ESP-600C Cutting Power Source: Instruction Manual

F-15-237
October, 1995
INSTRUCTION MANUAL
ESP-600C
Cutting Power Source
A
5
4
200 300 400 6
100 500 3
0 7
600
D-C AMPERE
S
8
MIN
MAX
V HIGH CURRENT MAIN
PILOT POWER
ARC PANEL
20 30
10 40
0 OVER
50 TEMP
LOW REMOTE
D-C VOLTS
CONTACTOR
ON
FAULT
POWER
RESET
FAULT
This manual provides installation, operation, maintenance, and troubleshooting instructions for the following units:
ESAB P/N 35609 - 460 V ac, 60 Hz

ESAB P/N 35610 - 400 V ac, 50 Hz
ESAB P/N 35611 - 575 V ac, 60 Hz
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe
practices for arc welding equipment, we urge you to read our booklet, "Precautions and Safe Practices for Arc Welding,
Cutting, and Gouging," Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do
NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not
fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions
before installing or operating this equipment.
Be sure this information reaches the operator. ESAB Welding &

You can get extra copies through your supplier. Cutting Products
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying
labels and/or inserts when installed, operated, maintained, and repaired in accordance with the instructions provided.
This equipment must be checked periodically. Defective equipment should not be used. Parts that are broken, miss-
ing, worn, distorted, or contaminated should be replaced immediately. Should such repair or replacement become
necessary, the manufacturer recommends that a telephone or written request for service advice be made to the
Authorized Distributor from whom purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The
user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty
maintenance, damage, improper repair, or alteration by anyone other than the manufacturer or a service facility
designated by the manufacturer.
TABLE OF CONTENTS
SECTION TITLE PAGE
PARAGRAPH
SECTION 1 DESCRIPTION ................................................................................................. 5

1.1 Introduction ....................................................................................................... 5
1.2 Description ........................................................................................................ 5
SECTION 2 INSTALLATION ................................................................................................ 8

2.1 General ............................................................................................................. 8
2.2 Unpacking and Placement ................................................................................ 8
2.3 Input Power Connections .................................................................................. 8
2.4 Output Connections .......................................................................................... 9
2.5 Parallel Installation ............................................................................................ 10
SECTION 3 OPERATION ..................................................................................................... 11

3.1 Introduction ....................................................................................................... 11
3.2 Control Panel .................................................................................................... 11
3.3 Volt-Ampere (Slope) Characteristics ................................................................. 12
3.4 Sequence of Operation ..................................................................................... 12
3.5 Arc Initiation Settings ........................................................................................ 13
SECTION 4 MAINTENANCE ............................................................................................... 16

4.1 General ............................................................................................................. 16
4.2 Cleaning ............................................................................................................ 16
4.3 Lubrication ........................................................................................................ 16
SECTION 5 TROUBLESHOOTING ..................................................................................... 17

5.1 General ............................................................................................................. 17
5.2 Indicators .......................................................................................................... 17
5.3 Fault Isolation .................................................................................................... 18
5.4 Testing and Replacing Components .................................................................. 26
SECTION 6 REPLACEMENT PARTS .................................................................................. 29

6.1 General ............................................................................................................. 29
6.2 Ordering ............................................................................................................ 29
2
SAFETY PRECAUTIONS
WARNING: These Safety Precautions are for 5. Do not use equipment beyond its ratings. For example,
your protection. They summarize precaution- overloaded welding cable can overheat and create a fire
ary information from the references listed in hazard.
Additional Safety Information section. Before 6. After completing operations, inspect the work area to
performing any installation or operating procedures, be make certain there are no hot sparks or hot metal which
sure to read and follow the safety precautions listed below could cause a later fire. Use fire watchers when neces-
as well as all other manuals, material safety data sheets, sary.
labels, etc. Failure to observe Safety Precautions can result 7. For additional information, refer to NFPA Standard 51B,
in injury or death. "Fire Prevention in Use of Cutting and Welding Pro-
cesses", available from the National Fire Protection Asso-
PROTECT YOURSELF AND OTHERS -- ciation, Batterymarch Park, Quincy, MA 02269.
Some welding, cutting, and gouging
processes are noisy and require ear ELECTRICAL SHOCK -- Contact with live
protection. The arc, like the sun, emits electrical parts and ground can cause
ultraviolet (UV) and other radiation and severe injury or death. DO NOT use AC
can injure skin and eyes. Hot metal can cause burns. welding current in damp areas, if move-
Training in the proper use of the processes and equipment is confined, or if there is danger of
ment is essential to prevent accidents. Therefore: falling.
1. Always wear safety glasses with side shields in any work 1. Be sure the power source frame (chassis) is connected
area, even if welding helmets, face shields, and goggles
to the ground system of the input power.
are also required.
2. Use a face shield fitted with the correct filter and cover 2. Connect the workpiece to a good electrical ground.
plates to protect your eyes, face, neck, and ears from 3. Connect the work cable to the workpiece. A poor or
sparks and rays of the arc when operating or observing missing connection can expose you or others to a fatal
operations. Warn bystanders not to watch the arc and shock.
not to expose themselves to the rays of the electric-arc 4. Use well-maintained equipment. Replace worn or dam-
or hot metal. aged cables.
3. Wear flameproof gauntlet type gloves, heavy long-sleeve 5. Keep everything dry, including clothing, work area, cables,
shirt, cuffless trousers, high-topped shoes, and a weld- torch/electrode holder, and power source.
ing helmet or cap for hair protection, to protect against 6. Make sure that all parts of your body are insulated from
arc rays and hot sparks or hot metal. A flameproof apron work and from ground.
may also be desirable as protection against radiated 7. Do not stand directly on metal or the earth while working
heat and sparks.
in tight quarters or a damp area; stand on dry boards or
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cuffs, or pockets. Sleeves and collars should be an insulating platform and wear rubber-soled shoes.
kept buttoned, and open pockets eliminated from the 8. Put on dry, hole-free gloves before turning on the power.
front of clothing 9. Turn off the power before removing your gloves.
5. Protect other personnel from arc rays and hot sparks 10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)
with a suitable non-flammable partition or curtains. for specific grounding recommendations. Do not mistake
6. Use goggles over safety glasses when chipping slag or the work lead for a ground cable.
grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety glasses. ELECTRIC AND MAGNETIC FIELDS —
May be dangerous. Electric current flow-
FIRES AND EXPLOSIONS -- Heat from ing through any conductor causes lo-
flames and arcs can start fires. Hot slag calized Electric and Magnetic Fields
or sparks can also cause fires and ex- (EMF). Welding and cutting current cre-
plosions. Therefore: ates EMF around welding cables and
welding machines. Therefore:
1. Remove all combustible materials well away from the
work area or cover the materials with a protective non- 1. Welders having pacemakers should consult their physi-
flammable covering. Combustible materials include wood, cian before welding. EMF may interfere with some pace-
cloth, sawdust, liquid and gas fuels, solvents, paints and makers.
coatings, paper, etc.
2. Exposure to EMF may have other health effects which are
2. Hot sparks or hot metal can fall through cracks or
crevices in floors or wall openings and cause a hidden unknown.
smoldering fire or fires on the floor below. Make certain 3. Welders should use the following procedures to minimize
that such openings are protected from hot sparks and exposure to EMF:
metal.“ A. Route the electrode and work cables together. Secure
3. Do not weld, cut or perform other hot work until the them with tape when possible.
workpiece has been completely cleaned so that there B. Never coil the torch or work cable around your body.
are no substances on the workpiece which might pro- C. Do not place your body between the torch and work
duce flammable or toxic vapors. Do not do hot work on cables. Route cables on the same side of your body.
closed containers. They may explode. D. Connect the work cable to the workpiece as close as
4. Have fire extinguishing equipment handy for instant use, possible to the area being welded.
such as a garden hose, water pail, sand bucket, or E. Keep welding power source and cables as far away
portable fire extinguisher. Be sure you are trained in its
use. from your body as possible.
11/95
3
FUMES AND GASES -- Fumes and perform any electrical work unless you are qualified to
gases, can cause discomfort or harm, perform such work.
particularly in confined spaces. Do 2. Before performing any maintenance work inside a power
not breathe fumes and gases. Shield- source, disconnect the power source from the incoming
ing gases can cause asphyxiation. electrical power.
Therefore: 3. Maintain cables, grounding wire, connections, power cord,
and power supply in safe working order. Do not operate
1. Always provide adequate ventilation in the work area by any equipment in faulty condition.
natural or mechanical means. Do not weld, cut, or gouge 4. Do not abuse any equipment or accessories. Keep
on materials such as galvanized steel, stainless steel, equipment away from heat sources such as furnaces, wet
copper, zinc, lead, beryllium, or cadmium unless positive conditions such as water puddles, oil or grease, corrosive
mechanical ventilation is provided. Do not breathe fumes atmospheres and inclement weather.
from these materials. 5. Keep all safety devices and cabinet covers in position and
2. Do not operate near degreasing and spraying opera- in good repair.
tions. The heat or arc rays can react with chlorinated 6. Use equipment only for its intended purpose. Do not
hydrocarbon vapors to form phosgene, a highly toxic modify it in any manner.
gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat irritation ADDITIONAL SAFETY INFORMATION -- For
while operating, this is an indication that ventilation is not more information on safe practices for elec-
adequate. Stop work and take necessary steps to im- tric arc welding and cutting equipment, ask
prove ventilation in the work area. Do not continue to your supplier for a copy of "Precautions and
operate if physical discomfort persists. Safe Practices for Arc Welding, Cutting and
4. Refer to ANSI/ASC Standard Z49.1 (see listing below) Gouging", Form 52-529.
for specific ventilation recommendations.
The following publications, which are available from the
American Welding Society, 550 N.W. LeJuene Road, Miami,
CYLINDER HANDLING -- Cylinders, if FL 33126, are recommended to you:
mishandled, can rupture and violently 1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
release gas. Sudden rupture of cylin- 2. AWS C5.1 - "Recommended Practices for Plasma Arc
der, valve, or relief device can injure or Welding"
kill. Therefore: 3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
1. Use the proper gas for the process and use the proper 4. AWS C5.3 - "Recommended Practices for Air Carbon Arc
pressure reducing regulator designed to operate from Gouging and Cutting"
the compressed gas cylinder. Do not use adaptors. 5. AWS C5.5 - "Recommended Practices for Gas Tungsten
Maintain hoses and fittings in good condition. Follow Arc Welding“
manufacturer's operating instructions for mounting regu- 6. AWS C5.6 - "Recommended Practices for Gas Metal Arc
lator to a compressed gas cylinder. Welding"“
2. Always secure cylinders in an upright position by chain 7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.
or strap to suitable hand trucks, undercarriages, benches, 8. ANSI/AWS F4.1, "Recommended Safe Practices for Weld-
walls, post, or racks. Never secure cylinders to work ing and Cutting of Containers That Have Held Hazardous
tables or fixtures where they may become part of an Substances."
electrical circuit.
3. When not in use, keep cylinder valves closed. Have This symbol appearing throughout this manual
valve protection cap in place if regulator is not con- means Attention! Be Alert! Your safety is
nected. Secure and move cylinders by using suitable involved.
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder. The following definitions apply to DANGER, WARNING,
5. For additional information, refer to CGA Standard P-1, CAUTION found throughout this manual:
"Precautions for Safe Handling of Compressed Gases in
Used to call attention to immediate haz-
Cylinders", which is available from Compressed Gas
ards which, if not avoided, will result in
Association, 1235 Jefferson Davis Highway, Arlington,
immediate, serious personal injury or loss
VA 22202.
of life.
EQUIPMENT MAINTENANCE -- Faulty or im- Used to call attention to potential haz-
properly maintained equipment can cause ards which could result in personal injury
injury or death. Therefore: or loss of life.
1. Always have qualified personnel perform the installa- Used to call attention to hazards which
tion, troubleshooting, and maintenance work. Do not could result in minor personal injury.
4
SECTION 1 DESCRIPTION
1.1 INTRODUCTION fans. If the flow of cooling air is inadequate, the ESP-600C
may overheat. If the power source does overheat, ther-
The ESP-600C cutting power source is designed for high mal switches provide protection for the main transformer
speed plasma cutting applications. It is normally used and power semiconductor components. These switches
with equipment such as the ESAB ESP Mechanized automatically reset when the components have cooled to
Plasma System. For cutting currents beyond the rating of their normal operating temperature.
the ESP-600C, two power sources may be connected in
parallel. The ESP-600C may also be operated in parallel Solid state circuitry maintains constant-current output
with the Ultralife-300 or ESP-400 power sources. Refer to independent of component heating and line voltage varia-
figure 1-1 for technical specifications. tions (within ±10% of the rated load). If input voltage falls
substantially outside of the ±10% margin, the power
source will protect itself by safely shutting down.
1.2 DESCRIPTION
Nuisance tripping is reduced by an excitation circuit that
The ESP-600C is a solid state dc power source capable practically eliminates high input currents to the main
of producing 100 to 600 amperes of cutting current at transformer.
100% duty (no cool-down period required). Cutting cur-
rent is regulated either locally from the power source's The ESP-600C is designed for ease of moving and
front panel or remotely from a precision 0-10 volt refer- handling. Sufficient clearance at its base permits lifting
ence (VREF) signal. with a forklift truck. The power source may also be raised
with a crane or hoist using the lifting rings protruding
The ESP-600C uses a ripple cancellation technique to through the top cover.
produce cutting current with an extremely low ripple
current. The result is a longer life for plasma consumables.
Ripple cancellation is achieved by connecting the 180°
phase shifted outputs from two chopper (buck converter)
circuits in parallel.
Use both lifting rings when using a hoist or crane.
Using only one ring may distort and damage the
Internal components are maintained at proper operating
sheet metal parts.
temperatures by forced air drawn through the power
source. This cooling air is generated by three internal
5
ESP-600C ESP-600C ESP-600C

