Download ESP MP-600 Specifications

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. See
standard ESAB terms and conditions of sale
for a specific statement of ESAB’s
responsibilities and limitations on its liability.
ESAB Cutting Systems first priority is total
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 effort to
ensure our documentation is current. We
cannot guarantee that each piece of
documentation received by our customers
reflects the latest design enhancements.
Therefore, the information contained in this
document is subject to change without notice.
This manual is ESAB Part Number F15682
This manual is for the convenience and use of the
cutting machine purchaser. It is not a contract or
other obligation on the part of ESAB Cutting
Systems.
©
ESAB Cutting Systems, 2001
Printed in U.S.A.
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
3.8
General
Unpacking
Placement
Input Power Connections
3.4.1 Primary Power
3.4.2 Input Conductors
3.4.3 Input Connection Procedure
Output Connections
3.5.1 Output Cables
3.5.2 Output Connection Procedure
Parallel Installation
System Interconnecting Block Diagram with Smart Flow II
System Interconnecting Block Diagram without Smart Flow II
1
1
2
2-5
3
4
4-5
5-6
5
5
6-7
8
9
Section 4 Operation
4.1
4.2
4.3
4.4
Introduction
Control Panel
Sequence of Operation
Arc Initiation Settings
4.4.1 Enable/Disable Arc Initiation Timer
4.4.2 Adjusting Arc Initiation Timer
4.4.3 Arc Initiation Controls
4.4.4 Start Current and Up-slope Timer
4.5 V-I Curve
1
1-3
4
4-7
6
6
7
7
8
i
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
6.4.1 Power Rectifiers
13
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
ii
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
7.10 Front Cross Section – Behind Front Panel
16-17
Customer/Technical Information
Back Manual Cover
iii
ESP-600C Plasma Power Source
This page intentionally left blank.
iv
Table of Contents
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.
Whether an individual is involved with operation,
servicing, or as an observer, compliance with
established precautions and safe practices must be
accomplished. Failure to observe certain precautions
could result in serious personnel injury or severe
equipment damage. The following precautions are
general guidelines applicable when working 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 cutting and welding
apparatus, obtain and read the publications listed in
the Recommended References.
1.2 Safety Notations And Symbols
The following words and symbols are used throughout
this manual. They indicate different levels of required
safety involvement.
!
ALERT or ATTENTION. Your safety is involved
or potential equipment failure exists. Used with
other symbols and information.
! DANGER
Used to call attention to immediate hazards
which, if not avoided, will result in serious
personal injury or loss of life.
! WARNING
Used to call attention to potential hazards
that could result in personal injury or loss of
life.
! CAUTION
Used to call attention to hazards that could
result in minor personal injury or equipment
damage.
CAUTION
Used to call attention to minor hazards to
equipment.
NOTICE
Used to call attention to important
installation, operation or maintenance
information not directly related to safety
hazards.
ESP-600Clasma Power Source -
1-1
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.
•
Fence off entire work cell to prevent personnel
from passing through area or standing in the
working envelope of the equipment.
•
Post appropriate WARNING signs at every work
cell entrance.
•
Follow lockout procedure before servicing any
equipment.
Failure to follow operating instructions
could result in death or serious injury.
Read and understand this operator’s manual before
using machine.
1-2
•
Read entire procedure before operating or
performing any system maintenance.
•
Special attention must be given to all hazard
warnings that provide essential information
regarding personnel safety and/or possible
equipment damage.
•
All safety precautions relevant to electrical
equipment and process operations must be
strictly observed by all having system
responsibility or access.
•
Read all safety publications made available by
your company.
ESP-600Clasma Power Source -
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. He can suggest certain precautions
regarding piping installation and machine lifting,
etc. to ensure maximum security.
•
Never attempt any machine modifications or
apparatus additions without first consulting a
qualified ESAB representative.
•
Observe machine clearance requirements for
proper operation and personnel safety.
•
Always have qualified personnel perform
installation, troubleshooting and maintenance of
this equipment.
•
Provide a wall mounted disconnect switch with
proper fuse sizes close to the power supply.
ESP-600Clasma Power Source -
1-3
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. Wear
goggles to protect eyes from burns and flying
debris generated during operation.
•
Chipped slag may be hot and fly far. Bystanders
should also wear goggles and safety glasses.
•
Noise from plasma arc can damage hearing. Wear
correct ear protection when cutting above water.
Burn hazard.
Hot metal can burn.
1-4
•
Do not touch metal plate or parts immediately after
cutting. Allow metal time to cool, or douse with
water.
•
Do not touch plasma torch immediately after
cutting. Allow torch time to cool.
ESP-600Clasma Power Source -
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.
•
Wear insulating gloves, shoes and clothing to
insulate yourself from workpiece and electrical
ground.
•
Keep gloves, shoes, clothing, work area, and
equipment dry.
•
Replace worn or damaged cables.
Fume hazard.
Fumes and gases generated by the plasma cutting
process can be hazardous to your health.
•
Do NOT breathe fumes.
•
Do not operate plasma torch without fume removal
system operating properly.
•
Use additional ventilation to remove fumes if
necessary.
•
Use approved respirator if ventilation is not
adequate.
•
Provide positive mechanical ventilation when
cutting galvanized steel, stainless steel, copper,
zinc, beryllium, or cadmium. Do not breathe these
fumes.
•
Do not operate near degreasing and spraying
operations. Heat or arc rays can react with
chlorinated hydrocarbon vapors to form phosgene,
a highly toxic gas and other irritant gases.
ESP-600Clasma Power Source -
1-5
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. 14
! WARNING
•
Replace glasses/goggles when lenses are pitted or
broken
•
Warn others in area not to look directly at the arc
unless wearing appropriate safety glasses.
•
Prepare cutting area to reduce reflection and
transmission of ultraviolet light.
§
Use special paint on walls to absorb UV
light.
§
Install protective screens or curtains to
reduce ultraviolet transmission.
Burn Hazard.
Heat, spatter, and sparks cause fire and burns.
1-6
•
Do not cut near combustible material.
•
Do not have on your person any combustibles (e.g.
butane lighter).
•
Pilot arc can cause burns. Keep torch nozzle
away from yourself and others when activating
plasma process.
•
Wear correct eye and body protection.
•
Wear gauntlet gloves, safety shoes and hat.
•
Wear flame-retardant clothing covering all exposed
areas.
•
Wear cuffless trousers to prevent entry of sparks
and slag.
•
Have fire extinguishing equipment available for use.
ESP-600Clasma Power Source -
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. butane lighter)
•
Do not cut containers that have held combustibles.
ESP-600Clasma Power Source -
1-7
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.
•
Keep all panels and covers in place when machine
is connected to power source.
•
Keep gloves, shoes, clothing, work area, and
equipment dry.
•
Inspect power and ground leads cables for wear or
cracking. Replace worn or damaged cables. Do
not use if damaged.
•
Never bypass safety interlocks.
•
Follow lock-out procedures.
Establish and adhere to preventive maintenance. A
composite program can be established from
recommended schedules.
Avoid leaving test equipment or hand tools on
machine. Severe electrical or mechanical damage
could occur to equipment or machine.
! CAUTION
Extreme caution should be used when probing
circuitry with an oscilloscope or voltmeter. Integrated
circuits are susceptible to over voltage damage.
Power off before using test probes to prevent
accidental shorting of components.
All circuit boards securely seated in sockets, all cables
properly connected, all cabinets closed and locked, all
guards and covers replaced before power is turned
on.
1-8
ESP-600Clasma Power Source -
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.
•
“Precautions and Safe Practices in Welding and Cutting with
Oxygen-Fuel Gas Equipment,” Form 2035. ESAB Cutting
Systems.
•
“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 Welding
Society, 2501 NW 7th Street, Miami, Florida, 33125.
•
“Recommended Safe Practices for Shielded 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 C5.2, American
Welding Society.
•
“Safe Practices” - AWS SP, American Welding Society.
•
“Standard for Fire Protection in Use of Cutting and Welding
Procedures” - NFPA 51B, National Fire Protection Association, 60
Batterymarch Street, Boston, Massachusetts, 02110.
•
“Standard for Installation and Operation of Oxygen - Fuel Gas
Systems for Welding and Cutting” - NFPA 51, National Fire
Protection Association.
•
“Safety Precautions for Oxygen, Nitrogen, Argon, Helium, Carbon
Dioxide, Hydrogen, and Acetylene,” Form 3499. ESAB Cutting
Systems. Obtainable through your ESAB representative or local
distributor.
•
"Design and Installation of Oxygen Piping Systems," Form 5110.
ESAB Cutting Systems.
•
“Precautions for Safe Handling of Compressed Gases in
Cylinders”, CGA Standard P-1, Compressed Gas Association.
Literature applicable to safe practices in welding and cutting with
gaseous materials is also available from the Compressed Gas
Association, Inc., 500 Fifth Ave., New York, NY 10036.
ESP-600Clasma Power Source -
1-9
SECTION 1
SAFETY
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1-10
ESP-600Clasma Power Source -
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.
•
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 transformer
and power semiconductor components
•
Top lifting rings or base forklift clearance for
transport
•
Parallel secondary power source capabilities to
extend current output range.
2.2 General Specifications
Color Scheme
Part Number
ESP-600C 400V,
50Hz
Black
Yel-gry
35879
35610
Current range
DC
INPUT
50A to 600A
120KW
Power
Open Circuit
Voltage (OCV)
Voltage
(3-phase)
Current
(3- phase)
ESP-600C 575V,
60Hz
Black
Yel-gry
35880
35611
200 V dc
Voltage
OUTPUT (100
% duty cycle)
ESP-600C 460V,
60Hz
Black
Yel-gry
35878
35609
427 V dc
400 V
460 V
575 V
206 A RMS
179 A RMS
143 A RMS
50/60 HZ
60 Hz
60 Hz
KVA
142.7 KVA
142.6 KVA
142.4 KVA
Power
129.9 KW
129.8 KW
129.6 KW
Frequency
91 %
Power Factor
Fuse Recom.
250A
250A
ESP 600C Plasma Power Source -
200A
2-1
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"
(114.3cm)
2-2
ESP 600C Plasma Power Source -
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.
•
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.
ESP-600C Plasma Power Source -
3-1
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.
•
Environment should be relatively free of dust,
fumes and excessive heat. These factors will
affect cooling efficiency.
Conductive Dust And Dirt Inside
Power Source May Cause Arc FlashOver
CAUTION
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
! WARNING
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.
3-2
ESP-600C Plasma Power Source -
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. 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.
ESP-600C Plasma Power Source -
3-3
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. 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.
Primary
Terminals
Power Input Cable
Access opening
(rear panel)
3-4
Chassis Ground
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.
ESP-600C Plasma Power Source -
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.
3.5 Output Connections
! WARNING
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.
ESP-600C Plasma Power Source -
3-5
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.
3.6 Parallel Installation
Two power sources may be connected together to
extend the output current range.
CAUTION
Parallel 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.
3-6
ESP-600C Plasma Power Source -
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. Connect the positive (+) and negative (-)
conductors between the power sources.
3 - 4/0 600V
positive
leads
to
workpiece
1 - 14 AWG 600V
4/0 600V
Cable jumpers lead to pilot arc
between units connection in
plumbing box
(h.f. generator)
3 - 4/0 600V
negative
leads in
plumbing
box (h.f.
generator)
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”.
Electric Shock Can Kill!
! WARNING
Exposed Electrical Conductors Can
Be Hazardous!
Secondary Power
Source
work
electrode
(+)
(-)
Primary Power
Source
work
electrode
(+)
(-)
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”.
3 - 4/0 600V
positive leads to
workpiece
Disconnect
negative
connection from
secondary power source
and insulate to
convert from two
to one power
sources
3 - 4/0 600V
negative leads
to plumbing box
(high freq.
generator)
ESP-600C Plasma Power Source - CE
3-7
SECTION 3
Installation
3.7 System Interconnecting Block Diagram with Smart Flow II
3 phase
w/ground
CNC
Remote to
CNC
ESP
Fron 600C
t vie
w
C
-600
ESP view
Back
600C
CNC I/O to
Smart Flow II
N2
O2
Air
H-35
On/Off
Control
Torch (-)
Pilot Arc
Work (+)
Smart
Flow II
Cut Water
Pump
(for PT-15)
WC-7
Water
Cooler
Cooling Water
To Torch
Cooling Water
From Torch
Voltage
Height
Control
Plasma Torch
Bundle and
Torch
Earth Ground
3-8
ESP-600C Plasma Power Source -
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. On-Off
on-off
Interlocks
Injection Water
Start Gas
Flow Control
Plumbing Box
Cut Gas
Volt-Feedback
Work piece
voltage
Process
OK
Interlocks
Current Ref
Estop
Process on-off
Height
Control
Gas
Cutting Machine
Control
Pilot arc High Freq
Height Ref.
TORCH
PT-15 OR PT-600
injection water
Coolant to
Current to
Coolant From
Work Piece
ESP-600C Plasma Power Source -
3-9
SECTION 3
Installation
This page intentionally left blank.
3-10
ESP-600C Plasma Power Source -
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.
Over Temp
Indicator illuminates when power source has
overheated.
Contactor On
Indicator illuminates when the main contactor is
energized.
ESP-600C Plasma Power Source -
4-1
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.
• Place in the PANEL position for control using
the current potentiometer.
• Place in REMOTE position for control from an
external signal (CNC).
Remote Connection
Amphenol 19 pin plug for connecting power source
to CNC.
Pilot Arc HIGH/LOW Switch
Used to select amount of pilot arc current desired.
As a general rule, for 100 amperes and below, a
setting of LOW is used. This can vary depending
on gas, material and torch used. High/Low settings
are specified in cutting data included in the torch
manual.
4-2
ESP-600C Plasma Power Source -
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.
Final adjustment is made after the torch has started
cutting to achieve a more precise current.
! WARNING
Dangerous Voltages and Current!
Electric Shock Can Kill!
Before operation, ensure installation and
grounding procedures have been followed.
Do not operate this equipment with covers
removed.
ESP-600C Plasma Power Source -
4-3
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. Adjust current
until the approximate desired value is shown on
the ammeter.
5. Begin plasma cutting operation. This may
include manually setting up other options,
depending on the total plasma package.
ACTUAL AMPS
6. If using panel mode, after cutting has begun,
adjust current to desired amount.
PRESET AMPS
Begin
Cutting
7. Check for fault light. If a fault light illuminates,
refer to troubleshooting section.
Note: The fault light flashes when the contactor is
first turned on signifying the DC Bus powered up
normally.
