EPP-360 - ESAB equipment... · • Local or remote front panel control • Thermal switch protection for main transformer and power semiconductor components • Top lifting eyes or

EPP-360Plasma Power Source

Instruction Manual (EN)

0558007925 09/2011

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This equipment will perform in conformity with the description thereof contained in this manual and accompa-nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-tions 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 imme-diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone 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 maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a ser-vice facility designated by the manufacturer.

BE surE thIs INforMatIoN rEachEs thE opErator.You caN gEt Extra copIEs through Your supplIEr.

these INstructIoNs are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc 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.

cautIoN

usEr rEspoNsIBIlItY

rEaD aND uNDErstaND thE INstructIoN MaNual BEforE INstallINg or opEratINg.

protEct YoursElf aND othErs!

3

taBlE of coNtENts

section / title page1.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

2.0 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72.2 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72.3 Dimensions and Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

3.0 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93.3 Placement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93.4 Input Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103.4.1 Primary Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103.4.2 Input Conductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113.4.3 Input Connection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113.5 Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123.5.1 Output Cables (customer supplied). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123.5.2 Output Connection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133.6 Parallel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143.6.1 Connections for Two EPP-360’s in Parallel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143.6.2 Marking with Two Parallel EPP-360’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163.7 Interface Cable Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163.7.1 CNC Interface Cables with Mating Power Source Connector and Unterminated CNC Interface . . . . .173.7.2 CNC Interface Cables with Mating Power Source Connectors at Both Ends . . . . . . . . . . . . . . . . . . . . . . . .173.7.3 Water Cooler Interface Cables with Mating Power Source Connectors at Both Ends . . . . . . . . . . . . . . . .183.7.4 Power Source Parallel Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

4.0 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194.1 EPP-360 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194.2 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204.2 Control Panel (con’t.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214.3 Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224.3.2 Multiple Power Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254.4 Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5.0 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

6.0 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296.1 Troubleshooting Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296.2 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296.3 Help Code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306.4 Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .316.4.1 Fans Not Working. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .316.4.2 Torch Will Not Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

7.0 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .337.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .337.2 Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

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DECLARATION OF CONFORMITYaccording to the Low Voltage Directive 2006/95/EC, according to the EMC Directive 2004/108/EC

FÖRSÄKRAN OM ÖVERENSSTÄMMELSEenligt Lågspänningsdirektivet 2006/95/EG, enligt EMC-Direktivet 2004/108/EG

Type of equipment MaterialslagPlasma Cutting Console

Brand name or trade mark Fabrikatnamn eller varumärkeESAB

Type designation etc. Typbeteckning etc.EPP-201, (0558007800) & EPP-360 (0558007831)Manufacturer or his authorised representative established within the EEA Name, address, telephone No, telefax No: Tillverkarens namn, adress, telefon, telefax:ESAB AB

Esabvägen, SE-695 81 Laxå, SwedenPhone: +46 586 81000, Fax: +46 584 411 924

The following harmonised standard in force within the EEA has been used in the design:Följande harmoniserande standarder har använts i konstruktionen:EN 60974-1, Arc welding equipment – Part 1: Welding power sourcesEN 60974-10, Arc welding equipment – Part 10: Electromagnetic compatibility (EMC) requirements

Additional information: / Tilläggsinformation: Restrictive use, Class A equipment, intended for use in locations other thanresidential

By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorisedrepresentative established within the EEA, that the equipment in question complies with the safety requirementsstated above.Genom att underteckna detta dokument försäkrar undertecknad såsom tillverkare, eller tillverkarens representant inomEES, att angiven materiel uppfyller säkerhetskraven angivna ovan.

Date / DatumLaxå 2007-12-20

Signature / Underskrift Position / Befattning Global Director Equipment and AutomationKent EimbrodtClarification

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sEctIoN 1 safEtY prEcautIoNs

1.0 safety precautions

Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of welding or plasma cutting equipment. The following recommendations should be observed in addition to the standard regulations that apply to the workplace.

All work must be carried out by trained personnel well acquainted with the operation of the welding or plasma cutting equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the operator and damage to the equipment.

1. Anyone who uses welding or plasma cutting equipment must be familiar with: - its operation - location of emergency stops - its function - relevant safety precautions - welding and / or plasma cutting

2. The operator must ensure that: - no unauthorized person stationed within the working area of the equipment when it is started up. - no one is unprotected when the arc is struck.

3. The workplace must: - be suitable for the purpose - be free from drafts

4. Personal safety equipment: - Always wear recommended personal safety equipment, such as safety glasses, flame proof clothing, safety gloves. - Do not wear loose fitting items, such as scarves, bracelets, rings, etc., which could become trapped or cause burns.

5. General precautions: - Make sure the return cable is connected securely. - Work on high voltage equipment may only be carried out by a qualified electrician. - Appropriate fire extinquishing equipment must be clearly marked and close at hand. - Lubrication and maintenance must not be carried out on the equipment during operation.