460 V, 60 Hz 400 V, 50 Hz 575 V, 60 Hz
(P/N 35609) (P/N 35610) (P/N 35611)
Voltage 200 V dc
Current Range DC 100 A to 600 A

OUTPUT
(100% DUTY) Power 120 KW
Open Circuit 427 V dc
Voltage (OCV)
Voltage (3-phase) 460 V ac 400 V ac 575 V ac
Current (3-phase) 179 A RMS 206 A RMS 143 A RMS

Frequency 60 Hz 50/60 Hz 60 Hz
INPUT
KVA 142.6 KVA 142.7 KVA 142.4 KVA
Power 129.8 KW 129.9 KW 129.6 KW

Power Factor 91%
Height 40.25 in (102.24 cm)

DIMENSIONS
Width 37.25 in (94.62 cm)
(without skids)
Depth 45.00 in (114.3 cm)
NET WEIGHT 2040 lbs (925.34 kg)
Table 1-1. ESP-600C Specifications
6
Figure 1-1. ESP-600C Functional Block Diagram
7
SECTION 2 INSTALLATION
2.1 GENERAL 2.3 INPUT POWER CONNECTIONS
Proper installation will contribute to safe, satisfactory, and

trouble-free operation of the ESP-600C. This section
should be studied carefully and closely followed.
Electric shock can kill! Take precau-
tionary measures to provide maximum
2.2 UNPACKING AND PLACEMENT protection against electrical shock. Before making
electrical connections between the power source
CAUTION and the line (wall) disconnect switch, be sure that all
Use the two lifting eyes whenever lifting the unit. Do power is off by opening the line (wall) disconnect
not use just one of the lifting eyes. switch.
A. Primary Power
A. Immediately upon receipt of the equipment, in-
spect for damage which may have occurred in
The ESP-600C is a 3-phase unit and must be
transit. Notify the carrier of any defects or dam-
connected to a 3-phase power line. Input power
age at once.
must be provided from a line (wall) disconnect
switch that contains fuses or circuit breakers
B. After removing the components from the ship-
sized in accordance with figure 2-1. Although
ping container(s), check the container(s) for any
equipped with line voltage compensation, it is
loose parts. Remove all packing materials.
suggested that the ESP-600C be connected to a
dedicated power line to prevent impaired perfor-
C. Check air passages of the ESP-600C for any
mance due to an overloaded circuit.
packing materials that may obstruct air flow
through the power source.
B. Input Conductors (not supplied)
D. If the equipment is not to be installed immedi-
Primary power is applied to the ESP-600C through
ately, store it in a clean, dry, well-ventilated area.
four insulated copper conductors (three power
leads and one ground lead) sized in accordance
E. The location of the power source should be
with table 2-1. The leads may consist of a heavy
relatively close to a properly fused supply of
rubber covered cable or may be run in a solid or
electrical power.
flexible conduit.
F. Locate the ESP-600C in an open area where air
NOTE
can circulate freely. If space is at a premium,
Input conductors must be terminated with ring terminals
leave at least 2 feet of clearance between the
sized for ½-inch hardware before being attached to the
nearest obstruction and the front and rear of the
ESP-600C.
power source. Also, keep the area beneath the
power source free of equipment and debris. The
1. Remove the left side panel of the ESP-600C.
area around the power source should be rela-
tively free of dust, fumes, and excessive heat. It
2. Thread the conductor cables through the access
is also suggested to locate the power source so
opening in the rear panel of the ESP-600C.
the top cover and side panels can be removed
easily for cleaning and maintenance.
3. Secure the cables with a strain relief or conduit
coupling (not supplied) at the access opening.
Take precautionary measures to ensure ring termi-

nals have sufficient clearance between the side panel
and main transformer. Also, make sure the input
cables do not interfere with cooling fan rotation.
Otherwise, damage to the ESP-600C and personal
injury may occur.
8
4. Connect the ground lead to the stud on the 2.4 OUTPUT CONNECTIONS
chassis base below the primary terminals as
shown in figure 2-1.
Before making any connections to

the power source output bus bars,
make sure the power source is
It is of the utmost importance that the chassis be deenergized by opening the line (wall)
connected to an approved electrical ground to pre- disconnect switch. To be doubly safe,
vent accidental shock. Be sure the ground lead is have a qualified person check the output bus bars
NOT connected to any primary terminal. (positive and negative) with a voltmeter to be sure all
power is off.
5. Connect the power lead ring terminals to the
primary terminals with the supplied bolts, wash- A. Output Cables (not supplied)
ers, and nuts as shown in figure 2-1.
Select plasma cutting output cables on the basis
6. Connect the input conductors to the line (wall) of one 4/0 AWG, 600-volt insulated copper cable
disconnecth. for each 400 amps of output current. Do NOT use
ordinary 100-volt insulated welding cable.
Rated Load Input & Time-Delay
Gnd. Fuse Size 1. Remove the access panel on the lower-front
Volts Amps Conductor* Amps panel of the power source.
CU/AWG
2. Thread the output cables through the openings at
400 206 4/0 250
the bottom of the front panel or at the bottom of
460 179 3/0 250**
575 143 1/0 200 the power supply immediately behind the front
panel.
* Sizes per National Electric Code for 90 °C rated copper
conductors @ 40 °C ambient. Not more than three conductors in 3. Connect cables to the designated terminals
raceway or cable. Local codes should be followed if they specify
sizes other than those listed above. mounted inside the power source using UL listed
pressure wire connectors.
** During heavy duty cutting at 600 A, input current can
momentarily rise above 200 A and cause nuisance blowing of
200 A fuses. When cutting currents are below 500 A, 200 A fuses
are sufficient.
Table 2-1. Recommended Input Conductor and

