ESP-600C Plasma Power Source equipment/power... · 2015-11-17 · ESP-600C Plasma Power Source Table of Contents i Page Section 1 Safety 1.1 Introduction 1 1.2 Safety Notations And

F-15-656 Jun., 2005

Installation, Operation, and Maintenance for the

ESP-600CPlasma Power Source

The equipment described in this manual ispotentially hazardous. Use caution when installing,operating and maintaining this equipment.

Purchaser is solely responsible for the safeoperation and use of all products purchased,including compliance with OSHA and othergovernment standards. ESAB CuttingSystems has no liability for personal injury orother damage arising out of the use of anyproduct manufactured or sold by ESAB. Seestandard ESAB terms and conditions of salefor a specific statement of ESAB’sresponsibilities and limitations on its liability.

ESAB Cutting Systems first priority is totalcustomer satisfaction. We constantly look forways to improve our products, service anddocumentation. As a result, we makeenhancements and/or design changes asrequired. ESAB makes every possible effort toensure our documentation is current. Wecannot guarantee that each piece ofdocumentation received by our customersreflects the latest design enhancements.Therefore, the information contained in thisdocument is subject to change without notice.

This manual is ESAB Part Number F15656This manual is ESAB Part Number F15656This manual is ESAB Part Number F15656This manual is ESAB Part Number F15656

This manual is for the convenience and use of thecutting machine purchaser. It is not a contract orother obligation on the part of ESAB CuttingSystems.

©©©© ESAB Cutting Systems, 2000

Printed in U.S.A.

ESP-600C Plasma Power Source Table of Contents

i

PageSection 1 Safety1.1 Introduction 11.2 Safety Notations And Symbols 11.3 General Safety Information 21.4 Installation Precautions 31.5 Electrical Grounding 41.6 Operating A Plasma Cutting Machine 4-71.7 Service Precautions 81.8 Safety References 9

Section 2 Description2.1 General 12.2 General Specifications 12.3 Dimensions and Weight 2

Section 3 Installation3.1 General 13.2 Unpacking 13.3 Placement 23.4 Input Power Connections 2-5 3.4.1 Primary Power 3 3.4.2 Input Conductors 4 3.4.3 Input Connection Procedure 4-53.5 Output Connections 5-6 3.5.1 Output Cables 5 3.5.2 Output Connection Procedure 53.6 Parallel Installation 6-73.7 System Interconnecting Block Diagram with Smart Flow II 83.8 System Interconnecting Block Diagram without Smart Flow II 9

Section 4 Operation4.1 Introduction 14.2 Control Panel 1-34.3 Sequence of Operation 44.4 Arc Initiation Settings 4-7 4.4.1 Enable/Disable Arc Initiation Timer 6 4.4.2 Adjusting Arc Initiation Timer 6 4.4.3 Arc Initiation Controls 7 4.4.4 Start Current and Up-slope Timer 74.5 V-I Curve 8


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Section 5 Maintenance

5.1 General 1

5.2 Cleaning 1

5.3 Fan Lubrication 2

Section 6 Troubleshooting

6.1 General 1

6.2 Fault Indicators 1-3

6.3 Fault Isolation (Diagnostics) 4-10

6.3.1 Fans 4

6.3.2 Power not on or Low Voltage 4

6.3.3 Fault Light Illumination 5-8

6.3.4 Torch will not Fire 9

6.3.5 Fuses 1 and 2 Blown 10

6.3.6 Intermittent, interrupted or Partial Operation 10-12

6.4 Testing and Replacing Components 13

6.4.1 Power Rectifiers 14

Negative Plate 14

Positive Plate 15

Electrode Plate 15

6.4.2 Freewheeling Diodes and IGBTs 16-18

6.4.3 Power Shunt Installation 18

6.4.4 Procedure for Verifying Calibration of Digital Meters 19

6.5 ESP-600C Schematic Diagrams 20-27

6.6 Wiring Diagrams 28-35

6.7 PC Controller Board (PCB1 - P/N 38032) Schematics 36-40

6.8 PCB Digital Meter Board (PCB4 – P/N 38139) Schematics 41-43

6.9 IGBT Driver Board (PCB2,3 – P/N 38030) Schematics 44-46


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Section 7 Replacement Parts

7.1 General 1

7.2 Ordering 1

7.3 Outside View - Front and Back 2-3

7.4 Front View With PCBs Exposed 4-5

7.5 Right Side View 6-7

7.6 Left Side View 8-9

7.7 Top View 10-11

7.8 Back Inside View 12-13

7.9 Middle Cross Section 14-15

7.10 Front Cross Section – Behind Front Panel 16-17

Customer/Technical Information Back Manual Cover


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SECTION 1 SAFETY

ESP-600Clasma Power SourceESP-600Clasma Power SourceESP-600Clasma Power SourceESP-600Clasma Power Source 1-1

DANGER!

WARNING!

CAUTION!

CAUTION

NOTICE

1.1 Introduction

The process of cutting metals with plasma equipmentprovides industry with a valuable and versatile tool.ESAB cutting machines are designed to provide bothoperation safety and efficiency. However, as with anymachine tool, sensible attention to operatingprocedures, precautions, and safe practices isnecessary to achieve a full measure of usefulness.Whether an individual is involved with operation,servicing, or as an observer, compliance withestablished precautions and safe practices must beaccomplished. Failure to observe certain precautionscould result in serious personnel injury or severeequipment damage. The following precautions aregeneral guidelines applicable when working withcutting machines. More explicit precautions pertainingto the basic machine and accessories are found in theinstruction literature. For a wide scope of safetyinformation on the field of cutting and weldingapparatus, obtain and read the publications listed inthe Recommended References.

1.2 Safety Notations And Symbols The following words and symbols are used throughoutthis manual. They indicate different levels of requiredsafety involvement.

!ALERT or ATTENTION. Your safety is involvedor potential equipment failure exists. Used withother symbols and information.

Used to call attention to immediate hazardswhich, if not avoided, will result in seriouspersonal injury or loss of life.

Used to call attention to potential hazardsthat could result in personal injury or loss oflife.

Used to call attention to hazards that couldresult in minor personal injury or equipmentdamage.

Used to call attention to minor hazards toequipment.

Used to call attention to importantinstallation, operation or maintenanceinformation not directly related to safetyhazards.

SECTION 1 SAFETY

ESP-600Clasma Power SourceESP-600Clasma Power SourceESP-600Clasma Power SourceESP-600Clasma Power Source1-2

1.3 General Safety Information

WARNING!Machinery often starts automatically.

This equipment moves in various directions andThis equipment moves in various directions andThis equipment moves in various directions andThis equipment moves in various directions andspeeds.speeds.speeds.speeds.

• Moving machinery can crush.Moving machinery can crush.Moving machinery can crush.Moving machinery can crush.

• Only qualified personnel should operate or serviceOnly qualified personnel should operate or serviceOnly qualified personnel should operate or serviceOnly qualified personnel should operate or servicethis power source.this power source.this power source.this power source.

• Keep all personnel, materials, and equipment notKeep all personnel, materials, and equipment notKeep all personnel, materials, and equipment notKeep all personnel, materials, and equipment notinvolved in production process clear of entireinvolved in production process clear of entireinvolved in production process clear of entireinvolved in production process clear of entiresystem area.system area.system area.system area.

• Fence off entire work cell to prevent personnelFence off entire work cell to prevent personnelFence off entire work cell to prevent personnelFence off entire work cell to prevent personnelfrom passing through area or standing in thefrom passing through area or standing in thefrom passing through area or standing in thefrom passing through area or standing in theworking envelope of the equipment.working envelope of the equipment.working envelope of the equipment.working envelope of the equipment.

• Post appropriate WARNING signs at every workPost appropriate WARNING signs at every workPost appropriate WARNING signs at every workPost appropriate WARNING signs at every workcell entrance.cell entrance.cell entrance.cell entrance.

• Follow lockout procedure before servicing anyFollow lockout procedure before servicing anyFollow lockout procedure before servicing anyFollow lockout procedure before servicing anyequipment.equipment.equipment.equipment.

WARNING!Failure to follow operating instructionscould result in death or serious injury.

Read and understand this operator’s manual beforeRead and understand this operator’s manual beforeRead and understand this operator’s manual beforeRead and understand this operator’s manual beforeusing machine.using machine.using machine.using machine.

• Read entire procedure before operating orRead entire procedure before operating orRead entire procedure before operating orRead entire procedure before operating orperforming any system maintenance.performing any system maintenance.performing any system maintenance.performing any system maintenance.

• Special attention must be given to all hazardSpecial attention must be given to all hazardSpecial attention must be given to all hazardSpecial attention must be given to all hazardwarnings that provide essential informationwarnings that provide essential informationwarnings that provide essential informationwarnings that provide essential informationregarding personnel safety and/or possibleregarding personnel safety and/or possibleregarding personnel safety and/or possibleregarding personnel safety and/or possibleequipment damage.equipment damage.equipment damage.equipment damage.

• All safety precautions relevant to electricalAll safety precautions relevant to electricalAll safety precautions relevant to electricalAll safety precautions relevant to electricalequipment and process operations must beequipment and process operations must beequipment and process operations must beequipment and process operations must bestrictly observed by all having systemstrictly observed by all having systemstrictly observed by all having systemstrictly observed by all having systemresponsibility or access.responsibility or access.responsibility or access.responsibility or access.

• Read all safety publications made available byRead all safety publications made available byRead all safety publications made available byRead all safety publications made available byyour company.your company.your company.your company.

SECTION 1 SAFETY


WARNING!Failure to follow safety warning labelinstructions could result in death orserious injury.

Read and understand all safety warning labels onRead and understand all safety warning labels onRead and understand all safety warning labels onRead and understand all safety warning labels onmachine.machine.machine.machine.

Refer to operator’s manual for additional safetyRefer to operator’s manual for additional safetyRefer to operator’s manual for additional safetyRefer to operator’s manual for additional safetyinformation.information.information.information.

1.4 Installation Precautions

WARNING! Improperly Installed Equipment Can CauseInjury Or Death.

Follow these guidelines while installing machine:Follow these guidelines while installing machine:Follow these guidelines while installing machine:Follow these guidelines while installing machine:

• Contact your ESAB representative beforeContact your ESAB representative beforeContact your ESAB representative beforeContact your ESAB representative beforeinstallation. He can suggest certain precautionsinstallation. He can suggest certain precautionsinstallation. He can suggest certain precautionsinstallation. He can suggest certain precautionsregarding piping installation and machine lifting,regarding piping installation and machine lifting,regarding piping installation and machine lifting,regarding piping installation and machine lifting,etc. to ensure maximum security.etc. to ensure maximum security.etc. to ensure maximum security.etc. to ensure maximum security.

• Never attempt any machine modifications orNever attempt any machine modifications orNever attempt any machine modifications orNever attempt any machine modifications orapparatus additions without first consulting aapparatus additions without first consulting aapparatus additions without first consulting aapparatus additions without first consulting aqualified ESAB representative.qualified ESAB representative.qualified ESAB representative.qualified ESAB representative.

• Observe machine clearance requirements forObserve machine clearance requirements forObserve machine clearance requirements forObserve machine clearance requirements forproper operation and personnel safety.proper operation and personnel safety.proper operation and personnel safety.proper operation and personnel safety.

• Always have qualified personnel Always have qualified personnel Always have qualified personnel Always have qualified personnel performperformperformperforminstallation, troubleshooting and maintenance ofinstallation, troubleshooting and maintenance ofinstallation, troubleshooting and maintenance ofinstallation, troubleshooting and maintenance ofthis equipment.this equipment.this equipment.this equipment.

• Provide a wall mounted disconnect switch withProvide a wall mounted disconnect switch withProvide a wall mounted disconnect switch withProvide a wall mounted disconnect switch withproper fuse sizes close to the power supply.proper fuse sizes close to the power supply.proper fuse sizes close to the power supply.proper fuse sizes close to the power supply.

SECTION 1 SAFETY


1.5 Electrical Grounding

Electrical grounding is imperative for proper machineoperation and SAFETY. Refer to this manual’sInstallation section for detailed grounding instructions.

WARNING!Electric shock hazard.

Improper grounding can cause severe injury or death.Improper grounding can cause severe injury or death.Improper grounding can cause severe injury or death.Improper grounding can cause severe injury or death.

Machine must be properly grounded before put intoMachine must be properly grounded before put intoMachine must be properly grounded before put intoMachine must be properly grounded before put intoservice.service.service.service.

1.6 Operating A Plasma Cutting Machine

WARNING! Flying debris and loud noise hazards.

• Hot spatter can burn and injure eyes. WearHot spatter can burn and injure eyes. WearHot spatter can burn and injure eyes. WearHot spatter can burn and injure eyes. Weargoggles to protect eyes from burns and flyinggoggles to protect eyes from burns and flyinggoggles to protect eyes from burns and flyinggoggles to protect eyes from burns and flyingdebris generated during operation.debris generated during operation.debris generated during operation.debris generated during operation.

• Chipped slag may be hot and fly far. BystandersChipped slag may be hot and fly far. BystandersChipped slag may be hot and fly far. BystandersChipped slag may be hot and fly far. Bystandersshould also wear goggles and safety glasses.should also wear goggles and safety glasses.should also wear goggles and safety glasses.should also wear goggles and safety glasses.

• Noise from plasma arc can damage hearing. WearNoise from plasma arc can damage hearing. WearNoise from plasma arc can damage hearing. WearNoise from plasma arc can damage hearing. Wearcorrect ear protection when cutting above water.correct ear protection when cutting above water.correct ear protection when cutting above water.correct ear protection when cutting above water.

WARNING! Burn hazard.

Hot metal can burn.Hot metal can burn.Hot metal can burn.Hot metal can burn.

• Do not touch metal plate or parts immediately afterDo not touch metal plate or parts immediately afterDo not touch metal plate or parts immediately afterDo not touch metal plate or parts immediately aftercutting. Allow metal time to cool, or douse withcutting. Allow metal time to cool, or douse withcutting. Allow metal time to cool, or douse withcutting. Allow metal time to cool, or douse withwater.water.water.water.

• Do not touch plasma torch immediately afterDo not touch plasma torch immediately afterDo not touch plasma torch immediately afterDo not touch plasma torch immediately aftercutting. Allow torch time to cool.cutting. Allow torch time to cool.cutting. Allow torch time to cool.cutting. Allow torch time to cool.

SECTION 1 SAFETY


WARNING! Hazardous voltages. Electric shockcan kill.

• Do NOT touch plasma torch, cutting table or cableDo NOT touch plasma torch, cutting table or cableDo NOT touch plasma torch, cutting table or cableDo NOT touch plasma torch, cutting table or cableconnections during plasma cutting process.connections during plasma cutting process.connections during plasma cutting process.connections during plasma cutting process.

• Always turn power off to plasma power suppliesAlways turn power off to plasma power suppliesAlways turn power off to plasma power suppliesAlways turn power off to plasma power suppliesbefore touching or servicing plasma torch.before touching or servicing plasma torch.before touching or servicing plasma torch.before touching or servicing plasma torch.

• Always turn power off to plasma power suppliesAlways turn power off to plasma power suppliesAlways turn power off to plasma power suppliesAlways turn power off to plasma power suppliesbefore servicing any system component.before servicing any system component.before servicing any system component.before servicing any system component.

• Do not touch live electrical parts.Do not touch live electrical parts.Do not touch live electrical parts.Do not touch live electrical parts.

• Keep all panels and covers in place when machineKeep all panels and covers in place when machineKeep all panels and covers in place when machineKeep all panels and covers in place when machineis connected to power source.is connected to power source.is connected to power source.is connected to power source.

• Wear insulating gloves, shoes and clothing toWear insulating gloves, shoes and clothing toWear insulating gloves, shoes and clothing toWear insulating gloves, shoes and clothing toinsulate yourself from insulate yourself from insulate yourself from insulate yourself from workpiece and electricalworkpiece and electricalworkpiece and electricalworkpiece and electricalground.ground.ground.ground.

• Keep gloves, shoes, clothing, work area, andKeep gloves, shoes, clothing, work area, andKeep gloves, shoes, clothing, work area, andKeep gloves, shoes, clothing, work area, andequipment dry.equipment dry.equipment dry.equipment dry.

• Replace worn or damaged cables.Replace worn or damaged cables.Replace worn or damaged cables.Replace worn or damaged cables.

WARNING!Fume hazard.

Fumes and gases generated by the plasma cuttingFumes and gases generated by the plasma cuttingFumes and gases generated by the plasma cuttingFumes and gases generated by the plasma cuttingprocess can be hazardous to your health.process can be hazardous to your health.process can be hazardous to your health.process can be hazardous to your health.

• Do NOT breathe fumes.Do NOT breathe fumes.Do NOT breathe fumes.Do NOT breathe fumes.

• Do not operate plasma torch without fume removalDo not operate plasma torch without fume removalDo not operate plasma torch without fume removalDo not operate plasma torch without fume removalsystem operating properly.system operating properly.system operating properly.system operating properly.

• Use additional ventilation to remove fumes ifUse additional ventilation to remove fumes ifUse additional ventilation to remove fumes ifUse additional ventilation to remove fumes ifnecessary.necessary.necessary.necessary.

• Use approved respirator if ventilation is notUse approved respirator if ventilation is notUse approved respirator if ventilation is notUse approved respirator if ventilation is notadequate.adequate.adequate.adequate.

• Provide positive mechanical ventilation whenProvide positive mechanical ventilation whenProvide positive mechanical ventilation whenProvide positive mechanical ventilation whencutting galvanized steel, stainless steel, copper,cutting galvanized steel, stainless steel, copper,cutting galvanized steel, stainless steel, copper,cutting galvanized steel, stainless steel, copper,zinc, beryllium, or cadmium. Do not breathe thesezinc, beryllium, or cadmium. Do not breathe thesezinc, beryllium, or cadmium. Do not breathe thesezinc, beryllium, or cadmium. Do not breathe thesefumes.fumes.fumes.fumes.

• Do not operate near degreasing and sprayingDo not operate near degreasing and sprayingDo not operate near degreasing and sprayingDo not operate near degreasing and sprayingoperations. Heat or arc rays can react withoperations. Heat or arc rays can react withoperations. Heat or arc rays can react withoperations. Heat or arc rays can react withchlorinated hydrocarbon vapors to form phosgene,chlorinated hydrocarbon vapors to form phosgene,chlorinated hydrocarbon vapors to form phosgene,chlorinated hydrocarbon vapors to form phosgene,a highly toxic gas and other irritant gases.a highly toxic gas and other irritant gases.a highly toxic gas and other irritant gases.a highly toxic gas and other irritant gases.

SECTION 1 SAFETY


WARNING! Radiation hazard.

Arc rays can injure eyes and burn Arc rays can injure eyes and burn Arc rays can injure eyes and burn Arc rays can injure eyes and burn skin.skin.skin.skin.

• Wear correct eye and body protection.Wear correct eye and body protection.Wear correct eye and body protection.Wear correct eye and body protection.