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sEctIoN 1 safEtY prEcautIoNs

WElDINg aND plasMa cuttINg caN BE INJurIous to YoursElf aND othErs. taKE prEcautIoNs WhEN WElDINg or cuttINg. asK for Your EMploYEr’s safEtY practIcEs WhIch shoulD BE BasED oN MaNufacturErs’ haZarD Data.

ElEctrIc shocK - Can kill. - Install and earth (ground) the welding or plasma cutting unit in accordance with applicable standards. - Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing. - Insulate yourself from earth and the workpiece. - Ensure your working stance is safe.

fuMEs aND gasEs - Can be dangerous to health. - Keep your head out of the fumes. - Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone and the general area.

arc raYs - Can injure eyes and burn skin. - Protect your eyes and body. Use the correct welding / plasma cutting screen and filter lens and wear protective clothing. - Protect bystanders with suitable screens or curtains.

fIrE haZarD - Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NoIsE - Excessive noise can damage hearing. - Protect your ears. Use earmuffs or other hearing protection. - Warn bystanders of the risk.

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

rEaD aND uNDErstaND thE INstructIoN MaNual BEforE INstallINg or opEratINg.

protEct YoursElf aND othErs!

WarNINg

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sEctIoN 2 DEscrIptIoN

2.1 Introduction

The EPP power source is designed for marking and high speed plasma mechanized cutting applications. It can be used with other ESAB products such as the PT-15, PT-19XLS, PT-600 and PT-36 torches along with the Smart Flow II, a computerized gas regulation and switching system.

• 10 to 36 amperes for marking• 30 to 360 amperes cutting current range• Forced air cooled • Solid state DC power• Input voltage protection• Local or remote front panel control• Thermal switch protection for main transformer and power semiconductor components• Top lifting eyes or base forklift clearance for transport• Parallel supplemental power source capabilities to extend current output range.

EPP-360, CCC/CE, 380 / 400V,50 / 60Hz

Part Number 0558007831

Output (100 % duty cycle)

Voltage 200 VDC

Current range DC (marking) 10A to 36A

Current range DC (cutting) 30A to 360A

Power 72 KW

* Open Circuit Voltage (OCV) 360 VDC

Input

Voltage (3-phase) 380 / 400V

Current (3- phase) 140 / 132A RMS

Frequency 50 / 60 HZ

KVA 91.6 KVA

Power 82.5 KW

Power Factor 90.0 %

Input Fuse Rec. 200A

2.2 general specifications

2.0 Description

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sEctIoN 2 DEscrIptIoN

2.3 Dimensions and Weight

40.75”(1035 mm)

47.25”(1200 mm)

23.75”(603.25 mm)

Weight = 1085 lb

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sEctIoN 3 INstallatIoN

3.1 general

faIlurE to folloW INstructIoNs coulD lEaD to DEath, INJurY or DaMagED propErtY. folloW thEsE INstructIoNs to prE-vENt INJurY or propErtY DaMagE. You Must coMplY WIth lo-cal, statE aND NatIoNal ElEctrIcal aND safEtY coDEs.

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3.2 unpacking

• Inspect for transit damage immediately upon receipt.• Remove all components from shipping container and check for loose parts in container.• Inspect louvers for air obstructions.

3.3 placement

• A minimum of 1 meter (3 ft.) clearance on front and back for cooling air flow.• Plan for top panel and side panels having to be removed for maintenance, cleaning and inspection. • Locate the EPP-360 relatively close to a properly fused electrical power supply.• Keep area beneath power source clear for cooling air flow.• Environment should be relatively free of dust, fumes and excessive heat. These factors will affect cool-

ing efficiency.

conductive dust and dirt inside power source may cause arc flash-over. Equipment damage may occur. Electrical shorting may occur if dust is allowed to build-up inside power source. see maintenance section.

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3.0 Installation

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3.4 Input power connection

ElEctrIc shocK caN KIll!provIDE MaxIMuM protEctIoN agaINst ElEctrIcal shocK.BEforE aNY coNNEctIoNs arE MaDE INsIDE thE MachINE, opEN thE lINE Wall DIscoNNEct sWItch to turN poWEr off.

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3.4.1 primary power

EPP-360 is a 3-phase unit. Input power must be provided from a line (wall) disconnect switch that contains fuses or circuit breakers in accordance to local or state regulations.

Dedicated power line may be necessary.Epp-360 is equipped with line voltage compensation but to avoid impaired performance due to an overloaded circuit, a dedicated power line may be required.

NotIcE

Input current =(V arc) x (I arc) x 0.73

(V line)

* Sizes per National Electrical Code for a 90° C (194˚ F) rated copper conductors @ 40° C (104˚ F) ambient. Not more than three conductors in raceway or cable. Local codes should be followed if they specify sizes other than those listed above.

