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SECTION 3 Installation

ESP-400C Plasma Power Source

3-7

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 600V

negative leads

to plumbing box

(high freq.
generator)

3 - 4/0 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 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 600V

negative
leads in
plumbing
box (h.f.
generator)

3 - 4/0 600V

positive
leads
to
workpiece

Primary Power

Source

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)

pilot arc

Connections for Parallel Installation

of 2 Power sources

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Содержание 0558001729

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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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