ESAB ESP ULTRA-LIFE 300 Cutting Power Source Manual de usuario

Marca: ESAB

Modelo: ESP ULTRA-LIFE 300 Cutting Power Source

Categoría: Sistema de soldadura

Tipo: Manual de usuario

ESP ULTRA-LIFE 300

Cutting Power Source

Instruction Manual

F-15-141-A 03/2005

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

TABLE OF CONTENTS

1.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.1 Safety - English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.2 Safety - Spanish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

1.3 Safety - French . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

2.0 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

2.2 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

2.3 Cool-Down Periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

2.4 Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

2.5 Parallel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

3.0 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

3.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

3.3 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

3.4 Testing and Replacing Bridge Assembly Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

4.0 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.2 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.3 Recommended Fuse and Input Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5.0 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5.2 Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Section / Title Page

TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS

1.0 Safety Precautions

1.1 Safety - English

WARNING: These Safety Precautions are

for your protection. They summarize pre-

cautionary information from the references

listed in Additional Safety Information sec-

tion. 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.

PROTECT YOURSELF AND OTHERS --

Some welding, cutting, and gouging

processes are noisy and require ear

protection. The arc, like the sun, emits

ultraviolet (UV) and other radiation

and can injure skin and eyes. 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. Use a 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 operat

ing or observing operations. Warn bystanders not

to watch the arc and not to 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 protec-

tion against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

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

ﬂames and arcs can start ﬁres. Hot

slag or sparks can also cause ﬁres and

explosions. Therefore:

1. Remove all combustible materials well away from

the work area or cover the materials with a protec

tive 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

crevices in ﬂoors or wall openings and cause a hid-

den smoldering ﬁre or ﬁres on the ﬂoor below. Make

certain that such openings are protected from hot

sparks and metal.“

3. Do not weld, cut or perform other hot work until the

workpiece has been completely cleaned so that there

are no substances on the workpiece 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 ex-

ample, 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 Standard

51B, "Fire Prevention in Use of Cutting and Welding

Processes", available from the National Fire Protec-

tion Association, Batterymarch Park, Quincy, MA

02269.

ELECTRICAL SHOCK -- Contact with

live electrical parts and ground can

cause severe injury or death. DO NOT

use AC welding current in damp areas,

if movement is conﬁned, or if there is

danger of falling.

SECTION 1 SAFETY PRECAUTIONS

1. Be sure the power source frame (chassis) is con-

nected to the ground system of the input power.

2. Connect the workpiece to a good electrical

ground.

3. Connect the work cable to the workpiece. 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. Keep everything dry, including clothing, work

area, 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 Z49.1 (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 cur

rent ﬂowing through any conduc-

tor causes localized Electric and

Magnetic Fields (EMF). Welding and

cutting current creates EMF around welding cables

and welding machines. Therefore:

1. Welders having pacemakers should consult their

physician before welding. EMF may interfere with

some pacemakers.

2. Exposure to EMF may have other health eﬀects which

are unknown.

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. Connect the work cable to the workpiece 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, can cause discomfort or harm,

particularly in conﬁned spaces. Do

not breathe fumes and gases. Shield

ing gases can cause asphyxiation.

Therefore:

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, stain

less steel, copper, zinc, lead, beryllium, or cadmium

unless positive mechanical ventilation is provided.

Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying opera

tions. 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 ir

ritation 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 discom-

fort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)

for speciﬁc ventilation recommendations.

SECTION 1 SAFETY PRECAUTIONS

5. WARNING: This product, when used for welding

or cutting, produces fumes or gases

which contain chemicals known to

the State of California to cause birth

defects and, in some cases, cancer.

(California Health & Safety Code

§25249.5 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. Locate cylinders away from heat, sparks, and ﬂames.

Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-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 or

improperly 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. Maintain cables, 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. Keep all safety 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 equip

ment, ask your supplier for a copy of

"Precautions and Safe Practices for Arc

Welding, Cutting and Gouging", Form

52-529.

The following publications, which are available from

the American Welding Society, 550 N.W. LeJuene Road,

Miami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc

Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc

Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon

Arc Gouging and Cutting"

SECTION 1 SAFETY PRECAUTIONS

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."

MEANING OF SYMBOLS - As used

throughout this manual: Means Atten

tion! Be Alert! Your safety is involved.

Means immediate hazards which,

if not avoided, will result in im-

mediate, serious personal injury

or loss of life.

Means potential hazards which

could result in personal injury or

loss of life.

Means hazards which could result

in minor personal injury.

SECTION 1 SEGURIDAD

1.2 Safety - Spanish

ADVERTENCIA: Estas Precauciones de Se-

guridad son para su protección. Ellas hacen

resumen de información proveniente de las

referencias listadas en la sección "Información Adi

cional Sobre La Seguridad". Antes de hacer cualquier

instalación o procedimiento de operación , asegúrese

de leer y seguir las precauciones de seguridad listadas

a continuación así como también todo manual, hoja

de datos de seguridad del material, calcomanias, etc.

El no observar las Precauciones de Seguridad puede

resultar en daño a la persona o muerte.

PROTEJASE USTED Y A LOS DEMAS--

Algunos procesos de soldadura, corte

y ranurado son ruidosos y requiren

protección para los oídos. El arco,

como el sol , emite rayos ultravioleta

(UV) y otras radiaciones que pueden dañar la piel

y los ojos. El metal caliente causa quemaduras. EL

entrenamiento en el uso propio de los equipos y

sus procesos es esencial para prevenir accidentes.

Por lo tanto:

1. Utilice gafas de seguridad con protección a los lados

siempre que esté en el área de trabajo, aún cuando

esté usando careta de soldar, protector para su cara

u otro tipo de protección.

2. Use una careta que tenga el ﬁltro correcto y lente

para proteger sus ojos, cara, cuello, y oídos de las

chispas y rayos del arco cuando se esté operando y

observando las operaciones. Alerte a todas las per

sonas cercanas de no mirar el arco y no exponerse

a los rayos del arco eléctrico o el metal fundido.

3. Use guantes de cuero a prueba de fuego, camisa

pesada de mangas largas, pantalón 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 metal fundido.

En ocaciones un delantal a prueba de fuego es

necesario para protegerse del calor radiado y las

chispas.

4. Chispas y partículas de metal caliente puede alojarse

en las mangas enrolladas de la camisa , el ruedo del

pantalón o los bolsillos. Mangas y cuellos deberán

mantenerse abotonados, bolsillos al frente de la

camisa deberán ser cerrados o eliminados.

5. Proteja a otras personas de los rayos del arco y chis

pas calientes con una cortina adecuada no-ﬂamable

como división.

6. Use careta protectora además de sus gafas de segu

ridad cuando esté removiendo escoria o puliendo.

La escoria puede estar caliente y desprenderse con

velocidad. Personas cercanas deberán usar gafas

de seguridad y careta protectora.

FUEGO Y EXPLOSIONES -- El calor de

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 área

de trabajo o cubra los materiales con una cobija a

prueba de fuego. Materiales combustibles incluyen

madera, ropa, líquidos y gases ﬂamables, solventes,

pinturas, papel, etc.

2. Chispas y partículas de metal pueden introducirse en

las grietas y agujeros de pisos y paredes causando

fuegos escondidos en otros niveles o espacios.

Asegúrese de que toda grieta y agujero esté cubierto

para proteger lugares adyacentes contra fuegos.

3. No corte, suelde o haga cualquier otro trabajo

relacionado hasta que la pieza de trabajo esté to

talmente limpia y libre de substancias que puedan

producir gases inﬂamables o vapores tóxicos. No

trabaje dentro o fuera de contenedores o tanques

cerrados. Estos pueden explotar si contienen vapores

inﬂamables.

4. Tenga siempre a la mano equipo extintor de fuego

para uso instantáneo, como por ejemplo una

manguera con agua, cubeta con agua, cubeta con

arena, o extintor portátil. Asegúrese que usted esta

entrenado para su uso.

5. No use el equipo fuera de su rango de operación. Por

ejemplo, el calor causado por cable sobrecarga en

los cables de soldar pueden ocasionar un fuego.

6. Después de termirar la operación del equipo, inspec

cione el área de trabajo para cerciorarse de que las

chispas o metal caliente ocasionen un fuego más

tarde. Tenga personal asignado para vigilar si es

necesario.

7. Para información adicional , haga referencia a la

publicación NFPA Standard 51B, "Fire Prevention in

Use of Cutting and Welding Processes", disponible

a través de la National Fire Protection Association,

Batterymarch Park, Quincy, MA 02269.

CHOQUE ELECTRICO -- El contacto

con las partes eléctricas energizadas

y tierra puede causar daño severo o

muerte. NO use soldadura de corri

ente alterna (AC) en áreas húmedas,

de movimiento conﬁnado en lugares estrechos o

si hay posibilidad de caer al suelo.

SECTION 1 SEGURIDAD

1. Asegúrese de que el chasis de la fuente de poder

esté conectado a tierra através del sistema de

electricidad primario.

2. Conecte la pieza de trabajo a un buen sistema de

tierra física.

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 eléctrico fatal.

4. Use el equipo solamente si está en buenas condi-

ciones. Reemplaze cables rotos, dañados o con

conductores expuestos.

5. Mantenga todo seco, incluyendo su ropa, el área de

trabajo, los cables, antorchas, pinza del electrodo,

y la fuente de poder.

6. Asegúrese que todas las partes de su cuerpo están

insuladas de ambos, la pieza de trabajo y tierra.

7. No se pare directamente sobre metal o tierra mien-

tras trabaja en lugares estrechos o áreas húmedas;

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 de energizar

el equipo.

9. Apage el equipo antes de quitarse sus guantes.

10. Use como referencia la publicación ANSI/ASC

Standard Z49.1 (listado en la próxima página) para

recomendaciones especíﬁcas 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

COS - Son peligrosos. La corriente

eléctrica ﬂuye através de cualquier

conductor causando a nivel local

Campos Eléctricos y Magnéticos

(EMF). Las corrientes en el área 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 corazón deberán consultar a su médico antes de

soldar. El Campo Electromagnético (EMF) puede

interferir con algunos marca-pasos.

2. Exponerse a campos electromagnéticos (EMF) puede

causar otros efectos de salud aún desconocidos.

3. Los soldadores deberán 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

quiere soldar. Asegúrelos 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 sólo lado de su cuerpo.

D. Conecte el cable de trabajo a la pieza de trabajo

lo más cercano posible al área de la soldadura.

E. Mantenga la fuente de poder y los cables de soldar

lo más lejos posible de su cuerpo.

HUMO Y GASES -- El humo y los

gases, pueden causar malestar o

daño, particularmente en espacios

sin ventilación. No inhale el humo

o gases. El gas de protección puede

causar falta de oxígeno.

Por lo tanto:

1. Siempre provea ventilación adecuada en el área

de trabajo por medio natural o mecánico. No solde,

corte, o ranure materiales con hierro galvanizado,

acero inoxidable, cobre, zinc, plomo, berílio, o cad

mio a menos que provea ventilación mecánica

positiva . No respire los gases producidos por

estos materiales.

2. No opere cerca de lugares donde se aplique sub-

stancias químicas en aerosol. El calor de los rayos

del arco pueden reaccionar con los vapores de

hidrocarburo clorinado para formar un fosfógeno,

o gas tóxico, y otros irritant es.

3. Si momentáneamente desarrolla inrritación de

ojos, nariz o garganta mientras est á operando, es

indicación de que la ventilación no es apropiada.

Pare de trabajar y tome las medidas necesarias

para mejorar la ventilación en el área de trabajo.

No continúe operando si el malestar físico per-

siste.

4. Haga referencia a la publicación ANSI/ASC Standard

Z49.1 (Vea la lista a continuación) para recomen-

daciones especíﬁcas en la ventilación.

SECTION 1 SEGURIDAD

5. ADVERTENCIA-- Este producto cuando se uti-

liza para soldaduras o cortes,

produce humos o gases, los

cuales contienen químicos

conocidos por el Estado de Cali-

fornia de causar defectos en el

nacimiento, o en algunos casos,

Cancer. (California Health &

Safety Code §25249.5 et seq.)

MANEJO DE CILINDROS-- Los

cilindros, si no son manejados

correctamente, pueden romp

erse y liberar violentamente

gases. Rotura repentina del

cilindro, válvula, o válvula de

escape puede causar daño o

muerte. Por lo tanto:

1. Utilize el gas apropiado para el proceso y utilize

un regulador diseñado para operar y reducir la

presión del cilindro de gas . No utilice adapta-

dores. Mantenga las mangueras y las conexiones

en buenas condiciones. Observe las instrucciones

de operación del manufacturero para montar el

regulador en el cilindro de gas comprimido.

2. Asegure siempre los cilindros en posición vertical

y amárrelos con una correa o cadena adecuada

para asegurar el cilindro al carro, transportes, tab

lilleros, paredes, postes, o armazón. Nunca asegure

los cilindros a la mesa de trabajo o las piezas que

son parte del circuito de soldadura . Este puede ser

parte del circuito elélectrico.

3. Cuando el cilindro no está en uso, mantenga la

válvula del cilindro cerrada. Ponga el capote de

protección sobre la válvula si el regulador no

está conectado. Asegure y mueva los cilindros

utilizando un carro o transporte adecuado. Evite

el manejo brusco de los

MANTENIMIENTO DEL EQUIPO -- Equipo

defectuoso o mal mantenido puede cau-

sar daño o muerte. Por lo tanto:

1. Siempre tenga personal cualiﬁcado para efec-

tuar l a instalación, diagnóstico, y mantenimiento

del equipo. No ejecute ningún trabajo eléctrico a

menos que usted esté cualiﬁcado para hacer el

trabajo.

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, cable a tierra, conexciones,

cable primario, y cualquier otra fuente de poder

en buen estado operacional. No opere ningún

equipo en malas condiciones.

4. No abuse del equipo y sus accesorios. Mantenga

el equipo lejos de cosas que generen calor como

hornos, también lugares húmedos como charcos

de agua , aceite o grasa, atmósferas corrosivas y

las inclemencias del tiempo.

5. Mantenga todos los artículos de seguridad y

coverturas del equipo en su posición y en buenas

condiciones.