4.4 Arc Initiation Settings
The time to achieve full current can be adjusted to
suit your particular system. This feature uses 50%
of the cutting current to start, dwell and then
gradually (less than a second) achieve full current.
The ESP-600C is factory shipped with this feature
enabled. The default settings are:
4-4
Minimum Start Current
40A
Start Current
50% of cut current
Timing to achieve full current
800 msec
Dwell Time
50 msec
ESP-600C Plasma Power Source -
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. 2 msec time to
full current
Time
DC Output Current
Start Current Waveform With Arc
Initiation Timer ON
Cut Current
1OUT = 80 VREF
Start Current
Dwell
Time to
full current
800 msec
Time
! WARNING
Electric Shock Can Kill!
Shut off power at the line (wall) disconnect
before removing any covers or making any
adjustments to the power source.
ESP-600C Plasma Power Source -
4-5
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
4.4.2 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 40A.
Switch #5 = 80A min. start current
Switch #6 = 40A min. start current
Switch #7 = 20A min. start current
Switch #8 = 10A min. start current
Factory default settings shown
1
2
3
4
5
6
7
8
Default setting is with all switches off. = 40A
ON
Dwell Time
OFF
SW2
Controlled by selections of positions 1 through 4 of
SW2 on PCB1. When a switch is pushed on, its
value is added to the minimum dwell time of 10
msec.
Switch #1 = 10 msec dwell time
Switch #2 = 20 msec dwell time
Switch #3 = 40 msec dwell time
Switch #4 = 80 msec dwell time
The default setting is with switch #3 on. 40 msec +
10 msec (minimum) = 50 msec
4-6
ESP-600C Plasma Power Source -
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. Factory default =
800 msec.
40%
30%
20%
10%
0%
0
1
2
3
4
5
6
7
8
9
10 MAX
Left position = 250 msec
Center position = 800 msec
Right Position = 1200 msec
Start Current Pot Setting
ESP-600C Plasma Power Source -
4-7
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 = 0.625V
RATING
200
INTERNAL CURRENT LIMIT
250
MIN
OUTPUT VOLTAGE (Volts)
400
50
0
0
100
200
300
400
500
OUTPUT CURRENT (Amperes)
4-8
ESP-600C Plasma Power Source -
600
700
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.
5.2 Cleaning
Regularly scheduled cleaning of the power source is
required to help keep the unit running trouble free.
The frequency of cleaning depends on environment
and 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 front
of the unit. Dust insulates, reducing heat
dissipation. Be sure to wear eye protection.
ESP-600C Plasma Power Source -
5-1
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.
Electric Shock Hazard!
Be sure to replace any covers removed
during cleaning before turning power back
on.
5-2
ESP-600C Plasma Power Source -
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.
6.2 Fault Indicators
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
OVER
TEMP
REMOTE
CONTACTOR
ON
FAULT
6 0 0 C
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.
POWER
RESET
FAULT
Fault Indicator used with:
LED 3
LED 4
Front Panel Fault Indicators
LED 5
PCB1 Located
LED 7
behind this panel.
LED 8
Power Reset Fault Indicator used with:
LED 6
LED 9
LED 10
LED 11
LED 12
LED 13
ESP 400C and 600C Plasma Power Sources
6-1
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.(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.
6-2
ESP 400C and 600C Plasma Power Sources
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.
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.
ESP 400C and 600C Plasma Power Sources
6-3
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.
Broken or disconnected wire in fan
motor circuit.
Faulty fan(s)
Action
None
Repair wire.
Replace fans
6.3.2 Power Not On or LOW Voltage
Problem
Power source inoperable:
Main Power lamp is off.
Low Open Circuit Voltage
6-4
Possible Cause
Missing 3-phase input voltage
Action
Restore all 3 phases of input voltage
to within ±10% of nominal line.
Missing 1 of 3-phase input voltage
Fuse F3 blown
Restore all 3 phases of input voltage
to within ±10% of nominal line.
Replace F3
Pilot arc Contactor (K4) faulty
Replace K4
Faulty Control PCB1
Replace Control PCB1 (P/N 38032)
ESP 400C and 600C Plasma Power Sources
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.
Maintain phase voltage imbalance of
less than 5%.
Restore and maintain input power
within ±10% nominal
Faulty control PCB1
LED 4 – (amber) High Bus
LED 5 – (amber) Low Bus
One or more phases of input voltage
exceed nominal line voltage by more
than 20%.
Replace PCB1 P/N 38032
Restore and maintain line voltage
within ±10%
Faulty control PCB1
Replace PCB1 P/N 38032
One or more shorted diode rectifiers
(D25-D28) on the “Electrode Plate”
One or more phases of input voltage
are lower than nominal by more than
15%.
Replace shorted diode rectifiers
Blown F1 and F2 fuses
See F1 and F2 in Blown Fuses
Section
Over temp Light comes on.
See over temp in Fault Light Section
Imbalanced 3-phase input power
Maintain phase voltage imbalance of
less than 5%
Momentary loss of one phase of
input power
Restore and maintain within ±10% of
nominal
Faulty Main Contactor (K1)
Replace K1
FAULTY Control PCB1
Replace PCB1 P/N 30832
Restore and maintain with in ±10%
of nominal
ESP 400C and 600C Plasma Power Sources
6-5
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.
Action
Turn the output current down to
400A
Cutting at over 250A with a faulty
left side (left side output = 0)
See faulty left or right side
Right current transducer connector
loose or unplugged. PCB loose.
Secure connections
Loose or unplugged connector at
right PWM/Drive Printed circuit
board.
Secure connection
P2 at left of PWM/Drive PCB loose or
unplugged.
Secure connection
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).
Replace right current transducer
(TD2)
Faulty PCB1
Replace PCB1 P/N 30832
Faulty right PWM/Drive PCB
Replace right PWM/Drive PCB P/N
38030
Output current of the left side
exceeds 250A because of operating
the power source over 400.
Turn the output current down to
400A
Cutting at over 250A with a faulty
right side (right side output = 0)
See faulty right side
Left current transducer connector
loose or unplugged. PCB loose.
Secure connections
Loose or unplugged connector at left
PWM/Drive Printed circuit board.
Secure connection
P2 at right of PWM/Drive PCB loose
or unplugged.
Secure connection
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).
Replace left current transducer (TD1)
Faulty PCB1
Replace PCB1 P/N 38032
Faulty left PWM/Drive PCB
Replace left PWM/Drive PCB P/N
38030
ESP 400C and 600C Plasma Power Sources
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 P3 of the left PWM/Drive
PCB (PCB2) is disconnected.
Replace PCB1 P/N 38032
Secure connector
Shorted Freewheeling Diode(s)
Replace freewheeling diode(s)
Loose or unplugged P1 connector at
the left PWM/Drive PCB
Secure P1
Loose or unplugged P10 connector
at PCB1
Secure P10
Faulty PCB1
Replace PCB1 P/N 38032
Faulty left PWM/Drive PCB
Replace PCB2 P/N 38030
Black wire connecting IGBT (Q4)
collector to P3 of the right
PWM/Drive PCB (PCB3) is
disconnected.
Secure connector
Shorted Freewheeling Diode(s)
Replace freewheeling diode(s)
Loose or unplugged P1 connector at
the left PWM/Drive PCB
Secure P1
Loose or unplugged P10 connector
at PCB1
Secure P11
Faulty PCB1
Replace PCB1 P/N 38032
Faulty right PWM/Drive PCB
Replace PCB3 P/N 38030
ESP 400C and 600C Plasma Power Sources
6-7
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
the left PWM/Drive PCB
Loose or unplugged P11 connector
at PCB1
Secure P11 connector
Faulty right PWM/Drive PCB
Replace right PWM/Drive PCB P/N
38030
Replace the pair of IGBTs containing
the shorted IGBT
Shorted IGBT
Current pot set too high
Lower the current setting
Faulty left PWM/Drive PCB
Replace left PWM/Drive PCB
High remote current signal
Decrease remote current signal
Faulty PCB1
One or more fans inoperable
Replace PCB1 P/N 38032
Repair or replace fan(s)
Broken wire or unplugged connector
at thermal switch.
Repair broken wires and unplugged
connector
Obstruction to air flow closer than 2
feet to rear of power source.
Allow 2 ft. minimum between the rear
of the power source and any object
that may restrict air flow.
Excessive dirt restricting cooling 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).
Obstructed air intake
Check and clear any obstructions
from the bottom, front, and top rear
of the Power Source.
ESP 400C and 600C Plasma Power Sources
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.
Start current pot, located behind
the cover for the control PCB is
set too low.
Open connection between the
power source positive output and
the work.
Increase the start current post
setting to “7”.
Fuse F6 in the Pilot arc circuit is
blown.
Replace F6
Fuse F7 in the pilot arc circuit is
blown.
Replace F7
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)
Change Pilot arc to “High”
position. (Refer to process data
included in torch manuals)
Pilot arc contactor (K4) faulty.
Replace K4
Faulty PCB1
Replace PCB1 P/N 38032
Arc does not start. There is no
arc at the torch. Open circuit
voltage is OK at 400 –460V
Action
Repair connection
ESP 400C and 600C Plasma Power Sources
6-9
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.
Replace shorted freewheeling
diode and F1-F2
One or more shorted diode
rectifiers (D13-D18) on “POS
Plate”.
Replace all diode rectifiers on the
“POS Plate”.
One or more shorted diode
rectifiers (D7-D12) on “NEG
Plate”.
Replace all diode rectifiers on the
“NEG Plate”.
6.3.6 Intermittent, Interrupted or Partial Operation
Problem
Possible Cause
Works OK at 250A or less- Over
current – Faulty Left Side
6-10
Action
Loose or unplugged connector at
left PWM/Drive PCB (PCB2)
Secure connector
Faulty left PWM/Drive PCB
Replace right PWM/Drive PCB
P/N 38030
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.
Replace control transformer T5
ESP 400C and 600C Plasma Power Sources
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.
“Contactor On” signal is removed
from unit.
Replace control transformer T7
Momentary loss of primary input
power.
Restore and maintain input
voltage within ±10% of nominal.
Faulty condition, indicated by
illumination of the fault lamp.
Remove control PCB (PCB1)
access panel to determine the
fault causing the shutdown.
Refer to fault light illumination
section.
Faulty condition, indicated by the
illumination of the power reset
fault lamp.
Remove control PCB (PCB1)
access panel to determine the
fault causing the shutdown.
Refer to fault light illumination
section.
Current setting too low.
Increase current setting
Remote current signal removed
during cut.
Fix remote current signal
Power source is OK. Trouble
shoot process controller.
ESP 400C and 600C Plasma Power Sources
6-11
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.
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.
Replace the current control pot.
Replace the control PCB (PCB1)
P/N 38032
ESP 400C and 600C Plasma Power Sources
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.
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
ESP 400C and 600C Plasma Power Sources
6-13
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. These are accessed
from underneath.
Power Rectifiers located
behind the front panel.
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
Location of Neg. Plate
Location of fuses F8 and F9
6-14
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.
ESP 400C and 600C Plasma Power Sources
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.
If resistance is 2 ohms or less in either case, replace
all the diodes on the NEG Plate.
Troubleshooting POS Plate
Location of Positive 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.
Fuses F8 and F9
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
D27,28
D25,26
Bus
Cathode
Leads
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.
ESP 400C and 600C Plasma Power Sources
6-15
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.
CAUTION
Emitter
Gate
CAUTION
Electrostatic Discharge Hazard
Electrostatic discharge may damage these
components.
6-16
•
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.
ESP 400C and 600C Plasma Power Sources
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. D6)
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.
Red Wire
The red snubber leads are numbered as viewed
from the rear of the power source:
D1 - Left
D2 - Right
D3 - Left
D4 - Right
D5 - Left
D6 - Right
Cover snubber capacitor self leads with sleeving
P/N 95193486
ESP 400C and 600C Plasma Power Sources
6-17
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. The
strap to #1 is mounted on top of the copper bus
under the mounting hardware and in direct contact
with the copper bus.
NOTICE
6.4.3 Power Shunt Installation
Instability Or Oscillation In Cutting Current
Can Be Caused By Improper Dressing Of
Shunt Pick-Up Leads.
CAUTION
Poor torch consumable life will be the
result.
There are two cables that attach to the shunt pickup 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.
Terminals
parallel to
bus bars
6-18
•
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.
ESP 400C and 600C Plasma Power Sources
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.
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%.