• Wear dark safety glasses or goggles with Wear dark safety glasses or goggles with Wear dark safety glasses or goggles with Wear dark safety glasses or goggles with sidesidesidesideshields. Refer to following chart for recommendedshields. Refer to following chart for recommendedshields. Refer to following chart for recommendedshields. Refer to following chart for recommendedlens shades for plasma cutting:lens shades for plasma cutting:lens shades for plasma cutting:lens shades for plasma cutting:

Arc CurrentArc CurrentArc CurrentArc Current Lens Shade Lens Shade Lens Shade Lens ShadeUp to 100 AmpsUp to 100 AmpsUp to 100 AmpsUp to 100 Amps Shade No. 8Shade No. 8Shade No. 8Shade No. 8100-200 Amps100-200 Amps100-200 Amps100-200 AmpsShade No. 10Shade No. 10Shade No. 10Shade No. 10200-400 Amps200-400 Amps200-400 Amps200-400 AmpsShade No. 12Shade No. 12Shade No. 12Shade No. 12Over 400 AmpsOver 400 AmpsOver 400 AmpsOver 400 Amps Shade No. 14Shade No. 14Shade No. 14Shade No. 14

• Replace glasses/goggles when lenses are pitted orReplace glasses/goggles when lenses are pitted orReplace glasses/goggles when lenses are pitted orReplace glasses/goggles when lenses are pitted orbrokenbrokenbrokenbroken

• Warn others in area not to look directly at the arcWarn others in area not to look directly at the arcWarn others in area not to look directly at the arcWarn others in area not to look directly at the arcunless wearing appropriate safety glasses.unless wearing appropriate safety glasses.unless wearing appropriate safety glasses.unless wearing appropriate safety glasses.

• Prepare cutting area to reduce reflection andPrepare cutting area to reduce reflection andPrepare cutting area to reduce reflection andPrepare cutting area to reduce reflection andtransmission of ultraviolet light.transmission of ultraviolet light.transmission of ultraviolet light.transmission of ultraviolet light.

Use special paint on walls to absorb UVUse special paint on walls to absorb UVUse special paint on walls to absorb UVUse special paint on walls to absorb UVlight.light.light.light.

Install protective screens or curtains toInstall protective screens or curtains toInstall protective screens or curtains toInstall protective screens or curtains toreduce ultraviolet transmission.reduce ultraviolet transmission.reduce ultraviolet transmission.reduce ultraviolet transmission.

WARNING! Burn Hazard.

Heat, spatter, and sparks cause fire and burns.Heat, spatter, and sparks cause fire and burns.Heat, spatter, and sparks cause fire and burns.Heat, spatter, and sparks cause fire and burns.

• Do not cut near combustible material.Do not cut near combustible material.Do not cut near combustible material.Do not cut near combustible material.

• Do not have on your person any combustibles (e.g.Do not have on your person any combustibles (e.g.Do not have on your person any combustibles (e.g.Do not have on your person any combustibles (e.g.butane lighter).butane lighter).butane lighter).butane lighter).

• Pilot arc can cause burns. Keep torch nozzlePilot arc can cause burns. Keep torch nozzlePilot arc can cause burns. Keep torch nozzlePilot arc can cause burns. Keep torch nozzleaway from yourself and others when activatingaway from yourself and others when activatingaway from yourself and others when activatingaway from yourself and others when activatingplasma process.plasma process.plasma process.plasma process.

• Wear correct eye and body protection.Wear correct eye and body protection.Wear correct eye and body protection.Wear correct eye and body protection.

• Wear gauntlet gloves, safety shoes and hat.Wear gauntlet gloves, safety shoes and hat.Wear gauntlet gloves, safety shoes and hat.Wear gauntlet gloves, safety shoes and hat.

• Wear flame-retardant clothing covering all exposedWear flame-retardant clothing covering all exposedWear flame-retardant clothing covering all exposedWear flame-retardant clothing covering all exposedareas.areas.areas.areas.

• Wear Wear Wear Wear cuffless trousers to prevent entry of sparkscuffless trousers to prevent entry of sparkscuffless trousers to prevent entry of sparkscuffless trousers to prevent entry of sparksand slag.and slag.and slag.and slag.

• Have Have Have Have fire extinguishing equipment available for use.fire extinguishing equipment available for use.fire extinguishing equipment available for use.fire extinguishing equipment available for use.

SECTION 1 SAFETY


WARNING! Explosion hazard.

• Certain molten aluminum-lithium (Al-Certain molten aluminum-lithium (Al-Certain molten aluminum-lithium (Al-Certain molten aluminum-lithium (Al-Li) alloys canLi) alloys canLi) alloys canLi) alloys cancause explosions when plasma cut OVER water.cause explosions when plasma cut OVER water.cause explosions when plasma cut OVER water.cause explosions when plasma cut OVER water.

These alloys should only be dry cut on a dryThese alloys should only be dry cut on a dryThese alloys should only be dry cut on a dryThese alloys should only be dry cut on a drytable.table.table.table.

DO NOT dry cut over water.DO NOT dry cut over water.DO NOT dry cut over water.DO NOT dry cut over water. Contact your aluminum supplier forContact your aluminum supplier forContact your aluminum supplier forContact your aluminum supplier for

additional safety information regardingadditional safety information regardingadditional safety information regardingadditional safety information regardinghazards associated with these alloyshazards associated with these alloyshazards associated with these alloyshazards associated with these alloys.

• Do not cut in atmospheres containing explosiveDo not cut in atmospheres containing explosiveDo not cut in atmospheres containing explosiveDo not cut in atmospheres containing explosivedust or vapors.dust or vapors.dust or vapors.dust or vapors.

• Do not carry any combustibles on your personDo not carry any combustibles on your personDo not carry any combustibles on your personDo not carry any combustibles on your person(e.g. butane lighter)(e.g. butane lighter)(e.g. butane lighter)(e.g. butane lighter)

• Do not cut containers that have held combustibles.Do not cut containers that have held combustibles.Do not cut containers that have held combustibles.Do not cut containers that have held combustibles.

SECTION 1 SAFETY


1.7 Service Precautions

WARNING! Hazardous voltages. Electric shockcan kill.

• Do NOT touch plasma torch, cutting table or cableDo NOT touch plasma torch, cutting table or cableDo NOT touch plasma torch, cutting table or cableDo NOT touch plasma torch, cutting table or cableconnections during plasma cutting process.connections during plasma cutting process.connections during plasma cutting process.connections during plasma cutting process.

• Always turn power off to plasma power suppliesAlways turn power off to plasma power suppliesAlways turn power off to plasma power suppliesAlways turn power off to plasma power suppliesbefore touching or servicing plasma torch.before touching or servicing plasma torch.before touching or servicing plasma torch.before touching or servicing plasma torch.

• Always turn power off to plasma power suppliesAlways turn power off to plasma power suppliesAlways turn power off to plasma power suppliesAlways turn power off to plasma power suppliesbefore removing covers or panels to service anybefore removing covers or panels to service anybefore removing covers or panels to service anybefore removing covers or panels to service anysystem component.system component.system component.system component.

• Do not touch live electrical parts.Do not touch live electrical parts.Do not touch live electrical parts.Do not touch live electrical parts.

• Keep all panels and covers in place when machineKeep all panels and covers in place when machineKeep all panels and covers in place when machineKeep all panels and covers in place when machineis connected to power source.is connected to power source.is connected to power source.is connected to power source.

• Keep gloves, shoes, clothing, work area, andKeep gloves, shoes, clothing, work area, andKeep gloves, shoes, clothing, work area, andKeep gloves, shoes, clothing, work area, andequipment dry.equipment dry.equipment dry.equipment dry.

• Inspect power and ground leads cables for wear orInspect power and ground leads cables for wear orInspect power and ground leads cables for wear orInspect power and ground leads cables for wear orcracking. Replace worn or damaged cables. Docracking. Replace worn or damaged cables. Docracking. Replace worn or damaged cables. Docracking. Replace worn or damaged cables. Donot use if damaged.not use if damaged.not use if damaged.not use if damaged.

• Never bypass safety interlocks.Never bypass safety interlocks.Never bypass safety interlocks.Never bypass safety interlocks.

• Follow Follow Follow Follow lock-out procedures.lock-out procedures.lock-out procedures.lock-out procedures.

CAUTION Establish and adhere to preventive maintenance. AEstablish and adhere to preventive maintenance. AEstablish and adhere to preventive maintenance. AEstablish and adhere to preventive maintenance. Acomposite program can be established fromcomposite program can be established fromcomposite program can be established fromcomposite program can be established fromrecommended schedules.recommended schedules.recommended schedules.recommended schedules.

Avoid leaving test equipment or hand tools onAvoid leaving test equipment or hand tools onAvoid leaving test equipment or hand tools onAvoid leaving test equipment or hand tools onmachine. Severe electrical or mechanical damagemachine. Severe electrical or mechanical damagemachine. Severe electrical or mechanical damagemachine. Severe electrical or mechanical damagecould occur to equipment or machine.could occur to equipment or machine.could occur to equipment or machine.could occur to equipment or machine.

CAUTION! Extreme caution should be used when probingExtreme caution should be used when probingExtreme caution should be used when probingExtreme caution should be used when probingcircuitry with an oscilloscope or voltmeter. Integratedcircuitry with an oscilloscope or voltmeter. Integratedcircuitry with an oscilloscope or voltmeter. Integratedcircuitry with an oscilloscope or voltmeter. Integratedcircuits are susceptible to over voltage damage.circuits are susceptible to over voltage damage.circuits are susceptible to over voltage damage.circuits are susceptible to over voltage damage.Power off before using test probes to preventPower off before using test probes to preventPower off before using test probes to preventPower off before using test probes to preventaccidental shorting of components.accidental shorting of components.accidental shorting of components.accidental shorting of components.

All circuit boards securely seated in sockets, all cablesAll circuit boards securely seated in sockets, all cablesAll circuit boards securely seated in sockets, all cablesAll circuit boards securely seated in sockets, all cablesproperly connected, all cabinets closed and locked, allproperly connected, all cabinets closed and locked, allproperly connected, all cabinets closed and locked, allproperly connected, all cabinets closed and locked, allguards and covers replaced before power is turnedguards and covers replaced before power is turnedguards and covers replaced before power is turnedguards and covers replaced before power is turnedon.on.on.on.

SECTION 1 SAFETY


1.8 Safety References

The following nationally recognized publications on safety in weldingand cutting operations are recommended. These publications havebeen prepared to protect persons from injury or illness and to protectproperty from damage, which could result from unsafe practices.Although some of these publications are not related specifically to thistype of industrial cutting apparatus, the principles of safety applyequally.

• “Precautions and Safe Practices in Welding and Cutting withOxygen-Fuel Gas Equipment,” Form 2035. ESAB CuttingSystems.

• “Precautions and Safe Practices for Electric Welding and Cutting,”Form 52-529. ESAB Cutting Systems.

• “Safety in Welding and Cutting” - ANSI Z 49.1, American WeldingSociety, 2501 NW 7th Street, Miami, Florida, 33125.

• “Recommended Safe Practices for Shielded Gases for Welding andPlasma Arc Cutting” - AWS C5.10-94, American Welding Society.

• “Recommended Practices for Plasma Arc Welding” - AWS C5.1,American Welding Society.

• “Recommended Practices for Arc Cutting” - AWS C5.2, AmericanWelding Society.

• “Safe Practices” - AWS SP, American Welding Society.

• “Standard for Fire Protection in Use of Cutting and WeldingProcedures” - NFPA 51B, National Fire Protection Association, 60Batterymarch Street, Boston, Massachusetts, 02110.

• “Standard for Installation and Operation of Oxygen - Fuel GasSystems for Welding and Cutting” - NFPA 51, National FireProtection Association.

• “Safety Precautions for Oxygen, Nitrogen, Argon, Helium, CarbonDioxide, Hydrogen, and Acetylene,” Form 3499. ESAB CuttingSystems. Obtainable through your ESAB representative or localdistributor.

• "Design and Installation of Oxygen Piping Systems," Form 5110.ESAB Cutting Systems.

• “Precautions for Safe Handling of Compressed Gases inCylinders”, CGA Standard P-1, Compressed Gas Association.

Literature applicable to safe practices in welding and cutting withgaseous materials is also available from the Compressed GasAssociation, Inc., 500 Fifth Ave., New York, NY 10036.

SECTION 1 SAFETY



SECTION 2 Description

ESP 600C Plasma Power SourceESP 600C Plasma Power SourceESP 600C Plasma Power SourceESP 600C Plasma Power Source 2-1

2.1 IntroductionThe ESP power Source is designed for high speedplasma mechanized cutting applications. It can beused with other ESAB products such as the PT-15and PT-600 torches along with the Smart Flow II, acomputerized gas regulation and switching system.

• 50 to 600 Amperes cutting current range

• Forced air cooled

• Solid state DC power

• Input voltage protection

• Local or remote front panel control

• Thermal switch protection for main transformerand power semiconductor components

• Top lifting rings or base forklift clearance fortransport

• Parallel secondary power source capabilities toextend current output range.

2.2 General SpecificationsESP-600C 400V,ESP-600C 400V,ESP-600C 400V,ESP-600C 400V,

50Hz50Hz50Hz50HzESP-600C 460V,ESP-600C 460V,ESP-600C 460V,ESP-600C 460V,

60Hz60Hz60Hz60HzESP-600C 575V,ESP-600C 575V,ESP-600C 575V,ESP-600C 575V,

60Hz60Hz60Hz60HzColor SchemeColor SchemeColor SchemeColor Scheme

Part NumberPart NumberPart NumberPart NumberBlackBlackBlackBlack35879358793587935879

Yel-gryYel-gryYel-gryYel-gry35610356103561035610

BlackBlackBlackBlack35878358783587835878


BlackBlackBlackBlack35880358803588035880


VoltageVoltageVoltageVoltage 200 V dc

Current rangeCurrent rangeCurrent rangeCurrent rangeDCDCDCDC 50A to 600A

PowerPowerPowerPower 120KW

OUTPUT (100OUTPUT (100OUTPUT (100OUTPUT (100% duty cycle)% duty cycle)% duty cycle)% duty cycle)

Open CircuitOpen CircuitOpen CircuitOpen CircuitVoltage (OCV)Voltage (OCV)Voltage (OCV)Voltage (OCV) 427 V dc

VoltageVoltageVoltageVoltage(3-phase)(3-phase)(3-phase)(3-phase) 400 V 460 V 575 V

CurrentCurrentCurrentCurrent(3- phase)(3- phase)(3- phase)(3- phase) 206 A RMS 179 A RMS 143 A RMS

FrequencyFrequencyFrequencyFrequency 50/60 HZ 60 Hz 60 Hz

KVAKVAKVAKVA 142.7 KVA 142.6 KVA 142.4 KVA

PowerPowerPowerPower 129.9 KW 129.8 KW 129.6 KW

INPUTINPUTINPUTINPUT

Power FactorPower FactorPower FactorPower Factor 91 %

Fuse Fuse Fuse Fuse Recom.Recom.Recom.Recom. 250A 250A 200A

SECTION 2 Description

ESP 600C Plasma Power SourceESP 600C Plasma Power SourceESP 600C Plasma Power SourceESP 600C Plasma Power Source2-2

VOLTS

AMPS

OUTPUT

ACTUAL AMPS

PRESET AMPS

LOW

HIGHPILOTARC

50MIN

100

200

300400

500

600MAX

0 MAINPOWERCURRENT

PANEL

REMOTE

OVERTEMP

CONTACTORON

FAULT

POWERRESETFAULT

6 0 0 C6 0 0 C6 0 0 C6 0 0 C

37.25"(94.62cm)

40.25"(102.24cm)

45.00"(114.3cm)

2.3 Dimensions and Weight

Front View

Side View

Weight = 2040 lbs.(925.34 kg.)

SECTION 3 Installation

ESP-600C Plasma Power Source 3-1

WARNING!

CAUTION

6 0 0 C

3.1 General

Failure To Follow Instructions Could Lead To Death, Injury Or Damaged Property Follow these instructions to prevent injury or property damage. You must comply with local, state and national electrical and safety codes.

3.2 Unpacking

Using One Lifting Eye Will Damage Sheet Metal And Frame Use both lifting eyes when transporting with overhead method. Unit weighs over 2000 lbs. Use approved straps or cables in good condition.

• Inspect for transit damage immediately upon

receipt.

• Remove all components from shipping container and check for loose parts in container.

• Inspect louvers for air obstructions.



WARNING!

3.3 Placement Note: Use both lifting eyes when transporting

from overhead.

• A minimum of 2 ft. clearance on front and back for cooling air flow.

• Plan for top panel and side panels having to be removed for maintenance, cleaning and inspection.

• Locate the ESP-600C relatively close to a properly fused electrical power supply.

• Keep area beneath power source clear for cooling air flow.

• Environment should be relatively free of dust, fumes and excessive heat. These factors will affect cooling efficiency.

CAUTION Conductive Dust And Dirt Inside Power Source May Cause Arc Flash-Over Equipment damage may occur. Electrical shorting may occur if dust is allowed to build-up inside power source. See maintenance section.

3.4 Input Power Connection

Electric Shock Can Kill! Provide maximum protection against electrical shock. Before any connections are made inside the machine, open the line wall disconnect switch to turn power off.

Power Source



3.4.1 Primary Power ESP-600C is a 3-phase unit. Input power must be

provided from a line (wall) disconnect switch that contains fuses or circuit breakers in accordance to local or state regulations. Recommended input conductor and line fuse sizes:

Rated Load

Volts Amperes

Input and Ground

conductor* CU/AWG

Time delay Fuse size (amperes)

400 460 575

206 179 143

4/0 3/0 1/0

250 250**

200 *Sizes per National Electrical Code for a 90 °C rated

copper conductors @ 40 °C ambient. Not more than three conductors in raceway or cable. Local codes should be followed if they specify sizes other than those listed above. **During heavy duty cutting at 600A, input current can momentarily rise above 200A and cause nuisance blowing of 200A fuses. When cutting currents are below 500A, 200A fuses are sufficient.

NOTICE

Dedicated power line may be necessary. ESP-600C is equipped with line voltage compensation but to avoid impaired performance due to an overloaded circuit, a dedicated power line may be required.



NOTICE

3.4.2 Input Conductors • Customer supplied

• May consist either of heavy rubber covered copper conductors (three power and one ground) or run in solid or flexible conduit.

• Sized according to the chart. Input conductors must be terminated with

ring terminals. Input conductors must be terminated with ring terminals sized for ½" hardware before being attached to the ESP-600C.

3.4.3 Input Connection Procedure

1. Remove left side panel of the ESP-600C

2. Thread cables through the access opening in the rear panel.

3. Secure cables with a strain relief or conduit coupling (not supplied) at the access opening.

4. Connect the ground lead to the stud on the chassis base.

5. Connect the power lead ring terminals to the primary terminals with supplied bolts, washers and nuts.

6. Connect the input conductors to the line (wall) disconnect.

Chassis Ground Power Input Cable Access opening (rear panel)

Primary Terminals



WARNING!

WARNING!

WARNING!

Electric Shock Can Kill! Ring terminals must have clearance between side panel and main transformer. Clearance must be sufficient to prevent possible arcing Make sure cables do not interfere with cooling fan rotation.

Improper Grounding Can Result In

Death or Injury. Chassis must be connected to an approved electrical ground. Be sure ground lead is NOT connected to any primary terminal.

3.5 Output Connections

Electric Shock Can Kill! Dangerous Voltage And Current! Any time working around a plasma power source with covers removed: • Disconnect power source at the line(wall)

disconnect. • Have a qualified person check the output

bus bars (positive and negative) with a voltmeter.

3.5.1 Output Cables (customer supplied)

Choose plasma cutting output cables (customer supplied) on the basis of one 4/0 AWG, 600 volt insulated copper cable for each 400 amps of output current. Note: Do not use 100 volt insulated welding cable.