To estimate the input current for a wide range of output conditions, use the formula below.

Input at rated load Input and ground conductor* cu/

mm2 (aWg)

time delay fuse size (amperes)volts amperes

380 140 50 (1) 200

400 132 35 (2) 150 slo-blo +10%/-0

Rated load is output of 360A at 200V

* * *Recommended input conductor and line fuse sizes:* * *

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• Customer supplied• May consist either of heavy rubber covered copper conductors (three power and one ground) or run

in solid or flexible conduit.• Sized according to the chart.

3.4.2 Input conductors

1. Remove small rear panel of the EPP-360.2. Thread cables through the access opening in the rear panel.3. Secure cables with strain relief at the access opening.4. Connect the ground lead to the stud on the chassis.5. Connect the power leads to the primary terminals.6. Connect the input conductors to the line (wall) disconnect.7. Before applying power, replace the rear cover panel.

3.4.3 Input connection procedure

power Input cable access opening (rear panel)


primary terminalschassis ground

IMpropEr grouNDINg caN rEsult IN DEath or INJurY.chassIs Must BE coNNEctED to aN approvED ElEctrIcal grouND. BE surE grouND lEaD Is Not coNNEctED to aNY prI-MarY tErMINal.

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ElEctrIc shocK caN KIll! DaNgErous voltagE aND currENt!aNY tIME WorKINg arouND a plasMa poWEr sourcE WIth cov-Ers rEMovED:

• DIscoNNEct poWEr sourcE at thE lINE (Wall) DIscoNNEct.

• havE a QualIfIED pErsoN chEcK thE output Bus Bars (posI-tIvE aND NEgatIvE) WIth a voltMEtEr.

3.5 output connections

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3.5.1 output cables (customer supplied)

Choose plasma cutting output cables (customer supplied) on the basis of one 4/0 AWG, 600 volt insulated cop-per cable for each 400 amps of output current.

Note: Do not use 100 volt insulated welding cable.


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3.5.2 output connection procedure

Front AccessPanel Opened

1. Open access panel on the lower front of the power source.2. Thread output cables through the openings at the bottom of the power source immediately behind the front

panel.3. Connect cables to designated terminals mounted inside the power source using UL listed pressure wire con-

nectors.4. Close front access panel.

Front AccessPanel Closed

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Note: Primary power source has the electrode (-) conductor jumpered. The supplemental power

source has the work (+) jumpered.

1. Connect the negative (-) output cables to the arc starter box (high frequency generator).2. Connect the positive (+) output cables to the workpiece.3. Connect the positive (+) and negative (-) conductors between the power sources.4. Connect the pilot arc cable to the pilot arc terminal in the primary power source. The pilot arc connection in

the supplemental power source is not used. The pilot arc circuit is not run in parallel.5. Connect a power source paralleling control cable between the two power sources.6. Connect the CNC control cable to the primary power source.

Connections for parallel installation of two EPP-360 power sources with both power sources in operation.

3.6.1 connections for two Epp-360’s in parallel

S u p p l e m e n t a l Power Source

Primary PowerSource

work(+)

electrode(-)

pilot arc

2 - 4/0 600Vpositive leads to workpiece

1 - 14 AWG 600Vlead to pilot arc con-nection in arc starter

box (h.f. generator)

2 - 4/0 600Vnegative leads

in arc starter box (h.f. generator)

EPP-360 EPP-360

work(+)

electrode(-)

P/S Parallel Control Cable

CNCControlCable

Control cable to water cooler

Two EPP-360 power sources may be connected together in parallel to extend the output current range.

3.6 parallel Installation

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ElEctrIc shocK caN KIll!

ExposED ElEctrIcal coNDuctors caN BE haZarDous!

Do Not lEavE ElEctrIcallY “hot“ coNDuctors ExposED. WhEN DIscoNNEctINg thE supplEMENtal poWEr sourcE froM thE prIMarY, vErIfY thE corrEct caBlEs WErE DIscoNNEctED. IN-sulatE thE DIscoNNEctED ENDs.

WhEN tWo poWEr sourcEs arE coNNEctED IN parallEl aND oNE of thE tWo Is Not poWErED, or If thE parallElINg caBlE DoEs Not coNNEct thE tWo, thE NEgatIvE ElEctroDE coNDuc-tor Must BE DIscoNNEctED froM thE supplEMENtal poWEr sourcE aND thE pluMBINg Box. faIlurE to Do thIs WIll lEavE thE supplEMENtal ElEctrIcallY “hot”, uNsafE, as WEll as IN-opEratIvE.

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Do Not opEratE thE Epp-360 WIth covErs rEMovED. hIgh voltagE coMpoNENts arE ExposED INcrEasINg shocK haZ-arD. INtErNal coMpoNENts MaY BE DaMagED BEcausE cool-INg faNs WIll losE EffIcIENcY.

