ESAB 0558001729 Installation, Operation And Maintenance Manual Download

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SECTION 6 Troubleshooting

ESP 400C and 600C Plasma Power Sources

6-47

6.8 Wiring Diagrams – 575V 60H

Drawing 2 – Part 2 (P/N 35880)

C2(+) BLU
C2(-) YEL

R10

R11

1 2

R53

R54

K7-4 BLK

"A"

"B"

"C"

C23-2 VIO

C4(+) WHT

C24-1 VIO

C10(+) WHT

T1-CX4 WHT

T1-BX2 RED

C8(+) BLU

C8(-) 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

BLK

C41 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

POS

PLATE

NEGATIVE PLATE

7-1

BRN

CB1

4-1 W

-9

CB1

6-1 ORN

-9

R52

3 4

5 6

9 10 11 12 13

TB7

VIEW G-G

SECTION D-D

Note: From ESP-400C/600C//575V

Drawing No. 0558002852, sheet 2 of 5

Summary of Contents for 0558001729

Page 1: ...F 15 657 Jun 2005 Installation Operation and Maintenance for the ESP 400C Plasma Power Source...

Page 2: ...l customer satisfaction We constantly look for ways to improve our products service and documentation As a result we make enhancements and or design changes as required ESAB makes every possible effor...

Page 3: ...acement 2 3 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 5 3 5 Output Connections 5 6 3 5 1 Output Cables 5 3 5 2 Output Connection P...

Page 4: ...wn 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 Freewheel...

Page 5: ...ing 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...

Page 6: ...ESP 400C Plasma Power Source Table of Contents iv This page intentionally left blank...

Page 7: ...king with cutting machines More explicit precautions pertaining to the basic machine and accessories are found in the instruction literature For a wide scope of safety information on the field of cutt...

Page 8: ...before servicing any Follow lockout procedure before servicing any Follow lockout procedure before servicing any equipment equipment equipment equipment WARNING Failure to follow operating instructio...

Page 9: ...ion 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 or Never att...

Page 10: ...ped slag may be hot and fly far Bystanders Chipped slag may be hot and fly far Bystanders Chipped slag may be hot and fly far Bystanders Chipped slag may be hot and fly far Bystanders should also wear...

Page 11: ...cables Replace worn or damaged cables Replace worn or damaged cables WARNING Fume hazard Fumes and gases generated by the plasma cutting Fumes and gases generated by the plasma cutting Fumes and gase...

Page 12: ...traviolet light transmission of ultraviolet light Use special paint on walls to absorb UV Use special paint on walls to absorb UV Use special paint on walls to absorb UV Use special paint on walls to...

Page 13: ...supplier for Contact your aluminum supplier for Contact your aluminum supplier for additional safety information regarding additional safety information regarding additional safety information regardi...

Page 14: ...s 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 Es...

Page 15: ...Gases for Welding and Plasma 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...

Page 16: ...SECTION 1 SAFETY ESP 400CPlasma Power Source ESP 400CPlasma Power Source ESP 400CPlasma Power Source ESP 400CPlasma Power Source 1 10 This page intentionally left blank...

Page 17: ...460V 60Hz 60Hz 60Hz 60Hz ESP 400C 575V ESP 400C 575V ESP 400C 575V ESP 400C 575V 60Hz 60Hz 60Hz 60Hz Part Number Part Number Part Number Part Number 0558001730 0558001730 0558001730 0558001730 055800...

Page 18: ...0C Plasma Power Source ESP 400C Plasma Power Source ESP 400C Plasma Power Source ESP 400C Plasma Power Source 2 2 2 3 Dimensions and Weight Weight 2040 lbs 925 34 kg 37 25 inches 94 6 mm 45 inches 114...

Page 19: ...omply 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...

Page 20: ...neath 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 Insid...

Page 21: ...ctor CU AWG Time delay Fuse size amperes 400 460 575 138 120 96 4 0 3 0 1 0 200 150 125 Sizes per National Electrical Code for a 90 C rated copper conductors 40 C ambient Not more than three conductor...

Page 22: ...ardware before being attached to the ESP 400C 3 4 3 Input Connection Procedure 1 Remove left side panel of the ESP 400C 2 Thread cables through the access opening in the rear panel 3 Secure cables wit...

Page 23: ...cal 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...

Page 24: ...inside the power source using UL listed pressure wire connectors 4 Replace panel removed during the first step 3 6 Parallel Installation Two 400A power sources may be connected together to extend the...

