F-15-682 Jun, 2005 Installation, Operation, and Maintenance for the ESP-600C Plasma Power Source
The equipment described in this manual is potentially hazardous. Use caution when installing, operating and maintaining this equipment. Purchaser is solely responsible for the safe operation and use of all products purchased, including compliance with OSHA and other government standards. ESAB Cutting Systems has no liability for personal injury or other damage arising out of the use of any product manufactured or sold by ESAB.
ESP-600C Plasma Power Source Table of Contents Page Section 1 Safety 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 Introduction Safety Notations And Symbols General Safety Information Installation Precautions Electrical Grounding Operating A Plasma Cutting Machine Service Precautions Safety References 1 1 2 3 4 4-7 8 9 Section 2 Description 2.1 General 2.2 General Specifications 2.3 Dimensions and Weight 1 1 2 Section 3 Installation 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.
ESP-600C Plasma Power Source Table of Contents 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 6.4.
ESP-600C Plasma Power Source Table of Contents 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.
ESP-600C Plasma Power Source This page intentionally left blank.
SECTION 1 SAFETY 1.1 Introduction The process of cutting metals with plasma equipment provides industry with a valuable and versatile tool. ESAB cutting machines are designed to provide both operation safety and efficiency. However, as with any machine tool, sensible attention to operating procedures, precautions, and safe practices is necessary to achieve a full measure of usefulness.
SECTION 1 SAFETY 1.3 General Safety Information ! WARNING ! WARNING Machinery often starts automatically. This equipment moves in various directions and speeds. • Moving machinery can crush. • Only qualified personnel should operate or service this power source. • Keep all personnel, materials, and equipment not involved in production process clear of entire system area.
SECTION 1 SAFETY Failure to follow safety warning label instructions could result in death or serious injury. ! WARNING Read and understand all safety warning labels on machine. Refer to operator’s manual for additional safety information. 1.4 Installation Precautions ! WARNING Improperly Installed Equipment Can Cause Injury Or Death. Follow these guidelines while installing machine: • Contact your ESAB representative before installation.
SECTION 1 SAFETY 1.5 Electrical Grounding Electrical grounding is imperative for proper machine operation and SAFETY. Refer to this manual’s Installation section for detailed grounding instructions. ! WARNING Electric shock hazard. Improper grounding can cause severe injury or death. Machine must be properly grounded before put into service. 1.6 Operating A Plasma Cutting Machine ! WARNING ! WARNING Flying debris and loud noise hazards. • Hot spatter can burn and injure eyes.
SECTION 1 SAFETY ! WARNING ! WARNING Hazardous voltages. Electric shock can kill. • Do NOT touch plasma torch, cutting table or cable connections during plasma cutting process. • Always turn power off to plasma power supplies before touching or servicing plasma torch. • Always turn power off to plasma power supplies before servicing any system component. • Do not touch live electrical parts. • Keep all panels and covers in place when machine is connected to power source.
SECTION 1 SAFETY ! WARNING Radiation hazard. Arc rays can injure eyes and burn skin. • Wear correct eye and body protection. • Wear dark safety glasses or goggles with side shields. Refer to following chart for recommended lens shades for plasma cutting: Arc Current Lens Shade Shade No. 8 Up to 100 Amps 100-200 Amps AmpsShade Shade No. 10 200-400 Amps AmpsShade Shade No. 12 Over 400 Amps Shade No.
SECTION 1 SAFETY ! WARNING Explosion hazard. • Certain molten aluminum-lithium (Al(Al-Li) Li) alloys can cause explosions when plasma cut OVER water. § § § These alloys should only be dry cut on a dry table. DO NOT dry cut over water. Contact your aluminum supplier for additional safety information regarding hazards associated with these alloys. • Do not cut in atmospheres containing explosive dust or vapors. • Do not carry any combustibles on your person (e.g.