6. Use el equipo sólo para el propósito que fue

diseñado. No modiﬁque el equipo en ninguna

manera.

INFORMACION ADICIONAL DE SEGU

RIDAD -- Para más información sobre las

prácticas de seguridad de los equipos de

arco eléctrico para soldar y cortar, pregunte

a su suplidor por una copia de "Precautions

and Safe Practices for Arc Welding, Cutting

and Gouging-Form 52-529.

Las siguientes publicaciones, disponibles através 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 C5.2 - "Recommended Practices for Plasma Arc

Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon

Arc Gouging and Cutting"

SECTION 1 SEGURIDAD

SIGNIFICADO DE LOS SIMBOLOS

-- Según usted avanza en la lectura

de este folleto: Los Símbolos Sig-

niﬁcan ¡Atención! ¡Esté Alerta! Se

trata de su seguridad.

Signiﬁca riesgo inmediato que,

de no ser evadido, puede resultar

inmediatamente en serio daño

personal o la muerte.

Signiﬁca el riesgo de un peligro

potencial que puede resultar en

serio daño personal o la muerte.

Signiﬁca el posible riesgo que

puede resultar en menores daños

a la persona.

SECTION 1 SÉCURITÉ

1.3 Safety - French

INCENDIES ET EXPLOSIONS -- La

chaleur provenant des ﬂammes ou de

l'arc peut provoquer un incendie. Le

laitier incandescent ou les étincelles

peuvent également provoquer un

incendie ou une explosion. Par conséquent :

1. Éloignez suﬃsamment tous les matériaux combus

tibles de l'aire de travail et recouvrez les matériaux

avec un revêtement protecteur ininﬂammable. Les

matériaux combustibles incluent le bois, les vête

ments, la sciure, le gaz et les liquides combustibles,

les solvants, les peintures et les revêtements, le

papier, etc.

2. Les étincelles et les projections de métal incan

descent peuvent tomber dans les ﬁssures dans

les planchers ou dans les ouvertures des murs et

déclencher un incendie couvant à l'étage inférieur

Assurez-vous que ces ouvertures sont bien protégées

des étincelles et du métal incandescent.

3. N'exécutez pas de soudure, de coupe ou autre tra

vail à chaud avant d'avoir complètement nettoyé la

surface de la pièce à traiter de façon à ce qu'il n'ait

aucune substance présente qui pourrait produire

des vapeurs inﬂammables ou toxiques. N'exécutez

pas de travail à chaud sur des contenants fermés

car ces derniers pourraient exploser.

4. Assurez-vous qu'un équipement d'extinction

d'incendie est disponible et prêt à servir, tel qu'un

tuyau d'arrosage, un seau d'eau, un seau de sable

ou un extincteur portatif. Assurez-vous d'être bien

instruit par rapport à l'usage de cet équipement.

5. Assurez-vous de ne pas excéder la capacité de

l'équipement. Par exemple, un câble de soudage

surchargé peut surchauﬀer et provoquer un in

cendie.

6. Une fois les opérations terminées, inspectez l'aire de

travail pour assurer qu'aucune étincelle ou projec

tion de métal incandescent ne risque de provoquer

un incendie ultérieurement. Employez des guetteurs

d'incendie au besoin.

7. Pour obtenir des informations supplémentaires,

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 ÉLECTRIQUE -- Le contact avec

des pièces électriques ou les pièces

de mise à la terre sous tension peut

causer des blessures graves ou mor

telles. NE PAS utiliser un courant de

soudage c.a. dans un endroit humide, en espace

restreint ou si un danger de chute se pose.

AVERTISSEMENT : Ces règles de sécurité

ont pour but d'assurer votre protection. Ils

récapitulent les informations de précaution

provenant des références dans la section

des Informations de sécurité supplémentaires. Avant de

procéder à l'installation ou d'utiliser l'unité, assurez-vous

de lire et de suivre les précautions de sécurité ci-des

sous, dans les manuels, les ﬁches d'information sur la

sécurité du matériel et sur les étiquettes, etc. Tout défaut

d'observer ces précautions de sécurité peut entraîner

des blessures graves ou mortelles.

PROTÉGEZ-VOUS -- Les processus de

soudage, de coupage et de gougeage

produisent un niveau de bruit élevé et

exige l'emploi d'une protection auditive. L'arc, tout

comme le soleil, émet des rayons ultraviolets en plus

d'autre rayons qui peuvent causer des blessures à la

peau et les yeux. Le métal incandescent peut causer

des brûlures. Une formation reliée à l'usage des

processus et de l'équipement est essentielle pour

prévenir les accidents. Par conséquent:

1. Portez des lunettes protectrices munies d'écrans la-

téraux lorsque vous êtes dans l'aire de travail, même

si vous devez porter un casque de soudeur, un écran

facial ou des lunettes étanches.

2. Portez un écran facial muni de verres ﬁltrants et de

plaques protectrices appropriées aﬁn de protéger

vos yeux, votre visage, votre cou et vos oreilles des

étincelles et des rayons de l'arc lors d'une opération

ou lorsque vous observez une opération. Avertissez

les personnes se trouvant à proximité de ne pas re-

garder l'arc et de ne pas s'exposer aux rayons de l'arc

électrique ou le métal incandescent.

3. Portez des gants ignifugiés à crispin, une chemise

épaisse à manches longues, des pantalons sans

rebord et des chaussures montantes aﬁn de vous

protéger des rayons de l'arc, des étincelles et du métal

incandescent, en plus d'un casque de soudeur ou

casquette pour protéger vos cheveux. Il est également

recommandé de porter un tablier ininﬂammable aﬁn

de vous protéger des étincelles et de la chaleur par

rayonnement.

4. Les étincelles et les projections de métal incandescent

risquent de se loger dans les manches retroussées,

les rebords de pantalons ou les poches. Il est recom-

mandé de garder boutonnés le col et les manches et

de porter des vêtements sans poches en avant.

5. Protégez toute personne se trouvant à proximité des

étincelles et des rayons de l'arc à l'aide d'un rideau ou

d'une cloison ininﬂammable.

6. Portez des lunettes étanches par dessus vos lunettes

de sécurité lors des opérations d'écaillage ou de

meulage du laitier. Les écailles de laitier incandescent

peuvent être projetées à des distances considérables.

Les personnes se trouvant à proximité doivent égale-

ment porter des lunettes étanches par dessus leur

lunettes de sécurité.

SECTION 1 SÉCURITÉ

3. Les soudeurs doivent suivre les procédures suivantes

pour minimiser l'exposition aux champs électriques

et magnétiques :

A. Acheminez l'électrode et les câbles de masse

ensemble. Fixez-les à l'aide d'une bande adhésive

lorsque possible.

B. Ne jamais enrouler la torche ou le câble de masse

autour de votre corps.

C. Ne jamais vous placer entre la torche et les câbles

de masse. Acheminez tous les câbles sur le même

côté de votre corps.

D. Branchez le câble de masse à la pièce à traiter le

plus près possible de la section à souder.

E. Veillez à garder la source d'alimentation pour le

soudage et les câbles à une distance appropriée

de votre corps.

LES VAPEURS ET LES GAZ -- peuvent

causer un malaise ou des dommages

corporels, plus particulièrement

dans les espaces restreints. Ne re

spirez pas les vapeurs et les gaz. Le

gaz de protection risque de causer

l'asphyxie. Par conséquent :

1. Assurez en permanence une ventilation adéquate

dans l'aire de travail en maintenant une ventila

tion naturelle ou à l'aide de moyens mécanique.

N'eﬀectuez jamais de travaux de soudage, de coup-

age ou de gougeage sur des matériaux tels que

l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc,

le plomb, le berylliym ou le cadmium en l'absence

de moyens mécaniques de ventilation eﬃcaces. Ne

respirez pas les vapeurs de ces matériaux.

2. N'eﬀectuez jamais de travaux à proximité d'une

opération de dégraissage ou de pulvérisation.

Lorsque la chaleur

ou le rayonnement de l'arc entre en contact avec les

vapeurs d'hydrocarbure chloré, ceci peut déclencher

la formation de phosgène ou d'autres gaz irritants,

tous extrêmement toxiques.

3. Une irritation momentanée des yeux, du nez ou de la

gorge au cours d'une opération indique que la ven

tilation n'est pas adéquate. Cessez votre travail aﬁn

de prendre les mesures nécessaires pour améliorer

la ventilation dans l'aire de travail. Ne poursuivez

pas l'opération si le malaise persiste.

4. Consultez ANSI/ASC Standard Z49.1 (à la page

suivante) pour des recommandations spéciﬁques

concernant la ventilation.

1. Assurez-vous que le châssis de la source

d'alimentation est branché au système de mise à

la terre de l'alimentation d'entrée.

2. Branchez la pièce à traiter à une bonne mise de

terre électrique.

3. Branchez le câble de masse à la pièce à traiter et

assurez une bonne connexion aﬁn d'éviter le risque

de choc électrique mortel.

4. Utilisez toujours un équipement correctement

entretenu. Remplacez les câbles usés ou endom-

magés.

5. Veillez à garder votre environnement sec, incluant

les vêtements, l'aire de travail, les câbles, le porte-

électrode/torche et la source d'alimentation.

6. Assurez-vous que tout votre corps est bien isolé

de la pièce à traiter et des pièces de la mise à la

terre.

7. Si vous devez eﬀectuer votre travail dans un espace

restreint ou humide, ne tenez vous pas directe-

ment sur le métal ou sur la terre; tenez-vous sur

des planches sèches ou une plate-forme isolée et

portez des chaussures à semelles de caoutchouc.

8. Avant de mettre l'équipement sous tension, isolez

vos mains avec des gants secs et sans trous.

9. Mettez l'équipement hors tension avant d'enlever

vos gants.

10. Consultez ANSI/ASC Standard Z49.1 (listé à

la page suivante) pour des recommandations

spéciﬁques concernant les procédures de mise à

la terre. Ne pas confondre le câble de masse avec

le câble de mise à la terre.

CHAMPS ÉLECTRIQUES ET MAGNÉ

TIQUES — comportent un risque

de danger. Le courant électrique

qui passe dans n'importe quel con-

ducteur produit des champs élec-

triques et magnétiques localisés. Le soudage et le

courant de coupage créent des champs électriques

et magnétiques autour des câbles de soudage et

l'équipement. Par conséquent :

1. Un soudeur ayant un stimulateur cardiaque doit

consulter son médecin avant d'entreprendre une

opération de soudage. Les champs électriques et

magnétiques peuvent causer des ennuis pour cer

tains stimulateurs cardiaques.

2. L'exposition à des champs électriques et magné-

tiques peut avoir des eﬀets néfastes inconnus pour

la santé.

SECTION 1 SÉCURITÉ

1. Efforcez-vous de toujours confier les tâches

d'installation, de dépannage et d'entretien à un

personnel qualiﬁé. N'eﬀectuez aucune réparation

électrique à moins d'être qualiﬁé à cet eﬀet.

2. Avant de procéder à une tâche d'entretien à

l'intérieur de la source d'alimentation, débranchez

l'alimentation électrique.

3. Maintenez les câbles, les ﬁls de mise à la terre, les

branchements, le cordon d'alimentation et la source

d'alimentation en bon état. N'utilisez jamais un

équipement s'il présente une défectuosité quel-

conque.

4. N'utilisez pas l'équipement de façon abusive. Gardez

l'équipement à l'écart de toute source de chaleur,

notamment des fours, de l'humidité, des ﬂaques

d'eau, de l'huile ou de la graisse, des atmosphères

corrosives et des intempéries.

5. Laissez en place tous les dispositifs de sécurité et

tous les panneaux de la console et maintenez-les

en bon état.

6. Utilisez l'équipement conformément à son usage

prévu et n'eﬀectuez aucune modiﬁcation.

INFORMATIONS SUPPLÉMENTAIRES RELA

TIVES À LA SÉCURITÉ -- Pour obtenir de

l'information supplémentaire sur les règles

de sécurité à observer pour l'équipement

de soudage à l'arc électrique et le coupage,

demandez un exemplaire du livret "Precau-

tions and Safe Practices for Arc Welding,

Cutting and Gouging", Form 52-529.

Les publications suivantes sont également recomman

dées et mises à votre disposition par l'American Welding

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 C5.2 - "Recommended Practices for Plasma Arc

Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon

Arc Gouging and Cutting"

5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé

dans une opération de soudage ou de

coupage, dégage des vapeurs ou des

gaz contenant des chimiques consi-

déres par l'état de la Californie comme

étant une cause des malformations

congénitales et dans certains cas, du

cancer. (California Health & Safety

Code §25249.5 et seq.)

MANIPULATION DES CYLINDRES --

La manipulation d'un cylindre, sans

observer les précautions nécessaires,

peut produire des fissures et un

échappement dangereux des gaz.

Une brisure soudaine du cylindre, de la soupape ou

du dispositif de surpression peut causer des bles

sures graves ou mortelles. Par conséquent :

1. Utilisez toujours le gaz prévu pour une opération

et le détendeur approprié conçu pour utilisation

sur les cylindres de gaz comprimé. N'utilisez jamais

d'adaptateur. Maintenez en bon état les tuyaux et

les raccords. Observez les instructions d'opération

du fabricant pour assembler le détendeur sur un

cylindre de gaz comprimé.

2. Fixez les cylindres dans une position verticale, à

l'aide d'une chaîne ou une sangle, sur un chariot

manuel, un châssis de roulement, un banc, un mur,

une colonne ou un support convenable. Ne ﬁxez

jamais un cylindre à un poste de travail ou toute autre

dispositif faisant partie d'un circuit électrique.

3. Lorsque les cylindres ne servent pas, gardez les

soupapes fermées. Si le détendeur n'est pas bran-

ché, assurez-vous que le bouchon de protection de

la soupape est bien en place. Fixez et déplacez les

cylindres à l'aide d'un chariot manuel approprié.

Toujours manipuler les cylindres avec soin.

4. Placez les cylindres à une distance appropriée

de toute source de chaleur, des étincelles et des

ﬂammes. Ne jamais amorcer l'arc sur un cylindre.

