Professional Documents
Culture Documents
Instruction Manual
0558007676
04/2009
caution
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 before installing or operating 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. 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 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 service facility designated by the manufacturer.
table of contents
Section / Title
Page
1.0
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Safety - English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Safety - Spanish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Safety - French . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.0
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3 Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.0
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3 Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.4 Input Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.5 Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.6 Parallel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.7 Interface Cable Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.0
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1 EPP-360 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.3 Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.4 Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.0
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.0
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.2 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.3 Help Code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.4 Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.0
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.2 Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
table of contents
section 1
safety precautions
section 1
safety precautions
1. Be sure the power source frame (chassis) is connected to the ground system of the input power.
Therefore:
2. Do not operate near degreasing and spraying operations. The heat or arc rays 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 irritation while operating, this is an indication that
ventilation is not adequate. Stop work and take
necessary steps to improve ventilation in the work
area. Do not continue to operate if physical discomfort persists.
section 1
safety precautions
1. Always have qualified personnel perform the installation, 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. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do
not operate any equipment in faulty condition.
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 instructions for mounting regulator to a compressed gas
cylinder.
section 1
safety precautions
secCION 1
sEGURIDAD
secCion 1
sEGURIDAD
3. Los soldadores debern usar los siguientes procedimientos para minimizar exponerse al EMF:
A. Mantenga el electrodo y el cable a la pieza de
trabajo juntos, hasta llegar a la pieza que usted
quiere soldar. Asegrelos 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 a
un slo lado de su cuerpo.
D. Conecte el cable de trabajo a la pieza de trabajo
lo ms cercano posible al rea de la soldadura.
E. Mantenga la fuente de poder y los cables de soldar
lo ms lejos posible de su cuerpo.
HUMO Y GASES -- El humo y los
gases, pueden causar malestar o
dao, particularmente en espacios
sin ventilacin. No inhale el humo
o gases. El gas de proteccin puede
causar falta de oxgeno.
Por lo tanto:
1. Siempre provea ventilacin adecuada en el rea
de trabajo por medio natural o mecnico. No solde,
corte, o ranure materiales con hierro galvanizado,
acero inoxidable, cobre, zinc, plomo, berlio, o cadmio a menos que provea ventilacin mecnica
positiva . No respire los gases producidos por
estos materiales.
2. No opere cerca de lugares donde se aplique substancias qumicas en aerosol. El calor de los rayos
del arco pueden reaccionar con los vapores de
hidrocarburo clorinado para formar un fosfgeno,
o gas txico, y otros irritant es.
3. Si momentneamente desarrolla inrritacin de
ojos, nariz o garganta mientras est operando, es
indicacin de que la ventilacin no es apropiada.
Pare de trabajar y tome las medidas necesarias
para mejorar la ventilacin en el rea de trabajo.
No contine operando si el malestar fsico persiste.
4. Haga referencia a la publicacin ANSI/ASC Standard
Z49.1 (Vea la lista a continuacin) para recomendaciones especficas en la ventilacin.
10
secCion 1
sEGURIDAD
secCion 1
sEGURIDAD
SIGNIFICADO DE LOS sImbolOs
-- Segn usted avanza en la lectura
de este folleto: Los Smbolos Significan Atencin! Est Alerta! Se
trata de su seguridad.
Significa riesgo inmediato que,
de no ser evadido, puede resultar
inmediatamente en serio dao
personal o la muerte.
Significa el riesgo de un peligro
potencial que puede resultar en
serio dao personal o la muerte.
Significa el posible riesgo que
puede resultar en menores daos
a la persona.
12
section 1
sCURIT
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 consquent :
1. loignez suffisamment tous les matriaux combustibles de l'aire de travail et recouvrez les matriaux
avec un revtement protecteur ininflammable. Les
matriaux combustibles incluent le bois, les vtements, la sciure, le gaz et les liquides combustibles,
les solvants, les peintures et les revtements, le
papier, etc.