SECTION 1 SAFETY 1.7 Service Precautions ! WARNING CAUTION Hazardous voltages. Electric shock can kill. • Do NOT touch plasma torch, cutting table or cable connections during plasma cutting process. • Always turn power off to plasma power supplies before touching or servicing plasma torch. • Always turn power off to plasma power supplies before removing covers or panels to service any system component. • Do not touch live electrical parts.
SECTION 1 SAFETY 1.8 Safety References The following nationally recognized publications on safety in welding and cutting operations are recommended. These publications have been prepared to protect persons from injury or illness and to protect property from damage, which could result from unsafe practices. Although some of these publications are not related specifically to this type of industrial cutting apparatus, the principles of safety apply equally.
SECTION 1 SAFETY This page intentionally left blank.
SECTION 2 Description 2.1 Introduction The ESP power Source is designed for high speed plasma mechanized cutting applications. It can be used with other ESAB products such as the PT-15 and PT-600 torches along with the Smart Flow II, a computerized gas regulation and switching system.
SECTION 2 Description 2.3 Dimensions and Weight Front View 400 300 500 OUTPUT 600 MAX 200 AMPS 100 50 MIN VOLTS ACTUAL AMPS PRESET AMPS PILOT HIGH ARC LOW 0 CURRENT MAIN POWER PANEL 600C OVER TEMP REMOTE CONTACTOR ON FAULT POWER RESET FAULT 40.25" (102.24cm) 37.25" (94.62cm) Side View Weight = 2040 lbs. (925.34 kg.) 45.00" (114.
SECTION 3 Installation 3.1 General ! WARNING 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 CAUTION Using One Lifting Eye Will Damage Sheet Metal And Frame Use both lifting eyes when transporting with overhead method. 6 0 0 C Unit weighs over 2000 lbs. Use approved straps or cables in good condition.
SECTION 3 Installation 3.3 Placement Note: Use both lifting eyes when transporting from overhead. Power Source • 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.
SECTION 3 Installation 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 Input and Time delay Ground Fuse size Volts Amperes conductor* (amperes) CU/AWG 400 206 4/0 250 460 179 3/0 250** 575 143 1/0 200 *Sizes per National Electrical Code for a 90 °C rated copper conductors @ 40 °C ambient.
SECTION 3 Installation 3.4.2 Input Conductors • Customer supplied • May consist either of heavy rubber covered copper conductors (three power and one ground) or run in solid or flexible conduit. • Sized according to the chart. Input conductors must be terminated with ring terminals. NOTICE 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.
SECTION 3 Installation ! 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. ! WARNING 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.
SECTION 3 Installation 3.5.2 Output Connection Procedure Access Panel 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.
SECTION 3 Installation Note: Primary power source has the electrode (-) conductor jumpered. The secondary power source has the work (+) jumpered. Connections for Parallel Installation of 2 Power sources Secondary Power Source work electrode (+) (-) Primary Power Source electrode (-) work (+) pilot arc 1. Connect the negative (-) output cables to the plumbing box (high frequency generator). 2. Connect the positive (+) output cables to the workpiece. 3.
SECTION 3 Installation 3.
SECTION 3 Installation 3.8 System Interconnecting Block Diagram with Manual Flow Control Wall Box Gas Regulators (+) Return Lead Input power Power Source (-) Cut Current Pilot Arc O2 Cut gas Coolant OnOff N2 Start Gas Coolant Return Cooler (WC-7) Cut Water Pump Coolant Output Start Gas Solenoid Cut gas Solenoid High Freq.
SECTION 3 Installation This page intentionally left blank.
SECTION 4 Operation 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 with Covers Removed. High voltage components are exposed increasing shock hazard. Internal component may be damaged because cooling fans will lose efficiency. 4.2 Control Panel Main Power Indicator illuminates when input power is applied to the power source.
SECTION 4 Operation Fault Indicator illuminates when there are abnormalities in the cutting process or when the input line voltage falls outside of the required nominal value by ±10%. Power Reset Fault Indicator illuminates when a serious fault is detected. Input power must be disconnected for at least 5 seconds and then reapplied. Current Dial (Potentiometer) ESP-600C dial shown. ESP-600C has a range of 50 to 600 A. Used only in panel mode. Panel Remote Switch Controls the location of current control.
