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ESAB Precision Plasmarc EPP-600 Instruction Manual Download Page 51

51

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  0558038287

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  0558038287

Faulty left PWM / Drive PCB

Replace PCB2  P/N 0558038308

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  0558038287

Faulty right PWM / Drive PCB

Replace PCB3  P/N 0558038308

Summary of Contents for Precision Plasmarc EPP-600

Page 1: ...EPP 600 Plasma Power Source Instruction Manual 0558006514 08 2010 ...

Page 2: ...from improper use faulty maintenance damage improper repair or alteration by anyone other than the manufacturer or a ser vice facility designated by the manufacturer Be sure this information reaches the operator You can get extra copies through your supplier These INSTRUCTIONS are for experienced operators If you are not fully familiar with the principles of operation and safe practices for arc we...

Page 3: ...rc Initiation Settings 37 4 5 EPP 600 V I Curves 40 5 0 Maintenance 43 5 1 General 43 5 2 Cleaning 43 5 3 Lubrication 44 6 0 Troubleshooting 45 6 1 General 45 6 2 Fault Indicators 45 6 3 Fault Isolation 48 6 4 Testing and Replacing Components 56 6 5 Control Circuit Interface Using J1 and J6 Connectors 62 6 6 Auxiliary Main Contactor K3 and Solid State Contactor Circuits 64 6 7 Main Contactor K1A K...

Page 4: ...4 ...

Page 5: ... clothing 5 Protect other personnel from arc rays and hot sparks with a suitable non flammable partition or curtains 6 Usegogglesoversafetyglasseswhenchippingslag orgrinding Chippedslagmaybehotandcanflyfar Bystanders should also wear goggles over safety glasses FIRES AND EXPLOSIONS Heat from flames and arcs can start fires Hot slagorsparkscanalsocausefiresand explosions Therefore 1 Remove all comb...

Page 6: ... 2 ExposuretoEMFmayhaveotherhealtheffectswhich are unknown 3 Welders should use the following procedures to minimize exposure to EMF A Route the electrode and work cables together Secure them with tape when possible B Never coil the torch or work cable around your body C Do not place your body between the torch and work cables Route cables on the same side of your body D Connecttheworkcabletothewo...

Page 7: ...s available from Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 EQUIPMENT MAINTENANCE Faulty or improperly maintained equipment can cause injury or death Therefore 1 Alwayshavequalifiedpersonnelperformtheinstal lation troubleshooting and maintenance work Do not perform any electrical work unless you are qualified to perform such work 2 Before performing any maintenance ...

Page 8: ...d Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances Meaning of symbols As used throughout this manual Means Atten tion Be Alert Your safety is involved Meansimmediatehazardswhich if not avoided will result in im mediate serious personal injury or loss of life Means potential hazards which could result in personal injury or loss of life Meanshazardswhichcouldr...

Page 9: ...ascalientesconunacortina adecuadano flamable como división 6 Usecaretaprotectoraademásdesusgafasdesegu ridad cuando esté removiendo escoria o puliendo La escoria puede estar caliente y desprenderse con velocidad Personas cercanas deberán usar gafas de seguridad y careta protectora FUEGO Y EXPLOSIONES El calor de lasflamasyelarco puedenocacionar fuegos Escoria caliente y las chispas pueden causar f...

Page 10: ...lectromagnéticos EMF puede causar otros efectos de salud aún desconocidos 3 Los soldadores deberán usar los siguientes proced imientos para minimizar exponerse al EMF A Mantenga el electrodo y el cable a la pieza de trabajo juntos hasta llegar a la pieza que usted quiere soldar Asegúrelos uno junto al otro con cinta adhesiva cuando sea posible B Nunca envuelva los cables de soldar alrededor de su ...

Page 11: ... Equipo defectuoso o mal mantenido puede cau sar daño o muerte Por lo tanto 1 Siempre tenga personal cualificado para efec tuar l a instalación diagnóstico y mantenimiento del equipo No ejecute ningún trabajo eléctrico a menos que usted esté cualificado para hacer el trabajo 2 Antes de dar mantenimiento en el interior de la fuente de poder desconecte la fuente de poder del suministro de electricid...