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The EPP-360 does not have an ON/OFF switch. The main power is controlled through the line (wall) disconnect switch.

Connections for parallel installation of two EPP-360 power sources with only one power source in operation.

S u p p l e m e n t a l Power Source

Primary PowerSource

work work electrodeelectrode

2 - 4/0 600Vpositive leads to workpiece

2 - 4/0 600Vnegative leads

in arc starter box (h.f. generator)

Disconnect negative connection from sec-ondary power source and insulate to con-vert from two to one power source

EPP-360 EPP-360

Control cable to water cooler

P/S Parallel Control Cable

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E-Stop Connector


3.7 Interface cable connectors

3.6.2 Marking with two parallel Epp-360’s

Two EPP-360’s, connected in parallel, and can be used for marking down to 10A and cutting from 30A up to 720A.

opEratIoN of tWo parallEl Epp-360’s:

1. Provide start/stop, Cut/Mark, “HI CURRENT” logic signals and either logic or analog inputs to control the pilot current signals to primary unit for both cutting and marking. When marking, both power sources are pow-ered up, but the mark signal disables the output of the supplemental power source.

Remote Control (CNC)Parallel Power Source

Coolant Circulator

17


3.7.1 cNc Interface cables with Mating power source connector and unterminated cNc Inter-face

3.7.2 cNc Interface cables with Mating power source connectors at Both Ends

GRN/YEL

RED #4

GRN/YEL

RED #4

18


3.7.3 Water cooler Interface cables with Mating power source connectors at Both Ends

3.7.4 power source parallel control cable

19

sEctIoN 4 opEratIoN

4.1 Epp-360 Block Diagram

380/400V 3 ~Input

ControlPowerFuses

1 ~Control

Transformer

MainContactor

SoftStartRelay Relay / Interface

Board

MainTransformer

3 x 2 Ohm300 WattResistors

3 ~Rectifier

2 x 6000uf450V

Capacitors

IGBT DriverBoard

4 x 400 AmpIGBT’s

Inductor

Output

Main ControlBoard

Front PanelDisplay

CNCInterface

&Isolation

DaNgErous voltagEs aND currENt! ElEctrIc shocK caN KIll!BEforE opEratIoN, ENsurE INstallatIoN aND grouNDINg pro-cEDurEs havE BEEN folloWED. Do Not opEratE thIs EQuIp-MENt WIth covErs rEMovED.

WarNINg

4.0 operation

20

sEctIoN 4 opEratIoN

4.2 control panel

B

c

D

fE

a

J

h

21

a - preset / operate switch

“Center” position = will show actual cut parameters

“Up” position = Pilot Arc Current Preset for either the Panel or Remote mode

“Down” position = Cut Current Preset for either the Panel or Remote mode

B - over temp

Indicator illuminates when power source has overheated.

c - fault

Indicator illuminates when errors have occurred which require a main power reset of the unit.

D - current Dial (potentiometer)

EPP-360 dial shown. EPP-360 has a range of 10 to 360 A. Used only in panel mode.

sEctIoN 4 opEratIoN

E - panel remote switch

Controls the location of current control. • Place in the PANEL position for control using the current potentiometer.• Place in REMOTE position for control from an external signal (CNC).

4.2 control panel (con’t.)

f - Meters

Displays voltage and amperage when cutting. The ammeter can be activated when not cutting to view an es-timation of the cutting/marking current or pilot arc current before cutting begins. See “A” above. Also displays various error codes that may occur.

g - E-stop connector (not shown)The E-stop connector provides a normally closed contact of the E-stop switch. The contact is connected to J4-A and J4-B. The contact opens after the E-stop button is pushed. This provides a signal to the plasma control that the power source is in an E-stop condition.

h - E-stop ButtonThe E-stop button operates the E-stop switch. When the button is pushed in an E-stop condition exists which prevents the power source from providing output even when a start signal is provided.

J - cB1 - 3 ampCircuit breaker for 115 vac to CNC.

22

sEctIoN 4 opEratIoN

pa0 pa1

off off no change

on off value increased by 12.5%

off on value increased by 25%

on on value increased by 37.5%

4.3 Modes of operation

The EPP-360 operates in the Cutting Mode through a single continuously adjustable output current range from 30 amps through 360 amps using either the Current Potentiometer on the front panel, or a remote current refer-ence signal fed into connector J1.

When using a remote signal, 1 volt corresponds to 36 amps, and 360 amps corresponds to a signal of 10.00 VDC.

The EPP-360 defaults to the Cutting Mode of operation unless the command signal from a remote control for Marking Mode is supplied.

The power source is placed in Marking Mode with an external isolated relay or switch contact connecting J1-R (115VAC) to J1-C. See Schematic Diagram included inside back cover. This contact closure must be made before (50 mS or longer) issuing a Start or Contactor On command.