SECTION 4 Operation Meters Displays voltage and amperage when cutting. The ammeter can be activated when not cutting to view an estimation of the cutting current before cutting begins. Actual/Preset Switch Spring return toggle switch defaults to ACTUAL position. When pressed down, the AMMETER displays an estimate of the actual current. This permits the operator to preset the cutting current close to the desired current using the current potentiometer.
SECTION 4 Operation 4.3 Sequence of Operation Apply Power PANEL REMOTE PILOT ARC HIGH LOW 1. Apply power by closing the line (wall) switch. (The ESP-600C does not have an on/off switch). The main power light will illuminate and the fault light will flash and then go out. 2. Select the Panel/Remote setting. 3. Set pilot arc High/Low switch. (Refer to cutting data in the torch manual.) 4. If using panel mode, view preset amps with the ACTUAL/PRESET AMPS switch.
SECTION 4 Operation DC Output Current Start Current Waveform With Arc Initiation Timer OFF These timing functions can be disabled or adjusted to suit individual system requirements. Cut Current 1OUT = 80 VREF approx.
SECTION 4 Operation 4.4.1 Enable/Disable Arc Initiation Timer Factory default setting shown. 1 1. Remove access panel on the upper-right corner of the front panel. Be sure to replace this panel after adjustments have been made. 2 ON 2. Locate SW1 and PCB1 and push both rocker switches down to disable. To enable push both switches up. (If one switch is up and the other is down, arc initiation time is considered on.) OFF SW1 4.4.
SECTION 4 Operation 4.4.3 Arc Initiation Controls Start Current Pot UP-Slope Timer SW1 SW2 4.4.4 Start Current and Up-Slope Timer Starting Curent (%) and Pot Setting Relationship 90% Start Current Set using potentiometer located above and to the left of center of PCB1. Factory default setting is 7. 80% Percentage (%) of Cutting Current 70% 60% 50% Up-Slope Timer Three position switch located next to the start current potentiometer. Time is from start current (after dwell ends) to full current.
SECTION 4 Operation 4.5 ESP-600C V-I Curves ESP-600C V-I CURVES IOUT = (80) x (VREF) 427V Open Circuit (460V & 575V Models) 410V Open Circuit (400V Model) 450 Output of Boost/Start Circuit 350 Max Output Voltage @ Nominal Line 300 MAX RATING VREF = 7.500V VREF = 7.000V VREF = 6.000V VREF = 5.000V VREF = 4.000V VREF = 3.000V VREF = 2.000V 100 VREF = 1.000V 150 VREF = 0.
SECTION 5 Maintenance 5.1 General ! WARNING Electric Shock Can Kill! Shut off power at the line (wall) disconnect before attempting any maintenance. ! WARNING ! CAUTION Eye Hazard When Using Compressed Air To Clean. • Wear approved eye protection with side shields when cleaning the power source. • Use only low pressure air. Maintenance On This Equipment Should Only Be Performed By Trained Personnel. 5.
SECTION 5 Maintenance Air Restrictions May Cause ESP600C To Over Heat. CAUTION Thermal Switches may be activated causing interruption of function. Do not use air filters on this unit. Keep air passages clear of dust and other obstructions. 5.3 Lubrication ! WARNING • Some units are equipped with oil tubes on the fans. These fans should be oiled after 1 year of service. • All other ESP-600Cs have fan motors that are permanently lubricated and require no regular maintenance.
SECTION 6 Troubleshooting 6.1 General ! WARNING 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.
SECTION 6 Troubleshooting 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.
SECTION 6 Troubleshooting 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.
SECTION 6 Troubleshooting 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 All Three fans do not run One or two fans do not run. Possible Cause This is normal when not cutting. Fans run only when “Contactor On” signal is received.