ESP 400C and 600C Plasma Power Sources
6-19
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 .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
6-20
ESP 400C and 600C Plasma Power Sources
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 .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
Rectifier silicone forward 85A
2
L1,2
Inductor Assy
2
R23
Resistor 1 ohm 300w
3
D34
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
ESP 400C and 600C Plasma Power Sources
6-21
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
Resistor 4.7k ohms 2w 10%
K3,5-7
Relay 3pdt brkt mt
4
R51
Pot 10k 2w
4
PL4,5
Lamp LED red 12v
ESP 400C and 600C Plasma Power Sources
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 .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
ESP 400C and 600C Plasma Power Sources
6-23
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
6.6 Wiring Diagrams – 460V 60Hz Drawing 1 – Part1 (P/N 35878)
D7,D8
C47
C48
D9,D10
D11,
D12
C49
ELECTRODE BUS BLK
WORK BUS BLU
BLU
YEL
BR "C" BUS
BR"A" BUS
D13
D14
BR "B" BUS
D15,
D16
C50
TB10
C37
FN1
FN2
3
WHT
D17,
D18
C51
C38
WHT
C52
TB9-21 BLK TS3-1 WHT C39
D25,
D26
1
D27,
D28
C40
WHT WHT
TS7
2
3
"B" COIL
"B" COIL
K4-T1 YEL
GND4 GRN
X1
GND4 GRN
X1
Section A-A
L2
"A" COIL
L1
"A" COIL
PCB4 P1-1 GRN
X1
TB1-10 BLK
TB1-12 BLK
H1
X1
PCB4 P1-2 GRN/YEL
T9
X3 YEL
TB11-3 YEL
H2
TB11-2 YEL
PCB4 P1-3 GRN
Ammeter
8
2
1
7
8
PCB4 P1-11 VIO
2
BRN
BLU
ORN
YEL
7
WHT
RED
BLK
GRN
1
X4 YEL
Voltmeter
Section B-B
PCB4 P1-12 GRY
B
2
3
PCB4
A
R19-2 ORN
R17-1 YEL
D29/30 BUS WHT
S2-6 GRY
N
U
C
D
P E
R
V S F
G
T
K J
H
S2
4 5 6
1 2 3
3
S2-3 RED
R50 2
R50-2 RED
1 TB1-3 VIO
PCB1 P8-2 VIO
TB1-4 ORN
TB1-12
WHT
TB1-11 WHT
FN4-3 BLK
TB1-10-A BLK
M
R24-2 BRN
L
POS PLATE RED
TB1-5 BLU
PCB1 P8-1 GRY
TB1 6
GRY
R50-3 GRY
B
PL1
PL2
PL3
PL4
TB1-9 RED
TB1-10-B BLK
PCB1 P7-10 GRY
R51
123
PCB1 P7-15 WHT
S3
PCB1 P7-14 BRN
36
PCB1 P7-13 RED
BR "A"
BUS
F5-1 BLU
L1
FN2-2 BLU
PCB4 P1-4 BLU
PL5
PCB1 P9-11 VIO
PCB1 P9-5 GRY
TB9-21 BLK
R23-1 BRN
FN1-1 BLK
PCB4 P3-1 BLK
FN1-3 GRN
FN2-3 GRN
TS4-1 WHT
X2
X3
X4 2
X5 TS1
1
X6
X7
X8
"A"
H1
H2
F3-1 BRN
X2
X3
X4 2
X5 TS2
X6 1
X7
X8
T1
"B"
H1
H2
A
K1C-T1.2.3 BLK
GND 4
L2
PCB1 P7-12 VIO
PCB1 P7-11 BLK
BR "C"
BUS
M3-1 WHT
M2-1 WHT
M1-1 WHT
F4-1 BRN
D33 BUS GRY
25
X2
X3
X4 2
"C"
X5
TS3
X6 1
X7
TS7-2 WHT
X8
H1
H2
14
B
PCB4
P1
P3
1 ELECTRODE BUS-BLK
T9-GRN
T9-GRN/YEL
T9-GRN
WORK BUS-BLU
TB1-15 RED
TB1-16 BLK
SH1 +
TB9-2 WHT
TB9-1 ORN
PCB4 P1-10 BLK ESP-400C
10 PCB4 P1-9 BLK
11 S4-1 VIO
12 S4-2 GRY
1
2
3
4
5
6
7
8
9
6-28
K1A-T1.2.3 BLK
K1B-T1.2.3 BLK
M3-2 RED
M2-2 RED
M1-2 RED
BR "B"
BUS
A
F5-2 BLU
TB1-18 BRN
TB9-24 YEL
TB9-24 YEL
CB1
T2-X2
BLU
GND 1
K3-4 RED
ELECTRODE BUS
S1
5 6
3 4
1 2
K4-L1 BLK
A
B
C
D
E
F
G
H
J
K
J1
TB1-1 BRN
TB1-2 YEL
TB1-4 ORN
TB1-5 BLU
TB1-9 RED
TB1-7 BLK
TB1-8 WHT
GND 5 GRN
TB1-13 GRY
TB1-14 VIO
WORK BUS
P2-5
P2-6
P2-7
P2-8
P2-1
P2-2
P2-3
P2-4
S4
1
Note: From ESP-400C/600C//460V
Drawing No. 35719, sheet 1 of 5
Rev E
ESP 400C and 600C Plasma Power Sources
SECTION 6
Troubleshooting
6.6 Wiring Diagrams – 460V 60Hz Drawing 1 – Part2 (P/N 35878)
M1-3 GRN
M2-3 GRN
F2-1 ORN
T1-CX4 WHT
GND-2 GRN
1
3
1
R3
K2-L1 BLK
2
R1
M1
2
1
2
K2-L3 RED
TB4 BLU
T1-BX2 RED
R2
1
2
K2-L2 WHT
F1-1 VIO
D35-C VIO
ELECTRODE PLATE GRY
2
R21
1
2
R18
1
K4-T2 WHT
F7-2 ORN
F7-1 BRN
TD2 (SPLICE) BLK
C32 (-) BLU
1
1
R22
R19
T1-CX4 WHT
GND-2 GRN
TD1 (SPLICE) BLK
2
2
R16
R17
1
1
3
1
K1B-L1 YEL
WHT
K1C-L1 BLK
H1
H2
H3
H4
H5
H6
X1
T2
X2
X3
X4
GND 3 GRN
2
F4-2 BLK
CB1-1 BLU
TB8-15 YEL
M2
2
FN4-4 WHT
2
T1-BX2 RED
S1-1 YEL
ORN
S1-3 ORN
1
R20
2
1
R23
2
TB8-16 RED
C27(-) WHT
POS PLATE BLU
K4-L3 RED
T1-AX7 BRN
Note: From ESP-400C/600C//460V
Drawing No. 35719, sheet 1 of 5
Rev E
ESP 400C and 600C Plasma Power Sources
6-29
SECTION 6
Troubleshooting
6.6 Wiring Diagrams – 460V 60Hz Drawing 2 – Part 1 (P/N 35878)
SEE VIEW K-K
K1A
K1C
K1B
K2-B WHT
R33
C26
R32
TB1-11 WHT
1
1
2
K7-9 ORN
K4-B ORN
K2-A ORN
C25
K1C-B GRY
2
K7-7 GRY
R2-1 VIO
K2
K1C-A ORN
F1
K3-7 ORN
R3-1 ORN
NEG PLATE
TB5 GRY
F2
S1-4 RED
TB6 BRN
TB5
TB4
C33(+) RED
R26-2 RED
TB6
C34-2 BLK
BLK
D34
POS PLATE
D33
T1-CX7 GRY
R25-2 GRY
ELECTRODE PLATE
SEE VIEW L-L
R28-2 YEL
T2-H1 YEL
TB5 BLK
TB5 BLK
K1A-A/K1C-A ORN
TB5 BLK
K1B-B GRY
K1A-B/K1C-B GRY
TB4 BLK
K1B-A/C25-1 ORN
TB4 BLK
TB6 BLK
TB4 BLK
T2-H6 BLK
TB6 BLK
TB6 BLK
L1
L2
L3
L1
K1B-A ORN
A K1A
L2
L3
A K1B
B
L1
B
L2
A K1C
L3
C23-2 VIO
T1-AH1 BLK
T1
T2
T3
T1
T2
T3
T1
T2
C
T3
T1-AH1 BLK
K2-T3 RED
T1-AH1 BLK
C10(+) WHT
1
R10
G
R54
1 2
R53
1 2
C2(+) BLU
C2(-) YEL
K2-T2 WHT
K2-T1 BLK
C24-1 VIO
C4(+) WHT
K1-B/C25-2 GRY
B
2
C8(+) BLU
C8(-) YEL
1
R11
2
T1-BH2/CH1 BLK
T1-AH2/BH1 BLK
R3-2 RED
T1-BH2/CH1 BLK
T1-AH2/BH1 BLK
T1-CX4 WHT
T1-BX2 RED
T1-BH2/CH1 BLK
T1-AH2/BH1 BLK
R2-2 WHT
M3
R1-2 BLK
VIEW K-K
C26-2 WHT
C26-1 ORN
G
K1A-T3 BLK
K1B-T3 WHT
K1B-L1 BLK
K1C-T3 RED
K1B-L2 BLK
C
K1B-L3 BLK
K1C-L1 BLK
K1A-L3 BLK
K1C-L2 BLK
K1A-L2 BLK
"A"
K1C-L3 BLK
"C"
"B"
K1A-L1 BLK
TB4
TB5
TB6
R1-1 BLU
F2-2 GRN
X1
K7-4 BLK
C60
C61
C62
400V 50HZ
UNITS ONLY
R55
R57
R56
VIEW L-L
6-30
X1
X1
F8
F1-2 GRY
ESP 400C and 600C Plasma Power Sources
F9
SECTION 6
Troubleshooting
6.6 Wiring Diagrams – 460V 60Hz Drawing 2 – Part 2 (P/N 35878)
C23-2 VIO
C24-1 VIO
C10(+) WHT
C4(+) WHT
C
1
R10
G
R54
1 2
R53
1 2
C2(+) BLU
C2(-) YEL
C8(+) BLU
C8(-) YEL
2
1
R11
2
T1-CX4 WHT
T1-BX2 RED
M3
G
C
"A"
"C"
"B"
X1
X1
X1
F9
F8
K7-4 BLK
K5-9 RED
SECTION D-D
5
6
7
TB1-9 RED
4
8
9 10 11 12 13
K6-9 RED
3
2
F7-1 BRN
1
PCB1 P4-1 WHT
TB7
PCB1 P6-1 ORN
R45
VIEW G-G
R52
TB7
PRA1 YEL
NEGATIVE PLATE
PCB1 P7-9 BLU
NEG PLATE YEL
PRA1
C28(+) BLU
ELECTRODE PLATE GRY
R20-2 BLU
PCB1 P5-9 BLK
F3-2 BLK
K4-T3 ORN
D31
D32
C43 C44
BLK
POS
PLATE
ORN
C41 C42
D29
D30
C27(-) WHT
S1-2 WHT
ELECTRODE PLATE
PRA1 GRY
C29(-) GRY
R21-2 GRY
TD2 (SPLICE) GRY
TD1 (SPLICE) GRY
ESP 400C and 600C Plasma Power Sources
6-31
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.
PCB1 P7-1
PCB1 P7-4
PCB1 P7-2
PCB1 P7-3
P1 1 2 3 4
TB1-15 RED(TP)
1
2
3
4
PCB4 P1-4 BLU
P1
PCB1 P1-2 BLK(TP)
P1 1 2 3 4
PCB1 P7-5
PCB1 P7-8
PCB1 P7-6
PCB1 P7-7
BLK
RED
GRN
WHT
R16-2 (SPLICE) BLK
(-)
SH1
(+)
3
R17-2 (SPLICE) BLK
D20-2 BRN
1
R13
1
R12
TD1
TD2
2
1
R15
1
R14
2
D20-1 ORN
D19-1 ORN
ELECTRODE PLATE (SPLICE) GRY
D19-2 BRN
2
2
D22-1 ORN
D21-1 ORN
ELECTRODE PLATE (SPLICE) GRY
D22-2 BRN
D21-2 BRN
R22-2 BLK
T1-CX5 BRN
TB11-8 RED
S1-6 BRN
F6-1 VIO
C29(-) GRY
T1-BX7 BRN
D31-A BLK
2
2
2
2
C32
1
2
F3
K4
L1
A
R37
T3
T2
T1
F5
2
1
F6
2
1
F7
2
2
R31-2 GRY
R16-1 WHT
GRY 2
C29
C27
+
R31
+
R41
L2
1
R43
2
BLK
C34
R40
R34
R25-1 YEL
BLK
B
2
C31
L3
D34-A BLK
1
2
D29/D30 BUS WHT
D35
R21-1 VIO
R27-2 VIO
ELECTRODE PLATE GRY
F4
1
C32(-) BLU
D33 BUS GRY
POS PLATE RED
D35-C VIO
+
R30
R28
R39
1
C33
1
2
1 RED 1
1
C36
+
R44
POS PLATE BLU
R30-1 BLU
J
J
K4-T1 YEL
F6-2 VIO
K4-T2 WHT
R31-1 VIO
C29 (+) VIO
C28 (+) BLU
R18-1 ORN
H
C29(+) VIO
ELECTRODE PLATE YEL
C33(+) RED
C34-1 YEL
C35-1 BRN
C36-1 ORN
1
T1-BX5 BLU
R27-1 ORN
1
C28
2
1
1
R29-1 RED
POS PLATE RED
R29-2 BLU
C36-2 BLU
R22-1 BLU
R36
C32(-) BLU
+
1
C30
R42
R29
R38
R25
T1-AX5 BLU
R24-1 VIO
TB7-5 BRN
R19-1 BRN
R26
C35
R23-2 RED
S1-5 BLK
C26-1 ORN
PCB1 P2-5 YEL
D32-A ORN
C30-2 WHT
R18-2 WHT
C30-1 YEL
TB10 YEL
R27
BLK
R35
2
R26-1 BRN
H
VIEW E-E
Note: From ESP-400C/600C//460V
35719, sheet 3 of 5
Rev E
6-32
ESP 400C and 600C Plasma Power Sources
SECTION 6
Troubleshooting
6.6 Wiring Diagrams – 460V 60Hz Drawing 4
(P/N 35878)
PCB2
PCB3
P1
P2
1
2
3
4
5
6
