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section 6

troubleshootinG

6.4.2 iGbt / freewheeling diode (fwd) replacement

the emitter and the gate of each affected 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 insufficient thermal contact to the heat sink. Hardware too long or too short can

cause module damage due to over heating.

Содержание Plasmarc EPP-601

Страница 1: ...EPP 601 Plasmarc RU 0558007979 06 2012...

Страница 2: ...52 529...

Страница 3: ......

Страница 4: ...4...

Страница 5: ...1 12 3 4 2 13 3 4 3 13 3 5 14 3 5 1 14 3 5 2 14 3 6 15 3 6 1 EPP 601 16 3 6 2 EPP 601 18 3 7 19 3 7 1 19 3 7 2 20 3 7 3 20 4 0 21 4 1 21 4 2 24 4 2 1 29 4 3 28 4 4 29 4 4 1 30 4 4 2 30 4 4 3 30 4 4 4...

Страница 6: ...38 6 3 1 38 6 3 2 100 A 38 6 3 3 38 6 3 4 39 6 3 5 39 6 3 6 43 6 3 7 F1 F2 44 6 3 8 44 6 4 46 6 4 1 47 6 4 2 49 6 4 3 51 6 4 4 52 6 5 J1 J6 52 6 6 K3 54 6 7 K1A K1B K1C 55 6 8 56 6 9 U 57 6 10 58 6 1...

Страница 7: ...7 1 1 0 ESAB 1 B 2 3 4 5 IP 12 60 IP 23S 15 15...

Страница 8: ...8 1...

Страница 9: ...7733 0558007734 0558007735 3 380 380 400 460 575 3 217 217 206 179 143 50 50 50 60 60 A 142 8 142 8 142 7 142 6 142 4 128 5 128 5 128 4 128 4 128 2 90 90 90 90 90 4 0 AWG 4 0 AWG 4 0 AWG 3 0 AWG 1 0 A...

Страница 10: ...10 2 2 3 850 1143 mm 45 00 946 mm 37 25 1022 mm 40 25...

Страница 11: ...11 3 3 1 3 2 3 3 1 EPP 601...

Страница 12: ...12 3 3 4 3 4 1 EPP 601 3 I U x I x 0 68 U 2 2 EPP 601...

Страница 13: ...13 2 2 3 4 2 EPP 601 12 7 1 EPP 601 2 3 4 5 6 3 4 3 1 3 2 1 2 3 3 TB4 TB6...

Страница 14: ...14 3 5 3 5 1 600 4 0 AWG 400 600 100 4 0 AWG 600 100 3 3 5 2 1 2 3 UL 4 1...

Страница 15: ...15 3 EPP 600 3 6 100 100 600 4 0 AWG 600 14 AWG EPP 601 600 100 4 0 AWG 600 600 4 0 AWG...

Страница 16: ...16 3 1 2 3 4 5 HIGH LOW LOW 6 HIGH LOW HIGH 7 0 00 10 00 J1 G 0 00 10 00 J1 P x 160 EPP 601 3 6 1 EPP 601 EPP 601...

Страница 17: ...17 3 EPP 601 EPP 601 EPP 601 3 6 1 EPP 601 600 100 EPP 601 EPP 601 EPP 601 600 4 0 AWG 600 4 0 AWG 600 14 AWG 600 4 0 AWG 600 4 0 AWG 600 4 0 AWG...

Страница 18: ...18 3 EPP 601 20 100 1000 A 10 20 10 1 2 A K12 B TB7 7 and TB7 8 HI LOW 3 6 2 EPP 601 EPP 601 1 U 2 I 20 x U I 10 x U 3 Low I 20 x U 100 I 10 x U 4 High I 160 x U 100 Low...

Страница 19: ...19 3 3 7 24 8 3 7 1 4 647032...

Страница 20: ...20 3 4 3 7 2 647032 2010549 3 7 3 647257 2062105...

Страница 21: ...21 4 4 1 2 H 3 T1 300 375 300U120 0 0 10 0 I U x 80 High S T T T L1 L2 T T1 T1 425 250 R R EPP 601...

Страница 22: ...Versus Output Voltage 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0 0 50 100 150 200 250 300 350 Output Voltage Volts RMS Ripple Current Amperes Choppers Synchronized and Switchng in Unison 10KHz Ripple Cho...

Страница 23: ...23 U U EPP 601 430 K10 380 400 50 380 360 4 EPP 601 4 1 T1 300 375 T1 375 300 375 EPP 601 10000 25000 430 375 4 1...

Страница 24: ...24 4 4 2 A Main Power Contactor On Over Temp Fault 10 Power Reset Fault Current Dial EPP 601 EPP 601 10 100 A 50 600 A B Panel Remote PANEL REMOTE...

Страница 25: ...25 4 24 8 HIGH LOW 100 EPP 601 LOW 4 2 EPP 601 100 A 600 J1 R J1 T EPP 601 TB8 1 TB8 2 TB8 E Stop Connector J4 A J4 B E Stop Button B...

Страница 26: ...26 4 Actual Preset Actual Preset S4 Actual Preset Actual Up OUTPUT AMMETER Preset Down U 0 00 10 00 CURRENT POTENTIOMETER Panel Remote Panel Up J1 J J1 L Panel Remote Remote Down 4 2...

