Home

EPP-362 Plasma Power Source - ESAB Welding & Cutting Products

1. 55 Hall Sensors HS1 HS2 0558006886 56 Output Inductor LI 0558007 234 cos quent rat ana VT 57 gis V I m 2 58 Arc O Block DIA u uyu FRA EIE b C b CERTE EDU SES UNE ee 58 Filter and Start Up Board PCB3 0558038391 59 Filter B ard PCD3 0558038391 ero SORIA TCR ANUS au UNIS TUNIS PUN SC 60 EPP 362 Plasma Power Source gud v 61 TJemparature ELE EMEUR 62 COOL AHE 6 SDC CIN CANONS eee 63 So fos 7932292229 a a elvan idis ida bys 64 65 sane TT 66 COCO ARR s ss 66 Test nd 67 PC51 COLE dd 68 PCB1 Schematics 0558038362 68 Current Monitoring o es een 69 PCB1 Voltage Monitoring Circuits 0558038362 70 10359038307 Meda ata a cd 71 FEBI Output Circuits 105209000262 ir 71 PCB Input CIRC
2. 8 8 ti en h 8 3 3 tole el LOL t t te 7 Tm i 8 K V ub 5 gd 4 it ei rs 79 sm K 8 I j 3 mM S V de D i 969 ge val em on m em zw nj adhi ra C C om 1 Te opua T PAS EAS z R 167 1 m on 99 p y m OhI tes 069 e 2 som ji n j diffi 8 b u d up A gt I ow vo5 a ser 2 c9 selu elu e etin e 60 gt T CER C sal ni m 2 Le x em m 2 E Vn 9 T H M 188 69 eo 8 chs sls n q E o N ala 1 2 ETN rod 1 dO e 69a V del era an B tea Lt T k e93 i m K 21 T9 8 08GG0 x i 090 _ sp ev 49r La
3. 8 gt g Le B E E 8 1 40 0 3 3 3 AE ES eo i s dad o gt 252 ZA 5 4 t Zs ER S We 4 3 3 H 8 ios ar ACTUA 2 47 3 opor Y 5 44 EN A 7 lt gt a n LES AD N O TEA ved E 045 66288 U43 198 D gt 8 A k w 055 622 Y a 33 8 8 33 om i Caos EE OL IO IE IATA uaa __ A da H e o mox de ele ee ri ES ou En SRE 8 8 8 8 in E ea a 5 n s 8 R 8 4 Bau 000000000000 O 00000000000 PCB1 Board Layout DESCRIPTION OF OPERATION PCB1 BOM 0558038362 ITEM 0558038362 Control Assembly Components SYMBOL C1 C3 C10 C12 C13 C14 C15 C61 C68 C74 C79 C82 C 86 C90 C93 C101 C102 C109 C110 C114 C115 C117 C121 C122 C126 C133 C135 C138 C139 C140 C141 C 145 C146 C147 C148 C149 C150 C151 C152 C162 C1 66 C167 C171 C172 C173 C183 C184 C188 C189 C19 0 191 192 195 196 200 2 11 20 35 36 37 38 39 40 41 42 43 44 45 52 54 56 67 104 C4 C5 C8 C9 C21 C22 C23 C24 C25 C26 C27 C28 C2 9 630 16 46 47 48 49 50 51 53 55 60 123 1 53 C154 C155 C1
4. Appendix inclusis So Electrostatic ap ins Ohms and Watts LAWS CHEERS IER IIR REIP Glossary General Definitions and Symbols Used in this Manual Glossary General Definitions and Symbols Used in this Glossary General Definitions and Symbols Used in this Manual Mao O em IEEE Diode epa EPA CPP P PUO CR eSI nt radar IGT REPLACEMENT IGBT Assembly Testing 0558006183 NES A seg EPP 362 Plasma Power Source SAFETY SAFETY SAFETY Safety English WARNING These Safety Precautions are for your protection They summarize precautionary information from the references listed in Additional Safety Information section Before performing any instal lation or operating procedures sure to read and follow the safety precautions listed below as well as all other manuals material safety data sheets labels etc Failure to observe Safety Precautions can result in injury or death PROTECT YOURSELF AND OTHERS 1 Some welding cutting and gouging Qa processes are noisy and require ear protection Thearc like the sun emits ultraviolet UV and other radiation and can injure skin and eye
5. MH1 FASTON 1 4 TERMINAL HOLE 0v330 0v156 PLATED 59 FASTON 1 4 TERMINAL DESCRIPTION OF OPERATION Filter Board PCB3 0558038391 ELECTRODE PILUT ARC MHe J3 0558038391 REV A KK DRILL CHART to BUTTUM ALL UNITS IN MILS Tem Quantity Reference ra 56uF 450V CAPACITOR ALUMINUM ELECTROLYTIC 56uF 450 TOL 2096 C2 C3 C4 0 22uF 1kV CAPACITOR METALIZED FILM 0 22uF 1000 VDC TOL 20 J1 J2 J3 FASTON 1 4 TERMINAL FASTON 1 4 Faston Blade 0v330 0v156 PLATED Mounting Hole 60 DESCRIPTION OF OPERATION Filter Bus The Filter Bus consists of a 6000 microfarad capacitor used to smooth out the rectified input power This capacitor C1 is connected between the input bridge and the IGBTs The filter cap provides 360 VDC to the IGBTs to supply the output of the power supply Connected in parallel with the filter capacitor is R8 a 3 K Ohm 100 watt resistor used as a bleeder resistor This is used to drain the left over charge on the capacitor once the power supply is turned off The time required to dissipate the charge is as follows 18 seconds 63 2196 of the charge reduced or 132 VDC remaining 53 seconds 94 81 96 of the charge reduced or 18 VDC remaining Capacitor Information Serious Shock Possible Bus cap warning Serious Shock Possible The bus capacitor in the EPP 362 will maintain a voltage charge for lt BLEEDER
6. Recommended Practices for Gas Tung sten Arc Welding 6 AWS 5 6 Recommended Practices for Gas Metal Arc Welding 7 AWS SP Safe Practices Reprint Welding Hand book 8 ANSI AWS F4 1 Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances 9 CSA Standard W117 2 Safety in Welding Cutting and Allied Processes 21 SAFETY SIGNIFICATION DES SYMBOLES Ce symbole utilis partout dans ce manuel signifie Attention Soyez vigilant Votre s curit est en jeu Signifie un danger imm diat La situation peut entrainer des blessures graves ou mortelles Signifieun danger potentiel qui peut entrainer des blessures graves ou mortelles Signifieun danger qui peutentrainer des blessures corporelles mineures Classe de protection de l enveloppe L indice de protection codification IP indique la classe de protection de l enveloppe c est dire le degr de protection contre les corps solides trangers ou l eau L enveloppe prot ge contre le toucher la p n tration d objets solides dont le diam tre d passe 12 mm et contre l eau pulv ris e un angle de jusqu 60 degr s dela verticale Les quipements portant la marque IP21S peuvent tre entrepos s l ext rieur mais ne sont pas concus pour tre utilis s l ext rieur pendant une pr cipitation moins d tre l abri Ce produit a t concu pour la d coupe au plasma
7. TO PCBI J9 3 HS1 S TERMINATE SHIELD ELECT OTHER END ONLY OUTPUT PRE LOAD R9 5 OHM 1004 TO PCB1 J9 2 TO PCB1 J9 8 TO 1 J9 3 TERMINATE SHIELD OTHER END ONLY PL WORK 4 00 REF 4 ELECTRODE J pegas WS FILTER PCB 0558038391 WORK JI TO PCB1 J12 MAIN CONTROL PCB 57 DESCRIPTION OF OPERATION Pilot Arc In the power supply sequence of events the pilot arc ON must be detected before main arc ON signal can be issued When power supply receives a start signal from the CNC Process Controller it goes through start up sequence refer to Sequence of Events in the Introduction section Once the bus filter capacitor is fully charged main micro issues 115 VAC to the HF Ignitor inside the RAS box and Pilot Arc ON and PWM ON signals to servo micro Servo micro then issues PWM signals to pilot arc IGBT and main IGBT s Since the process controller has already started the gas flow due to the availability of HF signal and open circuit voltage from power supply an arc is established between electrode and nozzle which is called PILOT ARC When pilot arc is established the hall sensor HS1 reads the current which is used to turn OFF the 115 VAC to HF Ignitor When plate work is close enough to the torch electrode the arc will transfer to the plate forming the current path detected by hall sensor HS2 which helps the servo micro to regulate the PWM signals for
8. 7 Pourobtenirdesinformations suppl mentaires consultez le NFPA Standard 51B Fire Prevention in Use of Cutting and Welding Processes disponible au National Fire Protection Association Batterymarch Park Quincy MA 02269 CHOC LECTRIQUE Le contact avec des pi ces lec triques ou les pi ces de mise la terre e sous tension peut causer des blessures graves ou mortelles NE PAS utiliser un courant de soudage c a dans un endroit humide en espace restreint ou si un danger de chute se pose 19 SAFETY 1 Assurez vous que le chassis de la source d alimentation est branch au syst me de mise la terre de l alimentation d entr e 2 Branchez la pi ce traiter une bonne mise de terre lectrique 3 Branchez le cable de masse la pi ce traiter et assurezune bonne connexion afin d viter le risque de choc lectrique mortel 4 Utilisez toujours un quipement correctement entretenu Remplacez les c bles us s ou endom mag s 5 Veillez garder votre environnement sec incluant les v tements l aire de travail les c bles le porte lectrode torche et la source d alimentation 6 Assurez vous que tout votre corps est bien isol de la piece traiter et des pieces de la mise a la terre 7 Sivous devez effectuer votre travail dans un espace restreint ou humide ne tenez vous pas directe ment sur le m tal ou sur la terre tenez vous sur des planches s ches ou une plate forme isol e
9. 742C163103 77 DESCRIPTION OF OPERATION ITEM SYMBOL DESCRIPTION FUNCTION R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R1 0 5 16 817 818 819 820 821 822 823 824 RES 1 00 190 5 1206 PKG THICK FILM 46 R25 R33 R38 R45 R112 R147 R165 R185 RES 1 80K 1 SMT 0603 THICK FILM R26 R66 R106 R113 R119 R125 R138 R139 R152 R15 3 R161 R162 R176 R186 R204 R205 R207 R208 R210 R211 R213 R214 R253 R254 R259 R262 R271 R273 R 274 R279 R292 R293 45 A N UJ N RES 10 0K 1 SMT 0603 PKG THICK FILM R27 R28 R29 R30 R31 R32 R39 R40 R41 R42 R43 R4 4 R263 R264 R265 R266 R281 R282 R284 R285 R29 7 R298 BA N RES 680 1 SMT 1206 PKG THICK FILM R34 R62 R65 R68 R69 R72 R75 R78 R79 R80 R129 R14 2 R180 R189 R203 R206 R209 R212 R228 R233 R238 R243 R269 R270 R289 R290 R301 50 R35 R60 R257 3 51 R36 R61 R63 R124 R131 R154 R191 R216 R222 52 R37 R92 R94 R97 R121 R123 R198 R200 R46 R47 R48 R49 R50 R51 R52 R53 R54 R55 R56 R57 N RES 1 00K 1 SMT 0603 PKG THICK FILM RES 15 0K 1 SMT 0603 PKG THICK FILM RES 2 70K 1 SMT 0603 PKG THICK FILM RES 3 30K 1 SMT 0603 PKG THICK FILM Ui UJ NA R58 R59 R132 R133 R148 R149 R158 R170 R171 R172 RES 270 1 SMT 0603 PKG THICK FILM R64 R95 R98 R1 99 R225 R230 R23 RES 180 196 SMT 0603 PKG THICK FILM NO 00 RES 680 1 SMT 0603 PKG THICK FILM 55 R67 1 R70 R71 R73 R74 R76 R77 R226 R231 R235 R240 R26 7 7 7 7 I 7
10. Locate cylinders away from heat sparks and flames Never strike an arc on a cylinder 5 Foradditional information refer to CGA Standard 1 Precautions for Safe Handling of Compressed Gases in Cylinders which is available from Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 EQUIPMENT MAINTENANCE Faulty orim A properly maintained equipment can cause injury or death Therefore 1 Always have qualified personnel perform the instal lation troubleshooting and maintenance work Do not perform any electrical work unless you are qualified to perform such work 2 Before performing any maintenance work inside a power source disconnect the power source from the incoming electrical power 3 Maintaincables grounding wire connections power cord and power supply in safe working order Do not operate any equipment in faulty condition 4 Do not abuse any equipment or accessories Keep equipment away from heat sources such as furnaces wet conditions such as water puddles oil or grease corrosive atmospheres and inclement weather 5 Keepallsafety devices and cabinet covers in position and in good repair 6 Use equipment only for its intended purpose Do not modify it in any manner ADDITIONAL SAFETY INFORMATION For more information on safe practices for electric arc welding and cutting equipment ask your supplier for a copy of Precautions and Safe Practices for Arc Weldin
11. Polypropylene Port Size 1 4 NPT Female Input Power 4 5 VDC to 24 VDC Output 4 5 VDC to 24 VDC Pulse Sourcing Low Flow Accuracy 7 Standard Flow Accuracy 7 Maximum Pressure PSI 100 Minimum Temperature F 20 Maximum Temperature 180 000 Electrical Termination 22 AWG 24 24 PVC Cable Recommended Filtration 150 micron 65 DESCRIPTION OF OPERATION Level Switch Level switch is used to tell if the level of coolant in the tank drops below certain level When the level of the coolant drops below level switch position in the tank control board reads the switch open signal an error signal is sent to CNC Process controller by the power supply through CAN communication DESCRIPTION PLASTIC SIDE MOUNTED SWITCH STEM POLYPROPYLENE FLOAT POLYPROPYLENE MAX TEMP 105C NOM CURRENT 30VA SPST SWITCH FLOAT SG 0 60 MAX PRESSURE 100PSIG LEADS 22GA 24INCHES Coolant Filter A filter is used to prevent the foreign particles entering the power source through coolant and damaging the equipment DESCRIPTION 3 4 MINI T STRAINER W CLEAR BOWL 66 DESCRIPTION OF OPERATION Test Procedure Test Flowmeter Test Pressure Gauge Supply EPP 362 Throttle Valve Return Field Test Procedure Test Procedure Connect as shown above using 0 38 9 5 mm ID hose Open throttle valve completely Fill tank with Plasmarc torch coolant Power ON the EPP 362 power source Adjus
12. The transformer is the source of high induction current and it is the isolated secondary power distribution to the 360V bus Due to it s size and weight the transformer is mounted near the unit s center of gravity The secondary windings are connected in a Wye which not only provides isolation from the primary power line it also supplies the proper voltage for the 360 VDC bus Additional windings are configured to produce step down voltages for different load requirements CDIL B COIL C COIL iul H4 be e E Ei I 90 200 230V 90 200 230V xe x3 x3 1472V xe 230 460V INPUT ov gt XI x 141 8V 8 380V INPUT 149 4V 6 200 400V INPUT A COIL WINDING FOR amp FANS X4 5 X6 X7 X8 X9 X10 lt lz E gt al 2 gt amp a gt 1 gt 25 o O lo 00 5 00 oio 00 o QJ Gia GJ Vig Y gt gt gt gt gt gt gt 2 in omo 2 QJ g Sj ul 48 DESCRIPTION OF OPERATION Fan Cooling Fan Cooling of the EPP 362 is accomplished with one fan This fan M1 2062334 is a 230 VAC 50 60 HZ 1 3 horsepower motor rated at 2 8 230 VAC Amps This unit is connected on one side to the X7 tap and the other side is connected to the 1 3 for fan control The X5 tap is the common return and is routed to PB1 3 for fan control This fan provides air cooling fo
13. approximately 2 minutes after power is removed from the input of the ici A machine 600 V Insulation The arcing caused by discharging a capacitor into a short circuit can cause injury and component damage To eliminate the voltage from the capacitor connect the bleeder resistor across the poles of a charged capacitor and the stored energy will dis charge harmlessly through the resistor The approximate discharge time is 30 seconds When discharged the cap can be partially tested by using a multimeter set to the ohms scale When checking a capacitor Connect the meter lead to the pole of the capacitor and the lead to the pole The meter display will show a number that will change while the leads are connected if the meter leads are reversed the display will change polarity and the value will change in the opposite direction from the first test if the capacitor is good 61 DESCRIPTION OF OPERATION Temparature Monitoring Two thermal switches connected in series monitor the internal temperature of the EPP 362 TS1 mounted the IGBTs cold plate rated to open at temperature 176 F and 52 mounted on the bridge rectifier is rated to open at 212 F Surface mount Thermistor RT1 on the control board 1 monitors the ambient temperature in the control box Therm istor sends an analog voltage signal proportional to the ambient temperature Main micro 019 on PCB1 read these temperature sensors information for fault
14. autour de votre corps C Ne jamais vous placer entre la torche etles cables de masse Acheminez tous les c bles sur le m me c t de votre corps D Branchez le c ble de masse la pi ce traiter le plus pr s possible de la section souder E Veillez garder la source d alimentation pour le soudage et les c bles une distance appropri e de votre corps LES VAPEURS ET LES GAZ peuvent causerunmalaise ou des dommages corporels plus particuli rement dans les espaces restreints Ne re spirez pas les vapeurs et les gaz Le gaz de protection risque de causer l asphyxie Par cons quent 1 Assurez en permanence une ventilation ad quate dans l aire de travail en maintenant une ventila tion naturelle ou l aide de moyens m canique N effectuez jamais de travaux de soudage de coup age ou de gougeage sur des mat riaux tels que l acier galvanis l acier inoxydable le cuivre le zinc le plomb le berylliym ou le cadmium en l absence de moyens m caniques de ventilation efficaces Ne respirez pas les vapeurs de ces mat riaux 2 N effectuez jamais de travaux proximit d une op ration de d graissage ou de pulv risation Lorsque la chaleur ou le rayonnement l arc entre en contact avec les vapeurs d hydrocarbure chlor ceci peut d clencher la formation de phosg ne ou d autres gaz irritants tous extr mement toxiques 3 Uneirritation momentan e des yeux dunezou dela gorge au
15. riaux combustibles incluent le bois les v tements la sciure le gazetlesliquides combustibles les solvants les peintures et les rev tements le papier etc 2 Les tincelles et les projections de m tal incandescent peuvent tomber dans les fissures dans les planchers ou dans les ouvertures des murs et d clencher un incendie couvant l tage inf rieur Assurez vous que ces ouver tures sont bien prot g es des tincelles et du m tal incandescent 3 N ex cutez pas de soudure de coupe ou autre travail chaud avant d avoir compl tement nettoy la surface de la pi ce atraiter de fa on qu il n aitaucune substance pr sente qui pourrait produire des vapeurs inflammables ou toxiques N ex cutez pas de travail chaud sur des contenants ferm s car ces derniers pourraient exploser 4 Assurez vous qu un quipement d extinction d incendie est disponible et pr t servir tel qu un tuyau d arrosage un seau d eau un seau de sable ou un extincteur portatif Assurez vous d tre bien instruit par rapport l usage de cet quipement 5 Assurez vous de ne pas exc der la capacit de l quipement Par exemple un cable de soudage sur charg peut surchauffer et provoquer un incendie 6 Une fois les op rations termin es inspectez l aire de travail pour assurer qu aucune tincelle ou projection de m tal incandescent ne risque de provoquer un incendie ult rieurement Employez des guetteurs d incendie au besoin