Line Fuse Sizes
Figure 2-1. Interconnection Diagram
9
NOTE B. Connect the positive (+) output cables to the

Each bus bar terminal is labeled with a polarity mark to workpiece.
help facilitate a standard plasma hookup (negative bus to
torch electrode and positive bus to the workpiece). For C. Connect the positive (+) and negative (-) connec-
parallel operation connections, refer to paragraph 2.5. tions between the power sources as shown in
figure 2-2.
4. Attach access panel removed in step 1.
D. Connect the pilot arc cable to the "appropriate
5. Complete the plasma system installation in place in power source "No. 1."
accordance with the appropriate instructional
literature. E. Set the PILOT ARC HIGH/LOW switch in power
source "No. 2" to LOW.
2.5 PARALLEL INSTALLATION
F. Set PILOT ARC HIGH/LOW switch in power
source "No. 1" to HIGH.
In order to provide an extended output current range, two
power sources may be connected together forming a
parallel output circuit. See figure 2-2.
NOTE Whenever power source "No. 1" is used

For cutting currents below 200 A, use only one power by itself in a parallel installation, the
source. negative output from power source "No.
2" must be disconnected from power
A. Connect the negative (-) output cables to the source "No. 1." Failure to disconnect
power receptacles located on the plumbing box will make power source "No. 2" electrically "hot"
(high frequency generator) used in the cutting when power source "No. 1" is energized.
setup.
Ensure there is a safe means of disconnecting power
source 2 without exposing any electrical "hot" conduc-
tors. This can be accompished by disconnecting the
Electrode
Work negative output cable of the power source 2 at both ends
First (power source 2 and at the plumbing box). Insulate both
Unit ends with electrical tape.
Second
Unit
4/0, 600 Volt
Cable Jumpers
Between Units
Electrode -
+
-
+
3-4/0, 600 Volt Neg.

Leads to Plumbing
Work Box (Hi-Freq Gen)
3-4/0, 600 Volts
Pos. Leads to Power Receipts
Workplace
Figure 2-2. Parallel Configuration Diagram
10
SECTION 3 OPERATION
3.1 INTRODUCTION D. FAULT indicator illuminates when there are ab-

normalities in the cutting process or when the
This section is intended to familiarize personnel with the input line voltage falls outside of the required
operational procedures applicable to the ESP-600C cut- nominal value by ±10%.
ting power source. Read carefully before operating the
power source. E. POWER RESET FAULT indicator illuminates
when a serious fault is detected. Input power
must be disconnected for at least 5 seconds and
then reapplied.
Never operate the ESP-600C with the top cover or F. PANEL/REMOTE switch controls the location of
side panels removed. In addition to the safety hazard, current control. Place in the PANEL position for
improper cooling may cause damage to internal com- control from the power source (CURRENT po-
ponents. tentiometer). Place in the REMOTE position for
control from an external signal (CNC).
3.2 CONTROL PANEL (FIGURE 3-1) G. PILOT ARC HIGH/LOW switch allows selection
for either high pilot arc and low pilot arc.
A. MAIN POWER indicator illuminates when input
power is applied to the power source. H. Voltmeter displays arc voltage when cutting.
B. OVER TEMP indicator illuminates when the power I. Ammeter displays current while cutting.
source has overheated.
C. CONTACTOR ON indicator illuminates when

the main contactor is energized.
400
A 300 500
400
200 600 200 600
V
0 D-C AMPERES 800
100
0
MAIN
CURRENT POWER
V PILOT HIGH PANEL
ARC OVER
+-
TEMP
200 300
100 400
LOW REMOTE
CONTACTOR
D-C VOLTS
ON
0 500
FAULT
POWER
RESET
FAULT
Figure 3-1. ESP-600C Control Panel
11
SECTION 3 OPERATION
3.3 VOLT-AMPERE (SLOPE) B. Select the location from which welding current
CHARACTERISTICS will be regulated on the PANEL/REMOTE switch,
either locally from the front panel or from a
precision remote reference.
The curves shown in figure 3-2 represent the volt-ampere
static characteristics of the ESP-600C. These curves C. Set PILOT ARC HIGH/LOW switch to HIGH for
show the output voltage available at any given output cutting currents 250 A or higher. Set switch to
current between the minimum and maximum settings of LOW for cutting currents below 250 A.
the "current control pot." Values for other settings fall
between the minimum and maximum curves. The output D. Commence plasma cutting operation in accor-
curve is regulated with precision to within 1% of full output dance with the appropriate system instruction
by the 0-10 volt reference signal (VREF) from the CNC manuals.
control.
E. If a fault light illuminates, refer to section 5 for
3.4 SEQUENCE OF OPERATION troubleshooting information.
A. Apply power by closing the line (wall) disconnect

switch. (The ESP-600C does not have an "ON/
OFF" switch.) The MAIN POWER light will illumi-
nate and the FAULT light will flash and then go
out.
450
427 V - OPEN CIRCUIT
400
I OUT = 80 V REF
THIS OUTPUT IS FROM
DC OUTPUT VOLTAGE (VOLTS)
THE BOOST/START CIRCUIT
MAX. OUTPUT VOLTAGE AT NOMINAL LINE

300
MIN. CURRENT RATING VREF = 1.25 V
MAX. CURRENT RATING VREF = 7.50 V
INTERNAL MAX. CURRENT LIMIT
200
THRESHOLD
OF CURRENT
DETECTOR
VREF = 4.00 V
VREF = 3.00 V
VREF = 2.00 V
VREF = 1.00 V
VREF = 8.00 V
VREF = 7.00 V
VREF = 6.00 V
VREF = 5.00 V
100
0
0 100 200 300 400 500 600 700
DC OUTPUT CURRENT (AMPERES)
Figure 3-2. Volt-Ampere Curves
12
SECTION 3 OPERATION
3.5 ARC INITIATION SETTINGS A. - D. below) must be made to the power source. To
make these modifications, the access panel on the upper-
The ESP-600C is equipped with an arc initiation feature right corner of the front panel must be removed. After the
called Soft-Start. This feature uses a percentage of the settings are changed, make sure the access panel is
cutting current (start current) to ignite the arc and then replaced.
"ramps up" to the full cutting currrent. Figure 3-3 shows
the relationship between start current, dwell time, and up- To disable Soft-Start, locate SW1 on PCB1 (refer to table
slope time. The ESP-600C is factory shipped with Soft- 3-2) and push both rockers down. To enable Soft-Start
Start enabled and with the default settings shown in table again, push both rockers up. Do not leave the rockers in
3-1. In order to change these default settings to suit your different positions.
particular system, internal modifications (see paragraphs
Start Current Waveform vs. Time with Soft-Start OFF (Bang Start) Start Current Waveform vs. Time with Soft-Start ON
DC OUTPUT CURRENT
DC OUTPUT CURRENT
Cut Current Cut Current
IOUT = 80 VREF IOUT = 80 VREF
Dwell Time
approximately 2 msec
rise time
Start
Current
Upslope Time
TIME TIME
Figure 3-3. Start Current Waveforms
A. Minimum Start Current is controlled by the

Minimum Start Current 80 A
selection of positions 5 thru 8 of SW2 on PCB1
Start Current 50% of cut current (refer to figure 3-4). When a rocker is pushed on,
its value (refer to table 3-2) is added to the factory
Up-Slope Time 800 msec set threshold of 40 A.
Dwell Time 50 msec
B. Start Current. Start current is set using the
START CURRENT potentiometer located for-
Table 3-1. Factory Default Settings ward of PCB1 under the access panel. Refer to
table 3-4 for settings. If start current is set at less
than minimum start current (B.), the ESP-600C
will not initiate the cutting arc.
C. Up-Slope Time. A three-position switch located

Electric shock can kill! Take precau- next to the START CURRENT knob is used to
tionary measures to provide maximum change up-slope time.
protection against electrical shock. Be-
fore making electrical connections be- D. Dwell Time. Dwell time is controlled by the
tween the power source and the line (wall) discon- selection of positions 1 thru 4 of SW2 on PCB1.
nect switch, be sure that all power is off by opening When a position rocker is pushed on, its value is
the line (wall) disconnect switch. added to the minimum dwell time of 10 msec.
Refer to table 3-2 for positional values.
13
SECTION 3 OPERATION
SW2 SW1
Figure 3-4. PCB1 Switch Locations
FACTORY DEFAULT POSITIONS SHOWN
#1 - 10 mS DWELL TIME *
#2 - 20 mS DWELL TIME *
1 2 3 4 5 6 7 8 #3 - 40 mS DWELL TIME *
ON #4 - 80 mS DWELL TIME *
#5 - 80 A MIN START CURRENT