SECTION 6 Troubleshooting 6.3.3 Fault Light Illumination Problem Fault light illuminates at the end of cut but goes off at the start of the next. LED 3 – (amber) Bus Ripple Possible Cause 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. Imbalance of 3-phase input power Momentary loss of one phase of input power Action Reprogram cutting process to ensure arc is terminated only by removing the “Contactor On” signal.
SECTION 6 Troubleshooting Problem LED 6 – (red) Right Over Current Note: If operation at 250A or less is possible, then the LEFT side is not working. LED 6 – (red) Left Over Current Note: If operation at 250A or less is possible, then the Right side is not working. 6-6 Possible Cause Output current of the right side exceeds 200A because of operating the power source over 400A.
SECTION 6 Troubleshooting Problem Very high Output current accompanied by either a left or right over current (LED 6) LED 10 - (red) Left IGBT Unsaturated LED 11 - (red) Right IGBT Unsaturated Possible Cause Shorted IGBT Current pot set too high Action Replace the pair of IGBTs containing the shorted IGBT Lower the current setting Faulty left PWM/Drive PCB Replace left PWM/Drive PCB High remote current signal Decrease remote current signal Faulty PCB1 Black wire connecting IGBT (Q4) collector to
SECTION 6 Troubleshooting Problem LED 12 – (red) Left –12V Missing LED 12 – (red) Right –12V Missing 6-8 Action Secure P1 connector Loose or unplugged P10 connector at PCB1 Secure P10 connector Faulty left PWM/Drive PCB Replace left PWM/Drive PCB P/N 38030 Secure P1 connector Loose or unplugged P1 connector at the right PWM/Drive PCB Very high Output current accompanied by either a left or right over current (LED 6) Over Temp Lamp illuminates Possible Cause Loose or unplugged P1 connector at t
SECTION 6 Troubleshooting 6.3.4 Torch Will Not Fire Problem Possible Cause 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 Place Panel/Remote switch in “Panel” position Remote current control present but signal missing. Check for current reference signal at TB1-4(+) and TB1-5(-). See Signal vs. Output Current Curve this section. Current pot set too low. Increase current pot setting.
SECTION 6 Troubleshooting 6.3.5 Fuses F1 and F2 Blown Problem Possible Cause Fuses F1 and F2 blown. Action Process controller ignites pilot arc too soon after providing the “Contactor On” signal 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. Faulty negative (Electrode) output cable shorting to earth ground. Repair cable Shorted freewheeling diode.
SECTION 6 Troubleshooting Problem Possible Cause Works OK at 250A or less- Over current – Faulty Right Side Power Supply turns off prematurely in the middle of the cut. Action Loose or unplugged connector at Right PWM/Drive PCB (PCB3) Secure connector Faulty Right PWM/Drive PCB Replace right PWM/Drive PCB P/N 38030 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.
SECTION 6 Troubleshooting Problem Possible Cause Output current is unstable and drifts above or below the setting. 6-12 Action 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. Fix the remote current control signal to operate the PANEL/REMOTE switch in the “PANEL” position. Select “PANEL” on the PANEL/REMOTE switch and adjust the current control pot.
SECTION 6 Troubleshooting 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.
SECTION 6 Troubleshooting 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.
SECTION 6 Troubleshooting NEG Plate Diode Rectifier “C” bus “B” bus “A” bus 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. POS Plate Electrode Plate B. Measure between NEG Plate and BR “C” bus.
SECTION 6 Troubleshooting 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.
SECTION 6 Troubleshooting 4. Remove bus bars between capacitor banks, IGBTs and freewheeling diodes. PCB3 PCB2 Failure To Route Leads Properly Can Lead To Failure Of Freewheeling Diodes. CAUTION 3 Snubber Resistor (ex. R9) 1 2 1 2 2 Dressing Of Freewheeling Diode Snubber Leads. 3 3 1 View of freewheeling diodes and capacitor banks with bus bars removed. (PCB2 and PCB3 are shown still in place) Snubber Capacitor (ex.C18) Freewheeling Diode (ex.