3.5.2 Output Connection Procedure

1. Remove access panel on the lower front of the power source.

2. Thread output cables through the openings at the bottom of the front panel or at the bottom of the power source immediately behind the front panel.

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

4. Replace panel removed during the first step.

3.6 Parallel Installation

Two power sources may be connected together to extend the output current range.

CAUTIONParallel power source start currents exceed recommended amounts when cutting below 100A. Use Only One Power Source For Currents Below 100A. We recommend disconnecting the negative lead from the secondary power source when changing to currents below 100 amperes. This lead should be safely terminated (insulated) to protect against electric shock.

Access Panel



WARNING!

Note: Primary power source has the electrode (-) conductor jumpered. The secondary power source has the work (+) jumpered. 1. Connect the negative (-) output cables to the

plumbing box (high frequency generator).

2. Connect the positive (+) output cables to the workpiece.

3. Connect the positive (+) and negative (-) conductors between the power sources.

4. Connect the pilot arc cable to the pilot arc terminal in the primary power source. The pilot arc connection in the secondary power source is not used. The pilot arc circuit is not run in parallel.

5. Set the Pilot Arc HIGH/LOW switch on the secondary power source to “LOW”.

6. Set the Pilot Arc HIGH/LOW switch on the primary power source to “HIGH”.

electrode(-)

work(+)

electrode(-)

work(+)

3 - 4/0 600Vnegative leads

to plumbing box(high freq.generator)

3 - 4/0 600Vpositive leads to

workpiece

Primary PowerSource

Secondary PowerSource

Disconnectnegative

connection fromsecondary power source

and insulate toconvert from two

to one powersources

Electric Shock Can Kill! Exposed Electrical Conductors Can Be Hazardous! Do not leave electrically “hot “ conductors exposed. When disconnecting the secondary power source from the primary, verify the correct cables were disconnected. Insulate the disconnected ends. When using only one power source in a parallel configuration, the negative electrode conductor must be disconnected from the secondary power source and the plumbing box. Failure to do this will leave the secondary electrically “hot”.

electrode(-)

work (+)

electrode (-)

work (+)

3 - 4/0 600Vnegative leadsto plumbing box

3 - 4/0 600V positive leads to

workpiece

Primary PowerSource

Secondary Power Source

4/0 600V Cable jumpers

between units

1 - 14 AWG 600V lead to pilot

arc connection in plumbing box

(h.f. generator)(h.f. generator)

pilot arc

Connections for Parallel Installation of 2 Power sources



3.7 System Interconnecting Block Diagram with Smart Flow II

600C

ESP-600CFront viewESP-600C

Back view

N2 O2 Air H-35

SmartFlow II

Pilot Arc

Torch (-)

On/OffControl

Remote toCNC

Cooling WaterTo Torch

Cooling WaterFrom Torch

Work (+)

Earth Ground

Plasma TorchBundle and

Torch

3 phasew/ground

CNC I/O toSmart Flow II

WC-7WaterCooler

VoltageHeightControl

CNC

Cut WaterPump

(for PT-15)



GasRegulators

WallBox

Power Source

Cooler(WC-7)

CutWaterPump

Flow Control Plumbing Box

HeightControl

TORCHPT-15 OR PT-600

Cutting MachineControl

Work Piece

ProcessOK

(+) ReturnLead

Inputpower

O2 Cut gas

N2 StartGas

Coolant On-Off Coolant Return

Coolant Output

Start Gas Solenoid

Cut gas Solenoid

High Freq. On-Off

Interlocks

(-) CutCurrent

Pilot Arc

Gas

Pilot arc High Freq

injection waterCoolant toCurrent to

Coolant From

Height Ref.

Process on-off

E-stop

Current RefInterlocks

Volt-Feedback

Work piecevoltage

Cut Gas

Injection Water

on-off

Start Gas

3.8 System Interconnecting Block Diagram with Manual Flow Control




SECTION 4 Operation

ESP-600C Plasma Power SourceESP-600C Plasma Power SourceESP-600C Plasma Power SourceESP-600C Plasma Power Source 4-1

4.1 Introduction

The ESP-600C does not have an ON/OFF switch.The main power is controlled through the line(wall)disconnect switch.

WARNING!Do not operate the ESP-600C withCovers Removed.

High voltage components are exposedincreasing shock hazard.

Internal component may be damagedbecause cooling fans will lose efficiency.

4.2 Control Panel

Main PowerMain PowerMain PowerMain Power

Indicator illuminates when input power is applied tothe power source.

Over TempOver TempOver TempOver Temp

Indicator illuminates when power source hasoverheated.

Contactor OnContactor OnContactor OnContactor On

Indicator illuminates when the main contactor isenergized.

SECTION 4 Operation

ESP-600C Plasma Power SourceESP-600C Plasma Power SourceESP-600C Plasma Power SourceESP-600C Plasma Power Source4-2

FaultFaultFaultFault

Indicator illuminates when there are abnormalities inthe cutting process or when the input line voltagefalls outside of the required nominal value by ±10%.

Power Reset FaultPower Reset FaultPower Reset FaultPower Reset Fault

Indicator illuminates when a serious fault isdetected. Input power must be disconnected for atleast 5 seconds and then reapplied.

Current Dial (Potentiometer)Current Dial (Potentiometer)Current Dial (Potentiometer)Current Dial (Potentiometer)

ESP-600C dial shown. ESP-600C has a range of50 to 600 A. Used only in panel mode.

Panel Remote SwitchPanel Remote SwitchPanel Remote SwitchPanel Remote Switch

Controls the location of current control.• Place in the PANEL position for control using

the current potentiometer.• Place in REMOTE position for control from an

external signal (CNC).

Remote ConnectionRemote ConnectionRemote ConnectionRemote Connection

Amphenol 19 pin plug for connecting power sourceto CNC.

Pilot Arc HIGH/LOW SwitchPilot Arc HIGH/LOW SwitchPilot Arc HIGH/LOW SwitchPilot Arc HIGH/LOW Switch

Used to select amount of pilot arc current desired.As a general rule, for 100 amperes and below, asetting of LOW is used. This can vary dependingon gas, material and torch used. High/Low settingsare specified in cutting data included in the torchmanual.

SECTION 4 Operation


WARNING!

MetersMetersMetersMeters

Displays voltage and amperage when cutting. Theammeter can be activated when not cutting to viewan estimation of the cutting current before cuttingbegins.

Actual/Preset Switch

Spring return toggle switch defaults to ACTUALposition. When pressed down, the AMMETERdisplays an estimate of the actual current. Thispermits the operator to preset the cutting currentclose to the desired current using the currentpotentiometer.

Final adjustment is made after the torch has startedcutting to achieve a more precise current.

Dangerous Voltages and Current!

Electric Shock Can Kill!

Before operation, ensure installation andBefore operation, ensure installation andBefore operation, ensure installation andBefore operation, ensure installation andgrounding procedures have been followed.grounding procedures have been followed.grounding procedures have been followed.grounding procedures have been followed.

Do not operate this equipment with coversDo not operate this equipment with coversDo not operate this equipment with coversDo not operate this equipment with coversremoved.removed.removed.removed.

SECTION 4 Operation


BeginCutting

ACTUAL AMPS

PRESET AMPS

HIGH

LOW

PILOTARC

PANEL

REMOTE

Apply Power

4.3 Sequence of Operation

1. Apply power by closing the line (wall) switch.(The ESP-600C does not have an on/offswitch). The main power light will illuminateand the fault light will flash and then go out.

2. Select the Panel/Remote setting.

3. Set pilot arc High/Low switch. (Refer to cuttingdata in the torch manual.)

4. If using panel mode, view preset amps with theACTUAL/PRESET AMPS switch. Adjust currentuntil the approximate desired value is shown onthe ammeter.

5. Begin plasma cutting operation. This mayinclude manually setting up other options,depending on the total plasma package.

6. If using panel mode, after cutting has begun,adjust current to desired amount.

7. Check for fault light. If a fault light illuminates,refer to troubleshooting section.

Note: The fault light flashes when the contactor isNote: The fault light flashes when the contactor isNote: The fault light flashes when the contactor isNote: The fault light flashes when the contactor isfirst turned on signifying the DC Bus powered upfirst turned on signifying the DC Bus powered upfirst turned on signifying the DC Bus powered upfirst turned on signifying the DC Bus powered upnormally.normally.normally.normally.

4.4 Arc Initiation SettingsThe time to achieve full current can be adjusted tosuit your particular system. This feature uses 50%of the cutting current to start, dwell and thengradually (less than a second) achieve full current.The ESP-600C is factory shipped with this featureenabled. The default settings are:

Minimum Start Current 40A

Start Current 50% of cut current

Timing to achieve full current 800 msec

Dwell Time 50 msec

SECTION 4 Operation


WARNING!

DC

Ou

tpu

t C

urr

ent

Time

Cut Current

approx. 2 msec time tofull current

Start Current Waveform With ArcInitiation Timer OFF

DC

Ou

tpu

t C

urr

ent

Time

Cut Current

Start Current Waveform With ArcInitiation Timer ON

Start Current

Dwell Time tofull current800 msec

1OUT = 80 VREF

1OUT = 80 VREF

These timing functions can be disabled or adjustedto suit individual system requirements.


Shut off power at the line (wall) disconnectbefore removing any covers or making anyadjustments to the power source.

SECTION 4 Operation


1 2

ON

OFF

ON

OFF

1 2 3 4 5 6 7 8

SW2

4.4.1 Enable/Disable Arc Initiation Timer

Factory default setting shown.1. Remove access panel on the upper-right corner

of the front panel. Be sure to replace this panelafter adjustments have been made.

2. Locate SW1 and PCB1 and push both rockerswitches down to disable. To enable push bothswitches up. (If one switch is up and the otheris down, arc initiation time is considered on.)

4.4.2 Adjusting Arc Initiation Timer

Minimum Start Current

Controlled by selection of positions 5 through 8 ofSW2. When a switch is pushed on, its value isadded to the factory set minimum value of 40A.

Switch #5 = 80A min. start currentSwitch #6 = 40A min. start currentSwitch #7 = 20A min. start currentSwitch #8 = 10A min. start current

Default setting is with all switches off. = 40A

Dwell Time

Controlled by selections of positions 1 through 4 ofSW2 on PCB1. When a switch is pushed on, itsvalue is added to the minimum dwell time of 10msec.

Switch #1 = 10 msec dwell timeSwitch #2 = 20 msec dwell timeSwitch #3 = 40 msec dwell timeSwitch #4 = 80 msec dwell time

The default setting is with switch #3 on. 40 msec +10 msec (minimum) = 50 msec

SW1

Factory default settings shown

SECTION 4 Operation


4.4.3 Arc Initiation Controls

4.4.4 Start Current and Up-Slope Timer

90%

80%

70%

60%

50%

40%

30%

20%

10%

0%

0 1 2 3 4 5 6 7 8 9 10 MAX

Start Current Pot Setting

Per

cen

tag

e (%

) o

f C

utt

ing

Cu

rren

t

Starting Curent (%) and Pot SettingRelationship

Start CurrentStart CurrentStart CurrentStart CurrentSet using potentiometer located above and to theleft of center of PCB1. Factory default setting is 7.

Up-Slope TimerUp-Slope TimerUp-Slope TimerUp-Slope TimerThree position switch located next to the startcurrent potentiometer. Time is from start current(after dwell ends) to full current. Factory default =800 msec.

Left position = 250 msecCenter position = 800 msecRight Position = 1200 msec

SW2

SW1

Start Current Pot UP-Slope Timer

SECTION 4 Operation


4.5 ESP-600C V-I Curves

ESP-600C V-I CURVES

0

50

100

150

200

250

300

350

400

450

0 100 200 300 400 500 600 700

OUTPUT CURRENT (Amperes)

OU

TPU

T V

OLT

AG

E (

Vol

ts)

VR

EF

= 0.

625V

MIN

R

ATI

NG

VR

EF

= 4.

000V

VR

EF

= 3.

000V

VR

EF

= 2.

000V

VR

EF

= 1.

000V

INTE

RN

AL

CU

RR

EN

T LI

MIT

VR

EF

= 7.

500V

VR

EF

= 7.

000V

VR

EF

= 6.

000V

VR

EF

= 5.

000V

MA

X R

ATI

NG

427V Open Circuit (460V & 575V Models)410V Open Circuit (400V Model)

Output of Boost/Start Circuit

Max Output Voltage @ Nominal Line

IOUT = (80) x (VREF)

SECTION 5 Maintenance


WARNING!

WARNING!

CAUTION!

5.1 General


Shut off power at the line (wall) disconnectbefore attempting any maintenance.

Eye Hazard When UsingCompressed Air To Clean.

• Wear approved eye protection with sideshields when cleaning the powersource.

• Use only low pressure air.

Maintenance On This EquipmentShould Only Be Performed ByTrained Personnel.

5.2 CleaningRegularly scheduled cleaning of the power source isrequired to help keep the unit running trouble free.The frequency of cleaning depends on environmentand use.

1. Turn power off at wall disconnect.2. Remove side panels.3. Use low pressure compressed dry air, remove

dust from all air passages and components.Pay particular attention to heat sinks in the frontof the unit. Dust insulates, reducing heatdissipation. Be sure to wear eye protection.Be sure to wear eye protection.Be sure to wear eye protection.Be sure to wear eye protection.

SECTION 5 Maintenance


CAUTION Air Restrictions May Cause ESP-600C To Over Heat.

Thermal Switches may be activatedcausing interruption of function.

Do not use air filters on this unit.

Keep air passages clear of dust and otherobstructions.

5.3 Lubrication

• Some units are equipped with oil tubes on thefans. These fans should be oiled after 1 year ofservice.

• All other ESP-600Cs have fan motors that arepermanently lubricated and require no regularmaintenance.

WARNING!Electric Shock Hazard!

Be sure to replace any covers removedduring cleaning before turning power backon.

SECTION 6 Troubleshooting

ESP 400C and 600C Plasma Power Sources 6-1

VOLTS

AMPS

OUTPUT

ACTUAL AMPS

PRESET AMPS

LOW

HIGHPILOTARC

50MIN

100

200

300400

500

600MAX

0 MAINPOWERCURRENT

PANEL

REMOTE

OVERTEMP

CONTACTORON

FAULT

POWERRESETFAULT

6 0 0 C

WARNING!

6.1 General

Electric Shock Can Kill! Do not permit untrained persons to inspect or repair this equipment. Electrical work must be performed by an experienced electrician.

CAUTION! Stop Work Immediately If Power Source Does Not Work Properly. Have only trained personnel investigate the cause. Use only recommended replacement parts.

6.2 Fault Indicators

Fault indicators are found on the front panel Used with the LEDs on PCB1 (located behind the cover with the ESP label) problems can be diagnosed. NOTE: Momentary lighting (flashing) is normal and does not indicated a fault. Fault Indicator used with: LED 3 LED 4 LED 5 LED 7 LED 8 Power Reset Fault Indicator used with: LED 6 LED 9 LED 10 LED 11 LED 12 LED 13

Front Panel Fault Indicators PCB1 Located behind this panel.



Fault Indicator (Front Panel)

Illuminates when there are abnormalities in the cutting process or when the input voltage falls ±10% outside the normal value. Momentary illumination is normal. If continuously lit, check LEDs 3, 4, 5, 7, and 8 on PCB1 for further diagnosis.

LED 3 – (amber) Bus Ripple Fault - Momentarily illuminates at the beginning of each cut. Continuously lit during single-phasing or imbalanced line-to-line voltages of the three phase input line.(Excessive Ripple) Power Source is shut down.

LED 4 – (amber) High Bus Fault – Illuminates when input line voltage is too high for proper operation (approx. 20% above nominal line voltage rating). Power source is shut down.

LED 5 – (amber) Low Bus Fault – Illuminates when input line voltage is approx. 20% below nominal line voltage rating. PS is shut down.

LED 7 – (amber) Arc Voltage Saturation Fault – Illuminates when the cutting arc voltage is too high and cutting current drops below preset level. LED will extinguish after voltage decreases and current rises.

LED 8 – (amber) Arc Voltage Cutoff Fault – Illuminates when arc voltage increases over the preset value. PS is shut down.



Power Reset Fault Indicator (on front panel)

Illuminates when a serious fault is detected. Input power must be disconnected for a least 5 seconds to clear this fault. Check PCB1 Red LEDs 6, 9, 10, 11, 12, and 13 if this fault is illuminated for further diagnosis.

LED 6 – (red) Right Overcurrent Fault – Illuminates when the current out of the right side chopper is too high (300 amps). This current is measured by the right-side hall sensor. The power source is shut down.

LED 9 – (red) Left Overcurrent Fault – Illuminates when the current from the left side chopper is too high (300 amps). Measured by the left hall sensor. Power source is shut down.

LED 10 _ (red) Left IGBT Unsaturated Fault – Illuminates when left IGBT is not fully conducting. PS (PS) is shut down.

LED 11 – (red) Right IGBT Unsaturated Fault – Illuminates when right IGBT is not fully conducting. Power Source (PS) is shut down.

LED 12 – (red) Left -(neg) 12V Bias Supply Fault – Illuminates when negative 12 V bias supply to the left side IGBT gate drive circuit (located on PWM-drive board PCB2) is missing. PS is shut down.

LED 13 – (red) Right –(neg) 12V Bias Supply Fault - Illuminates when negative 12 V bias supply to the right side IGBT gate drive circuit (located on PWM-drive board PCB3) is missing. PS is shut down.



6.3 Fault Isolation Many of the most common problems are listed by

symptom. 6.3.1 Fans not working

6.3.2 Power not on

6.3.3 Fault Light Illumination

6.3.4 Torch won’t fire

6.3.5 Fusses Blown F1 and F2

6.3.6 Intermittent, Interrupted or Partial Operation

6.3.1 Fans Not Working

Problem Possible Cause Action All Three fans do not run This is normal when not cutting.

Fans run only when “Contactor On” signal is received.

None

One or two fans do not run. Broken or disconnected wire in fan motor circuit. Faulty fan(s)

Repair wire. Replace fans

6.3.2 Power Not On or LOW Voltage

Problem Possible Cause Action Power source inoperable: Main Power lamp is off.

Missing 3-phase input voltage Missing 1 of 3-phase input voltage

Restore all 3 phases of input voltage to within ±10% of nominal line. Restore all 3 phases of input voltage to within ±10% of nominal line.

Low Open Circuit Voltage Fuse F3 blown Pilot arc Contactor (K4) faulty Faulty Control PCB1

Replace F3 Replace K4 Replace Control PCB1 (P/N 38032)



6.3.3 Fault Light Illumination

Problem Possible Cause Action Fault light illuminates at the end of cut but goes off at the start of the next.

Normal condition caused by terminating the arc by running the torch off the work or the arc being attached to a part that falls away.

Reprogram cutting process to ensure arc is terminated only by removing the “Contactor On” signal.

LED 3 – (amber) Bus Ripple Imbalance of 3-phase input power Momentary loss of one phase of input power Faulty control PCB1

Maintain phase voltage imbalance of less than 5%. Restore and maintain input power within ±10% nominal Replace PCB1 P/N 38032

LED 4 – (amber) High Bus One or more phases of input voltage exceed nominal line voltage by more than 20%. Faulty control PCB1 One or more shorted diode rectifiers (D25-D28) on the “Electrode Plate”

Restore and maintain line voltage within ±10% Replace PCB1 P/N 38032 Replace shorted diode rectifiers

LED 5 – (amber) Low Bus One or more phases of input voltage are lower than nominal by more than 15%. Blown F1 and F2 fuses Over temp Light comes on. Imbalanced 3-phase input power Momentary loss of one phase of input power Faulty Main Contactor (K1) FAULTY Control PCB1

Restore and maintain with in ±10% of nominal See F1 and F2 in Blown Fuses Section See over temp in Fault Light Section Maintain phase voltage imbalance of less than 5% Restore and maintain within ±10% of nominal Replace K1 Replace PCB1 P/N 30832



Problem Possible Cause Action

LED 6 – (red) Right Over Current Note: If operation at 250A or less is possible, then the LEFT side is not working.