5. Pour de l'information supplémentaire, consultez

CGA Standard P-1, "Precautions for Safe Handling

of Compressed Gases in Cylinders", mis à votre dis-

position par le Compressed Gas Association, 1235

Jeﬀerson Davis Highway, Arlington, VA 22202.

ENTRETIEN DE L'ÉQUIPEMENT -- Un équipe-

ment entretenu de façon défectueuse ou

inadéquate peut causer des blessures

graves ou mortelles. Par conséquent :

SECTION 1 SÉCURITÉ

SIGNIFICATION DES SYMBOLES

Ce symbole, utilisé partout dans ce manuel,

signiﬁe "Attention" ! Soyez vigilant ! Votre

sécurité est en jeu.

Signiﬁe un danger immédiat. La situation peut

entraîner des blessures graves ou mortelles.

Signiﬁe un danger potentiel qui peut entraîner des

blessures graves ou mortelles.

Signiﬁe un danger qui peut entraîner des blessures

corporelles mineures.

DANGER

AVERTISSEMENT

ATTENTION

SECTION 2 DESCRIPTION

2.1 Introduction

The ESP ULTRA-LIFE 300 Plasma Power Source is designed for high speed plasma cutting applications. It is normally used

with equipment such as the ESAB Smart Plasma 1000 System (ESP). For additional operating data and electrical character-

istics of this machine, refer below to Table 2-1, ESP ULTRA-LIFE 300 Speciﬁcations.

2.2 Description

The ESP ULTRA-LIFE 300 Plasma Power Source is a silicon controlled rectiﬁer (SCR), three-phase transformer/rectiﬁer type dc

unit with solid state circuitry. The unit can be operated from 50 to 300 amperes at duty cycles shown in Table 2-1 above. A

current control Panel-Remote Switch determines the location from which the output current will be regulated: either locally

from the Power Source front panel ("Panel" position) or remotely ("Remote" position) from a precision 0-10 volt reference

(V ref) signal.

The Power Source circuitry receiving the V ref signal is electrically (galvanically) isolated. This means that the common for

this signal may be tied to any voltage less than 150 V ac or dc with respect to earth ground.

The ESP ULTRA-LIFE 300 is powered by two 3-phase main transformers which combine with solid state control to provide

volt-amperes curve output characteristics required for plasma cutting (see Figure 2-1). Two 3-phase full wave SCRs and

two diode bridge rectiﬁers are used to convert the ac output current from the transformers to dc cutting current, and also

control the output current through the SCRs. A network of integrally-mounted capacitors and resistors provide transient

and high frequency voltage protection to the rectiﬁer SCRs and diodes. Protection for main transformer bridge rectiﬁers

and inductors is provided by over-temperature thermal switches which interrupt power in the event of an overheating

condition and automatically reset when the components have cooled to their normal operating temperature. Filtering of

the dc output current is provided by an inductor.

The solid state circuitry of the ESP ULTRA-LIFE 300 produces stable cutting current and eliminates changes in output cur

rent as components heat up and/or if input line voltage changes within ±10% of nominal. This feature ensures consistency

in cutting conditions. The oxygen consumable life is extended by using a ripple cancellation technique. This technique is

achieved by connecting two power sources in parallel in a manner whereby the ripple from one

Rated Output Duty Cycles Power Factor THD* Input**

300 A @ 130 V 100% DUTY 0.81 0.52 460 V @ 80 A

575 V @ 64 A

300 A @ 200 V 60% DUTY 0.88 0.45 575 V @ 86 A

460 V @ 108 A

Output Current Range 50 to 300 Amperes***

Open Circuit Voltage 375 V dc

Dimensions Width

Depth

Height

Weight

44.50 in. (1130.30 mm)

32.00 in. (812.80 mm)

33.00 in. (838.20 mm)

1636 lbs (742.08 kg)

*Total Harmonic Distortion

**60 Hz, 3-phase

***Units manufactured before S/N C94B-46623 have output current range

of 100 to 300 amperes.

TABLE 2-1. SPECIFICATIONS

SECTION 2 DESCRIPTION

power source cancels the ripple from the other. Actual load current and voltage are indicated by an ammeter and voltmeter

mounted on the front panel.

Connections for control functions from the Flow Control assembly are made from a 19-pin plug receptacle on the front

panel. This receptacle provides connection for auxiliary 115 volts out, remote current control.

The Power Source is designed for ease in moving and handling. Suﬃcient clearance and reinforcement at its base permits

lifting with a fork lift truck; or raising with a crane or hoist using the lifting rings in the top cover.

When moving the Power Source, always use both lifting rings in order to keep the

Power Source level, otherwise serious internal damage may occur.

2.3 Cool-Down Periods

There is no cool-down period required for the 130 V/300 A output rating (100% duty). However, the 200 V/300 A output

rating requires a 4-minute cool-down period with fan motor running for every 6-minute application (60% duty).

Output ratings are designed and based on an unobstructed supply of cooling air

ﬂow over internal components. DO NOT USE FILTERS ON THIS UNIT. Periodically

blow out dirt accumulations, using low pressure air.

2.4 Volt-Ampere Curves

The volt-ampere curves show the output voltage available at any given output current for the various current control (or V

ref signals from CNC control) settings. Values for settings other than those shown in ﬁgure 2-1, fall between the Minimum

and Maximum curves shown.

2.5 Parallel Operation

Parallel operation is the use of two Power Sources connected in parallel to provide an extended output current range. In

the case of the Ultra-Life 300, parallel connection provides an output current range from 50-600 A.

In order to avoid confusion between the two Power Sources being connected, the terms Master and Slave will be used.

The Master Power Source is the Ultra-Life 300 to which the Pilot Arc Wire is connected. It is also connected to the front of

the Flow Control by a 19-conductor cable. The Slave Power Source is connected to the back of the Flow Control with a 19-

conductor cable.

A. Parallel Operation for S/Ns before C94B-46623 (100 A Minimum Output)

1. For operation from 100-200 A, use the Master Power Source only. "Pilot Arc Current" switches on both Power Sources

may be in either "LOW" or "HIGH" positions.

2. For operation from 200-600 A, use both Power Sources. The "Pilot Arc Current" switch on the Master Power Source

should be in the "HIGH" position. The Slave Unit's "Pilot Arc Current" switch may be in either position.

B. Parallel Operation for S/N's after C94B-46623 (50 A Minimum Output)

1. For operation from 50-200 A, use the Master Power Source only. The Master's "Output Current Range" switch must

be in the "LOW" position for 50-100 A or the "HIGH" position for the 100-200 A.

2. For operation from 200-600 A, use both Power Sources. The "Output Current Range" switch on both Master and

Slave Power Sources must be in the "HIGH" position.

WHENEVER THE MASTER POWER SOURCE IS USED BY ITSELF IN A PARALLEL INSTALLATION,

THE NEGATIVE OUTPUT FROM THE SLAVE UNIT SHOULD BE DISCONNECTED FROM THE

MASTER. FAILURE TO DISCONNECT WILL MAKE THE SLAVE POWER SOURCE ELECTRICALLY

"HOT" WHEN THE MASTER POWER SOURCE IS ENERGIZED.

Ensure that there is a safe means of disconnecting the Slave Power Source without exposing any electrically "hot" conduc

tors. This can usually be accomplished by disconnecting the negative output cable of the Slave Unit at both ends (at the

Slave Power Source and at the Plumbing Box). Insulate both ends with electrical tape.

THE V

REF

DESIGNATION SHOWN ON THE TYPICAL V/A CURVES (ABOVE) CORRESPONDS TO AN ABSOLUTE

VOLTAGE REFERENCE SIGNAL (0 TO 10 VOLTS RANGE) FROM THE CNC (CUTTING) CONTROL THAT ESTAB-

LISHES THE PRECISE OUTPUT ARC CURRENT OF THE POWER SOURCE. THESE CURVES ARE DERIVED FROM

THE FORMULA I

ARC

= 30V

REF

. WHEN OPERATING TWO POWER SOURCES IN PARALLEL, THE RELATIONSHIP

BECOMES I

ARC

= 60V

REF

Figure 2-1. Volt-Ampere Curves

SECTION 2 DESCRIPTION

SECTION 3 INSTALLATION

3.1 General

If this equipment does not operate properly, stop work immediately and investigate the cause of the malfunction. Main-

tenance 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.

TO PREVENT ACCIDENTAL ELECTRIC SHOCK, BE SURE THAT THE WALL DISCONNECT

SWITCH OR CIRCUIT BREAKER IS OPEN BEFORE ATTEMPTING ANY INSPECTION OR

WORK INSIDE THE POWER SOURCE.

3.2 Cleaning

Since there are no moving parts (other than the fan) in the Power Source, maintenance consists mainly of keeping the interior

of the cabinet clean. Periodically, remove the cover from the cabinet and blow accumulated dust and dirt from the air pas-

sages and the interior components, using clean, dry low pressure air. It is imperative that the air passages to the interior of

the unit be kept free of dirt accumulation to ensure adequate circulation of cooling air, especially over the extrusion ﬁns of

bridge rectiﬁer. This unit is NOT designed to be used with air ﬁlters of any kind. Any obstruction to the free ﬂow of cooling

air may damage the machine and void the warranty. The frequency of cleaning needed depends upon the amount of dirt

that is drawn into the unit.

3.3 Lubrication

Fan motors with oil tubes located on the side of the motor require lubrication after one year of service. Motors without oil

tubes are permanently lubricated and should not require any attention.

3.4 Testing and Replacing Bridge Assembly Components

The silicon diodes and SCRs used in the Power Source are devices which allow current to ﬂow in only one direction. They

block current ﬂow in the other direction. The diodes and SCRs used in this Power Source are designed to provide long

trouble-free operation; however, should a failure occur, they require replacement. The location and replacement parts data

for the diodes and SCRs are shown in ﬁgures 5-1 through 5-4.

If after troubleshooting (see Section 4), the "trouble symptom" appears to be in a bridge network, the following three-part

procedure can be used to determine the faulty component(s): Visual Analysis, Component Group Testing, and Individual

Component/Isolation Testing.

If repair or replacement of bridge components is necessary, removing the bridge assembly is recommended.

Before removing a bridge assembly for servicing, carefully tag (identify) all intercon-

necting wires and bus connections to facilitate proper reinstallation. Also, refer to

the diagrams and illustrations in the back of this book.

A. Visual Analysis For Defective Bridge Components.

1. Remove top, left side, and right side panels of Power Source. Inspect the 150 A bridge fuse links (F1/F2 on the left

- F3/F4 on the right) mounted on the phenolic plates in front of Main Transformers to see if they have blown.

2. If either or both of the fuses protecting its respective bridge assembly are open, it's a sign that one or more of the

diodes or SCRs in that particular bridge may be shorted.

3. Check for cracked or broken ceramic around each diode pigtail of SCR body. If cracked, it's a sign of a shorted diode

or SCR. When the larger diodes or SCRs fail, they most commonly fail shorted.

B. Testing Left and Right Bridge Assemblies.

Each bridge assembly essentially contains three groups of components to be tested. The left side bridge contains Power

Diodes D1, D2, and D3; Freewheeling Diodes D4 and D5; and SCRs 1, 2, and 3. The right side bridge contains Power

Diodes D6, D7, and D8; Freewheeling Diodes D9 and D10; and SCRs 4, 5, and 6. The group testing sequence does not

require electrical isolation; however, to determine the speciﬁc faulty component in a group, some form of isolation may

be required as follows:

1. Checking Power Diode Groups.

(a) If fuse links are not blown, use an ohmmeter set at its lowest resistance scale and check the diode group as

described in step 1.(c). Checking any one diode within the group will determine if the group is good or if a

shorted condition exists. If there is a short, you must electrically isolate to determine the speciﬁc component.

Electrical isolation is accomplished by unbolting the pigtail of the diode being tested.

(b) If one or more fuse links are blown, the diodes must be isolated and checked individually.

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.

1 Place one test probe on NEG heatsink (diode stud) and the other probe to each diode pigtail's SCR

heatsink. Note the resistance readings obtained. All three readings should be similar (high or low).

2 Reverse the test probes and recheck the diodes. Note each resistance reading. All three readings

should be similar; but, opposite of those noted in the ﬁrst reading.

3 Diodes are good if they test high in one direction and low in the opposite direction. Diodes are

bad if the resistance readings are low in both directions. High readings in both directions when using

a digital ohmmeter indicates a good diode.

4 Diodes are bad when they show no, or very low, resistance in both directions indicating they are shorted.

Although it is possible for power rectiﬁer diodes to fail "open", such failures are rare, particularly for

the larger diodes. In the vast majority of cases, a high resistance reading in either or both directions

indicate a good diode.

SECTION 3 INSTALLATION

2. Checking Freewheeling Diodes.

These diodes must be checked in the circuit using the same procedures outlined in steps 1.(a), 1.(b), and 1.(c). If

each diode tests "good", nothing else need be done; however, if a diode tests "bad", you must disconnect its pigtail

and retest it for veriﬁcation.

3. Checking SCR Groups.

NOTE

Before proceeding with the following SCR tests, all diodes should have been checked

and defective (shorted) diodes electrically isolated.

(a) If fuse links are not blown and are still connected to the bridge heatsink, used an ohmmeter set to its lowest

resistance scale and check the SCR group as described in step 3.(c). Checking any one SCR within the group

will determine if the group is good or if a shorted condition exists. If there is a short, you must electrically

isolate to determine the speciﬁc faulty component, see step 3.(d).

(b) If one or more fuse links are blown, the SCRs must be isolated and checked individually. Refer to step 3.(d).

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.

(d) If the diagnosis indicates a defective SCR within the group, you must disconnect the fuses to electrically isolate

the SCRs (assuming all diodes have checked good, or defective diodes previously isolated), and repeat the

ohmmeter tests in steps

1, 2, and 3 above for each SCR.

D. 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. Torque procedure for SCRs and diodes.

Use a torque wrench to tighten stud mounted SCRs and diodes. Recommended torques are listed in table 3-1.