OFF #6 - 40 A MIN START CURRENT
NOTES:
Total DWELL TIME equals 10 mS plus the sum of times for SW2 positions 1, 2, 3, and 4 that are
"ON". Factory default DWELL TIME is 10 mS plus 40 mS (position 3) equals 50 mS.
MIN START CURRENT equals 40 A plus the sum of currents for SW2 positions 5, 6, 7, and 8 that
are "ON". Factory default MIN START CURRENT is 40 A plus 40 A (position 6) equals 80 A.
Table 3-2. Switch 2 (SW2) Settings on Control PCB
14
SECTION 3 OPERATION
FACTORY DEFAULT POSITIONS SHOWN
1 2
ON BOTH SWITCHES "ON" - SOFT START
OFF BOTH SWITCHES "OFF" - BANG START
Table 3-3. (SW1) Settings on Control PCB
90.0%
80.0%
70.0%
PERCENTAGE (%) OF CUTTING CURRENT
60.0%
50.0%
40.0%
30.0%
20.0%
10.0%
0.0%
0 1 2 3 4 5 6 7 8 9 10
(MIN) (MAX)
START CURRENT SETTING
Figure 3-5. Start Current Settings
15
SECTION 4 MAINTENANCE
4.1 GENERAL remove the cover from the cabinet and, wearing proper
eye protection, blow accumulated dust and dirt from the
air passages and the interior components using clean low
pressure air. It is imperative that the air passages to the
interior of the unit be kept free of dirt accumulation to
Electric shock can kill! Ensure the line ensure adequate circulation of cooling air, especially over
(wall) disconnect switch or circuit the heat sink extrusions and aluminum heat sinks in the
breaker is open before attempting any front of the power source. This power source is NOT
inspection or work on the inside of the power source. designed to be used with air filters of any kind. Any
Always wear safety goggles with side shields when obstruction to the free flow of cooling air may damage the
blowing out the power source with low pressure air. machine and void the warranty. The length of time be-
tween cleaning will depend on the location of the unit and
Maintenance work must be performed by an experienced the amount of dust in the atmosphere.
person. Do not permit untrained persons to inspect,
clean, or lubricate this equipment. 4.3 LUBRICATION
4.2 CLEANING Fan motors with oil tubes located on the side of the motor
require lubrication after 1 year of service. Motors without
Since there are no moving parts (other than the internal oil tubes are permanently lubricated for life and should not
fans) in the power source, maintenance consists mainly require any attention.
of keeping the interior of the cabinet clean. Periodically,
16
SECTION 5 TROUBLESHOOTING
5.1 GENERAL 5. LED 8 (Amber) - Arc Voltage Cutoff Fault

illuminates when arc voltage increases over the
preset value. The power source is shut down
when this fault is detected. To change the factory
default of 300 volts, refer to paragraph 3.3 in
section 3.
Electric shock can kill! Open wall (line)
B. POWER RESET FAULT Indicator illuminates when a
disconnect switch or circuit breaker
serious fault is detected. Input power must be discon-
before attempting inspection or work
nected for at least 5 seconds and then reapplied to clear
inside of the power source.
this fault. If any of the LEDs listed below are illuminated,
then the power RESET fault indicator will also illuminate.
If the power source does not operate properly, stop work
immediately and investigate the cause of the malfunction.
LEDs on PCB1 (refer to Figure 5-1)
Troubleshooting work must be performed by an experi-
1. LED 6 (Red) - Right Overcurrent Fault illumi-
enced person, and electrical work by a trained electrician.
nates when the current out of the right-side
Do not permit untrained personnel to inspect or repair this
chopper is too high (>375 amps). This current is
equipment. Use only recommended replacement parts.
measured by the right-side hall sensor. The
power source is shut down.
5.2 INDICATORS
2. LED 9 (Red) - Left Overcurrent Fault illumi-
A. The FAULT Indicator illuminates when there are nates when the current out of the left-side chop-
abnormalities in the cutting process or when the input line per is too high (>375 amps). This current is
voltage falls outside of the required nominal value by measured by the left-side hall sensor. The power
±10%. If any of the LEDs listed below are illuminated, source is shut down.
then the FAULT indicator will also illuminate.
3. LED 10 (Red) - Left IGBT Unsaturated Fault
LEDs on PCB1 (refer to Figure 5-1) illuminates when the left IGBT is not fully satu-
1. LED 3 (Amber) - Bus Ripple Fault illuminates rated during its conduction period. The power
when input power is first applied to the power source is shut down.
source and when single-phasing. When single-
phasing, an increased ripple in the bus voltage is 4. LED 11 (Red) - Right IGBT Unsaturated Fault
detected and the power source is shut down. illuminates when the right IGBT is not fully con-
ducting. The power source is shut down.
2. LED 4 (Amber) - High Bus Fault illuminates
when input line voltage is too high for proper 5. LED 12 (Red) - Left -12 V Bias Supply Fault
operation (approx. 20% above nominal line volt- illuminates when the negative (-) 12-volt bias
age rating). The power source is shut down. supply to the left-side IGBT gate drive circuit
(located on PWM-drive board PCB2) is missing.
3. LED 5 (Amber) - Low Bus Fault illuminates The power source is shut down.
when input line voltage is too low for proper
operation (approx. 20% below nominal line volt- 6. LED 13 (Red) - Right -12 V Bias Supply Fault
age rating). The power source is shut down. illuminates when the negative (-) 12-volt bias
supply to the right-side IGBT gate drive circuit
4. LED 7 (Amber) - Arc Voltage Saturation Fault (located on PWM-drive board PCB3) is missing.
illuminates when the cutting arc voltage is too The power source is shut down.
high and cutting current is below the preset level.
LED will extinguish after voltage decreases and
current rises to the preset level.
17
LED 3 LED 4 LED 5 LED 6 LED 7 LED 8
LED 9 LED 10 LED 11 LED 12 LED 13
Figure 5-1. LED Switch Locations
5.3 FAULT ISOLATION If the cause of the malfunction cannot be located quickly,
open the power source and perform a simple visual
Check the problem using the following troubleshooting inspection of all components and wiring. Check for secure
guide (Table 5-1). The potential problems are listed in terminal and plug connections, loose or burned wiring or
"most probable" order, and the remedy may be quite components, bulged or leaking capacitors, or any other
simple. sign of damage or discoloration.
18
Table 5-1. Troubleshooting Guide (Sheet 1 of 7)
PROBLEM POSSIBLE CAUSE ACTION

All three fans do not run. This is normal when not cutting. Fans run None.
only when "CONTACTOR ON" signal is
received.
One or two fans do not run. Broken or disconnected wire in fan motor Repair wire.
circuit.
Faulty Fan(s). Replace fan(s).
Power Supply inoperable: Missing 3-phase input voltage. Restore all three phases of input
MAIN POWER Lamp is off. voltage to within ±10% of nominal line.
Missing one phase of 3-phase input Restore all three phases of input
voltage. voltage to within ±10% of nominal line.
Main Arc transfers to the PANEL/REMOTE switch in "REMOTE" Place PANEL/REMOTE switch in
work with a short "pop" position with no remote control of current. "PANEL" position.
placing only a small dimple
in the work. Remote Current Control present but Check for Current Reference Signal at
signal missing. TB1-4(+) and TB1-5(-). See Figure 3-2
for the value of the Current Reference
Signal versus Output Current.
CURRENT Pot set too low. Increase CURRENT Pot setting.
Start Current Pot, located behind the Increase the Start Current Pot setting to
cover for the Control PCB, is set too low. "7".
FAULT Light illuminates at This is a normal condition caused by Reprogram cutting process to ensure
end of cut but goes off at terminating the arc by running the torch arc is terminated only by removing the
the start of the next. off the work or the arc being attached to a "Contactor On" signal from the unit.
part that falls away.
Power Supply turns off "Contactor On" signal is removed from Power Supply is OK. Troubleshoot
prematurely in the middle unit. process controller.
of the cut.
Momentary loss of primary input power. Restore and maintain input voltage
within ±10% of nominal.
Fault condition, indicated by the Remove Control PCB access panel to

illumination of the FAULT lamp. determine the fault causing the
shutdown, and refer to the specfic fault
in the "Problem" column.
Fault condition, indicated by the Remove Control PCB access panel to

illumination of the POWER RESET determine the fault causing the
FAULT lamp. shutdown, and refer to the specific fault
in the "Problem" column.
Current setting too low. Increase the current setting.
19

Power Supply turns off Remote Current Signal removed during Fix remote Current Signal or operate
prematurely in the middle cut. the Power Supply with the
of the cut - (Cont) PANEL/REMOTE switch in the
"PANEL" position.
FAULT:BUS RIPPLE Imbalanced 3-phase input power. Maintain phase voltage imbalance of
(LED3 - amber) less than 5%.
Momentary loss of one phase of input Restore and maintain input power
power. within ±10% of nominal voltage.
Faulty Control Printed Circuit Board Replace Control PCB P/N 38032.
(PCB).
FAULT:HIGH BUS (LED4 - One or more phases of input voltage Restore and maintain input voltage
amber) exceed nominal line voltage by more than within ±10% of nominal.
20%.
(PCB).
One or more shorted diode rectifiers Replace shorted diode rectifiers.

(D25-D28) on the "ELECTRODE
PLATE".
FAULT: LOW BUS One or more phases of input voltage are Restore and maintain input voltage
(LED5 - amber) lower than nominal line voltage by more within ±10% of nominal.
than 15%.
Blown F1 and F2. See F1 and F2 Blown under the

PROBLEM column.
OVER TEMPerature Light comes on. See "OVER TEMP Light Comes on"
under the PROBLEM column.
Imbalanced 3-phase input power. Maintain phase voltage imbalance of

less than 5%.
Momentary loss of one phase of input Restore and maintain input power
power. within ±10 of
Faulty Main Contactor (K1). Replace K1.
(PCB).
20

POWER RESET FAULT: Output current of the right side exceeds Turn the output current down to 600 A.
RIGHT OVER CURRENT 325 A because of operating the Power
(LED6 - red). Supply over 600 A
NOTE: Cutting at over 300 A with a faulty left See "Faulty Left Side" in PROBLEM
If operation at 300 A or side (left side output = 0 amperes). column.
less is possible, then the
LEFT SIDE is not working. Right Current Transducer connector Secure connector.
See "Faulty Left Side" loose or unplugged Printed Circuit Board
under the PROBLEM (PCB) loose.
column.
Loose or unplugged connector at right Secure connector.
PWM/DRIVE Printed Circuit Board
(PCB).
P2 at left PWM/DRIVE Printed Circuit Secure connector.

