to 10 VDC. The reference signal is obtained from the current

potentiometer when the control switch PANEL/REMOTE is in the local operating

mode PANEL (up) and from a remote reference (J1-J / J1-L(+)) when the control

switch is in control switch mode, REMOTE (down). In both high and low current

modes the displayed setpoint value is an approximate value for the actual value that

the current receives.

The switch can be set between ACTUAL AMPS and PRESET AMPS at any time

without affecting the cutting process.

5.1.3 Operate modes: cu ttin g with h ig h respectively low current an d marking

mode

1. The power source has two cutting modes: high current and low current. In low

current mode, the cutting currents from 35 to 100 A can be used, corresponding

voltage reference V

ref

3.50 to 10,00 V. In high current mode, the cutting current

can be regulated steplessly from 50 to 450 A using the current potentiometer on

the control panel or with a r emote reference signal connected to J1. The power

source has low current mode as standard setting. If the high current mode is

used, 115 VAC must supply J1-T by connecting an isolated contact between

J1-T and J1- R.

When the remote signal is used, 50 A reference signal voltage corresponds to

1.00 VDC and 450 A corresponds to 9.00 VDC. If the remote reference voltage

exceeds 9.00 VDC, internal limiting circuits in the power source limit the cutting

current to a maximum of 475 A.

The power source has cutting as standard setting. T o switch to marking mode,

the control signal for this must be supplied from a remote control unit.

2. The switch is set to marking mode with the external, isolated relay or external,

isolated switch that connects J1-R (115 VAC) with J1-M. The electrical circuit

diagram is in the inside of the rear panel. Contact closure for marking mode must

occur at least 50 ms before start command (signal for contact on) is given.

In marking mode, the outgoing current can be regulated steplessly from 10 to

100 A using the current potentiometer on the control panel or with a remote

reference signal connected to J1. In marking mode, the power source

automatically switches to low current mode.

During remote operation in low current mode, 10 A reference signal voltage

corresponds to 1.00 VDC and 100 A corresponds to 10.00 VDC. During remote

operation in high current mode, 50 A reference signal voltage (V

ref

) corresponds

to 1.00 VDC and 450 A corresponds to 9.00 VDC. If the remote reference

voltage exceeds 9.00 VDC, internal limiting circuits in the power source limit the

cutting current to a maximum of 475 A.

In marking mode, the auxiliary circuit is used for arc lighting in cutting mode off.

Resulting idle voltage is about 360 V at nominal incoming mains voltage*. K12

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then closes and connects R60 to R67 in the output circuit. These resistors

stabilise the current when marking with low current. The power source can be

run with intermittence factor 100% in marking m ode in the entire current range

10 to 100 A.

10 A output current is obtained using resistors R60 to R67. Default set lowest

starting current (set using switch set SW2) is 3 A. Standard setting for switch set

2 (SW2) on the control card behind the access door up to the right in the front

panel is that switches 5, 6, 7 and 8 are off (down).

* Approx. 345 V in the version for 380/400 V during operation with 380 V mains

voltage.

5.2 Sequence of operation

1. Power the equipment by switching on the switch at the power

socket (the power source does not have its own mains power

switch). The m ains power lamp comes on and the fault

indication lamp flashes and then goes out.

2. Pull out the emergency stop button.

3. Select local or remote operation from the control panel.

4. Set the pilot switch to the desired mode (HIGH or LOW). If

HIGH or LOW mode for the pilot arc is to be operated remotely,

the switch on the panel must be in LOW mode, see cutting data

in the torch user manual.

5. During local operation from the panel you can display the

current's setpoint value using the display switch ACTUAL

AMPS/PRESET AMPS. Adjust the setpoint current until the

desired value is displayed in the ammeter display window.

During remote operation, the display switch must be in

PRESET AMPS mode to display the setpoint current the

remote operation system has initially been set to.

6. Start plasma cutting. This can consist of manually setting other

options, depending on the equipment's configuration and

scope.

7. During local operation from the control panel, adjust the current

to the desired value since cutting started.

8. If cutting or marking operation does not start, check the fault

indication lamps. If any fault indication lamp comes on, see the

fault tracing chapter.

Note:

The fault indication lamp flashes when the contactor is first

switched on, to indicate that the d irect current bus is powered

normally.

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ESAB EPP-450 User manual

Brand: ESAB

Model: EPP-450

Category: Welding System

Type: User manual

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ESAB EPP-450 User manual

ESAB EPP-450 User manual

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