16. 6 IGBT Gate 6 RED 7 IGBT Emitter 7 WHT 115 GENERAL INFORMATION IGBT Assembly Testing 0558006183 This assembly consists of 4 ea 400A 1200V IGBTs that combine the simple gate drive characteristics of the MOSFET with the high current and low saturation voltage capability of BJTs by combining an isolated gate FET for the control input and a bipolar power transistor as a switch in a single device When on these IGBTs allow current to flow to the electrode Test With the IGBT disconnected and your meter in the diode scale check the internal diodes by making connections found in the table listed below IGBT Test Meter in Diode Scale Probe Probe Reverse the leads across the bipolar power transistor Connect the black lead to 2 and the red lead to 1 Now gate on the IGBT by connecting a 9V battery to G2 and E2 of the IGBT In the diode scale your meter s reading should change from OL to 0 7 when the IGBT has been gated on Reverse the battery leads to gate the IGBT off 2 25 LG 2 The IGBT Assembly consists of all wire connec tors and tubing needed for proper connection POSITION 1 of the IGBT module POSITION 2 WHT NOTES 1 APPLY HEAT SHRINK TUBING ITEM 10 TO COVER SOLDER JOINT AND THE GATE TERMINAL 6 AND THE EMITTER TERMINAL 7 2 SEE NOTES 1 amp 3 WHT 2 TWIST RED AND WHT WIRES TOGETHER FORMING A MINIMUM OF 2 1 2 AND A SEENOTES 1 amp 3 1
17. Function _ Ta nRefPwmChannel Reference PWM signal __ T nMainPwmChannel MainPWMsignalforiGBTs aswe Rectified Unregulated Voltage oo ms ArcVoltage measuring point oma Work Common Reference veus Bus voltage measuring reference 84 DESCRIPTION OF OPERATION 85 tt 6675 1864 6 19614 SETA 6914 9 sm 8 1 1858508660 00000000 0 O0 00 0 0 0 0 0 00 0 no m y 2 Y e 0 t T 559 9 4 A 2 ER T T vs 65 7 Se vsa tsa t 8 053 67 262 174 ri 8 9 29 s 2 8888 PCB2 Layout 0558038381 DESCRIPTION OF OPERATION PCB2 BOM 0558038382 0558038382 Driver Board Component List ITEM SYMBOL DESCRIPTION 1 470 16VDC 20 0805 X7R 2 4 15 22 26 27 31 35 38 44 45 13 46 56 3 C5 C6 C25 C48 C62 CAP Nichicon UD series 220uF 50V Electrolytic Capacitor UWD1H221MNL1GS CAP Nichicon UD series 100uF 35V Electrolytic Capacitor 4 C7 C8 C20 C43 C50 C60 NM UWD1V101MNL1GS 10 0uF 16VDC 20 1206 X7R MLCC oris
18. K4 K5 are enclosed double pole double throw 10 amp relays K4 and K5 are connected in parallel to provide extra set of contacts The coil is operated by 24 VAC and has a resistance of 75 ohms This is the PS Enable relay wired into the E Stop circuit of the cutting machine This relay opens for an E stop event or interruption in controller enable signal K4 K5 Relay Power Path These relays are energized when there is no emergency stop issues on the system The K4 K5 relay coils in series with the E Stop circuits of the cutting machine A break in the E Stop chain removes power from the K4 and K5 coils If the cut ting machine E Stop chain is broken the power supply will halt power output When K4 is de energized it opens the three sets of contacts These contacts provide power to the coil of K2 the soft start contactor the second set of contacts is in the K1 power path and third set of contacts provide 120 VAC to HF circuit in the RAS box when HF relay close command is issued from PCB1 With open no power reaches the main transformer T1 When K5 is de energized which happens simultaneously with K4 it opens one set of contacts which interupts PS Enables to 1 Should you attempt to start the EPP 202 the Control board will issue an error 23 indicating a fault The power path for the K4 K5 relay starts with 24 VAC from the control transformer T2 connected to TB3 pins 6 and 8 TB3 pin 6 is connected to B This then passes thr
19. Voltage Monitoring Circuits 0558038362 The voltage monitoring circuits are in place to monitor the bus and arc voltage levels for main process control and fault monitoring Driver Board PCB2 reads the voltages directly from the respective positions in the power supply and scales the values down to the microcontroller range Refer to PCB2 Driver Board section for PCB2 details The Servo Micro 017 reads the voltages from Driver Board PCB2 through J12 or J13 connector and OPAMP U32 and U33 circuitry Servo micro processes the scaled values and outputs the scaled integer values to the main micro through SPI communication Refer to Help Codes for voltage related error codes See Appendix B for detailed schematics Control Board Voltage Monitoring Circuit AVdd 5 00 AVdd 5v00 100 AVdd_5v00 6 80K 0 1W AVdd 3v30 e usa O e w Sale O AVdd_3v30 E THS4521ID o 500 80K 470 0 1W AVdd 3v30 e use 0 1W Q x AVdd 3 30 Driver Board Voltage Monitoring Circuit ALVdd 5v00 R39 5500 7 2 70 0 1W R42 2 70K C11 C56 C2 C44 0 1W 1 00uF 100nF 100nF ALVdd_5v00 R38 R33 100nF ALGND C35 C22 10 0K 120 HGND 100nF 100nF 0 1W 0 1W ALVdd_5v00 VOUT R37 AN VarcP J4 R61 R53 R60 R52 R58 HVdd_5v00 ALGND 120 0 1W 100K 100K 100K 100K 100K ALVdd 5v00 FASTON 0 25W
20. aide d une cha ne ou une sangle sur un chariot manuel un ch ssis de roulement un banc un mur une colonne ou un support convenable Ne fixez jamais un cylindre un poste de travail ou toute autre dispositif faisant partie d un circuit lectrique 3 Lorsquelescylindres servent pas gardezles soupapes ferm es Si le d tendeur n est pas branch assurez vous que le bouchon de protection de la soupape est bien en place Fixez et d placez les cylindres l aide d un chariot manuel appropri Toujours manipulerles cylindres avec soin 4 Placez les cylindres une distance appropri e de toute source de chaleur des tincelles etdes flammes Ne jamais amorcer l arc sur un cylindre 5 Pour de l information suppl mentaire consultez CGA Standard P 1 Precautions for Safe Handling of Com pressed Gases in Cylinders mis votre disposition par le Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 ENTRETIEN DEL QUIPEMENT Un quipe ment entretenu de facon d fectueuse ou inad quate peut causer des blessures graves ou mortelles Par cons quent 1 Efforcez vous de toujours confier les t ches d installation de d pannage et d entretien un personnel qualifi N effectuez aucune r paration lectrique moins d tre qualifi cet effet 2 Avant de proc der une t che d entretien l int rieur de la source d alimentation d branchez l alimentation lectrique 3 Ma
21. bag when not installed 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 bus 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 contacting 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 The module gate plugs must be plugged into the PWM Gate Drive PC Board whenever the power source is in operation CAUTI Failure to plug them in will result i
22. board 2 Check the input power to the interface control 3 Check for all the dip switches on the IC board are toward the display 4 Check for SW5 on the control board in the power supply is set to CLOSE 5 Check for coiling of the CAN cable near power leads 1 Check that the piercing distance of the torch is at the recommended level 2 Check that the ignition distance of the torch is at the recommended level 3 Check the consumables This will normally correct itself if not replace the control board Hall Sensor Connector is removed or 1 Check the hall sensor feedback connector for proper wiring jumper is missing 93 TROUBLESHOOTING Input Voltage Configuration and Changeover 380 VAC 400 VAC and 460 VAC Models As shipped from the factory these models of EPP 362 are configured for the single input voltage listed on the rating plate If using other input voltages it is possible to configure these units for 380 VAC 400 VAC or 460 VAC input There are 3 steps to follow when making this conversion 1 Reconfigure the voltage tap on the control transformer T2 for the proper input voltage SEC 120V 2A BLK 24V 1A 4X BRN ORG YEL BLU 13V 1A VIO 34VCT 1A RED RED YEL RED 5 BE34134001 G14 1440 d Made in Mexico 380V 230V 200V H4 H3 H2 H1 pri so eonz hg H6 5 Move this wire connection to 460 VAC H6 as shown 400 VAC H5 380 VAC H4 94 TROUBLESHOOTING 380 VAC 400
23. causa quemaduras EL entrenamiento en el uso propio de los equipos y sus procesos es esencial para prevenir accidentes Por lo tanto Ac 1 Utilice gafas de seguridad con protecci n a los lados siempre que est en el rea de trabajo a n cuando est usando careta de soldar protector para su cara u otro tipo de protecci n 2 Use una careta que tenga el filtro correcto y lente para proteger sus ojos cara cuello y o dos de las chispas y rayos del arco cuando se est operando y observando las operaciones Alerte a todas las personas cercanas de no mirar el arco y exponerse a los rayos del arco el ctrico o el metal fundido 3 Use guantes de cuero a prueba de fuego camisa pesada de mangas largas pantal n de ruedo liso zapato alto al tobillo y careta de soldar con capucha para el pelo para proteger el cuerpo de los rayos y chispas calientes provenientes del metalfundido En ocacionesun delantal a prueba de fuego es necesario para protegerse del calor radiado y las chispas 4 Chispas y part culas de metal caliente puede alojarse en las mangasenrolladas dela camisa el ruedo del pantal n o los bolsillos Mangas y cuellos deber n mantenerse abotonados bolsillos al frente de la camisa deber n ser cerrados o eliminados 5 Proteja a otras personas de los rayos del arco y chispas Calientes con una cortina adecuada no flamable como divisi n 6 Use careta protectora adem s de sus gafas de seguridad cuando est rem
24. connections 6 Check the ribbon cable connection between J6 and Relay Module RB1 7 Check the multi color ribbon cable connection between J12 on 1 to J2 on PCB2 8 Check the 24VAC supply on the control transformer N N N N w UJ UJ UJ N N N N UJ UJ UJ UJ 39 Output voltage fell below 70 volts during cutting or below 40 volts during marking Output or Arc voltage detected before START signal issued Main contactor failed to engage or disengage Work current is greater than Electrode current plus threshold limit during cutting The power supply enable signal is missing There was an SPI communication error between the main and servo micro on control board The EEPROM on the control has failed The servo and supervisor on the control board of the power supply has firmware version mismatch Jumper in the RAS box is missing The servo on the control board has fault Coolant flow is below 0 45GPM Coolant flow is above 2 4GPM There was a watchdog error on the CAN bus Ignition Arc lost in dwell state immedi ately after it attached to the plate The station constant s CRC received from the controller did not match the calculated CRC TROUBLESHOOTING 1 Check for short in the torch cable 2 Check cutting or marking height is too low 3 Check for short between electrode and nozzle 4 Check for short between Work 4 and Ele
25. could be caused by blown fuses F1 or F2 3 If the FAULT light is ON then check the CNC Process Controller display screen for the type of error message from power source Fault Light Main Contactor and Main Fan status for different errors faults Type of Fault Fault Light Status Fault Light Frequency K1 and Main Fan Status Servo Fault TOGGLE 5096 duty cycle with a period of 1 second All other Faults TOGGLE 5096 duty cycle with a period of 2 seconds 91 5 Error code UJ A N UJ TROUBLESHOOTING When fault light is in either one of the above mentioned states check the CNC Process Controller screen for the complete description of the error The list of errors with detail description for the power source are shown in the table below Supply Line Voltage exceeded or dropped below 1596 of rated input when machine is in Idle mode Supply Line Voltage exceeded or dropped below or 2096 of rated input while cutting Control Transformer not supplying proper voltage to control board or the 24 and 15 volt bias supplies are not balanced There is a thermal fault inside the power supply Fix any coolant flow er rors before investigating this error CYCLE START signal is high while the power source is booting up Failed to fire ignition did not take place within 4 seconds after HF is turned ON Torch error Electrode current was
26. en los cables de soldar pueden ocasionar un fuego 6 Despu sdetermirarlaoperaci n del equipo inspeccione el rea de trabajo para cerciorarse de que las chispas o metal caliente ocasionen un fuego m s tarde Tenga personal asignado para vigilar si es necesario 7 Para informaci n adicional haga referencia a la pub licaci n NFPA Standard 51B Fire Prevention in Use of Cutting and Welding Processes disponible a trav s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 CHOQUE ELECTRICO El contacto con las partes el c tricas energizadas y tierra puede causar da o severo omuerte NO use soldadura de corriente alterna AC en reas humedas mov imiento confinado en lugares estrechos o si hay posibilidad de caer al suelo ENG 15 SAFETY 1 Aseg rese de que el chasis de la fuente de poder est conectado a tierra atrav s del sistema de electricidad primario 2 Conecte la pieza de trabajo a un buen sistema de tierra f sica 3 Conecte el cable de retorno a la pieza de trabajo Cables y conductores expuestos o con malas conexiones pueden exponer al operador u otras personas a un choque el ctrico fatal 4 Use el equipo solamente si est en buenas condi ciones Reemplaze cables rotos da ados o con conductores expuestos 5 Mantengatodo seco incluyendo su el rea de trabajo los cables antorchas pinza del electrodo y la fuente de poder 6 Asegurese que tod
27. exposure to hexavalent chromium must be below the Permissible Exposure Limit PEL of 5 ug m3 for an eight hour time weighted average Workplace or job specific monitoring must be done to establish areas of potential exposure and to quantify the potential exposure e Employees who be exposed to levels of Cr VI at or above the new PEL must be informed and corrective measures implemented Protective clothing and respiratory protection must be given to employees who have potential exposure Medical surveillance of employees with potential exposure to Cr VI must be conducted e Areas of potential exposure to Cr VI must be indicated with warning signs containing the text shown at left e Engineering control must be used to reduce exposures to safe levels in compliance with the new PEL The specific details of the standard are complex and may require the assistance of an occupational health professional to reach full compliance Hexavalent Chromium Cr VI is a toxic chemical component within fume and dust particles created in a variety of processes including plasma cutting of stainless steel For additional information about Hexavalent Chromium contact your occupational health professional and read the OSHA web page at http www osha gov SLT C hexavalentchromium 24 INTRODUCTION INTRODUCTION INTRODUCTION Introduction The purpose of this manual is to provide qualified repair personne
28. oes AME aaa uses areas CAP 10uF 50VDC 2096 1210 75 MLCC 12 C53 C61 C65 C67 C68 C70 C75 C76 8 CAP 68 0nF 50VDC 20 0603 X7R MLCC CAP 1 00uF 50VDC 20 0805 X7R MLCC 20V 1500W Transient Voltage Suppressor 1 HEADER AMP 26 PIN Straight High Temp Pin In Paste N3429 6502RB 19 J3 1 Phoenix 2 Pin Vert Thru Hole Reflow Connector CCVA 2 5 2 G 5 08P26THR 20 467 FASTON 1 4 Faston Blade 20 21 J5 1 Phoenix 3 Pin Vert Thru Hole Reflow Connector CCVA 2 5 3 G 5 08P26THR J8 J9 10 J11 Termina Phoenix 2 Connector 55 deg Terminal 86 DESCRIPTION OF OPERATION ma S INDUCTOR INDUCTOR Coilcraft MSS1278 series 56uH 81mOhm 1 9Arms MSS1278 series 56uH 81mOhm 1 9Arms Inductor muRata LQH32C_53 series chip inductor 1210 package LQH32CN470K53L INDUCTOR Coilcraft MSS1278 series 33uH 61 9mOhm 2 3Arms MSS1278 333ML O A 5665 RES 4 70 1 SMT 1206 PKG THICK FILM q AE RES 100 1 SMT 1206 PKG THICK FILM RES 150 1 SMT 0603 PKG THICK FILM R11 R18 R21 R22 R23 R24 R28 R29 R31 R33 R37 0 nl a R46 R49 R54 R59 RES 120 1 SMT 0603 PKG THICK FILM RES 33 0 1 SMT 0603 PKG THICK FILM RES 10 0K 1 SMT 0603 PKG THICK FILM 35 R15 R19 R25 R34 R43 R47 R50 R55 8 RES 2 20K 196 SMT 0603 PKG THICK FILM RES 1 00K 196 SMT 0603 PKG THICK FILM 38 R27 R36 R40 R45 R56 R63 R65 R70 8 RES 1 00 196 SMT 1206 PKG THICK FILM Doo
29. power to the high speed electronic switches These switches are known as IGBTs Insulated Gate Bipolar Transistors The IGBTs are the electronic switches that in the EPP 362 turn on and off at a frequency ranging from 15 KHZ 25 KHZ They provide the pulses of power filtered by the inductor The Free Wheeling Diodes provide the path for reverse current to flow when the IGBTs are off The Hall Sensors are current transducers that monitor the output currents and provide the feedback signals for the control circuit Sequence of Events The EPP 362 has no power switch installed in the unit The wall breaker is the power disconnect for this power supply Once the wall breaker is closed the following events occur 1 Poweris applied to the control transformer T2 This supplies power to the circuit boards PCB1 the Control board and PCB2 the Driver board Main micro on the control board PCB1 establishes the digital communication with CNC Process Controller through CAN or analog interface through DB25 connector 2 Pump Motor M2 turns ON Coolant pumps out to the torch and comes back into the tank through radiators filter flow sensor and IGBTs cold plate respectively The Control board performs a fault error check If there are no faults errors the power up sequence will continue 4 PowerLight PL on the front panel will be ON all time indicating there is input power available and Fault Light FL will be OFF indicating there are no faults err