Board (PCB) loose or unplugged.
Check the voltage between P7-6 and Replace the Right Current Transducer
P7-7. A voltage in either polarity of (TD2).
greater than 0.10 V indicates a faulty
Right Current Transducer (TD2).
(PCB).
Faulty right PWM/Drive Printed Circuit Replace right PWM/DRIVE PCB P/N
Board (PCB). 38030.
POWER RESET FAULT: Output current of the left side exceeds Turn the output current down to 600 A.
LEFT OVER CURRENT 325 A because of operating the Power
(LED6 - red). Supply over 600 A.
NOTE: Cutting at over 300 A with a faulty right See "Faulty Right Side" in PROBLEM
If operation at 300 A or side (right side output = 0 amperes). column.
less is possible, then the
RIGHT SIDE is not Left Current Transducer connector loose Secure connector.
working. See "Faulty Right or unplugged.
Side" under the PROBLEM
column. P7 at Control Printed Circuit Board (PCB) Secure connector.
loose.
Loose or unplugged connector at left Secure connector.

PWM/DRIVE Printed Circuit Board
(PCB).
P2 at right PWM/DRIVE Printed Circuit Secure connector.

Board (PCB) loose or unplugged.
21

POWER RESET FAULT: Check the voltage between P7-2 and Replace the Left Current Transducer
LEFT OVER CURRENT P7-3. A voltage in either polarity of (TD1).
(LED6 - red) - (Cont) greather than 0.10 V indicates a faulty
Left Current Transducer (TD1).
(PCB).
Faulty left PWM/DRIVE Printed Circuit Replace left PWM/DRIVE PCB P/N
Board (PCB). 38030.
POWER RESET FAULT: Black wire connecting IGBT (Q1) Secure connector.
LEFT IGBT collector to P3 of the left PWM/DRIVE
UNSATURATED (LED10 - PCB (PCB2) is disconnected.
red)
Shorted Freewheeling Diode(s). Replace shorted Freewheeling
Diode(s).
Loose or unplugged P1 connector at the Secure P1 Connector.

left PWM/DRIVE Printed Circuit Board
(PCB).

Control Printed Circuit Board (PCB).
(PCB).
Faulty left PWM/DRIVE Printed Circuit Replace left PWM/DRIVE PCB P/N
Board (PCB). 38030.
POWER RESET FAULT: Black wire connecting IGBT (Q4) Secure connector.
RIGHT IGBT collector to P3 of the right PWM/DRIVE
UNSATURATED PCB (PCB3) is disconnected.
(LED11-red)
Shorted Freewheeling Diode(s). Replace shorted Free Wheeling
Diode(s).

right PWM/DRIVE Printed Circuit Board
(PCB).
Loose or unplugged P11 connector at the Secure P11 connector.

(PCB).
Faulty right PWM/DRIVE Printed Circuit Replace right PWM/DRIVE PCB P/N
Board (PCB). 38030.
22

POWER RESET FAULT: Loose or unplugged P1 connector at the Secure P1 Connector.
LEFT -12V MISSING left PWM/DRIVE Printed Circuit Board
(LED12 - red) (PCB).

Faulty left PWM/Drive Printed Circuit Replace left PWM/DRIVE PCB P/N
Board (PCB). 38030.
POWER RESET FAULT: Loose or unplugged P1 connector at the Secure P1 Connector.
RIGHT -12V MISSING right PWM/DRIVE Printed Circuit Board
(LED13 - red) (PCB).

Faulty right PWM/Drive Printed Circuit Replace right PWM/DRIVE PCB P/N
Board (PCB). 38030.
OK for Cutting at 300 A The side not exhibiting the Over Current See "Faulty Left Side" and "Faulty Right
and Less, but Over Current Fault is not putting out any current. Side" in the PROBLEM column.
Fault occurs over 300 A.
Faulty Left Side - Power Loose or unplugged connector at left Secure connector.
Supply works OK at 300 A PWM/Drive PCB (PCB2).
and less.
Faulty left PWM/DRIVE PCB. Replace left PWM/DRIVE PCB.
Check the voltage between P5-1 and Replace Control Transformer T5.
P5-2 at the left PWM/DRIVE PCB (PCB2)
should be 20 Vac, and between P5-1 &
P5-3 should be 40 Vac. If not, the
Control Transformer (T5) is faulty.
Faulty Right Side - Power Loose or unplugged connector at right Secure connector.
Supply works OK at 300 A PWM/Drive PCB (PCB3).
and less
Faulty right PWM/DRIVE Printed Circuit Replace right PWM/DRIVE PCB.
Board (PCB).
Check the voltage between P5-1 and Replace Control Transformer T7.
P5-2 at the right PWM/DRIVE PCB
(PCB3) should be 20 V ac, and between
P5-1 and P5-3 should be 40 V ac. If not,
the Control Transformer (T7) is faulty.
23

Very Hight Output Current Shunt pickup lead loose. Secure lead.
accompanied by either a
Left or Right Over Current Shorted IGBT Replace the pair of IGBT’s containing
Power Reset Fault. the shorted IGBT.
CURRENT Pot set too high. Lower the current setting.
Faulty left PWM/DRIVE Printed Circuit Replace left PWM/DRIVE PCB.

Board (PCB).
Faulty right PWM/DRIVE Printed Circuit Replace right PWM/DRIVE PCB.

Board (PCB).
High Remote Current signal. Decrease Remote Current signal.
(PCB).
Output current is unstable Place the PANEL/REMOTE switch in the Fix the remote current control signal or
and drifts above or below "PANEL" position and adjust the current operate with the PANEL/REMOTE
the setting. using the CURRENT Control Pot. If switch in the "PANEL" position.
current no longer drifts, the remote
current control signal is faulty.
Place the PANEL/REMOTE switch in the Replace the CURRENT Control Pot.
"PANEL" position and adjust the current
using the CURRENT Control Pot. If
current still drifts, measure the Current
Reference Signal at TB1-4(+) and TB1-5 Replace the Control PCB P/N 38032.
(-). If this signal drifts, the CURRENT
Control Pot is faulty. If this signal does
not drift, then the Control PCB is faulty.
Arc does not start. There Open connection between the Power Repair connection.
is no arc at the torch - Supply Positive Output and the work.
Open Circuit voltage is OK
at 400 - 460 V. 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 Place the PILOT ARC switch in the
"LOW" position when using torch "HIGH" position.
consumables for 250 A or higher cutting.
Pilot Arc Contactor (K4) faulty. Replace K4.
(PCB).
24

Low Open Circuit Voltage. Fuse F3 blown. Replace F3.
Pilot Arc Contactor (K4) faulty. Replace K4.
(PCB).
OVER TEMP lamp One or more fans inoperable. Repair or replace fan motor.
illuminates.
Broken wire or unplugged connector at a Repair broken wires and unplugged
thermal switch. connector.
Faulty (open) thermal switch.
Obstruction to air flow closer than 2 feet Allow 2 feet minimum between the rear
to rear of Power Supply. of the Power Supply and any object that
may restrict or alter air flow.
Excessive dirt restricting cooling air flow. Clean out excessive dirt, especially in
the extrusions for the IGBT’s 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 Supply.
Fuses F1 and F2 Blown. Process controller ignites Pilot Arc too Process Controller must allow at least
soon after providing the "Contactor On" 300 mS to lapse between the
signal. application of the "Contactor On" signal
and the ignition of the Pilot Arc. Fix
Process Controller logic and replace
fuses.
Faulty Negative (Electrode) Output cable Repair cable.

shorting to earth ground.
Shorted Freewheeling Diode. Replace shorted Freewheeling Diode,

F1 and F2.
One or more shorted diode rectifiers (D13 Replace all diode rectifiers on the "POS
- D18) on the "POS PLATE." PLATE."
One or more shorted diode rectifiers (D7 - Replace all diode rectifiers on the "NEG
D12) on the "NEG PLATE." PLATE."
25
5.4 TESTING AND REPLACING

COMPONENTS b. Remove "incoming" bus bars.
c. Remove PCB2 and PCB3 from IGBTs. (PC