1 PCB1 P10-1 BLK
2 PCB1 P10-2 WHT
3 PCB1 P10-3 GRN
4 PCB1 P10-4 RED
5 PCB1 P10-7 BLU
6 PCB1 P10-8 ORN
7 PCB1 P10-9 YEL
8 PCB1 P10-10 BRN
9 PCB1 P10-5 GRY
10 PCB1 P10-6 VIO
PCB2 P2-3
PCB3 P2-2
PCB2 P2-1
PCB3 P2-4
PCB3 P2-3
YEL
CLR(TP)
YEL
SHLD
BLK(TP)
P5
1 T5-X1 BRN
2 T5-X4 GRN/YEL
3 T5-X7 RED
P1
P2
1 PCB1 P11-1 BLK
2 PCB1 P11-2 WHT
3 PCB1 P11-3 GRN
4 PCB1 P11-4 RED
5 PCB1 P11-7 BLU
6 PCB1 P11-8 ORN
7 PCB1 P11-9 YEL
8 PCB1 P11-10 BRN
9 PCB1 P11-5 GRY
10 PCB1 P11-6 VIO
1
2 PCB2 P2-2 CLR(TP)
3 PCB2 P2-5 BLK(TP)
4 PCB2 P2-4 SHLD(TP)
5
6
P5
1 T7-X1 BRN
2 T7-X4 GRN/YEL
3 T7-X7 RED
P6
P6
1 T6-X1 BRN
2 T6-X4 GRN/YEL
3 T6-X7 RED
1 T8-X1 BRN
2 T8-X4 GRN/YEL
3 T8-X7 RED
PCB2 P5-1 BRN
G
R
Y
X2X1
X3
T5
X4
L
YE X5
X6
X7
U
L
B
PCB2 P5-3 RED
GR
PCB2 P5-2 GRN/YEL N
PCB3 P6-1 BRN
TB2-2 BLK
Y
T5-H2 BLK
H2
R
T6-H1 BLK
TB2-1 BLK
G
T5-H1 BLK
H1
X2X1
X3
T8
X4
L
YE X5
X6
X7
LU
B
PCB3 P6-3 RED
GR
PCB3 P6-2 GRN/YEL N
TB3-1 BLK
TB3
1
T8-H2 BLK
TB3-2 WHT
2
TB3-2 BLK
H2
T8-H1 BLK
T7-H1 BLK
TB2
1
TB3-1 BLK
H1
2
T7-H2 WHT
T6-H2 WHT
T5
R15-2 ORN
C11
C5 +
R15-1 BRN
+
PCB3 P3 BLK
C20
TB9-15 WHT
TB3
C22
T8
D20
+
2
1
D22
Q4-C BLK
P6
P5
E
TB2-2 WHT
C12
R52-1 VIO
R13-1 BRN
TB2
R13-2 ORN
C6 +
TB2-1 BLK
TB9-20 BLK
C
Q4 C
C10
C4 +
P2
P3
E
+
2
2
C9
C23
D24
D23
C3 +
PCB2
P1
PCB3
C24
+
P1
1
1
C2 +
K2
C8
P2
+
E
P3
Q1-C BLK
Q3 C
C Q1
E
P5
P6
C1 +
C7
1
D19
2
D21
T6
T7
C19
TB2-1 BLK
H1
R14-1 BRN
R54-1 VIO
R
G
Y
PCB2 P6-1 BRN
R14-2 ORN
R11-2 YEL
R11-1 BLU
R54-2 WHT
R10-2 BLU
R53-2 WHT
R10-1 YEL
PCB2 P3 BLK
H2
R12-2 ORN
B
X7
X6
L
X5
YE PCB2 P6-2 GRN/YEL
X4
T6
X3 GR
N
X2
X1
R12-1 BRN
PCB2 P6-3 RED
LU
TB2-2 WHT
C21
+
TB3-2 WHT
VIEW F-F (WITH BUS BARS)
TB3-1 BLK
PCB3 P5-3 RED
LU
B
H2
H1
X7
X6
L
X5
YE PCB3 P5-2 GRN/YEL
X4
T7
X3 GR
N
X2
X1
R
G
Y
PCB3 P5-1 BRN
Note: From ESP-400C/600C//460V
35719, sheet 4 of 5
Rev E
ESP 400C and 600C Plasma Power Sources
6-33
SECTION 6
Troubleshooting
6.6 Wiring Diagrams – 460V 60Hz Drawing 5 – Part 1 (P/N 35878)
PCB1
P1
P6
1 SH1(+) CLR(TP)
2 SH1(-) BLK(TP)
3 TB1-6 GRY
SH1-3 SHLD
1
2
3
4
5
6
P2
1
2
3
4
5
6
TB8-4 ORN
TB8-3 BLK
P3
TB1
TS6-2 BRN
PL3-2 BRN
P4
K7-A BRN
18
1
2
3
4
5
17
PCB4 P1-6 BLK
SH1(-) BLK(TP)
16
PCB4 P1-5 RED
J1-K VIO
SH1(+) RED(TP)
15
T9-H2 WHT
T4-H2 BLK
TB9-14 WHT
C26-2 WHT
FN4-4 WHT
T4-H1 BLK
13
PL1-2 WHT
12
PL2-2 WHT
TB7-7 WHT
TB1-6 GRY
1
2
3
4
5
6
WHT
11
PL1-1 BLK
CB1-2 BLK
TB9-20 BLK
T9-H1 BLK
TB7-8 RED
10
PL2-1 RED
J1-E RED
9
J1-G WHT
TB8-8 RED
FN4-2 WHT
8
J1-F BLK
FN4-1 BLK
PCB1 P1-3 GRY
PCB1 P4-2 GRY
7
TB8-7 BLK
S2-6 GRY
S2-4 BLU
J1-D BLU
J1-C ORN
S2-1 ORN
P5
1 TB9-1 RED
2 TB9-2 WHT
3 TB9-3 BRN
4 TB9-4 VIO
5 TB9-5 GRY
6 TB9-6 ORN
7 TB9-7 YEL
8 TB9-8 VIO
9 PRA1-BLK
10 T3-X1 BRN
11 TB9-24 YEL
T3-X4 GRN/YEL
12 T3-X7 RED
6
C45
J1-H GRN
TB8-12 BLU
5
GND 5
TB8-11 ORN
4
C46
P10
1 PCB3 P1-1 BLK
2 PCB3 P1-2 WHT
3 PCB3 P1-3 GRN
4 PCB3 P1-4 RED
5 PCB3 P1-9 GRY
6 PCB3 P1-10 VIO
7 PCB3 P1-5 BLU
8 PCB3 P1-6 ORN
9 PCB3 P1-7 YEL
10 PCB3 P1-8 BRN
11
12
S2-5 GRY
S2-2 VIO
T4-X1 BRN
T4-X4 GRN/YEL
T4-X7 RED
P11
1 PCB2 P1-1 BLK
2 PCB2 P1-2 WHT
3 PCB2 P1-3 GRN
4 PCB2 P1-4 RED
5 PCB2 P1-9 GRY
6 PCB2 P1-10 VIO
7 PCB2 P1-5 BLU
8 PCB2 P1-6 ORN
9 PCB2 P1-7 YEL
10 PCB2 P1-8 BRN
11
12
PCB1 P5-8 VIO
R50-1 VIO
3
J1-B YEL
VIO
VIO
VIO
VIO
VIO
PL5(+) VIO
12 TB11-2 YEL
13 TB11-4 YEL
14
P8
TB8-5 VIO
TB8-6 YEL
14
J1-J GRY
PL4(+) GRY
1 TD1 P1-1 BLK
2 TD1 P1-3 GRN
3 TD1 P1-4 WHT
4 TD1 P1-2 RED
5 TD2 P1-1 BLK
6 TD2 P1-3 GRN
7 TD2 P1-4 WHT
8 TD2 P1-2 RED
9 PRA1- BLU
10 R51-1 GRY
11 R51-2 BLK
12 R51-3 VIO
13 S3-1 RED
14 S3-2 BRN
15 S3-3 WHT
1
2 K6-A BLU
3 PCB1 P2-6 WHT
PCB1 P6-2 WHT
GRY
GRY
GRY
GRY
6
7
8
9
10
11
P7
K4-A YEL
TB9-14 WHT
PCB P3-3 WHT
7 FN3-4 ORN
8 FN3-3 GRY
P9
1
2
3
4
5
TB7-9 ORN
PCB1 P3-3 WHT
TB9-11 GRY
TB9-10 BLU
TB9-9 BLK
FN3-2 YEL
2
FN3-1 BRN
J1-A BRN
1
P7
H1
PCB1 P5-10 BRN
T4
LU
L
YEPCB1 P8-5 GRN/YEL
GR
N
T3
PCB1
TB1
P5
Y
T4
TB1-10 BLK
X6
X5
X4
X3
X2
X1
R
X7
H2
G
B
TB1-12 BLK
P6
P8
PCB1 P8-6 RED
P9
P10
P11
P1
G
GND5
P2
P3
GR
PCB1 P5-11 GRN/YEL N
X2
X3
X4
L
X5
X6
YE
P4
RY
PCB1 P8-4 BRN
PCB1 P5-12 RED
FN4
B
LU
X1
TB9-20 BLK
T3
TB9-15 WHT
X7
FN3
TB9
VIEW H-H
JUMPER
K6-B BLK
JUMPER
T3-H1 BLK
JUMPER
JUMPER
JUMPER
K5-6 BLK
PCB1 P5-11 YEL
PL4(-) YEL
PL5(-) YEL
TB1-7 BLK
BLK
PCB1 P2-8 GRY
3
1
FN3
(LINE)
TB1-2 YEL
(LOAD)
PCB1 P2-7 ORN
4
2
24
23
TS7-1 BLK
PL3-1 BLK
K3-6 BLK
22
21
TB3-1 BLK
TB1-10 BLK
20
19
18
17
TB3-2 WHT
K3-B WHT
K7-B WHT
TB8-17 WHT
16
15
TB1-12 WHT
PCB1 P2-8 WHT
T3-H2 WHT
14
13
PCB1 P6-3 GRY
12
11
10
PCB1 P6-5 BLK
9
PCB1 P6-4 BLU
PCB1 P5-7 YEL
8
7
PCB1 P5-6 ORN
6
PCB1 P5-4 VIO
PCB1 P5-5 GRY
5
4
PCB1 P5-2 WHT
PCB4 P1-8 WHT
PCB4 P1-9 ORN
PCB1 P5-3 BRN
3
2
1
TB9
PCB1 P5-1 RED
TB1-1 BRN
(LINE)
TB1-8 WHT
3
1
FN4
2
4
CB1-2 BLK
(LOAD)
T2-X1 WHT
TB1-11 WHT
Note: From ESP-400C/600C//460V
35719, sheet 5 of 5
Rev E
6-34
ESP 400C and 600C Plasma Power Sources
SECTION 6
Troubleshooting
6.6 Wiring Diagrams – 460V 60Hz Drawing 5 – Part 2 (P/N 35878)
2
3
1
2
3
1
2
3
1
2
3
4
5
6
4
5
6
4
5
6
4
5
6
7
8
9
7
8
9
7
8
9
7
8
K7-6 YEL
C53
TB9-22 BLK
B
TB9-16 WHT
C25-1 ORN
TB8-19 BLU
T1-AX2 RED
TB7-8 RED
TB9-22 BLK
TB8-1 BLU
9
A
B
TB8-2 WHT
TB8-18 VIO
C54
A
TB7-8 RED
B
TB9-22 BLK
TB8-10 BRN
PCB1 P3-2 BLU
C26-1 ORN
K3-9 YEL
A
TB8-9 GRY
TB1-18 BRN
B
TB9-16 WHT
C25-2 GRY
A
T1-AX1 BLK
K3
K6
K6
K7
1
TB8
TB8
20
K3-A BLU
K7
K6
K5
K3
19
K6-6 VIO
JUMPER
18
TB9-17 WHT
17
T2-X4 RED
16
T2-X3 YEL
15
14
13
TB1-5 BLU
12
TB1-4 ORN
11
K6-7 BRN
10
K6-1 GRY
9
TB1-9 RED
8
TB1-7 BLK
7
PCB1 P4-5 YEL
6
PCB1 P4-4 VIO
5
PCB1 P2-2 ORN
VIEW J-J
4
PCB1 P2-3 BLK
3
K5-B WHT
2
K5-A BLU
1
TS5-2 WHT
VIEW F-F
(WITHOUT BUS BARS)
TB1-18 BRN
2
TS6
1
C2
C1
D1
RED
D2
3
1
RED
D4
1
RED
D5
1
3
C6
C5
D6
RED
3
C18
2
R9
C17
2
R8
C16
2
R7
R6
2
C15
2
R5
2
C14
1 2
C13
TS5
R4
TS5-1 WHT
RED
D3
RED
C4
C1
C3
TS1-2 WHT
1
3
C7
3
3
1
C9
C8
C10
1
C11
C12
TS4
1 2
TS5-1 WHT
TS1-2 WHT
Note: From ESP-400C/600C//460V
35719, sheet 5 of 5
Rev E
ESP 400C and 600C Plasma Power Sources
6-35
SECTION 6
Troubleshooting
6.7 Wiring Diagrams – 400V 50Hz Drawing 1 – Part 1 (P/N 35879)
D7,D8
C47
C48
D9,D10
D11,
D12
C49
ELECTRODE BUS BLK
WORK BUS BLU
BLU
YEL
BR "C" BUS
BR"A" BUS
D13
D14
BR "B" BUS
D15,
D16
C50
TB10
C51
C37
FN1
FN2
3
WHT
C38
WHT
D17,
D18
C52
TB9-21 BLK TS3-1 WHT C39
D25,
D26
1
D27,
D28
C40
WHT WHT
TS7
2
3
"B" COIL
"B" COIL
K4-T1 YEL
GND4 GRN
X1
GND4 GRN
X1
Section A-A
L2
"A" COIL
L1
"A" COIL
PCB4 P1-1 GRN
X1
TB1-10 BLK
TB1-12 BLK
H1
X1
PCB4 P1-2 GRN/YEL
T9
X3 YEL
TB11-3 YEL
H2
TB11-2 YEL
PCB4 P1-3 GRN
Ammeter
8
Voltmeter
2
1
7
8
PCB4 P1-11 VIO
2
BRN
BLU
ORN
YEL
7
WHT
RED
BLK
GRN
1
X4 YEL
Section B-B
PCB4 P1-12 GRY
B
2
3
PCB4
A
R19-2 ORN
R17-1 YEL
D29/30 BUS WHT
S2-6 GRY
N
K J
H
S2
4 5 6
1 2 3
3
S2-3 RED
R50 2
R50-2 RED
1 TB1-3 VIO
PCB1 P8-2 VIO
TB1-4 ORN
PL1
PL2
PL3
PL4
TB1-9 RED
TB1-10-B BLK
PCB1 P7-10 GRY
R51
123
PCB1 P7-15 WHT
S3
PCB1 P7-14 BRN
36
PCB1 P7-13 RED
BR "A"
BUS
F5-1 BLU
L1
FN2-2 BLU
PCB4 P1-4 BLU
R23-1 BRN
PL5
PCB1 P9-11 VIO
PCB1 P9-5 GRY
TB9-21 BLK
FN1-1 BLK
PCB4 P3-1 BLK
FN1-3 GRN
FN2-3 GRN
TS4-1 WHT
X2
X3
X4 2
X5 TS1
1
"A"
X6
X7
X8
X9
H1
H2
F3-1 BRN
X2
X3
X4 2
X5 TS2
X6 1
X7
X8
X9
T1
H1
H2
"B"
A
K1C-T1.2.3 BLK
GND 4
L2
PCB1 P7-12 VIO
PCB1 P7-11 BLK
BR "C"
BUS
M3-1 WHT
M2-1 WHT
M1-1 WHT
F4-1 BRN
D33 BUS GRY
25
X2
X3
X4 2
"C"
X5
TS3
X6 1
X7
TS7-2 WHT
X8
H1
H2
X9
14
B
PCB4
P1
P3
1 ELECTRODE BUS-BLK
T9-GRN
T9-GRN/YEL
T9-GRN
WORK BUS-BLU
TB1-15 RED
TB1-16 BLK
SH1 +
TB9-2 WHT
TB9-1 ORN
PCB4 P1-10 BLK ESP-400C
10 PCB4 P1-9 BLK
11 S4-1 VIO
12 S4-2 GRY
1
2
3
4
5
6
7
8
9
6-36