30. the circuits on the board Positive and Negative 15 VDC Bias Supply The board receives centered tapped 34 VAC from control transformer TB3 13 TB3 14 and TB3 15 on pins 1 2 and 3 of con nector J3 This center tapped supply is used to provide both positive and negative output bias voltages Positive 15 VDC Bias Supply The 17 VAC input on pins 1 and 2 of connector J3 is rectified through diode bridge rectifier circuit D7 D8 D11 and D12 and filtered by a capacitor This filtered DC is sent through a regulator U8 to have 15 VDC which powers the circuits needing 15 volts The filtered DC is also fed through a regulator U7 to have 5 VDC bias supply which powers the circuits needing 5 volts The positive 15 volts is also sent to the microcontroller for monitoring the 15 VDC bias supply availability Negative 15VDC Bias Supply The 17 VAC input on pins 2 and 3 of connector J3 is rectified through diode bridge rectifier circuit D7 D8 D11 and D12 and filtered by a capacitor This filtered DC is sent through a negative 15 volt 3 pin regulator U9 to have 15 VDC bias supply which powers the circuits needing 15 volts The negative 15 volts is also sent to the micro controller for monitoring the 15 VDC bias supply availability Positive 24 VDC Low Power Bias Supply The board receives 24 VAC from control transformer TB3 4 and TB3 5 on pins 4 and 5 of connector J3 This 24 VAC is recti fied through diode bridge rectifier circuit D5 D
31. 0 25W 0 25W 0 25W 0 25W U10 R24 1 5 vont B vpp2 VIN El VOUT 3 47 VIN S VOUT 2n m VWORK GND1 GND2 HGND 20788 R18 6 R73 R69 R72 R68 R71 AN 2 1 NW ANN ANN ANN ANN 420 100K 100K 100K 100K 100K 0 1W FASTON 1 4 TERMINAL 0 25W 0 25W 0 25W 0 25W 0 25W R67 C59 ALVdd 5v00 221 10 0nF U13 1 8 dd gt 3 vpp2 AV ONE 37 VIN VOUT s TP14 VIN i VOUT VBUS ll nba 2 GND2 5 R50 R55 0 1W 784 lt ANV 31 NN ALVdd 5v00 ALGND 2 20K 2 20K KA 0 1W 0 1W HGND FASTON 1 4 TERMINAL 74 27 054 10 0 LVdd 3v30 10 0nF ALGND 100nF HGND R47 R43 wd AN AN LGND 2 20K 2 20K 0 1W 0 1W G 4 3310E 4 2 1648E 4 2 1648E 4 4 3310E 4 VworkOut VbusOut VworkOut VArcOut VworkIn VbusIn VworkIn VarcIn ce an bru ALGND 70 DESCRIPTION OF OPERATION PCB1 PWM 0558038362 The Pulse Width Modulator Circuit referred to as PWM is the circuit that generates the pulses to trigger IGBTs ON and OFF The Servo Micro U17 generates the PWM signals ranging from 15 KHz to 25 KHz based on the current signal These PWM signals from the servo micro are fed through logic gates to generate positive and negative pulses These pulses are sent to the Driver Board PCB2 Refer to PCB2 Driver Board section for PCB2 details through J12 or J13 connector on the 1 where IGBT gate and emitter connections are made Reference the PCB1 and 2 test point
32. 00 AM to 5 00 PM EST Part Numbers Technical Applications Specifications Equipment Recommendations LITERATURE REQUESTS Telephone 843 664 5562 Fax 843 664 5548 Hours 7 30 AM to 4 00 PM EST WELDING EQUIPMENT REPAIRS Telephone 843 664 4487 Fax 843 664 5557 Hours 7 30 AM to 3 30 PM EST Repair Estimates Repair Status 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 WELDING PROCESS ASSISTANCE Telephone 800 ESAB 123 Hours 7 30 AM to 4 00 PM EST TECHNICAL ASST CONSUMABLES Telephone 800 933 7070 Hours 7 30 AM to 5 00 PM EST IF YOU DO NOT KNOW WHOM TO CALL Telephone 800 ESAB 123 Fax 843 664 4462 Hours 7 30 AM to 5 00 PM EST or visit us on the web at http www esabna com The ESAB web site offers Comprehensive Product Information Material Safety Data Sheets Warranty Registration Instruction Literature Download Library Distributor Locator Global Company Information Press Releases Customer Feedback amp Support yg ESAB EP ESAB Welding amp Cutting Products PO Box 100545 Florence SC 29501 0545
33. 24 D49 1 LED Yellow Diffused 2 00V CMD15 21VYD TR8 25 Phoenix Mini 6 Pin Vert Thru Hole Reflow Connector MCV 1 5 6 G 3 81 Phoenix 3 Pin Vert Thru Hole Reflow Connector anie CCVA 2 5 3 G 5 08P26THR 27 J3 Phoenix 5 Vert Thru Hole Reflow Connector CCVA 2 5 5 G 5 08P26THR 28 JA 1 CONECTOR Tyco 2 6 pin Non ROHS connector 102202 3 29 15 J6 CONNECTOR AMP 14 Pin Shrouded Right Angle Header High Temp Pin In Paste N3314 5002RB 37 310 CONECTOR Tyco 2 5 pin Non ROHS connector 31 Phoenix MiniCombicon 4 Pin Vert Thru Hole Reflow Connector MCV 1 5 4 G 3 81 32 Jo Phoenix 8 Pin Vert Thru Hole Reflow Connector CCVA 2 5 8 G 5 08P26THR 33 nr 1 HEADER 3M 20 Pin Straight High Temp Pin In Paste N3428 6502RB HEADER AMP 26 PIN Straight High Temp Pin In CONNECTOR Phoenix Minicombicon 3 Pos ROHS Pin In Paste Reflow 1937619 36 18 Phoenix Mini 10 Pin Vert Thru Hole Reflow Connector MCV 1 5 10 G 3 81P26THR 37 142 INDUCTOR 150 21 SAONE 1 20Arms MSS1260 154KL 38 13 INDUCTOR Coilcraft MSS1278 series 27uH 45mOhm 2 6Arms MSS1278 273ML 39 14 INDUCTOR Coilcraft MSS1260 series 82uH 132mOhm 1 60Arms MSS1260 823ML Inductor muRata LOH32C 53 series chip inductor 1210 package LQH32CN470K53L MH1 MH2 Lm Mounting Hole Transistor SMT Version of 2N3904 NPN in SOT23 Package RN3 RN4 RN5 RN7 RN9 RN10 RN11 RN12 RN13 RN1 4 RN15 RES 16 PIN SMT
34. 27 INTRODUCTION Service Manual Format The machine operation flow diagram shows the breakdown of the functionality of the EPP 362 Each of the major compo nents is divided into sections which are described in the pages that follow Each section in the flow chart has a matching section on the main schematic and is applied to the description pages Each section starts with the schematic view with description if the section includes a printed circuit PC board it is followed by a PC board schematic the layout of the board and then the component list for the board Some PC boards will also have mini descriptions of selected circuits This in formation is for troubleshooting purposes only PC board repair is not recommended Circuit Description The power circuit utilized in the EPP 362 is commonly referred to as a Chopper High speed electronic switches turn on and off several thousand times per second providing pulses of power to the output A filter circuit consisting primarily of an inductor sometimes called a choke converts the pulses to a relatively constant DC Direct Current output The EPP 362 Block Diagram 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 360V DC Bus The Bus Rectifiers convert the three phase output of T1 to the 360V DC bus voltage A capacitor bank provides filtering and energy storage that supplies
35. 56 C157 C158 C159 C160 C161 C16 4 C165 C178 C179 C185 C186 C199 C31 C62 C63 C65 C66 C57 C58 C76 C96 C97 C105 C112 O lt gt UT UT NA 7 e 11 13 14 15 17 NO 20 N N C64 C69 C71 C83 C84 C85 C89 C108 C113 C116 C1 18 125 131 136 137 142 163 170 194 C 1 97 C198 D3 D13 D17 D26 D27 D32 D33 D35 D48 D51 D56 D6 4 D65 D67 D69 D71 D74 D76 D78 D4 D5 D6 D7 D8 D9 D10 D11 D12 D18 D31 D34 D19 D20 D21 D22 D23 D24 D36 D37 D38 D39 D41 D42 D43 D44 D66 D68 D70 D72 D73 D75 D77 D79 D80 D81 D82 D83 D84 D85 D86 D87 D88 D89 D90 D91 D92 NO 2 1 4 NO 12 UJ UT DESCRIPTION FUNCTION CAP 100nF 16VDC 20 0603 X7R MLCC CAP 1 00uF 50VDC 20 0805 X7R MLCC CAP Nichicon UD series 220uF 50V Electrolytic Capacitor UWD1H221MNL1GS CAP 10 0nF 50VDC 20 0603 X7R MLCC CAP Nichicon UD series 100uF 35V Electrolytic Capacitor UWD1V101MNL1GS CAP 10 0uF 16VDC 20 1206 X7R MLCC CAP 47 0nF 50VDC 20 0603 X7R MLCC CAP 470nF 16VDC 2096 0805 X7R MLCC CAP 0 1uF 50V DC 20 0603 X7R MLCC LED Red Diffused 2 00V 20mA CMD15 21VRD TR8 Diode 400V Peak Reverse Voltage SMC package Diode General Purpose 1N4148 75V 200mA Diode 0603 PKG DESCRIPTION OF OPERATION ITEM SYMBOL DESCRIPTION FUNCTION Diode ON Semi 60V 3A Schottkey Diode D47 D50 D53 D54 D57 LED Green Diffused m CMD15 21VGD
36. 6 D9 and D10 and filtered by a capacitor This filtered DC is sent through a regulator U6 to have regulated 24 VDC This regulated 24 VDC besides powering the circuits requiring 24 volts also sent to microcontroller for monitoring the 24 VDC bias supply availability 72 DESCRIPTION OF OPERATION Positive 24 HVDC High Power Bias Supply The board receives 24 VAC from the control transformer TB3 9 and TB3 10 on pins 1 and 2 of connector J2 The 24 VAC is rectified through diode bridge rectifier circuit D4 D18 D31 and D34 and filtered by a capacitor This filtered DC is sent though a regulator U2 to have 24 HVDC This regulated high power 24 HVDC is used to power the isolated digital inputs U 1W R235 8 10 0K 560 0 1W 0 1W R245 Terminating 2 120 Resistar L 0 1W 2 C149 PWM FAULT2N lt 100nF R236 R211 180 10 0K 0 1W R238 0 1W R237 VARC2N 1 00K 470 0 1W 0 1W AVdd 500 AVdd 5v00 U R239 VBUS2P 1 00K AVdd_5v00 y OAW 5 4 R241 5452110 180 0 1W R243 130 1 00K 470 0 1W 0 1W Terminating Resister Gain 0 5 Gain 2 1277 itle EPP 202 362 Servo Micro Size Document Number D 0558038361 Date Tuesday April 23 2013 Sheet 5 of 6 1 73 DESCRIPTION OF OPERATION PCB1 Test Points ETA A amont Work Curent Signal fom the hallensor 28 VOC 0 Amps OS VOC 360Ampe ms RAW Panne Cn mv _ G c
37. 7 7 7 0 56 7 R268 R287 R288 R300 15 RES 560 1 SMT 0603 PKG THICK FILM 57 R81 R82 R83 R84 R85 R86 R87 R88 R89 58 R90 R91 2 mw 62 2 RES 180 1 SMT 1206 PKG THICK FILM R105 R114 R116 R120 R126 R127 R141 R143 R178 R 0 63 179 R181 R197 R202 13 RES 5 60K 196 SMT 0603 PKG THICK FILM POT muRATA 3mm 1k sealed trimmer pot 64 R107 R108 R109 R110 4 PVG3A102C01R00 65 R115 R117 R135 R136 R155 R156 R166 R167 RES 3 30 196 SMT 1206 PKG THICK FILM R118 1 67 R128 R130 R188 R190 R137 R146 R164 R177 69 R192 A 8 RES 68 0 196 SMT 0603 PKG THICK FILM RES 33 0K 196 SMT 0603 PKG THICK FILM RES 47 5K 1 SMT 0603 PKG THICK FILM RES 3 90K 196 SMT 0603 PKG THICK FILM RES 330 196 SMT 0603 PKG THICK FILM Ignore This is a virtual nonexistant part RES 1 20K 196 SMT 0603 PKG THICK FILM RES 6 80K 196 SMT 0603 PKG THICK FILM RES 12 1K 1 SMT 0603 PKG THICK FILM N DESCRIPTION OF OPERATION RES 1 50K 196 SMT 0603 PKG THICK FILM 72 2 RES 270 1 SMT 1206 PKG THICK FILM 5 81 SW1 SW2 SW3 SW4 4 TP1 TP2 TP3 TP4 TP5 TP6 TP7 TP8 TPO TP10 TP11 TP 12 TP13 TP14 TP15 TP16 TP17 TP18 TP19 TP20 TP21 RES 470 1 SMT 0603 PKG THICK FILM RES 120 1 SMT 0603 PKG THICK FILM RES 2 0K 1 SMT 0603 PKG THICK FILM RES 37 4K 1 SMT 0603 PKG THICK FILM RES 270 1 SMT 0603 PKG THICK FILM RES 120 1 SMT 0603 PKG THICK FILM RES 20 0K 1 SMT 0603 PKG THICK FILM RES 20 0K 1 SMT 0603 PKG THICK FILM OMRON 6 pin
38. 900 watts at 45 F 25 C temperature difference between high coolant temperature and ambient air tempera ture using ESAB coolant 2596 propylene glycol 75 distilled water Max Delivery Pressure 175 psig 12 bars Reservoir Capacity 4 gallons 15 2 liters 63 DESCRIPTION OF OPERATION Operation As soon as the power source is supplied input power the coolant pump motor turns ON and pumps the coolant Coolant pumps out to the torch and returns back to the coolant tank through radiators filter flow sensor and IGBTs cold plate re spectively The pump has an internal adjustable bypass valve set to 225 psi 15 5 bar There is also an external adjustable regulator set to 175 psi 12 bar to bypass the coolant flow if pressure exceeds 175 psi 12 bar The coolant flow diagram is as shown in the figure below SUPPLY IGBT COLD PLATE FILTER TANK oC LS1 lt FILTER RADIATOR FLOW SENSOR FS1 LEVEL SENSOR RETURN gt gt Coolant Flow Diagram Please refer to Replacement Parts section in the back of this manual for more details 64 DESCRIPTION OF OPERATION Flow sensor RotorFlow Sensor is used to monitor the flow rate of the coolant Operation The rotor reacts to turbulence pulsation entrained air and other flow anomalies induced in the flow stream by other process hardware For optimum performance install RotorFlow units wh
39. ESAB 362 Plasma Power Source ecsion Plas u GRZ Service Manual 0558011929 01 2015 EPP 362 Plasma Power Source SURE THIS INFORMATION 5 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 welding and cutting equipment we urge you to read our booklet Precautions and Safe Practices for Arc Welding Cutting and Gouging Form 52 529 Do NOT permit untrained persons to install operate or maintain this equipment Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions If you do not fully understand these instructions contact your supplier for further information Be sure to read the Safety Precautions be fore installing or operating this equipment USER RESPONSIBILITY This equipment will perform in conformity with the description thereof contained in this manual and accompanying la bels and or inserts when installed operated maintained and repaired in accordance with the instructions provided This equipment must be checked periodically Malfunctioning or poorly maintained equipment should not be used Parts that are broken missing worn distorted or contaminated should be replaced immediately Should such repair or replacement become necessary the manufacturer recommends that a telephon
40. GBT Testing in the General Information section PCB2 DRIVER P N 05580038382 J4 J6 M6 TORQUE 36 IN LBS A4 10 0 1 2 30 50 2 4 61 40 3 7 93 00 4 2 106 40 NOTE TERMINALS NOT INSTALLED IN POSITIONS 4 AND 5 DESCRIPTION OF OPERATION IGBT Driver Board PCB2 0558038362 Bias Supply The Driver board has a bias supply built onboard to power its own circuitry The board receives 24 VAC in from the control transformer T2 The voltage is rectified filtered regulated and then sent to the various circuits on the board 24 VAC input J5 pins 1 and 3 is rectified by the full wave bridge D2 D3 D5 D6 and filtered by capacitor bank C5 C6 C25 C48 C62 The voltage from capacitor bank is provided to U12 and U2 which will then provide regulated 24 HVDC and 9 HVDC output voltages Test point To check the 15 VDC supply check the voltage between TP1 415 VDC and TP2 common This should read 15 VDC 1096 PCB2 ICBT DRIVER P N 05580038382 co gt m 55 DESCRIPTION OF OPERATION Hall Sensors HS1 HS2 0558006886 The Current sensors HS1 and HS2 Hall Sensors or Hall Effect Sensors provide current feedback to the Control Board PCBI These two sensors detect the amount of current flowing through them and provide a signal back to the Control Board for output current regulation and passing to controller through CAN communications The
41. IMUM OF 4 1 2 TWISTS RED 3 CUT RED AND WHITE WIRES USED IN TWISTED PAIR TO 4 5 MEASURED BEFORE TERMINAL 6 TERMINATING AND TWISTING TERMINAL 77 4 PERFORM ASSEMBLY AT STATIC SAFE STATION SURFACE MAT WRIST STRAP amp GROUNDED SOLDERING IRON USE WITH P N 951833 THERMAL PAD GENERAL INFORMATION IGBT Testing LARGE BLACK LARGE RED SMALL YELLOW CLIP CLIP CLIP IGBT TESTER SCHEMATIC oW 1 3M 117 OQ Appendix Appendix A Machine schematics Appendix B Control Board PCB1 schematics Appendix C Driver Board PCB2 schematics Appendix D Wiring Diagrams Appendix E Connectors Information Appendix F Replacement Parts 5 REVISION HISTORY Originally released 08 2013 Revision 10 2013 help codes Revision 04 2014 added Interface Adaptor Box to optional accessories not to be added to transla tions revision 06 2014 updated helpcodes updated BOM ESAB Welding amp Cutting Products Florence SC COMMUNICATION GUIDE CUSTOMER SERVICES CUSTOMER SERVICE QUESTIONS Telephone 800 362 7080 Fax 800 634 7548 Hours 8 00 AM to 7 00 PM EST Order Entry Product Availability Pricing Order Information Returns ENGINEERING SERVICE Telephone 843 664 4416 Fax 800 446 5693 Hours 7 30 AM to 5 00 PM EST Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting TECHNICAL SERVICE Telephone 800 ESAB 123 Fax 843 664 4452 Hours 8
42. OUBLESHOOTING Troubleshooting ELECTRIC SHOCK CAN KILL WARNING DO NOT PERMIT UNTRAINED PERSONS TO INSPECT OR REPAIR THIS EQUIPMENT ELECTRICAL WORK MUST BE PERFORMED BY AN EXPERIENCED ELECTRICIAN Stop work immediately if power source does not work properly AU O N Have only trained personnel investigate the cause Use only recommended replacement parts Check the problem against the symptoms in the following troubleshooting guide The remedy may be quite simple If the cause cannot be quickly located shut off the input power open up the unit and perform simple visual inspection of all the components and wiring Check for secure terminal connections loose or burned wiring or components bulged or leaking capacitors or any other sign of damage or discoloration The cause of control malfunctions can be found by referring to the sequence of operations electrical schematics and checking the various components A volt ohmmeter will be necessary for some of these checks Troubleshooting Guide When the input power is applied to EPP 362 power source pump motor should turn ON immediately the power light on the front panel will be ON and fault light will be OFF if there are no errors faults indicating normal operation Check the following 1 If pump motor doesn t turn ON fuse F3 might be bad or check for a bad connection to pump motor 2 If POWER light doesn t turn ON or main contactor and main fan doesn t turn ON then it
43. RB1 2 4 match line BUSS PRE CHARGE RELAY K2 20H TB1 ak El 2211 r 7 2 1 10 1 L K2 F2 2 1 I LL Li 1 15 AMP SLO BLON 5 1 emm u mus C gt a L_ _J I GND1 MAIN CONTACTOR I K1 I I 575 VOLTS l I 3 PHASE 60 50 Hz d 1 p PRIMARY m 115vac TB2 TO RELAY Is 9 TO REUAY RB1 3 14 9 TO RELAY 1 2 11 z 3 PH TO BUS BRIDGE TO RELA RB1 3 11 2 6000 uf usd TT BUSS DISCHARGE R4 8 OHM Moov 300 2 DRIVER ya P N 05580038382 J2 Es is us MAIN CONTRO V I vel TERMINATE SHIELD TO FILTER PCB En OTHER END OMY OUTPUT PRE LOAD ELECTRODE i E J pg Y PCB1 J9 2 FILTER PCB TO 49 8 0558038391 TO PCB1 19 3 _ WORK TERMINATE SHIELD OTHER END ONLY WORK O 9 SCHEMATIC LAYOUT match line g j ste E 4 Ms 13 14 u 1516 174 2 11 1 gt TO RELAY RB1 4 14 H