NOTE boards are held in place by four screws each.)
Do not replace a PC board until you have made all of the
checks listed in the previous guide. Always disconnect NOTE
power before removing or installing a PC board. Take When PCB2 and/or PCB3 is removed, the emitter (E) and
great care not to grasp or pull on components when gate (G) of each affected IGBT must be connected
removing a PC board and always place a removed board together with a piece of conductive plastic or jumpered
on a static-free surface. If a PC board is found to be the together to prevent electrostatic damage.
problem, check with your ESAB distributor for a replace-
ment. Provide the distributor with the part number of the d. Remove bus bars between capacitor banks, IGBTs,
board, as well as the serial number of the power source. and freewheeling diodes.
Do not attempt to repair the board yourself. Warranty
on a PC board will be null and void if repaired by NOTE
customer or any unauthorized repair shop. Dressing the shunt pick up leads that provide the current
feedback signal to the control PC board is critical. Failure
A. Power Semiconductor Components to strictly adhere to the proper dressing can cause an
instability or oscillation in the cutting current. This can
The ESP-600C contains three categories of power semi- result in poor torch consumable life.
conductor components; power rectifiers, freewheeling
diodes, and IGBTs. These components are designed to There are two cables which attach to the shunt pickup
provide long, trouble-free operation; however, should a points: A two conductor cable which drives the ammeter
failure occur, they may require replacement. and a 3-conductor cable which provides the current
feedback signal to the control PC board. Dressing of the
1. Power Rectifiers wires from the two conductor cable is not critical. The
following is the current dressing procedure for the 3-
a. Remove top cover and side panels. conductor cable (see Figure 5-2):
b. Locate and disconnect plug in rear of ammeter The breakout point should be physically at the
(attached to one red wire and one black wire). middle of the shunt. The breakout point is the
place where the conductors come out of the outer
c. Remove PILOT ARC switch. insulation jacket.
d. Locate and disconnect blue (positive) and black The black and clear insulated wires must be kept
(negative) wires from rear of voltmeter. next to the shunt and under the cable ties.
e. Locate and disconnect orange and yellow wires The wire terminals for the black and clear insu-
from relay K4. lated wires should be oriented in parallel with the
bus bars as shown in Figure 5-2.
f. Locate and remove two bolts from left-side "floor"
of front panel. It is very important that the crimped portion, the
barrel, of the terminal for the black lead be
g. Locate and remove three bolts from the bottom of pointing to the front panel, and the barrel of the
front panel. terminal for the clear lead be pointing to the rear
panel. It is equally acceptable that the black lead
h. Locate two bolts on right-side "floor" of front barrel point to the rear panel and the clear lead
panel. Remove bolt on left and loosen bolt on barrel point to the front panel. It is not important
right. which barrel points which way, but that one points
to the front and the other to the rear.
i. Swing out front panel to gain access to power
rectifier components. The third wire attaches to the bus bar on the left
by way of the shunt mounting hardware. Dress-
2. Freewheeling Diodes and IGBTs ing of this wire is not critical.
a. Remove top cover.

26
Breakout point Clear wire lies flat

In center of shunt against shunt
Barrels parallel to
bus bars This barrel points in
opposite direction of
barrel with black
lead.
Black wire lies flat

against shunt
Bus Bar
Figure 5-2. Shunt
Refer to Figure 5-3 for proper routing of the free

wheeling diode snubber leads. Failure to route the
leads properly can lead to failure of the free wheeling C17 D5
diodes.
Red Wire
1 2 3
1 2 3
Free Wheeling
Diodes
R8
3 2 1
D6
Snubber
Capacitor Red Wire
C18
Snubber Capacitor
Resistor Self Lead
R9
NOTE 1: Red wire must be routed under capacitor self lead. Terminal on red wire must have 1/8" minimum clearance from the bus bar on diode
terminal number 2.
NOTE 2: The bus bar connecting to terminal number 3 of the free wheeling diodes is not shown for purpose of better visibility.
NOTE 3: Red snubber leads as viewed from rear of power source.
D1 - Left D4 - Right
D2 - Right D5 - Left
D3 - Left D6 - Right
NOTE 4: Sleeve snubber capacitor self leads with sleeving P/N 95193486.
Figure 5-3. Routing of Snubber Leads
27
B. Troubleshooting Procedures 3. Calibration Procedure for Ammeter:
1. Procedure for Determining Shorted Diode Set up the PT-15 torch and cutting conditions for
Rectifiers on the "Neg" Plate": 600 ampere nitrogen cutting. Zero the ammeter
using the adjustment screw on the front of the
a. Perform a visual inspection. Check Fuses F8 meter. Attach the pickup leads of a digital meter
and F9 and replace them if they show signs of capable of 0.1 mV resolution to the shunt. (See
being blown or melted. If any of the diodes are Figure 5-2.)
ruptured or burnt, replace all diodes on the NEG
PLATE. If the diodes appear okay, proceed to Adjust the cutting current so that the digital meter
the next step. reads 75.0 mV. The shunt resistance is 125 µ
ohms (100 mV/800 A), and 75.0 mV corresponds
b. With an ohmmeter on the RX1 scale, place one to 600 A. Adjust the trimpot on the back of the
lead on the NEG PLATE and the second lead on meter to read 600 A.
the BR "A" BUS. A reading of 2 ohms or less
indicates one or more shorted diodes. If any Alternate calibration procedure. Set up the PT-
diodes are shorted, replace all diodes on the 15 torch and cutting conditions for 600 ampere
NEG PLATE. nitrogen cutting. Zero the ammeter using the
adjustment screw on the front of the meter.
c. If either or both fuses, F8 or F9, were open for the Place the PANEL/REMOTE switch on the front
ohmmeter check in step b. above, make two panel to the "PANEL" position. Adjust the CUR-
more ohmmeter readings: measure the resis- RENT Control Potentiometer so that 7.50 V ap-
tance between the NEG PLATE and the BR "B" pear across P8-2(+) of the Control PCB and TB1-
BUS; and measure the resistance between the 6 (-). Run a cut - the current will be 600 A. Adjust
NEG PLATE and the BR "C" BUS. If either the trimpot on the back of the meter to read 600
reading is 2 ohms or less, replace all the diodes A.
on the NEG PLATE.
4. Procedure for Determining Shorted Diode
2. Procedure for Determining Shorted Diode Rectifiers on the "POS PLATE":
Rectifiers on the "Electrode Plate":
a. Perform a visual inspection. Check Fuses F8
a. Perform a visual inspection. If any of the diodes and F9 and replace them if they show signs of
are ruptured or burnt, replace the ruptured or being blown or melted. If any of the diodes are
burnt diodes. If the diodes appear okay, proceed ruptured or burnt, replace all diodes on the POS
to the next step. PLATE. If the diodes appear okay, proceed to
the next step.
b. With an ohmmeter on the RX1 scale, place one
lead on the ELECTRODE PLATE and the sec- b. With an ohmmeter on the RX1 scale, place one
ond lead on the parallel pig tails (cathode leads) lead on the POS PLATE and the second lead on
of D25 and D26. A reading of 2 ohms or less the BR "A" BUS. A reading of 2 ohms or less
indicates one or more shorted diodes. If any indicates one or more shorted diodes. If any
diodes are shorted, separate the parallel cath- diodes are shorted, replace all diodes on the
ode leads and check each diode independently. POS PLATE.
It is necessary to replace only the shorted diodes.
c. If either or both fuses, F8 or F9, were open for the
c. With an ohmmeter on the RX1 scale, place one ohmmeter check in step b. above, then make two
lead on the ELECTRODE PLATE and the sec- more ohmmeter readings: measure the resis-
ond lead on the parallel pig tails (cathode leads) tance between the POS PLATE and the BR "B"
of D27 and D28. A reading of 2 ohms or less BUS; and measure the resistance between the
indicates one or more shorted diodes. If any POS PLATE and the BR "C" BUS. If either
diodes are shorted, separate the parallel cath- reading is 2 ohms or less, replace all the diodes
ode leads and check each diode independently. on the POS PLATE.
It is necessary to replace only the shorted diodes.
28
3 PHASE INPUT
FAN TB4 TB5 TB6
GND1 # TYPICAL OF SN1,
M3 POWER WITH $ CORE SATURABLE, 952002
SN2,SN3,& SN4
GROUND 15A 15A CORE SATURABLE, (8)951199
F1 F2
FAN
M2 L1 CAPACITOR: 951998
1 L2 1 L3 1
K1 R1 K1 R2 K1 0.27 F 1200VDC
300W 300W R3 300W
T1 T2 T3 2000V / S MIN DV / DT FRED MODULE:
GND2 T1 T2 T3 P/N 951996
K2 K2 K2
FAN L1 L2 L3
M1 K3 @ TYPICAL OF H5 (400V) H1
4 7 CLAMP1 & CLAMP2 H6 (460V)
10 F 1 TB8-15 H7 (575V)
MAIN TRANSFORMER (T1) ASSY
X3
A
TB2-2 TB2-2 C25 24V
TB2-1 TB2-1
R32 220K K1 (MC) T2 (CONTROL XFMR)
X4
120V 120V
TB8-16 50/60 HZ
RECTIFIER ASSEMBLY 4 7
H1 T5 H2 H1 T6 H2 CAPACITOR:
& CAPACITOR ASSY K7 5.0 F 800VDC
PRI 120V PRI 120V P/N 951966
SEC 40VCT SEC 40VCT
B _
+
X1 X2
20V 20V 20V 20V
P6-3
.033 10 TB3-1 TB3-2 TB3-1 TB3-2
P5-1 P5-3 P6-1 630V 50W 120V
P5-2 P6-2 P3 TYP 120V 120V TB8-17
TYP 1
Z BIAS H BIAS D20 8 300W C14 TB1-12
C20 R5 CB1 10A
H1 H2 H1 H2
# R13 T7 T8
SN1 $ PRI 120V PRI 120V GND3
1 L P1-1 +15T
BLK E SEC 40VCT SEC 40VCT TB1-10 TB1-11
Q2
ERROR LEFT 1 PL1
2 L P1-2 C H N
WHT SIGNAL PWM/GATE D2 20V 20V 20V 20V
DRIVE BD G R53 P5-1 P5-3
3 L P1-3 T COM
GRN C23 D23 2 25W P5-2 P6-1 P6-3 ELECTRODE
@ .033 10
CLAMP1 P6-2 630V 50W PLATE
4 L P1-4 -15T Z BIAS T1-C T1-B T1-A
RED P3 TYP TYP 1
8 300W H BIAS 8 300W 1 1 1
D22 C13 R4 TB9-21
5 L
BLU
P1-5
IGBT PCB2 # C19 R12 C16 R7
#
C22
R15 TS7 TS3 TS2 TS1
D19
UNSAT
6 L P1-6 SN2 % SN3 $ TS6 TS5 TS4
ORN $ E 1 1 1 TB9-14
E
Q1 RIGHT Q4
C IGBT FWD IGBT
SYNC C PWM/GATE D1 TB9-20
P2-1 D4 L HS HS R HS
CLOCK MASTER G DRIVE BD G
D24 R54 PL3
MASTER Z COM C24
P2-3 A
P2-4 P2-2 @ CLAMP2 2 25W
CLOCK K7
-12H IGBT SIGNAL SLAVE 1
MISSING ON/OFF P2-5 P2-3
HALL ARROW C18 R9 C15 R6
D21 8 300W
P1-8 P1-9 P1-10
$
1 R
PCB3 C21 R33 220K
P1-7 TD1 P1-1 +15T # R14 $
L1 BLK
K3-3 K7-3
YEL BRN GRY VIO ERROR SN4 C26 10 F 370V
D25 D6 2 R P1-2 D3
WHT SIGNAL E 6 9 6 9
7 L 8 L 9 L 10 L C38 Q3
F D
C37 FRD100BA60 3 R P1-3 T COM C R8
GRN C17 R37 TB7-8 A
.01 D26 .01 HALL SENSOR R30 TYP 3 PCS G K2
4 R P1-4 -15T
1K 100W RED $ 10 1W STARTING
BLK D R16 8 300W + -12H CONTACTOR
F R41 10K 8W 10K 8W R42 5 R P1-5 1 F
GRY BLU IGBT MISSING 600V K4
LO D5
GRY 1 2 + C28 + UNSAT C31 PILOT ARC
BLK C27 6 R P1-6
M ORN _ IGBT A CONTACTOR
R17 S1 HI 1900 F 450V 1900 F 450V FRD100BA60 .1 F
ON/OFF A
8 .01 + _ + _ TYP 3 PCS
K C41 .01 C43
300W D29 D31 P1-7 P1-8 P1-9 P1-10 HALL ARROW A
K6-2
K3
BOOST & 85HF120 9 6 TB8-18 TB8-19
YEL BRN GRY VIO TD2 (AMC)
START TYP (4)
R23 1 1 J J 2 M K
(T1) R R 9 R R 10 G TB7-8
F3 15A 300W
L3 7 8
1 ASIOB START TB8-8
C42 .01 K4 D27 RELAY TB1-9
T3 .01
10K 8W D30 D32 C39 C40
L2 HALL SENSOR TB8-1
R43 .01 A PL2
F6 D28 R28 K5-1
.01
1900 F + 15A R24 8 300W C44 1K 100W
R36 220K 1W K5
6 9
450V 1 6 HI
C29 P LO 4
LO 3 T C36
S1 J1-E
S1 HI TB8-2
R31 K4 5 K4 R18 F7 R19 10K 8W 10K 8W 3 4
PILOT 10 F
1K 100W 370VAC R39 R40 FN4 10A
ARC T1 L1 L2 T2 4 4 R20 R27 1 2
30A 10
300W 300W 4 + C32 +
220K R38 1W 300W 300W C33 CONTACTOR
D35
1900 F 450V 1900 F 450V SIGNAL TB1-7 TB1-8
10K 8W
60 F 370VAC R21 TB8-7 GND5
C30 R44 R29 1K 100W BIASED J1-H
SHIELDED 1 1 J1-F
300W R22 J1-G
TB1-15 TWISTED 300W 220K 1W 220K 1W SNUBBER
E
+ PAIR R34 R35
1 2 3 GND4
FN1 + SHUNT X R26
C34 C35
800A
TRIM 100mV SH1 1
R25
10
AM BOARD Y FN2 J1-J TB1-13
3 800A 1 2 10
_ _ 15A F4 1 0 F 1 0 F 100W
TB10 Z 100W
GND4 PCB4 370VAC 370VAC
J1-K TB1-14
500V TB1-16 (T1)
E _ VM +
D33 D34
T
ELECTRODE
_ NOZZLE WORK +
Figure 5-4. ESP 600C Schematic Diagram (Sheet 1 of 6)
40
41
TO K1-T1 TO K1-T2 TO K1-T3
"A" COIL "B" COIL "C" COIL