Page 25: ...600V positive leads to workpiece Primary Power Source Secondary Power Source Disconnect negative connection from secondary power source and insulate to convert from two to one power sources Electric...

Page 26: ...SECTION 3 Installation ESP 400C Plasma Power Source 3 8 3 7 System Interconnecting Block Diagram with Smart Flow II 400C N2 O2 Air H 35 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18...

Page 27: ...Front view 3 Rear view 4 Remote to CNC 5 CNC 6 CNC Input Output to Smart Flow II 7 Torch Lead 8 Pilot Arc Lead 9 Work Lead 10 SmartFlow II 11 Cut Water Pump required for PT 15 12 Cooling Water to Tor...

Page 28: ...00C Plasma Power Source 3 10 3 8 System Interconnecting Block Diagram with Manual Flow Control 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38...

Page 29: ...400C 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 Main Powe...

Page 30: ...ter ESP 400C dial shown ESP 400C has a range of 50 to 600 A Used only in panel mode Panel Remote Switch Panel Remote Switch Panel Remote Switch Panel Remote Switch Controls the location of current con...

Page 31: ...t close to the desired current using the current potentiometer Final adjustment is made after the torch has started cutting to achieve a more precise current Dangerous Voltages and Current Electric Sh...

Page 32: ...nel 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...

Page 33: ...Waveform With Arc Initiation Timer OFF DC Output Current Time Cut Current Start Current Waveform With Arc Initiation Timer ON Start Current Dwell Time to full current 800 msec 1OUT 50 VREF 1OUT 50 VRE...

Page 34: ...on 4 4 2 Adjusting Arc Initiation Timer Minimum Start Current Controlled by selection of positions 5 through 8 of SW2 When a switch is pushed on its value is added to the factory set minimum value of...

Page 35: ...ing Curent and Pot Setting Relationship Start Current Start Current Start Current Start Current Set using potentiometer located above and to the left of center of PCB1 Factory default setting is 7 Up...

Page 36: ...I Curves ESP 400C V I CURVES 0 100 200 300 400 0 100 200 300 400 500 OUTPUT CURRENT Amperes 427V Open Circuit 460V 575V Models 410V Open Circuit 400V Model INTERNAL CURRENT LIMIT MAX CURRENT RATING V...

Page 37: ...ir Maintenance On This Equipment Should Only Be Performed By Trained Personnel 5 2 Cleaning Regularly scheduled cleaning of the power source is required to help keep the unit running trouble free The...

Page 38: ...rruption of function Do not use air filters on this unit Keep air passages clear of dust and other obstructions 5 3 Lubrication Some units are equipped with oil tubes on the fans These fans should be...

Page 39: ...y 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...

Page 40: ...ges 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 lin...

Page 41: ...t 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 whe...

Page 42: ...ting 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...

Page 43: ...er 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 rectifier...

Page 44: ...de 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 operatio...

Page 45: ...e 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 Dr...

Page 46: ...t 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...

Page 47: ...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 v...

Page 48: ...e 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 PO...

Page 49: ...maturely 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...

Page 50: ...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 t...

Page 51: ...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 we...

Page 52: ...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 r...

Page 53: ...eplace 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 a...

Page 54: ...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 Ele...

Page 55: ...ON Failure 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 wir...

Page 56: ...illation 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 c...

Page 57: ...ct 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 Am...

Page 58: ...hm 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 C...

Page 59: ...v 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...

Page 60: ...citor 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 Re...

Page 61: ...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 01uf 125vdc 5 S3 Switch toggle DPDT 3 pos 5 R50 Pot 15k 2w 5...

Page 62: ...SECTION 6 Troubleshooting ESP 400C and 600C Plasma Power Sources 6 24 Schematic Diagram Drawing 3...

Page 63: ...SECTION 6 Troubleshooting ESP 400C and 600C Plasma Power Sources 6 25 Schematic Diagram Drawing 4...

Page 64: ...SECTION 6 Troubleshooting ESP 400C and 600C Plasma Power Sources 6 26 Schematic Diagram Drawing 5 Part1...

Page 65: ...SECTION 6 Troubleshooting ESP 400C and 600C Plasma Power Sources 6 27 Schematic Diagram Drawing 5 Part2...