Output current of the right side exceeds 200A because of operating the power source over 400A. Cutting at over 250A with a faulty left side (left side output = 0) Right current transducer connector loose or unplugged. PCB loose. Loose or unplugged connector at right PWM/Drive Printed circuit board. P2 at left of PWM/Drive PCB loose or unplugged. Check voltage between P7-6 and P7-7. A voltage in either polarity of greater than 0.01 V indicates a faulty right current transducer (TD2). Faulty PCB1 Faulty right PWM/Drive PCB

Turn the output current down to 400A See faulty left or right side Secure connections Secure connection Secure connection Replace right current transducer (TD2) Replace PCB1 P/N 30832 Replace right PWM/Drive PCB P/N 38030

LED 6 – (red) Left Over Current Note: If operation at 250A or less is possible, then the Right side is not working.

Output current of the left side exceeds 250A because of operating the power source over 400. Cutting at over 250A with a faulty right side (right side output = 0) Left current transducer connector loose or unplugged. PCB loose. Loose or unplugged connector at left PWM/Drive Printed circuit board. P2 at right of PWM/Drive PCB loose or unplugged. Check voltage between P7-2 and P7-3. A voltage in either polarity of greater than 0.01 V indicates a faulty left current transducer (TD1). Faulty PCB1 Faulty left PWM/Drive PCB

Turn the output current down to 400A See faulty right side Secure connections Secure connection Secure connection Replace left current transducer (TD1) Replace PCB1 P/N 38032 Replace left PWM/Drive PCB P/N 38030




Very high Output current accompanied by either a left or right over current (LED 6)

Shorted IGBT Current pot set too high Faulty left PWM/Drive PCB High remote current signal Faulty PCB1

Replace the pair of IGBTs containing the shorted IGBT Lower the current setting Replace left PWM/Drive PCB Decrease remote current signal Replace PCB1 P/N 38032

LED 10 - (red) Left IGBT Unsaturated

Black wire connecting IGBT (Q4) collector to P3 of the left PWM/Drive PCB (PCB2) is disconnected. Shorted Freewheeling Diode(s) Loose or unplugged P1 connector at the left PWM/Drive PCB Loose or unplugged P10 connector at PCB1 Faulty PCB1 Faulty left PWM/Drive PCB

Secure connector Replace freewheeling diode(s) Secure P1 Secure P10 Replace PCB1 P/N 38032 Replace PCB2 P/N 38030

LED 11 - (red) Right IGBT Unsaturated

Black wire connecting IGBT (Q4) collector to P3 of the right PWM/Drive PCB (PCB3) is disconnected. Shorted Freewheeling Diode(s) Loose or unplugged P1 connector at the left PWM/Drive PCB Loose or unplugged P10 connector at PCB1 Faulty PCB1 Faulty right PWM/Drive PCB

Secure connector Replace freewheeling diode(s) Secure P1 Secure P11 Replace PCB1 P/N 38032 Replace PCB3 P/N 38030




LED 12 – (red) Left –12V Missing

Loose or unplugged P1 connector at the left PWM/Drive PCB Loose or unplugged P10 connector at PCB1 Faulty left PWM/Drive PCB

Secure P1 connector Secure P10 connector Replace left PWM/Drive PCB P/N 38030

LED 12 – (red) Right –12V Missing

Loose or unplugged P1 connector at the right PWM/Drive PCB Loose or unplugged P11 connector at PCB1 Faulty right PWM/Drive PCB

Secure P1 connector Secure P11 connector Replace right PWM/Drive PCB P/N 38030

Very high Output current accompanied by either a left or right over current (LED 6)

Shorted IGBT Current pot set too high Faulty left PWM/Drive PCB High remote current signal Faulty PCB1

Replace the pair of IGBTs containing the shorted IGBT Lower the current setting Replace left PWM/Drive PCB Decrease remote current signal Replace PCB1 P/N 38032

Over Temp Lamp illuminates One or more fans inoperable Broken wire or unplugged connector at thermal switch. Obstruction to air flow closer than 2 feet to rear of power source. Excessive dirt restricting cooling air flow Obstructed air intake

Repair or replace fan(s) Repair broken wires and unplugged connector Allow 2 ft. minimum between the rear of the power source and any object that may restrict air flow. Clean out excessive dirt, especially in the extrusions for the IGBTs and freewheeling diodes, the POS, NEG and Electrode Plates, the main transformer (T1) and the filter inductors (L1 and L2). Check and clear any obstructions from the bottom, front, and top rear of the Power Source.



6.3.4 Torch Will Not Fire

Problem Possible Cause Action Main Arc Transfers to the work with a short “pop”, placing only a small dimple in the work.

Panel/Remote switch in “Remote” with no remote control of the current Remote current control present but signal missing. Current pot set too low. Start current pot, located behind the cover for the control PCB is set too low.

Place Panel/Remote switch in “Panel” position Check for current reference signal at TB1-4(+) and TB1-5(-). See Signal vs. Output Current Curve this section. Increase current pot setting. Increase the start current post setting to “7”.

Arc does not start. There is no arc at the torch. Open circuit voltage is OK at 400 –460V

Open connection between the power source positive output and the work. Fuse F6 in the Pilot arc circuit is blown. Fuse F7 in the pilot arc circuit is blown. Pilot arc High/Low switch is in the ”LOW” position when using consumables for 100A or higher (Refer to process data included in torch manuals) Pilot arc contactor (K4) faulty. Faulty PCB1

Repair connection Replace F6 Replace F7 Change Pilot arc to “High” position. (Refer to process data included in torch manuals) Replace K4 Replace PCB1 P/N 38032



6.3.5 Fuses F1 and F2 Blown

Problem Possible Cause Action Fuses F1 and F2 blown. Process controller ignites pilot arc

too soon after providing the “Contactor On” signal Faulty negative (Electrode) output cable shorting to earth ground. Shorted freewheeling diode. One or more shorted diode rectifiers (D13-D18) on “POS Plate”. One or more shorted diode rectifiers (D7-D12) on “NEG Plate”.

Process controller must allow at least 300MS to lapse between the application of the “Contactor On” signal and the ignition of the pilot arc. Fix process controller logic and replace diodes. Repair cable Replace shorted freewheeling diode and F1-F2 Replace all diode rectifiers on the “POS Plate”. Replace all diode rectifiers on the “NEG Plate”.

6.3.6 Intermittent, Interrupted or Partial Operation

Problem Possible Cause Action Works OK at 250A or less- Over current – Faulty Left Side

Loose or unplugged connector at left PWM/Drive PCB (PCB2) Faulty left PWM/Drive PCB Check voltage between P5-1 and P5-2 at the left PWM/Drive PCB (PCB2). Should be 20V AC. Between P5-1 and P5-3 should be 40V AC. If not the control transformer (T5) is faulty.

Secure connector Replace right PWM/Drive PCB P/N 38030 Replace control transformer T5




Works OK at 250A or less- Over current – Faulty Right Side

Loose or unplugged connector at Right PWM/Drive PCB (PCB3) Faulty Right PWM/Drive PCB Check voltage between P5-1 and P5-2 at the right PWM/Drive PCB (PCB3). Should be 20V AC. Between P5-1 and P5-3 should be 40V AC. If not the control transformer (T7) is faulty.

Secure connector Replace right PWM/Drive PCB P/N 38030 Replace control transformer T7

Power Supply turns off prematurely in the middle of the cut.

“Contactor On” signal is removed from unit. Momentary loss of primary input power. Faulty condition, indicated by illumination of the fault lamp. Faulty condition, indicated by the illumination of the power reset fault lamp. Current setting too low. Remote current signal removed during cut.

Power source is OK. Trouble shoot process controller. Restore and maintain input voltage within ±10% of nominal. Remove control PCB (PCB1) access panel to determine the fault causing the shutdown. Refer to fault light illumination section. Remove control PCB (PCB1) access panel to determine the fault causing the shutdown. Refer to fault light illumination section. Increase current setting Fix remote current signal




Output current is unstable and drifts above or below the setting.

Place the PANEL/REMOTE switch in the “PANEL” position. Adjust current control pot. If current no longer drifts, the remote current control signal is faulty. Select “PANEL” on the PANEL/REMOTE switch and adjust the current control pot. The current still drifts, measure the current reference signal at TB1-4 (+) and TB1-5 (-). If the signal drifts, the current control pot is faulty. If the signal does not drift, the Control PCB (PCB1) is faulty.

Fix the remote current control signal to operate the PANEL/REMOTE switch in the “PANEL” position. Replace the current control pot. Replace the control PCB (PCB1) P/N 38032



6.4 Testing and Replacing Components

NOTICE

• Replace a PC board only until a problem was isolated to that board.

• Always disconnect power before removing or installing a PC board.

• Do not grasp or pull on board components.

• Always place a removed board on a static free surface.

• If a PC board is found to be a problem, check with your ESAB distributor for a replacement. Provide the distributor with the part number of the board as well as the serial number of the power source.

• Do not attempt to repair the board yourself. Warranty will be voided if repaired by the customer or an unauthorized repair shop.

Power Semiconductor Components

Three categories of power semiconductors include;

• Power Rectifiers

• Freewheeling Diodes

• IGBTs



6.4.1 Power Rectifiers

Power Rectifiers – Procedure to access behind the front panel 1. Remove top cover and side panels

2. Locate and disconnect plug in rear of ammeter (white plug with one red and one black wire)

3. Remove pilot arc switch

4. Disconnect voltmeter

5. Disconnect orange and yellow wires from relay K4.

6. Remove two bolts holding the left side of the front panel to the base.

7. Remove three bolts holding across the center base of the front panel. These are accessed from underneath.

8. Remove one of the bolts holding the right side of the front panel to the base. Loosen the second bolt. Of these two bolts, remove the bolt on the left and loosen the bolt on the right.

9. Swing the front panel out to gain access to power rectifier components.

Troubleshooting Procedures –Negative Plate

1. Visually inspect fuses F8 and F9. Replace if they show signs of being blown or melted. Inspect diodes. If ruptured or burned, replace all diodes on the NEG Plate. If diodes appear to be OK, proceed to next step.

Power Rectifiers located behind the front panel.

Location of fuses F8 and F9

Location of Neg. Plate



1. Check ohms between NEG Plate and BR “A”

Bus. A reading of 2 ohms or less indicates one or more shorted diodes. Replace all Diodes on NEG Plate.

2. If fuses F8 and/or F9 were open in the first step,

make two more ohmmeter readings. A. Measure resistance between the NEG Plate and BR “B” bus. B. Measure between NEG Plate and BR “C” bus. If resistance is 2 ohms or less in either case, replace all the diodes on the NEG Plate.

Troubleshooting POS Plate

1. Check ohms between POS Plate and BR “A” Bus. A reading of 2 ohms or less indicates one or more shorted diodes. Replace all Diodes on POS Plate.

2. If fuses F8 and/or F9 were open in the first step,

make two more ohmmeter readings. A. Measure resistance between the POS Plate and BR “B” bus. B. Measure between POS Plate and BR “C” bus. If resistance is 2 ohms or less in either case, replace all the diodes on the POS Plate.

Troubleshooting Electrode Plate

D27,28D25,26

1. Visually inspect for ruptured or burned diodes. Replace only those damaged.

2. Check resistance between Electrode Plate and the parallel pig tails (cathode leads) of D25 and D26. If reading is 2 ohms or less, disconnect leads from bus and check each diode. Replace only shorted diodes.

Repeat procedure for D27 and D28. Replace only shorted diodes.

“C” bus“B” bus “A” bus

NEG Plate

Electrode Plate POS Plate

Diode Rectifier

Cathode Leads

Bus

Location of Positive Plate

Fuses F8 and F9



CAUTION

CAUTION

6.4.2 Troubleshooting Freewheeling Diode and IGBTs

Freewheeling Diodes and IGBTs 1. Remove top cover.

2. Remove “incoming” bus bars.

3. Remove PCB2 and PCB3 from IGBTs. (PC boards are held in place by four screws each.)

After PCB2 and/or PCB3 have been

removed, protect against electrostatic damage. The emitter and the gate of each affected IGBT must be jumpered together to prevent electrostatic damage.

Electrostatic Discharge Hazard

Electrostatic discharge may damage these components.

• Damage is accumulative and may only appear as shortened component life and not as a catastrophic failure.

• Wear a protective ground strap when handling to prevent damage to PCB components.

• Always place a pc board in a static-free bag when not installed.

Emitter Gate



321

3

1

2

2

1

3

Snubber Capacitor(ex.C18)

Freewheeling Diode(ex. D6)

Snubber Resistor(ex. R9)

Red Wire

4. Remove bus bars between capacitor banks, IGBTs and freewheeling diodes.

View of freewheeling diodes and capacitor banks with bus bars removed. (PCB2 and PCB3 are shown still in place)

CAUTIONFailure To Route Leads Properly Can Lead To Failure Of Freewheeling Diodes.

Dressing Of Freewheeling Diode Snubber

Leads. Red wire of snubber resistor must be routed under capacitor self lead. Red wire terminal must have a minimum 1/8" clearance from the bus bar on diode terminal #2. Note: Bus bar connecting terminal no. 3 is not shown for terminal clarity. The red snubber leads are numbered as viewed from the rear of the power source:

D1 - Left D4 - Right D2 - Right D5 - Left D3 - Left D6 - Right Cover snubber capacitor self leads with sleeving

P/N 95193486

PCB3PCB2



NOTICE

Some power sources may contain snubber resistors and capacitors in a molded module similar in size and mounting to the free wheeling diode modules. These snubber modules utilize two conductive straps. One strap attaches to the free wheeling diode terminal #1 and the other to terminal #3. Strap to #3 is sandwitched between the free wheeling diode and the stamped copper bus. The strap to #1 is mounted on top of the copper bus under the mounting hardware and in direct contact with the copper bus.

6.4.3 Power Shunt Installation

CAUTIONInstability Or Oscillation In Cutting Current Can Be Caused By Improper Dressing Of Shunt Pick-Up Leads. Poor torch consumable life will be the result.

There are two cables that attach to the shunt pick-up points: a two conductor cable drives the ammeter a three conductor which provides the current feedback signal to PCB1 (control PCB). Dressing of the 2 conductor cable is not critical. The following is the dressing procedure for the 3 conductor cable. • The breakout point should be physically at the

middle of the shunt. The breakout point is the place where the conductors exit from the outer insulation jacket.

• The black and clear insulated wires must be

kept next to the shunt and under the cable ties. • The wire terminals for the black and clear

insulated wires should be oriented in parallel with bus bars as shown.

Terminals parallel to bus bars



• It is important to have the barrels of the black and clear insulated wires, from the three lead cable, be pointing in opposite directions.

• The third wire attaches to the bus bar on the left

with the shunt mounting hardware. Orientation of this wire is not critical.

6.4.4 Procedure For Verifying Calibration Of Digital Meters.

Voltmeter

1. Connect a digital meter known to be calibrated to the positive and negative output bus bars.

2. Compare the power source voltmeter reading to the calibrated meter reading. Readings should match within ± 0.75%

Ammeter

1. External to the power source, connect a precision shunt in series with the work lead(s). The best shunt is one with a value of 100 µΩ (50mV/500A or 100mV/1000A) and a calibrated tolerance of ± 0.25%.

2. Use a calibrated 4 ½ digit meter to measure the output of the shunt. The amperage indicated with the external shunt and meter should match power source ammeter to within ± 0.75%.