44. Rd as 35 COMPOnent LOCO 26 spade eects deere ete een cud tees er nee ue esa ETE TENE 35 Schematic Section Map 0558010795 36 Schematic Section Map 0558010795 sheet 2 38 DESCRIPTION of OPERATION Relay CONTACTOS KE EPIIT DAR TE 43 Main Contactor 922001 re euere einen nt 43 K1 Relay Contactor Relay nennen 44 K2 Relay Soft Start Relay u Pto er ee REPERTA 45 K4 K5 Relay PS Enable Relay 0558007736 46 K4 K5 Relay PS Enable Relay 0558007736 47 MO rinn er i T ee 48 Fall een o E NA 49 Control KINSTO u oru EE SR s EEREN aue EEE SEEN 50 Control Transformer Winding 51 l I er vetet P ds ae ee CINES te NU RE 52 Input Rectifiers 0558003657 Forward 0558003658 53 IOBIT 01502 10559000189 RESCUE ST ee Sa UT ERU SH ia 54 05580060153 I BE tase eects ELEC EM ELLA AERE RI 54 IGBT Driver Board PCB2 0558038362
45. Rotary SMT DIP switch A6RS 162 SWITCH SLIDE DPDT 6VDC 0 3A SMT TEST POINT Keystone Miniature SMT Test Point UJ UJ 1P22 1P23 1P24 T1P25 1P26 1P27 1P28 1P29 1P50 1 P31 TP32 TP33 TP34 5015 84 U1 1 3V 5 5V TSSOP RS 232 Driver Receiver SN75C3221EPW 85 U2 U6 U7 U8 A National 500kHz Buck C Ori LM22676TJ ADJ 04 0 U3 U4 U5 U43 U44 U45 OPTOCOUPLER Vishay Dual 4kV ISO 6396 1 2596 ILD206T 87 9 ON Semiconductor Voltage Regulator 15V Rating MC7915CD2TR4G ON Semiconductor Darlington Transistor Array 7 i x Transistor Pairs MC1413DR2G U12 U24 U25 3 ON Semi QUAD NAND Gate SOIC MC74LCX00D 92 015 018 2 021 023 2 ON Semiconductor 3 3V CMOS Hex Inverter MC74ACO5DR2 ON Semiconductor 3 3V 1 0A SOT223 Regulator NCP1117ST33T3G I C Dual 4 to 1 multiplexor SOIC SN74HC153D IC 8 pin SOIC package SPI EEPROM 256Kbits Microchip 16 bit DSP dsPIC33FJ16GS5041 PT Microchip 16 bit DSP dsPIC33FJ256GP710PF TI 6 4MHz Rail Rail JFET Low Voltage OPAMP TLV2464AIDR 7 O DESCRIPTION OF OPERATION ITEM SYMBOL DESCRIPTION FUNCTION TI 150mA 3 3V LDO 30mV dropout men IER U29 I C TI Dual Positive LC TI Dual Positive Edge Flip Flops SN74AC74D Flip Flops SN74AC74D U31 8 Murata 3kV isolation 5V 5V DC DC Converter OPAMP TI Rail To Rail Fully Differential OpAmp TI Quad Differential Line Receiver SNG5LVDSO48A Differentia
46. SvM LIf OL gJ LOWPCBL 41 5 TO PCB1 J1 4 NOTE 1 NOTE 1 Q3 and Q4 AND C2 are used only in EPP362 gt TO TB3 1 D TO TB3 2 TO 1 J12 MAIN CONTROL L1 SCHEMATIC LAYOUT Schematic Section Map 0558010795 sheet 2 Refer to Appendix B in the back section of this manual for complete schematics 38 TO TB3 9 TO TB5 10 TO K4 4 TO K1 E TO TB2 7 TO M1 2 TO TB3 17 TO FL1 2 TO J1 RAS G TO J1 RAS D TO CB1 2 TO J1 RAS C lt 24 VAC 24 BUSS PRE CHARGE i 115VAC COMMON 1 14 PIN RIBBON match line lt PRIMARY CONTACTOR 115VAC I 2 230VAC COMMON 230VAC i FAULT p LOAD BANK MARK MODE 20 PIN RIBBON lt TEST PORT 518 120 VAC x 7 HF IGNITOR I I I i 4 24 VDC N C lt RELAY TERM BLK ee 24 VDC COMMON i RB1 1 I I 3 3 VDC J8 1 Note 3 ne i FLOW SENSOR FS1 MachinelD 2 8 3 I I 45 FS RED M at w 2j 1 COMMON J16 2 o 59 Flow Sensor Freq Input 16 3 i WwW Flow Sensor Connection I I I s i TO PCB2 J2 26 PIN RIBBON IGBT DRIVER BOARD I I SHIELD J9 1 ro Hs1 1 lt 15V TO HALL SENS A BLK J9 2 ro uenia 15V TO HALL SENS i RED 19 3 ro HS1 2 CURRENT SIGNAL FROM Hst iy 4 J9 5 I lt 15V TO HALL SENS 49 6 TO HS2 1
47. US 0558038302 oos cett a 71 PCBT Bias S pply 0558038362 sent Ga to cc tance 72 Positive a a Negative 15 VDC Blas Supply 72 Positive 24 VDC Low Power Bias 72 Positive 24 HVDC High Power Bias Supply 73 POBI Test POING P 74 9 18 NE OU E 75 PCBILBORNTIOSS805353DZ u 2 e eames 76 PCB2 Driver Board 0558038382 81 Blas vin 82 PCBZ PWM Pulse CIRCUIT a a io 83 PORTES due cv E M 84 PCD2 Layout 0558038381 A ee ee ee 85 PCB2 BOM 0558038382 sss PEEEA Pe RE REPE see sure 86 TROUBLESHOOTING TEFOUDICSNOOUNG eo SR tisay tee os ET AER one ira area 91 Troubleshooting GUNS dead de a ee nern 91 Help ale 552655 92 REPLACEMENT PARTS Replacement Pall ba TA TA 99 ERR E 99 A o n ae ee n E EE z ne m 99 EPP 362 Plasma Power Source GENERAL INFORMATION General Information
48. VAC and 460 VAC Models continued ae 2 Reconfigure TB2 terminal strip for proper voltage 9 Or Q Q e a Q Ja Or JO JUMPER POSITIONS FOR 460 VAC JUMPER POSITIONS FOR 380 VAC u f NOTE Wires connected on main transformer tap must be re connected to 460 400 or 380 main transformer taps on all 3 coils Be sure to replace insulating vinyl covering over connections Access Panel T 400 Y 7 i 3 Reconfigure secondary taps on all three main transformer coils A removable service panel is located above the transformer connections to improve access 575 VAC Models this model is not configurable to any other input voltage 95 96 TROUBLESHOOTING REPLACEMENT PARTS 98 REPLACEMENT PARTS REPLACEMENT PARTS Replacement Parts General Always provide the serial number of the unit on which the parts will be used The serial number is stamped on the unit nameplate Ordering To ensure proper operation it is recommended that only genuine ESAB parts and products be used with this equipment The use of non ESAB parts may void your warranty Replacement 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 NOTE Schematics and Wiring Diag
49. ables and hoses are not damaged flattened or kinked With input power disconnected and wearing proper eye and face protection blow out accumulated dirt and foreign materials for the inside of unit Extra attention should be given to the finned heatsinks Water or oil occasionally accumulates in compressed lines Be sure CAUTI O N to direct the first blast of air away from the equipment to avoid damage to the 300 103 GENERAL INFORMATION Electrostatic Discharge WARNING STATIC ELECTRICITY can damage circuit boards and electronic components Observe precautions for handling electrostatic S sensitive devices Use proper static proof bags and boxes What is ESD A sudden transfer or discharge of static electricity from one object to another ESD stands forElec trostatic Discharge How does ESD damage occur ESD can cause damage to sensitive electrical components but is not dangerous to people ESD damage occurs when an ungrounded person or object with a static charge comes intocontact with a component or assembly that is grounded A rapid discharge can occur causing damage This damage can take the form of immediate failure but it is more likelythat system performance will be affected and the component will fail prematurely How do we prevent ESD damage ESD damage can be prevented by awareness If static electricity is prevented from buildingup on you or on anything at your work station then there
50. as las partes de su cuerpo est n insuladas de ambos la pieza de trabajo y tierra 7 Noseparedirectamente sobre metalotierra mien tras trabaja en lugares estrechos o reas h medas trabaje sobre un pedazo de madera seco o una plataforma insulada y use zapatos con suela de goma 8 Use guantes secos y sin agujeros antes deenergizar el equipo 9 Apage el equipo antes de quitarse sus guantes 10 Use como referencia la publicaci n ANSI ASC Standard Z49 1 listado enla pr xima p gina para recomendaciones espec ficas de como conectar el equipo a tierra No confunda el cable de soldar a la pieza de trabajo con el cable a tierra CAMPOS ELECTRICOS Y MAGNETI 2 COS Son peligrosos La corriente el ctrica fluye atrav s de cualquier conductor causando a nivel local Campos El ctricos y Magn ticos Las corrientes enel rea de corte y soldadura crean EMF alrrededor de los cables de soldar y las maquinas Por lo tanto 1 Soldadores u Operadores que use marca pasos para el coraz n deber n consultar a su m dico antes de soldar El Campo Electromagn tico EMF puede interferir con algunos marca pasos 2 Exponersea campos electromagn ticos EMF puede causar otros efectos de salud a n desconocidos 16 3 Los soldadores deber n 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 quier
51. as pr cticas de se guridad delos equipos de arcoel ctrico para soldar y cortar pregunte a su suplidor por unacopia de Precautions andSafe Practices for ArcWelding Cutting and Gouging Form 52 529 Las siguientes publicaciones disponibles atrav s de la American Welding Society 550 N W LeJuene Road Miami FL 33126 son recomendadas para usted 1 ANSI ASC Z49 1 Safety in Welding and Cutting 2 AWS C5 1 Recommended Practices for Plasma Arc Welding 3 AWS 5 2 Recommended Practices for Plasma Arc Cutting 4 AWS 5 3 Recommended Practices for Air Carbon Arc Gouging and Cutting 5 AWS C5 5 Recommended Practices for Gas Tung sten Arc Welding 6 AWS 5 6 Recommended Practices for Gas Metal Arc Welding 7 AWS SP Safe Practices Reprint Welding Hand book 8 ANSI AWS F4 1 Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances 9 CSA Standard W117 2 Safety in Welding Cutting and Allied Processes 17 SAFETY SIGNIFICADO DE LOS SIMBOLOS Seg n usted avanza en la lectura de este folleto Los S mbolos Significan Atenci n Este Alerta Se trata de su seguridad Significa riesgo inmediato que de no ser evadido puede resultar inmediata PE LIG RO mente en serio da o personal o la muerte Significa el riesgo de un peligro potencial que puede resultar en serio da o personal o la muerte CUIDADO Significa e
52. cannot be any static discharges Nonconductive materials e g fabrics or insulators e g plastics generate and hold staticcharge so you should not bring unnecessary nonconductive items into the work area It is obviously difficult to avoid all such items so various means are used to drain off anystatic discharge from persons to prevent the risk of ESD damage This is done by simpledevices wrist straps connected to ground and conductive shoes Work surfaces carts and containers must be conductive and grounded use only antistaticpackag ing materials Overall handling of ESD sensitive devices should be minimized to prevent damage 104 GENERAL INFORMATION Ohm s and Watt s Laws PRESSURE IN VOLTS CURRENT IN AMPERES RESISTANCE IN OHMS W POWER IN WATTS THE DIAGRAM ABOVE SHOWS ALL THE FORMULAS FOR DETERMINING E I AND R WITH OHM S AND WATT S LAWS To find W when E 10 and R 5 substitute 10 for E and 5 for R 2 10 x 10 100 100 5R 20WATTS 105 GENERAL INFORMATION Glossary General Definitions and Symbols Used in this Manual SYMBOL NOTATION NAME VALUES DESCRIPTION BEEN V D MEN 7 sn Electromotive force effectively the pressure of electron movement Amount of electrical storage in a capacitor A voltage used to control or stabilize an electronic circuit A forward bias is voltage applied in the direction of the current flow within a transistor BIAS tube or ci
53. chart See Appendix for detailed schematics PCB1 Output Circuits 0558038362 EPP 362 power source interfaces with CNC Process Controller through either CAN communication or analog connection CAN Communication Interface Control board interfaces with CNC or Process Controller through CAN communication protocol There are two sets of com munication circuits available on the PCB1 U26 U46 comprise one set and U27 U38 comprise other Via CAN communica tion power source sends the required output signals to CNC or Process Controller Analog Interface The control board sends the output signals to control various functions Refer to Appendix D for the output connector information See Appendix B for detailed schematics PCB1 Input Circuits 0558038362 As mentioned in previous section EPP 362 power source interfaces with CNC Process Controller through either CAN com munication or analog connection CAN Communication Interface The control board via CAN communication reads the inputs from the CNC or Process Controller These input signals are used by the main micro U19 for the main process sequence Analog Interface Control board reads the input signal information from the external circuitry Refer to Appendix D for the input connector information See Appendix B for detailed schematics 71 DESCRIPTION OF OPERATION PCB1 Bias Supply 0558038362 The control board PCB1 generates the onboard supply voltages to power
54. ckthe arc voltage feedback connection on the driver board from the Electrode terminal 4 Check IGBT gate pulse voltage connection on the driver board 1 Check for shorted IGBT 2 Check for shorted diode D9 3 Check the IGBT gate pulse voltage connection on the driver board If there is positive voltage then replace the driver board 4 Check the hall sensors and their connections to the control board 5 Replace the control board 1 Check the fuses in the disconnect box for bad fuse 2 Check the main contactor contacts for any damage 3 Verify the input to the power supply is providing all 3 phases 1 Check for short between the electrode and nozzle 2 Check for short between the electrode cable and a connection to the work output of the power supply 3 Check for an open IGBT 4 Check the IGBT gate pulse voltage connection on the driver board 5 Check the multi color ribbon connection from J12 on PCB1 to J2 on PCB2 1 Check the temperature inside the control panel if it reads below 55C and still the error is present then replace the control board 2 Cool the area around the power supply to below 40C This is the upper limit of the rated operating range for the power supply 1 Check for faulty input fuse 2 Check for shorted bus filter capacitor 3 Check the bus charger contactor K2 contacts and coil for any damage 4 Check the bus charger contactor relay RB1 1 for failure 5 Check bus charger resistors
55. cours d une op ration indique que la ven tilation n est pas ad quate Cessez votre travail afin de prendre les mesures n cessaires pour am liorer la ventilation dans l aire de travail Ne poursuivez pas l op ration si le malaise persiste 4 Consultez ANSI ASC Standard Z49 1 la page suivante pour des recommandations sp cifiques concernant la ventilation SAFETY 5 AVERTISSEMENT Ce produit lorsqu il estutilis dans une op ration de soudage ou decoupage d gage des vapeurs ou des gaz contenant des chimiques consid res par l tat de la Californie comme tant une cause des malformations cong nitales et dans certains cas du cancer California Health amp Safety Code 525249 5 et seq MANIPULATION DES CYLINDRES La manipulation d un cylindre sans 677 observerlespr cautions n cessaires peut produire des fissures et un chappement dangereux des gaz Une brisure soudaine du cylindre de la soupape ou du dispositif de surpression peut causer des blessures graves ou mortelles Par cons quent ER 1 Utilisez toujours le gaz pr vu pour une op ration et le d tendeur appropri concu pour utilisation sur les cyl indres de gaz comprim N utilisez jamais d adaptateur Maintenezen bon tatlestuyauxetles raccords Observez les instructions d op ration du fabricant pour assembler le d tendeur sur un cylindre de gaz comprim 2 Fixez les cylindres dans une position verticale l
56. ctrode terminals on the power supply 5 Check for coiled or looped up electrode or work cables 1 Check for a shorted IGBT 2 Check the gate pulse voltage to IGBT from driver board If there is a positive voltage during idle replace the driver board 3 Checkthe IGBT gate pulse voltage connections and make sure they are as per schematics 4 Check the arc voltage feedback connections on the driver board 5 Check for shorted diode D9 6 Check the multi color ribbon cable connection between J12 on PCB1 and J2 on PCB2 1 Check the input fuses inside the disconnect box 2 Check the main contactor K1 contacts 3 Check the main transformer auxiliary windings connection on TB2 for 115VAC 4 Check the relay RB1 2 on the relay module RB1 5 Check the ribbon cable connection between J6 and relay module RB1 1 Check the feedback from the hall sensors 2 Check the connection from hall sensors to the control board 3 Replace the control board 1 Check the power supply enable signal is present This should be a dry contact output from the CNC 2 Check for the power supply enable signal going to J1 connector on PCB1 3 Check the enable signal contacts on relay 4 Check control transformer 24VAC voltage on TB3 powering 4 and K5 5 Replace the control board 1 Shut off the power supply for at least 5 minutes If the error clears check the grounding of the machine and the power supply 2 Replace the control boa
57. e or written request for service advice be made to the Authorized Distributor from whom it was purchased This equipment or any of its parts should not be altered without the prior written approval of the manufacturer The user of this equipment shall have the sole responsibility for any malfunction which results from improper use faulty mainte nance damage improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING PROTECT YOURSELF AND OTHERS EPP 362 Plasma Power Source EPP 362 Plasma Power Source Contents SAFETY TESTER ERE 11 KE ee 15 ee ee ee 19 INTRODUCTION INTOQUCION Re o 27 E A e E NEE 27 Power Specifications sena creta rre dra a P euer 27 Service Manual FON di unsere std nt tes 28 EICHE O O D Ou u aS RES EEE TRES TESTS EERS Fade PANES FREU P REPE PLI RIS I IPC 28 Seguen e ol EV COGS once rinri aan nae wees neous eee ene ene papu wq 28 Machine Operation Flow Diagram 29 Tic Dig O 31 SCHEMATIC LAYOUT Schematic LaUOUL TRUE RU CIUS VIII Mau Rd a X eR P