Page 12: ...ata de su seguridad Significa riesgo inmediato que de no ser evadido puede resultar inmediatamente en serio daño personal o la muerte Significa el riesgo de un peligro potencial que puede resultar en serio daño personal o la muerte Significa el posible riesgo que puede resultar en menores daños a la persona secCion 1 sEGURIDAD ...

Page 13: ...nt les informations de précaution provenant des références dans la section desInformationsdesécuritésupplémentaires Avantde procéderàl installationoud utiliserl unité assurez vous de lire et de suivre les précautions de sécurité ci des sous dans les manuels les fiches d information sur la sécuritédumatérieletsurlesétiquettes etc Toutdéfaut d observer ces précautions de sécurité peut entraîner des ...

Page 14: ...I ASC Standard Z49 1 à la page suivante pour des recommandations spécifiques concernant la ventilation 1 Assurez vous que le châssis de la source d alimentation est branché au système de mise à la terre de l alimentation d entrée 2 Branchez la pièce à traiter à une bonne mise de terre électrique 3 Branchez le câble de masse à la pièce à traiter et assurezunebonneconnexionafind éviterlerisque de ch...

Page 15: ...ant des chimiques consi déresparl étatdelaCaliforniecomme étant une cause des malformations congénitales et dans certains cas du cancer California Health Safety Code 25249 5 et seq MANIPULATION DES CYLINDRES La manipulation d un cylindre sans observerlesprécautionsnécessaires peut produire des fissures et un échappement dangereux des gaz Unebrisuresoudaineducylindre delasoupapeou du dispositif de ...

Page 16: ...tre sécurité est en jeu Signifie un danger immédiat La situation peut entraîner des blessures graves ou mortelles Signifieundangerpotentielquipeutentraînerdes blessures graves ou mortelles Signifieundangerquipeutentraînerdesblessures corporelles mineures DANGER AVERTISSEMENT ATTENTION section 1 sÉCURITÉ ...

Page 17: ...forklift clearance for transport Parallel supplemental power source capabilities to extend current output range EPP 600380 400V 50 60Hz CE EPP 600 460V 60Hz EPP 600 575V 60Hz Part Number 0558006473 0558006474 0558006475 Output 100 duty cycle Voltage 200 VDC Current range DC marking 12A to 600A Current range DC cutting 50A to 600A Power 120 KW Open Circuit Voltage OCV 402 423 VDC 427 VDC 427 VDC In...

Page 18: ...18 section 2 description 2 3 Dimensions and Weight 114 3 mm 45 00 94 6 mm 37 25 102 2 mm 40 25 Weight 825 kg 1814 lbs ...

Page 19: ...ct louvers for air obstructions 3 3 Placement Note Use both lifting eyes when transporting from overhead A minimum of 1 M 3 ft clearance on front and back for cooling air flow Plan for top panel and side panels having to be removed for maintenance cleaning and inspection Locate the EPP 600 relatively close to a properly fused electrical power supply Keep area beneath power source clear for cooling...

Page 20: ...in raceway or cable Local codes should be followed if they specify sizes other than those listed above During heavy duty cutting at 600A input current can momentarily rise above 200A and cause nuisance blowing of 200A fuses When cutting currents are below 500A 200A fuses are sufficient To estimate the input current for a wide range of output conditions use the formula below Dedicated power line ma...

Page 21: ...PP 600 NOTICE 1 Remove left side panel of the EPP 600 2 Thread cables through the access opening in the rear panel 3 Secure cables with a strain relief or conduit coupling not sup plied at the access opening 4 Connect the ground lead to the stud on the chassis base 5 Connect the power lead ring terminals to the primary termi nals with supplied bolts washers and nuts 6 Connect the input conductors ...