Two LeadsThree Leads

Clear Insulation



6.5 ESP-400C Schematic Diagrams - Drawing 1 - Part1

1a2a

3a4a

5a

6a7a

8a9a

BLK

BLKGRY

GRY

LOC SYM Descrip LOC SYM Descrip LOC SYM Descrip

1 M1,2 Motor ,fan 1/3 hp 1 C14-16 Capacitor .033uf 630v 2 C24 Capacitor 5uf 600vdc

1 M3 Motor, fan 230v 50/60hz 1 D19,20,23 Module diode rectifier 630v 2 C13,15,17 Capacitor .033uf 630v

1 T1 Transformer main 1 R12,13 Resistor 8ohm 300w 2 K2 Contactor 3 pole 90A

1 T2 Transformer control 1 D2,4 Module diode Red 2 K4 Contactor 3 pole 40A

1 T5-8 Transformer 117/12/12/24ct 1 R5,7 Resistor 10ohm 50w 2 PL1 Lamp neon wht

1 K1A,B,C Contactor 3pole 90A 1 R53,54 Resistor 2ohm 25w 2 PL2 Lamp neon wht

1 PCB2 PC board circuit IGBT Driver 2 TD1,2 Transducer Current 2 PL3 Lamp indicator Amber

1 Q1-2 Module IGBT 600A 600V 2 PCB3 PC board IGBT driver 2 TS4,5,6 Switch thermal 176 deg.F

1 C19,20 Capacitor 27uf 1200vdc 2 Q3,4 Module IGBT 600A 600v 2 TS7 Switch thermal 194 deg.F

1 C23 Capacitor 5uf 800vdc 2 C21,22 Capacitor 27uf 1200vdc 2 TS1,2,3 Switch thermal 176 deg.F



Schematic Diagram - Drawing 1 – Part2

1b2b

3b 4b

5b

6b7b

8b9b

2 C18 Capacitor .033uf 630v 2 C41-43,44 Capacitor .01uf 125vdc 3 R44 Resistor 10k 8w

2 R4,6,8,9 Resistor 10ohm 50w 2 D29,30 Rectifier silicone reverse 85A 3 C30 Capacitor 60uf 370v

2 D1,3,5,6 Module diode dual 100A 600V 2 D31,32 Rectifier silicone forward 85A 3 C39,40 Capacitor .01uf 125vdc

2 D21,22,24 Module dual diode rectifier 630V 2 F3 Fuse slo-blo 15A 600v 3 D27,28 Diode rect reverse 800v 300A

2 R14,15 Resistor 8ohm 300w 2 F6 Fuse n-t delay 15A 3 D33,35 Rectifier silicone reverse 85A

2 L1,2 Inductor Assy 2 R23 Resistor 1 ohm 300w 3 D34 Rectifier silicone forward 85A

2 D25,26 Resistor 10ohm 300w 2 R24 Resistor 8 ohm 300w 3 R25,26 Resistor 10 ohm

2 C37,38 Capacitor .01uf 125vdc 2 FN1,FN2 Filter PC board 3 R39,40 Resistor 10k 8w

2 R30 Resistor 1k 100w 3 PCB4 PC board digital meter 3 R34,35,36 Resistor 220k 1w

2 R16,17 Resistor 8ohm 300w 3 SH1 Shunt 100mV 800A 3 R29 Resistor 1k 100w

2 S1 Switch toggle 3pst 2 pos 3 R31 Resistor 1k 100w 3 R21,22 Resistor 10ohm 300w

2 R41-43 Resistor 10k 8w 3 R18,19,20 Resistor 4 ohm 300w 3 R27 Resistor 10ohm 300w

2 C27,28,29 Capacitor 2900uf 450w 3 R38 Resistor 220k 1w




LOC SYM Descrip LOC SYM Descrip LOC SYM Descrip

C32,33 Capacitor 1900uf 450v 4 C25 Capacitor 10uf 370v 4 K6 Relay 3pdt

C34,35,36 Capacitor 10uf 370vac 4 R32 Resistor 220k 4 TD1 Transducer Current

R1,2,3 Resistor 1 ohm 300w 4 FN4 Filter RFI 4 TD2 Transducer Current

F1,2 Fuse 15A 4 R37 Resistor 10ohm 1w 4 R46-48 Resistor 133k 1/2w

TB4,5,6 Terminal Assy 4 C31 Capacitor 1uf 600v 4 R52 Resistor 4.7k ohms 2w 10%

4 K3,5-7 Relay 3pdt brkt mt 4 R51 Pot 10k 2w 4 PL4,5 Lamp LED red 12v




LOC SYM DESCRIPTION LOC SYM DESCRIPTION LOC SYM DESCRIPTION

4 T3,4 XMFR 117/12/12/24ct 5 C45,46 Capacitor .01uf 125vdc 5 S3 Switch toggle DPDT 3 pos

5 R50 Pot 15k 2w 5 R45 Resistor 10k 8w 5%

5 S2 Switch toggle DPDT 2 pos 5 FN3 Filter EMI



Schematic Diagram - Drawing 3



Schematic Diagram - Drawing 4









6.6 Wiring Diagrams – 460V 60Hz Drawing 1 – Part1 (P/N 35878)

YEL

ELECTRODE BUS BLK

BLU WORK BUS BLU

TB10

FN1 FN2

GND4 GRN K4-T1 YEL GND4 GRN

3 3

Section A-A

TB1-10 BLK

TB1-12 BLK

PCB4 P1-1 GRN

PCB4 P1-2 GRN/YEL

PCB4 P1-3 GRN

H1

H2T9

C47 D7,D8

BR"A" BUS

C50D13D14

C48 D9,D10

BR "B" BUS

C51D15,D16

C49 D11,D12

C52D17,D18

BR "C" BUS

D27,D28

C39

C40

TS3-1 WHTTB9-21 BLK

D25,D26

WHTWHT

C38

C37

WHT

WHT

TS71 2

"B" COIL "B" COIL

L1"A" COIL

L2"A" COIL

X1

X1

X1

X1

X3 YEL

X4 YEL

TB11-3 YEL

TB11-2 YEL

Section B-BAmmeter Voltmeter

K4-L1 BLK

R19-2 ORNR17-1 YELD29/30 BUS WHT

S2-6 GRY

S2-3 RED

TB1-3 VIOTB1-4 ORN

PCB1 P8-2 VIOR50-2 RED

R50-3 GRY

TB1 6GRY

PCB1 P8-1 GRYTB1-5 BLU

POS PLATE REDR24-2 BRN

FN4-3 BLK

TB1-10-A BLK

T2-X2BLU

PCB1 P7-10 GRY

PCB1 P7-15 WHT

PCB1 P7-14 BRN

PCB1 P7-13 RED

PCB1 P7-12 VIOPCB1 P7-11 BLK

TB1-12WHT

TB1-11 WHT

TB1-9 REDTB1-10-B BLK

TB1-18 BRNTB9-24 YEL

TB9-24 YEL

PCB1 P9-11 VIOPCB1 P9-5 GRY

TB9-21 BLK

FN1-1 BLK

PCB4 P3-1 BLK

FN1-3 GRNFN2-3 GRN

FN2-2 BLU

PCB4 P1-4 BLU

J1A TB1-1 BRNB TB1-2 YELC TB1-4 ORND TB1-5 BLUE TB1-9 REDF TB1-7 BLKG TB1-8 WHTH GND 5 GRNJ TB1-13 GRYK TB1-14 VIO

K3-4 RED

BR "A"BUS

F5-1 BLU

R23-1 BRN

M3-2 REDM2-2 REDM1-2 RED

BR "B"BUS

F5-2 BLU

F3-1 BRN

X2X3X4X5X6X7X8

X2X3X4X5X6X7X8

X2X3X4X5X6X7X8

BR "C"BUS

M3-1 WHTM2-1 WHTM1-1 WHT

F4-1 BRND33 BUS GRY

2

1

2

1

2

1

TS4-1 WHT

H1H2

H1H2

H1H2

TS7-2 WHT

K1C-T1.2.3 BLK

K1B-T1.2.3 BLK

K1A-T1.2.3 BLK

GND 1

L1

L2GND 4

A

A

B

B

"A"TS1

TS2

TS3

T1

"B"

"C"

WO

RK

BU

SE

LE

CT

RO

DE

BU

S

R50

R51

PL1 PL2 PL3 PL4 PL5

3 21

1 2 3

S3

3

2

1

6

5

4

CB1

S15 31

6 42

4 5 61 2 3

S2

S4

12

3

PCB4

P2-

1P

2-2

P2-

3P

2-4

P2-

5P

2-6

P2-

7P

2-8

WH

TR

ED

BL

KG

RN

BR

NB

LU

OR

NY

EL

PCB4 P1-11 VIO

PCB4 P1-12 GRY

AB C

DE

FG

HJK

L

M

NP R

ST

U V

1 7 8 2 1 7 8 2

1 T9-GRN2 T9-GRN/YEL3 T9-GRN4 WORK BUS-BLU5 TB1-15 RED6 TB1-16 BLK7 SH1 +8 TB9-2 WHT9 TB9-1 ORN PCB4 P1-10 BLK10 PCB4 P1-9 BLK11 S4-1 VIO12 S4-2 GRY

PCB4P1 P3

1 ELECTRODE BUS-BLK

ESP-400C

Note: From ESP-400C/600C//460VDrawing No. 35719, sheet 1 of 5

Rev E



6.6 Wiring Diagrams – 460V 60Hz Drawing 1 – Part2 (P/N 35878)

M1-3 GRN

M2-3 GRN

F2-1 ORN

K2-L3 RED

F1-1 VIO

ELECTRODE PLATE GRY

K4-T2 WHT

F7-1 BRN

C32 (-) BLU

T1-CX4 WHTGND-2 GRN

T1-BX2 RED

K1B-L1 YEL

K1C-L1 BLK

WHT

FN4-4 WHT

GND 3 GRN

CB1-1 BLU

TB8-15 YEL

TB8-16 RED

F4-2 BLK

S1-3 ORN

T1-AX7 BRN

T2

H1H2H3H4H5H6

X1

X2

X3

X4

K4-L3 RED

POS PLATE BLU

C27(-) WHT

S1-1 YELT1-BX2 RED

GND-2 GRNT1-CX4 WHT

M21

2

3

R20

R23

1

1

1

12

2

2

2

ORN

1

2

2

1

2

2

1

1

R22 R19 R16 R17

R21

R18

TD1 (SPLICE) BLK

TD2 (SPLICE) BLK

F7-2 ORN

D35-C VIO

K2-L2 WHT

TB4 BLU

K2-L1 BLK

R3

R2

R1M1

1 2

1 2

12

1

2

3


Rev E



6.6 Wiring Diagrams – 460V 60Hz Drawing 2 – Part 1 (P/N 35878)

T1-BH2/CH1 BLK

C61 C62C60

R57R56

R55

F1-2 GRY

R1-1 BLU

K1A-L1 BLK

F2-2 GRN

K1A-L2 BLK

K1A-L3 BLK

K1C-L3 BLK

K1C-L2 BLK

K1C-L1 BLKK1B-L3 BLK

K1B-L2 BLK

K1B-L1 BLK

TB4 TB5 TB6

VIEW L-L

400V 50HZUNITS ONLY

K1C-T3 RED

K1B-T3 WHT

K1A-T3 BLK

C26-1 ORN

R1-2 BLK

R2-2 WHT

R3-2 RED

C26-2 WHT

K2-T1 BLK

T1-AH1 BLK

T1-AH1 BLK

T1-AH1 BLK

K1B-A ORN

T1-AH2/BH1 BLK

T1-AH2/BH1 BLK

T1-AH2/BH1 BLK

K2-T2 WHT

T1-BH2/CH1 BLK

T1-BH2/CH1 BLK

K2-T3 RED

K1-B/C25-2 GRY

TB6 BLK

TB6 BLK

TB6 BLK

T2-H6 BLK

K1B-A/C25-1 ORN

K1A-B/K1C-B GRY

TB5 BLK

TB5 BLK

TB5 BLK T2-H1 YEL

K1A-A/K1C-A ORN

K1B-B GRY

TB4 BLK

TB4 BLK

TB4 BLK

L1 L2 L3L1 L2 L3L1 L2 L3

T1 T2 T3T1 T2 T3T1 T2 T3

A K1A B A K1B B A K1C B

C2(+) BLUC2(-) YEL

1 2R10 R111 2

1 2 1 2R53 R54

K7-4 BLK

"A" "B" "C"

X1X1 X1

F8 F9

C23-2 VIO

C4(+) WHT

C24-1 VIO

C10(+) WHT

T1-CX4 WHTT1-BX2 RED

M3

C

GC

G

R28-2 YEL

R25-2 GRY

T1-CX7 GRY

C34-2 BLK

R26-2 REDC33(+) RED

S1-4 RED

ELECTRODE PLATE

POS PLATE

NEG PLATE

BL

K

D33

D34

TB6 BRN

TB5 GRY

K3-7 ORN

K1C-A ORN

K7-7 GRY

K1C-B GRY

K2-A ORN

K4-B ORN

K7-9 ORN

TB1-11 WHT

K2-B WHT

F1

F2

R2-1 VIO

R3-1 ORN

C25

C26

R32

R33

1

2

1

2

K1A K1B K1C

K2

SEE VIEW K-K

TB4 TB5 TB6

SEE VIEW L-L

C8(+) BLUC8(-) YEL

VIEW K-K




C2(+) BLUC2(-) YEL

1 2R10 R111 2

1 2 1 2R53 R54

K7-4 BLK

"A" "B" "C"

X1X1 X1

F8 F9

C23-2 VIO

C4(+) WHT

C24-1 VIO

C10(+) WHT


M3

C

GC

G

C8(+) BLUC8(-) YEL

PCB1 P7-9 BLU

NEG PLATE YEL

ELECTRODE PLATE GRY

PCB1 P5-9 BLK

PRA1

TB7

PRA1 YEL

C28(+) BLU

R20-2 BLU

F3-2 BLK

D31 D32

D29 D30

BLKC41 C42

C43 C44

ORN

K4-T3 ORN

C27(-) WHT

S1-2 WHT

PRA1 GRY

C29(-) GRY

R21-2 GRY

TD2 (SPLICE) GRY

TD1 (SPLICE) GRY

ELECTRODE PLATE

POSPLATE

NEGATIVE PLATE

F7-

1 B

RN

PC

B1

P4-

1 W

HT

TB

1-9

RE

D

K6-

9 R

ED

PC

B1

P6-

1 O

RN

K5-

9 R

ED

R45R52

21 3 4 5 6 7 9 10 11 12 138TB7

VIEW G-G

SECTION D-D



6.6 Wiring Diagrams – 460V 60Hz Drawing 3 (P/N 35878)

R30-1 BLU

POS PLATE BLU

R16-1 WHT

D29/D30 BUS WHT

R31-2 GRY

ELECTRODE PLATE GRY

D31-A BLK

T1-BX7 BRN

D21-1 ORN

D22-1 ORN

D22-2 BRN

D21-2 BRN

TB11-8 RED

C29(-) GRY

R22-2 BLK

R14

R151 2

1 2

F3F4

11 22

R16-2 (SPLICE) BLK

TD2

C29

C28

C27

C30

+

+

+

1

2

R38

R43

R42

R41

R44

GRY

R31 R30

1 1

2 2F5

F6

F7

1

1 2

2

1 2

T3

T2

T1

L3

L2

L1 A

B

K4

BL

K

C31

R37

R18

-1 O

RN

C29

(+)

VIO

T1-

BX

5 B

LU

C29

(+)

VIO

C28

(+)

BL

U

R31

-1 V

IO

F6-

2 V

IO

K4-

T2

WH

T

K4-

T1

YE

L

R19

-1 B

RN

TB

7-5

BR

NR

24-1

VIO

T1-

AX

5 B

LU

TB

10 Y

EL

C30

-1 Y

EL

R18

-2 W

HT

C30

-2 W

HT

D32

-A O

RN

PC

B1

P2-

5 Y

EL

C26

-1 O

RN

S1-

5 B

LK

R23

-2 R

ED

R29

-1 R

ED

PO

S P

LA

TE

RE

DR

29-2

BL

UC

36-2

BL

UR

22-1

BL

U

C36

-1 O

RN

C35

-1 B

RN

C34

-1 Y

EL

C33

(+)

RE

D

EL

EC

TR

OD

E P

LA

TE

Y

EL

C33

C32

BL

K

R39

R40

+

+

RED1 11 1 1

22 22 2

R27 R26 R25 R29 R28

R27-1 ORN

C32(-) BLU

R26-1 BRN

R25-1 YEL

C32(-) BLUD33 BUS GRY

POS PLATE REDD35-C VIO

D34-A BLK

BL

K

R34

R35

R36

1

1

2

1

2

2

C34

C35

C36

F6-1 VIOS1-6 BRN

D19-2 BRN

D19-1 ORN

D20-1 ORN

D20-2 BRN

1

1

2

2R12

R13TD1

ELECTRODE PLATE (SPLICE) GRY

R17-2 (SPLICE) BLK

R21-1 VIOR27-2 VIO D

35

T1-CX5 BRN


(-) (+)SH13

SH1(-) (+)

PC

B1

P1-

1 C

LR

(T

P)

TB

1-15

RE

D(T

P)

TB

11-1

BL

U

PC

B1

P1-

3 S

HL

D

PC

B1

P1-

2 B

LK

(TP

)T

B1-

16 B

LK

(TP

)

TD1

1 2 3 4P1

1 PCB1 P7-1 BLK2 PCB1 P7-4 RED3 PCB1 P7-2 GRN4 PCB1 P7-3 WHT

P11 PCB1 P7-5 BLK2 PCB1 P7-8 RED3 PCB1 P7-6 GRN4 PCB1 P7-7 WHT

1 2 3 4

TD2

P1

P1

R59

R63

R58

BL

K

1

2

3

4

5

6

7

8

TB11SHT BUS POS BLU

PCB1 P9-12 YELL2-X4 YEL

L2-X3 YEL

PCB1 P9-13 YEL

RIGHT COLLECTOR BUS RED Note: Wires on shunt(+) and (-) must be

dressed in location anddirection shown.

Note1:Splice must pass through

transducers TD1 and TD2 indirection shown.

H

J

H

J

VIEW E-E

Note: From ESP-400C/600C//460V35719, sheet 3 of 5

Rev E

PC

B4

P1-

4 B

LU




R12

-1 B

RN

R12

-2 O

RN

PC

B2

P3

BL

K

R10

-1 Y

EL

R10

-2 B

LU

R53

-2 W

HT

R54

-2 W

HT

R11

-1 B

LU

R11

-2 Y

EL

R54

-1 V

IO

R14

-2 O

RN

R14

-1 B

RN

X7 X6

X5 X4 X3 X2

X1

BLU

YEL

GRN

GRY

H1

H2T6

PCB2 P6-3 RED

PCB2 P6-2 GRN/YEL

PCB2 P6-1 BRN

TB2-2 WHT

TB2-1 BLK

X7 X6

X5 X4 X3 X2

X1

BLU

YEL

GRN

GRY

H1

H2T7 PCB3 P5-2 GRN/YEL

PCB3 P5-1 BRN

TB3-2 WHT

TB3-1 BLK

PCB3 P5-3 RED

C21T7

D2121

ECQ3

P5

C7

C8

+

+

C1

C2

+

+

D19

C19

T6

E C Q1

P6P3

P1

K2

PCB2C23

1

2

D23

Q1-C BLK

P2

P5

TB2

T5C20

D20

E C

R13

-1 B

RN

R13

-2 O

RN

R52

-1 V

IO

C6 +

C5 +

C4 +

C3 + C9

C10

C12

+

+

+

C11

+

PC

B3

P3

BL

K

R15

-2 O

RN

R15

-1 B

RN

D22

C22

T8

TB3

12

ECQ4

D24 C24

P3

P1

P2

Q4-C BLK

P6

2

1

TB2-1 BLK

TB9-20 BLK

TB2-2 WHT

TB9-15 WHT

T8-H1 BLKT7-H1 BLK

T8-H2 BLK

T7-H2 WHT

TB3

1

2

T8H1

H2

X1X2X3

X4X5X6

X7

TB3-1 BLK

TB3-2 BLK

PCB3 P6-1 BRN

PCB3 P6-2 GRN/YEL

PCB3 P6-3 RED

GRY

GRN

YEL

BLU

T5H1

H2

X1X2X3

X4X5X6

X7

TB2-1 BLK

TB2-2 BLK

PCB2 P5-1 BRN

PCB2 P5-2 GRN/YEL

PCB2 P5-3 RED

GRY

GRN

YEL

TB2T5-H1 BLK

T6-H1 BLK

T5-H2 BLK

T6-H2 WHT

TB3-1 BLK

TB3-2 WHT

1

2

1 PCB1 P10-1 BLK2 PCB1 P10-2 WHT3 PCB1 P10-3 GRN4 PCB1 P10-4 RED5 PCB1 P10-7 BLU6 PCB1 P10-8 ORN7 PCB1 P10-9 YEL8 PCB1 P10-10 BRN9 PCB1 P10-5 GRY10 PCB1 P10-6 VIO

1 PCB2 P2-3 YEL2 PCB3 P2-2 CLR(TP)3 PCB2 P2-1 YEL4 PCB3 P2-4 SHLD5 PCB3 P2-3 BLK(TP)6

1 T5-X1 BRN2 T5-X4 GRN/YEL3 T5-X7 RED


PCB2P1 P2

P5

P6


12 PCB2 P2-2 CLR(TP)3 PCB2 P2-5 BLK(TP)4 PCB2 P2-4 SHLD(TP)56



PCB3

P1 P2

P5

P6

VIEW F-F (WITH BUS BARS)

PCB3


Rev E

BLU




1 SH1(+) CLR(TP)2 SH1(-) BLK(TP)3 TB1-6 GRY SH1-3 SHLD

12 TB8-4 ORN3 TB8-3 BLK45 K4-A YEL6 TB9-14 WHT PCB P3-3 WHT7 FN3-4 ORN8 FN3-3 GRY

12 K6-A BLU3 PCB1 P2-6 WHT PCB1 P6-2 WHT

1 TB7-7 WHT2 TB1-6 GRY34 TB8-5 VIO5 TB8-6 YEL

1 2 3 4 5

6 7 8 91011

12 TB11-2 YEL13 TB11-4 YEL14

GRYGRYGRYGRY

VIOVIOVIOVIOVIO

PL4(+) GRY

PL5(+) VIO

1 TB9-1 RED2 TB9-2 WHT3 TB9-3 BRN4 TB9-4 VIO5 TB9-5 GRY6 TB9-6 ORN7 TB9-7 YEL8 TB9-8 VIO9 PRA1-BLK10 T3-X1 BRN11 TB9-24 YEL T3-X4 GRN/YEL12 T3-X7 RED

1 PCB2 P1-1 BLK2 PCB2 P1-2 WHT3 PCB2 P1-3 GRN4 PCB2 P1-4 RED5 PCB2 P1-9 GRY6 PCB2 P1-10 VIO7 PCB2 P1-5 BLU8 PCB2 P1-6 ORN9 PCB2 P1-7 YEL10 PCB2 P1-8 BRN1112