K1A-T1.2.3 BLK
K1B-T1.2.3 BLK
M3-2 RED
M2-2 RED
M1-2 RED
A
F5-2 BLU
TB1-18 BRN
TB9-24 YEL
TB9-24 YEL
CB1
T2-X2
BLU
K3-4 RED
BR "B"
BUS
TB1-12
WHT
TB1-11 WHT
FN4-3 BLK
TB1-10-A BLK
M
R24-2 BRN
L
POS PLATE RED
TB1-5 BLU
PCB1 P8-1 GRY
TB1 6
GRY
R50-3 GRY
C
D
P E
R
V S F
U
G
T
B
GND 1
J1
TB1-1 BRN
TB1-2 YEL
TB1-4 ORN
TB1-5 BLU
TB1-9 RED
TB1-7 BLK
TB1-8 WHT
GND 5 GRN
TB1-13 GRY
TB1-14 VIO
ELECTRODE BUS
S1
5 6
3 4
1 2
K4-L1 BLK
A
B
C
D
E
F
G
H
J
K
WORK BUS
1
P2-5
P2-6
P2-7
P2-8
P2-1
P2-2
P2-3
P2-4
S4
Note: From ESP-400C/600C//400V
0558002859, sheet 1 of 5
ESP 400C and 600C Plasma Power Sources
SECTION 6
Troubleshooting
6.7 Wiring Diagrams – Drawing 1 – Part 1 400V 50Hz (P/N 35879)
M1-3 GRN
M2-3 GRN
F2-1 ORN
T1-CX4 WHT
GND-2 GRN
1
3
1
R3
K2-L1 BLK
2
R1
M1
2
1
2
K2-L3 RED
TB4 BLU
T1-BX2 RED
R2
1
2
K2-L2 WHT
F1-1 VIO
D35-C VIO
ELECTRODE PLATE GRY
2
R21
1
2
R18
1
K4-T2 WHT
F7-2 ORN
F7-1 BRN
TD2 (SPLICE) BLK
C32 (-) BLU
1
1
R22
R19
T1-CX4 WHT
GND-2 GRN
TD1 (SPLICE) BLK
2
2
R16
R17
1
1
3
1
FN4-4 WHT
K1B-L1 YEL
WHT
K1C-L1 BLK
H1
H2
H3
H4
H5
H6
X1
T2
X2
X3
X4
GND 3 GRN
2
F4-2 BLK
CB1-1 BLU
TB8-15 YEL
M2
2
2
T1-BX2 RED
S1-1 YEL
ORN
S1-3 ORN
1
R20
2
1
R23
2
TB8-16 RED
C27(-) WHT
POS PLATE BLU
T1-AX7 BRN
K4-L3 RED
Note: From ESP-400C/600C//400V,50 Hz
Drawing No. 0558002859, sheet 1 of 5
OR
ESP 400C and 600C Plasma Power Sources
6-37
SECTION 6
Troubleshooting
6.7 Wiring Diagrams – Drawing 2 – Part 1 400V 50Hz (P/N 35879)
SEE VIEW K-K
F
F
E
E
D
K1A
K1C
K1B
K2-B WHT
R33
1
R32
TB1-11 WHT
C26
1
2
K7-9 ORN
K4-B ORN
K2-A ORN
C25
2
K1C-B GRY
K7-7 GRY
R2-1 VIO
K2
K1C-A ORN
F1
K3-7 ORN
R3-1 ORN
NEG PLATE
TB5 GRY
F2
S1-4 RED
TB6 BRN
TB4
TB5
C33(+) RED
R26-2 RED
TB6
C34-2 BLK
BLK
D34
POS PLATE
D33
T1-CX7 GRY
SECTION C-C
R25-2 GRY
ELECTRODE PLATE
SEE VIEW L-L
D
R28-2 YEL
T2-H1 YEL
TB5 BLK
TB5 BLK
K1A-A/K1C-A ORN
K1B-L1 BLK
TB5 BLK
K1B-B GRY
K1B-L2 BLK
K1A-B/K1C-B GRY
TB4 BLK
K1B-A/C25-1 ORN
TB4 BLK
TB6 BLK
TB4 BLK
K1B-L3 BLK
K1C-L1 BLK
K1A-L3 BLK
K1C-L2 BLK
T2-H6 BLK
K1A-L2 BLK
K1C-L3 BLK
TB6 BLK
TB6 BLK
K1A-L1 BLK
TB4
L1
L2
L3
K1B-A ORN
A K1A
B
L1
L2
L3
A K1B
L1
B
L2
A K1C
TB5
TB6
R1-1 BLU
L3
K1-B/C25-2 GRY
B
F2-2 GRN
F1-2 GRY
T1-AH1 BLK
T1
T2
T3
T1
T2
T3
T1
T2
T3
T1-AH1 BLK
K2-T3 RED
T1-AH1 BLK
K2-T2 WHT
K2-T1 BLK
T1-BH2/CH1 BLK
C60
C61
C62
T1-AH2/BH1 BLK
R3-2 RED
T1-AH2/BH1 BLK
T1-AH2/BH1 BLK
R2-2 WHT
R1-2 BLK
C26-1 ORN
K1A-T3 BLK
L1
L2
T1
T2
R55
B
VIEW K-K
T3
K1B-T3 WHT
K1C-T3 RED
6-38
R57
R56
VIEW L-L
L3
C26-2 WHT
A K2
400V 50HZ
UNITS ONLY
T1-BH2/CH1 BLK
T1-BH2/CH1 BLK
Note: From ESP-400C/600C//400V,50 Hz
Drawing No. 0558002859, sheet 2 of 5
OR
ESP 400C and 600C Plasma Power Sources
SECTION 6
Troubleshooting
6.7 Wiring Diagrams – Drawing 2 – Part 2 400V 50Hz (P/N 35879)
C23-2 VIO
C24-1 VIO
C10(+) WHT
C4(+) WHT
C
1
2
R10
G
R54
1 2
R53
1 2
C2(+) BLU
C2(-) YEL
C8(+) BLU
C8(-) YEL
1
R11
2
T1-CX4 WHT
T1-BX2 RED
M3
G
C
T2
"A"
"C"
"B"
X1
X1
X1
F9
F8
K7-4 BLK
K5-9 RED
SECTION D-D
R45
VIEW G-G
5
6
7
8
9 10 11 12 13
PCB1 P6-1 ORN
3 4
TB1-9 RED
2
K6-9 RED
1
F7-1 BRN
TB7
PCB1 P4-1 WHT
R52
TB7
PRA1 YEL
NEGATIVE PLATE
PCB1 P7-9 BLU
NEG PLATE YEL
PRA1
C28(+) BLU
ELECTRODE PLATE GRY
R20-2 BLU
PCB1 P5-9 BLK
F3-2 BLK
K4-T3 ORN
D31
D32
C43 C44
BLK
POS
PLATE
ORN
C41 C42
D29
D30
C27(-) WHT
S1-2 WHT
ELECTRODE PLATE
PRA1 GRY
C29(-) GRY
R21-2 GRY
Note: From ESP-400C/600C//400V,50 Hz
Drawing No. 0558002859, sheet 2 of 5
OR
TD2 (SPLICE) GRY
TD1 (SPLICE) GRY
ESP 400C and 600C Plasma Power Sources
6-39
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.
PCB1 P1-1 CLR (TP)
RIGHT COLLECTOR BUS RED
PCB1 P1-3 SHLD
8
TB1-16 BLK(TP)
R58
7
(+)
SH1
(-)
TD2
TD1
P1
1
2
3
4
TB11-1 BLU
BLK
RED
GRN
WHT
TB1-15 RED(TP)
Note1:
Splice must pass through
transducers TD1 and TD2 in
direction shown.
PCB1 P7-1
PCB1 P7-4
PCB1 P7-2
PCB1 P7-3
PCB4 P1-4 BLU
P1
1
2
3
4
PCB1 P1-2 BLK(TP)
P1 1 2 3 4
P1 1 2 3 4
PCB1 P7-5
PCB1 P7-8
PCB1 P7-6
PCB1 P7-7
BLK
RED
GRN
WHT
R16-2 (SPLICE) BLK
(-)
SH1
(+)
3
R17-2 (SPLICE) BLK
D20-2 BRN
1
R13
1
R12
TD1
TD2
2
1
R15
1
R14
2
D20-1 ORN
D19-1 ORN
ELECTRODE PLATE (SPLICE) GRY
D19-2 BRN
2
2
D22-1 ORN
D21-1 ORN
ELECTRODE PLATE (SPLICE) GRY
D22-2 BRN
D21-2 BRN
R22-2 BLK
T1-CX5 BRN
TB11-8 RED
S1-6 BRN
F6-1 VIO
C29(-) GRY
T1-BX7 BRN
D31-A BLK
C32
2
2
1
F7
2
C29
R29
R28
1
1
1 RED 1
1
R39
1
C30
C28
2
1
+
R44
POS PLATE BLU
R30-1 BLU
J
J
C36
+
R30
VIEW E-E
K4-T1 YEL
F6-2 VIO
K4-T2 WHT
R31-1 VIO
C28 (+) BLU
C29 (+) VIO
R18-1 ORN
H
C29(+) VIO
ELECTRODE PLATE YEL
C33(+) RED
C34-1 YEL
C35-1 BRN
C36-1 ORN
1
T1-BX5 BLU
R29-1 RED
POS PLATE RED
R29-2 BLU
C36-2 BLU
R22-1 BLU
R36
2
+
C27
+
1
R41
F5
F6
T1-AX5 BLU
R24-1 VIO
TB7-5 BRN
R19-1 BRN
R25
C33
6-40
T1
1
1
R31
R23-2 RED
S1-5 BLK
C26-1 ORN
PCB1 P2-5 YEL
D32-A ORN
C30-2 WHT
R18-2 WHT
C30-1 YEL
TB10 YEL
R26
BLK
R35
R27
C35
1
R27-1 ORN
A
T2
+
2
R26-1 BRN
L1
T3
R31-2 GRY
D29/D30 BUS WHT
R16-1 WHT
GRY 2
2
R42
2
2
2
K4
2
F3
R43
2
1
L2
1
2
R38
2
BLK
R34
C34
R40
BLK
R25-1 YEL
C32(-) BLU
B
2
R37
L3
D34-A BLK
C31
D35
R21-1 VIO
R27-2 VIO
ELECTRODE PLATE GRY
F4
1
C32(-) BLU
D33 BUS GRY
POS PLATE RED
D35-C VIO
H
Note: From ESP-400C/600C//400V,50 Hz
Drawing No. 0558002859, sheet 3 of 5
OR
ESP 400C and 600C Plasma Power Sources
SECTION 6
Troubleshooting
6.7 Wiring Diagrams – Drawing 4 400V 50Hz (P/N 35879)
PCB2
PCB3
P1
P2
1
2
3
4
5
6
1 PCB1 P10-1 BLK
2 PCB1 P10-2 WHT
3 PCB1 P10-3 GRN
4 PCB1 P10-4 RED
5 PCB1 P10-7 BLU
6 PCB1 P10-8 ORN
7 PCB1 P10-9 YEL
8 PCB1 P10-10 BRN
9 PCB1 P10-5 GRY
10 PCB1 P10-6 VIO
PCB2 P2-3
PCB3 P2-2
PCB2 P2-1
PCB3 P2-4
PCB3 P2-3
YEL
CLR(TP)
YEL
SHLD
BLK(TP)
P5
1 T5-X1 BRN
2 T5-X4 GRN/YEL
3 T5-X7 RED
P1
P2
1 PCB1 P11-1 BLK
2 PCB1 P11-2 WHT
3 PCB1 P11-3 GRN
4 PCB1 P11-4 RED
5 PCB1 P11-7 BLU
6 PCB1 P11-8 ORN
7 PCB1 P11-9 YEL
8 PCB1 P11-10 BRN
9 PCB1 P11-5 GRY
10 PCB1 P11-6 VIO
1
2 PCB2 P2-2 CLR(TP)
3 PCB2 P2-5 BLK(TP)
4 PCB2 P2-4 SHLD(TP)
5
6
P5
1 T7-X1 BRN
2 T7-X4 GRN/YEL
3 T7-X7 RED
P6
P6
1 T6-X1 BRN
2 T6-X4 GRN/YEL
3 T6-X7 RED
1 T8-X1 BRN
2 T8-X4 GRN/YEL
3 T8-X7 RED
PCB2 P5-1 BRN
RY
G
X2X1
X3
T5
X4
L X5
YE
X6
X7
LU
B
PCB2 P5-3 RED
GR
PCB2 P5-2 GRN/YEL N
PCB3 P6-1 BRN
TB2-2 BLK
Y
T5-H2 BLK
H2
R
T6-H1 BLK
TB2-1 BLK
G
T5-H1 BLK
H1
X2X1
X3
T8
X4
L X5
E
Y
X6
X7
U
L
B
PCB3 P6-3 RED
GR
PCB3 P6-2 GRN/YEL N
TB3-1 BLK
TB3
1
T8-H2 BLK
TB3-2 WHT
2
TB3-2 BLK
H2
T8-H1 BLK
T7-H1 BLK
TB2
1
TB3-1 BLK
H1
2
T7-H2 WHT
T6-H2 WHT
R15-2 ORN
C11
C5 +
T5
R15-1 BRN
+
PCB3 P3 BLK
C20
TB9-15 WHT
TB3
C22
T8
D20
+
2
1
D22
Q4-C BLK
P6
P5
E
TB2-2 WHT
C12
R52-1 VIO
R13-1 BRN
TB2
R13-2 ORN
C6 +
TB2-1 BLK
TB9-20 BLK
C
P2
E
Q4 C
C10
C4 +
P3
+
2
2
C9
C23
D24
D23
C3 +
PCB2
P1
PCB3
C24
+
P1
1
1
C2 +
K2
C8
P2
+
E
P3
Q1-C BLK
Q3 C
C Q1
E
P5
P6
C1 +
C7
1
D19
2
D21
T6
T7
C19
TB2-1 BLK
H1
R14-1 BRN
R54-1 VIO
R14-2 ORN
R11-2 YEL
R11-1 BLU
R54-2 WHT
R10-2 BLU
R53-2 WHT
R10-1 YEL
R12-2 ORN
H2
PCB2 P3 BLK
B
X7
X6
L
X5
YE PCB2 P6-2 GRN/YEL
X4
T6
X3 GR
N
X2
X1
R12-1 BRN
PCB2 P6-3 RED
LU
TB2-2 WHT
C21
+
PCB3 P5-3 RED
LU
B
G
RY
PCB2 P6-1 BRN
VIEW F-F (WITH BUS BARS)
TB3-2 WHT
TB3-1 BLK
H2
H1
X7
X6
L
X5
YE PCB3 P5-2 GRN/YEL
X4
T7
X3 GR
N
X2
X1
G
R
Y
PCB3 P5-1 BRN
Note: From ESP-400C/600C//400V,50 Hz
Drawing No. 0558002859, sheet 4 of 5
OR
ESP 400C and 600C Plasma Power Sources
6-41
SECTION 6
Troubleshooting
6.7 Wiring Diagrams – Drawing 5 – Part 1 400V 50Hz (P/N 35879)
PCB1
P1
P6
1 SH1(+) CLR(TP)
2 SH1(-) BLK(TP)
3 TB1-6 GRY
SH1-3 SHLD
1
2
3
4
5
6
P2
1
2
3
4
5
6
TB8-4 ORN
TB8-3 BLK
P3
TB1
PL3-2 BRN
TS6-2 BRN
K7-A BRN
18
P4
1
2
3
4
5
17
PCB4 P1-6 BLK