In the CNC Marking mode, the output current is adjusted through a single continuously adjustable range from 0 amps through 36 amps using the remote current reference signal fed into connector J1. In the Panel Mark-ing mode, the output current can be adjusted from 0 - 36 amps using the panel potentiometer, as the unit is shipped. If SW1-1 (which is open on the control board) is closed, the range becomes 0 -18 amps max.

When using a remote signal, 1 volt corresponds to 3.6 amps, and 36A corresponds to a signal of 10.00 VDC.

4.3.1. single power source (used with the cNc, two basic modes of operation are possible)

1. panel Mode - (switch is provided on the power source) Put Panel/Remote switch to Panel position. Used with a limited capability CNC that can only provide a start/stop signal to the power source. The microcontroller in the power source will accept the analog setting from the panel potentiometer as the cut current information. Based on this value it will calculate the initial current value, the pilot arc and the upslope time. The cut value and P.A. value can be displayed prior to cutting by moving the spring return switch on the power source to the cut current preset, and the pilot arc preset positions. If the pilot arc current is deemed insufficient, the CNC can increase it by providing inputs on the PA0 and PA1 control leads. The increased values are as fol-lows:

23

sEctIoN 4 opEratIoN

3A

not used

EPP-360

10K

24 CONDUCTOR CABLE

+

E-STOP: ISOLATED CONTACTCLOSED TO RUN

MARK MODE SELECT

CUT CURRENT REF

CURRENT REF COMJ

L

A

G

Z

M

T

Q

Y

S

N

C

D

E

F

H

K

R

U

V

W

X

B

P

CUT CURRENT REF+

MARK MODE SELECT

I mark = (3.6) X (Vcut cur ref)CLOSED FOR MARKING

POWER SOURCE FAULT

RED 09

MASTER SELECT - CONNECT H TO R (ALWAYS PRESENT)

RED 22

RED 01

RED 18

RED 13

RED 12

RED 15

RED 23

RED 17

RED 07

RED 11

RED 04

RED 02

RED 14

RED 03

RED 05

RED 08

RED 06

RED 10

RED 16

RED 20

RED 19

RED 21

115V AC NEUTRAL

WC LEVEL (ON W/ LEVEL OK)

ON WITH FAULT

+

K4

WC LEVEL: OFFWITH FAULT

PA CURRENT SELECT

E-STOP

PA CURRENT SELECT

E-STOP

PA CURRENT SELECT

CNC

(PARALLEL OPERATION ONLY)

Icut = (36) X (Vcut cur ref)

CURRENT HI/LOCLOSED FOR 720A; OPEN FOR 360A

Ipa = (4.5) X (Vpa cur ref)

+

FOR HI: Icut = (72) X (Vcut cur ref)

PLASMA START

PS 24V DC COMMON

HI RANGE (720A)

PLASMA START

FOR LO: Icut = (36) X (Vcut cur ref)

15V CNCCOMMON

PA CURRENT SELECT

24V DCCOMMON

PA ON

CNC +15V DC

WC FLOW FAULT: ON WITH FLOW OK

CABLEWIRE ID

ARC ON

+

MASTER SELECT

115V

AC

NE

UTR

AL

+

Plasma System Control

POWER SOURCE FAULT

20K

115V AC H

24V AC

PA ON

PA CURRENT REF

CN

C +

15V

DC

20K

PA CURRENT REF

ARC ON

not used

GRN/YEL

PROCESS CONTROL SELECTION

24-

CO

ND

UC

TOR

CO

NN

EC

TOR

CNC ANALOG COMMON

CHASSIS

WC FLOW FAULT: OFF WITH LO FLOW

PA1

HALL TRANSDUCER

OPEN FOR INTERNAL CONTROL

+MASTER CURRENT

115V

AC

CLOSED FOR EXTERNAL CONTROL

10K

10K

10K

10K

10K

10K

MASTER OUTPUT CURRENTSIGNAL 1.0V = 100A

10K

PA0

FUS

E

24V24V

15V15V

0 TO 10V0 TO 10V0 TO 10V0 TO 10V

24

pa0 pa1 pilot current in amp

open open 10

closed open 20

open closed 30

closed closed 40

sEctIoN 4 opEratIoN

cut current (amps)

start current (amps)

pilot arc current command (amps)

upslope time (msec)

30 20 15 200

50 25 20 250

100 50 25 500

200 100 30 800

300 150 35 900

360 180 40 950

The table used to calculate the initial current, pilot current and upslope values are stored in the micro and con-tains the following information:

If values other than the table values are used for the cut current, the corresponding values are calculated assum-ing a linear slope for all the required parameters.

a. partial cNc operation - (CNC cable pin “V” open, open for internal control) In this mode of operation the panel/remote switch needs to be in the REMOTE position. The CNC should be providing the cut current refer-ence and start/stop signal to the power source. Based on the cut reference the micro in the power source will compute the initial current, pilot current and upslope time.