1 TB7-9 ORN2 PCB1 P3-3 WHT3 TB9-11 GRY4 TB9-10 BLU5 TB9-9 BLK6

1 S2-5 GRY2 S2-2 VIO34 T4-X1 BRN5 T4-X4 GRN/YEL6 T4-X7 RED


1 TD1 P1-1 BLK2 TD1 P1-3 GRN3 TD1 P1-4 WHT4 TD1 P1-2 RED5 TD2 P1-1 BLK6 TD2 P1-3 GRN7 TD2 P1-4 WHT8 TD2 P1-2 RED9 PRA1- BLU10 R51-1 GRY11 R51-2 BLK12 R51-3 VIO13 S3-1 RED14 S3-2 BRN15 S3-3 WHT

TB9

PC

B4

P1-

9 O

RN

PC

B1

P5-

1 R

ED

PC

B4

P1-

8 W

HT

PC

B1

P5-

2 W

HT

PC

B1

P5-

3 B

RN

PC

B1

P5-

4 V

IO

PC

B1

P5-

5 G

RY

PC

B1

P5-

6 O

RN

PC

B1

P5-

7 Y

EL

PC

B1

P6-

5 B

LK

PC

B1

P6-

4 B

LU

PC

B1

P6-

3 G

RY

TB

1-12

WH

TP

CB

1 P

2-8

WH

TT

3-H

2 W

HT

TB

3-2

WH

TK

3-B

WH

TK

7-B

WH

TT

B8-

17 W

HT

TB

3-1

BL

KT

B1-

10 B

LK

TS

7-1

BL

K

PL

3-1

BL

KK

3-6

BL

K

K5-

6 B

LK

PC

B1

P5-

11 Y

EL

PL

5(-)

YE

LP

L4(

-) Y

EL

K6-

B B

LK

T3-

H1

BL

K

JUM

PE

R

JUM

PE

R

JUM

PE

R

JUM

PE

R

JUM

PE

R

BLK

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

TB1-1 BRN

(LINE)TB1-2 YEL

PCB1 P2-8 GRY

(LOAD)PCB1 P2-7 ORN

FN31

2

3

4

PCB1 P5-10 BRN

PCB1 P5-11 GRN/YEL

PCB1 P5-12 RED

TB9-20 BLK

TB9-15 WHT

GRY

GRN

YEL

BLU

T3

X1X2

X3X4

X5X6

X7

TB1-7 BLK

(LINE)TB1-8 WHT

CB1-2 BLK

(LOAD)T2-X1 WHT

TB1-11 WHT

FN41

2

3

4

TB1-12 BLK

TB1-10 BLK

PCB1 P8-6 RED

PCB1 P8-5 GRN/YEL

PCB1 P8-4 BRN

BLU

YEL

GRN

GRY

T4H1

H2

X1X2

X3X4X5

X6X7

T4

GND5

P7 P6

P10 P11

P9

P8

P1 P2 P3 P4

P5PCB1 T3

FN3

FN4

TB9

PL3-2 BRN

PCB4 P1-6 BLK

PCB4 P1-5 RED

J1-K VIO

J1-J GRY

PL1-2 WHT

PL2-2 WHT WHT

PL1-1 BLKCB1-2 BLK

PL2-1 REDJ1-E RED

J1-G WHT

J1-F BLK

TB8-7 BLKS2-6 GRYS2-4 BLUJ1-D BLUJ1-C ORNS2-1 ORN

R50-1 VIO

J1-B YEL

J1-A BRN

TS6-2 BRN

K7-A BRN

SH1(-) BLK(TP)

SH1(+) RED(TP)

T9-H2 WHTT4-H2 BLK

TB9-14 WHTC26-2 WHTFN4-4 WHTT4-H1 BLK

TB9-20 BLKT9-H1 BLKTB7-8 RED

TB8-8 REDFN4-2 WHT

FN4-1 BLKPCB1 P1-3 GRYPCB1 P4-2 GRY

TB8-12 BLU

TB8-11 ORN

PCB1 P5-8 VIO

FN3-2 YEL

FN3-1 BRN

C45

C46

J1-H GRN

GND 5

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

TB1

P1

P2

P3

P4

P5

P6

P7

P8

P9

P10

P11

PCB1

TB1

VIEW H-H


Rev E




TB1-18 BRN

TS61

2

C2 C3 C4 C5 C6

C7 C8 C9 C10 C11 C12

D1 D2 D3 D4 D5 D6

R4

R5

R6 R7

R8

R91 2

1 2

TS5-1 WHT

TS1-2 WHT

TS5

TS4

C13

C14

C15

C16 C17

C18

1

2

3

1

2

3

1

2

3

3

2

1

3

2

1

3

2

1

RED RED RED RED RED RED

C1 C1

TS5-1 WHT

TS1-2 WHT

TS5-2 WHT

1 2 3

4 5 6

7 8 9

1 2 3

4 5 6

7 8 9

1 2 3

4 5 6

7 8 9

1 2 3

4 5 6

7 8 9

A BA BA BA B

C54 C53

K3K6K6K7

T1-

AX

1 B

LK

C25

-2 G

RY

TB

1-18

BR

N

TB

9-16

WH

T

C26

-1 O

RN

K3-

9 Y

EL

TB

8-9

GR

Y

TB

8-10

BR

NP

CB

1 P

3-2

BL

U

TB

9-22

BL

K

TB

7-8

RE

D

TB

8-18

VIO

TB

8-1

BL

U

TB

8-2

WH

T

TB

7-8

RE

D

TB

9-22

BL

K

T1-

AX

2 R

ED

C25

-1 O

RN

TB

8-19

BL

U

TB

9-16

WH

T

K7-

6 Y

EL

TB

9-22

BL

K

K3K5K6K7

TB8

K3-A BLU

K6-6 VIO

TB9-17 WHT

T2-X4 RED

T2-X3 YEL

TB1-5 BLU

TB1-4 ORN

K6-7 BRN

K6-1 GRY

TB1-9 RED

TB1-7 BLK

PCB1 P4-5 YEL

PCB1 P4-4 VIO

PCB1 P2-2 ORN

PCB1 P2-3 BLK

K5-B WHT

K5-A BLU

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

JUMPER

TB8

VIEW J-J

VIEW F-F(WITHOUT BUS BARS)


Rev E




YEL

ELECTRODE BUS BLK

BLU WORK BUS BLU

TB10

FN1 FN2


3 3

Section A-A

TB1-10 BLK

TB1-12 BLK

PCB4 P1-1 GRN

PCB4 P1-2 GRN/YEL

PCB4 P1-3 GRN

H1

H2T9

C47 D7,D8

BR"A" BUS

C50D13D14

C48 D9,D10

BR "B" BUS

C51D15,D16

C49 D11,D12

C52D17,D18

BR "C" BUS

D27,D28

C39

C40

TS3-1 WHTTB9-21 BLK

D25,D26

WHTWHT

C38

C37

WHT

WHT

TS71 2

"B" COIL "B" COIL

L1"A" COIL

L2"A" COIL

X1

X1

X1

X1

X3 YEL

X4 YEL

TB11-3 YEL

TB11-2 YEL


K4-L1 BLK


S2-6 GRY

S2-3 RED

TB1-3 VIOTB1-4 ORN


R50-3 GRY

TB1 6GRY



FN4-3 BLK

TB1-10-A BLK

T2-X2BLU

PCB1 P7-10 GRY

PCB1 P7-15 WHT

PCB1 P7-14 BRN

PCB1 P7-13 RED


TB1-12WHT

TB1-11 WHT



TB9-24 YEL


TB9-21 BLK

FN1-1 BLK

PCB4 P3-1 BLK

FN1-3 GRNFN2-3 GRN

FN2-2 BLU

PCB4 P1-4 BLU


K3-4 RED

BR "A"BUS

F5-1 BLU

R23-1 BRN


BR "B"BUS

F5-2 BLU

F3-1 BRN

X2X3X4X5X6X7X8

X2X3X4X5X6X7X8

X2X3X4X5X6X7X8

BR "C"BUS


F4-1 BRN

D33 BUS GRY

2

1

2

1

2

1

TS4-1 WHT

H1H2

H1H2

H1H2

TS7-2 WHT

K1C-T1.2.3 BLK

K1B-T1.2.3 BLK

K1A-T1.2.3 BLK

GND 1

L1

L2GND 4

A

A

B

B

"A"TS1

TS2

TS3

T1

"B"

"C"

WO

RK

BU

SE

LE

CT

RO

DE

BU

S

R50

R51

PL1 PL2 PL3 PL4 PL5

3 21

1 2 3

S3

3

2

1

6

5

4

CB1

S15 31

6 42

4 5 61 2 3

S2

S4

12

3

PCB4

P2-

1P

2-2

P2-

3P

2-4

P2-

5P

2-6

P2-

7P

2-8

WH

TR

ED

BL

KG

RN

BR

NB

LU

OR

NY

EL

PCB4 P1-11 VIO

PCB4 P1-12 GRY

AB C

DE

FG

HJK

L

M

NP R

ST

U V

1 7 8 2 1 7 8 2

1 T9-GRN2 T9-GRN/YEL3 T9-GRN4 WORK BUS-BLU5 TB1-15 RED6 TB1-16 BLK7 SH1 +8 TB9-2 WHT9 TB9-1 ORN PCB4 P1-10 BLK10 PCB4 P1-9 BLK11 S4-1 VIO12 S4-2 GRY

PCB4P1 P3

1 ELECTRODE BUS-BLK

ESP-400C

X9

X9

X9




6.7 Wiring Diagrams – Drawing 1 – Part 1 400V 50Hz (P/N 35879)

M1-3 GRN

M2-3 GRN

F2-1 ORN

K2-L3 RED

F1-1 VIO

ELECTRODE PLATE GRY

K4-T2 WHT

F7-1 BRN

C32 (-) BLU

T1-CX4 WHTGND-2 GRN

T1-BX2 RED

K1B-L1 YEL

K1C-L1 BLK

WHT

FN4-4 WHT

GND 3 GRN

CB1-1 BLU

TB8-15 YEL

TB8-16 RED

F4-2 BLK

S1-3 ORN

T1-AX7 BRN

T2

H1H2H3H4H5H6

X1X2X3X4

K4-L3 RED

POS PLATE BLU

C27(-) WHT

S1-1 YELT1-BX2 RED

GND-2 GRNT1-CX4 WHT

M21

2

3

R20

R23

1

1

1

12

2

2

2

ORN

1

2

2

1

2

2

1

1

R22 R19 R16 R17

R21

R18

TD1 (SPLICE) BLK

TD2 (SPLICE) BLK

F7-2 ORN

D35-C VIO

K2-L2 WHT

TB4 BLU

K2-L1 BLK

R3

R2

R1M1

1 2

1 2

12

1

2

3

Note: From ESP-400C/600C//400V,50 HzDrawing No. 0558002859, sheet 1 of 5

OR




T1-BH2/CH1 BLK

C61 C62C60

R57R56

R55

F1-2 GRY

R1-1 BLU

K1A-L1 BLK

F2-2 GRN

K1A-L2 BLK

K1A-L3 BLK

K1C-L3 BLK

K1C-L2 BLK


K1B-L2 BLK

K1B-L1 BLK

TB4 TB5 TB6

VIEW L-L

400V 50HZUNITS ONLY

K1C-T3 RED

K1B-T3 WHT

K1A-T3 BLK

C26-1 ORN

R1-2 BLK

R2-2 WHT

R3-2 RED

C26-2 WHT

K2-T1 BLK

T1-AH1 BLK

T1-AH1 BLK

T1-AH1 BLK

K1B-A ORN

T1-AH2/BH1 BLK

T1-AH2/BH1 BLK

T1-AH2/BH1 BLK

K2-T2 WHT

T1-BH2/CH1 BLK

T1-BH2/CH1 BLK

K2-T3 RED

K1-B/C25-2 GRY

TB6 BLK

TB6 BLK

TB6 BLK

T2-H6 BLK

K1B-A/C25-1 ORN

K1A-B/K1C-B GRY

TB5 BLK

TB5 BLK

TB5 BLK T2-H1 YEL

K1A-A/K1C-A ORN

K1B-B GRY

TB4 BLK

TB4 BLK

TB4 BLK

L1 L2 L3L1 L2 L3L1 L2 L3

T1 T2 T3T1 T2 T3T1 T2 T3


R28-2 YEL

R25-2 GRY

T1-CX7 GRY

C34-2 BLK

R26-2 REDC33(+) RED

S1-4 RED

ELECTRODE PLATE

POS PLATE

NEG PLATE

BL

K

D33

D34

TB6 BRN

TB5 GRY

K3-7 ORN

K1C-A ORN

K7-7 GRY

K1C-B GRY

K2-A ORN

K4-B ORN

K7-9 ORN

TB1-11 WHT

K2-B WHT

F1

F2

R2-1 VIO

R3-1 ORN

C25

C26

R32

R33

1

2

1

2

K1A K1B K1C

K2

SEE VIEW K-K

TB4 TB5 TB6

SEE VIEW L-L

VIEW K-K

F F E E

D

D

SECTION C-C

A K2 B

L1 L2 L3

T1 T2 T3


OR




C2(+) BLUC2(-) YEL

1 2R10 R111 2

1 2 1 2R53 R54

K7-4 BLK

"A" "B" "C"

X1X1 X1

F8 F9

C23-2 VIO

C4(+) WHT

C24-1 VIO

C10(+) WHT


M3

C

GC

G

C8(+) BLUC8(-) YEL

PCB1 P7-9 BLU

NEG PLATE YEL

ELECTRODE PLATE GRY

PCB1 P5-9 BLK

PRA1

TB7

PRA1 YEL

C28(+) BLU

R20-2 BLU

F3-2 BLK

D31 D32

D29 D30

BLKC41 C42

C43 C44

ORN

K4-T3 ORN

C27(-) WHT

S1-2 WHT

PRA1 GRY

C29(-) GRY

R21-2 GRY

TD2 (SPLICE) GRY

TD1 (SPLICE) GRY

ELECTRODE PLATE

POSPLATE

NEGATIVE PLATE

F7-

1 B

RN

PC

B1

P4-

1 W

HT

TB

1-9

RE

D

K6-

9 R

ED

PC

B1

P6-

1 O

RN

K5-

9 R

ED

R45R52

21 3 4 5 6 7 9 10 11 12 138TB7

VIEW G-G

SECTION D-D

T2


OR



6.7 Wiring Diagrams – Drawing 3 400V 50Hz (P/N 35879)

R30-1 BLU

POS PLATE BLU

D29/D30 BUS WHT

R31-2 GRY

ELECTRODE PLATE GRY

D31-A BLK

T1-BX7 BRN

D21-1 ORN

D22-1 ORN

D22-2 BRN

D21-2 BRN

TB11-8 RED

C29(-) GRY

R22-2 BLK

R14

R151 2

1 2

F3F4

11 22

R16-2 (SPLICE) BLK

TD2

C29

C28

C27

C30

+

+

+

1

2

R38

R43

R42

R41

R44

GRY

R31 R30

1 1

2 2F5

F6

F7

1

1 2

2

1 2

T3

T2

T1

L3

L2

L1 A

B

K4

BL

K

C31

R37

R18

-1 O

RN

C29

(+)

VIO

T1-

BX

5 B

LU

C29

(+)

VIO

C28

(+)

BL

U

R31

-1 V

IO

F6-

2 V

IO

K4-

T2

WH

T

K4-

T1

YE

L

R19

-1 B

RN

TB

7-5

BR

NR

24-1

VIO

T1-

AX

5 B

LU

TB

10 Y

EL

C30

-1 Y

EL

R18

-2 W

HT

C30

-2 W

HT

D32

-A O

RN

PC

B1

P2-

5 Y

EL

C26

-1 O

RN

S1-

5 B

LK

R23

-2 R

ED

R29

-1 R

ED

PO

S P

LA

TE

RE

DR

29-2

BL

UC

36-2

BL

UR

22-1

BL

U

C36

-1 O

RN

C35

-1 B

RN

C34

-1 Y

EL

C33

(+)

RE

D

EL

EC

TR

OD

E P

LA

TE

Y

EL

C33

C32

BL

K

R39

R40

+

+

RED1 11 1 1

22 22 2

R27 R26 R25 R29 R28

R27-1 ORN

C32(-) BLU

R26-1 BRN

R25-1 YEL



D34-A BLK

BL

K

R34

R35

R36

1

1

2

1

2

2

C34

C35

C36

F6-1 VIOS1-6 BRN

D19-2 BRN

D19-1 ORN

D20-1 ORN

D20-2 BRN

1

1

2

2R12

R13TD1


R17-2 (SPLICE) BLK


35

T1-CX5 BRN


(-) (+)SH13

SH1(-) (+)

PC

B1

P1-

1 C

LR

(T

P)

TB

1-15

RE

D(T

P)

TB

11-1

BL

U

PC

B1

P1-

3 S

HL

D

PC

B1

P1-

2 B

LK

(TP

)T

B1-

16 B

LK

(TP

)

TD1

1 2 3 4P1



1 2 3 4

TD2

P1

P1

R59

R63

R58

BL

K1

2

3

4

5

6

7

8

TB11SHT BUS POS BLU


L2-X3 YEL

PCB1 P9-13 YEL





H

J

H

J

VIEW E-E

PC

B4

P1-

4 B

LU


OR

R16-1 WHT



6.7 Wiring Diagrams – Drawing 4 400V 50Hz (P/N 35879)

R12

-1 B

RN

R12

-2 O

RN

PC

B2

P3

BL

K

R10

-1 Y

EL

R10

-2 B

LU

R53

-2 W

HT

R54

-2 W

HT

R11

-1 B

LU

R11

-2 Y

EL

R54

-1 V

IO

R14

-2 O

RN

R14

-1 B

RN

X7 X6

X5 X4 X3 X2

X1

BLU

YEL

GRN

GRY

H1

H2T6

PCB2 P6-3 RED

PCB2 P6-2 GRN/YEL

PCB2 P6-1 BRN

TB2-2 WHT

TB2-1 BLK

X7 X6

X5 X4 X3 X2

X1

BLU

YEL

GRN

GRY

H1


PCB3 P5-1 BRN

TB3-2 WHT

TB3-1 BLK

PCB3 P5-3 RED

C21T7

D2121

ECQ3

P5

C7

C8

+

+

C1

C2

+

+

D19

C19

T6

E C Q1

P6P3

P1

K2

PCB2C23

1

2

D23

Q1-C BLK

P2

P5

TB2

T5C20

D20

E C

R13

-1 B

RN

R13

-2 O

RN

R52

-1 V

IO

C6 +

C5 +

C4 +

C3 + C9

C10

C12

+

+

+

C11

+

PC

B3

P3

BL

K

R15

-2 O

RN

R15

-1 B

RN

D22

C22

T8

TB3

12

ECQ4

D24 C24

P3

P1

P2

Q4-C BLK

P6

2

1

TB2-1 BLK

TB9-20 BLK

TB2-2 WHT

TB9-15 WHT

T8-H1 BLKT7-H1 BLK

T8-H2 BLK

T7-H2 WHT

TB3

1

2

T8H1

H2

X1X2X3

X4X5X6

X7

TB3-1 BLK

TB3-2 BLK

PCB3 P6-1 BRN

PCB3 P6-2 GRN/YEL

PCB3 P6-3 RED

GRY

GRN

YEL

BLU

T5H1

H2

X1X2X3

X4X5X6

X7

TB2-1 BLK

TB2-2 BLK

PCB2 P5-1 BRN

PCB2 P5-2 GRN/YEL

PCB2 P5-3 RED

GRY

GRN

YEL

TB2T5-H1 BLK

T6-H1 BLK

T5-H2 BLK

T6-H2 WHT

TB3-1 BLK

TB3-2 WHT

1

2





PCB2P1 P2

P5

P6





PCB3

P1 P2

P5

P6


PCB3

BLU


OR








1 2 3 4 5

6 7 8 91011

12 TB11-2 YEL13 TB11-4 YEL14

GRYGRYGRYGRY

VIOVIOVIOVIOVIO

PL4(+) GRY

PL5(+) VIO







TB9

PC

B4

P1-

9 O

RN

PC

B1

P5-

1 R

ED

PC

B4

P1-

8 W

HT

PC

B1

P5-

2 W

HT

PC

B1

P5-

3 B

RN

PC

B1

P5-

4 V

IO

PC

B1

P5-

5 G

RY

PC

B1

P5-

6 O

RN

PC

B1

P5-

7 Y

EL

PC

B1

P6-

5 B

LK

PC

B1

P6-

4 B

LU

PC

B1

P6-

3 G

RY

TB

1-12

WH

TP

CB

1 P

2-8

WH

TT

3-H

2 W

HT

TB

3-2

WH

TK

3-B

WH

TK

7-B

WH

TT

B8-

17 W

HT

TB

3-1

BL

KT

B1-

10 B

LK

TS

7-1

BL

K

PL

3-1

BL

KK

3-6

BL

K

K5-

6 B

LK

PC

B1

P5-

11 Y

EL

PL

5(-)