Страница 27: ...50 600 J1 EPP 601 115 J1 T J1 R 0 625 50 600 7 50 9 00 475 EPP 601 2 J1 R 115 J1 M 50 10 100 J1 EPP 601 1 00 10 100 10 00 U 50 600 0 625 7 50 7 50 680 360 K12 R60 R67 10 100 A 100 10 A R60 R67 SW2 5...

Страница 28: ...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 Sta...

Страница 29: ...29 4 4 4 EPP 601 5 A 50 800 2 2 I 80 U I 10 U 800 I 80 U I 10 U...

Страница 30: ...30 4 4 1 4 1 2 SW1 PCB1 4 4 2 1 4 SW2 PCB1 2 1 2 2 4 3 8 4 16 2 4 4 3 5 8 SW2 5 A 5 40 A 6 20 A 7 10 A 8 5 A 5 8 0 A 0 A 0 A 0 A 5 A 5 A 1 2 3 4 5 6 7 8 SW2 SW1 1 2 3 4 5 6 7 8 SW2 SW2 1 2 3 4 5 6 7 8...

Страница 31: ...31 4 4 4 4 38 4 4 5 PCB1 7 50 800 250 800 1200 90 80 70 60 50 40 30 20 10 0 0 1 2 3 4 5 6 7 8 9 10 SW1 SW2...

Страница 32: ...100 150 200 250 300 350 400 450 0 100 200 300 400 500 600 700 4 4 5 1 EPP 450 U I 431 I 80 x U U 7 000 U 6 000 U 1 000 U 1 00 min U 4 000 U 0 625 U 10 00 max U 2 000 U 7 500 U 3 000 U 5 000 U 5 00 U 3...

Страница 33: ...nce 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 o...

Страница 34: ...assages 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 service All other EPP 601s ha...

Страница 35: ...LEDsonPCB1 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...

Страница 36: ...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 Pow...

Страница 37: ...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 f...

Страница 38: ...e Faulty fan s Replace fans 6 3 1 No output with contactor signal applied 6 3 2 Output limited to 100A Problem Possible Cause Action Powersourcewillnotgoover 100A High current range signal missing Ext...

Страница 39: ...ut 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 0558038313 L...

Страница 40: ...24 LED 9 red Left Over Current Note If operation at 400A or less is possible then the Right side is not working Cuttingatover400A withafaultyrightside right side output 0 See faulty right side Left cu...

Страница 41: ...cure 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...

Страница 42: ...t 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...

Страница 43: ...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 t...

Страница 44: ...plugged 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 Sh...

Страница 45: ...n 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 cur...

Страница 46: ...surface If a PC board is found to be a problem check with your ESAB distributor for a replacement Provide the distributor with the part number of the board as well as the serial number of the power so...

Страница 47: ...rneath 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 th...

Страница 48: ...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...

Страница 49: ...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...

Страница 50: ...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 cl...

Страница 51: ...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 insul...

Страница 52: ...tate Contactor Circuits and Subsection 6 10 Pilot Arc Hi lo Cut mark Circuits J1 E and J1 F are the input connections for the Emergency Stop function For Emergency Stop to operate the Jumper between T...

Страница 53: ...J1 L J1 J REMOTE CUTTING CURRENT REFERENCE VOLTAGE Vref Icut Vref x 80 EPP 450 POWER SOURCE 0 10V Vref LEVEL SWITCH OK K15 LO J1 Y CONTACTOR FOR PUMP FAN H J1 D J1 E J1 H J1 C J1 A J1 B CONTROL COOLAN...

Страница 54: ...the remote Contactor Signal is present The 115V AC Contactor Signal is fed to TB1 9 TB7 8 and resistors R45 and R45 A These resistors reduce the 115V to approximately 16V AC fed into the Control PC B...

Страница 55: ...nce the K1 s are closed the contacts of the Starting Contactor K2 are bypassed and full primary line power is supplied to the Main Transformer through the contacts of the K1 s Because the starting seq...

Страница 56: ...TOP LOOP MUST BE CLOSED FOR POWER SOURCE TO FUNCTION 21 F M TB8 18 E STOP TB8 19 J4 A J1 E TO T2 X3 TO CB2 2 A 24 VAC E STOP BUTTON J1 F J4 B S5 115 VAC K2 K2 K2 E STOP EMERGENCY STOP MAIN CONTACTOR K...

Страница 57: ...stand 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 t...

Страница 58: ...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 601 will respond to a change in VREF within 10 mS When the n...

Страница 59: ...currents required for marking In the Cutting mode the minimum stable output current is 50A in the high current range 35A in the low current range and 10A in the marking mode In the marking mode the no...

Страница 60: ...PC Board to change the switching frequency from 10 KHz to 25 KHz The higher switching frequency results in the more power dissipation by the heat sinks on PCB 3 Therefore in the LOW current mode a sma...

Страница 61: ...the back page of this manual for a list of customer service phone numbers 7 2 Ordering Items listed in the following Bill of Materials that do not have a part number shown are not available from ESAB...

Страница 62: ...notes...

Страница 63: ...ded E stop information throughout manual Included Replacement Parts section in Schematic Wiring Diagram package Changed power supply name from EPP 600 to EPP 601 3 Revision 08 2010 Updated with new DO...

Страница 64: ...30 55 North and South America ARGENTINA CONARCO Buenos Aires Tel 54 11 4 753 4039 Fax 54 11 4 753 6313 BRAZIL ESAB S A Contagem MG Tel 55 31 2191 4333 Fax 55 31 2191 4440 CANADA ESAB Group Canada Inc...

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