2. remote Mode -

b. remote with full cNc Mode - (CNC cable pin “V” closed, closed for external control) Panel/remote switch on the power source is set to REMOTE. The CNC should activate the input labeled “full CNC control” on pin “V” of the interconnect cable. In this mode all parameters are controlled by the CNC, including start current, pilot current and sloping times. The control of the pilot current can be done either by logic inputs or by an analog input. If the analog input is less than 0.5 volts the power source will use the logic inputs PA0 and PA1 to provide the requested pilot arc current, based on the following combination:

If the analog reference is used, 10 VDC will provide 45 amps or 1 V = 4.5 amps.

Marking - Can be done in both panel and remote mode and requires the mark mode select input to be closed by the CNC. In the panel mode the maximum marking current (set by the panel potentiometer) is 36 amps. If SW1-1 (which is open on the control board) is closed, the range becomes 0 -18 amps max. In the remote mode the marking current is set by the main reference input and 10 VDC will provide 36 amps or 1 V = 3.6 amps of marking current.

25

sEctIoN 4 opEratIoN

1. parallel Mode of operation - Connect power sources together as shown in section 3.6. Set the panel/remote switches on both power sources to remote. If the units will be used for cutting and both power sources are to contribute to the cut current value, activate the logic input labeled “HI CURRENT” (pin “T”) on the CNC cable. In this manner a maximum current of 720 amps can be provided for an analog input of 10 VDC from the CNC. If the “HI CURRENT” input is deactivated the supplemental power source will not provide any output even though it is connected to the primary power source. In marking mode only the primary power source will supply the mark-ing current. If alternating marking and cutting operations are done, the “HI CURRENT” input can be maintained and the mark input will control whether both or only one power source will provide output current. The marking current range is from 10 to 36 amps and the cut current range is from 30 to 720 amps.

4.4 sequence of operation

4.3.2 Multiple power sources

A. Apply power by closing the line (wall) switch. The EPP-360 does not contain its own power On/Off switch. Once power is supplied, the EPP-360 display board will display “EPP-360” briefly, followed by the display “Pr x.xx”, indicating the software program revision number, then “0 amps” and “0 volts”.

C. Begin plasma cutting operation. This may require setting of other variables such as gas pressures, flow rates, and torch height etc.

D. If for any reason cutting or marking fails to initiate, the EPP-360 should display an error code indicating the reason for the shutdown. See “Help Codes” in the troubleshooting section.

B. Select Panel / Remote setting for current control depending on whether your CNC has remote current con-trol capability.

1. If using the “Panel” mode, the selected cutting current may be viewed by holding the front panel switch in the “Cut Current Preset” position. In the “Panel” mode, the Pilot Arc Current, Initial Current, and Up-slope Time are determined by the power source based on the selected cutting current. The selected Pilot Arc Current can be viewed by holding the front panel switch in the “PA Current Preset” position. See section 4.2 Control Panel.

2. If using the “Remote” mode, there are two possible modes of operation.

a. The default mode is similar to the “Panel” mode with the exception that the cutting current com-mand is supplied by the CNC instead of the front panel potentiometer. Scaling of the remote cur-rent command is 1.0 V DC = 36 amps. This mode is useful if the CNC does not have the capability of controlling the initial current and sloping of the output. For remote control connections see the CNC interface diagram.

b. If your CNC has the capability of controlling Initial Current and Slopes, place the Panel/Remote switch in “Remote” and supply a contact closure between pins “R” and “V” of the CNC interface connector. In this mode the CNC must supply the analog signal to control Initial Current, Upslope, and Cut Cur-rent level. Scaling is the same as default mode. Pilot Arc current will be controlled by a second 0 – 10 V DC analog signal, if available, or by supplying a binary coded signal as defined in the CNC interface diagram. Scaling of the pilot arc signal is 10 V DC = 45 amps.

26

sEctIoN 4 opEratIoN

27

section 5 maintenance

5.1 General

electric shock can kill!shut off power at the line (wall) disconnect before at-temptinG any maintenance.

warninG

warninGeye hazard when usinG compressed air to clean.

• Wear approved eye protection with side shields when cleaning thepowersource.

• Useonlylowpressureair.

caution maintenance on this equipment should only be performed by trained personnel.

5.2 cleaning

Regularlyscheduledcleaningofthepowersourceisrequiredtohelpkeeptheunitrunningtroublefree.Thefrequencyofcleaningdependsonenvironmentanduse.