58. e ser parte del circuito el lectrico 3 Cuando el cilindro no est en uso mantenga la v lvula del cilindro cerrada Ponga el capote de protecci n sobre la v lvula si el regulador no est conectado Asegure y mueva los cilindros utilizando un carro o transporte adecuado Evite el manejo brusco de los 1 Siempre tenga personal cualificado para efec tuar la instalaci n diagn stico y mantenimiento del equipo No ejecute ning n trabajo el ctrico a menos que usted est cualificado para hacer el trabajo MANTENIMIENTO DEL EQUIPO Equipo defectuoso o mal mantenido puede cau sar da o o muerte Por lo tanto 2 Antes de dar mantenimiento en el interior de la fuente de poder desconecte la fuente de poder del suministro de electricidad primaria 3 Mantenga los cables cablea tierra conexciones cable primario y cualquier otra fuente de poder en buen estado operacional No opere ning n equipo en malas condiciones 4 No abuse del equipo y sus accesorios Mantenga el equipolejos de cosas que generen calor como hornos tambi n lugares h medos como charcos de agua aceite o grasa atm sferas corrosivas y las inclemencias del tiempo 5 Mantenga todos los art culos de seguridad y coverturas del equipo en su posici n y en buenas condiciones 6 Use el equipo s lo para el prop sito que fue disehado No modifique el equipo en ninguna manera INFORMACION ADICIONAL DE SEGURIDAD Para m s informaci n sobre l
59. e soldar Aseg relos uno junto al otro con cinta adhesiva cuando sea posible B Nunca envuelva los cables de soldar alrededor de su cuerpo C Nunca ubique su cuerpo entre la antorcha y el cable a la pieza de trabajo Mantega los cables un s lo lado de su cuerpo D Conecte el cable de trabajo la pieza de trabajo lo m s cercano posible al rea de la soldadura E Mantengala fuente de poder y los cables de soldar lo m s lejos posible de su cuerpo HUMO Y GASES El humo y los Ls gases pueden causar malestar o da o particularmente en espacios sin ventilaci n No inhale el humo o gases El gas de protecci n puede causar falta de ox geno Por lo tanto 1 Siempre provea ventilaci n adecuada en el rea de trabajo por medio natural o mec nico No solde corte o ranure materiales con hierro galvanizado acero inoxidable cobre zinc plomo ber lio o cad mio a menos que provea ventilaci n mec nica positiva No respire los gases producidos por estos materiales 2 No opere cerca de lugares donde se aplique sub stancias qu micas en aerosol El calor de los rayos del arco pueden reaccionar con los vapores de hidrocarburo clorinado para formar un fosf geno O gas t xico y otros irritant es 3 Si moment neamente desarrolla inrritaci n de ojos nariz ogarganta mientras est operando es indicaci n de que la ventilaci n no es apropiada Pare de trabajar y tome las medidas necesarias para mejorar la v
60. entilaci n en el rea de trabajo No contin e operando si el malestar f sico per siste 4 ala publicaci n ANSI ASC Standard 749 1 Vea la lista a continuaci n para recomen daciones espec ficas en la ventilaci n SAFETY 5 ADVERTENCIA Este producto cuando se utiliza para soldaduras o cortes produce humos o gases los cuales contienen qu micos cidos por el Estado de California de causar defectos en el nacimiento o en algunos ca sos Cancer California Health amp Safety Code 825249 5 et seq MANEJO DE CILINDROS Los cilin dros si no son manejados correcta mente pueden romperse y liberar violentamente gases Rotura repen tina del cilindro v lvula o v lvula de escape puede causar da o o muerte Por lo tanto ee 1 Utilize el gas apropiado el proceso y utilize un regulador dise ado para operar y reducir la presi n del cilindro de gas No utilice adapta dores Mantenga las mangueras y las conexiones en buenas condiciones Observe las instrucciones de operaci n del manufacturero para montar el regulador en el cilindro de gas comprimido 2 Asegure siempre loscilindros en posici n vertical y am rrelos con una correa o cadena adecuada para asegurar el cilindro al carro transportes tab lilleros paredes postes o armaz n Nunca asegure los cilindros la mesa de trabajo o las piezas que son parte del circuito de soldadura Este pued
61. ere nominal flow conditions exist with ports located at the top Incoming flow may be placed to either port A minimum of 8 of straight pipe on the inlet side is recommended Frequency output RFO is determined by the velocity of the monitored fluid acting on the sensor rotor Input piping with an orifice smaller than that of the sensor input will effect the sensor output Installation RotorFlow sensors connect to piping via NPT mating thread forms The following guidelines are provided to assist with installation for a leak free seal without damage to the unit 1 Apply pipe thread sealant to male pipe threads 2 Thread RotorFlow unit onto male pipe thread until hand tight 3 Tighten pipe 1 to 1 1 2 additional turns 4 If improper seal results continue turning pipe into unit in 1 4 turn increments Recommended Pipe Sealants a Permatex No More Leaks b Teflon Thread Tape Filteration and Cleaning 150 micron filteration is recommended However should foreign particles enter the RotorFlow sensor accumulation is easily cleared by removing the lens from the body The lens is removed by turning its center rib 45 counter clockwise and then pulling it out To reinstall the lens simply reverse the process Pressure must be relieved from the system prior to sensor clean out DESCRIPTION Sensor Type RotorFlow Low Flow Range 0 1 1 0 Standard Flow Range 0 5 5 0 Flow Range GPM 0 1 5 0 Body Material
62. et portez des chaussures a semelles de caoutchouc 8 Avant de mettre l quipement sous tension isolez vos mains avec des gants secs et sans trous 9 Mettez l quipement hors tension avant d enlever vos gants 10 Consultez ANSI ASC Standard 749 1 list la page suivante pour des recommandations sp cifiques concernant les proc dures de mise la terre Ne pas confondre le c ble de masse avec cable de mise la terre CHAMPS LECTRIQUES ET MAGN TIQUES com portent un risque de danger Le 89 courant lectrique qui passe dans a gt n importe quel conducteur produit N des champs lectriques et magn tiques localis s Le soudage et le courant de coupage cr ent des champs lectriques et magn tiques autour des c bles de soudage et l quipement Par cons quent 1 Un soudeur ayant un stimulateur cardiaque doit consulter son m decin avant d entreprendre une op ration de soudage Les champs lectriques et magn tiques peuvent causer des ennuis pour cer tains stimulateurs cardiaques 2 L exposition des champs lectriques et magn tiques peut avoir des effets n fastes inconnus pour la sant 20 3 Les soudeurs doivent suivre les proc dures suivantes pour minimiser l exposition auxchamps lectriques et magn tiques A Acheminez l lectrode et les c bles de masse ensemble Fixez les l aide d une bande adh sive lorsque possible B Ne jamais enrouler la torche ou le cable de masse
63. g DESCRIPTION OF OPERATION Control board monitors the output current all the time for proper operation Servo micro controller section of the control board reads the current signals from the Hall Sensors HS1 and HS2 connected to J9 pins 4 and 8 Since micro controller re quires voltage signal the current signal from the hall sensor is fed through a small resistor of 6 6 Ohms The voltage across this resistor is fed through OPAMP U23 circuitry which will generate respective voltage signal proportional to the scaled current signal Servo micro processes these signals and outputs scaled integer value to main micro controller through SPI communication Main micro uses these values for main process control and fault monitoring Control board has a provision for monitoring four closed loop hall sensor inputs See Appendix B for detailed schematics Refer to Help Codes for current related error codes Current Sensor Connector Note Pin 5 on the plug should have jumper connecting ta pin 3 The cable shields should be tied to pin 1 CurrentConnectorFlag PHOENIX HEADER 8 3v30 e R202 C153 Lo Current Sensor Inputs Current Sensor 2000 1 3604 2000 180mA Voltage Conversion 18 m 6 6 Ohm 1 188V Transfer Function Output Margins Nearly 15 at the bound aries leaving a 70 oper ating range Vout 5 6k 2 7k 180 Vin 5 6k 3 3k 1 Zk Vra 334 145 6k 2 7E 180 5 B5
64. g Cut ting and Gouging Form 52 529 The following publications which are available from the AmericanWelding Society 550 N W LeJuene Road Miami FL 33126 are recommended to you 1 ANSI ASC 249 1 Safety in Welding and Cutting 2 AWS C5 1 Recommended Practices for Plasma Arc Welding 3 AWSC5 2 Recommended Practices for Plasma Arc Cutting 4 AWS C5 3 Recommended Practices for Air Carbon Arc Gouging and Cutting 5 AWS C5 5 Recommended Practices for Gas Tung sten Arc Welding 6 AWS C5 6 Recommended Practices for Gas Metal Arc Welding 7 AWS SP Safe Practices Reprint Welding Hand book 8 ANSI AWS F4 1 Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances 9 CSA Standard W117 2 Safety in Welding Cutting and Allied Processes 13 SAFETY MEANING OF SYMBOLS As used throughout this manual Means Attention Be Alert Your safety is involved DANGER gt Means immediate hazards which if not avoided will result in immediate serious personal injury or loss of life A CAUTION Means potential hazards which could result personal injury loss of life A WARNING Means hazards which could result in minor personalinjury Enclosure Class The IP code indicates the enclosure class i e the degree of protection against penetration by solid objects or water Pro tection is provided against touch with a finger penetra
65. g the 9 volts supply This 9 VDC is fed through U6 to have 5 VDC which is used for the IGBT gating pulses D3 J5 D 400V 3A SMC HVdd 9v00 1 i 1 D2 R45 C5 24v0 PHOENIX HEADER 3 D 400V 3A SMC HVdd 9 00 1 00 220uF 0 25W D5 R56 C6 C64 C58 C66 C60 C50 R40 10uF 100nF 10 0uF 100uF 100uF 400 SMC 1 00 220uF Tr 0 25W 1 00 D6 0 25W 25 R63 R36 HVdd 9v00 D 400V 3A SMC 220uF 1 00 0 25W 1 00 C48 0 25W R65 HVdd 24v0 R27 220uF 1 00 C62 0 25W 1 00 0 25W C28 C17 C34 C20 C7 R70 220uF 10uF 100nF 10 0uF 100uF 100uF 1 00 0 25W HGND PCB2 Driver board also gets 5 VDC and 3 3 VDC from Control Board PCB1 via ribbon cable connector to have same com mon for the analog signals voltage and differential PWM pulses 82 DESCRIPTION OF OPERATION PCB2 PWM Pulse Circuit Main IGBTs The pulse circuit accepts the pulses from the control board PCB1 and then isolates them through opto coupler In this way the control board is isolated from the IGBTs and the gating pulses will have sufficient drive current to push the IGBTs The pulses from the control board are sent via ribbon cable connector as low voltage 3 3 VDC differential signals which are combined together and isolated to form high voltage 5 0 VDC PWM pulse signal These PWM signals are fed to IGBT gate driver U14 U14 is 24 VDC bias supplied IC which will output 24 VDC PWM pulses corresponding to the PWM pulses from the control b
66. haussures montantes afin de vous prot ger des rayons de l arc des tincelles et du m tal incandescent en plus d un casque de soudeur ou casquette pour prot ger vos cheveux ll est galementrecommand de porteruntablier ininflammable afin de vous prot ger des tincelles et de la chaleur par rayonnement 4 Les tincelles et les projections de m tal incandescent risquent de se loger dans les manches retrouss es les rebords de pantalons ou les poches est recommand de garder boutonn s le col et les manches et de porter des v tements sans poches en avant 5 Prot geztoute personne se trouvant a proximit des tin celles et des rayons de l arc l aide d un rideau ou d une cloison ininflammable 6 Portez des lunettes tanches par dessus vos lunettes de s curit lors des op rations d caillage ou de meulage du laitier Les cailles de laitier incandescent peuvent tre projet es des distances consid rables Les personnes se trouvant proximit doivent galement porter des lunettes tanches par dessus leur lunettes de s curit INCENDIES ET EXPLOSIONS La chaleur provenant des flammes ou de l arc peut provoquer un incendie Le laitier incandescent ou les tincelles peuvent galement provoquer un incendie ou une explosion Par cons quent 1 loignez suffisamment tous les mat riaux combustibles de l aire de travail et recouvrez les mat riaux avec un rev tement protecteur ininflammable Les mat
67. hms D2 4 and 6 0558003658 Forward Resistance 660 K Ohms Reverse Resistance 6 M Ohms NOTE When replacing these diodes new parts must be mounted to flat surfaces and torqued at 275 325 in lbs A conductive heat sink compound is re quired Recommended Heat sink Compound Dow 340 ESAB part number 73585976 ELECTRODE DISCHARGE 52 DESCRIPTION OF OPERATION Input Rectifiers 0558003657 Forward 0558003658 Reverse DESCRIPTION RATINGS 300 AMPS 1200 VOLTS FORWARD POLARITY CATHODE STUD 5 75 MIN 7 00 MAX 0 EEE SAG CATHODE STUD DESCRIPTION RATINGS 300 AMPS 1200 VOLTS REVERSE POLARITY 7 00 MAX 5877 53 DESCRIPTION OF OPERATION IGBT Q1 Q2 0558006183 The IGBTs are the devices used as an electronic switch to turn the output of the power supply on and off During operation these transistors are switched on and off 15000 24000 times a second to produce the output current of the EPP 362 These transistors are part of the IGBT block and are key components allowing a variable output of the power supply These tran sistors produce heat during normal operation which must be removed A cold plate water cooled mechanism is used to remove the heat from the IGBTs Failure to remove this heat will result in the destruction of transistors The IGBTs installed in the EPP 362 are rated for 400 amps of continuous current output and up to 1200 Volts DC of input Testing see I
68. hrough 6 In case of MARKING CNC Process Controller will send the marking mode ON signal to power source via CAN Communica tion Power source then closes RB1 5 relay to send 115 VAC to RAS box where the marking mode VDR ratio is selected for proper operation The rest of operation is same as mentioned in steps 1 through 7 from the plasma unit 30 INTRODUCTION Timing Diagram M2 Coolant Pump Motor Error Check K4 PS Enable K2 Soft Start K1 Main Contactor M1 Main Fan 360 VDC Bus Voltage Plasma START Signal HF Relay Pilot Arc Main Arc CUT Current STOP Current Work Current Ram A Steady Ram State DOWN Input Power PLASMA STOP 200 VDC or 900 mSec 31 32 INTRODUCTION SCHEMATIC LAYOUT 34 SCHEMATIC LAYOUT Schematic Layout Component Locator SCHEMATIC LAYOUT EPP 362 Components SYMBOL DESCRIPTION LARGE AMBER 12V PNL MT 3 LAMP WHITE 14V PNL MT 3 D1 3 5 DIODE REVERSE 300A 1200V PCB1 PCB CONTROL PGM D 11 T C F F F K K K K L M Q T T L1 L1 S 2 1 B1 B2 B3 B4 B5 B6 B1 1 2 3 1 2 4 5 1 1 5 1 2 S1 S2 T T 35 SCHEMATIC LAYOUT Schematic Section Map 0558010795 Refer to Appendix A in the back section of this manual for complete schematics 36
69. i J15 B CAN 49 1 3 J9 2 6 19 3 i G J9 4 i J9 5 19 6 J4 CAN2 19 7 bs T 19 8 B E E rx yes ul V V ay NA 11 4 1 Y 3 CAN CND E v n2 1 CAN Pr Portes V gt A imt 7 77 ES 8 Es J2 o 9 Illo TO PCB1 J20 26 PIN RIBBON 2 ANALOG INTERFACE Ill 9 lllo 1122 V gt J1 RAS L IIIe o l p UD M sg 5 2 24 VAC E STOP m mu TO RELY RBI 5 14 lt ITO PCBI J1 2 TO RELAY RB1 6 14 lt TB5 12 lt O TB3 6 lt 0 TB3 8 lt 10 1 1 4 lt TO RELAY 1 5 11 lt a 24W SUPPLY 24VAC 24VDC COM 120 VAC MARK MODE TORCH TYPE SELECTION HIGH FREQ ON REVERSING VALVE 120 VAC COM TB4 1 O00000 Of J1 RAS RAS CONTROL 14 PIN FEMALE 4 40 SCHEMATIC LAYOUT DESCRIPTION of OPERATION 42 DESCRIPTION OF OPERATION DESCRIPTION OF OPERATION Relay Contactors There are 4 contact relays installed in this power supply for proper operation They are K1 Main Contact
70. input fuses three 2 Ohm resistors and the soft start contactor K2 When power source is powered up or a start command is issued if the machine is in idle state and if there are no errors in the power supply the main control board closes the K2 relay This allows the bus filter capacitors to charge at slower rate due to the 2 Ohm resistors restricting the initial current flow When the bus filter capacitors reach 200 volts DC the main control board sends the signal to close the main contactor 1 to allow the full current to be delivered to the input rectifier If the bus filter does not reach 200 Volts DC in 500 milliseconds or less the main control board halts the process and sends an error to the CNC K2 RELAY POWER PATH The K2 bus charger or soft start contactor is energized when input breaker is closed or a start signal is issued from the CNC if the machine is in idle state and there are no errors faults in the power source The Control Board sends the Bus Charger Relay ON signal to the relay terminal block through J6 pin1 to close RB1 1 relay The contacts of RB1 1 close which provide 24 VAC to K2 relay coil which closes its contacts to charge the bus filter capacitor to 200 VDC See diagram below TB1 1 _ 1_ 2 20 24 TB3 9 L2 x1 2 11 1 1 1 460 1472 VAC 14 KA K2 X2 L3 TB3 10 51 9 24VAC TB1 3 NEUTRAL ILS T3 K1 45 DESCRIPTION OF OPERATION 4 K5 Relay PS Enable Relay 0558007736
71. intenez les c bles les fils de mise la terre les branchements le cordon d alimentation et la source d alimentation en bon tat N utilisez jamais un quipe ment s il pr sente une d fectuosit quelconque 4 N utilisez pas l quipement de facon abusive Gardez l quipement l cart de toute source de chaleur notamment des fours de l humidit des flaques d eau de l huile ou dela graisse des atmosph res corrosives et des intemp ries 5 Laissez place tous les dispositifs de s curit et tous les panneaux de la console et maintenez les en bon tat 6 Utilisez l quipement conform ment son usage pr vu et n effectuez aucune modification INFORMATIONS SUPPL MENTAIRES RELATIVES S CURIT Pour obtenir de l information suppl mentaire sur les r gles de s curit observer pour l quipement de soudage l arc lectrique et le coupage demandez un exem plaire du livret Precautions and Safe Practices for Arc Welding Cutting and Gouging Form 52 529 Les publications suivantes sont galementrecomman d es et mises votre disposition par l American Weld ing Society 550 N W LeJuene Road Miami FL 33126 1 ANSI ASC Z49 1 Safety in Welding and Cutting 2 AWS C5 1 Recommended Practices for Plasma Arc Welding 3 AWS 5 2 Recommended Practices for Plasma Arc Cutting 4 AWS 5 3 Recommended Practices for Air Carbon Arc Gouging and Cutting 5 AWS 5 5