2. Les tincelles et les projections de mtal incandescent peuvent tomber dans les fissures dans
les planchers ou dans les ouvertures des murs et
dclencher un incendie couvant l'tage infrieur
Assurez-vous que ces ouvertures sont bien protges
des tincelles et du mtal incandescent.
3. N'excutez pas de soudure, de coupe ou autre travail chaud avant d'avoir compltement nettoy la
surface de la pice traiter de faon ce qu'il n'ait
aucune substance prsente qui pourrait produire
des vapeurs inflammables ou toxiques. N'excutez
pas de travail chaud sur des contenants ferms
car ces derniers pourraient exploser.
4. Assurez-vous qu'un quipement d'extinction
d'incendie est disponible et prt 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 excder la capacit de
l'quipement. Par exemple, un cble de soudage
surcharg peut surchauffer et provoquer un incendie.
6. Une fois les oprations termines, inspectez l'aire de
travail pour assurer qu'aucune tincelle ou projection de mtal incandescent ne risque de provoquer
un incendie ultrieurement. Employez des guetteurs
d'incendie au besoin.
7. Pour obtenir des informations supplmentaires,
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.
section 1
sCURIT
section 1
sCURIT
section 1
sCURIT
DANGER
Signifie un danger immdiat. La situation peut
entraner des blessures graves ou mortelles.
AVERTISSEMENT
Signifie un danger potentiel qui peut entraner des
blessures graves ou mortelles.
ATTENTION
Signifie un danger qui peut entraner des blessures
corporelles mineures.
16
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.
EPP-360 460V,
60Hz
EPP-360 575V,
CSA, 60Hz
0558006832
0558006833
Part Number
Voltage
200 VDC
10A to 36A
30A to 360A
72 KW
360 VDC
Voltage (3-phase)
460V
575V
115A RMS
92A RMS
60 HZ
60 HZ
KVA
91.6 KVA
91.6 KVA
Power
82.5 KW
82.5 KW
90.0 %
90.0 %
150A
125A
Frequency
Input
Power Factor
Input Fuse Rec.
17
section 2 description
2.3 Dimensions and Weight
47.25
(1200 mm)
23.75
(603.25 mm)
40.75
(1035 mm)
Weight = 1085 lb
18
section 3 installation
3.1 General
WARNING
3.2 Unpacking
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 cooling efficiency.
caution
Conductive dust and dirt inside power source may cause arc flashover. Equipment damage may occur. Electrical shorting may occur if
dust is allowed to build-up inside power source.
See maintenance section.
19
section 3 installation
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.
WARNING
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.
Amperes
Time delay
Fuse size
(amperes)
460
115
35 (2)*
150
575
92
35 (2)*
125
* 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 current =
NOTICE
20
section 3 installation
3.4.2 Input Conductors
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.
WARNING
Chassis Ground
Primary Terminals
1.
2.
3.
4.
5.
6.
7.
section 3 installation
WARNING
HAVE A QUALIFIED PERSON CHECK THE OUTPUT BUS BARS (POSITIVE AND NEGATIVE) WITH A VOLTMETER.
Note:
22
section 3 installation
Front Access
Panel Opened
23
section 3 installation
3.6 Parallel Installation
Two EPP-360 power sources may be connected together in parallel to extend the output current range.
Primary power source has the electrode (-) conductor jumpered. The supplemental power
source has the work (+) jumpered.
1.
2.
3.
4.
Connect the negative (-) output cables to the arc starter box (high frequency generator).
Connect the positive (+) output cables to the workpiece.
Connect the positive (+) and negative (-) conductors between the power sources.
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.
EPP-360
EPP-360
Supplemental
Power Source
electrode
work
(-)
(+)
Primary Power
Source
work
(+)
pilot arc
electrode
(-)
2 - 4/0 600V
positive leads
to workpiece
24
2 - 4/0 600V
negative leads
in arc starter box
(h.f. generator)
section 3 installation
The EPP-360 does not have an ON/OFF switch. The main power is controlled through the line (wall) disconnect switch.