Page 22: ... terminal Electric Shock Can Kill Dangerous Voltage And Current Any time working around a plasma power source with cov ers removed DISCONNECT POWER SOURCE AT THE LINE WALL DISCONNECT HAVE A QUALIFIED PERSON CHECK THE OUTPUT BUS BARS POSI TIVE AND NEGATIVE WITH A VOLTMETER 3 5 Output Connections WARNING WARNING WARNING 3 5 1 Output Cables customer supplied Choose plasma cutting output cables custom...

Page 23: ... using UL listed pressure wire connectors 4 Replace panel removed during the first step Two EPP 600 power sources may be connected together in parallel to extend the output current range 3 6 Parallel Installation caution Parallel power source minimum output current exceeds recommend ed amounts when cutting below 100A Use only one power source for cutting below 100A We recommend disconnecting the n...

Page 24: ...e to HIGH 7 If a remote 0 00 to 10 00 VDC current reference signal is used to set the output current feed the same signal into both power sources Connect J1 G positive 0 00 to 10 00 VDC of both power sources together and connect J1 P negative of both power sources together With both power sources operating the output current can be predicted using the following formula output current amps referenc...

Page 25: ...G S u p p l e m e n t a l Power Source Primary Power Source work work electrode electrode 3 4 0 600V positive leads to workpiece 3 4 0 600V negative leads in arc starter box h f generator Disconnect nega tive connection from supplemental power source and insulate to convert from two to one power source EPP 600 EPP 600 Do not operate the EPP 600 with Covers Removed High voltage components are expos...

Page 26: ...ALLEL EPP 600 S 1 Provide Contactor On Off Cut Mark Pilot Arc Hi Lo signals to both Primary Supplemental units for both cutting marking When marking both power sources are powered up but the Mark Signal disables the output of the Supple mental Power Source if it has been modified for marking down to 12A If the Supplemental Power Source has not been modified it will provide the same output current ...

Page 27: ... 3 installation 3 7 1 CNC Interface Cables with Mating Power Source Connector and Unterminated CNC Interface 3 7 2 CNC Interface Cables with Mating Power Source Connectors at Both Ends GRN YEL RED 4 GRN YEL RED 4 ...

Page 28: ...28 section 3 installation 3 7 3 Water Cooler Interface Cables with Mating Power Source Connectors at Both Ends ...

Page 29: ... 0 10 0V DC Vref Iout Vref x 80 CNC Common Floating S T T Common Connected to Earth Grounded Work Through the Output Feedback for Constant Current Servo Twisted Pair Left IGBT Modules See Note Right IGBT Modules T Left Hall Sensor Right Hall Sensor L1 Blocking Diodes Blocking Diodes L2 Free Wheeling Diodes See Note T T1 T1 Contact on Pilot Arc Contactor 425V Peak 250V Peak Boost Starting Circuit B...

Page 30: ...ronic switches some small fluctuations of output called ripple remain The EPP 600 utilizes a patented power circuit combining the output of two choppers each providing approximately half the total output in a manner that reduces ripple The choppers are synchronized so that when the ripple from the first chopper is increasing output the second chopper is decreasing output The result is the ripple f...

Page 31: ...or establishing a pilot arc This circuit disengages when the cutting or marking arc is established The Bus voltage for the 400V 50Hz model is approximately 320V DC section 4 operation The EPP 600 Block Diagram after Subsection 6 4 4 shows the main functional elements of the power source T1 the Main Transformer provides isolation from the primary power line as well as the proper voltage for the 375...

Page 32: ... overheated D Fault Indicator illuminates when there are abnormalities in the cutting process or when the input line voltage falls outside of the required nominal value by 10 E Power Reset Fault Indicator illuminates when a serious fault is detected Input power must be disconnected for at least 5 seconds and then reapplied F Current Dial Potentiometer EPP 600 dial shown EPP 600 has a range of 12 t...

Page 33: ...ecting the power source to CNC remote control L 8 pin plug for connecting the power source to the water cooler I Pilot Arc HIGH LOW Switch Used to select amount of pilot arc current desired As a general rule for 100 amperes and below a setting of LOW is used This can vary depending on gas material and torch used High Low settings are specified in cutting data included in the torch manual When the ...