72. k 3 3k 1 2k VreF 165 TransferFunc l 188V D 4756V TransferFune 0 000V 2 7898Y The Op mp biasing will introduce some error into the signal Chassis GND MH2 1 HOLE_0v330 0v156_PLATED Vdd_3v30 D80 2 5 60 R192 Io 0 1W 12 1K R201 0 1W e 1 50K 0 1W gt D81 9 c O NY 1 2 3 O Vdd_15v0 4 Vdd nt5v0 1 5 6 electrode2 d A 8 l wok J J electrode2 R179 R198 R188 5 60K AVdd_3v30 01W TP11 3 30K 1 20K LJ 0 1W 0 1W AVdd 3v30 U R191 R199 electrode1 R126 ANY lelectrode1 2 70K 180 3 R167 0 1W 0 1W TLV2464AID 5 60 3 30 0 1W C103 0 25W C134 R180 T 680pF 68 0pF 1 00K 0 1W R166 gt 3 30 O 0 25W AVdd_1v65 R141 R121 R128 AVdd_3v30 04W TP9 3 30K 1 20 0 1W 0 1W AVdd 3v30 R114 ANY Iwork TLV2464AID 5 60 0 1W C99 T U AVdd_1v65 R142 AVdd_3v30 C dew AVdd_3v30 2 70K 180 5 E R156 0 1W 0 1W TLV2464AID 5 60K 3 30 0 1W C94 0 25W C130 R189 680pF 8 0pF 1 00K 0 1W R155 3 30 0 25W AVdd 1v65 R143 R123 R130 5 60K AVdd_3v30 O 04W TP32 3 30K 1 20K 0 1W 0 1W AVdd 3v30 R131 R144 extra R120 ANY lextra 2 70K 180 10 R136 0 1W 0 1W TLV2464AID 5 60K 3 30 BH 0 1W C98 0 25W 119 R129 680 68 0pF 1 00K 0 1W R135 3 30 0 25W AVdd 1v65 69 DESCRIPTION OF OPERATION PCB1
73. l Line Receiver SN65LVDSOA8A TI Quad Differential Line Driver SOIC U41 NXP 5V HS CAN NXP 5V HS CAN driver PCA82C251TDT PCA82C251TD T National Semiconductor Frequency to Voltage Converter CRYSTALI0 0000MHz 18pF SMD 80 DESCRIPTION OF OPERATION PCB2 Driver Board 0558038382 The driver board PCB2 is used to a filter and condition the IGBT gating signals b scale down the bus voltage and output Arc voltage signals Refer to Appendix B for complete schematics The IGBT gating signals are filtered and conditioned to reduce noise and stray voltages that could damage the IGBTs These signals are distributed to each of the two IGBTs The driver board receives IGBT gating pulses and command signals from the control board PCB1 81 DESCRIPTION OF OPERATION PCB2 Bias Supply The driver board has bias supply built onboard to power its own circuitry The board receives 24 VAC from the control trans former TB3 1 and TB3 2 on pins 1 and 3 of connector J5 This AC voltage is rectified through a diode bridge rectifier D2 D3 D5 and D6 and filtered by a capacitor The filtered DC voltage is fed through a regulator U12 to have a regulated 24 VDC bias supply This 24 VDC is used to power the circuits requiring 24 volts bias supply The filtered DC from the rectifier bridge and capacitor filter is fed through resistor voltage divider to have 9 VDC bias supply which powers the circuits requirin
74. l posibleriesgo que puede resultar en menores da os a la persona Clase de envolvente El c digo IP indica la clase de envolvente es decir el grado de protecci n contra la penetraci n de objetos s lidos o agua Se provee protecci n contra el toque con un dedo penetraci n de objetos s lidos de un tama o superior a 12 mm y contra roc o de agua de hasta 60 grados de la vertical El equipo marcado IP21S se puede almacenar pero no se debe usar en el exterior durante periodos de precipitaciones a menos que est protegido Este producto s lo se debe usar para corte por plasma Cualquier otro uso puede causar lesiones f sicas y o danos en los equipos Inclinaci n Si el equipo se coloca sobre una superficie con una m xima permitida inclinaci n superior a 15 se puede producir un vol camiento Es posible que se produzcan lesiones f si 1 cas y o da os importantes en los equipos 15 Para evitar lesiones fisicas y o da os en los equipos levante mediante el m todo y los puntos de sujeci n que se indican en esta ilustraci n 18 SAFETY Safety French AVERTISSEMENT Ces r gles de s curit ont pour but d assurer votre protection Ils r capitulent les informations de caution provenant des r f rences dans la section des Informations de s curit suppl men taires Avant de proc der al installation ou d utiliser l unit assurez vous de lire et de suivre les pr ca
75. l with technical information which will assist in trouble shooting and repairing malfunctions General The EPP 362 power source is designed for mechanized plasma cutting applications It can be used with other ESAB prod ucts such as the PT 36 torch along with the m3 gas interface a computerized gas regulation and switching system System features e 25to 360 amperes cutting current range and as low as 10 for marking 36 amp regulated pilot arc e Forced air cooled Water Cooled IGBTs e Internal Coolant Circulator Solid state DC power Input voltage protection e Thermal switch protection for IGBTs and input rectifier e lifting rings or base forklift clearance for transport Power Specifications EPP 362 EPP 362 EPP 362 EPP 362 460V 380V CCC 400V 575V 60Hz 50Hz 50Hz 60Hz 0558011314 0558011315 0558011316 0558011317 Voltage 200 VDC Part Number Output Current range DC marking 10A to 36A 100 96 Current range DC cutting 30A to 360A duty cycle power 72KW Open Circuit Voltage OCV 360 VDC 364 VDC 360 VDC 360 VDC Voltage 3 phase 460 V 380 V 400 V 575 Current 3 phase 109 A RMS 134 A RMS 128 A RMS 92 ARMS Frequency 60 Hz 50 Hz 50 Hz 60 Hz KVA 88 7 KVA 88 5 KVA 88 6 KVA 91 6 KVA Power 83 7 KW 85 1 KW 84 7 KW 82 5 KW Power Factor 94 96 96 9090 Input Fuse recommended 150A 175 A 175 125 A Weight lbs kg 1130 514 1130 514 1140 518 1130 514
76. lay block module relay one RB1 1 is energized This passes 24 VAC to the coil of K2 the soft start relay This puts main line power to the Main Transformer T1 with a 2 ohm resistor in series with each phase to initially limit the amount of current This is done for two reasons a Due to the large input filter capacitors a very large current would be seen on the output of the main trans former b To limit current in case there is a short on the rectifier the capacitors or the transformer 2 After K2 is closed PCB1 monitors the bus voltage across C1 main micro on PCB1 looks for bus filter capacitor voltage to reach 4200 VDC or 500 ms time out If 200 VDC is present the micro initiates commands to pull in the main contactor K1 turn ON main fan M1 and then open K2 After K1 is pulled in the power supply waits few milli seconds for the bus to reach its full voltage of 360VDC If bus filter capacitor voltage does not reach 4200 VDC before 500 ms timer time out then power supply will send Error 15 to CNC Process Controller via CAN and toggle the Fault Light FL on front panel with 5096 duty cycle 3 Once bus is fully charged and main micro read all the respective currents and ramping times from CNC Process Controller through CAN communication main micro will issue the PWM start signal to servo micro which then will provide 25 KHZ frequency pulses to IGBTs At this point main micro monitors the Open Circuit Voltage OCV on the outpu
77. lt as A E et TO 52 2 lt 4141 O L A 53 UD J14 3 O 14 PIN 26 PIN 1 3 1 4 26 J2 1 J2 2 2 3 8 05580038362 MAIN CONTROL E PCB PORT 3 match line 13 Ji 4 RIBBON J146 26 RIN RIBB J2 VDC 1 J2 1 J8 2 J2 N C i 12 3 2 18 3 PCB1 we P N 05580038362 MAIN CONTRDL PCB 24 VDC p 24V0C COMMON J1 2 TORCH SELECTION 1135 THERMAL SWITCH SCHEMATIC LAYOUT To Second Relay Block Optional To Second Driver Board Optional N C 3141 COOLANT LEVEL INPUT TB7 1 CLOSED OK gt TO JI RAS J gt TO 152 1 PS ENABLE SIGNAL TO DB 25 ON ANALOG INTERFACE CONNECTOR TB4 2 7 2 Note 3 00 01 11 TB4 2 KS V TO TS1 1 EPP540 gt Connect 48 2 to 720 gt Connect J8 2 to Harness connection for machine ID EPP202 gt Connect J8 2 to J8 4 and 48 5 to J8 4 EPP362 gt Connect J8 2 to J8 4 and 48 5 to 8 1 J8 1 and 48 5 to 8 4 J8 1 and aa PENES ki CEE RTL ANALOG INTERFACE 1 CONNECTOR 24 VAC 1 24 VAC 2 17 13 2 17 0 17 AC COMMON 16 1 17 VAC 016 2 i EU 24 VAC 1 3 4 24 vac 2 gt TB3 9 gt TO TB3 10 gt TO TB3 13 gt TO TB3 14 gt TB3 15 gt TO TB5 4 gt TO 3 5
78. m Rectifier at peak output ESAS Rectifier turns off Rectifier turns on Capacitive energy Rectifier at low part of output RE IEE TIC current to load and filter Filtered waveform EN MM Filter supplying current to load 112 GENERAL INFORMATION Voltage Measurement Voltage measurement from the 3 phase AC V Delta primary and Wye secondary3 phase AC Voutput for the bridge rectifier 120 out of phase 120 out of phase A mA uA Vap Note Delta primary the supply voltage is is the same across all the winding coils Wye secondary coil the voltage measured across the coils A B C between X1 and X3 5006 respectively are 127 8 Volts AC Because the voltage is 120 deg out of phase NU 127 8 multiplied by 1 73 square root of 3 the phase output voltage across X3 is 221 0794 V 113 GENERAL INFORMATION IGBT Testing The emitter and the gate of each affected IGBT must be jum C AUTI O N pered together to prevent electrostatic damage Each power source is supplied with six jumper plugs that mate to the IGBT Gate Emitter Plug Electrostatic Discharge Hazard Electrostatic discharge may damage these components Damage is accumulative and may only appear as shortened com CAU ponent 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
79. m e RES 2 70K 1 SMT 0603 PKG THICK FILM R52 R53 R58 R60 R61 R68 R69 R71 R72 R73 R78 0 R79 R80 R97 R98 RES 100K 1 SMT 1206 PKG THICK FILM R81 R82 R87 R88 R89 R90 R95 R96 R99 R100 R1 RES 22 0 1 SMT 1206 PKG THICK FILM 05 R106 R107 R108 R113 R114 R117 R118 R125 R126 R127 R128 R135 R136 R144 R149 R150 R1 55 R156 R169 R1 70 R183 R186 R199 R200 R213 43 36 R157 R158 R159 R160 R165 R166 R167 R168 R1 71 R172 R173 R174 R179 R180 R181 R182 R187 R188 R189 R190 R195 R196 R197 R198 R201 R2 02 R203 R204 R209 R210 R211 R212 44 32 RES 10 0 1 SMT 1206 PKG THICK FILM 87 DESCRIPTION OF OPERATION ITEM SYMBOL DESCRIPTION TP1 TP2 TP3 TP4 TP5 TP6 TP7 TP8 TP9 TP10 TP1 EN 1LTP12 TP13 TP14 TP15 TP16 TP17 TP18 TP19 mE TEST POINT Keystone Miniature SMT Test Point 5015 A I C Quad CMOS Digital Isolator 4kV isolation ISO7241MDW EEE U12 I C National 500kHz 3 0A Buck Converter I C Avago Isolated Gate Driver 2 5A 3 75kVrms Breakdown SMT ACPL J313 500E OPAMP TI Rail To Rail Fully Differential OpAmp THS45211D MUrATA 3kVDC isolation 24V 12V DC DC Converter PWR Supply National 1 5A TO 263 Adjustable Voltage Regulator LM1086CS ADJ U9 I C TI Dual Differential Line Receiver SN65LVDS9637D I C TI Differential Driver and Receiver Pair SN65LVDS179D Avago Sigma Delta Analog Isolator 5kVrms Isolation 88 TROUBLESHOOTING 90 TROUBLESHOOTING TR
80. monitoring 62 DESCRIPTION NORMALLY CLOSED THERMAL SWITCH OPEN TEMP 212 5 CLOSE TEMP 192 7 F CONTACT RATINGS 12 MIN 12OVAC 8 MIN 24 EPOXY SEAL ON THE DISC CUP AND TERMINALS U L RECOGNIZED CSA CERTIFIED PRODUCT 1 23 20 14 DIA MIN 250 FASTON TAB 0 88 MAX 0 69 MAX DESCRIPTION NORMALLY CLOSED THERMAL SWITCH OPEN TEMP 176 5 CLOSE TEMP 156 5 CONTACT RATINGS 15 AMP MIN 120VAC 8 AMP MIN 24OVAC EPOXY SEAL ON THE DISC CUP AND TERMINALS U L RECOGNIZED CSA CERTIFIED PRODUCT 1 23 MAX di 20 14 DIA MIN 250 FASTON TAB 0 88 MAX DESCRIPTION OF OPERATION Coolant Circulator EPP 362 Power Source has inbuilt coolant circulator which circulates coolant to torch and IGBTs cold plate Circulator con sists of Pump Motor Radiators Regulator Flow Sensor and Level Switch Specifications Pump Type Positive displacement rotary vane type with adjustable by pass valve 225 psi 15 5 bars CW rotation as viewed from nameplate Radiator Type Copper tubing aluminum finned air to water type with galvanized steel frame 50Hz 1 Phase Input Power 60Hz 1 Phase Input Power AC Input Voltages 230 V 10 Pump Capacity 1 60 gpm at 175 psi 1 60 gpm at 175 psi 6 0 l min at 12 bars 6 0 l min at 12 bars Cooling Capacity 1 60 gpm 6 0 l min 16 830 BTU hr 4900 watts 20 200 BTU hr 5
81. n electric material to create an electrical signal with a very precise frequency LAMP Emitter Dedicated location for obtaining quantification Schematic representation of physical connection of wires Produces light by heating a filament lt gt m 62 1 DE 107 GENERAL INFORMATION Glossary General Definitions and Symbols Used in this Manual LOGIC SYMBOLS SYMBOL NAME DESCRIPTION An AND gate can have two or more inputs The output of an AND gate is true when all its inputs are true OUTPUT o 1 OR gate can have two or more inputs The output of an OR gate is true when at least one of its inputs is true OUTPUT a 1 gate have two or more inputs The o on the output means not showing that it is Not AND gate The output of a NAND gate is true unless all its inputs are true NAND GATE was Ld a 1 9 not showing that it is Not OR gate The output of a NOR gate is true when none of its inputs are true OUTPUT 1 EA NOT gate can only have one input The o on the output means The output of a NOT gate is the inverse opposite of its input so the output is true when the input is false A NOT gate is also called inverter NOT NL A INVERTER 1 0 108 GENERAL INFORMATION Meter Use Relay Voltage Drop as a means of voltage in ci
82. n damage to the module and possible damage to the torch 114 GENERAL INFORMATION IGBT REPLACEMENT 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 heating 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 Different in terfaces can cause the modules to operate at different temperatures resulting in un equal current sharing The imbalance 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 heatsink and module holes If heat sink compound is used in place of a thermal pad apply a thin coat of even thick ness to the metal bottom of the module A thickness of 0 002 0 003 0 050 0 075mm is optimum Too much compound impedes heat transfer from the module to the heat sink resulting in short module life due to over heating D Insert the four M6 mou
83. nting 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 finger tight in the order A B C D See figure below Fully tighten in the same order above to a torque of 35 44 in Ibs 4 0 5 0 See figure 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 Ibs 4 0 5 0 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 Replace the top panel The module gate plugs must be plugged into the PWM Gate Drive C AUTI O N 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 Four Point Mounting Type Partial tightening A B C D A Fully tightening A B C D 1 IBGT Collector 2 IGBT Emitter N D Key Plug 3 FWD Cathode B Position 1 RED
84. oard In EPP 202 all the IGBTs connected to J8 J9 J10 and J11 are operated in parallel for either cutting or marking with a variable frequency ranging from 15KHz 25 KHz R100 R186 R82 R156 R81 R144 R118 R117 R99 22 0 22 0 22 0 22 0 22 0 22 0 22 0 22 0 22 0 48 0 25W 0 25W 0 25W 0 25W 0 25W 0 25W 0 25W 0 25W 0 25W HVdd 9 00 R125 R106 22 0 22 0 0 25W 0 25W HGND 19 U15A C MC74AC14D 2 1 nMainPwmChannel HVdd 9v00 HGND os gt HVdd 5 00 R74 2450 10 0 0 1W HVdd 24 0 R57 4 MainPwmChannel 10 0K 0 1W PwmEnable IXDD630YI HGND HVdd_9v00 R136 R114 22 0 22 0 0 25W 0 25W HVdd 9 00 83 DESCRIPTION OF OPERATION Pilot Arc IGBT Pulse circuit accepts the low voltage 3 3 VDC differential PWM pulses from control board are combined together and isolated to form high voltage 5 0 VDC PWM pulses These pulses are fed to Pilot Arc IGBT Q5 connected to J3 R22 LVdd 3v30 LVdd 3 30 120 09 0 1W 8 nPalgbtP MA t7 1B LVdd_3v30 lt 1 Q1 1 2 7 2 2N3904 6 nMainPwm2P ca voi ANODE 4 2A 5 nMainPwm2N C31 m I vo2 CATH 0 25W 5 U3 GND 2B 100nF VE NC2 4 SN65LVDS9637D R31 ACPL J313 500E 150 LGND 0 1W 120 LGND 0 1W C51 1 00uF a ti 2 FE 1 M 0 25W PCB2 Test Points TestPoint Expected Value Signal
85. oil X7 X8 is 24 VAC provides power to driver board PCB2 at J5 pins 1 and 3 which then rectified through diode bridge rectifier D2 D3 D5 D6 Refer Schematic Layout section for detail schematics Secondary coil Y1 Y2 is 13 VAC provides power to power light PL and fault light FL which indi cate the status of the power supply Refer Schematic Layout section for detail schematics Secondary coil Z1 Z2 Z3 is a center tapped 34 VAC provides power to control board PCB1 at pins 1 2 and 3 which then rectified through diode bridge rectifier D7 D8 D11 D12 Refer Sche matic Layout section for detail schematics 51 DESCRIPTION OF OPERATION Rectifier D1 D6 Input Rectifier The input rectifier consists of six high current diodes configured to rectify the three phase input power delivered from the main transformer Each phase has two diodes associated with it one for the positive half cycle and one for the negative half cycle The input rectifiers convert the three phase output of T1 to the DC bus voltage D1 thru D6 is a full wave rectifier with filter capacitor C1 used to reduce ripple D1 3 and 5 0558003658 Reverse D2 4 and 6 0558003657 Forward The input rectifier consists of 6 stud mount diode rectifiers The output of this assembly is connected to the filter capacitor C1 which supplies 360 VDC to the IGBTs Testing D1 3 and 5 0558003657 Forward Resistance 780 Ohms Reverse Resistance 5 5 M o