YE

LP

L4(

-) Y

EL

K6-

B B

LK

T3-

H1

BL

K

JUM

PE

R

JUM

PE

R

JUM

PE

R

JUM

PE

R

JUM

PE

R

BLK

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

TB1-1 BRN

(LINE)TB1-2 YEL

PCB1 P2-8 GRY

(LOAD)PCB1 P2-7 ORN

FN31

2

3

4

PCB1 P5-10 BRN

PCB1 P5-11 GRN/YEL

PCB1 P5-12 RED

TB9-20 BLK

TB9-15 WHT

GRY

GRN

YEL

BLU

T3

X1X2

X3

X4

X5X6

X7

TB1-7 BLK

(LINE)TB1-8 WHT

CB1-2 BLK

(LOAD)T2-X1 WHT

TB1-11 WHT

FN41

2

3

4

TB1-12 BLK

TB1-10 BLK

PCB1 P8-6 RED

PCB1 P8-5 GRN/YEL

PCB1 P8-4 BRN

BLU

YEL

GRN

GRY

T4H1

H2

X1X2

X3X4X5

X6X7

T4

GND5

P7 P6

P10 P11

P9

P8

P1 P2 P3 P4

P5PCB1 T3

FN3

FN4

TB9

PL3-2 BRN

PCB4 P1-6 BLK

PCB4 P1-5 RED

J1-K VIO

J1-J GRY

PL1-2 WHT

PL2-2 WHT WHT

PL1-1 BLKCB1-2 BLK

PL2-1 REDJ1-E RED

J1-G WHT

J1-F BLK


R50-1 VIO

J1-B YEL

J1-A BRN

TS6-2 BRNK7-A BRN

SH1(-) BLK(TP)

SH1(+) RED(TP)

T9-H2 WHTT4-H2 BLK



TB8-8 REDFN4-2 WHT


TB8-12 BLU

TB8-11 ORN

PCB1 P5-8 VIO

FN3-2 YEL

FN3-1 BRN

C45

C46

J1-H GRN

GND 5

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

TB1

P1

P2

P3

P4

P5

P6

P7

P8

P9

P10

P11

PCB1

TB1

VIEW H-H


OR




TB1-18 BRN

TS61

2

C2 C3 C4 C5 C6

C7 C8 C9 C10 C11 C12

D1 D2 D3 D4 D5 D6

R4

R5

R6 R7

R8

R91 2

1 2

TS5-1 WHT

TS1-2 WHT

TS5

TS4

C13

C14

C15

C16 C17

C18

1

2

3

1

2

3

1

2

3

3

2

1

3

2

1

3

2

1


C1 C1

TS5-1 WHT

TS1-2 WHT

TS5-2 WHT

1 2 3

4 5 6

7 8 9

1 2 3

4 5 6

7 8 9

1 2 3

4 5 6

7 8 9

1 2 3

4 5 6

7 8 9

A BA BA BA B

C54 C53

K3K6K6K7

T1-

AX

1 B

LK

C25

-2 G

RY

TB

1-18

BR

N

TB

9-16

WH

T

C26

-1 O

RN

K3-

9 Y

EL

TB

8-9

GR

Y

TB

8-10

BR

NP

CB

1 P

3-2

BL

U

TB

9-22

BL

K

TB

7-8

RE

D

TB

8-18

VIO

TB

8-1

BL

U

TB

8-2

WH

T

TB

7-8

RE

D

TB

9-22

BL

K

T1-

AX

2 R

ED

C25

-1 O

RN

TB

8-19

BL

U

TB

9-16

WH

T

K7-

6 Y

EL

TB

9-22

BL

K

K3K5K6K7

TB8

K3-A BLU

K6-6 VIO

TB9-17 WHT

T2-X4 RED

T2-X3 YEL

TB1-5 BLU

TB1-4 ORN

K6-7 BRN

K6-1 GRY

TB1-9 RED

TB1-7 BLK

PCB1 P4-5 YEL

PCB1 P4-4 VIO

PCB1 P2-2 ORN

PCB1 P2-3 BLK

K5-B WHT

K5-A BLU

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

JUMPER

TB8

VIEW J-J



OR




YEL

ELECTRODE BUS BLK

BLU WORK BUS BLU

TB10

FN1 FN2


3 3

Section A-A

TB1-10 BLK

TB1-12 BLK

PCB4 P1-1 GRN

PCB4 P1-2 GRN/YEL

PCB4 P1-3 GRN

H1

H2T9

C47 D7,D8

BR"A" BUS

C50D13D14

C48 D9,D10

BR "B" BUS

C51D15,D16

C49 D11,D12

C52D17,D18

BR "C" BUS

D27,D28

C39

C40

TS3-1 WHTTB9-21 BLK

D25,D26

WHTWHT

C38

C37

WHT

WHT

TS71 2

"B" COIL "B" COIL

L1"A" COIL

L2"A" COIL

X1

X1

X1

X1

X3 YEL

X4 YEL

TB11-3 YEL

TB11-2 YEL


K4-L1 BLK


S2-6 GRY

S2-3 RED

TB1-3 VIOTB1-4 ORN


R50-3 GRY

TB1 6GRY



FN4-3 BLK

TB1-10-A BLK

T2-X2BLU

PCB1 P7-10 GRY

PCB1 P7-15 WHT

PCB1 P7-14 BRN

PCB1 P7-13 RED


TB1-12WHT

TB1-11 WHT



TB9-24 YEL


TB9-21 BLK

FN1-1 BLK

PCB4 P3-1 BLK

FN1-3 GRNFN2-3 GRN

FN2-2 BLU

PCB4 P1-4 BLU


K3-4 RED

BR "A"BUS

F5-1 BLU

R23-1 BRN


BR "B"BUS

F5-2 BLU

F3-1 BRN

X2X3X4X5X6X7X8

X2X3X4X5X6X7X8

X2X3X4X5X6X7X8

BR "C"BUS


F4-1 BRND33 BUS GRY

2

1

2

1

2

1

TS4-1 WHTH1

H2

H3

H4

TS7-2 WHT

K1C-T1.2.3 BLK

K1B-T1.2.3 BLK

K1A-T1.2.3 BLK

GND 1

L1

L2GND 4

A

A

B

B

"A"TS1

TS2

TS3

T1

"B"

"C"

WO

RK

BU

SE

LE

CT

RO

DE

BU

S

R50

R51

PL1 PL2 PL3 PL4 PL5

3 21

1 2 3

S3

3

2

1

6

5

4

CB1

S15 31

6 42

4 5 61 2 3

S2

S4

12

3

PCB4

P2-

1P

2-2

P2-

3P

2-4

P2-

5P

2-6

P2-

7P

2-8

WH

TR

ED

BL

KG

RN

BR

NB

LU

OR

NY

EL

PCB4 P1-11 VIO

PCB4 P1-12 GRY

AB C

DE

FG

HJK

L

M

N P R

ST

U V

1 7 8 2 1 7 8 2

1 T9-GRN2 T9-GRN/YEL3 T9-GRN4 SHUNT 1-3 -BLU5 TB1-15 RED (600C Only)6 TB1-16 BLK7 TB1-15 (400C Only)8 TB9-2 WHT9 TB9-1 ORN PCB4 P1-10 ORN10 PCB4 P1-9 ORN11 S4-1 VIO12 S4-2 GRY

PCB4P1 P3

1 ELECTRODE BUS-BLK

ESP-400C

X9

X9

X9


OR

H1

H2

H3

H4

H1

H2

H3

H4




M1-3 GRN

M2-3 GRN

F2-1 ORN

K2-L3 RED

F1-1 VIO

ELECTRODE PLATE GRY

K4-T2 WHT

F7-1 BRN

C32 (-) BLU

T1-CX4 WHTGND-2 GRN

T1-BX2 RED

K1B-L1 YEL

K1C-L1 BLK

WHT

FN4-4 WHT

GND 3 GRN

CB1-1 BLU

TB8-15 YEL

TB8-16 RED

F4-2 BLK

S1-3 ORN

T1-AX7 BRN

T2

H1H2H3H4H5H6H7

X1

X2

X3

X4

K4-L3 RED

POS PLATE BLU

C27(-) WHT

S1-1 YELT1-BX2 RED

GND-2 GRNT1-CX4 WHT

M21

2

3

R20

R23

1

1

1

12

2

2

2

ORN

1

2

2

1

2

2

1

1

R22 R19 R16 R17

R21

R18

TD1 (SPLICE) BLK

TD2 (SPLICE) BLK

F7-2 ORN

D35-C VIO

K2-L2 WHT

TB4 BLU

K2-L1 BLK

R3

R2

R1M1

1 2

1 2

12

1

2

3


OR

GND 3




T1-BH2/CH1 BLK

C61 C62C60

R57R56

R55

F1-2 GRY

R1-1 BLU

K1A-L1 BLK

F2-2 GRN

K1A-L2 BLK

K1A-L3 BLK

K1C-L3 BLK

K1C-L2 BLK


K1B-L2 BLK

K1B-L1 BLK

TB4 TB5 TB6

VIEW L-L

400V 50HZUNITS ONLY

K1C-T3 RED

K1B-T3 WHT

K1A-T3 BLK

C26-1 ORN

R1-2 BLK

R2-2 WHT

R3-2 RED

C26-2 WHT

K2-T1 BLK

T1-AH1 BLK

T1-AH1 BLK

T1-AH1 BLK

K1B-A ORN

T1-AH2/BH1 BLK

T1-AH2/BH1 BLK

T1-AH2/BH1 BLK

K2-T2 WHT

T1-BH2/CH1 BLK

T1-BH2/CH1 BLK

K2-T3 RED

K1-B/C25-2 GRY

TB6 BLK

TB6 BLK

TB6 BLK

T2-H6 BLK

K1B-A/C25-1 ORN

K1A-B/K1C-B GRY

TB5 BLK

TB5 BLK

TB5 BLK T2-H1 YEL

K1A-A/K1C-A ORN

K1B-B GRY

TB4 BLK

TB4 BLK

TB4 BLK

L1 L2 L3L1 L2 L3L1 L2 L3

T1 T2 T3T1 T2 T3T1 T2 T3


R28-2 YEL

R25-2 GRY

T1-CX7 GRY

C34-2 BLK

R26-2 REDC33(+) RED

S1-4 RED

ELECTRODE PLATE

POS PLATE

NEG PLATE

BL

K

D33

D34

TB6 BRN

TB5 GRY

K3-7 ORN

K1C-A ORN

K7-7 GRY

K1C-B GRY

K2-A ORN

K4-B ORN

K7-9 ORN

TB1-11 WHT

K2-B WHT

F1

F2

R2-1 VIO

R3-1 ORN

C25

C26

R32

R33

1

2

1

2

K1A K1B K1C

K2

SEE VIEW K-K

TB4 TB5 TB6

SEE VIEW L-L

VIEW K-K

F F E E

D

D

SECTION C-C

A K2 B

L1 L2 L3

T1 T2 T3 Note: From ESP-400C/600C//575VDrawing No. 0558002852, sheet 2 of 5

OR




C2(+) BLUC2(-) YEL

1 2R10 R111 2

1 2 1 2R53 R54

K7-4 BLK

"A" "B" "C"

X1X1 X1

F8 F9

C23-2 VIO

C4(+) WHT

C24-1 VIO

C10(+) WHT


M3

C

GC

G

C8(+) BLUC8(-) YEL

PCB1 P7-9 BLU

NEG PLATE YEL

ELECTRODE PLATE GRY

PCB1 P5-9 BLK

PRA1

TB7

PRA1 YEL

C28(+) BLU

R20-2 BLU

F3-2 BLK

D31 D32

D29 D30

BLKC41 C42

C43 C44

ORN

K4-T3 ORN

C27(-) WHT

S1-2 WHT

PRA1 GRY

C29(-) GRY

R21-2 GRY

TD2 (SPLICE) GRY

TD1 (SPLICE) GRY

ELECTRODE PLATE

POSPLATE

NEGATIVE PLATE

F7-

1 B

RN

PC

B1

P4-

1 W

HT

TB

1-9

RE

D

K6-

9 R

ED

PC

B1

P6-

1 O

RN

K5-

9 R

ED

R45R52

21 3 4 5 6 7 9 10 11 12 138TB7

VIEW G-G

SECTION D-D

T2


OR




R30-1 BLU

POS PLATE BLU

D29/D30 BUS WHT

R31-2 GRY

ELECTRODE PLATE GRY

D31-A BLK

T1-BX7 BRN

D21-1 ORN

D22-1 ORN

D22-2 BRN

D21-2 BRN

TB11-8 RED

C29(-) GRY

R22-2 BLK

R14

R151 2

1 2

F3F4

11 22

R16-2 (SPLICE) BLK

TD2

C29

C28

C27

C30

+

+

+

1

2

R38

R43

R42

R41

R44

GRY

R31 R30

1 1

2 2F5

F6

F7

1

1 2

2

1 2

T3

T2

T1

L3

L2

L1 A

B

K4

BL

K

C31

R37

R18

-1 O

RN

C29

(+)

VIO

T1-

BX

5 B

LU

C29

(+)

VIO

C28

(+)

BL

U

R31

-1 V

IO

F6-

2 V

IO

K4-

T2

WH

T

K4-

T1

YE

L

R19

-1 B

RN

TB

7-5

BR

NR

24-1

VIO

T1-

AX

5 B

LU

TB

10 Y

EL

C30

-1 Y

EL

R18

-2 W

HT

C30

-2 W

HT

D32

-A O

RN

PC

B1

P2-

5 Y

EL

C26

-1 O

RN

S1-

5 B

LK

R23

-2 R

ED

R29

-1 R

ED

PO

S P

LA

TE

RE

DR

29-2

BL

UC

36-2

BL

UR

22-1

BL

U

C36

-1 O

RN

C35

-1 B

RN

C34

-1 Y

EL

C33

(+)

RE

D

EL

EC

TR

OD

E P

LA

TE

Y

EL

C33

C32

BL

K

R39

R40

+

+

RED1 11 1 1

22 22 2

R27 R26 R25 R29 R28

R27-1 ORN

C32(-) BLU

R26-1 BRN

R25-1 YEL



D34-A BLK

BL

K

R34

R35

R36

1

1

2

1

2

2

C34

C35

C36

F6-1 VIOS1-6 BRN

D19-2 BRN

D19-1 ORN

D20-1 ORN

D20-2 BRN

1

1

2

2R12

R13TD1


R17-2 (SPLICE) BLK


35

T1-CX5 BRN


(-) (+)SH13

SH1(-) (+)

PC

B1

P1-

1 C

LR

(T

P)

TB

1-15

RE

D(T

P)

TB

11-1

BL

U

PC

B1

P1-

3 S

HL

D

PC

B1

P1-

2 B

LK

(TP

)T

B1-

16 B

LK

(TP

)

TD1

1 2 3 4P1



1 2 3 4

TD2

P1

P1

R59

R63

R58

BL

K1

2

3

4

5

6

7

8

TB11SHT BUS POS BLU


L2-X3 YEL

PCB1 P9-13 YEL





H

J

H

J

VIEW E-E

PC

B4

P1-

4 B

LU

R16-1 WHT


OR




R12

-1 B

RN

R12

-2 O

RN

PC

B2

P3

BL

K

R10

-1 Y

EL

R10

-2 B

LU

R53

-2 W

HT

R54

-2 W

HT

R11

-1 B

LU

R11

-2 Y

EL

R54

-1 V

IO

R14

-2 O

RN

R14

-1 B

RN

X7 X6

X5 X4 X3 X2

X1

BLU

YEL

GRN

GRY

H1

H2T6

PCB2 P6-3 RED

PCB2 P6-2 GRN/YEL

PCB2 P6-1 BRN

TB2-2 WHT

TB2-1 BLK

X7 X6

X5 X4 X3 X2

X1

BLU

YEL

GRN

GRY

H1


PCB3 P5-1 BRN

TB3-2 WHT

TB3-1 BLK

PCB3 P5-3 RED

C21T7

D2121

ECQ3

P5

C7

C8

+

+

C1

C2

+

+

D19

C19

T6

E C Q1

P6P3

P1

K2

PCB2C23

1

2

D23

Q1-C BLK

P2

P5

TB2

T5C20

D20

E C

R13

-1 B

RN

R13

-2 O

RN

R52

-1 V

IO

C6 +

C5 +

C4 +

C3 + C9

C10

C12

+

+

+

C11

+

PC

B3

P3

BL

K

R15

-2 O

RN

R15

-1 B

RN

D22

C22

T8

TB3

12

ECQ4

D24 C24

P3

P1

P2

Q4-C BLK

P6

2

1

TB2-1 BLK

TB9-20 BLK

TB2-2 WHT

TB9-15 WHT

T8-H1 BLKT7-H1 BLK

T8-H2 BLK

T7-H2 WHT

TB3

1

2

T8H1

H2

X1X2X3

X4X5X6

X7

TB3-1 BLK

TB3-2 BLK

PCB3 P6-1 BRN

PCB3 P6-2 GRN/YEL

PCB3 P6-3 RED

GRY

GRN

YEL

BLU

T5H1

H2

X1X2X3

X4X5X6

X7

TB2-1 BLK

TB2-2 BLK

PCB2 P5-1 BRN

PCB2 P5-2 GRN/YEL

PCB2 P5-3 RED

GRY

GRN

YEL

TB2T5-H1 BLK

T6-H1 BLK

T5-H2 BLK

T6-H2 WHT

TB3-1 BLK

TB3-2 WHT

1

2





PCB2P1 P2

P5

P6





PCB3

P1 P2

P5

P6


PCB3

BLU


OR








1 2 3 4 5

6 7 8 91011

12 TB11-2 YEL13 TB11-4 YEL14

GRYGRYGRYGRY

VIOVIOVIOVIOVIO

PL4(+) GRY

PL5(+) VIO







TB9

PC

B4

P1-

9 O

RN

PC

B1

P5-

1 R

ED

PC

B4

P1-

8 W

HT

PC

B1

P5-

2 W

HT

PC

B1

P5-

3 B

RN

PC

B1

P5-

4 V

IO

PC

B1

P5-

5 G

RY

PC

B1

P5-

6 O

RN

PC

B1

P5-

7 Y

EL

PC

B1

P6-

5 B

LK

PC

B1

P6-

4 B

LU

PC

B1

P6-

3 G

RY

TB

1-12

WH

TP

CB

1 P

2-8

WH

TT

3-H

2 W

HT

TB

3-2

WH

TK

3-B

WH

TK

7-B

WH

TT

B8-

17 W

HT

TB

3-1

BL

KT

B1-

10 B

LK

TS

7-1

BL

K

PL

3-1

BL

KK

3-6

BL

K

K5-

6 B

LK

PC

B1

P5-

11 Y

EL

PL

5(-)