WARNING
WARNING
EPP-360
Supplemental
Power Source
Primary Power
Source
work
electrode
work
electrode
2 - 4/0 600V
positive leads
to workpiece
Disconnect negative
connection from secondary power source
and insulate to convert from two to one
power source
25
Control cable to
water cooler
2 - 4/0 600V
negative leads
in arc starter box
(h.f. generator)
section 3 installation
3.6.2 Marking with Two Parallel EPP-360s
Two EPP-360s, connected in parallel, and can be used for marking down to 10A and cutting from 30A up to
720A.
26
Coolant Circulator
section 3 installation
3.7.1 CNC Interface Cables with Mating Power Source Connector and
Unterminated CNC Interface
GRN/YEL
RED #4
3.7.2 CNC Interface Cables with Mating Power Source Connectors at Both Ends
GRN/YEL
RED #4
27
section 3 installation
3.7.3 Water Cooler Interface Cables with Mating Power Source Connectors at Both Ends
28
section 4
operation
WARNING
Control
Power
Fuses
460V/575V 3 ~
Input
Soft
Start
Relay
Main
Contactor
Main
Transformer
3~
Rectifier
1~
Control
Transformer
Relay / Interface
Board
3 x 2 Ohm
300 Watt
Resistors
IGBT Driver
Board
Main Control
Board
2 x 6000uf
450V
Capacitors
4 x 400 Amp
IGBTs
Inductor
Front Panel
Display
Output
29
CNC
Interface
&
Isolation
section 4
operation
B
A
C
30
section 4
operation
31
section 4
operation
PA1
off
off
no change
on
off
off
on
on
on
32
section 4
operation
24 CONDUCTOR CABLE
CABLE
WIRE ID
RED 01
15V
15V CNC
COMMON
0 TO 10V
PLASMA START
RED 04
RED 05
RED 06
RED 10
10K
115V AC NEUTRAL
ARC ON
PA CURRENT SELECT
PA CURRENT SELECT
F
G
CNC +15V DC
PLASMA START
20K
10K
PA CURRENT REF
ARC ON
RED 14
Q PA0
RED 15
RED 16
RED 17
FOR LO: Icut = (36) X (Vcut cur ref)
CURRENT HI/LO FOR HI: Icut = (72) X (Vcut cur ref)
CLOSED FOR 720A; OPEN FOR 360A
RED 18
(PARALLEL OPERATION ONLY)
not used
24V AC
K4
E-STOP
E-STOP
20K
PA CURRENT REF
Ipa = (4.5) X (Vpa cur ref) RED 13
MASTER CURRENT
RED 12
RED 03
RED 07
MASTER SELECT - CONNECT H TO R (ALWAYS PRESENT)
RED 08
CNC ANALOG COMMON
WC LEVEL: OFF
RED 09
WITH FAULT
0 TO 10V
RED 19
RED 20
RED 21
PA CURRENT SELECT
not used
GRN/YEL
PA1
10K
RED 23
10K
115V AC H
HI RANGE (720A)
RED 22
PA CURRENT SELECT
10K
10K
10K
24V
PS 24V DC COMMON
HALL TRANSDUCER
33
FUSE
PA ON
115V AC
RED 02
115V AC NEUTRAL
EPP-360
CNC +15V DC
PA ON
CNC
24CONDUCTOR
CONNECTOR
24V DC
COMMON
3A
section 4
operation
The table used to calculate the initial current, pilot current and upslope values are stored in the micro and contains the following information:
Cut Current
(amps)
Start Current
(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
If values other than the table values are used for the cut current, the corresponding values are calculated assuming a linear slope for all the required parameters.
2. Remote Mode 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 reference 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.
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:
PA0
PA1
open
open
10
closed
open
20
open
closed
30
closed
closed
40
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.