SECTION 6 Troubleshooting 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.
SECTION 6 Troubleshooting Clear Insulation Three Leads • 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. Two Leads 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.
SECTION 6 Troubleshooting 6.5 ESP-400C Schematic Diagrams - Drawing 1 - Part1 2a 1a 4a 3a 5a 6a 7a 8a 9a GRY BLK GRY BLK 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 .
SECTION 6 Troubleshooting Schematic Diagram - Drawing 1 – Part2 1b 2b 3b 4b 5b 6b 7b 8b 9b 2 C18 Capacitor .033uf 630v 2 C41-43,44 Capacitor .01uf 125vdc 3 R44 2 R4,6,8,9 Resistor 10ohm 50w 2 D29,30 Rectifier silicone reverse 85A 3 C30 Resistor 10k 8w Capacitor 60uf 370v 2 D1,3,5,6 Module diode dual 100A 600V 2 D31,32 Rectifier silicone forward 85A 3 C39,40 Capacitor .
SECTION 6 Troubleshooting Schematic Diagram - Drawing 2 – Part1 LOC 4 6-22 SYM Descrip LOC SYM Descrip LOC SYM C32,33 Capacitor 1900uf 450v 4 C25 Capacitor 10uf 370v 4 K6 Descrip Relay 3pdt C34,35,36 Capacitor 10uf 370vac 4 R32 Resistor 220k 4 TD1 Transducer Current Transducer Current R1,2,3 Resistor 1 ohm 300w 4 FN4 Filter RFI 4 TD2 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 Resist
SECTION 6 Troubleshooting Schematic Diagram - Drawing 2 – Part2 LOC SYM DESCRIPTION LOC SYM DESCRIPTION LOC SYM DESCRIPTION 4 T3,4 XMFR 117/12/12/24ct 5 C45,46 Capacitor .
SECTION 6 Troubleshooting Schematic Diagram - Drawing 3 6-24 ESP 400C and 600C Plasma Power Sources
SECTION 6 Troubleshooting Schematic Diagram - Drawing 4 ESP 400C and 600C Plasma Power Sources 6-25
SECTION 6 Troubleshooting Schematic Diagram - Drawing 5 – Part1 6-26 ESP 400C and 600C Plasma Power Sources
SECTION 6 Troubleshooting Schematic Diagram - Drawing 5 – Part2 ESP 400C and 600C Plasma Power Sources 6-27
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.6 Wiring Diagrams – 460V 60Hz Drawing 3 (P/N 35878) TB11 SHT BUS POS BLU R63 R59 BLK 1 PCB1 P9-12 YEL L2-X4 YEL 2 3 L2-X3 YEL 4 PCB1 P9-13 YEL 5 6 Note: Wires on shunt (+) and (-) must be dressed in location and direction shown. PCB1 P1-1 CLR (TP) RIGHT COLLECTOR BUS RED PCB1 P1-3 SHLD 8 TB1-16 BLK(TP) R58 7 (-) (+) SH1 TD2 TD1 BLK RED GRN WHT P1 1 2 3 4 TB11-1 BLU Note1: Splice must pass through transducers TD1 and TD2 in direction shown.
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.7 Wiring Diagrams – Drawing 3 400V 50Hz (P/N 35879) TB11 SHT BUS POS BLU R63 R59 BLK 1 PCB1 P9-12 YEL L2-X4 YEL 2 3 L2-X3 YEL 4 PCB1 P9-13 YEL 5 6 Note: Wires on shunt (+) and (-) must be dressed in location and direction shown.