SECTION 3 INSTALLATION

Table 3-1. Recommended Torques

Diodes

Min., 20 in-lbs (1.7 ft•lbs)

Max., 30 in-lbs (2.5 ft•lbs)

SCRs

Min., 125 in-lbs (10.4 ft•lbs)

Max., 150 in-lbs (12.5 ft•lbs)

SECTION 3 INSTALLATION

SECTION 4 OPERATION

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. If the cause cannot be quickly located, open up the unit and perform a simple visual inspection of all the components

and wiring. Check for proper terminal connections, loose or burned wiring or components, blown fuses, bulged or leaking

capacitors, or any other sign of damage or discoloration.

4.2 Troubleshooting Guide

A. Fan Not Running.

1. No input power. Check main line (customer's) switch fuses.

2. Defective control transformer. Check for continuity.

3. Fan motor defective. Check motor and leads, and replace if necessary.

B. No Output.

1. No incoming three-phase power. Wall disconnect switch may be open, or fuse(s) blown.

2. Poor connections at output terminals. Tighten or replace connections.

3. Main contactor (K1) will not energize.

a. Thermal overload device(s) tripped. Check left and right thermal overload lights on front panel.

b. Missing "start" signal.

c. Defective AMC or Main Contactor (K1).

C. No Current Control or Erratic Output Current.

1. No current control.

a. Missing power or blown fuse links in bridge assemblies.

b. Defective SCR board (PCB1 - left side, PCB3 - right side).

c. Defective constant current (CC) board (PCB2).

2. Pilot arc without transfer (pops then goes out).

SECTION 4 OPERATION

a. Missing Vref signal from remote source. Check voltage from pins P1-2 to P1-1 on CC board for Vref signal.

Put switch in "Panel" position and use panel control.

b. Missing "current control" signal to SCR boards (defective CC board). Check "current control" signal at pins

P1-2 and P2-8 on SCR boards.

c. Pilot arc fuse(s) (F5/F6) blown.

3. If current remains ﬁxed at approximately 300 amperes (in Panel position), the bottom of the current control poten

tiometer (R50) may not be connected. This applies +10 volts straight into CC board. Check remote control switch

(SW1) for continuity and proper common connection.

4. Current control to 175 A only.

a. Current Range Switch in "LOW" position. Put switch in "HIGH" position.

b. Left or right side power source not operating. Measure signal (mV) from left and right SCR boards at P1-10

and P1-11.

c. Defective left or right side bridge assemblies or bridge fuses.

d. Defective SCR board (PCB1 - left side, PCB3 - right side).

5. Erratic current control.

a. Defective current control potentiometer (R50) (panel and/or remote location).

b. Defective remote control switch (SW1). Check continuity.

c. Defective SCR board (PCB1 - left side, PCB3 - right side).

d. Defective CC board (PCB2).

D. Short (Torch) Tip Life -- Double Arcing.

1. Defective SCR board (PCB1 - left side, PCB3 - right side).

2. Defective CC board (PCB2).

3. Defective SCR in bridge assemblies.

4. Excessive ripple voltage. Measure ripple voltage with a true RMS AC voltmeter at output of machine. It should

read less than 2 V ac RMS with system operating at 260 A/130 V with 0.5 ohm resistive load. Actual waveform can

be measured with an oscilloscope on the CC board (refer to Figures 4-1 and 4-2).

5. Faulty Pilot Arc Connection at Power Source (refer to Figure 5-2).

6. Faulty Pilot Arc Connection at plumbing box (refer to ESP manual).

SECTION 4 OPERATION

Figure 4-1. ESP ULTRA-LIFE 300 CC Board Test Points

for Measuring Output Current

Oscilloscope must be isolated from ground when taking measurement.

TEST POINT

(NEG)

TEST POINT

(POS)

SECTION 4 OPERATION

Must not overshoot output current

80 ms/DIV

NOTE: Oscilloscope set at 2 V/DIV (60 A/DIV).

Figure 4-2. ESP ULTRA-LIFE 300 Load Bank Start and Output

Current Waveform

4.3 Recommended Fuse and Input Cable Sizes

Rated Output

Rated Input

Input &

Ground

Conductor*

CU/AWG

Time-Delay

or Slow Blow

Fuse Size

Amps**

Voltage Frequency Amperes

300 A @ 200 V 460 V 60 Hz 108 2 125

300 A @ 200 V 575 V 60 Hz 86 3 100

* Sized per National Electric code for 75 °C rated copper conductors @ 30 °C ambient. Not more than three

conductors in raceway or cable. Local codes should be followed if they specify sizes others than those listed

above.

** Selection of adequate fuses or circuit breakers for this unit is critical because the in-rush current for large

magnetic components like the main transformers is several times greater than its steady state full load

current draw. We therefore recommend using only slow blowing or time-delay fuses that are sized in

accordance with the table recommendations. If a breaker is used, it should be of the slow tripping variety.

Thermally activated breakers are preferable to magnetically activated breakers.

Figure 4-5. SCR Board (PCB1, 3) Component Layout

SECTION 4 OPERATION

Figure 4-6. Constant Current Board (PCB2) Component Layout

SECTION 4 OPERATION

Figure 4-7. Filter Board (PCB4, 5) Component Layout

SECTION 4 OPERATION

Figure 4-8. ESP ULTRA-LIFE 300 Left Terminal Board (TB1)

SECTION 4 OPERATION

TB2 IS NOT MODIFIED FOR VOLTAGE CHANGEOVER

Figure 4-9. ESP ULTRA-LIFE 300 Right Terminal Board (TB2)

SECTION 4 OPERATION

NOTE:

Schematics and Wiring Diagrams on 11” x 17”

paper are included

inside the back cover of this manual.

SECTION 5 REPLACEMENT PARTS

5.1 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.

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.

5.2 Ordering

Bill of material items that have blank part numbers are provided for customer information only.

Hardware items should be available through local sources.

Note

5.0 Replacement Parts

Figure 5-1. ESP ULTRA-LIFE 300 Power Source (Front View)

118,9,106

5743

SECTION 5 REPLACEMENT PARTS

1 1 2062290 VOLTMETER, DC, 500 V VM

2 1 647288 AMMETER, DC, 300 A AM

3 1 33997 PANE, TOP

4 1 672508 SWITCH, TOGGLE, 3PST S1

5 1 598227 LIGHT, PILOT PL2, 3

6 1 634716 LIGHT, PILOT PL1

7 1 950122 CIRCUIT BREAKER, 10 A CB1

8 1 2062170 KNOB

9 1 673999 SHAFT, LOCK

10 1 950715 POTENTIOMETER, CURRENT CONT. R50

11 1 634518 SWITCH, TOGGLE, DPDT S5

12 1 1006733 CONNECTOR, 19-PIN, AMPHENOL J1

13 1 33995 PANEL, SIDE, RIGHT

14 1 33996 PANEL, SIDE, LEFT

Item No. Qty Req. Part No. Description Circuit Symbol

Figure 5-2. ESP ULTRA-LIFE 300 Power Source (Left Side View)

REF: PILOT ARC

CONNECTION

SECTION 5 REPLACEMENT PARTS

Item

No.

Qty

Req.

Part

No.

Description

Ckt.

Symbol

33993

674970

17300016

17300008

677329

30833

33998

32091

33994

951491

672772

30855

PANEL, FRONT

P.C. BD. ASSEMBLY, FILTER

RESISTOR, 16 OHM, 300 W

RESISTOR, 8 OHM, 300 W

BOARD, TERMINAL

TRANSFORMER, MAIN (LEFT)

BAIL ASSEMBLY

BOARD, TERMINAL (LEFT)

PANEL, REAR

CONTACTOR, MAIN, 120 V, 90 A

CAPACITOR, 10 µF @ 370 WVDC

INDUCTOR

PCB4, 5

R38

R39-41

TB3

TB1

Figure 5-3. ESP ULTRA-LIFE 300 Power Source (Left Side Top View)

SECTION 5 REPLACEMENT PARTS

1 8 17280010 RESISTOR, 10 OHM, 100 W R19-24, R33-34

2 8 672772 CAPACITOR, 10 µF @ 370 WVDC C25-32

3 1 950826 BLOCK, TERMINAL (5 POINT) TB6

4 1 17280010 RESISTOR, 10 OHM, 100 W R35

Item No. Qty Req. Part No. Description Circuit Symbol

Figure 5-4. ESP ULTRA-LIFE 300 Power Source (Right Side View)

SECTION 5 REPLACEMENT PARTS

Item No. Qty Req. Part No. Description Circuit Symbol

1 1 30855 INDUCTOR L2

2 1 34005 TRANSFORMER, MAIN (RIGHT) T2

3 1 677384 TRANSFORMER, CONTROL T3

4 4 17300008 RESISTOR, 8 OHM, 300 W R42-45

Figure 5-5. ESP ULTRA-LIFE 300 Power Source (Top View)

SECTION 5 REPLACEMENT PARTS

Item

No.

Qty

Req.

Part

No.

Description

Ckt.

Symbol

676453

672330

673676

2062334

680912

635568

2080196

635568

672772

950116

951275

31444

993539

31492

SEAL, WEATHERSTRIP

SHROUD, FAN

BLADE, FAN

MOTOR, FAN

BOARD, TERMINAL (RIGHT)

BLOCK, TERMINAL

CONTACTOR (AUX) RELAY, 3PDT

BLOCK, TERMINAL (8 POINT)

CAPACITOR, 10 µF @ 370 WVDC

FILTER, 2 A

FILTER, 10 A

P.C. BD. ASSEMBLY, S.C.R.

CAPACITOR, ALLUM., 1500 µF, 50 V

P.C. BD. ASSEMBLY, CONST.

CURRENT

M1, M2

TB2

TB4

TB5

C46

FN2

FN4

PCB1, 3

C36, 37

PCB 2

Figure 5-6. ESP ULTRA-LIFE 300 Power Source (Top View Cutaway)

11, 12

8, 9

SECTION 5 REPLACEMENT PARTS

1 2 674969 FILTER, P.C. BD. ASSEMBLY FN1, 2

2 1 17280110 RESISTOR, 100K OHM, 110 W R49

3 5 951312 CAPACITOR, ALUM., 1300 µF, 450 V C33,34,47-49

4 2 17280210 RESISTOR, 1K OHM, 100 W R57,58

5 1 950255 CAPACITOR, 60 µF, 370 V AC C35

6 1 673458 CONTACTOR, PILOT ARC K2

7 1 672772 CAPACITOR, 10 µF @ 370 WVDC C44

8 2 639514 FUSE BLOCK

9 2 951527 FUSE, 15 A F5, 6

10 1 17250230 RESISTOR, 3K OHM, 50 W R46

11 1 950627 CAPACITOR, 4200 µF, 350 V C50

12 1 17315247 RESISTOR, 4.7K OHMS, 12 W R59

Item No. Qty Req. Part No. Description Circuit Symbol

NOTES

Figure 4-3. ESP ULTRA-LIFE

300 Power Source Schematic

Diagram (Sheet 1 of 8)

APPLIES TO S/N's BEFORE C94B-46623

LEFT SIDE (except where noted)

ESP ULTRA-LIFE 300 Power Source

Figure 4-3. ESP ULTRA-LIFE

300 Power Source Schematic

Diagram (Sheet 2 of 8)

APPLIES TO S/N's AFTER C94B-46623

LEFT SIDE (except where noted)

ESP ULTRA-LIFE 300 Power Source

Figure 4-3. ESP ULTRA-LIFE

300 Power Source Schematic

Diagram (Sheet 3 of 8)

APPLIES TO S/N's BEFORE C94B-46623

RIGHT SIDE

ESP ULTRA-LIFE 300 Power Source

Figure 4-3. ESP ULTRA-LIFE

300 Power Source Schematic

Diagram (Sheet 4 of 8)

APPLIES TO S/N's AFTER C94B-46623

RIGHT SIDE

ESP ULTRA-LIFE 300 Power Source

Figure 4-3. ESP ULTRA-LIFE

300 Power Source Schematic

Diagram (Sheet 5 of 8)

LEFT MAIN TRANSFORMER (T1)

ESP ULTRA-LIFE 300 Power Source

Figure 4-3. ESP ULTRA-LIFE

300 Power Source Schematic

Diagram (Sheet 6 of 8)

RIGHT MAIN TRANSFORMER (T2)

ESP ULTRA-LIFE 300 Power Source

Figure 4-3. ESP ULTRA-LIFE

300 Power Source Schematic

Diagram (Sheet 7 of 8)

SCR BOARD (PCB1, 3)

ESP ULTRA-LIFE 300 Power Source

Figure 4-3. ESP ULTRA-LIFE

300 Power Source Schematic

Diagram (Sheet 8 of 8)

CONSTANT CURRENT BOARD (PCB2)

ESP ULTRA-LIFE 300 Power Source

Figure 4-4. ESP ULTRA-LIFE

300 Power Source Wiring

Diagram (Sheet 1 of 6)

APPLIES TO S/N's BEFORE C94B-46623

ESP ULTRA-LIFE 300 Power Source

Figure 4-4. ESP ULTRA-LIFE

300 Power Source Wiring

Diagram (Sheet 2 of 6)

APPLIES TO S/N's AFTER C94B-46623

ESP ULTRA-LIFE 300 Power Source

Figure 4-4. ESP ULTRA-LIFE

300 Power Source Wiring

Diagram (Sheet 3 of 6)

APPLIES TO S/N's BEFORE C94B-46623

ESP ULTRA-LIFE 300 Power Source

Figure 4-4. ESP ULTRA-LIFE

300 Power Source Wiring

Diagram (Sheet 4 of 6)

APPLIES TO S/N's AFTER C94B-46623

ESP ULTRA-LIFE 300 Power Source

Figure 4-4. ESP ULTRA-LIFE

300 Power Source Wiring

Diagram (Sheet 5 of 6)

APPLIES TO S/N's BEFORE C94B-46623

ESP ULTRA-LIFE 300 Power Source

Figure 4-4. ESP ULTRA-LIFE

300 Power Source Wiring

Diagram (Sheet 6 of 6)

APPLIES TO S/N's AFTER C94B-46623

FILTER BOARD DETAIL

REVISION HISTORY

Revision 09/2004 - Updated Figure 5-6, Section 5 - Replacement Parts, item 4 deleted “DC” & reformat-

ted descriptions.