Page 66: ...YEL TB9 24 YEL PCB1 P9 11 VIO PCB1 P9 5 GRY TB9 21 BLK FN1 1 BLK PCB4 P3 1 BLK FN1 3 GRN FN2 3 GRN FN2 2 BLU PCB4 P1 4 BLU J1 A TB1 1 BRN B TB1 2 YEL C TB1 4 ORN D TB1 5 BLU E TB1 9 RED F TB1 7 BLK G...

Page 67: ...1 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 H1 H2 H3 H4 H5 H6 X1 X2 X3 X4 K4 L3 RED POS PLATE BLU C27 WHT S1 1 YEL T1 BX2 RED GND 2 GRN T1...

Page 68: ...H1 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 L3 L1 L2 L3...

Page 69: ...X4 WHT T1 BX2 RED M3 C G C G C8 BLU C8 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 BLK C41 C42 C43 C44 ORN K4 T3 ORN...

Page 70: ...2 BLK R39 R40 RED 1 1 1 1 1 2 2 2 2 2 R27 R26 R25 R29 R28 R27 1 ORN C32 BLU R26 1 BRN R25 1 YEL C32 BLU D33 BUS GRY POS PLATE RED D35 C VIO D34 A BLK BLK R34 R35 R36 1 1 2 1 2 2 C34 C35 C36 F6 1 VIO S...

Page 71: ...X5 X6 X7 TB3 1 BLK TB3 2 BLK PCB3 P6 1 BRN PCB3 P6 2 GRN YEL PCB3 P6 3 RED G R Y GRN YEL B LU T5 H1 H2 X1 X2 X3 X4 X5 X6 X7 TB2 1 BLK TB2 2 BLK PCB2 P5 1 BRN PCB2 P5 2 GRN YEL PCB2 P5 3 RED G R Y GRN...

Page 72: ...B1 P5 1 RED PCB4 P1 8 WHT PCB1 P5 2 WHT PCB1 P5 3 BRN PCB1 P5 4 VIO PCB1 P5 5 GRY PCB1 P5 6 ORN PCB1 P5 7 YEL PCB1 P6 5 BLK PCB1 P6 4 BLU PCB1 P6 3 GRY TB1 12 WHT PCB1 P2 8 WHT T3 H2 WHT TB3 2 WHT K3...

Page 73: ...3 4 5 6 7 8 9 A B A B A B A B C54 C53 K3 K6 K6 K7 T1 AX1 BLK C25 2 GRY TB1 18 BRN TB9 16 WHT C26 1 ORN K3 9 YEL TB8 9 GRY TB8 10 BRN PCB1 P3 2 BLU TB9 22 BLK TB7 8 RED TB8 18 VIO TB8 1 BLU TB8 2 WHT...

Page 74: ...4 YEL TB9 24 YEL PCB1 P9 11 VIO PCB1 P9 5 GRY TB9 21 BLK FN1 1 BLK PCB4 P3 1 BLK FN1 3 GRN FN2 3 GRN FN2 2 BLU PCB4 P1 4 BLU J1 A TB1 1 BRN B TB1 2 YEL C TB1 4 ORN D TB1 5 BLU E TB1 9 RED F TB1 7 BLK...

Page 75: ...L 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 H1 H2 H3 H4 H5 H6 X1 X2 X3 X4 K4 L3 RED POS PLATE BLU C27 WHT S1 1 YEL T1 BX2 RED GND 2 GRN T1 CX4...

Page 76: ...2 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...

Page 77: ...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 BLK C41 C42 C43 C44 ORN K4 T3 ORN C27 WHT S1 2 WHT PRA1 GRY C29 GRY R21...

Page 78: ...1 1 1 1 2 2 2 2 2 R27 R26 R25 R29 R28 R27 1 ORN C32 BLU R26 1 BRN R25 1 YEL C32 BLU D33 BUS GRY POS PLATE RED D35 C VIO D34 A BLK BLK R34 R35 R36 1 1 2 1 2 2 C34 C35 C36 F6 1 VIO S1 6 BRN D19 2 BRN D...

Page 79: ...B3 1 BLK TB3 2 BLK PCB3 P6 1 BRN PCB3 P6 2 GRN YEL PCB3 P6 3 RED G R Y GRN YEL B LU T5 H1 H2 X1 X2 X3 X4 X5 X6 X7 TB2 1 BLK TB2 2 BLK PCB2 P5 1 BRN PCB2 P5 2 GRN YEL PCB2 P5 3 RED G R Y GRN YEL TB2 T5...

