F-15-108-A May, 1997 ESP-400 CUTTING POWER SOURCE P/N 33518 PANEL REMOTE CURRENT CONTROL MAINTENANCE MANUAL These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for electric welding 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.
USER RESPONSIBILITY This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Defective equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately.
SAFETY PRECAUTIONS WARNING: These Safety Precautions are for your protection. They summarize precautionary information from the references listed in Additional Safety Information section. Before performing any installation or operating procedures, be 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. 5. Do not use equipment beyond its ratings.
FUMES AND GASES -- Fumes and gases, can cause discomfort or harm, particularly in confined spaces. Do not breathe fumes and gases. Shielding gases can cause asphyxiation. Therefore: 2. 3. 1. Always provide adequate ventilation in the work area by natural or mechanical means. Do not weld, cut, or gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead, beryllium, or cadmium unless positive mechanical ventilation is provided. Do not breathe fumes from these materials. 2.
SECTION 2 2.1 DESCRIPTION Introduction The ESP-400 Plasma Power Source is designed for high speed plasma cutting applications. It is normally used with equipment such as the ESAB Smart Plasma System (ESP). For cutting currents beyond the rating of the ESP-400, parallel operation of these units is permissible. It is also possible to operate in parallel (see ref on figure 5-2) with the ULTRA-LIFE 300 or ESP-600 cutting Power Source.
SECTION 2 DESCRIPTION The ESP-400 is powered by a three-phase main transformer which combines with solid state control to provide voltamperes curve output characteristics required for plasma cutting (see figure 2-1). A three-phase full wave SCR and diode bridge rectifier are used to convert the ac output current from the transformer to dc cutting current, and also control the output current through the SCRs.
SECTION 2 DESCRIPTION THE VREF DESIGNATION SHOWN ON THE TYPICAL V/A CURVES (ABOVE) CORRESPONDS TO AN ABSOLUTE VOLTAGE REFERENCE SIGNAL (0 TO 10 VOLT RANGE) FROM THE CNC (CUTTING) CONTROL THAT ESTABLISHES THE PRECISE OUTPUT ARC CURRENT OF THE POWER SOURCE. THESE CURVES ARE DERIVED FROM THE FORMULA I ARC = 50 VREF Figure 2-1. Volt-Ampere Curves 2.5 Power Source Connections A. For operation of two ESP-400 Power Sources in parallel, there is one master power source and one slave power source.
DESCRIPTION SECTION 2 B. For single Power source operation, either the master or the slave unit may be used, provided items 1. through 5. below are addressed. It is not necessary to reconnect the main transformer in the slave unit. Both the standard and alternate configurations work equally well for single power source operation. Implementation of items 4. and 5. below effectively convert the slave power source into a master power source. 1.
DESCRIPTION SECTION 2 TO CHANGE TO 380 V OR 415 V INPUT: On the main transformer (T1) - both master and slave: For 415 V input, move the wire from H4 to H3 for all three coils. For 380 V input, move the wire from H4 to H2 for all three coils. On the control transformer (T2): For 415 V input, move the brown wire on H9 to H6. For 380 V input, move the brown wire on H9 to H5. Figure 2-2.
MAINTENANCE SECTION 3 3.1 General If this equipment does not operate properly, stop work immediately and investigate the cause of the malfunction. Maintenance work must be performed by an experienced person, and electrical work by a trained electrician. Do not permit untrained persons to inspect, clean, or repair this equipment. Use only recommended replacement parts.
SECTION 3 A. MAINTENANCE Visual Analysis For Defective BR/BBR Components. 1. Remove top and left side panels of Power Source. Inspect the 500 A BR fuse links (F3 and F4) mounted in the Main Transformer secondary bus bars to see if they have blown. If not blown, check the 30 A BBR cartridge fuses (F1 and F2) with an ohmmeter to determine if they are open. 2.
SECTION 3 MAINTENANCE determine the specific component. Electrical isolation is accomplished by unbolting the pigtail of the diode being tested. (b) If one or more fuse links (F3/F4) are blown, the diodes must be isolated and checked individually. (c) Ohmmeter check of diodes (group or individual). NOTE Some analog meters and most digital meters will read similarly high both before and after reversing the meter leads when testing good diodes and SCRs. 2.
MAINTENANCE SECTION 3 (c) (d) C. Ohmmeter check of SCRs (group or individual). 1. Place one test probe on the POS heatsink (same as the shunt) and touch the other test probe to each of the SCR's anode heatsinks. The resistance reading across each SCR should be 1000 (1K) ohms or higher. 2. Reverse the test probes and repeat the check. Again, the resistance reading across each SCR should be 1000 (1K) ohms or higher. 3. SCRs are bad if they show no or very low resistance reading in either direction.