SH1(-) BLK(TP)
16
PCB4 P1-5 RED
J1-K VIO
SH1(+) RED(TP)
15
1
2
3
4
5
6
12
WHT
11
PL1-1 BLK
CB1-2 BLK
TB9-20 BLK
T9-H1 BLK
TB7-8 RED
10
PL2-1 RED
J1-E RED
9
J1-G WHT
TB8-8 RED
FN4-2 WHT
8
J1-F BLK
FN4-1 BLK
PCB1 P1-3 GRY
PCB1 P4-2 GRY
7
TB8-7 BLK
S2-6 GRY
S2-4 BLU
J1-D BLU
J1-C ORN
S2-1 ORN
1 TB9-1 RED
2 TB9-2 WHT
3 TB9-3 BRN
4 TB9-4 VIO
5 TB9-5 GRY
6 TB9-6 ORN
7 TB9-7 YEL
8 TB9-8 VIO
9 PRA1-BLK
10 T3-X1 BRN
11 TB9-24 YEL
T3-X4 GRN/YEL
12 T3-X7 RED
6
C45
J1-H GRN
TB8-12 BLU
5
GND 5
TB8-11 ORN
4
C46
P10
1 PCB3 P1-1 BLK
2 PCB3 P1-2 WHT
3 PCB3 P1-3 GRN
4 PCB3 P1-4 RED
5 PCB3 P1-9 GRY
6 PCB3 P1-10 VIO
7 PCB3 P1-5 BLU
8 PCB3 P1-6 ORN
9 PCB3 P1-7 YEL
10 PCB3 P1-8 BRN
11
12
S2-5 GRY
S2-2 VIO
T4-X1 BRN
T4-X4 GRN/YEL
T4-X7 RED
P11
1 PCB2 P1-1 BLK
2 PCB2 P1-2 WHT
3 PCB2 P1-3 GRN
4 PCB2 P1-4 RED
5 PCB2 P1-9 GRY
6 PCB2 P1-10 VIO
7 PCB2 P1-5 BLU
8 PCB2 P1-6 ORN
9 PCB2 P1-7 YEL
10 PCB2 P1-8 BRN
11
12
PCB1 P5-8 VIO
R50-1 VIO
3
J1-B YEL
VIO
VIO
VIO
VIO
VIO
PL5(+) VIO
12 TB11-2 YEL
13 TB11-4 YEL
14
P8
TB8-5 VIO
TB8-6 YEL
P5
T9-H2 WHT
T4-H2 BLK
TB9-14 WHT
C26-2 WHT
FN4-4 WHT
T4-H1 BLK
13
PL1-2 WHT
PL2-2 WHT
TB7-7 WHT
TB1-6 GRY
14
J1-J GRY
PL4(+) GRY
1 TD1 P1-1 BLK
2 TD1 P1-3 GRN
3 TD1 P1-4 WHT
4 TD1 P1-2 RED
5 TD2 P1-1 BLK
6 TD2 P1-3 GRN
7 TD2 P1-4 WHT
8 TD2 P1-2 RED
9 PRA1- BLU
10 R51-1 GRY
11 R51-2 BLK
12 R51-3 VIO
13 S3-1 RED
14 S3-2 BRN
15 S3-3 WHT
1
2 K6-A BLU
3 PCB1 P2-6 WHT
PCB1 P6-2 WHT
GRY
GRY
GRY
GRY
6
7
8
9
10
11
P7
K4-A YEL
TB9-14 WHT
PCB P3-3 WHT
7 FN3-4 ORN
8 FN3-3 GRY
P9
1
2
3
4
5
TB7-9 ORN
PCB1 P3-3 WHT
TB9-11 GRY
TB9-10 BLU
TB9-9 BLK
FN3-2 YEL
2
FN3-1 BRN
J1-A BRN
1
P7
H1
PCB1 P5-10 BRN
T4
LU
L
YEPCB1 P8-5 GRN/YEL
GR
N
T3
PCB1
TB1
P5
Y
T4
TB1-10 BLK
X6
X5
X4
X3
X2
X1
R
X7
H2
G
B
TB1-12 BLK
P6
P8
PCB1 P8-6 RED
P9
X2
X3
GR
PCB1 P5-11 GRN/YEL N
P10
P11
P1
G
GND5
P2
P3
YE
P4
L
RY
PCB1 P8-4 BRN
PCB1 P5-12 RED
FN4
X1
X5
X6
B
LU
TB9-20 BLK
T3
X4
TB9-15 WHT
X7
FN3
TB9
VIEW H-H
JUMPER
K6-B BLK
JUMPER
T3-H1 BLK
JUMPER
JUMPER
JUMPER
PL4(-) YEL
PL5(-) YEL
TB1-7 BLK
BLK
PCB1 P2-8 GRY
3
1
FN3
(LINE)
TB1-2 YEL
(LOAD)
PCB1 P2-7 ORN
4
2
24
K5-6 BLK
PCB1 P5-11 YEL
23
TS7-1 BLK
PL3-1 BLK
K3-6 BLK
22
21
TB3-1 BLK
TB1-10 BLK
20
19
18
17
TB3-2 WHT
K3-B WHT
K7-B WHT
TB8-17 WHT
16
15
TB1-12 WHT
PCB1 P2-8 WHT
T3-H2 WHT
14
13
PCB1 P6-3 GRY
12
11
10
PCB1 P6-5 BLK
9
8
PCB1 P6-4 BLU
PCB1 P5-7 YEL
7
PCB1 P5-6 ORN
6
5
PCB1 P5-5 GRY
PCB1 P5-3 BRN
PCB1 P5-2 WHT
PCB4 P1-8 WHT
PCB4 P1-9 ORN
PCB1 P5-4 VIO
4
3
2
1
TB9
PCB1 P5-1 RED
TB1-1 BRN
(LINE)
TB1-8 WHT
3
1
FN4
2
4
CB1-2 BLK
(LOAD)
T2-X1 WHT
TB1-11 WHT
Note: From ESP-400C/600C//400V,50 Hz
Drawing No. 0558002859, sheet 5 of 5
OR
6-42
ESP 400C and 600C Plasma Power Sources
SECTION 6
Troubleshooting
6.7 Wiring Diagrams – Drawing 5 – Part 2 400V 50Hz (P/N 35879)
2
3
1
2
3
1
2
3
1
2
4
5
6
4
5
6
4
5
6
4
5
9
7
9
7
9
7
3
6
8
9
K7-6 YEL
C53
TB9-22 BLK
C25-1 ORN
TB8-19 BLU
T1-AX2 RED
TB7-8 RED
TB9-22 BLK
B
TB9-16 WHT
A
B
TB8-1 BLU
TB8-18 VIO
C54
8
A
TB7-8 RED
TB8-10 BRN
PCB1 P3-2 BLU
K3-9 YEL
B
TB8-2 WHT
8
A
TB8-9 GRY
TB9-16 WHT
C25-2 GRY
TB1-18 BRN
B
TB9-22 BLK
8
A
C26-1 ORN
7
T1-AX1 BLK
K3
K6
K6
K7
1
TB8
TB8
20
K3-A BLU
K7
K5
K6
K3
19
K6-6 VIO
JUMPER
18
TB9-17 WHT
17
T2-X4 RED
16
T2-X3 YEL
15
14
13
TB1-5 BLU
12
TB1-4 ORN
11
K6-7 BRN
10
K6-1 GRY
9
TB1-9 RED
8
TB1-7 BLK
PCB1 P4-5 YEL
5
PCB1 P2-2 ORN
VIEW J-J
7
6
PCB1 P4-4 VIO
4
PCB1 P2-3 BLK
3
K5-B WHT
2
K5-A BLU
1
TS5-2 WHT
VIEW F-F
(WITHOUT BUS BARS)
TB1-18 BRN
2
TS6
1
C2
C1
D1
RED
D2
1
1
3
RED
D4
RED
D5
1
3
C6
C5
D6
RED
3
C18
2
R9
2
R8
C17
R7
2
C16
C15
2
R6
C14
2
R5
2
R4
TS5
1 2
C13
TS5-1 WHT
RED
D3
RED
C4
C1
C3
TS1-2 WHT
3
3
1
C7
3
1
C9
C8
C10
1
C11
C12
TS4
1 2
TS5-1 WHT
TS1-2 WHT
Note: From ESP-400C/600C//400V,50 Hz
Drawing No. 0558002859, sheet 5 of 5
OR
ESP 400C and 600C Plasma Power Sources
6-43
SECTION 6
Troubleshooting
6.8 Wiring Diagrams – 575V 60Hz Drawing 1 – Part 1 (P/N 35880)
D7,D8
C47
C48
D9,D10
D11,
D12
C49
ELECTRODE BUS BLK
YEL
WORK BUS BLU
BLU
BR "C" BUS
BR"A" BUS
D13
D14
BR "B" BUS
D15,
D16
C50
TB10
C51
C37
FN1
FN2
3
WHT
C38
WHT
D17,
D18
C52
TB9-21 BLK TS3-1 WHT C39
D25,
D26
1
D27,
D28
C40
WHT WHT
TS7
2
3
"B" COIL
"B" COIL
K4-T1 YEL
GND4 GRN
X1
GND4 GRN
X1
Section A-A
TB1-10 BLK
TB1-12 BLK
L2
"A" COIL
L1
"A" COIL
PCB4 P1-1 GRN
X1
H1
X1
PCB4 P1-2 GRN/YEL
T9
X3 YEL
TB11-3 YEL
H2
TB11-2 YEL
PCB4 P1-3 GRN
Ammeter
8
Voltmeter
2
1
7
8
PCB4 P1-11 VIO
2
BRN
BLU
ORN
YEL
7
WHT
RED
BLK
GRN
1
X4 YEL
Section B-B
PCB4 P1-12 GRY
B
2
3
PCB4
A
R19-2 ORN
R17-1 YEL
D29/30 BUS WHT
S2-6 GRY
N
K J
H
S2
4 5 6
1 2 3
3
S2-3 RED
R50 2
R50-2 RED
1 TB1-3 VIO
PCB1 P8-2 VIO
TB1-4 ORN
TB1-12
WHT
TB1-11 WHT
FN4-3 BLK
TB1-10-A BLK
M
R24-2 BRN
L
POS PLATE RED
TB1-5 BLU
PCB1 P8-1 GRY
TB1 6
GRY
R50-3 GRY
C
D
P E
R
V S F
U
G
T
B
T2-X2
BLU
PL2
PL3
R51
123
PCB1 P7-15 WHT
S3
PCB1 P7-14 BRN
36
PCB1 P7-13 RED
BR "A"
BUS
F5-1 BLU
R23-1 BRN
L1
FN2-2 BLU
PCB4 P1-4 BLU
PL4
PL5
PCB1 P9-11 VIO
PCB1 P9-5 GRY
TB9-21 BLK
FN1-1 BLK
PCB4 P3-1 BLK
FN1-3 GRN
FN2-3 GRN
TS4-1 WHT
X2
X3
X4 2
X5 TS1
1
"A"
X6
X7
X8
F3-1 BRN
X9
H1
H3
H4
X2
X3
X4 2
X5 TS2
X6 1
X7
X8
X9
T1
H1
H2
"B"
H3
H4
A
K1C-T1.2.3 BLK
GND 4
L2
PCB1 P7-12 VIO
PCB1 P7-11 BLK
BR "C"
BUS
M3-1 WHT
M2-1 WHT
M1-1 WHT
F4-1 BRN
D33 BUS GRY
25
X2
X3
X4 2
"C"
X5
TS3
X6 1
X7
TS7-2 WHT
X8
H1
H2
H3
H4
X9
14
B
PCB4
P1
P3
1 ELECTRODE BUS-BLK
T9-GRN
T9-GRN/YEL
T9-GRN
SHUNT 1-3 -BLU
TB1-15 RED (600C Only)
TB1-16 BLK
TB1-15 (400C Only)
TB9-2 WHT
TB9-1 ORN
PCB4 P1-10 ORN ESP-400C
10 PCB4 P1-9 ORN
11 S4-1 VIO
12 S4-2 GRY
1
2
3
4
5
6
7
8
9
6-44
K1A-T1.2.3 BLK
H2
K1B-T1.2.3 BLK
M3-2 RED
M2-2 RED
M1-2 RED
A
BR "B"
BUS
TB1-18 BRN
TB9-24 YEL
TB9-24 YEL
TB1-9 RED
TB1-10-B BLK
PCB1 P7-10 GRY
K3-4 RED
F5-2 BLU
CB1
PL1
GND 1
J1
TB1-1 BRN
TB1-2 YEL
TB1-4 ORN
TB1-5 BLU
TB1-9 RED
TB1-7 BLK
TB1-8 WHT
GND 5 GRN
TB1-13 GRY
TB1-14 VIO
ELECTRODE BUS
S1
5 6
3 4
1 2
K4-L1 BLK
A
B
C
D
E
F
G
H
J
K
WORK BUS
1
P2-5
P2-6
P2-7
P2-8
P2-1
P2-2
P2-3
P2-4
S4
Note: From ESP-400C/600C//575V
Drawing No. 0558002852, sheet 1 of 5
OR
ESP 400C and 600C Plasma Power Sources
SECTION 6
Troubleshooting
6.8 Wiring Diagrams – 575V 60Hz Drawing 1 – Part 2 (P/N 35880)
M1-3 GRN
M2-3 GRN
F2-1 ORN
K2-L1 BLK
T1-CX4 WHT
GND-2 GRN
1
3
1
R3
2
R1
M1
2
1
2
K2-L3 RED
TB4 BLU
T1-BX2 RED
R2
1
2
K2-L2 WHT
F1-1 VIO
D35-C VIO
ELECTRODE PLATE GRY
2
R21
1
2
R18
1
K4-T2 WHT
F7-2 ORN
F7-1 BRN
TD2 (SPLICE) BLK
C32 (-) BLU
1
1
R22
R19
TD1 (SPLICE) BLK
T1-CX4 WHT
GND-2 GRN
2
2
R16
R17
1
1
3
1
FN4-4 WHT
K1B-L1 YEL
WHT
K1C-L1 BLK
H1
H2
H3
H4
H5
H6
H7
X1
T2
X2
X3
X4
GND 3 GRN
M2
2
2
2
T1-BX2 RED
F4-2 BLK
CB1-1 BLU
S1-1 YEL
ORN
TB8-15 YEL
S1-3 ORN
1
R20
2
1
R23
2
TB8-16 RED
C27(-) WHT
POS PLATE BLU
K4-L3 RED
T1-AX7 BRN
GND 3
Note: From ESP-400C/600C//575V
Drawing No. 0558002852, sheet 1 of 5
OR
ESP 400C and 600C Plasma Power Sources
6-45
SECTION 6
Troubleshooting
6.8 Wiring Diagrams – 575V 60Hz Drawing 2 – Part 1 (P/N 35880)
SEE VIEW K-K
F
F
E
E
D
K1A
K1C
K1B
K2-B WHT
R33
C26
R32
TB1-11 WHT
1
1
2
K7-9 ORN
K4-B ORN
K2-A ORN
C25
2
K1C-B GRY
K7-7 GRY
R2-1 VIO
K2
K1C-A ORN
F1
K3-7 ORN
R3-1 ORN
NEG PLATE
TB5 GRY
F2
S1-4 RED
TB6 BRN
TB4
TB5
C33(+) RED
R26-2 RED
TB6
C34-2 BLK
BLK
D34
POS PLATE
D33
T1-CX7 GRY
SECTION C-C
R25-2 GRY
ELECTRODE PLATE
SEE VIEW L-L
D
R28-2 YEL
T2-H1 YEL
TB5 BLK
TB5 BLK
K1A-A/K1C-A ORN
K1B-L1 BLK
TB5 BLK
K1B-B GRY
K1B-L2 BLK
K1A-B/K1C-B GRY
TB4 BLK
K1B-A/C25-1 ORN
TB4 BLK
TB6 BLK
TB4 BLK
K1B-L3 BLK
K1C-L1 BLK
K1A-L3 BLK
K1C-L2 BLK
T2-H6 BLK
K1A-L2 BLK
K1C-L3 BLK
TB6 BLK
TB6 BLK