Page 34: ...t reference signal Vref The reference signal comes from the CURRENTPOTENTIOMETERwiththePANEL REMOTEswitchinthePANEL UP position and from a remote reference signal J1 J J1 L with the PANEL REMOTE switch in the REMOTE DOWN position The value displayed on the OUTPUT AMMETER will be the value of Vref volts times 80 For example a reference signal of 5 00V will result in a preset reading of 400 Amps on ...

Page 35: ...e the output current is adjusted through a single continuously adjustable range from 12A through 600A using either the Current Potentiometer on the front panel or a remote current reference signal fed into connec tor J1 When using a remote signal 12A corresponds to a current reference signal of 0 15VDC and 600A corresponds to a signal of 7 50VDC For signals over 8 00V the power source internally l...

Page 36: ...ne 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 ...

Page 37: ...hieve full current 800 msec Dwell Time 50 msec These timing functions can be disabled or adjusted to suit individual system requirements Start Current Wave Form With Soft Start OFF Cut Current 1OUT 80 VREF Approx 2 msec time to full current DC Output Current Time Start Current Wave Form With Soft Start ON Cut Current 1OUT 80 VREF Start Current Time to full current 800 msec Dwell Time DC Output Cur...

Page 38: ...o the minimum dwell time of 10 msec Switch 1 10 msec dwell time Switch 2 20 msec dwell time Switch 3 40 msec dwell time Switch 4 80 msec dwell time The default setting is with switch 3 on 40 msec 10 msec minimum 50 msec 4 4 3 Adjusting the Minimum Start Current Minimum Start Current is controlled by selection of positions 5 through 8 of SW2 When a switch is pushed on its value is added to the fact...

Page 39: ...ingcurrent that is 50 of the cutting current Up Slope Timer Three position switch located next to the start current poten tiometer Time is from start current after dwell ends to full current Factory default 800 msec Left position 250 msec Center position 800 msec Right Position 1200 msec 90 80 70 60 50 40 30 20 10 0 0 1 2 3 4 5 6 7 8 9 10 Percentage of Cutting Current Start Current Pot Setting Sta...

Page 40: ...tart Circuit Off in Marking Mode Max Output Voltage Nominal Line I OUT 80 x V REF MIN MARK RATING VREF 0 150V DATA PLATE MAX RATING section 4 operation 4 5 1 EPP 600 V I Curves for 460V and 575V 60Hz Inputs Output Voltage Volts Output Current Amperes 427V Open Circuit Voltage Output of Boost Start Circuit Off in Marking Mode I OUT 80 x V REF Max Output Voltage Nominal Line Internal Current Limit M...

Page 41: ... Circuit Off in Marking Mode Max Output Voltage Nominal Line I OUT 80 x V REF MIN MARK RATING VREF 0 150V DATA PLATE MAX RATING section 4 operation 4 5 2 EPP 600 V I Curves for 380 400V 50 60Hz Inputs Output Voltage Volts Output Current Amperes 423V Open Circuit Voltage Output of Boost Start Circuit Off in Marking Mode I OUT 80 x V REF Max Output Voltage Nominal Line Internal Current Limit Max Cur...

Page 42: ...42 section 4 operation ...

Page 43: ...ance 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 off at wall disconnect 2 Remove side panels 3 Use low pressure compressed dry air remove dust from all air passages and components Pay particula...

Page 44: ...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 600s 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 ...

Page 45: ...dwith theLEDsonPCB1 locatedbehindthecoverwiththe EPP label problems can be diagnosed NOTE It is normal for momentary light ing flashing 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 Cutoff Power Reset Fault Indicator used...

Page 46: ...t line Excessive Ripple Power Source is shut down LED 4 amber High Bus Fault Illuminates when input line voltage is too high for proper operation approximately 20 above nominal line voltage rating Power source is shut down LED 5 amber Low Bus Fault Illuminates when input line voltage is approximately 20 below nominal line voltage rating Power Source is shut down LED 7 amber Arc Voltage Saturation ...