Page 80: ...ED PCB4 P1 8 WHT PCB1 P5 2 WHT PCB1 P5 3 BRN PCB1 P5 4 VIO PCB1 P5 5 GRY PCB1 P5 6 ORN PCB1 P5 7 YEL PCB1 P6 5 BLK PCB1 P6 4 BLU PCB1 P6 3 GRY TB1 12 WHT PCB1 P2 8 WHT T3 H2 WHT TB3 2 WHT K3 B WHT K7...

Page 81: ...8 9 A B A B A B A B C54 C53 K3 K6 K6 K7 T1 AX1 BLK C25 2 GRY TB1 18 BRN TB9 16 WHT C26 1 ORN K3 9 YEL TB8 9 GRY TB8 10 BRN PCB1 P3 2 BLU TB9 22 BLK TB7 8 RED TB8 18 VIO TB8 1 BLU TB8 2 WHT TB7 8 RED...

Page 82: ...VIO PCB1 P9 5 GRY TB9 21 BLK FN1 1 BLK PCB4 P3 1 BLK FN1 3 GRN FN2 3 GRN FN2 2 BLU PCB4 P1 4 BLU J1 A TB1 1 BRN B TB1 2 YEL C TB1 4 ORN D TB1 5 BLU E TB1 9 RED F TB1 7 BLK G TB1 8 WHT H GND 5 GRN J TB...

Page 83: ...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 H1 H2 H3 H4 H5 H6 H7 X1 X2 X3 X4 K4 L3 RED POS PLATE BLU C27 WHT S1 1 YEL T1 BX2 RED GND 2 GRN T1 CX...

Page 84: ...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 B...

Page 85: ...C8 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 BLK C41 C42 C43 C44 ORN K4 T3 ORN C27 WHT S1 2 WHT PRA1 GRY C29 GRY R...

Page 86: ...D 1 1 1 1 1 2 2 2 2 2 R27 R26 R25 R29 R28 R27 1 ORN C32 BLU R26 1 BRN R25 1 YEL C32 BLU D33 BUS GRY POS PLATE RED D35 C VIO D34 A BLK BLK R34 R35 R36 1 1 2 1 2 2 C34 C35 C36 F6 1 VIO S1 6 BRN D19 2 BR...

Page 87: ...7 TB3 1 BLK TB3 2 BLK PCB3 P6 1 BRN PCB3 P6 2 GRN YEL PCB3 P6 3 RED G R Y GRN YEL B LU T5 H1 H2 X1 X2 X3 X4 X5 X6 X7 TB2 1 BLK TB2 2 BLK PCB2 P5 1 BRN PCB2 P5 2 GRN YEL PCB2 P5 3 RED G R Y GRN YEL TB2...

Page 88: ...1 RED PCB4 P1 8 WHT PCB1 P5 2 WHT PCB1 P5 3 BRN PCB1 P5 4 VIO PCB1 P5 5 GRY PCB1 P5 6 ORN PCB1 P5 7 YEL PCB1 P6 5 BLK PCB1 P6 4 BLU PCB1 P6 3 GRY TB1 12 WHT PCB1 P2 8 WHT T3 H2 WHT TB3 2 WHT K3 B WHT...

Page 89: ...6 7 8 9 A B A B A B A B C54 C53 K3 K6 K6 K7 T1 AX1 BLK C25 2 GRY TB1 18 BRN TB9 16 WHT C26 1 ORN K3 9 YEL TB8 9 GRY TB8 10 BRN PCB1 P3 2 BLU TB9 22 BLK TB7 8 RED TB8 18 VIO TB8 1 BLU TB8 2 WHT TB7 8 R...

Page 90: ...SECTION 6 Troubleshooting ESP 400C and 600C Plasma Power Sources 6 52 6 9 PC Controller Board PCB1 P N 38032 REV C Schematics Drawing 1 Part 1...

Page 91: ...SECTION 6 Troubleshooting ESP 400C and 600C Plasma Power Sources 6 53 6 9 PC Controller Board PCB1 P N 38032 Schematics Drawing 1 Part 2...

Page 92: ...SECTION 6 Troubleshooting ESP 400C and 600C Plasma Power Sources 6 54 6 9 PC Controller Board PCB1 P N 38032 Schematics Drawing 2 Part 2 1 2 3 4 5...

Page 93: ...SECTION 6 Troubleshooting ESP 400C and 600C Plasma Power Sources 6 55 6 9 PC Controller Board PCB1 P N 38032 Schematics Drawing 2 Part 2 5 4 3 2 1...