Revision 03/2005 - updated format with TOC, correct page # layout, and moved schematics to 11 x 17

format.

F15-141-A 03/2005

A. 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

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 Hours: 8:00 AM to 5:00 PM EST

Part Numbers Technical Applications Speciﬁcations Equipment Recommendations

D. LITERATURE REQUESTS:

Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS:

Telephone: (843) 664-4487 / Fax: (843) 664-5557 Hours: 7:30 AM to 3:30 PM EST

Repair Estimates Repair Status

F. 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

G. WELDING PROCESS ASSISTANCE:

Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST

H. 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

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 & Support

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

Transcripción de documentos

ESP ULTRA-LIFE 300 Cutting Power Source Instruction Manual F-15-141-A 03/2005 BE SURE THIS INFORMATION REACHES THE OPERATOR. YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER. 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. 2 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 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 2.3 Cool-Down Periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 2.4 Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 2.5 Parallel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 3.0 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 3.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 3.3 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 3.4 Testing and Replacing Bridge Assembly Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 4.0 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 Recommended Fuse and Input Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 5.2 Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 3 25 25 25 25 TABLE OF CONTENTS 4 SECTION 1 1.0 SAFETY PRECAUTIONS Safety Precautions 1.1 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. Safety - English FIRES AND EXPLOSIONS -- Heat from ﬂames and arcs can start ﬁres. Hot slag or sparks can also cause ﬁres and explosions. Therefore: 1. Remove all combustible materials well away from the work area or cover the materials with a protective 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 crevices in ﬂoors or wall openings and cause a hidden smoldering ﬁre or ﬁres on the ﬂoor below. Make certain that such openings are protected from hot sparks and metal.“ 3. Do not weld, cut or perform other hot work until the workpiece has been completely cleaned so that there are no substances on the workpiece 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 Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. PROTECT YOURSELF AND OTHERS -Some welding, cutting, and gouging processes are noisy and require ear protection. The arc, like the sun, emits ultraviolet (UV) and other radiation and can injure skin and eyes. 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. Use a 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 operating or observing operations. Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric-arc or hot metal. 3. Wear ﬂameproof gauntlet type gloves, heavy longsleeve 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. Hot sparks or metal can lodge in rolled up sleeves, 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. ELECTRICAL SHOCK -- Contact with live electrical parts and ground can cause severe injury or death. DO NOT use AC welding current in damp areas, if movement is conﬁned, or if there is danger of falling. 5 SECTION 1 SAFETY PRECAUTIONS 1. Be sure the power source frame (chassis) is connected to the ground system of the input power. 3. Welders should use the following procedures to minimize exposure to EMF: 2. Connect the workpiece to a good electrical ground. A. Route the electrode and work cables together. Secure them with tape when possible. 3. Connect the work cable to the workpiece. A poor or missing connection can expose you or others to a fatal shock. 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. 4. Use well-maintained equipment. Replace worn or damaged cables. D. Connect the work cable to the workpiece as close as possible to the area being welded. 5. Keep everything dry, including clothing, work area, cables, torch/electrode holder, and power source. E. Keep welding power source and cables as far away from your body as possible. 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. 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. 8. Put on dry, hole-free gloves before turning on the power. Therefore: 9. Turn oﬀ the power before removing your gloves. 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. 10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for speciﬁc grounding recommendations. Do not mistake the work lead for a ground cable. 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. ELECTRIC AND MAGNETIC FIELDS — May be dangerous. Electric current ﬂowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding and cutting current creates EMF around welding cables and welding machines. Therefore: 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. 1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers. 4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for speciﬁc ventilation recommendations. 2. Exposure to EMF may have other health eﬀects which are unknown. 6 SECTION 1 SAFETY PRECAUTIONS 5. WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code §25249.5 et seq.) 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. CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release gas. Sudden rupture of cylinder, valve, or relief device can injure or kill. Therefore: 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. 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. 5. Keep all safety 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. 2. Always secure cylinders in an upright position by chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure cylinders to work tables or ﬁxtures where they may become part of an electrical circuit. 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 Welding, Cutting and Gouging", Form 52-529. 3. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable hand trucks. Avoid rough handling of cylinders. 4. Locate cylinders away from heat, sparks, and ﬂames. Never strike an arc on a cylinder. The following publications, which are available from the American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are recommended to you: 5. For additional information, refer to CGA Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", which is available from Compressed Gas Association, 1235 Jeﬀerson Davis Highway, Arlington, VA 22202. 1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting" 2. AWS C5.1 - "Recommended Practices for Plasma Arc Welding" 3. AWS C5.2 - "Recommended Practices for Plasma Arc Cutting" EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death. Therefore: 4. AWS C5.3 - "Recommended Practices for Air Carbon Arc Gouging and Cutting" 7 SECTION 1 SAFETY PRECAUTIONS 5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding“ 6. AWS C5.6 - "Recommended Practices for Gas Metal Arc Welding"“ 7. AWS SP - "Safe Practices" - Reprint, Welding Handbook. 8. ANSI/AWS F4.1, "Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances." MEANING OF SYMBOLS - As used throughout this manual: Means Attention! Be Alert! Your safety is involved. Means immediate hazards which, if not avoided, will result in immediate, serious personal injury or loss of life. Means potential hazards which could result in personal injury or loss of life. Means hazards which could result in minor personal injury. 8 SECTION 1 1.2 SEGURIDAD Safety - Spanish La escoria puede estar caliente y desprenderse con velocidad. Personas cercanas deberán usar gafas de seguridad y careta protectora. ADVERTENCIA: Estas Precauciones de Seguridad son para su protección. Ellas hacen resumen de información proveniente de las referencias listadas en la sección "Información Adicional Sobre La Seguridad". Antes de hacer cualquier instalación o procedimiento de operación , asegúrese de leer y seguir las precauciones de seguridad listadas a continuación así como también todo manual, hoja de datos de seguridad del material, calcomanias, etc. El no observar las Precauciones de Seguridad puede resultar en daño a la persona o muerte. FUEGO Y EXPLOSIONES -- El calor de 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 área de trabajo o cubra los materiales con una cobija a prueba de fuego. Materiales combustibles incluyen madera, ropa, líquidos y gases ﬂamables, solventes, pinturas, papel, etc. 2. Chispas y partículas de metal pueden introducirse en las grietas y agujeros de pisos y paredes causando fuegos escondidos en otros niveles o espacios. Asegúrese de que toda grieta y agujero esté cubierto para proteger lugares adyacentes contra fuegos. 3. No corte, suelde o haga cualquier otro trabajo relacionado hasta que la pieza de trabajo esté totalmente limpia y libre de substancias que puedan producir gases inﬂamables o vapores tóxicos. No trabaje dentro o fuera de contenedores o tanques cerrados. Estos pueden explotar si contienen vapores inﬂamables. 4. Tenga siempre a la mano equipo extintor de fuego para uso instantáneo, como por ejemplo una manguera con agua, cubeta con agua, cubeta con arena, o extintor portátil. Asegúrese que usted esta entrenado para su uso. 5. No use el equipo fuera de su rango de operación. Por ejemplo, el calor causado por cable sobrecarga en los cables de soldar pueden ocasionar un fuego. 6. Después de termirar la operación del equipo, inspeccione el área de trabajo para cerciorarse de que las chispas o metal caliente ocasionen un fuego más tarde. Tenga personal asignado para vigilar si es necesario. 7. Para información adicional , haga referencia a la publicación NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", disponible a través de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. PROTEJASE USTED Y A LOS DEMAS-Algunos procesos de soldadura, corte y ranurado son ruidosos y requiren protección para los oídos. El arco, como el sol , emite rayos ultravioleta (UV) y otras radiaciones que pueden dañar la piel y los ojos. El metal caliente causa quemaduras. EL entrenamiento en el uso propio de los equipos y sus procesos es esencial para prevenir accidentes. Por lo tanto: 1. Utilice gafas de seguridad con protección a los lados siempre que esté en el área de trabajo, aún cuando esté usando careta de soldar, protector para su cara u otro tipo de protección. 2. Use una careta que tenga el ﬁltro correcto y lente para proteger sus ojos, cara, cuello, y oídos de las chispas y rayos del arco cuando se esté operando y observando las operaciones. Alerte a todas las personas cercanas de no mirar el arco y no exponerse a los rayos del arco eléctrico o el metal fundido. 3. Use guantes de cuero a prueba de fuego, camisa pesada de mangas largas, pantalón 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 metal fundido. En ocaciones un delantal a prueba de fuego es necesario para protegerse del calor radiado y las chispas. 4. Chispas y partículas de metal caliente puede alojarse en las mangas enrolladas de la camisa , el ruedo del pantalón o los bolsillos. Mangas y cuellos deberán mantenerse abotonados, bolsillos al frente de la camisa deberán ser cerrados o eliminados. 5. Proteja a otras personas de los rayos del arco y chispas calientes con una cortina adecuada no-ﬂamable como división. 6. Use careta protectora además de sus gafas de seguridad cuando esté removiendo escoria o puliendo. 9 CHOQUE ELECTRICO -- El contacto con las partes eléctricas energizadas y tierra puede causar daño severo o muerte. NO use soldadura de corriente alterna (AC) en áreas húmedas, de movimiento conﬁnado en lugares estrechos o si hay posibilidad de caer al suelo. SECTION 1 SEGURIDAD 1. Asegúrese de que el chasis de la fuente de poder esté conectado a tierra através del sistema de electricidad primario. 2. Conecte la pieza de trabajo a un buen sistema de tierra física. 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 eléctrico fatal. 4. Use el equipo solamente si está en buenas condiciones. Reemplaze cables rotos, dañados o con conductores expuestos. 5. Mantenga todo seco, incluyendo su ropa, el área de trabajo, los cables, antorchas, pinza del electrodo, y la fuente de poder. 6. Asegúrese que todas las partes de su cuerpo están insuladas de ambos, la pieza de trabajo y tierra. 7. No se pare directamente sobre metal o tierra mientras trabaja en lugares estrechos o áreas húmedas; 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 de energizar el equipo. 9. Apage el equipo antes de quitarse sus guantes. 10. Use como referencia la publicación ANSI/ASC Standard Z49.1 (listado en la próxima página) para recomendaciones especíﬁcas de como conectar el equipo a tierra. No confunda el cable de soldar a la pieza de trabajo con el cable a tierra. 3. Los soldadores deberán 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. Asegúrelos 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 sólo lado de su cuerpo. D. Conecte el cable de trabajo a la pieza de trabajo lo más cercano posible al área de la soldadura. E. Mantenga la fuente de poder y los cables de soldar lo más lejos posible de su cuerpo. HUMO Y GASES -- El humo y los gases, pueden causar malestar o daño, particularmente en espacios sin ventilación. No inhale el humo o gases. El gas de protección puede causar falta de oxígeno. Por lo tanto: 1. Siempre provea ventilación adecuada en el área de trabajo por medio natural o mecánico. No solde, corte, o ranure materiales con hierro galvanizado, acero inoxidable, cobre, zinc, plomo, berílio, o cadmio a menos que provea ventilación mecánica positiva . No respire los gases producidos por estos materiales. 2. No opere cerca de lugares donde se aplique substancias químicas en aerosol. El calor de los rayos del arco pueden reaccionar con los vapores de hidrocarburo clorinado para formar un fosfógeno, o gas tóxico, y otros irritant es. 3. Si momentáneamente desarrolla inrritación de ojos, nariz o garganta mientras est á operando, es indicación de que la ventilación no es apropiada. Pare de trabajar y tome las medidas necesarias para mejorar la ventilación en el área de trabajo. No continúe operando si el malestar físico persiste. 