K1A-L1 BLK
TB4
L1
L2
L3
K1B-A ORN
A K1A
B
L1
L2
L3
A K1B
L1
B
L2
A K1C
TB5
TB6
R1-1 BLU
L3
K1-B/C25-2 GRY
B
F2-2 GRN
F1-2 GRY
T1-AH1 BLK
T1
T2
T3
T1
T2
T3
T1
T2
T3
T1-AH1 BLK
K2-T3 RED
T1-AH1 BLK
K2-T2 WHT
K2-T1 BLK
C60
T1-BH2/CH1 BLK
C61
C62
T1-AH2/BH1 BLK
R3-2 RED
T1-AH2/BH1 BLK
T1-AH2/BH1 BLK
R2-2 WHT
R1-2 BLK
C26-1 ORN
K1A-T3 BLK
K1B-T3 WHT
K1C-T3 RED
6-46
L1
L2
T1
T2
R55
B
T3
R57
R56
VIEW L-L
L3
C26-2 WHT
A K2
400V 50HZ
UNITS ONLY
T1-BH2/CH1 BLK
T1-BH2/CH1 BLK
VIEW K-K
Note: From ESP-400C/600C//575V
Drawing No. 0558002852, sheet 2 of 5
OR
ESP 400C and 600C Plasma Power Sources
SECTION 6
Troubleshooting
6.8 Wiring Diagrams – 575V 60Hz Drawing 2 – Part 2 (P/N 35880)
C23-2 VIO
C24-1 VIO
C10(+) WHT
C4(+) WHT
C
1
2
R10
G
R54
1 2
R53
1 2
C2(+) BLU
C2(-) YEL
C8(+) BLU
C8(-) YEL
1
R11
2
T1-CX4 WHT
T1-BX2 RED
M3
G
C
T2
"A"
"C"
"B"
X1
X1
X1
F9
F8
K7-4 BLK
K5-9 RED
SECTION D-D
4
5
6
7
TB1-9 RED
3
8
9 10 11 12 13
K6-9 RED
2
F7-1 BRN
1
PCB1 P4-1 WHT
TB7
PCB1 P6-1 ORN
R45
VIEW G-G
R52
TB7
PRA1 YEL
NEGATIVE PLATE
PCB1 P7-9 BLU
NEG PLATE YEL
PRA1
C28(+) BLU
ELECTRODE PLATE GRY
R20-2 BLU
PCB1 P5-9 BLK
F3-2 BLK
K4-T3 ORN
D31
D32
C43 C44
BLK
POS
PLATE
ORN
C41 C42
D29
D30
C27(-) WHT
S1-2 WHT
ELECTRODE PLATE
PRA1 GRY
C29(-) GRY
R21-2 GRY
TD2 (SPLICE) GRY
TD1 (SPLICE) GRY
Note: From ESP-400C/600C//575V
Drawing No. 0558002852, sheet 2 of 5
OR
ESP 400C and 600C Plasma Power Sources
6-47
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.
PCB1 P7-1
PCB1 P7-4
PCB1 P7-2
PCB1 P7-3
P1 1 2 3 4
P1
1
2
3
4
TB11-1 BLU
1
2
3
4
PCB4 P1-4 BLU
P1
PCB1 P1-2 BLK(TP)
P1 1 2 3 4
PCB1 P7-5
PCB1 P7-8
PCB1 P7-6
PCB1 P7-7
BLK
RED
GRN
WHT
R16-2 (SPLICE) BLK
(-)
SH1
(+)
3
R17-2 (SPLICE) BLK
D20-2 BRN
1
R13
1
R12
TD1
TD2
2
1
R15
1
R14
2
D20-1 ORN
D19-1 ORN
ELECTRODE PLATE (SPLICE) GRY
D19-2 BRN
2
2
D22-1 ORN
D21-1 ORN
ELECTRODE PLATE (SPLICE) GRY
D22-2 BRN
D21-2 BRN
R22-2 BLK
T1-CX5 BRN
TB11-8 RED
S1-6 BRN
F6-1 VIO
C29(-) GRY
T1-BX7 BRN
D31-A BLK
2
2
2
2
C32
1
K4
L1
A
T3
T2
T1
1
F5
2
1
F6
2
1
F7
2
2
2
F3
C29
C27
+
R31
+
R31-2 GRY
D29/D30 BUS WHT
R16-1 WHT
GRY 2
R41
L2
1
2
R43
2
BLK
C34
R40
R34
R25-1 YEL
BLK
B
2
R37
L3
D34-A BLK
C31
D35
R21-1 VIO
R27-2 VIO
ELECTRODE PLATE GRY
F4
1
C32(-) BLU
D33 BUS GRY
POS PLATE RED
D35-C VIO
+
R30
R28
R39
1
C33
1
2
1 RED 1
1
VIEW E-E
K4-T1 YEL
F6-2 VIO
K4-T2 WHT
R31-1 VIO
C29 (+) VIO
C28 (+) BLU
R18-1 ORN
H
C29(+) VIO
ELECTRODE PLATE YEL
C33(+) RED
C34-1 YEL
C35-1 BRN
C36-1 ORN
1
6-48
POS PLATE BLU
J
J
C36
+
R44
R30-1 BLU
T1-BX5 BLU
R27-1 ORN
1
C28
2
1
1
R29-1 RED
POS PLATE RED
R29-2 BLU
C36-2 BLU
R22-1 BLU
R36
C32(-) BLU
+
1
C30
R42
R29
R38
R25
T1-AX5 BLU
R24-1 VIO
TB7-5 BRN
R19-1 BRN
R26
C35
R23-2 RED
S1-5 BLK
C26-1 ORN
PCB1 P2-5 YEL
D32-A ORN
C30-2 WHT
R18-2 WHT
C30-1 YEL
TB10 YEL
R27
BLK
R35
2
R26-1 BRN
H
Note: From ESP-400C/600C//575V
Drawing No. 0558002852, sheet 3 of 5
OR
ESP 400C and 600C Plasma Power Sources
SECTION 6
Troubleshooting
6.8 Wiring Diagrams – 575V 60Hz Drawing 4 (P/N 35880)
PCB2
PCB3
P1
P2
1
2
3
4
5
6
1 PCB1 P10-1 BLK
2 PCB1 P10-2 WHT
3 PCB1 P10-3 GRN
4 PCB1 P10-4 RED
5 PCB1 P10-7 BLU
6 PCB1 P10-8 ORN
7 PCB1 P10-9 YEL
8 PCB1 P10-10 BRN
9 PCB1 P10-5 GRY
10 PCB1 P10-6 VIO
PCB2 P2-3
PCB3 P2-2
PCB2 P2-1
PCB3 P2-4
PCB3 P2-3
YEL
CLR(TP)
YEL
SHLD
BLK(TP)
P5
1 T5-X1 BRN
2 T5-X4 GRN/YEL
3 T5-X7 RED
P1
P2
1 PCB1 P11-1 BLK
2 PCB1 P11-2 WHT
3 PCB1 P11-3 GRN
4 PCB1 P11-4 RED
5 PCB1 P11-7 BLU
6 PCB1 P11-8 ORN
7 PCB1 P11-9 YEL
8 PCB1 P11-10 BRN
9 PCB1 P11-5 GRY
10 PCB1 P11-6 VIO
1
2 PCB2 P2-2 CLR(TP)
3 PCB2 P2-5 BLK(TP)
4 PCB2 P2-4 SHLD(TP)
5
6
P5
1 T7-X1 BRN
2 T7-X4 GRN/YEL
3 T7-X7 RED
P6
P6
1 T6-X1 BRN
2 T6-X4 GRN/YEL
3 T6-X7 RED
1 T8-X1 BRN
2 T8-X4 GRN/YEL
3 T8-X7 RED
PCB2 P5-1 BRN
RY
G
X2X1
X3
T5
X4
L X5
YE
X6
X7
U
L
B
PCB2 P5-3 RED
GR
PCB2 P5-2 GRN/YEL N
T5-H2 BLK
H2
PCB3 P6-1 BRN
Y
R
T6-H1 BLK
TB2-1 BLK
G
T5-H1 BLK
H1
TB2-2 BLK
X2X1
X3
T8
X4
L
YE X5
X6
X7
LU
B
PCB3 P6-3 RED
GR
PCB3 P6-2 GRN/YEL N
TB3-1 BLK
TB3
1
T8-H2 BLK
TB3-2 WHT
2
TB3-2 BLK
H2
T8-H1 BLK
T7-H1 BLK
TB2
1
TB3-1 BLK
H1
2
T7-H2 WHT
T6-H2 WHT
R15-2 ORN
R15-1 BRN
C11
C5 +
T5
PCB3 P3 BLK
C20
TB9-15 WHT
TB3
C22
T8
D20
+
2
1
D22
Q4-C BLK
P6
P5
E
TB2-2 WHT
C12
+
R52-1 VIO
R13-1 BRN
TB2
R13-2 ORN
C6 +
TB2-1 BLK
TB9-20 BLK
C
E
Q4 C
C10
C4 +
P3
+
P2
2
2
C9
C23
D24
D23
C3 +
PCB2
P1
PCB3
C24
+
P1
1
1
C2 +
K2
C8
P2
+
E
P3
Q1-C BLK
Q3 C
C Q1
E
P5
P6
C1 +
C7
1
D19
2
D21
T6
T7
C19
TB2-1 BLK
H1
R14-1 BRN
R54-1 VIO
R14-2 ORN
R11-2 YEL
R11-1 BLU
R54-2 WHT
R10-2 BLU
R53-2 WHT
R10-1 YEL
R12-2 ORN
H2
PCB2 P3 BLK
B
X7
X6
L
X5
YE PCB2 P6-2 GRN/YEL
X4
T6
X3 GR
N
X2
X1
R12-1 BRN
PCB2 P6-3 RED
LU
TB2-2 WHT
C21
+
PCB3 P5-3 RED
LU
B
G
RY
PCB2 P6-1 BRN
TB3-2 WHT
VIEW F-F (WITH BUS BARS)
TB3-1 BLK
H2
H1
X7
X6
L
X5
YE PCB3 P5-2 GRN/YEL
X4
T7
X3 GR
N
X2
X1
G
R
Y
PCB3 P5-1 BRN
Note: From ESP-400C/600C//575V
Drawing No. 0558002852, sheet 4 of 5
OR
ESP 400C and 600C Plasma Power Sources
6-49
SECTION 6
Troubleshooting
6.8 Wiring Diagrams – 575V 60Hz Drawing 5 – Part 1 (P/N 35880)
PCB1
P1
P6
1 SH1(+) CLR(TP)
2 SH1(-) BLK(TP)
3 TB1-6 GRY
SH1-3 SHLD
1
2
3
4
5
6
P2
1
2
3
4
5
6
TB8-4 ORN
TB8-3 BLK
P3
TB1
PL3-2 BRN
TS6-2 BRN
K7-A BRN
18
P4
1
2
3
4
5
17
PCB4 P1-6 BLK
SH1(-) BLK(TP)
16
PCB4 P1-5 RED
J1-K VIO
SH1(+) RED(TP)
15
1
2
3
4
5
6
12
WHT
11
PL1-1 BLK
CB1-2 BLK
TB9-20 BLK
T9-H1 BLK
TB7-8 RED
10
PL2-1 RED
J1-E RED
9
J1-G WHT
TB8-8 RED
FN4-2 WHT
8
J1-F BLK
FN4-1 BLK
PCB1 P1-3 GRY
PCB1 P4-2 GRY
7
TB8-7 BLK
S2-6 GRY
S2-4 BLU
J1-D BLU
J1-C ORN
S2-1 ORN
1 TB9-1 RED
2 TB9-2 WHT
3 TB9-3 BRN
4 TB9-4 VIO
5 TB9-5 GRY
6 TB9-6 ORN
7 TB9-7 YEL
8 TB9-8 VIO
9 PRA1-BLK
10 T3-X1 BRN
11 TB9-24 YEL
T3-X4 GRN/YEL
12 T3-X7 RED
6
C45
J1-H GRN
TB8-12 BLU
5
GND 5
TB8-11 ORN
4
C46
P10
1 PCB3 P1-1 BLK
2 PCB3 P1-2 WHT
3 PCB3 P1-3 GRN
4 PCB3 P1-4 RED
5 PCB3 P1-9 GRY
6 PCB3 P1-10 VIO
7 PCB3 P1-5 BLU
8 PCB3 P1-6 ORN
9 PCB3 P1-7 YEL
10 PCB3 P1-8 BRN
11
12
S2-5 GRY
S2-2 VIO
T4-X1 BRN
T4-X4 GRN/YEL
T4-X7 RED
P11
1 PCB2 P1-1 BLK
2 PCB2 P1-2 WHT
3 PCB2 P1-3 GRN
4 PCB2 P1-4 RED
5 PCB2 P1-9 GRY
6 PCB2 P1-10 VIO
7 PCB2 P1-5 BLU
8 PCB2 P1-6 ORN
9 PCB2 P1-7 YEL
10 PCB2 P1-8 BRN
11
12
PCB1 P5-8 VIO
R50-1 VIO
3
J1-B YEL
VIO
VIO
VIO
VIO
VIO
PL5(+) VIO
12 TB11-2 YEL
13 TB11-4 YEL
14
P8
TB8-5 VIO
TB8-6 YEL
P5
T9-H2 WHT
T4-H2 BLK
TB9-14 WHT
C26-2 WHT
FN4-4 WHT
T4-H1 BLK
13
PL1-2 WHT
PL2-2 WHT
TB7-7 WHT
TB1-6 GRY
14
J1-J GRY
PL4(+) GRY
1 TD1 P1-1 BLK
2 TD1 P1-3 GRN
3 TD1 P1-4 WHT
4 TD1 P1-2 RED
5 TD2 P1-1 BLK
6 TD2 P1-3 GRN
7 TD2 P1-4 WHT
8 TD2 P1-2 RED
9 PRA1- BLU
10 R51-1 GRY
11 R51-2 BLK
12 R51-3 VIO
13 S3-1 RED
14 S3-2 BRN
15 S3-3 WHT
1
2 K6-A BLU
3 PCB1 P2-6 WHT
PCB1 P6-2 WHT
GRY
GRY
GRY
GRY
6
7
8
9
10
11
P7
K4-A YEL
TB9-14 WHT
PCB P3-3 WHT
7 FN3-4 ORN
8 FN3-3 GRY
P9
1
2
3
4
5
TB7-9 ORN
PCB1 P3-3 WHT
TB9-11 GRY
TB9-10 BLU
TB9-9 BLK
FN3-2 YEL
2
FN3-1 BRN
J1-A BRN
1
P7
H1
PCB1 P5-10 BRN
T4
LU
L
YEPCB1 P8-5 GRN/YEL
GR
N
T3
PCB1
TB1
P5
Y
T4
TB1-10 BLK
X6
X5
X4
X3
X2
X1
R
X7
H2
G
B
TB1-12 BLK
P6
P8
PCB1 P8-6 RED
P9
X2
X3
GR
PCB1 P5-11 GRN/YEL N
P10
P11
P1
G
GND5
P2
P3
YE
P4
L
RY
PCB1 P8-4 BRN
PCB1 P5-12 RED
FN4
X1
X5
X6
B
LU
TB9-20 BLK
T3
X4
TB9-15 WHT
X7
FN3
TB9
VIEW H-H
JUMPER
K6-B BLK
JUMPER
T3-H1 BLK
JUMPER
JUMPER
JUMPER
PL4(-) YEL
PL5(-) YEL
TB1-7 BLK
BLK
PCB1 P2-8 GRY
3
1
FN3
(LINE)
TB1-2 YEL
(LOAD)
PCB1 P2-7 ORN
4
2
24
K5-6 BLK
PCB1 P5-11 YEL
23
TS7-1 BLK
PL3-1 BLK
K3-6 BLK
22
21
TB3-1 BLK
TB1-10 BLK
20
19
18
17
TB3-2 WHT
K3-B WHT
K7-B WHT
TB8-17 WHT
16
15
TB1-12 WHT
PCB1 P2-8 WHT
T3-H2 WHT
14
13