86. or Connects the Line voltage directly to the main transformer K2 Soft Start Connects the line voltage to the main transformer thru 2 ohm resistors for initial power up functions 4 K5 E stop PS enable and safety functions Main Contactor K1 952251 K1 is a 3 pole unit with 115 VAC coil Two different power rating contactors are used in the family of EPP 362 power supplies These are 1 3 pole 150 115 VAC with P N 0558010712 used in 0558011310 machine 2 3 pole 75A 115 VAC with P N 0558010751 used in 0558011311 0558011312 and 0558011313 machines L3 MAIN CONTACTOR u r WHT 43 DESCRIPTION OF OPERATION K1 Relay Main Contactor Relay It is used as the main contactor relay for the EPP 202 Once the bus has reached 200 volts the control board initiates turning on the main contactor and full bus voltage is developed at the filter caps This connects main power to the main transformer after the main bus voltage has reached 200 VDC See Sequence of Events in Introduction section for more information on this event K1 RELAY POWER PATH The main contactor K1 is energized by the Control Board PCB1 when the filter bus reaches 200 VDC The micro controller monitors the bus voltage and during a start cycle when the bus reaches 200 VDC in 500 ms or less the control board issues a Main Contactor Relay ON signal to the relay terminal block through J6 pin 2 to close RB1 2 relay The contac
87. ore physician before welding EMF may interfere with some pacemakers 2 Exposureto EMF may haveother health effects which are unknown 12 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 Connectthe work cable to the work piece as close as possible to the area being welded E Keep welding power source and cables as far away from your body as possible FUMES AND GASES Fumes and gases cancausediscomfortorharm b particularly in confined spaces Do notbreathefumes and gases Shield ing gases can cause asphyxiation Therefore 1 Always provide adequate ventilation in the workarea by natural or mechanical means Do not weld cut or gouge on materials such as galvanized steel stain less steel copper zinc lead beryllium or cadmium unless positive mechanical ventilation is provided Do not breathe fumes from these materials 2 Donotoperate near degreasing and spraying opera tions The heat orarcrays can react with chlorinated hydrocarbon vapors to form phosgene a highly toxic gas and other irritant gases 3 If you develop momentary eye nose or throat ir ritation while operating this is an indication that ventila
88. ors 5 The power supply enable relay will close if there are no errors faults in the power source and there is no inter ruption in PS Enable chain on the cutting machine 6 If above steps are satisfied then the Bus Pre Charge contactor K2 closes and charges the Bus Filter Capacitor C1 through a 2 Ohm resistor in each phase 7 Oncebusis pre charged to a threshold of 200 VDC then control baord issues the command to close the Main con tactor K1 Main Fan Motor M1 and open K2 This will allow the bus filter capacitor to charge up to the full voltage of 360 VDC 8 The bus will be high as soon as the wall breaker closed and there are no faults in the power supply K1 and M1 will stay ON for 5 minutes of Idle operation and then they will turn OFF hence bus filter capacitor voltage bleed through R8 3 kOhm 100W resistor 28 INTRODUCTION Machine Operation Flow Diagram 3 PHASE INPUT MAIN TRANSFORMER 3 PHASE RECTIFIER FILTER BUSS IGBT s IGBT DRIVER MAIN CONTROL CNC BOARD BOARD INTERFACE INDUCTOR OUTPUT 1 PHASE CONTROL COOLANT TRANSFORMER CIRCULATOR When the EPP 362 is commanded to start the plasma cut process the following events occur 1 Once a start signal is sent if bus is not high a soft start sequence begins The main control board PCB1 issues the command to close the bus pre charger relay K2 This signal is sent to the Relay Block Module RB1 through ribbon cable connector J6 On the re
89. ough the coil and out terminal A From here A is connected to the chassis connector J1 pin E and routed out of the power supply to a set of E Stop relay contacts of the cutting machine This signal is then returned to the power supply on chassis connector J1 pin F where is routed to TB3 pin 8 to complete the 24 VAC circuit See the diagram below 115 VAC 3 2 3 oe 115 VAC A 141111 TB3 B MAIN CONTACTOR 1 2 24 TO 183 9 24 11 183 10 lt NOTIS BUSS PRE CHARGE RB1 1 TO JI RAS G 5 120 VAC HOT JICRASD F 81 2 lt TO J1 RAS C H F IGNITOR RB1 6 Je E TB4 2 lt lt J1 6 PS ENABLE SIGNAL 7114 K5 ESTOP from CNC NC 46 DESCRIPTION OF OPERATION 4 K5 Relay PS Enable Relay 0558007736 DESCRIPTION COIL DATA 50 60 HZ VOLTAGE 24 VAC TEMP RANGE 45 C TO 55 C ENCLOSED TERMINATION 187 QUICK CONNECT TABS CONSTRUCTION ENCLOSED BRACKET MOUNTED CONTACTS 3PDT CONTACT DATA 10A 240 VAC 1 4 MAX 2 9 47 DESCRIPTION OF OPERATION Main Transformer T1 The Main Transformer T1 is a 3 phase transformer with a multi tapped secondary These come in 2 input voltage specifica tions one is 200 230 380 400 460 VAC model p n 0558010746 the other is 575 VAC model p n 0558011717 There are three identical coils A B and C These Coils are configured using a Delta primary and a Wye secondary
90. oviendo escoria o puliendo La escoria puede estar caliente y desprenderse con velocidad Personas cercanas deber n usar gafas de seguridad y careta protectora p FUEGO Y EXPLOSIONES El calor de A las flamas y el arco pueden ocacionar fuegos Escoria caliente y las chispas pueden causar fuegos y explosiones Por lo tanto 1 Remueva todo material combustible lejos del rea de trabajo o cubra los materiales con una cobija a prueba de fuego Materiales combustibles incluyen madera ropa l quidos y gases flamables solventes pinturas papel etc 2 Chispas y part culas de metal pueden introducirse en las grietas y agujeros de pisos y paredes causando fuegos escondidos en otros niveles o espacios Aseg rese de que toda grieta y agujero est cubierto para proteger lugares adyacentes contra fuegos 3 Nocorte sueldeo haga cualquierotrotrabajo relacionado hasta que la pieza de trabajo est totalmente limpia y libre de substancias que puedan producir gases inflam ables o vapores t xicos No trabaje dentro o fuera de contenedores otanques cerrados Estos pueden explotar si contienen vapores inflamables 4 Tenga siempre a la mano equipo extintor de fuego para uso instant neo como por ejemplo una manguera con agua cubeta con agua cubeta con arena o extintor port til Aseg rese que usted esta entrenado para su uso 5 No use el equipo fuera de su rango de operaci n Por ejemplo el calor causado por cable sobrecarga
91. pres ent before the PWM was enabled Arc voltage is greater than 40V in Idle mode Output current is greater than the minimum idle current A phase of the input power is missing Open circuit voltage did not reach 280 volts within 200 msec Ambient temperature exceeded 75 C in control enclosure Bus voltage failed to reach 200 VDC with in 500 ms 1 Check the input voltage to the machine with a voltage meter 2 Checkthe input power cable for correct size and resistance 3 Check the Main Transformer T1 voltage tapping connections 4 Check the input fuses in the PS 5 Checkthe input line fuses in the disconnect box 6 Check the multi color ribbon cable between J12 on PCB1 and J2 and PCB2 1 Check the input line voltages to the machine with a voltage meter 2 Checkthe input power cable for correct size and resistance 3 Check the Main Transformer T1 voltage tapping connections 4 Check the input fuses in the PS 5 Checkthe input line fuses in the disconnect box 6 Check the multi color ribbon cable between J12 on PCB1 and J2 and PCB2 7 Notify your power company of the line stiffness issues 1 Check the input voltage taps on the control transformer 2 Check the control transformer output voltages on TB3 if the voltages read within 15 of the specified value then replace the control board else replace control transformer 1 Wait 10 minutes for the unit to cool If the thermal fault clears on its o
92. r the EPP 362 across the lower end of the unit The control board sends the main fan relay ON signal to the relay terminal block through J6 pin 3 which closes RB1 3 relay See figure below TB1 1 I F1 K2 20 460 115 1 3 0 100 200 300 400 500 m3 hr 150 P 100 Static Pressure N N ri N s SR V Cu ST SO be gt Bn oe M 4 4 24875 5 875 0 0 50 100 150 200 250300 49 DESCRIPTION OF OPERATION Control Transformer The control transformer T2 provides control voltages to various control relays on the chassis and PC boards of the EPP 362 This unit is instrumental in the power up sequence providing the initial 120 VAC startup voltages and enabling the control relays to control the power supply T2 is designed to incorporate both auto transformer and regular primary secondary isolation transformer features The auto transformer operation of T2 is used to power the coolant pump motor Half of the pump motor input current is drawn from T2 and half from the source input wall supply T2 has a multi tapped single phase primary that is connected to the line voltage supplied to the EPP 362 The primary can accept a variety of voltage inputs to accommodate the voltages in use by the customer T2 has multiple secondary windings to supply variou
93. rams on 279 4 mm x 431 8 mm 11 x 17 paper are included inside the back cover of this manual Refer to Appendix A for complete schematics Items listed in the assembly drawing Bill of Materials included in the back of this publication that do not have a part number shown are not avail able from ESAB as a replaceable item and cannot be ordered Descriptions are shown for reference only Please use local retail hardware outlets as a source for these items 99 100 REPLACEMENT PARTS GENERAL INFORMATION 102 GENERAL INFORMATION GENERAL INFORMATION General Information Voltages in plasma cutting equipment are high enough to cause seri CAU ous injury or possibly death Be careful around equipment when the covers are removed Maintenance Maintenance A maintenance schedule should be created and based on the following variables amount of usage placement of machine and cleanliness of local environment A maximum time between should be no more the 90 days External Check work cable for worn insulation and confirm tight electrical connections Check safety ground ground at work piece and at power source Check torch cables for worn insulation and confirm tight electrical connections Drain moisture from the bowl of the input filter regulator Internal Check for discolored connections as they indicate a loose connection Check all plugs fittings and electrical con nections for tightness Make sure c
94. rcuit Areverse bias is voltage applied in the opposite direction open circuit votage o i G TE q s 0 m Negative element of device the banded end of a diode HE energy in the electrostatic field generated between two metal CAPACITOR plates separated by an insulator Typical values are in uF Electrolitic capacitors will be damaged if polarity is not correct Capaci tors can charge themselves from ambient electric fields and should be handled with caution ELECTROLITIC ICAPACITOR Component that opposes current flow proportionately to its Ohm W RESISTOR W rating Power dissapation is expressed in Watts W Tl 2 Device series with a load which opens the circuit if its current rating A is exceeded Device which opens and closes a circuit A semi conductor that conducts in only one direction A diode that permits high current flow without damage the reverse voltage remains almost constant over a wide range of currents used esp to regulate voltage FUSE nA nV SWn SWITCH DIODE n ZENER DIODE LIGHT EMITTING DIODE 2 Semiconductor diode that emits light when conducting current U T A 2 5 5 55 5 ae Device having primary and secondary inductors for altering a c signal amplitudes impedance matching and isolation purposes A reverse blocking triode thyristor SILICON CONTROLLED RECTIFIER Wound
95. rcuit troubleshooting In all series circuits the total circuit voltage is dropped across the load or electrical devices The higher the resistance of the load the higher the voltage drop The lower the load resistance the lower the voltage drop An open contact in a branch circuit with a load will show a high voltage drop because the meter and the open switch have a very high resistance when compared to the load While a closed contact that has a meter across it shows a very low voltage drop since the resistance across the switch is lower than the load So using the meter set at the proper voltage range you can test if the contacts are closed or open MAJORITY OF VOLTAGE DROP MAJORITY OF VOLTAGE DROP ACROSS HIGHER RESISTANCE ACROSS HIGHER RESISTANCE R1 R1 R1 METER HIGH RESISTANCE R1 METER LOW RESISTANCE RK COIL LOW RESISTANCE RK COIL HIGH RESISTANCE 120 VV 120 VV A mA uACOM e 109 GENERAL INFORMATION Ohm Testing Use X4 as Common and measure X5 and X6 check continuity Measured Resistance is less than 1 5 ohms 110 GENERAL INFORMATION Diode Testing 111 GENERAL INFORMATION Ripple 2 3 4 5 1 2 3 4 5 6 N D ce NN 221V 3 AC 120 out of phase T1 Secondary 14 of 313 V 43 82 V p p AC rip 86 of 313 269 18 6 Ripples Produced Unfiltered Ripple Waveform Rectifier supplying current to load and filter Unfiltered Ripple Wavefor
96. rd 1 Shut off the power supply for at least 5 minutes If the error clears check the grounding of the machine and the power supply 2 Replace the control board Replace the control board 1 Check the jumper inside the RAS box between pins L and J on the 14 pin Amphenol connector 2 Check for damaged control cable 3 Replace the control board 1 Check for bad hall sensor 2 Check for diode D9 connection on the IGBT module bus bars 3 Shut off the power supply for at least 5 minutes If the error clears check the grounding of the machine and the power supply 4 Replace the control board 1 Check the coolant level 2 Check for a clogged filter 3 Check for leaks in the coolant return line 4 Check the bypass regulator for bypassing too much coolant 5 Check input power to the pump 6 Check for proper pump function by looking for flow into the tank If there is no flow and the motor in running replace the pump head 7 Check the connection of the flow sensor to the control board 8 Check for the SW6 position set properly according the flow sensor either turbine flow or rotor flow sensor 9 Replace the control board 1 Check the connection of the flow sensor to the control board 2 Check for the SW6 position set properly according the flow sensor either turbine flow or rotor flow sensor 3 Replace the control board 1 Check the CAN connection between the interface control and the power supply s control
97. refore 1 Removeall combustible materials well away from the work area or cover the materials with a pro tective non flammable covering Combustible materials include wood cloth sawdust liquid and gas fuels solvents paints and coatings paper etc 2 Hot sparks or hot metal can fall through cracks or crevicesin floors or wall openings and causea hiddensmoldering fire orfiresonthefloor below Make certain that such openings are protected from hot sparks and metal 3 Donot weld cut or perform other hot work until the work piece has been completely cleaned so that there are no substances on the work piece which might produce flammable or toxic vapors Do not do hot work on closed containers They may explode 4 Have fire extinguishing equipment handy for instant use such as a garden hose water pail sand bucket or portable fire extinguisher Be sure you are trained in its use 5 Do not use equipment beyond its ratings For example overloaded welding cable can overheat and create a fire hazard 6 After completing operations inspect the work area to make certain there are no hot sparks or hot metal which could cause a later fire Use fire watchers when necessary 7 For additional information refer to NFPA Stan dard 51B Fire Prevention in Use of Cutting and Welding Processes available from the National Fire Protection Association Battery march Park Quincy MA 02269 224 ELECTRICAL SHOCK Contact with li
98. requested cutting currents The following schematic shows the pilot arc circuit used in EPP 362 power supply 8 OHM 11200 300w Arc On Block Diagram HALL SENSOR PCB1 HS2 CONTROL 58 DESCRIPTION OF OPERATION Filter and Start Up Board PCB3 0558038391 The board is in place to prevent high frequency noise from entering the power supply and either damaging the power sup ply or inducing transient fields in the Hall sensor that may send an inaccurate current signal to the CNC The filter networks are constructed so as to shunt high frequency AC signals to ground This PC board also has a Start up circuit which connects between nozzle and electrode The Start up circuit helps in estab lishing the pilot arc between nozzle and electrode The below schematic shows Filter and Start up circuit in which C1 R1 R2 forms the Start up circuit and remainder of the circuit forms the filter network A A 1 9 2 11 TO PCB1 J9 4 TO 1 12 RD TO PCB1 J9 3 MAIN CONTROL PCB L1 TERMINATE SHIELD X2 LECT OTHER END ONLY OUTPUT PRE LOAD FLECTRODE R9 OHM 100W J J TOPUR hasa FILTER PCB TO 1 J9 8 y 0558038391 TO 1 49 5 _ WORK TERMINATE SHIELD OTHER END ONLY J1 ELECTRODE 1 C2 ES C4 R1 R2 0 22uF 1kV 0 22uF 1kV 0 22uF 1kV 25 2K FASTON 1 4 TERMINAL WORK C1 J3 1 a 56uF 450V Chasis GND
99. s Hot metal can cause burns Training in the proper use of the processes and equipment is essential to prevent accidents Therefore 1 Always wear safety glasses with side shields in any work area even if welding helmets face shields and goggles are also required 2 Usea face shield fitted with the correct filter and cover plates to protect your eyes face neck and ears from sparks and rays of the arc when oper ating or observing operations Warn bystanders notto watch thearcand expose themselves to the rays of the electric arc or hot metal 3 Wear flameproof gauntlet type gloves heavy long sleeve shirt cuffless trousers high topped shoes and a welding helmet or cap for hair protection to protect against arc rays and hot sparks or hot metal A flameproof apron may also be desirable as protection against radiated heat and sparks 4 Hotsparks or metal canlodge in rolled upsleeves trouser cuffs or pockets Sleeves and collars should be kept buttoned and open pockets eliminated from the front of clothing 5 Protect other personnel from arc rays and hot sparks with a suitable non flammable partition or curtains 6 Use goggles over safety glasses when chipping slag or grinding Chipped slag may be hot and can fly far Bystanders should also wear goggles over safety glasses FIRES AND EXPLOSIONS Heat from 3 flames and arcs can start fires Hot slag or sparks can also cause fires and explosions The