4. Haga referencia a la publicación ANSI/ASC Standard Z49.1 (Vea la lista a continuación) para recomendaciones especíﬁcas en la ventilación. CAMPOS ELECTRICOS Y MAGNETICOS - Son peligrosos. La corriente eléctrica ﬂuye através de cualquier conductor causando a nivel local Campos Eléctricos y Magnéticos (EMF). Las corrientes en el área 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 corazón deberán consultar a su médico antes de soldar. El Campo Electromagnético (EMF) puede interferir con algunos marca-pasos. 2. Exponerse a campos electromagnéticos (EMF) puede causar otros efectos de salud aún desconocidos. 10 SECTION 1 SEGURIDAD 5. ADVERTENCIA-- Este producto cuando se utiliza para soldaduras o cortes, produce humos o gases, los cuales contienen químicos conocidos por el Estado de California de causar defectos en el nacimiento, o en algunos casos, Cancer. (California Health & Safety Code §25249.5 et seq.) 1. Siempre tenga personal cualiﬁcado para efectuar l a instalación, diagnóstico, y mantenimiento del equipo. No ejecute ningún trabajo eléctrico a menos que usted esté cualiﬁcado para hacer el trabajo. 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, cable a tierra, conexciones, cable primario, y cualquier otra fuente de poder en buen estado operacional. No opere ningún equipo en malas condiciones. 4. No abuse del equipo y sus accesorios. Mantenga el equipo lejos de cosas que generen calor como hornos, también lugares húmedos como charcos de agua , aceite o grasa, atmósferas corrosivas y las inclemencias del tiempo. 5. Mantenga todos los artículos de seguridad y coverturas del equipo en su posición y en buenas condiciones. 6. Use el equipo sólo para el propósito que fue diseñado. No modiﬁque el equipo en ninguna manera. MANEJO DE CILINDROS-- Los cilindros, si no son manejados correctamente, pueden romperse y liberar violentamente gases. Rotura repentina del cilindro, válvula, o válvula de escape puede causar daño o muerte. Por lo tanto: 1. Utilize el gas apropiado para el proceso y utilize un regulador diseñado para operar y reducir la presión del cilindro de gas . No utilice adaptadores. Mantenga las mangueras y las conexiones en buenas condiciones. Observe las instrucciones de operación del manufacturero para montar el regulador en el cilindro de gas comprimido. INFORMACION ADICIONAL DE SEGURIDAD -- Para más información sobre las prácticas de seguridad de los equipos de arco eléctrico para soldar y cortar, pregunte a su suplidor por una copia de "Precautions and Safe Practices for Arc Welding, Cutting and Gouging-Form 52-529. 2. Asegure siempre los cilindros en posición vertical y amárrelos con una correa o cadena adecuada para asegurar el cilindro al carro, transportes, tablilleros, paredes, postes, o armazón. Nunca asegure los cilindros a la mesa de trabajo o las piezas que son parte del circuito de soldadura . Este puede ser parte del circuito elélectrico. Las siguientes publicaciones, disponibles através de la American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, son recomendadas para usted: 3. Cuando el cilindro no está en uso, mantenga la válvula del cilindro cerrada. Ponga el capote de protección sobre la válvula si el regulador no está conectado. Asegure y mueva los cilindros utilizando un carro o transporte adecuado. Evite el manejo brusco de los 1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting" 2. AWS C5.1 - "Recommended Practices for Plasma Arc Welding" MANTENIMIENTO DEL EQUIPO -- Equipo defectuoso o mal mantenido puede causar daño o muerte. Por lo tanto: 3. AWS C5.2 - "Recommended Practices for Plasma Arc Cutting" 4. AWS C5.3 - "Recommended Practices for Air Carbon Arc Gouging and Cutting" 11 SECTION 1 SEGURIDAD SIGNIFICADO DE LOS SIMBOLOS -- Según usted avanza en la lectura de este folleto: Los Símbolos Signiﬁcan ¡Atención! ¡Esté Alerta! Se trata de su seguridad. Signiﬁca riesgo inmediato que, de no ser evadido, puede resultar inmediatamente en serio daño personal o la muerte. Signiﬁca el riesgo de un peligro potencial que puede resultar en serio daño personal o la muerte. Signiﬁca el posible riesgo que puede resultar en menores daños a la persona. 12 SECTION 1 1.3 SÉCURITÉ Safety - French INCENDIES ET EXPLOSIONS -- La chaleur provenant des ﬂammes ou de l'arc peut provoquer un incendie. Le laitier incandescent ou les étincelles peuvent également provoquer un incendie ou une explosion. Par conséquent : AVERTISSEMENT : Ces règles de sécurité ont pour but d'assurer votre protection. Ils récapitulent les informations de précaution provenant des références dans la section des Informations de sécurité supplémentaires. Avant de procéder à l'installation ou d'utiliser l'unité, assurez-vous de lire et de suivre les précautions de sécurité ci-dessous, dans les manuels, les ﬁches d'information sur la sécurité du matériel et sur les étiquettes, etc. Tout défaut d'observer ces précautions de sécurité peut entraîner des blessures graves ou mortelles. 1. Éloignez suﬃsamment tous les matériaux combustibles de l'aire de travail et recouvrez les matériaux avec un revêtement protecteur ininﬂammable. Les matériaux combustibles incluent le bois, les vêtements, la sciure, le gaz et les liquides combustibles, les solvants, les peintures et les revêtements, le papier, etc. 2. Les étincelles et les projections de métal incandescent peuvent tomber dans les ﬁssures dans les planchers ou dans les ouvertures des murs et déclencher un incendie couvant à l'étage inférieur Assurez-vous que ces ouvertures sont bien protégées des étincelles et du métal incandescent. 3. N'exécutez pas de soudure, de coupe ou autre travail à chaud avant d'avoir complètement nettoyé la surface de la pièce à traiter de façon à ce qu'il n'ait aucune substance présente qui pourrait produire des vapeurs inﬂammables ou toxiques. N'exécutez pas de travail à chaud sur des contenants fermés car ces derniers pourraient exploser. 4. Assurez-vous qu'un équipement d'extinction d'incendie est disponible et prêt à servir, tel qu'un tuyau d'arrosage, un seau d'eau, un seau de sable ou un extincteur portatif. Assurez-vous d'être bien instruit par rapport à l'usage de cet équipement. 5. Assurez-vous de ne pas excéder la capacité de l'équipement. Par exemple, un câble de soudage surchargé peut surchauﬀer et provoquer un incendie. 6. Une fois les opérations terminées, inspectez l'aire de travail pour assurer qu'aucune étincelle ou projection de métal incandescent ne risque de provoquer un incendie ultérieurement. Employez des guetteurs d'incendie au besoin. 7. Pour obtenir des informations supplémentaires, 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. PROTÉGEZ-VOUS -- Les processus de soudage, de coupage et de gougeage produisent un niveau de bruit élevé et exige l'emploi d'une protection auditive. L'arc, tout comme le soleil, émet des rayons ultraviolets en plus d'autre rayons qui peuvent causer des blessures à la peau et les yeux. Le métal incandescent peut causer des brûlures. Une formation reliée à l'usage des processus et de l'équipement est essentielle pour prévenir les accidents. Par conséquent: 1. Portez des lunettes protectrices munies d'écrans latéraux lorsque vous êtes dans l'aire de travail, même si vous devez porter un casque de soudeur, un écran facial ou des lunettes étanches. 2. Portez un écran facial muni de verres ﬁltrants et de plaques protectrices appropriées aﬁn de protéger vos yeux, votre visage, votre cou et vos oreilles des étincelles et des rayons de l'arc lors d'une opération ou lorsque vous observez une opération. Avertissez les personnes se trouvant à proximité de ne pas regarder l'arc et de ne pas s'exposer aux rayons de l'arc électrique ou le métal incandescent. 3. Portez des gants ignifugiés à crispin, une chemise épaisse à manches longues, des pantalons sans rebord et des chaussures montantes aﬁn de vous protéger des rayons de l'arc, des étincelles et du métal incandescent, en plus d'un casque de soudeur ou casquette pour protéger vos cheveux. Il est également recommandé de porter un tablier ininﬂammable aﬁn de vous protéger des étincelles et de la chaleur par rayonnement. 4. Les étincelles et les projections de métal incandescent risquent de se loger dans les manches retroussées, les rebords de pantalons ou les poches. Il est recommandé de garder boutonnés le col et les manches et de porter des vêtements sans poches en avant. 5. Protégez toute personne se trouvant à proximité des étincelles et des rayons de l'arc à l'aide d'un rideau ou d'une cloison ininﬂammable. 6. Portez des lunettes étanches par dessus vos lunettes de sécurité lors des opérations d'écaillage ou de meulage du laitier. Les écailles de laitier incandescent peuvent être projetées à des distances considérables. Les personnes se trouvant à proximité doivent également porter des lunettes étanches par dessus leur lunettes de sécurité. CHOC ÉLECTRIQUE -- Le contact avec des pièces électriques ou les pièces de mise à la terre 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. 13 SECTION 1 SÉCURITÉ 1. Assurez-vous que le châssis de la source d'alimentation est branché au système de mise à la terre de l'alimentation d'entrée. 2. Branchez la pièce à traiter à une bonne mise de terre électrique. 3. Branchez le câble de masse à la pièce à traiter et assurez une bonne connexion aﬁn d'éviter le risque de choc électrique mortel. 4. Utilisez toujours un équipement correctement entretenu. Remplacez les câbles usés ou endommagés. 5. Veillez à garder votre environnement sec, incluant les vêtements, l'aire de travail, les câbles, le porteélectrode/torche et la source d'alimentation. 6. Assurez-vous que tout votre corps est bien isolé de la pièce à traiter et des pièces de la mise à la terre. 7. Si vous devez eﬀectuer votre travail dans un espace restreint ou humide, ne tenez vous pas directement sur le métal ou sur la terre; tenez-vous sur des planches sèches ou une plate-forme isolée et portez des chaussures à semelles de caoutchouc. 8. Avant de mettre l'équipement sous tension, isolez vos mains avec des gants secs et sans trous. 9. Mettez l'équipement hors tension avant d'enlever vos gants. 10. Consultez ANSI/ASC Standard Z49.1 (listé à la page suivante) pour des recommandations spéciﬁques concernant les procédures de mise à la terre. Ne pas confondre le câble de masse avec le câble de mise à la terre. 3. Les soudeurs doivent suivre les procédures suivantes pour minimiser l'exposition aux champs électriques et magnétiques : A. Acheminez l'électrode et les câbles de masse ensemble. Fixez-les à l'aide d'une bande adhésive lorsque possible. B. Ne jamais enrouler la torche ou le câble de masse autour de votre corps. C. Ne jamais vous placer entre la torche et les câbles de masse. Acheminez tous les câbles sur le même côté de votre corps. D. Branchez le câble de masse à la pièce à traiter le plus près possible de la section à souder. E. Veillez à garder la source d'alimentation pour le soudage et les câbles à une distance appropriée de votre corps. LES VAPEURS ET LES GAZ -- peuvent causer un malaise ou des dommages corporels, plus particulièrement dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le gaz de protection risque de causer l'asphyxie. Par conséquent : 1. Assurez en permanence une ventilation adéquate dans l'aire de travail en maintenant une ventilation naturelle ou à l'aide de moyens mécanique. N'eﬀectuez jamais de travaux de soudage, de coupage ou de gougeage sur des matériaux tels que l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc, le plomb, le berylliym ou le cadmium en l'absence de moyens mécaniques de ventilation eﬃcaces. Ne respirez pas les vapeurs de ces matériaux. 2. N'eﬀectuez jamais de travaux à proximité d'une opération de dégraissage ou de pulvérisation. Lorsque la chaleur ou le rayonnement de l'arc entre en contact avec les vapeurs d'hydrocarbure chloré, ceci peut déclencher la formation de phosgène ou d'autres gaz irritants, tous extrêmement toxiques. 3. Une irritation momentanée des yeux, du nez ou de la gorge au cours d'une opération indique que la ventilation n'est pas adéquate. Cessez votre travail aﬁn de prendre les mesures nécessaires pour améliorer la ventilation dans l'aire de travail. Ne poursuivez pas l'opération si le malaise persiste. 4. Consultez ANSI/ASC Standard Z49.1 (à la page suivante) pour des recommandations spéciﬁques concernant la ventilation. CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — comportent un risque de danger. Le courant électrique qui passe dans n'importe quel conducteur produit des champs électriques et magnétiques localisés. Le soudage et le courant de coupage créent des champs électriques et magnétiques autour des câbles de soudage et l'équipement. Par conséquent : 1. Un soudeur ayant un stimulateur cardiaque doit consulter son médecin avant d'entreprendre une opération de soudage. Les champs électriques et magnétiques peuvent causer des ennuis pour certains stimulateurs cardiaques. 2. L'exposition à des champs électriques et magnétiques peut avoir des eﬀets néfastes inconnus pour la santé. 14 SECTION 1 SÉCURITÉ ENTRETIEN DE L'ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou inadéquate peut causer des blessures graves ou mortelles. Par conséquent : 5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé dans une opération de soudage ou de coupage, dégage des vapeurs ou des gaz contenant des chimiques considéres par l'état de la Californie comme étant une cause des malformations congénitales et dans certains cas, du cancer. (California Health & Safety Code §25249.5 et seq.) 1. Efforcez-vous de toujours confier les tâches d'installation, de dépannage et d'entretien à un personnel qualiﬁé. N'eﬀectuez aucune réparation électrique à moins d'être qualiﬁé à cet eﬀet. 2. Avant de procéder à une tâche d'entretien à l'intérieur de la source d'alimentation, débranchez l'alimentation électrique. 3. Maintenez les câbles, les ﬁls de mise à la terre, les branchements, le cordon d'alimentation et la source d'alimentation en bon état. N'utilisez jamais un équipement s'il présente une défectuosité quelconque. 