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.8 Wiring Diagrams – 575V 60Hz Drawing 3 (P/N 35880) TB11 SHT BUS POS BLU R63 R59 BLK 1 PCB1 P9-12 YEL L2-X4 YEL 2 3 L2-X3 YEL 4 PCB1 P9-13 YEL 5 6 Note: Wires on shunt (+) and (-) must be dressed in location and direction shown. RIGHT COLLECTOR BUS RED PCB1 P1-1 CLR (TP) PCB1 P1-3 SHLD 8 TB1-16 BLK(TP) R58 7 (-) (+) SH1 TD2 TD1 BLK RED GRN WHT TB1-15 RED(TP) Note1: Splice must pass through transducers TD1 and TD2 in direction shown.
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.
SECTION 6 Troubleshooting 6.11 IGBT Driver Board (PCB2,3 – P/N 38030) 7 TP03 R21 20K 6 TP04 2 5 C11 C12.0015 .01 1 C06 .47 V P1-02 P1-03 P1-04 P1-05 P1-06 IC03 TP09 +15Z TP19 8 R87 R41 # TP18 IC04 10 9 10K C18 .0015 3 10K MAX ERROR CW # POT4 # R34 10K 100K TP29 P1-09 R52 10K D13 C27 .01 R51 +15H IC10 R55 2.21K 8 -12H -12V INDICATOR C53 R86 .01 100K P6-3 P6-2 R84 221 4 2 1 4 M57962L IC06 5 5 TP32 6 1 6 ZD7 C23 -12H 4.7 7 C22 4.7 8 H TP31 R60 1.
SECTION 6 Troubleshooting 6.11 IGBT Driver Board (PCB2,3 – P/N 38030) Drawing 1 Part 2 +15Z 2- 100 Q1 RAMP 2 v ˜+1.25V 3 t 7 34001 + 4 IC01 R14 10 ˜-5.OV R01 2.2 1W # R02 2.2 1W IGBT 1 G C07 + 1000 + C08 1000 Q5 C04 .47 R05 10 1W E E Q4 6 D20 7 8 ZD4 # ZD3 C51 .033 630V +15Z TP10 R28 10 7 34001 + 4 IC05 R27 10 - C16 .47 C15 .47 Z -15Z P3-1 # R04 2.2 1W # R03 2.2 1W # R12 D04 C10 + 3.32K Z 3.3 LED2 7915 OUT REG2 -15Z D06 Z ZD1 5 D05 IN C05 .
SECTION 6 Troubleshooting 6.
SECTION 7 Replacement Parts 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.
SECTION 7 Replacement Parts 7.
SECTION 7 Replacement Parts 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 #
SECTION 7 Replacement Parts 7.
SECTION 7 Replacement Parts 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 ESP-600C Plasma Power Source - 7-5
SECTION 7 Replacement Parts 7.
SECTION 7 Replacement Parts 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
SECTION 7 Replacement Parts 7.
SECTION 7 Replacement Parts Item No Qty Part Number Description 1 3 35895 Kit Wire 600C 400V 3 4 951491 Contactor 3 pole 90A Circuit Symbol C60,61,62, R55-57 K2,K1a,1b,1c 4 2 2046333 Fuse Slo-Blo 15A 600V F1,2 5 2 672772 Capacitor 10 uf 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 35710 Inductor (REF) L1,2 952002 Core, Satu
SECTION 7 Replacement Parts 7.
CE SECTION 7 Replacement Parts 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 .
SECTION 7 Replacement Parts 7.
SECTION 7 Replacement Parts 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 ESP-600C Plasma Power Source - 7-13
SECTION 7 Replacement Parts 7.
SECTION 7 Replacement Parts 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 ESP-600C Plasma Power Source - 7-15
SECTION 7 Replacement Parts 7.
SECTION 7 Replacement Parts 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 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 ESP-600C Plasma Power Source - TB8 7-17
SECTION 7 Replacement Parts This page intentionally left blank.
REVISION HISTORY 1. 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.
Customer // Technical Support (843) 664-4405 (800) ESAB-123 (372-2123) ESAB Welding and Cutting Products PO BOX 100545 Ebenezer Road Florence, SC 29501-0545 http://www.esab.com 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 Phone 011-49-6039-400 Fax 011-49-6039-403-02 http://www.esab.de Printed in U.S.