Page 47: ... when the current from the left side chopper is too high 400 amps Measured by the left hall sensor Power source is shut down LED 10 _ red Left IGBT Unsaturated Fault Illuminates when left IGBT is not fully conducting PS PS is shut down LED 11 red Right IGBT Unsaturated Fault Illuminates when right IGBT is not fully conducting Power Source PS is shut down LED 12 red Left neg 12V Bias Supply Fault I...

Page 48: ...n 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 2 Power Not On or LOW Voltage Problem Possible Cause Action Power source inoperable Main power lamp is off 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 Restor...

Page 49: ...hasesofinputvoltage exceednominallinevoltagebymore than 15 Restore and maintain line voltage within 10 Faulty control PCB1 Replace PCB1 P N 0558038287 Oneormoreshorteddioderectifiers D25 D28 on the Electrode Plate Replace shorted diode rectifiers 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...

Page 50: ...8308 LED 9 red Left Over Current Note If operation at 400A or less is possible then the Right side is not working Outputcurrentoftheleftsideexceeds300A because of operating the power source over 600A Turn the output current down to 400A Cuttingatover400A withafaultyrightside right side output 0 See faulty right side Left current transducer connector loose or unplugged PCB loose Secure connections ...

Page 51: ...ecure 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 0558038287 Faulty left PWM Drive PCB Replace PCB2 P N 0558038308 LED 11 red Right IGBT Unsaturated Black wire connecting IGBT Q5 collector to P3 of the right PWM Drive PCB PCB3 ...

Page 52: ...nt pot set too high Lower the current setting Faulty left PWM Drive PCB Replace left PWM Drive PCB P N 0558038308 High remote current signal Decrease remote current signal Faulty PCB1 Replace PCB1 P N 0558038287 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...

Page 53: ...t 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 a...

Page 54: ...nplugged connector at left PWM Drive PCB PCB2 Secure connector Faulty left PWM Drive PCB Replace right PWM Drive PCB P N 0558038308 Check voltage between P5 1 and P5 2 at the left PWM Drive PCB PCB2 Should be 20V AC BetweenP5 1andP5 3shouldbe40VAC If not the control transformer T5 is faulty Replace control transformer T5 6 3 6 Intermittent Interrupted or Partial Operation NEVER attempt to power up...

Page 55: ...wn 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 PlacethePANEL REMOTEswitchinthe PANEL position Adjustcurrentcontrolpot Ifcurrent no longer drifts the remote current control signal is faulty F...

Page 56: ...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 semicondu...

Page 57: ...nter base of the front panel These are accessed from under neath 8 Remove one of the bolts holding the right side of the front panel to the base Loosen the second bolt Of thesetwobolts removetheboltontheleftandloosen the bold on the right 9 Swing the front panel out to gain access to power rectifier components Power Rectifiers located behind the front panel Troubleshooting Procedures Negative Plat...

Page 58: ...k 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 first 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 Pla...

Page 59: ... 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 th...

Page 60: ...e 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 Partial...

Page 61: ...3 conductor cable The breakout point should be physically at the middle of the shunt The breakout point is the place where the conductors exit from the outer insulation jacket The black and clear insulated wires must be kept next to the shunt and under the cable ties The wire terminals for the black and clear insulated wires should be oriented in parallel with bus bars as shown section 6 TROUBLESH...

Page 62: ...nal fed into J1 C When 115V AC from J1 R is fed into J1 C K11 is activated placing the EPP 600 in the Marking mode For more details concerning the opera tion of K11 and the Cut Mark modes refer to Subsection 6 10 Pilot Arc HI LO Cut Mark Circuits J6 connects to the water cooler J6 A and J6 B are 115VAC hot and neutral respectively This 115VAC activates the contactor for the pump J6 C and J6 D conn...

Page 63: ...63 section 6 TROUBLESHOOTING 80 ...