Page 94: ...SECTION 6 Troubleshooting ESP 400C and 600C Plasma Power Sources 6 56 6 9 PC Controller Board PCB1 P N 38032 Schematics Drawing 3...

Page 95: ...SECTION 6 Troubleshooting ESP 400C and 600C Plasma Power Sources 6 57 6 10 PCB Digital Meter Board PCB4 P N 38139 Drawing 1...

Page 96: ...SECTION 6 Troubleshooting ESP 400C and 600C Plasma Power Sources 6 58 1 2 3 4 5 6 6 10 PCB Digital Meter Board PCB4 P N 38139 Drawing 2 Part 1...

Page 97: ...SECTION 6 Troubleshooting ESP 400C and 600C Plasma Power Sources 6 59 1 2 3 4 5 6 6 10 PCB Digital Meter Board PCB4 P N 38139 Drawing 2 Part 2...

Page 98: ...TP23 MAX R43 10 1M 10K R45 R44 9 15 2 47 16 IC07 10 R35 10 8 7 47 1 R39 R37 10 C19 47 TP04 01 4 5V V MIN 5 2 C11 6 0015 C12 20K R41 SET 8 11 IC03 4 VSS 7 S R 6 10 R19 CLOCK OSCILLATOR IC02 20KHZ TP03...

Page 99: ...2 R02 1W R01 1 25V 10 G RAMP 5 OV v t POWER CONNECTIONS FOR IC1 R14 4 10 15Z IC01 7 34001 10 Z 47 47 C04 C05 C50 10K R11 TP02 Z R30 100 Q1 20K POT6 10K R10 3 3 10K IC01 3 R81 10K 2 34001 6 22 1K R16 S...

Page 100: ...SECTION 6 Troubleshooting ESP 400C and 600C Plasma Power Sources 6 62 6 11 IGBT Driver Board PCB2 3 P N 38030 Drawing 2...

Page 101: ...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...

Page 102: ...SECTION 7 Replacement Parts ESP 400C Plasma Power Source 7 2 7 3 Outside View Front And Back 1 2 3 4 5 6 7 8 9 11 10 12 13 14 15 16 17 18 19 20 22 21...

Page 103: ...715 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...

Page 104: ...SECTION 7 Replacement Parts ESP 400C Plasma Power Source 7 4 2 3 4 5 10 10 T 4 9 8 7 6 View with LED meter panel removed P1 P2 1 7 4 Front View With PCBs Exposed View with PCB Cover Removed...

Page 105: ...39 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 F...

Page 106: ...SECTION 7 Replacement Parts ESP 400C Plasma Power Source 7 6 7 5 Right Side View 11 1 7 8 9 8 7 6 10 2 3 4 5 10 12...

Page 107: ...1 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...

Page 108: ...SECTION 7 Replacement Parts ESP 400C Plasma Power Source 7 8 7 6 Left Side View 1 3 4 5 6 5 8 7 9 10 11 x4...

Page 109: ...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 uf 370V C25 26 34 36 6 2 17280210 Resistor 1K ohms 100W R10 11 28 31 7 3 17280010 Resistor...

Page 110: ...SECTION 7 Replacement Parts ESP 400C Plasma Power Source 7 10 7 7 Top View...

Page 111: ...9 10 4 950704 RECT SIL Reverse 85A 11 5 672772 Capacitor 10 f 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 951223 Shunt 100mV 500A SH1...

Page 112: ...SECTION 7 Replacement Parts ESP 400C Plasma Power Source 7 12 7 8 Back Inside View 2 1 4 2 3...

Page 113: ...cement Parts ESP 400C Plasma Power Source 7 13 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...

Page 114: ...SECTION 7 Replacement Parts ESP 400C Plasma Power Source 7 14 7 9 Middle Cross Section 5 2 3 4 3 2 F8 F9 1...

Page 115: ...Source 7 15 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...

Page 116: ...SECTION 7 Replacement Parts ESP 400C Plasma Power Source 7 16 7 10 Front Cross Section Behind Front Panel 1 2 3 4 5 4 6 7 7...

Page 117: ...ol 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 6 137...

Page 118: ...SECTION 7 Replacement Parts ESP 400C Plasma Power Source 7 18 This page intentionally left blank...

Page 119: ...ce 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 Modi ed bottom diagram and changed note to read Disconnect negative conne...

Page 120: ...5 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 Hancock GmbH Cutting Technologies P O Box 1128 D 61174 Karb...

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