34
section 4
operation
35
section 4
operation
36
section 5 maintenance
5.1 General
WARNING
WARNING
caution
Wear approved eye protection with side shields when cleaning the
power source.
Use only low pressure air.
5.2 Cleaning
Regularly scheduled cleaning of the power source is required to help keep the unit running trouble free. The
frequency of cleaning depends on environment and use.
1. Turn power off at wall disconnect.
2. Remove side panels.
3. Use low pressure compressed dry air, remove dust from all air passages and components. Pay particular
attention to heat sinks in the front of the unit. Dust insulates, reducing heat dissipation. Be sure to wear
eye protection.
caution
WARNING
37
section 5 maintenance
38
section 6 TROUBLESHOOTING
WARNING
caution
6.1 Troubleshooting
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 a 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.
39
section 6 TROUBLESHOOTING
6.3 Help Code list
HELP CODES
01 LINE VOLT, IDLE
08 TORCH ERROR
03 CONTROL BIAS
12 1 OPERATION, SHUTDOWN
05 START ON POWER UP
13 OCV FAILURE
06 FAIL TO FIRE
14 AMBIENT TEMP
Error number displays and their meaning for the EPP-360 power supply.
Error 1
Error 2
Error 3
Problem with the bias supplies on the control board. The +15 and -15 volt supplies are not balanced, board
should be replaced.
Error 4
Thermal switch has opened. Unit is disabled until overheated component cools down. Look for fans not
working or restrictions on input or output louvers.
Error 5
The start switch from the CNC was already on when the power source was powered up. Unit will not be
functional until start signal is removed and then reapplied.
Error 6
Ignition did not take place during the 10 seconds allowed for arc ignition.
Note: This should rarely occur since the CNC has a much shorter time allowed for the ignition time and
will reset the power source to idle.
Error 7
Not used.
Error 8
Electrode current was present before the PWM was enabled. Most likely caused by an electrode to nozzle
short on the torch.
Error 9
Open circuit voltage in idle mode was over 40 volts. Possible cause leaky IGBTs, faulty PWM drive.
Error 10
Open circuit voltage is over 70 volts when unit is powered up. Possible cause leaky IGBTs, faulty PWM.
Error 11
Not used.
Error 12
Shut down due to single phasing. Fuse blown in supply line circuit.
Error 13
Open circuit voltage did not reach 300 volts in the allowed time. Check PWM circuit & E-Stop on J1.
Error 14
Error 15
Bus voltage did not reach 100 volts during the allowed time. Bus charge relay or surge limiting resistors
defective
Error 16
Not used
Error 17
Error 18
Cutting voltage fell below 70 volts during cutting or below 40 volts during marking.
Error 19
Master is requested to engage slave power supply but slave is not present.
Error 20
Error 113
40
section 6 TROUBLESHOOTING
6.4 Fault Isolation
6.4.1 Fans Not Working
Problem
All 3 fans do not run
Possible Cause
Action
Replace fans
Possible Cause
Action
Replace PCB1
41
section 6 TROUBLESHOOTING
42
section 7
replacement parts
7.2 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.
EPP-360 Information
Part Number
EPP-360 460V,
60Hz
EPP-360 575V,
CSA, 60Hz
0558006832
0558006833
Note
Items listed in the following Bill of Materials that do not have a part number
shown are not available 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.
Note
Replacement Parts, Schematics and Wiring Diagrams are
printed on 279.4mm x 431.8mm (11 x 17) paper and are
included inside the back cover of this manual.
43
notes
44
revision history
1.
2.
3.
4.
5.
45
B.
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
C.
TECHNICAL SERVICE:
Telephone: (800) ESAB-123/ Fax: (843) 664-4452
Part Numbers
Technical Applications
Specifications
D.
LITERATURE REQUESTS:
Telephone: (843) 664-5562 / Fax: (843) 664-5548
E.
F.
G.
H.
0558007676
04/2009