121V (460)
111V (400)
TO K1 COIL H1 H2 H1 H2 H1 H2
400 (5.556V/T) (5.556V/T) (5.556V/T)
CIRCUIT
460 (6.389V/T) (6.389V/T) (6.389V/T)
72T 72T 72T
19T 1T 3T 19T 1T 3T 19T 1T 3T
0V X1 X2 X3 X4 X1 X2 X3 X4 X1 X2
F8 600A F9
600A
460V 400V
INPUT INPUT 111.1V (400) 127.8V (400)
127.8V (460) 146.9V (460)
PHASE VOLTAGE PHASE VOLTAGE
(TYP) (TYP)
105.6V (400)
121.4V (460)
PHASE VOLTAGE
(TYP)
460V 400V 460V 400V
460V 400V INPUT INPUT INPUT INPUT
INPUT INPUT
3 PHASE TO
DIODE BRIDGE
221V (460)
221V (400)
PHASE TO PHASE
460V
460 400V
400
221V FOR INPUT INPUT
400V INPUT
TO FANS
232V FOR
460V INPUT
0V 27T 2T 3T 27T 2T 3T 27T 2T 3T
X5 X6 X7 X8 X5 X6 X7 X8 X5 X6 X7 X8
BLU BLU
F5
YEL
BRN
(400) 150.0V 161.1V (400) 177.8V (400)
(460) 172.5V 185.3V (460) 204.4V (460)
PHASE VOLTAGE PHASE VOLTAGE PHASE VOLTAGE
(TYP) (TYP) (TYP) BLK
BLK 460
400
460V 400V 460V 400V
INPUT INPUT INPUT INPUT
TO BOOST TO OUTPUT
321V (460) 185V (460)
CIRCUIT 308V (400) 178V (400) BIASED SNUBBER
Figure 5-4. ESP 600C Schematic Diagram, 460 V (Sheet 3 of 6)
42
TO K1-T1 TO K1-T2 TO K1-T3
460V 575V 460V 575V 460V 575V
H1 H2 H3 H4 H1 H2 H3 H4 H1 H2 H3 H4
460 (6.389V/T) 115 (6.389V/T) 460 (6.389V/T) 115 (6.389V/T) 460 (6.389V/T) 115 (6.389V/T)
72T 18T 72T 18T 72T 18T
19T 1T 127.8V PHASE 19T 1T 19T 1T

0V
VOLTAGE (TYP)
X1 F8 X2 X3 X1 X2 F9 X3 X1 X2
TO K1 COIL
3 PHASE TO
CIRCUIT
DIODE BRIDGE
121.4V
PHASE
221V PHASE TO PHASE
VOLTAGE
(TYP)
TO FANS 221V
27T 2T 27T 2T 27T 2T

185.3V PHASE
X4 X5 X6 X4 X5 X6 X4 X5 X6
VOLTAGE (TYP)
172.5V PHASE
0V VOLTAGE (TYP)
BLK BLK
TO BIASED
185.3V
SNUBBER
BLU BLU
F5
TO BOOST 321V
CIRCUIT
NOTE: VOLTAGES ARE THE SAME FOR BOTH 460V AND 575V.
Figure 5-4. ESP 600C Schematic Diagram, 575 V (Sheet 4 of 6)
43
FROM MAIN
TRANSFORMER (T1)
.01 F .01 F
C47 C50
D7 D13
D8 D14
.01 F .01 F
C48 C51
D9 D15
D10 D16
.01 F .01 F
C49 C52
D11 D17
D12 D18
C6 +
C12 +
C5 +
C11 +
C4 +
C10 +
TYP 6 PCS
1900 F 450V
TYP 6 PCS
1900 F 450V
C3 +
C9 +
C2 +
C8 +
C1 +
C7 +
R10 R11
_ + _ +
1K 100W 1K 100W
44
CTRL XFMR (T2) WITH CONNECTIONS SHOWN FOR 400/460/575V 1 PHASE
TO K1-L3
POSSIBLE VOLTAGE INPUTS:
400 400 575 200V 50/60HZ