Page 64: ... operation of K2 K4 is turned off when the Current Detector senses arc current and opens the contact connecting P2 5 to P2 6 on the Control PC Board In addition to operating K3 the Contactor Signal also activates the Solid State Contactor The Solid State Contactor is a logic and interlock circuit permitting the IGBT s to conduct whenever the remote Contactor Signal is present The 115V AC Contactor...

Page 65: ...e resistors eliminate the high surge currents typical of the turn on inrush transients associated with large transformers The high current surge of charging the Bus Capacitor Bank is also eliminated by initially powering the Main Transformer through K2 and the resistors The discharged Bus Capacitor Bank initially prevents the output of the Main transformer from reaching its normal value As the Bus...

Page 66: ...hstand a maximum peak voltage of 150V It can switch a maximum of 50 mA The transistor turns on whenever the arc current through the Work Lead exceeds 5A Pilot arcs not establishing main arcs will not turn on the transistor A second current detector output is available at TB8 3 and TB8 4 This output is supplied by an isolated relay contact rated for 150V 3 Amperes This contact is closed when the pr...

Page 67: ...switch selects the Vref fed into J1 L and J1 J The EPP 600 Output Current I out will follow Vref with the following relationship I out 80 x Vref The Control PC Board contains two inputs for Vref High Speed and Normal When the negative of the Vref signal is fed into the High Speed input P8 3 the EPP 600 will respond to a change in Vref within 10 mS When the negative of the Vref signal is fed into t...

Page 68: ...ting 115V AC from J1 R to J1 C operates K11 In the Marking mode a normally closed contact on K11 opens turning off K10 When K10 turns off the Boost supply is discon nected lowering the normal Cutting Mode 425V DC Open Circuit Voltage to 360V DC for Marking A normally open con tact on K11 activates K12 K12 connects the I min resistors necessary for stabilizing the low currents required for marking ...

Page 69: ...cement parts may be ordered from your ESAB Distributor Be sure to indicate any special shipping instructions when ordering replacement parts Refer to the Communications Guide located on the back page of this manual for a list of customer service phone numbers 7 2 Ordering Bill of material items that have blank part numbers are provided for customer information only Hardware items should be availab...

Page 70: ...70 section 7 replacement parts ...

Page 71: ...71 section 7 replacement parts ...

Page 72: ...72 section 7 replacement parts ...

Page 73: ...73 section 7 replacement parts ...

Page 74: ...74 section 7 replacement parts ...

Page 75: ...75 section 7 replacement parts EPP 400 Only 2 Places EPP 600 Only 2 Places ...

Page 76: ...76 section 7 replacement parts ...

Page 77: ...77 section 7 replacement parts 49 ...

Page 78: ...78 section 7 replacement parts ...

Page 79: ...79 section 7 replacement parts ...

Page 80: ...80 section 7 replacement parts ...

Page 81: ...81 section 7 replacement parts 35751Y 35752Y 0558006169 ...

Page 82: ...82 section 7 replacement parts 17280215 R10 11 Resistor 1 5K OHMS 100W R28 31 951198 L3 FERRITE CORE ...

Page 83: ...83 section 7 replacement parts ...

Page 84: ...84 section 7 replacement parts ...

Page 85: ...85 section 7 replacement parts ...

Page 86: ...86 section 7 replacement parts 0558954035 ...

Page 87: ...87 section 7 replacement parts 4600610 3 62 W ...

Page 88: ...88 notes ...

Page 89: ...89 revision history 1 Original release 08 2006 2 Changed 400V callout to 380 400V 3 Revision 08 2010 Updated with new DOC form ...

Page 90: ...ax 843 664 5557 Hours 7 30 AM to 3 30 PM EST Repair Estimates Repair Status F WELDING EQUIPMENT TRAINING Telephone 843 664 4428 Fax 843 679 5864 Hours 7 30 AM to 4 00 PM EST Training School Information and Registrations G WELDING PROCESS ASSISTANCE Telephone 800 ESAB 123 Hours 7 30 AM to 4 00 PM EST H TECHNICAL ASST CONSUMABLES Telephone 800 933 7070 Hours 7 30 AM to 5 00 PM EST IF YOU DO NOT KNOW...

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