4. N'utilisez pas l'équipement de façon abusive. Gardez l'équipement à l'écart de toute source de chaleur, notamment des fours, de l'humidité, des ﬂaques d'eau, de l'huile ou de la graisse, des atmosphères corrosives et des intempéries. 5. Laissez en place tous les dispositifs de sécurité et tous les panneaux de la console et maintenez-les en bon état. 6. Utilisez l'équipement conformément à son usage prévu et n'eﬀectuez aucune modiﬁcation. MANIPULATION DES CYLINDRES -La manipulation d'un cylindre, sans observer les précautions nécessaires, peut produire des fissures et un échappement dangereux des gaz. Une brisure soudaine du cylindre, de la soupape ou du dispositif de surpression peut causer des blessures graves ou mortelles. Par conséquent : 1. Utilisez toujours le gaz prévu pour une opération et le détendeur approprié conçu pour utilisation sur les cylindres de gaz comprimé. N'utilisez jamais d'adaptateur. Maintenez en bon état les tuyaux et les raccords. Observez les instructions d'opération du fabricant pour assembler le détendeur sur un cylindre de gaz comprimé. 2. Fixez les cylindres dans une position verticale, à l'aide d'une chaîne ou une sangle, sur un chariot manuel, un châssis de roulement, un banc, un mur, une colonne ou un support convenable. Ne ﬁxez jamais un cylindre à un poste de travail ou toute autre dispositif faisant partie d'un circuit électrique. 3. Lorsque les cylindres ne servent pas, gardez les soupapes fermées. Si le détendeur n'est pas branché, assurez-vous que le bouchon de protection de la soupape est bien en place. Fixez et déplacez les cylindres à l'aide d'un chariot manuel approprié. Toujours manipuler les cylindres avec soin. 4. Placez les cylindres à une distance appropriée de toute source de chaleur, des étincelles et des ﬂammes. Ne jamais amorcer l'arc sur un cylindre. 5. Pour de l'information supplémentaire, consultez CGA Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", mis à votre disposition par le Compressed Gas Association, 1235 Jeﬀerson Davis Highway, Arlington, VA 22202. INFORMATIONS SUPPLÉMENTAIRES RELATIVES À LA SÉCURITÉ -- Pour obtenir de l'information supplémentaire sur les règles de sécurité à observer pour l'équipement de soudage à l'arc électrique et le coupage, demandez un exemplaire du livret "Precautions and Safe Practices for Arc Welding, Cutting and Gouging", Form 52-529. Les publications suivantes sont également recommandées et mises à votre disposition par l'American Welding 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 C5.2 - "Recommended Practices for Plasma Arc Cutting" 4. AWS C5.3 - "Recommended Practices for Air Carbon Arc Gouging and Cutting" 15 SECTION 1 SÉCURITÉ SIGNIFICATION DES SYMBOLES Ce symbole, utilisé partout dans ce manuel, signiﬁe "Attention" ! Soyez vigilant ! Votre sécurité est en jeu. DANGER Signiﬁe un danger immédiat. La situation peut entraîner des blessures graves ou mortelles. AVERTISSEMENT Signiﬁe un danger potentiel qui peut entraîner des blessures graves ou mortelles. ATTENTION Signiﬁe un danger qui peut entraîner des blessures corporelles mineures. 16 SECTION 2 DESCRIPTION 2.1 Introduction The ESP ULTRA-LIFE 300 Plasma Power Source is designed for high speed plasma cutting applications. It is normally used with equipment such as the ESAB Smart Plasma 1000 System (ESP). For additional operating data and electrical characteristics of this machine, refer below to Table 2-1, ESP ULTRA-LIFE 300 Speciﬁcations. TABLE 2-1. SPECIFICATIONS Rated Output Duty Cycles Power Factor THD* Input** 300 A @ 130 V 100% DUTY 0.81 0.52 460 V @ 80 A 575 V @ 64 A 300 A @ 200 V 60% DUTY 0.88 0.45 575 V @ 86 A 460 V @ 108 A Output Current Range 50 to 300 Amperes*** Open Circuit Voltage 375 V dc Dimensions 44.50 in. (1130.30 mm) 32.00 in. (812.80 mm) 33.00 in. (838.20 mm) 1636 lbs (742.08 kg) Width Depth Height Weight *Total Harmonic Distortion **60 Hz, 3-phase ***Units manufactured before S/N C94B-46623 have output current range of 100 to 300 amperes. 2.2 Description The ESP ULTRA-LIFE 300 Plasma Power Source is a silicon controlled rectiﬁer (SCR), three-phase transformer/rectiﬁer type dc unit with solid state circuitry. The unit can be operated from 50 to 300 amperes at duty cycles shown in Table 2-1 above. A current control Panel-Remote Switch determines the location from which the output current will be regulated: either locally from the Power Source front panel ("Panel" position) or remotely ("Remote" position) from a precision 0-10 volt reference (V ref ) signal. The Power Source circuitry receiving the V ref signal is electrically (galvanically) isolated. This means that the common for this signal may be tied to any voltage less than 150 V ac or dc with respect to earth ground. The ESP ULTRA-LIFE 300 is powered by two 3-phase main transformers which combine with solid state control to provide volt-amperes curve output characteristics required for plasma cutting (see Figure 2-1). Two 3-phase full wave SCRs and two diode bridge rectiﬁers are used to convert the ac output current from the transformers to dc cutting current, and also control the output current through the SCRs. A network of integrally-mounted capacitors and resistors provide transient and high frequency voltage protection to the rectiﬁer SCRs and diodes. Protection for main transformer bridge rectiﬁers and inductors is provided by over-temperature thermal switches which interrupt power in the event of an overheating condition and automatically reset when the components have cooled to their normal operating temperature. Filtering of the dc output current is provided by an inductor. The solid state circuitry of the ESP ULTRA-LIFE 300 produces stable cutting current and eliminates changes in output current as components heat up and/or if input line voltage changes within ±10% of nominal. This feature ensures consistency in cutting conditions. The oxygen consumable life is extended by using a ripple cancellation technique. This technique is achieved by connecting two power sources in parallel in a manner whereby the ripple from one 17 SECTION 2 DESCRIPTION power source cancels the ripple from the other. Actual load current and voltage are indicated by an ammeter and voltmeter mounted on the front panel. Connections for control functions from the Flow Control assembly are made from a 19-pin plug receptacle on the front panel. This receptacle provides connection for auxiliary 115 volts out, remote current control. The Power Source is designed for ease in moving and handling. Suﬃcient clearance and reinforcement at its base permits lifting with a fork lift truck; or raising with a crane or hoist using the lifting rings in the top cover. When moving the Power Source, always use both lifting rings in order to keep the Power Source level, otherwise serious internal damage may occur. 2.3 Cool-Down Periods There is no cool-down period required for the 130 V/300 A output rating (100% duty). However, the 200 V/300 A output rating requires a 4-minute cool-down period with fan motor running for every 6-minute application (60% duty). Output ratings are designed and based on an unobstructed supply of cooling air ﬂow over internal components. DO NOT USE FILTERS ON THIS UNIT. Periodically blow out dirt accumulations, using low pressure air. 2.4 Volt-Ampere Curves The volt-ampere curves show the output voltage available at any given output current for the various current control (or V ref signals from CNC control) settings. Values for settings other than those shown in ﬁgure 2-1, fall between the Minimum and Maximum curves shown. 2.5 Parallel Operation Parallel operation is the use of two Power Sources connected in parallel to provide an extended output current range. In the case of the Ultra-Life 300, parallel connection provides an output current range from 50-600 A. In order to avoid confusion between the two Power Sources being connected, the terms Master and Slave will be used. The Master Power Source is the Ultra-Life 300 to which the Pilot Arc Wire is connected. It is also connected to the front of the Flow Control by a 19-conductor cable. The Slave Power Source is connected to the back of the Flow Control with a 19conductor cable. A. Parallel Operation for S/Ns before C94B-46623 (100 A Minimum Output) 1. 2. For operation from 100-200 A, use the Master Power Source only. "Pilot Arc Current" switches on both Power Sources may be in either "LOW" or "HIGH" positions. For operation from 200-600 A, use both Power Sources. The "Pilot Arc Current" switch on the Master Power Source should be in the "HIGH" position. The Slave Unit's "Pilot Arc Current" switch may be in either position. 18 SECTION 2 B. DESCRIPTION Parallel Operation for S/N's after C94B-46623 (50 A Minimum Output) 1. 2. For operation from 50-200 A, use the Master Power Source only. The Master's "Output Current Range" switch must be in the "LOW" position for 50-100 A or the "HIGH" position for the 100-200 A. For operation from 200-600 A, use both Power Sources. The "Output Current Range" switch on both Master and Slave Power Sources must be in the "HIGH" position. WHENEVER THE MASTER POWER SOURCE IS USED BY ITSELF IN A PARALLEL INSTALLATION, THE NEGATIVE OUTPUT FROM THE SLAVE UNIT SHOULD BE DISCONNECTED FROM THE MASTER. FAILURE TO DISCONNECT WILL MAKE THE SLAVE POWER SOURCE ELECTRICALLY "HOT" WHEN THE MASTER POWER SOURCE IS ENERGIZED. Ensure that there is a safe means of disconnecting the Slave Power Source without exposing any electrically "hot" conductors. This can usually be accomplished by disconnecting the negative output cable of the Slave Unit at both ends (at the Slave Power Source and at the Plumbing Box). Insulate both ends with electrical tape. THE VREF DESIGNATION SHOWN ON THE TYPICAL V/A CURVES (ABOVE) CORRESPONDS TO AN ABSOLUTE VOLTAGE REFERENCE SIGNAL (0 TO 10 VOLTS RANGE) FROM THE CNC (CUTTING) CONTROL THAT ESTABLISHES THE PRECISE OUTPUT ARC CURRENT OF THE POWER SOURCE. THESE CURVES ARE DERIVED FROM THE FORMULA IARC = 30VREF. WHEN OPERATING TWO POWER SOURCES IN PARALLEL, THE RELATIONSHIP BECOMES IARC = 60VREF. Figure 2-1. Volt-Ampere Curves 19 SECTION 2 DESCRIPTION 20 SECTION 3 INSTALLATION 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. TO PREVENT ACCIDENTAL ELECTRIC SHOCK, BE SURE THAT THE WALL DISCONNECT SWITCH OR CIRCUIT BREAKER IS OPEN BEFORE ATTEMPTING ANY INSPECTION OR WORK INSIDE THE POWER SOURCE. 3.2 Cleaning Since there are no moving parts (other than the fan) in the Power Source, maintenance consists mainly of keeping the interior of the cabinet clean. Periodically, remove the cover from the cabinet and blow accumulated dust and dirt from the air passages and the interior components, using clean, dry low pressure air. It is imperative that the air passages to the interior of the unit be kept free of dirt accumulation to ensure adequate circulation of cooling air, especially over the extrusion ﬁns of bridge rectiﬁer. This unit is NOT designed to be used with air ﬁlters of any kind. Any obstruction to the free ﬂow of cooling air may damage the machine and void the warranty. The frequency of cleaning needed depends upon the amount of dirt that is drawn into the unit. 3.3 Lubrication Fan motors with oil tubes located on the side of the motor require lubrication after one year of service. Motors without oil tubes are permanently lubricated and should not require any attention. 3.4 Testing and Replacing Bridge Assembly Components The silicon diodes and SCRs used in the Power Source are devices which allow current to ﬂow in only one direction. They block current ﬂow in the other direction. The diodes and SCRs used in this Power Source are designed to provide long trouble-free operation; however, should a failure occur, they require replacement. The location and replacement parts data for the diodes and SCRs are shown in ﬁgures 5-1 through 5-4. If after troubleshooting (see Section 4), the "trouble symptom" appears to be in a bridge network, the following three-part procedure can be used to determine the faulty component(s): Visual Analysis, Component Group Testing, and Individual Component/Isolation Testing. If repair or replacement of bridge components is necessary, removing the bridge assembly is recommended. Before removing a bridge assembly for servicing, carefully tag (identify) all interconnecting wires and bus connections to facilitate proper reinstallation. Also, refer to the diagrams and illustrations in the back of this book. 21 SECTION 3 INSTALLATION A. Visual Analysis For Defective Bridge Components. B. 1. Remove top, left side, and right side panels of Power Source. Inspect the 150 A bridge fuse links (F1/F2 on the left - F3/F4 on the right) mounted on the phenolic plates in front of Main Transformers to see if they have blown. 2. If either or both of the fuses protecting its respective bridge assembly are open, it's a sign that one or more of the diodes or SCRs in that particular bridge may be shorted. 3. Check for cracked or broken ceramic around each diode pigtail of SCR body. If cracked, it's a sign of a shorted diode or SCR. When the larger diodes or SCRs fail, they most commonly fail shorted. Testing Left and Right Bridge Assemblies. Each bridge assembly essentially contains three groups of components to be tested. The left side bridge contains Power Diodes D1, D2, and D3; Freewheeling Diodes D4 and D5; and SCRs 1, 2, and 3. The right side bridge contains Power Diodes D6, D7, and D8; Freewheeling Diodes D9 and D10; and SCRs 4, 5, and 6. The group testing sequence does not require electrical isolation; however, to determine the speciﬁc faulty component in a group, some form of isolation may be required as follows: 1. Checking Power Diode Groups. (a) If fuse links are not blown, use an ohmmeter set at its lowest resistance scale and check the diode group as described in step 1.(c). Checking any one diode within the group will determine if the group is good or if a shorted condition exists. If there is a short, you must electrically isolate to determine the speciﬁc component. Electrical isolation is accomplished by unbolting the pigtail of the diode being tested. (b) If one or more fuse links 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. 1 Place one test probe on NEG heatsink (diode stud) and the other probe to each diode pigtail's SCR heatsink. Note the resistance readings obtained. All three readings should be similar (high or low). 