1. Turnpoweroffatwalldisconnect.2. Removesidepanels.3. Uselowpressurecompresseddryair,removedustfromallairpassagesandcomponents.Payparticular

attentiontoheatsinksinthefrontoftheunit.Dustinsulates,reducingheatdissipation.Besuretoweareyeprotection.

air restrictions may cause epp-360 to over heat.thermal switches may be activated causing interruption of func-tion. do not use air filters on this unit. keep air passages clear of dust and other obstructions.

warninG

caution

electric shock hazard!be sure to replace any covers removed durinG cleaninG before turninG power back on.

5.0 maintenance

28

section 5 maintenance

29

section 6 troubleshootinG

electric shock can kill!do not permit untrained persons to inspect or repair this equipment. electrical work must be performed by an expe-rienced electrician.

warninG

stop work immediately if power source does not work properly.have only trained personnel investigate the cause.use only recommended replacement parts.

caution

6.1 troubleshooting introduction

Checktheproblemagainstthesymptomsinthefollowingtroubleshootingguide.Theremedymaybequitesimple.Ifthecausecannotbequicklylocated,shutofftheinputpower,openuptheunit,andperformasimplevisualinspectionofallthecomponentsandwiring.Checkforsecureterminalconnections,looseorburnedwir-ingorcomponents,bulgedorleakingcapacitors,oranyothersignofdamageordiscoloration.

Thecauseofcontrolmalfunctionscanbefoundbyreferringtothesequenceofoperations,electricalschematicsandcheckingthevariouscomponents.Avolt-ohmmeterwillbenecessaryforsomeofthesechecks.

6.2 troubleshooting Guide

Astheunitispoweredup,thedisplayshouldshowEPP-360foronesecondandthenshowtheprogramnumbersuchas:Pr3.01orhigher.Ifthedisplayremainsblank,lookforthefollowing: a.looseormissingdisplaycablebetweenthemaincontrolboardandthedisplayboard b.lackof+15voltbiassupplywhichcouldbecausedbyblownfusesF1orF2 c.anopencircuitbreakerCB1onthefrontpanel.IftheunitshowsError5aftertheprogramnumberdisplaytimesout,lookforaclosedstartswitch.Toresettheunitsimplyopenthestartswitch.Atthispointthedisplayshouldshow0’sinbothwindows.IfthepowersourceisnotconnectedtoaCNCatpowerup,theemergencystoprelay(K4)inthepowersourceisnotenergized,pre-ventinganyrelayoperationinthepowersourceitself.

IftheCNChasbeenbootedupthedisplayshouldread0forboththevoltsandamps.Theunitwillnotrespondtoastartsignaluntilit’smasterselectinput(pinHonJ1)isconnectedtothe“HOT“sideof115input(masterselectinput).ThisconnectionishandledintheCNCtoprimarysupplycable.NoteallinputsfromtheCNCarerelayclosures,providing115VACinputstotheisolationboard(PCB4inthepowersource).Theisolationboardconvertstheseinputstoopencollectortypeoutputs.Thecontrolwillmonitorvarioussignalsintheidlemodeandwillshutdownwithanerrorindicationiftheconditionisnotsatisfactory:Errors1,3,4,5,9or12(See6.3Helpcodelist).Asthestartswitchisactivatedandtheunitisbeingpreparedforcutting,additionalconditionsarebeingmoni-tored.Theresultingerrorconditionsareasfollows:Error2,6,8,12,13,14,15,17,18,19or113(See6.3Helpcodelist).

6.0 troubleshooting

30


6.3 help code list

error number displays and their meaning for the epp-360 power supply.

error 1 +/-15%deviationintheidlemodeisexceeded.

error 2 Linevoltageduringcutdropsbymorethan20%.

error 3 Problemwiththebiassuppliesonthecontrolboard.The+15and-15voltsuppliesarenotbalanced,boardshouldbereplaced.

error 4 Thermalswitchhasopened.Unitisdisableduntiloverheatedcomponentcoolsdown.Lookforfansnotworkingorrestrictionsoninputoroutputlouvers.

error 5 ThestartswitchfromtheCNCwasalreadyonwhenthepowersourcewaspoweredup.Unitwillnotbefunctionaluntilstartsignalisremovedandthenreapplied.

error 6 Ignitiondidnottakeplaceduringthe10secondsallowedforarcignition.note:ThisshouldrarelyoccursincetheCNChasamuchshortertimeallowedfortheignitiontimeandwillresetthepowersourcetoidle.

error 7 Notused.

error 8 ElectrodecurrentwaspresentbeforethePWMwasenabled.Mostlikelycausedbyanelectrodetonozzleshortonthetorch.

error 9 Opencircuitvoltageinidlemodewasover40volts.PossiblecauseleakyIGBTs,faultyPWMdrive.

error 10 Opencircuitvoltageisover70voltswhenunitispoweredup.PossiblecauseleakyIGBT’s,faultyPWM.

error 11 Notused.