MAINTENANCE SECTION 3 (c) D. An SCR is bad if it shows no, or very low resistance, in either direction. Replacing Faulty SCRs and Diodes. 1. Make sure that heatsink mounting surfaces are cleaned before replacing faulty components. 2. For diodes and SCRs, coat mounting surfaces with Alcoa No. 2 EJC Electrical Joint Compound. 3. Clamping procedure for Main Bridge SCRs (4, 5 and 6). 4. (a) Tighten the SCR clamp nuts by hand until fingertight.
SECTION 4 TROUBLESHOOTING 4.1 General DISCONNECT PRIMARY POWER AT WALL SWITCH, OR CIRCUIT BREAKER, BEFORE ATTEMPTING INSPECTION OR WORK INSIDE OF THE POWER SOURCE. If the Power Source is operating improperly, the following troubleshooting information may be used to locate the source of the trouble. Check the problem against the symptoms in the following troubleshooting guide. The remedy for the problem may be quite simple.
TROUBLESHOOTING SECTION 4 D. 2. Faulty SCRs or diodes in Boost Bridge assembly. Check per Section 3, paragraph 3.4, steps A and C. 3. SCR logic board defective. Replace board. No Current Control or Erratic Output Current (O.C.V. is okay). 1. 2. E. F. No current control -- none at all, fixed, or all out. a. Missing power or blown fuse links in Main or Boost Bridges. b. Defective SCR board. c. Defective constant current (CC) board. d.
SECTION 4 D-33071-B 17 TROUBLESHOOTING Figure 4-1.
SECTION 4 D-33072-B 18 TROUBLESHOOTING Figure 4-2.
SECTION 4 D-33072-B 19 TROUBLESHOOTING Figure 4-2.
SECTION 5 5.1 REPLACEMENT PARTS General Replacement Parts are illustrated on the following figures. When ordering replacement parts, order by part number and part name, as illustrated on the figure. DO NOT ORDER BY PART NUMBER ALONE. Always provide the series or serial number of the unit on which the parts will be used. The serial number is stamped on the unit nameplate. Replacement parts may be ordered from your ESAB distributor or from: ESAB Welding and Cutting Products Attn: Customer Service Dept. P.
SECTION 5 1 REPLACEMENT PARTS 2 3 5 4 6, 7, 8 9 10 11 12 PANEL REMOTE 13 CURRENT CONTROL 16 15 14 Figure 5-1. ESP-400 Power Source (Front View) Item No. Qty Req. Part No.
SECTION 5 REPLACEMENT PARTS 1 2 10 9 3 4 C21 C22 5 8 6 7 REF: BLACK JUMPER WIRE DISCONNECTED FROM C22(+) FOR PARALLEL OPERATION. CONNECT BOTH ENDS OF JUMPER WIRE TO C21(-) TO PREVENT LOOSE END FROM TOUCHING OTHER PARTS. RECONNECT ONE END OF WIRE TO C22(+) FOR SINGLE POWER SOURCE OPERATION. Figure 5-2. ESP-400 Power Source (Right Side View) Item No. Qty Req.
SECTION 5 REPLACEMENT PARTS 1, 2 3 REF: PILOT ARC WORK 4 16 REF: NEG OUTPUT TERMINALS 15 REF: WORK/ POS. OUTPUT TERMINALS 14, 13, 12 11 10 9 8, 7 6 5 SEE ITEM 14 FIGURE 5-1 Figure 5-3. ESP-400 Power Source (Left Side View) Item No. Qty Req. 1 2 3 4 5 1 1 1 1 1 2062357 951756 674970 951223 672772 6 7 8 1 1 1 951222 17300020 17280010 9 10 2 1 672577 950228 11 1 1 1 1 1 2 2 677384 2062211 2062334 673676 672330 17300001 17300008 12 13 14 15 16 Part No.
REPLACEMENT PARTS SECTION 5 2 1 3 4 5 14 14 14 7 12 13 11 10 7 9 7 6 Figure 5-4. ESP-400 Power Source (Top View) Item No. Qty Req. Part No.
REPLACEMENT PARTS SECTION 5 1, 2 6 11 (4 places) 10 6 1, 2 3, 4 (3 places) 7 5 (6 places) 8 9 Figure 5-5. ESP-400 Power Source Boost Bridge Rectifier Item No. Qty Req. 1 2 3 4 5 6 7 8 9 10 11 2 2 3 3 6 2 1 3 1 3 4 Part No.
ESAB Welding & Cutting Products, Florence, SC Welding Equipment COMMUNICATIONS GUIDE - CUSTOMER SERVICES A. CUSTOMER SERVICE QUESTIONS: Telephone (803) 664-5540/Fax: (800) 634-7548 Order Entry Product Availability Pricing Hours: 8:30 AM to 5:00 PM EST Order Changes Saleable Goods Returns Delivery Shipping Information B. ENGINEERING SERVICE: Telephone: (803) 664-4416 / Fax : (800) 446-5693 Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM EST Warranty Returns Authorized Repair Stations C.