2 Reverse the test probes and recheck the diodes. Note each resistance reading. All three readings should be similar; but, opposite of those noted in the ﬁrst reading. 3 Diodes are good if they test high in one direction and low in the opposite direction. Diodes are bad if the resistance readings are low in both directions. High readings in both directions when using a digital ohmmeter indicates a good diode. 4 Diodes are bad when they show no, or very low, resistance in both directions indicating they are shorted. Although it is possible for power rectiﬁer diodes to fail "open", such failures are rare, particularly for the larger diodes. In the vast majority of cases, a high resistance reading in either or both directions indicate a good diode. 22 SECTION 3 2. INSTALLATION Checking Freewheeling Diodes. These diodes must be checked in the circuit using the same procedures outlined in steps 1.(a), 1.(b), and 1.(c). If each diode tests "good", nothing else need be done; however, if a diode tests "bad", you must disconnect its pigtail and retest it for veriﬁcation. 3. Checking SCR Groups. NOTE Before proceeding with the following SCR tests, all diodes should have been checked and defective (shorted) diodes electrically isolated. (a) If fuse links are not blown and are still connected to the bridge heatsink, used an ohmmeter set to its lowest resistance scale and check the SCR group as described in step 3.(c). Checking any one SCR within the group will determine if the group is good or if a shorted condition exists. If there is a short, you must electrically isolate to determine the speciﬁc faulty component, see step 3.(d). (b) If one or more fuse links are blown, the SCRs must be isolated and checked individually. Refer to step 3.(d). (c) Ohmmeter check of SCRs (group or individual). (d) 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. If the diagnosis indicates a defective SCR within the group, you must disconnect the fuses to electrically isolate the SCRs (assuming all diodes have checked good, or defective diodes previously isolated), and repeat the ohmmeter tests in steps 1, 2, and 3 above for each SCR. D. 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. Torque procedure for SCRs and diodes. Use a torque wrench to tighten stud mounted SCRs and diodes. Recommended torques are listed in table 3-1. Table 3-1. Recommended Torques Diodes Min., 20 in-lbs (1.7 ft•lbs) Max., 30 in-lbs (2.5 ft•lbs) SCRs Min., 125 in-lbs (10.4 ft•lbs) Max., 150 in-lbs (12.5 ft•lbs) 23 SECTION 3 INSTALLATION 24 SECTION 4 OPERATION 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. If the cause cannot be quickly located, open up the unit and perform a simple visual inspection of all the components and wiring. Check for proper terminal connections, loose or burned wiring or components, blown fuses, bulged or leaking capacitors, or any other sign of damage or discoloration. 4.2 Troubleshooting Guide A. Fan Not Running. B. C. 1. No input power. Check main line (customer's) switch fuses. 2. Defective control transformer. Check for continuity. 3. Fan motor defective. Check motor and leads, and replace if necessary. No Output. 1. No incoming three-phase power. Wall disconnect switch may be open, or fuse(s) blown. 2. Poor connections at output terminals. Tighten or replace connections. 3. Main contactor (K1) will not energize. a. Thermal overload device(s) tripped. Check left and right thermal overload lights on front panel. b. Missing "start" signal. c. Defective AMC or Main Contactor (K1). No Current Control or Erratic Output Current. 1. 2. No current control. a. Missing power or blown fuse links in bridge assemblies. b. Defective SCR board (PCB1 - left side, PCB3 - right side). c. Defective constant current (CC) board (PCB2). Pilot arc without transfer (pops then goes out). 25 SECTION 4 OPERATION a. Missing Vref signal from remote source. Check voltage from pins P1-2 to P1-1 on CC board for Vref signal. Put switch in "Panel" position and use panel control. b. Missing "current control" signal to SCR boards (defective CC board). Check "current control" signal at pins P1-2 and P2-8 on SCR boards. c. Pilot arc fuse(s) (F5/F6) blown. 3. If current remains ﬁxed at approximately 300 amperes (in Panel position), the bottom of the current control potentiometer (R50) may not be connected. This applies +10 volts straight into CC board. Check remote control switch (SW1) for continuity and proper common connection. 4. Current control to 175 A only. 5. a. Current Range Switch in "LOW" position. Put switch in "HIGH" position. b. Left or right side power source not operating. Measure signal (mV) from left and right SCR boards at P1-10 and P1-11. c. Defective left or right side bridge assemblies or bridge fuses. d. Defective SCR board (PCB1 - left side, PCB3 - right side). Erratic current control. a. Defective current control potentiometer (R50) (panel and/or remote location). b. Defective remote control switch (SW1). Check continuity. c. Defective SCR board (PCB1 - left side, PCB3 - right side). d. Defective CC board (PCB2). D. Short (Torch) Tip Life -- Double Arcing. 1. Defective SCR board (PCB1 - left side, PCB3 - right side). 2. Defective CC board (PCB2). 3. Defective SCR in bridge assemblies. 4. Excessive ripple voltage. Measure ripple voltage with a true RMS AC voltmeter at output of machine. It should read less than 2 V ac RMS with system operating at 260 A/130 V with 0.5 ohm resistive load. Actual waveform can be measured with an oscilloscope on the CC board (refer to Figures 4-1 and 4-2). 5. Faulty Pilot Arc Connection at Power Source (refer to Figure 5-2). 6. Faulty Pilot Arc Connection at plumbing box (refer to ESP manual). 26 SECTION 4 OPERATION TEST POINT (NEG) TEST POINT (POS) Figure 4-1. ESP ULTRA-LIFE 300 CC Board Test Points for Measuring Output Current Oscilloscope must be isolated from ground when taking measurement. 27 SECTION 4 OPERATION Must not overshoot output current 80 ms/DIV NOTE: Oscilloscope set at 2 V/DIV (60 A/DIV). Figure 4-2. ESP ULTRA-LIFE 300 Load Bank Start and Output Current Waveform 4.3 Recommended Fuse and Input Cable Sizes Rated Input Rated Output Voltage Frequency Input & Ground Conductor* Amperes CU/AWG Time-Delay or Slow Blow Fuse Size Amps** 300 A @ 200 V 460 V 60 Hz 108 2 125 300 A @ 200 V 575 V 60 Hz 86 3 100 * Sized per National Electric code for 75 °C rated copper conductors @ 30 °C ambient. Not more than three conductors in raceway or cable. Local codes should be followed if they specify sizes others than those listed above. ** Selection of adequate fuses or circuit breakers for this unit is critical because the in-rush current for large magnetic components like the main transformers is several times greater than its steady state full load current draw. We therefore recommend using only slow blowing or time-delay fuses that are sized in accordance with the table recommendations. If a breaker is used, it should be of the slow tripping variety. Thermally activated breakers are preferable to magnetically activated breakers. 28 SECTION 4 OPERATION Figure 4-5. SCR Board (PCB1, 3) Component Layout 29 SECTION 4 OPERATION Figure 4-6. Constant Current Board (PCB2) Component Layout 30 SECTION 4 OPERATION Figure 4-7. Filter Board (PCB4, 5) Component Layout 31 SECTION 4 OPERATION Figure 4-8. ESP ULTRA-LIFE 300 Left Terminal Board (TB1) 32 SECTION 4 OPERATION TB2 IS NOT MODIFIED FOR VOLTAGE CHANGEOVER Figure 4-9. ESP ULTRA-LIFE 300 Right Terminal Board (TB2) 33 SECTION 4 OPERATION NOTE: Schematics and Wiring Diagrams on 11” x 17” paper are included inside the back cover of this manual. 34 SECTION 5 5.0 Replacement Parts 5.1 General REPLACEMENT PARTS Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on the unit nameplate. 5.2 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. Note Bill of material items that have blank part numbers are provided for customer information only. Hardware items should be available through local sources. 35 SECTION 5 REPLACEMENT PARTS 3 4 7 5 6 8,9,10 11 2 1 12 13 14 Figure 5-1. ESP ULTRA-LIFE 300 Power Source (Front View) Item No. Qty Req. Part No. Description Circuit Symbol 1 1 2062290 VOLTMETER, DC, 500 V VM 2 1 647288 AMMETER, DC, 300 A AM 3 1 33997 PANE, TOP 4 1 672508 SWITCH, TOGGLE, 3PST S1 5 1 598227 LIGHT, PILOT PL2, 3 6 1 634716 LIGHT, PILOT PL1 7 1 950122 CIRCUIT BREAKER, 10 A CB1 8 1 2062170 KNOB 9 1 673999 SHAFT, LOCK 10 1 950715 POTENTIOMETER, CURRENT CONT. R50 11 1 634518 SWITCH, TOGGLE, DPDT S5 12 1 1006733 CONNECTOR, 19-PIN, AMPHENOL J1 13 1 33995 PANEL, SIDE, RIGHT 14 1 33996 PANEL, SIDE, LEFT 36 SECTION 5 REPLACEMENT PARTS 12 11 1 10 9 2 REF: PILOT ARC CONNECTION 3 8 4 6 7 5 Figure 5-2. ESP ULTRA-LIFE 300 Power Source (Left Side View) Item No. Qty Req. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 1 2 2 2 1 1 1 1 1 1 33993 674970 17300016 17300008 677329 30833 33998 32091 33994 951491 672772 30855 1 Description PANEL, FRONT P.C. BD. ASSEMBLY, FILTER RESISTOR, 16 OHM, 300 W RESISTOR, 8 OHM, 300 W BOARD, TERMINAL TRANSFORMER, MAIN (LEFT) BAIL ASSEMBLY BOARD, TERMINAL (LEFT) PANEL, REAR CONTACTOR, MAIN, 120 V, 90 A CAPACITOR, 10 µF @ 370 WVDC INDUCTOR 37 Ckt. Symbol PCB4, 5 R38 R39-41 TB3 T1 TB1 K1 L1 SECTION 5 REPLACEMENT PARTS 1 2 3 1 2 4 Figure 5-3. ESP ULTRA-LIFE 300 Power Source (Left Side Top View) Item No. Qty Req. Part No. Description Circuit Symbol 1 8 17280010 RESISTOR, 10 OHM, 100 W R19-24, R33-34 2 8 672772 CAPACITOR, 10 µF @ 370 WVDC C25-32 3 1 950826 BLOCK, TERMINAL (5 POINT) TB6 4 1 17280010 RESISTOR, 10 OHM, 100 W R35 38 SECTION 5 REPLACEMENT PARTS 1 2 3 4 Figure 5-4. ESP ULTRA-LIFE 300 Power Source (Right Side View) Item No. Qty Req. Part No. Description Circuit Symbol 1 1 30855 INDUCTOR L2 2 1 34005 TRANSFORMER, MAIN (RIGHT) T2 3 1 677384 TRANSFORMER, CONTROL T3 4 4 17300008 RESISTOR, 8 OHM, 300 W R42-45 39 SECTION 5 REPLACEMENT PARTS 1 2 3 4 12 13 5 14 2 13 3 12 4 11 10 9 8 7 6 Figure 5-5. ESP ULTRA-LIFE 300 Power Source (Top View) Item No. Qty Req. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 2 2 2 2 1 1 1 1 1 1 1 2 2 1 676453 672330 673676 2062334 680912 635568 2080196 635568 672772 950116 951275 31444 993539 31492 Description SEAL, WEATHERSTRIP SHROUD, FAN BLADE, FAN MOTOR, FAN BOARD, TERMINAL (RIGHT) BLOCK, TERMINAL CONTACTOR (AUX) RELAY, 3PDT BLOCK, TERMINAL (8 POINT) CAPACITOR, 10 µF @ 370 WVDC FILTER, 2 A FILTER, 10 A P.C. BD. ASSEMBLY, S.C.R. CAPACITOR, ALLUM., 1500 µF, 50 V P.C. BD. ASSEMBLY, CONST. CURRENT 40 Ckt. Symbol M1, M2 TB2 TB4 K3 TB5 C46 FN2 FN4 PCB1, 3 C36, 37 PCB 2 SECTION 5 REPLACEMENT PARTS 1 2 3 3 11, 12 4 3 5 10 6 8, 9 7 Figure 5-6. ESP ULTRA-LIFE 300 Power Source (Top View Cutaway) Item No. Qty Req. Part No. Description Circuit Symbol 1 2 674969 FILTER, P.C. BD. ASSEMBLY FN1, 2 2 1 17280110 RESISTOR, 100K OHM, 110 W R49 3 5 951312 CAPACITOR, ALUM., 1300 µF, 450 V C33,34,47-49 4 2 17280210 RESISTOR, 1K OHM, 100 W R57,58 5 1 950255 CAPACITOR, 60 µF, 370 V AC C35 6 1 673458 CONTACTOR, PILOT ARC K2 7 1 672772 CAPACITOR, 10 µF @ 370 WVDC C44 8 2 639514 FUSE BLOCK 9 2 951527 FUSE, 15 A F5, 6 10 1 17250230 RESISTOR, 3K OHM, 50 W R46 11 1 950627 CAPACITOR, 4200 µF, 350 V C50 12 1 17315247 RESISTOR, 4.7K OHMS, 12 W R59 41 NOTES LEFT SIDE (except where noted) Figure 4-3. ESP ULTRA-LIFE 300 Power Source Schematic Diagram (Sheet 1 of 8) APPLIES TO S/N's BEFORE C94B-46623 LEFT SIDE (except where noted) ESP ULTRA-LIFE 300 Power Source Figure 4-3. ESP ULTRA-LIFE 300 Power Source Schematic Diagram (Sheet 2 of 8) APPLIES TO S/N's AFTER C94B-46623 RIGHT SIDE ESP ULTRA-LIFE 300 Power Source Figure 4-3. ESP ULTRA-LIFE 300 Power Source Schematic Diagram (Sheet 3 of 8) APPLIES TO S/N's BEFORE C94B-46623 RIGHT SIDE ESP ULTRA-LIFE 300 Power Source Figure 4-3. ESP ULTRA-LIFE 300 Power Source Schematic Diagram (Sheet 4 of 8) APPLIES TO S/N's AFTER C94B-46623 LEFT MAIN TRANSFORMER (T1) Figure 4-3. ESP ULTRA-LIFE 300 Power Source Schematic Diagram (Sheet 5 of 8) ESP ULTRA-LIFE 300 Power Source RIGHT MAIN TRANSFORMER (T2) Figure 4-3. ESP ULTRA-LIFE 300 Power Source Schematic Diagram (Sheet 6 of 8) ESP ULTRA-LIFE 300 Power Source SCR BOARD (PCB1, 3) ESP ULTRA-LIFE 300 Power Source Figure 4-3. ESP ULTRA-LIFE 300 Power Source Schematic Diagram (Sheet 7 of 8) CONSTANT CURRENT BOARD (PCB2) ESP ULTRA-LIFE 300 Power Source Figure 4-3. ESP ULTRA-LIFE 300 Power Source Schematic Diagram (Sheet 8 of 8) Figure 4-4. ESP ULTRA-LIFE 300 Power Source Wiring Diagram (Sheet 1 of 6) APPLIES TO S/N's BEFORE C94B-46623 ESP ULTRA-LIFE 300 Power Source Figure 4-4. ESP ULTRA-LIFE 300 Power Source Wiring Diagram (Sheet 2 of 6) APPLIES TO S/N's AFTER C94B-46623 ESP ULTRA-LIFE 300 Power Source Figure 4-4. ESP ULTRA-LIFE 300 Power Source Wiring Diagram (Sheet 3 of 6) APPLIES TO S/N's BEFORE C94B-46623 ESP ULTRA-LIFE 300 Power Source Figure 4-4. ESP ULTRA-LIFE 300 Power Source Wiring Diagram (Sheet 4 of 6) APPLIES TO S/N's AFTER C94B-46623 ESP ULTRA-LIFE 300 Power Source Figure 4-4. ESP ULTRA-LIFE 300 Power Source Wiring Diagram (Sheet 5 of 6) APPLIES TO S/N's BEFORE C94B-46623 ESP ULTRA-LIFE 300 Power Source FILTER BOARD DETAIL Figure 4-4. ESP ULTRA-LIFE 300 Power Source Wiring Diagram (Sheet 6 of 6) APPLIES TO S/N's AFTER C94B-46623 ESP ULTRA-LIFE 300 Power Source REVISION HISTORY 1. Revision 09/2004 - Updated Figure 5-6, Section 5 - Replacement Parts, item 4 deleted “DC” & reformatted descriptions. 2. Revision 03/2005 - updated format with TOC, correct page # layout, and moved schematics to 11 x 17 format. ESAB Welding & Cutting Products, Florence, SC Welding Equipment COMMUNICATION GUIDE - CUSTOMER SERVICES A. CUSTOMER SERVICE QUESTIONS: Telephone: (800)362-7080 / Fax: (800) 634-7548 Order Entry Product Availability Pricing Hours: 8:00 AM to 7:00 PM EST Order Information Returns 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 Hours: 8:00 AM to 5:00 PM EST Equipment Recommendations LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST D. E. F. G. H. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4487 / Fax: (843) 664-5557 Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST WELDING EQUIPMENT TRAINING Telephone: (843)664-4428 / Fax: (843) 679-5864 Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST 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 & Support F15-141-A 03/2005