YE

LP

L4(

-) Y

EL

K6-

B B

LK

T3-

H1

BL

K

JUM

PE

R

JUM

PE

R

JUM

PE

R

JUM

PE

R

JUM

PE

R

BLK

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

TB1-1 BRN

(LINE)TB1-2 YEL

PCB1 P2-8 GRY

(LOAD)PCB1 P2-7 ORN

FN31

2

3

4

PCB1 P5-10 BRN

PCB1 P5-11 GRN/YEL

PCB1 P5-12 RED

TB9-20 BLK

TB9-15 WHT

GRY

GRN

YEL

BLU

T3

X1X2

X3

X4

X5X6

X7

TB1-7 BLK

(LINE)TB1-8 WHT

CB1-2 BLK

(LOAD)T2-X1 WHT

TB1-11 WHT

FN41

2

3

4

TB1-12 BLK

TB1-10 BLK

PCB1 P8-6 RED

PCB1 P8-5 GRN/YEL

PCB1 P8-4 BRN

BLU

YEL

GRN

GRY

T4H1

H2

X1X2

X3X4X5

X6X7

T4

GND5

P7 P6

P10 P11

P9

P8

P1 P2 P3 P4

P5PCB1 T3

FN3

FN4

TB9

PL3-2 BRN

PCB4 P1-6 BLK

PCB4 P1-5 RED

J1-K VIO

J1-J GRY

PL1-2 WHT

PL2-2 WHT WHT

PL1-1 BLKCB1-2 BLK

PL2-1 REDJ1-E RED

J1-G WHT

J1-F BLK


R50-1 VIO

J1-B YEL

J1-A BRN

TS6-2 BRN

K7-A BRN

SH1(-) BLK(TP)

SH1(+) RED(TP)

T9-H2 WHTT4-H2 BLK



TB8-8 REDFN4-2 WHT


TB8-12 BLU

TB8-11 ORN

PCB1 P5-8 VIO

FN3-2 YEL

FN3-1 BRN

C45

C46

J1-H GRN

GND 5

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

TB1

P1

P2

P3

P4

P5

P6

P7

P8

P9

P10

P11

PCB1

TB1

VIEW H-H


OR




TB1-18 BRN

TS61

2

C2 C3 C4 C5 C6

C7 C8 C9 C10 C11 C12

D1 D2 D3 D4 D5 D6

R4

R5

R6 R7

R8

R91 2

1 2

TS5-1 WHT

TS1-2 WHT

TS5

TS4

C13

C14

C15

C16 C17

C18

1

2

3

1

2

3

1

2

3

3

2

1

3

2

1

3

2

1


C1 C1

TS5-1 WHT

TS1-2 WHT

TS5-2 WHT

1 2 3

4 5 6

7 8 9

1 2 3

4 5 6

7 8 9

1 2 3

4 5 6

7 8 9

1 2 3

4 5 6

7 8 9

A BA BA BA B

C54 C53

K3K6K6K7

T1-

AX

1 B

LK

C25

-2 G

RY

TB

1-18

BR

N

TB

9-16

WH

T

C26

-1 O

RN

K3-

9 Y

EL

TB

8-9

GR

Y

TB

8-10

BR

NP

CB

1 P

3-2

BL

U

TB

9-22

BL

K

TB

7-8

RE

D

TB

8-18

VIO

TB

8-1

BL

U

TB

8-2

WH

T

TB

7-8

RE

D

TB

9-22

BL

K

T1-

AX

2 R

ED

C25

-1 O

RN

TB

8-19

BL

U

TB

9-16

WH

T

K7-

6 Y

EL

TB

9-22

BL

K

K3K5K6K7

TB8

K3-A BLU

K6-6 VIO

TB9-17 WHT

T2-X4 RED

T2-X3 YEL

TB1-5 BLU

TB1-4 ORN

K6-7 BRN

K6-1 GRY

TB1-9 RED

TB1-7 BLK

PCB1 P4-5 YEL

PCB1 P4-4 VIO

PCB1 P2-2 ORN

PCB1 P2-3 BLK

K5-B WHT

K5-A BLU

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

JUMPER

TB8

VIEW J-J



OR



6.9 PC Controller Board (PCB1,P/N 38032, REV C) Schematics Drawing 1 Part 1



6.9 PC Controller Board (PCB1-P/N 38032) Schematics - Drawing 1 Part 2




1

2

3

4

5




5

4

3

2

1



6.9 PC Controller Board (PCB1-P/N 38032) Schematics - Drawing 3



6.10 PCB Digital Meter Board (PCB4-P/N 38139) Drawing 1



1

2

3

4

5

6

6.10 PCB Digital Meter Board (PCB4-P/N 38139) Drawing 2 Part 1



1

2

3

4

5

6

6.10 PCB Digital Meter Board (PCB4-P/N 38139) Drawing 2 Part 2



340013 -12H

LOSSIGBT SAT

-12V INDICATOR

SS CONTACTOR

.01 100K

P1-10

P1-09

P1-08221R84

LED3

R52

TP30

10K

221

R51.01

TP28

TP29

C27

D13

IC08

P1-07

P1-06

P1-05

IC10

R49

Q7R50

IC09100K

1M

TP26

TP27

R86

-12H

C53

R85100K.01

C52

ANALOGISOLATOR

R47

Q6

TP25

1M100KR48

TP24

T

.011KV

R42

C54#

R40-15Z

P6-2

C311000

+

20V

SS CONTACTOR

20V

Z

COMPARATOR

+15Z

IC08

20KR38

221

Z

R82 R83

Q3

.01C21

ON

TP22

OFF

10K

P6-3 R59

2W1.0 C32

.10

P6-11.02W

R60

H

1000

+~~

- +

BR2

C28

.10C33

TP31

4.7C22

4.7

H

Q

D

R21555

1

P1-02

P1-04

P1-03

P1-01

C06.47

+15Z

C25

C24R4610

C26 .01

˜-0.5V

TP23

MAXR4310

1M

10KR45

R44

915

2.47

#

16IC07

10R35

108

7

#

.471

R39

R3710

C19.47

TP04

.01

˜+4.5VV MIN

5 2C11

6

.0015C12

20K

#R41

SET8

11

IC03

4VSS7

SR6

10R19

CLOCK OSCILLATOR

IC02

20KHZ

TP03

3

7

4 8 3.32KR20

10KPOT5

CW

CLK

13=OPEN

3

10R

9 401312=OPEN

VDD14

Q1

C13.47

R2310

TP05

+15Z

C18.0015

R366801/2W

2N4401

D51

10K

R31.47

C20

2 -

+IC05

D10

TP16 D50

D11

TP13

6499R26 Q2

D12

Z

TP21

MAX ERROR

#100KR34

TP09

TP06

Z

CW

10K#POT4

+15Z 10K

TP20

R33

136

14

M57962LIC06

8

C23

1

ZD7

5

4

TP32

IC10

R552.21K

2

D09

1

+15H

TP17

+15Z

TP12

C14

R22IC042

2

1

+15Z

5

3

TP11

IC046

510

Z

7 .47

144

P2-1 P2-3

1K 10KR87

TP19

1KR24

+15ZR29 P2-6P2-5

D08TP18

8IC04

910 C17R32

221 560PF

Z

10K

R251K 12

IC0413

CWPOT1

+15Z

P2-4P2-2POT1˜3.32K

1

2

3

4

5

6

7

8

9

10

11

6.11 IGBT Driver Board (PCB2,3 – P/N 38030) Drawing 1 Part 1



TP15

R05

IN

D15

IN

D19

10

# ZD4

Q8

TP34

C301000

D17

7912REG4

H

OUT

D18

LEAVE OFF BOARD#

LED5+

R543.32K

-12H

10KR58

IGBT 3

TP33

1000C29

REG37815

D16

OUT

D14

3.32K+

LED4

R53 R56

2 1

IC09 1K

E

E

#

2.2 1WR07#

2.2 1W

630V.033C51

R06

ZD6

ZD5

G

E

E

ZD3

R5715K

+15H

R15C03

IGBT 2

IGBT 1

2.2 1W ZD2

Q4

#

R032.2

2.2#

1W

1WR04

D20

1W

Q5

G

P3-1

E

E

ZD1

TP01

2.2R02#

1WR01

˜+1.25V

.10

G

RAMP

˜-5.OVv

t

POWER CONNECTIONS FOR IC1

R14

4

10

-15Z

IC01

7-

+34001

10

Z.47

.47

C04

C05

C50

10KR11

TP02Z

R30

100 Q1

20KPOT6

10KR10

+3.3

10K

IC013 +

R8110K

-2

34001

6

22.1KR16

SPAN

CW

POT210K

D07

R80

+15ZPOSITION

1.0

P5-3

P5-2TP14

+15Z

20V

20V

~~

.102W 1.0

C02

-

R09

2W

Z

BR1 +

.10C01

P5-1 R08

LED2

-15Z

7

POWER CONNECTIONS FOR IC5

34001+

IC05

-

10

-15Z

.47

.47C15

4

R27

Z

7915

+15Z

D06

REG2IN

TP10

C16

R2810

OUT

3.32K

LED1

3.32K

+15ZREG17815

D02

D05

1000

C08+

1000C07+ TP08

IN

D03

C09D01 +

D04 +C10

3.3

R12

3.3

OUTR13

TP07

Z1

2

3

5

6

7

8

9

10

4

11

6.11 IGBT Driver Board (PCB2,3 – P/N 38030) Drawing 1 Part 2



6.11 IGBT Driver Board (PCB2,3 – P/N 38030) Drawing 2

SECTION 7 Replacement Parts

ESP 600C Plasma Power Source 7-1

7.1 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.

7.2 Ordering

To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this equipment. The use of non-ESAB parts may void your warranty. Replacement parts may be ordered from your ESAB Distributor or from: ESAB Welding and Cutting Products ATTN: Customer Service Department PO Box 100545 Ebenezer Road Florence, SC USA 29501-0545 Phone (843) 664-4405 (800) ESAB-123 (372-3123) ESAB Cutting Systems - Canada 6010 Tomken Road Mississauga, Ontario, Canada L5T 1X9 Phone (905) 670-0220 Fax (905) 670-4879 ESAB Cutting Systems GmbH Robert-Bosch-Strasse 20 Postfach 1128 D-61184 Karben 1 Germany Phone 011 49 60 39 400 Fax 011 49 60 39 403 02 http://www.esab.de Be sure to indicate any special shipping instructions when ordering replacement parts. Refer to the Communications Guide located on the last page of this manual for a list of customer service phone numbers.



7.3 Outside View – Front And Back

1

2

3456789

111012

13

14

15

16

17 18

19 20

22

21



Item No Qty Part Number Description Circuit Symbol 1 1 35749 Base 2 1 35751 Panel Right Side 3 1 35753 Cover Top 4 2 951032 Lamp LED Red 12V PL4, PL5 5 1 2134926 Lamp Indicator Amber PL3 6 2 951526 Lamp Neon White PL1, PL2 7 1 950122 Circuit Breaker 10A CB1 8 1 950715 Potentiometer 15K 2W R50 9 1 2062170 Knob 10 1 634518 Switch Toggle DPDT 2 pos S2 11 1 672508 Switch 10GL 3pst 2 pos S1 12 1 951061 Meter LED 5VDC 200MN #dp-350 VM 13 1 951061 Meter LED 5VDC 200MN #dp-350 AM 14 1 1006733 Conn Box Recp 19P J1 15 1 35752 Panel Left Side 16 1 35722 Panel Front 17 1 954932 Label PC Box Cover –ESP-400C

18 1 32338GY,BK,DG Plate Cover ESP-400C

19 1 35822GY,BK,DG Access Door

20 5 993426 Grommet Rubber 1.5 ID 21 1 634516 Switch Toggle SPDT 2 pos 10A 250V Q/D S4

22 1 35750GY,BK,DG Rear Panel



234510 10

(T-4)

9876

View with LED meter panel removed

P1

P2

1

7.4 Front View With PCBs Exposed

View with PCB Cover Removed



Item No Qty Part Number Description Circuit Symbol 1 1 38139 PCB Meter Digital PCB4 2 1 2062018 Potentiometer 10 K 2W R51 3 1 951502 Knob 4 1 950458 Switch Toggle DPDT 3 pos S3 5 1 38032 PC Board Control PCB1 6 1 635568 Terminal Block 18 pos TB1 7 1 951275 Filter RFI FN4 8 1 995103 Terminal Strip 24 pos TB9 9 1 950116 Filter OMI FN3 10 1 35779 Kit Wire 600C Control 460/575V



7.5 Right Side View

11

1

7

8

9

8

7

6

10

2

3

4

5

10

12



Item No Qty Part Number Description Circuit Symbol 1 1 35717 Transformer Control T2 2 2 674969 PCB Filter FN1,2 3 4 950704 RECT SIL Reverse 85A D29,30,35 4 3 950703 RECT SIL Forward 85A D31,32,34 5 1 973168 Terminal Strip 13 pos TB7 6 7 17300008 Resistor 8 OHM 300W R12-17,24 7 6 17300001 Resistor 1 OHM 300W R1-3,21-23 8 3 17300004 Resistor 4 OHM 300W 18-20 9 1 35750 Panel Rear 10 1 35710 Inductor L2 11 1 0558002525 Potted Resistor Assembly PRA1 12 6 950631 PC Board Support



7.6 Left Side View

13

4

5

6

5

8

7

9

10

11

x4



Item No Qty Part Number Description Circuit Symbol

1 3 35895 Kit Wire 600C 400V C60,61,62, R55-57

3 4 951491 Contactor 3 pole 90A K2,K1a,1b,1c 4 2 2046333 Fuse Slo-Blo 15A 600V F1,2 5 2 672772 Capacitor 10 µf 370V C25,26,34-36 6 2 17280210 Resistor 1K ohms 100W R10,11,28-31 7 3 17280010 Resistor 10 ohms 100W R25,26,27 8 1 950703 RECT SIL Forward 85A D34 9 1 950704 RECT SIL Reverse 85A D33 10 35710 Inductor (REF) L1,2 11 1 952002 Core, Saturable Amorphos



7.7 Top View



Item No Qty Part Number Description Circuit Symbol 1 2 38030 PCB IGBT Driver PCB2,3 2 6 17750051 Resistor 10ohm 50W Noninductive R4-9 3 6 951828 Capacitor .033 µf 630V C13-18 4 15 951635 Capacitor 1900 µf 450V C1-12,29,32,33 5 3 951085 Switch Thermal 176 DEG F TS4-6 6 4 35779 Kit Wire ESP Control 460/575V 7 6 0558001020 Module Diode Dual 100A 600V D1-6 8 2 pr 951951 IGBT Matched Pair 600A 600V 9 10 4 950704 RECT SIL Reverse 85A 11 5 672772 Capacitor 10 µf 370V C25,26,34,35,36 12 5 17300008 Resistor 8 ohm 300W R12-15,24 13 2 0558002348 Transducer Current TD1,2 14 1 951282 Shunt 100mV 500A SH1 15 4 951998 Capacitor .27 µf 1200 VDC C19-22 16 4 951996 Module Dual Diode Rectifier 600V 30A D19,22 17 2 2046333 Fuse Slo-Blo 15A 600V F3,4 18 19 2 951802 Capacitor 2900 µf 450V C27,28 20 1 950255 Capacitor 60 µf 370V C30 21 2 2062357 Fuse Slo-Blo 30A 250V F5,7 22 1 951527 Fuse 15A F6 23 1 673458 Contactor 3 pole 40A K4 24 2 952103 Fuse holder 60A 25 4 951199 Core Saturable 26 6 952002 Core Saturable Amorphous 27 2 0558002435 Capacitor 3100 µf 450V C27,28



7.8 Back Inside View

21

423



Item No Qty Part Number Description Circuit Symbol 1 2 2062334 Motor Fan 1/3 hP M1,2 2 6 17300001 Resistor 1 ohm 300W R1-3,21-23 3 3 17300004 Resistor 4 ohm 300W R18-20



7.9 Middle Cross Section

5

23432

F8 F9

1



Item No Qty Part Number Description Circuit Symbol 1 2 951997 Transducer Current (ref) TD1,2 2 2 17280210 Resistor 1K ohms 100W R10,11 3 2 23610413 Resistor 2 ohms 25W R53,54 4 1 951816 Fan 230 V 50/60 Hz M3 5 1 677298 Fuse Assembly F8,9



7.10 Front Cross Section –Behind Front Panel

1

2

3 45

4

67

7



Item No Qty Part Number Description Circuit Symbol 1 6 17280210 Resistor 1k ohms 100W R10,11,28-31 2 4 2080196 Relay 3 pos brkt MT K3,5,6,7 3 1 0558004783 Terminal Block 18 pos TB8 4 10 13730638 Diode Rectifier Reverse 800V 300A D7-12,25-28 5 6 13730639 Diode Rectifier Forward 800V 300A D13-18 6 1 950711 Switch Thermal 194 DegF TS7 7 2 35710 Inductor L1,2




REVISION HISTORY

Revision – Oct., 2004 – Added “1 - 14 AWG 600V lead to pilot arc connection in plumbing box (h.f. generator)” note to top diagram on page 3-7. Changed note 4 to read - “Connect the pilot arc cable to the pilot arc terminal in the primary power source. The pilot arc connection in the secondary power source is not used. The pilot arc circuit is not run in parallel” on page 3-7. Modified bottom diagram and changed note to read – “Disconnect negative connection from secondary power source and insu-late to convert from two to one power source” on page 3-7. Revision - June, 2005 - Section 6, Replaced 6.7 wiring diagram - drawing 1 - part 1 400v 50Hz to show new white wire connection from H2 to H4 on page 6-37.

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Customer // Technical Support(843) 664-4405

(800) ESAB-123 (372-2123)

ESAB Welding and Cutting ProductsPO BOX 100545 Ebenezer Road

Florence, SC 29501-0545http://www.esab.com

ESAB Cutting Systems – Canada6010 Tomken Road

Mississauga, Ontario Canada L5T 1X9Phone: (905) 670-0220

Fax: (905) 670-4879

ESAB-Hancock GmbHCutting Technologies

P.O Box 1128D-61174 Karben

Robert-Bosch-Strasse 20D-61184 Karben

Phone + 49 60 39 40-0Fax + 49 60 39 40 301_302

http://[email protected]

Printed in U.S.A

Documents

ESP-600C Plasma Power Source equipment/power... · 2015-11-17 · ESP-600C Plasma Power Source Table of Contents i Page Section 1 Safety 1.1 Introduction 1 1.2 Safety Notations And