PCB1 P6-3 GRY
12
11
10
PCB1 P6-5 BLK
9
8
PCB1 P6-4 BLU
PCB1 P5-7 YEL
7
PCB1 P5-6 ORN
6
5
PCB1 P5-5 GRY
PCB1 P5-3 BRN
PCB1 P5-2 WHT
PCB4 P1-8 WHT
PCB4 P1-9 ORN
PCB1 P5-4 VIO
4
3
2
1
TB9
PCB1 P5-1 RED
TB1-1 BRN
(LINE)
TB1-8 WHT
3
1
FN4
2
4
CB1-2 BLK
(LOAD)
T2-X1 WHT
TB1-11 WHT
Note: From ESP-400C/600C//575V
Drawing No. 0558002852, sheet 5 of 5
OR
6-50
ESP 400C and 600C Plasma Power Sources
SECTION 6
Troubleshooting
6.8 Wiring Diagrams – Drawing 5 – Part 2 575V 50Hz (P/N 35880)
2
3
1
2
3
1
2
3
1
2
4
5
6
4
5
6
4
5
6
4
5
7
8
9
7
8
9
7
8
9
7
6
8
9
K7-6 YEL
C53
TB9-22 BLK
B
TB9-16 WHT
C25-1 ORN
TB8-19 BLU
T1-AX2 RED
TB9-22 BLK
TB7-8 RED
B
TB8-1 BLU
TB7-8 RED
C54
3
A
TB8-2 WHT
A
TB8-18 VIO
B
TB9-22 BLK
TB8-10 BRN
PCB1 P3-2 BLU
TB8-9 GRY
K3-9 YEL
A
C26-1 ORN
TB1-18 BRN
C25-2 GRY
B
TB9-16 WHT
A
T1-AX1 BLK
K3
K6
K6
K7
1
TB8
TB8
20
K3-A BLU
K7
K5
K6
K3
19
K6-6 VIO
JUMPER
18
TB9-17 WHT
17
T2-X4 RED
16
T2-X3 YEL
15
14
13
TB1-5 BLU
12
TB1-4 ORN
11
K6-7 BRN
10
K6-1 GRY
TB1-9 RED
PCB1 P4-5 YEL
7
6
PCB1 P4-4 VIO
5
PCB1 P2-2 ORN
VIEW J-J
9
8
TB1-7 BLK
4
PCB1 P2-3 BLK
3
K5-B WHT
2
K5-A BLU
1
TS5-2 WHT
VIEW F-F
(WITHOUT BUS BARS)
TB1-18 BRN
2
TS6
1
C2
C1
D1
RED
D2
3
1
RED
D4
1
RED
D5
1
3
C6
C5
D6
RED
3
C18
2
R9
2
R8
C17
R7
2
C16
C15
2
R6
2
C14
2
R5
1 2
R4
TS5
C13
TS5-1 WHT
RED
D3
RED
C4
C1
C3
TS1-2 WHT
1
3
C7
3
3
1
C9
C8
C10
1
C11
C12
TS4
1 2
TS5-1 WHT
TS1-2 WHT
Note: From ESP-400C/600C//575V
Drawing No. 0558002852, sheet 5 of 5
OR
ESP 400C and 600C Plasma Power Sources
6-51
SECTION 6
Troubleshooting
6.9 PC Controller Board (PCB1,P/N 38032, REV C) Schematics
6-52
ESP 400C and 600C Plasma Power Sources
Drawing 1 Part 1
SECTION 6
Troubleshooting
6.9 PC Controller Board (PCB1-P/N 38032) Schematics - Drawing 1 Part 2
ESP 400C and 600C Plasma Power Sources
6-53
SECTION 6
Troubleshooting
6.9 PC Controller Board (PCB1-P/N 38032) Schematics - Drawing 2 Part 2
1
2
3
4
5
6-54
ESP 400C and 600C Plasma Power Sources
SECTION 6
Troubleshooting
6.9 PC Controller Board (PCB1-P/N 38032) Schematics - Drawing 2 Part 2
1
2
3
4
5
ESP 400C and 600C Plasma Power Sources
6-55
SECTION 6
Troubleshooting
6.9 PC Controller Board (PCB1-P/N 38032) Schematics - Drawing 3
6-56
ESP 400C and 600C Plasma Power Sources
SECTION 6
Troubleshooting
6.10 PCB Digital Meter Board (PCB4-P/N 38139)
ESP 400C and 600C Plasma Power Sources
Drawing 1
6-57
SECTION 6
Troubleshooting
6.10 PCB Digital Meter Board (PCB4-P/N 38139)
1
Drawing 2 Part
1
2
3
4
5
6
6-58
ESP 400C and 600C Plasma Power Sources
SECTION 6
Troubleshooting
6.10 PCB Digital Meter Board (PCB4-P/N 38139)
Drawing 2 Part 2
1
2
3
4
5
6
ESP 400C and 600C Plasma Power Sources
6-59
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
1.0
2W
20V
TP28
TP17
2
20V
P1-08
1
IC04
13
R33
TP27
R49
1M
R50
100K
IC09
R25
1K 12
D09
+15Z
MAX˜-0.5V
Z
R39
R43
14
10
D50 D51
#
R37
TP16
R44
10
TP23 1M
C19
D12
C25.47
R45
1
TP21
.47
10K
9
D11
15
7
C26 .01
D10
R36
IC07
C20
TP13
680
8
16
1/2W 13
2 10
R31 2
Q2
C24 .47
R26
R35 .47
R46
2N4401
10K
IC05 6 499
10
#
10
+
3 34001
R40
ANALOG
R82
-15Z
R83 10K
ISOLATOR
TP24
221
TP22
R42
COMPARATOR
#
OFF
C54
T
Z
Q3
ON
R38
.01
TP25
+15Z
1KV
20K
R47
C21
.01
1M R48
IC08
100K
Q6
IC10
IGBT SAT
C52 R85
Z
SS CONTACTOR
.01 100K LOSS
P6-1
Q7
D08
R32 C17
221 560
PF
TP20
+15Z
MIN ˜+4.5V
P1-07
6-60
P2-3
CW
POT1
10K
Z
TP26
P1-10
Z
R59
1.0 C32
2W
.10
C33
.10
H
9
BR2
+
3
IC02
555
P2-1
+15Z
1
14
TP11
VDD Q
5
3 CLK
D
1
R22
4013
9
IC04 3
12=OPEN Q 2
1K
10R 13=OPEN
2
11
SETVSS R S TP06
8 7 4 6
R20
3.32K
8
C14
.47
Z
+15Z
R24
1K
~
4
C13
.47
TP12
~
POT5
10K
CW
POT1˜3.32K
P2-4
P2-2
P2-5 P2-6
-
R23
10
R19
10
P1-01
+15Z
R29
10
TP05
5 14 4
IC04
6 7
+15Z
CLOCK OSCILLATOR
20KHZ
Drawing 1 Part 1
+ C28
1000
10
+ C31
1000
LED3
11
IC08
SS CONTACTOR
TP30 221
ESP 400C and 600C Plasma Power Sources
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
.47
-15Z
POWER CONNECTIONS FOR IC1
ZD2
+15Z
REG1 OUT
7815
R13
D02
D01 C09 + 3.32K
TP08
LED1
3.3
IN
BR1
R09
2W 1.0
.10 C02
P5-2
P5-3
R15
10
TP01
4
Z
+15Z
R81
10K
C03
.10
D03
~
TP14
6
IC01
3 + 34001
R30
1
20V
10K
CW
TP07
C01
.10
+
POT2SPAN
R16
22.1K
TP02
Z
20V
D07
R08
2W 1.0
-
TP15
P5-1
~
POSITION
R80
R11
20K
10K
R10 POT6
10K
10K
+ C50
3.3
POWER CONNECTIONS FOR IC5
IGBT 2
G
E
R06
2.2 1W
# R07
2.2 1W
E
IGBT 3
G
ZD6
ZD5
E
E
D14
TP33
9
IN
REG3
7815
D15
OUT
D16
+15H
R53
R57
R56
3.32K IC09
15K
1K
C29 +
LED4
1000
2 1
10
D19
11
IN
H
7912
REG4
D17
D18
R54
C30 + 3.32K
LED5
1000
Q8
R58
10K
OUT
-12H
TP34
# LEAVE OFF BOARD
ESP 400C and 600C Plasma Power Sources
6-61
SECTION 6
Troubleshooting
6.11 IGBT Driver Board (PCB2,3 – P/N 38030)
6-62
ESP 400C and 600C Plasma Power Sources
Drawing 2
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.
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.
ESP-600C Plasma Power Source -
7-1
SECTION 7
Replacement Parts
7.3 Outside View – Front And Back
22
11
12
10 9
8
7
6
5
4
17
3
18
13
21
2
14
15
1
16
19
7-2
20
ESP-600C Plasma Power Source -
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 #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
Label Set –ESP-600C
18
1
19
1
20
5
951528
32324GY,BK,D
G
35822GY,BK,D
G
993426
21
1
Switch Toggle SPDT 2 pos 10A 250V Q/D
22
1
634516
35750GY,BK,D
G
Plate Cover ESP-600C
Access Door
Grommet Rubber 1.5 ID
S4
Rear Panel
ESP-600C Plasma Power Source -
7-3
SECTION 7
Replacement Parts
7.4 Front View With PCBs Exposed
P2
P1
1
View with LED meter panel removed
5
10
6
3
4
7
View with PCB Cover Removed
7-4
10
(T-4)
2
ESP-600C Plasma Power Source -
8
9
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
7.5 Right Side View
5
4
6
10
7
3
8
9
8
7
2
12
10
11
1
7-6
ESP-600C Plasma Power Source -
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 Resistor Assembly
PRA1
12
6
950631
PC Board Support
ESP-600C Plasma Power Source -
7-7
SECTION 7
Replacement Parts
7.6 Left Side View
8
4
3 x4
1
5
5
7
9
10
11
7-8
6
ESP-600C Plasma Power Source -
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, Saturable Amorphos
10
11
1
ESP-600C Plasma Power Source -
7-9
SECTION 7
Replacement Parts
7.7 Top View
7-10
ESP-600C Plasma Power Source -
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 .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
8
2 pr
951951
IGBT Matched Pair 600A 600V
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
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
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
D1-6
9
Shunt 100mV 500A
SH1
18
ESP 600C Plasma Power Source CE
C27,28
7-11
SECTION 7
Replacement Parts
7.8 Back Inside View
4
2
2
1
7-12
ESP-600C Plasma Power Source -
3
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
7.9 Middle Cross Section
2
3
4
3
1
F9
F8
5
7-14
ESP-600C Plasma Power Source -
2
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
7.10 Front Cross Section –Behind Front Panel
2
1
3
4
4
5
6
7
7-16
7
ESP-600C Plasma Power Source -
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
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7-18
ESP-600C Plasma Power Source -
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. Modified bottom diagram
and changed note to read – “Disconnect negative connection from secondary power source and insulate to convert from two to one power source” on page 3-7.
2. 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.
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
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