error 12 Shutdownduetosinglephasing.Fuseblowninsupplylinecircuit.

error 13 Opencircuitvoltagedidnotreach300voltsintheallowedtime.CheckPWMcircuit&E-StoponJ1.

error 14 Ambienttemperatureexceeded55Cincontrolenclosure.

error 15 Busvoltagedidnotreach100voltsduringtheallowedtime.Buschargerelayorsurgelimitingresistorsdefective

error 16 Notused

error 17 IGBTdriverboarderror.

error 18 Cuttingvoltagefellbelow70voltsduringcuttingorbelow40voltsduringmarking.

error 19 Masterisrequestedtoengageslavepowersupplybutslaveisnotpresent.

error 20 OpencircuitvoltagedetectedbeforePWMwasengaged.

error 113 Errordetectedinslavepowersupply.

help codes01LINEVOLT,IDLE 08TORCHERROR 15BUSCHARGERFAILURE

02LINEVOLT,CUTTING 09OCVOVER40V,IDLE 17IGBTDRIVERERROR

03CONTROLBIAS 10OCVOVER70V,STARTUP 18CUT/MARKVOLTAGETOOLOW

04THERMAL(SWITCHOPEN) 121ФOPERATION,SHUTDOWN 19SLAVEP/SNOTDETECTED

05STARTONPOWERUP 13OCVFAILURE 20SHORTEDIGBT,BUSCHARGED

06FAILTOFIRE 14AMBIENTTEMP 113SLAVEP/SERROR

31

6.4 fault isolation

6.4.1 fans not working

problem possible cause action

All3fansdonotrunThisisnormalwhennotcutting.Fans run only when “Contactor On”signalisreceived.

None

1or2fansdonotrun.Broken or disconnected wire in fanmotorcircuit. Repairwire.

Faultyfan(s) Replacefans

6.4.2 torch will not fire


problem possible cause action

MainArcTransfers to theworkwithashort“pop”,placingonlyasmalldimpleinthework.

Remote control removes the startsignal when the main arc transfers tothework.

Panel/Remoteswitchin“Remote”withnoremotecontrolofthecurrent

Place Panel/Remote switch in “Panel”position

Remote current control present butsignalmissing.

Check for current reference signalbetweenJandLon24pinreceptacle-shouldbebetween0.5-10volts(10volts=360amps)

Currentpotsettoolow. Increasecurrentpotsetting.

Arcdoesnotstart.Thereisnoarcatthetorch.OpencircuitvoltageisOK.

Openconnectionbetweenthepowersourcepositiveoutputandthework. Repairconnection

Pilotcurrentand/orstartcurrentshouldbe increased for better starts whenusingconsumablesfor100Aorhigher(Refertoprocessdataincludedintorchmanuals)

Increasepilotcurrent.(Refertoprocessdataincludedintorchmanuals)

FaultyPCB1 ReplacePCB1

32


33

section 7 replacement parts

7.1 General

Alwaysprovidetheserialnumberoftheunitonwhichthepartswillbeused.Theserialnumberisstampedontheunitserialnumberplate.

Toensureproperoperation,itisrecommendedthatonlygenuineESABpartsandproductsbeusedwiththisequipment.Theuseofnon-ESABpartsmayvoidyourwarranty.

ReplacementpartsmaybeorderedfromyourESABDistributor.

Besuretoindicateanyspecialshippinginstructionswhenorderingreplacementparts.

RefertotheCommunicationsGuidelocatedonthebackpageofthismanualforalistofcustomerservicephonenumbers.

7.2 ordering

ItemslistedinthefollowingBillofMaterialsthatdonothaveapartnumbershownarenotavailablefromESABasareplaceableitemandcannotbe

ordered.Descriptionsareshownforreferenceonly.Pleaseuselocalretailhardwareoutletsasasourcefortheseitems.

note

7.0 replacement parts

NoteReplacementParts,SchematicsandWiringDiagramsareprintedon279.4mmx431.8mm(11”x17”)paperandare

includedinsidethebackcoverofthismanual.

epp-360 information

part numberEPP-360,CCC/CE,380/400V,

50/60Hz

0558007831

34

notes

35

revision history

1. Originalrelease-02/2008.2. Revision07/2008-UpdatedwithE-stopinfo.3. Revision09/2008-UpdatedreplacementpartsandBOM.4. Revision04/2009-UpdatedreplacementpartsandBOM.5. Revision06/2010-UpdatedRecommendedinputconductorandlinefusesizes,section3.4.1.6. Revision01/2011-UpdatedRecommendedinputconductorandlinefusesizes,section3.4.1.7. Revision09/2011-updatesperM.Wright’smark-up.

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www.esab.com

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EPP-360 - ESAB equipment... · • Local or remote front panel control • Thermal switch protection for main transformer and power semiconductor components • Top lifting eyes or

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