100. s voltages to PCBs and relays Reference the diagrams below A1 23 222 Y2 Y1 X8 7 X6 K5 X3 X2 X1 a INE TNA 1W of W gt Wal 242 ox gt a E 5 S amp 15 14 15 BLK 120V x e IBS 16 17 4 2 4 22 6 9 10 11 12 UN gt TO RELAY RB1 4 11 1 09 gt TO RELAY RB1 4 14 POWER FAULT dWv i RR d 189 G Ol H SvM LIP Ol 50 DESCRIPTION OF OPERATION Control Transformer Winding Outputs Secondary coil A1 A2 is 120 VAC it provides signal to the HF circuit and Mark mode VDR selection inside the RAS box through relay block protected by a circuit breaker Refer Sche matic Layout section for detail schematics Secondary coil X1 X2 is 24 VAC provides power to Bus Charger Relay K2 and Control board On the control board this AC voltage connected to J2 pins 1 and 3 1 is rectified through diode bridge rectifier D4 D18 D31 D34 to create 24 HVDC for isolated digital input signals connected to J1 1 Refer Schematic Layout section for detail schematics Secondary coil X3 X4 is 24 VAC provides power to PS Enable Relays K4 K5 Refer Schematic Lay out section for detail schematics Secondary coil X5 X6 is 24 VAC provides power to control board PCB1 at J3 pins 4 and 5 which then rectified through diode bridge rectifier D5 D6 D9 D10 Refer Schematic Layout section for detail schematics Secondary c
101. se two hall sensors are closed loop sensors and as such do not need to be referenced to common Functions The two hall sensors perform different functions on the EPP 362 HS1 detects the Pilot Arc and current to the electrode while HS2 is used to detect current through the work lead The only function that HS2 performs is Arc On detection The two hall sensors HS1 and HS2 are supplied with a positive and negative 15 VDC The feedback signal is taken from pin 2 of the hall sensors and sent back to the Control Board 1 J8 connector Testing Using an Ohm meter the hall sensors may be checked See the table below for resistance values gp ui umm NO I gt A T0 PCB1 9 2 N D9 LE COR ER m i WHT 2 o o TR KO RED PCB 49 4 YEL PCBI J12 X TO 1 J9 3 CONTROL Cm T o 0 RQ 3K OHM 100W BLK TO 49 2 Ji J3 KO TO PCBI 9 8 0558038391 TO 1 49 5 5 I WORK TERMINATE SHIELD OTHER END ONLY 56 DESCRIPTION OF OPERATION Output Inductor L1 0558007254 The output inductor L1 is in place to filter the output of the power supply and reduce output ripple En L PCBI 49 2 V 09 L ED TO PCB1 19 4
102. seulement Toute autre utilisation pourrait causer des blessures et ou endommager l appareil Angle Siu d inclinaison maximal L quipement pourrait basculer s il est plac sur une surface dont la pente d passe 15 Vous pourriez vous blesser ou endommager l quipement de facon importante 15 Soulevez l aide de la m thode et des points d attache illustr s afin d viter de vous blesser ou d endommager l quipement 22 SAFETY When plasma cutting stainless steel you must comply with the OSHA standard to protect your employees from Hexavalent Chromium exposure Engineering control must be used to reduce exposures to safe levels in compliance with the new PEL The specific details of the standard are complex and may require the assistance of an occupational health professional to reach full compliance For additional information about Hexavalent Chromium contact your occupational health professional and read the OSHA web page at http www osha gov SLTC hexavalentchromium 23 SAFETY CANCER HAZARD CAN DAMAGE SKIN EYES NASAL PASSAGES AND LUNGS AUTHORIZED PERSONNEL ONLY RESPIRATORS MAY BE REQUIRED CHROMIUM VI Cr VI HEXAVALENT CHROMIUM On February 28 2006 the Occupational Safety and Health Agency OSHA pub lished a revised standard to protect workers from the potential hazards of hexavalent chromium Occupational
103. t which should be at least 280 VDC for a period of 200 ms If this fails then power supply will shutdown toggles the fault light and sends Error 13 to the CNC Process Controller 4 If proper OCV is read main micro sends command to close HF relay which will provide 115 VAC to HF circuit in the RAS box and sends pilot arc enable signal to servo micro which then will provide PWM signal to pilot arc IGBT Q5 If HF is present at the torch Pilot Arc is established 29 INTRODUCTION 5 OncethePilot Arcis established if the torch is close enough to the work and the work piece is grounded Main Arc will transfer to work Once main arc is established which will be verified by sensing the work current through HS2 work current greater than 5A power supply will send the Arc ON signal to CNC Process Controller via CAN and begins to ramp up current in accordance with the TDF file or the internal matrix 6 After a cutis finished or stop signal is sent from the CNC Process Controller power supply ramps down the current according to TDF SDP file the fan stays ON and the K1 contactor remains closed for 5 minutes If another start sig nal is sent prior to the 5 minutes time out as the bus filter capacitor voltage will be at 360 VDC power supply will not go through the soft start sequence 7 After the 5 minutes timer timed out main fan turns off and K1 opens Now if a start signal is sent the EPP 362 will perform the sequence of operations steps 1 t
104. t throttle valve until test flowmeter reads 1 5 gpm 5 7 l min RE oM SS SS Check interior of EPP 362 power source for leaks Read pressure on test pressure gauge It should be between 160 185 psig 11 0 12 8 bar 67 DESCRIPTION OF OPERATION PCB1 Control Board 0558038362 Introduction The Control board on the EPP 362 governs the operation of the power supply The board consists of circuits that control the following Pulse generation Slave master functions Fault monitoring Initiation of Pilot Arc Initiation of the bus supply Current output regulation Arc Detection Arc On signal generation HF High Frequency Circuit Mark Mode VDR Circuit The use of a microcontroller on this board co ordinates these functions and interfaces directly to the CNC through CAN communication The Control Board connects directly to a pair of Hall Sensors for current detection and regulation supplies pulses to the IGBTs through the Driver Board PCB2 Control board 1 consists of two micro controllers one called Main micro which controls the process sequence com munication with controller digital and analog IO signals fault monitoring coolant flow and level monitoring etc other called Servo micro which is used to generate the PWM signals for switching IGBTs monitoring the currents and voltages PCB1 Schematics 0558038362 Refer to Appendix B in the back section of this manual for complete schematics 68 Current Monitorin
105. tion is not adequate Stop work and take necessary steps to improve ventilation in the work area Do not continueto operate if physical discom fort persists 4 Referto ANSI ASC Standard Z49 1 seelisting below for specific ventilation recommendations SAFETY 5 WARNING This product when used for welding or cutting produces fumes or gases which con tain chemicals known to the State of California to cause birth defects and in some cases can cer California Health amp Safety Code 525249 5 et seq CYLINDER HANDLING Cylinders if mishandled can rupture and vio lently release gas Sudden rupture of cylinder valve or relief device can injure or kill Therefore 1 Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder Do not use adaptors Maintain hoses and fittings in good condition Follow manufacturer s operating instruc tions for mounting regulator to a compressed gas cylinder 2 Always secure cylinders in an upright position by chain or strap to suitable hand trucks undercar riages benches walls post or racks Never secure cylinders to work tables or fixtures where they may become part of an electrical circuit 3 When not in use keep cylinder valves closed Have valve protection cap in place if regulator is not con nected Secure and move cylinders by using suitable hand trucks Avoid rough handling of cylinders 4
106. tion of solid objects greater than 12mm and against spraying water up to 60 degrees from vertical Equipment marked IP21S may be stored but is not intended to be used outside during precipitation unless sheltered This product is solely intended for plasma cutting Any other use may result in personal injury and or equipment damage If equipment is placed on a surface that slopes more than 15 toppling over may occur Personal injury and or significant damage to equipment is possible To avoid personal injury and or equipment damage lift using method and attachment points shown here 14 SAFETY Safety Spanish ADVERTENCIA Estas Precauciones de Seguridad son para su protecci n Ellas hacen resumen de informaci n prove niente de las referencias listadas en la secci n Informaci n Adicional SobreLa Seguridad Antes de hacer cualquier instalaci n o procedimiento de operaci n aseg rese deleery seguirlas precaucio nes de seguridad listadas a continuaci n as como tambi n todo manual hoja de datos de seguridad del material calcomanias etc El no observar las Precauciones de Seguridad puederesultar en dano ala persona o muerte PROTEJASE USTED Y A LOS DEMAS Algunos procesos de soldadura corte y ranurado son ruidosos y requiren protecci n para los o dos El arco como el sol emite rayos ultravioleta UV y otras radiaciones que pueden danar la piel y los ojos El metal caliente
107. ts of RB1 2 close which in turn provides 115 VAC to the K1 relay coil to close the contacts in order to connect the input power to main transformer The 115 VAC signal originates from the main transformer T1 coil A auxiliary winding X7 and is sent through a pair of PS Enable relay contacts pins 7 and 4 and through RB1 2 relay contacts to K1B is connected to X4 on TB2 to complete the 115 VAC circuit See the diagram below TB1 1 F1 K2 20 14 460 115 1 2 11 2 1 3 4 PS ENABLE L3 T3 K1 44 DESCRIPTION OF OPERATION K2 Relay Soft Start Relay K2 Relay soft start Relay K2 is a 3 pole 40 amp relay with a 24 VAC coil that has a resistance of 7 5 Ohms It is used as the excitation or soft start relay for the power supply When K2 closes the bus is precharged through three 2 ohm resistors This takes less than 500 ms and allows the bus to come up slowly This prevents a surge of current through the rectifier diodes and the filter capacitors that would otherwise damage them Soft Start Circuit The EPP 362 uses a Soft Start Circuit in order to precharge the bus before allowing the full current to be delivered to the input bridge and filter bus In this way initial current to the input rectifier and bus filter caps are limited so as to prevent an initial overload condition and damage these circuit components The soft start circuit is composed of a pair of
108. u tions de s curit ci dessous dans les manuels les fiches d information sur la s curit du mat riel et sur les tiquettes etc Tout d faut d observer ces pr cautions de s curit peut entrainer des blessures graves ou mortelles PROT GEZ VOUS Les processus de 2 soudage de et de gougeage QE produisent un niveau de bruit lev et exige l emploi d une protection auditive L arc tout comme le soleil met des rayons ultraviolets en plus d autre rayons qui peuvent causer des blessures la peau et les yeux Le m tal incandescent peut causer des br lures Une formation reli e l usage des proces sus et de l quipement est essentielle pour pr venir les accidents Par cons quent 1 Portez des lunettes protectrices munies d crans lat raux lorsque vous tes dans l aire de travail m me si vous de vez porter un casque de soudeur un cran facial ou des lunettes tanches 2 Portezun cranfacial muni deverresfiltrants et de plaques protectrices appropri es afin de prot ger vos yeux votre visage votre cou et vos oreilles des tincelles et des rayons del arclors d une op ration ou lorsque vous observezune op ration Avertissezles personnes se trouvant proximit de ne pas regarder l arc et de ne pas s exposer aux rayons de l arc lectrique ou le m tal incandescent 3 Portez des gants ignifugi s crispin une chemise paisse a manches longues des pantalons sans rebord et des c
109. ve electrical parts and ground can cause severe injury or death DO NOT use ACweldingcurrentin damp areas if movementis confined or if there is danger of falling 11 SAFETY 1 Be sure the power source frame chassis is con nected to the ground system of the input power 2 Connectthe work piece toa goodelectrical ground 3 Connect the work cable to the work piece A poor or missing connection can expose you or others to a fatal shock 4 Use well maintained equipment Replace worn or damaged cables 5 Keepeverything dry including clothing workarea cables torch electrode holder and power source 6 Make sure that all parts of your body are insulated from work and from ground 7 Do not stand directly on metal or the earth while working in tight quarters or a damp area stand on dry boards or an insulating platform and wear rubber soled shoes 8 Put on dry hole free gloves before turning on the power 9 Turn off the power before removing your gloves 10 Refer to ANSI ASC Standard 749 1 listed on next page for specific grounding recommenda tions Do not mistake the work lead for a ground cable ELECTRIC AND MAGNETIC FIELDS May be dangerous Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Weld SR ing and cutting current creates EMF 1 Welders having pacemakers should consult their around welding cables and welding machines Theref
110. w _ wn _ wawa saan n A Tm ACUTE 74 DESCRIPTION OF OPERATION 0000000000000 0000000000000 0000000000 AN 8 6 bug 0000000000000 0000000000 8 Lir sir vir 43 6Ir 2 gt ss ur nad p 2 D a jn 1 we PULL 25 o 6 0 ga 34 i len T VE Ouch sunl v 8 d a E Ob e zm 8 8 8 8 00000 00000 00000 s 35079 3 em d d RUM UNE NS 8 N 0 0 5 9 959 La v deal _ 3 m og I EM PUN p 2 wi amo Lert 8 I 4 Leme 8 n te M mu eto v Jl 18 1 ies fet om sow Franky Em EIUS ma Le 49 9914 Teta cer 5 eon 3 N sen i 5 um xm kh 5 e een 8 EN a id or lq 0 sa SL T t FEB d 5 se O m dio gt ia Sge 24 TEM a m V 1 1 ES C LE 3 to EMI cam pi pus ui m FR EN
111. wire device current through the coil generates a electro magnetic field causing inductive reactance which increases with number of turns and density Adding a core to a coil increases the inductance produced Wound wire device with a primary and secondary coil s which increases or decreases voltage applied to the primary based on coil and core configuration 1 1 transformers are used for isolation 2 COIL COIL Iron Core TRANSFORMER GROUND Identifies the earth ground connection NOTE Not for a protective earth connection GENERAL INFORMATION Glossary General Definitions and Symbols Used in this Manual NOTATION NAME NEUTRAL PLUG SYMBOL DESCRIPTION Electronic neutral or common Variously configured male female separable connectors CONNECTION Electro magnetically operated valve SOL SOLENOID MOTOR n HP V device which converts electrical energy to mechanical energy motion THERMISTOR THERMAL A resistor whose resistance changes with temperature T SWn Protective device that protects circuits from over temperature SWITCH SYMBOL _ Collector A transistor amplifies current 2 lt gt 7 A small base current controls the larger collector current TRANSISTOR TP TEST POINT RELAY nA nV Electro mechanical device for opening closing a circuit WIRE NODE Device using the mechanical resonance of a physical crystal of piezo CRYSTAL
112. wn then check for the ambient temperature being above 40C or dirt in the radiators 2 Check if main fan is functioning and it is pulling air through the power supply 3 Shut off the power supply and allow the machine to cool 4 Check the diode bridge for an open thermal switch If the switch is still open after certain time then replace the switch 5 Checkthe IGBT module for an open thermal switch If the switch is still open after certain time then replace the switch 1 Check the start signal to the power supply while the power supply is OFF If there is voltage on the input find and fix the wiring error 2 Check the start signal to the power supply while the power supply is ON If there is voltage on the input while CNC is OFF check the power supply control wiring for a short to the input 1 Check the distance from the work piece matches the recommended ignition height 2 Checkthe electrical connection from the work piece to the work connection on the power supply 3 Check the HF relay inside the power supply 4 Check the 115VAC voltage on the control transformer 5 Checkthe consumables 1 Check the jumper inside the RAS box between pins L and J on the 14 pin Amphenol connector 2 Check for short between electrode and nozzle 3 Check the IGBT gate pulse voltage connection on the driver board 4 Check for shorted IGBT 5 Check for shorted diode D9 1 Check for shorted IGBT 2 Check for shorted diode D9 3 Che

EPP-362 Plasma Power Source - ESAB Welding & Cutting Products

Contents

Download Pdf Manuals

Related Search

Related Contents

EPP-362 Plasma Power Source - ESAB Welding &amp; Cutting Products

Contents

Download Pdf Manuals

Related Search

Related Contents

EPP-362 Plasma Power Source - ESAB Welding & Cutting Products