230V 50/60HZ
460 315V 50/60HZ
460
TO K1-L2 575 345V 50/60HZ
375V 50/60HZ
400V 50/60HZ
430V 50/60HZ
0V 200 230 0V 200 230 345 460V 50/60HZ
H1 H2 H3 H4 H5 H6 H7 545V 50/60HZ
PRIMARY 575V 50/60HZ
CTRL TRANSFORMERS T3 THROUGH T8
(TYPICAL)
H1 PRIMARY H2
BLK BLK
120VAC
. . . SECONDARY
13V 7V 7V 13V
X1 X2 X3 X4 X5 X6 X7
GRY GRN YEL BLU
BRN GRN/YEL RED
45
(2)
(1) RESET ARC VOLTAGE D43 TP21 +15T
E +15T ARC VOLTAGE
INPUT (-) (2) TP42
R85 Q8 CUTOFF FAULT
MCR D42 MC 133K C48 EINH
13 (1) + C39 100 1.5mA @ 400V OUTPUT
+15T TP33 (4) 11 100K TP18 TP23 P9-5
D32 +15T 3.3 P5-9 .01 TP43 D47 D46 R219
R163 IC15
+15T 12 R157 C44 .47 R77 2K D13 -
R135 IC14 2 R162 VSAT R202
1M
C75
R134 R159 100K R75 10K
133K 10K
IC7
9 10 1 * 221
3 R173 1K D79
.001 499K R84 C47 1 100K .47
R138 13 (5,0) + 8 R171 C118 *
- R158 IC14 Q3 MCR 3 2 100K
D31 1 1K 9 R156 .01 X D44 100K IC15
1K 3 5 20K C43
LED8
IC12 4 R76 P5-6
12 14 + 10 100K .47 D45 R160 T
2 D41 8 +15T (2X)
R136 + C73 .1 IC14 6
IC14 Q7 2K (1)
C92 3.3 C88 .47 T C87 (3) 1M I 5 R172 T
10K TP39 TP40 D40 D38 R174
.01 TO VOLTAGE R161 100 1.5mA @ 400v MC C91
R137 T T P9-1 T .01 4 100K D48
221 CUTOFF METER 2.74K .47 6
C76
D39 1K * D49 +
R165
R164
MCR
(3) IC15 E
20K C74 R184 (1) LEFT IGBT'S
T +10T .47 * RIPPLE FAULT
C80 R140 .001 C93 OUTPUT 10K T ON/OFF
TP34 P5-7 +15T OUTPUT
10K 2 LED3 +15T SOLID STATE P10-5
.47 R228
133K R146 2.74K - (11) E T
+15T VOLTAGE
R141 1 CONTACTOR 22 +
R145 IC12 D33 P6-3 R82 CUTOFF
133K C77 .01 110K LEVEL MC L
110K 3 (1) T IC8 5 R168 10K
+ 382V
R139
13 R149 HI BUS 1K C50 2.74K MC MC (2)
P7-9 R147 9 TP35 C108 100K MCR R81 - 221
FAULT 4 TP41 R229
- 68.1K
.01 C84 EINH 12
11 100K OUTPUT 20K R86 6 .47 (3,0) 10K
(-) 6.81K IC13 +15T P6-4 (+) 1M C49 P10-6
C79 IC12 R209 .001 (10) P9-2
BUS 8 T
Q4 .01
10 R143 13 P11-5
INPUT .01
D105
+ +15T 6
- D12 R176 R80 R169 R231 20K
10K 7 D34 9 R150 49.9K 13
- 14 15.0K 11 TP52 +
IC12 R151 10 12 .001
R186 *
TP36 R144 221 * IC7 IC15 10K R
5 100K P6-5 IC8 Q9
T R208 + * 100K 8 1K .47 BR1
VCE=20.5V 10K 232V IC13 D51 + (1) EINH C126 R230 - 221
(2) 4.99K D35 C95 12 R170
MC Q12 (11) TP22 R78 3.32K TP20 2.74K
C83 .01 TP37 Q20 158 P11-6
D69 T LED4 R74 R234 20K
R210 EINH (1) T
R79 C45
LO BUS: 232V T 680 C127 RIGHT IGBT'S
20K 33.2K MC 18.2K
HI BUS: 382V 33.2K TP38 +15T .47 2W Q21 .1 ON/OFF
C85 + R211 D72
T T
10K
NOM BUS PEAK R212 D71 R233 R232 OUTPUT
.001 C109 D37 .01
@ NL: 325V R213 R152 1 R178 2K C132
R154 T
P6-1 P6-2
10
-15T (4) 100K 100K 221 P9-3
NOM BUS TROUGH T
E * 2
3 100K * D53
EXTERNAL RESISTOR
@ FL: 275V EINH (5) IC13 R196 1K .47 FOR 115V AC CONTACTORS T
D70
+15T 375 + TP26 C97 * LOW BUS (10)
(-) - 17A C57 D23 D22 T FAULT G MC N
E
R298 .001 13 11
R100
LED5 D92 (4)
OUTPUT 115VAC
% R104 13 IC9 5 R153 T R250 11 12 +15T
20K - R105 12 100K LEFT IGBT
+15T PR
R102 100K MCR 4
L T L 6 100K T UNSAT FAULT 100K LEFT IGBT
4.99K (2) 50mA MAX IC19 13 EINH C134
12 14 100K L IC13 OUTPUT Q17 R252 1K UNSAT FAULT
+ E D104 R292 P4-4 (9) .47
H11D2 INPUT
R103 +15T D36 (3) P9-8 R221 D90 R253
C56 IC10 9 D93 Q22
20K
IC9
R101
+15T
5 * 22 + R249
IC19
9
.01 10 LEFT OVR IC25 221 R187 10 C135 1K P10-7
(1,0) RESET R180 100K 8 100K
R293 C158 6 * .47
* 1M 4V
T
CUR FAULT 4 PILOT ARC ON C120 1K 100K
TIE TO "T" Q5 OUTPUT 1M C159 D81 8 .01
R181 TP25 .01 TP53
COMMON FOR PR MOV2 LED10 R251 4.99K P10-8
RESET 100 C100 D20 R175 P9-6 Q28 .01
P6-6 D59 (4,0) (6) E 1KV V130L20 T (9) E
.47 T T
(-)
375 +- 17A
* 221 1K R294 D94 (3)
+15T
C101
T
D61 R185 1K .47 D50 - T R255 1
PR
+15T
% .001 1 R182 C94 * MPSA42 RIGHT IGBT +15T
R299 TP27 IC9 P4-5 UNSAT FAULT 100K 3 2 C136 RIGHT IGBT
R188 R190 2 (5) 3 IC19 EINH
R 20K - 2 100K LED9 OUTPUT Q19 R257 1K UNSAT FAULT
4.99K 100K 3 EINH T P4-1 R290 1W (8) .47
P9-9 D91 INPUT
T R D62 R R223 D95 Q23 R258
T 5K 270 IC19
+ R191 R254 5 1K
1 RIGHT OVR 25W 2 221 * R197 C137 P11-7
C102
R189
IC10 100K 5 R183 CUR FAULT R289 * .47 1M 4V
20K IC9 +15T 221
IC25 9 - D83 C123
1K 100K 4
6 .01
.01 4 100K OUTPUT P4-2 1 IC7 TP54
6
D60 R177 P9-7 10 8
6 - LED11 R256 4.99K P11-8
T Q10 + T (7) E
R291 IC7
9 T 7 T T
- TP45 * 221
D52
100 T 5
+
D86 (1)
8 R198 1K T R237 12 +15T
IC10 .47 11 PR
INDUCTOR RIPPLE 10 C96 * # LEAVE OFF BOARD
T
LEFT -12V +15T
100K
INPUT (ARC V SAT + LED6 13 C128 LEFT -12V
FAULT IC18 EINH
DETECTOR) +15T VOLTAGE SATURATION DETECTOR
D68
OUTPUT Q14 (6)
R239 1K .47 FAULT
P9-13 P9-12 P3-1 D84 INPUT
T T P9-10 R220 D87 Q16 R240
T
K3-2 IC18
TP28 (0,1) R236 10 9 1K
P3-2 221 * R199 C129 P10-9
VSAT TP47 ARC VOLTAGE
* .47 1M 4V
R227 R226 D80 C119 1K 100K
+15T SAT FAULT 8 .01
22 22 +15T (3) Q11 P3-3 TP50
D55 OUTPUT LED12 R238 4.99K P10-10
TP44 R195 C58 EINH D64 K3-1
D25 T
TP31 R179 P9-4 T (8) E
332K .47 T T
R204 100K D65 D88 (2)
D56 VSAT * 221
6 R107 13 VSAT R200 1K D54 T R244 1 +15T
- R114 100K +15T 3 PR
1 R203 .47 RIGHT -12V +15T
IC10 100K 11
3
C98 * R287 2K FAULT 100K
2 RIGHT -12V
C124 R194 7 12 C105 D66 Q27 IC18 EINH C130
5 IC16 2 100K TP66 OUTPUT Q15 R246 1K FAULT
10K + IC16 LED7 (7) .47
C99 .01 .47 P9-11 D85 INPUT
X T R115 (0,1) T (11,0) R222 D89 Q18 R247
D57 TP46 (4) EINH IC18
100K PD T R286 C160 D103 R242 5 1K
R193 C104 8 221 * R201 4 C131 P11-9
10K
C60
C61
10 5 4 R207 E E * .47 1M 4V
.01 (11,0) 10K 1K 100K
.01
VSAT D67 .001 D82 C121 6 .01
D58 .01 9 D26 100K TP51
IC16 R205 6 R288 LED13 R245 4.99K P11-10
IC16 K3 T
C66 .1 100K R206 D68 100 T
T # T T
10K (5) MCR TP58 T
# NOTE: REMOVE R206 & D68
AUTO RESET MC RESET FOR AUTO RESET
Figure 5-5. ESP 600C Control PCB (Sheet 1 of 3)
46
+15S ICUT REF (-) SW2
R15 # TP16 CURRENT
+15T R110 C36 5K CW R73
MIN ISTART REF (+) 80A REF SIGNAL
CURRENT REF R12 TP1 24.9K 5 .01 POT6 20K
R111 R68
(0-10V) 22 REF: 1.66K TOTAL - (-)
R6 R37 40A 1K 13 .01 C42
POT2 49.9K 6
I=(80)X(VREF) R3 D4 R18 10K R36 (-) P5-1 IC6 TP19 CRS
22 22 1K CW R41 R112 12 14 D10
D1 200K 20A + - (1,0)
HI SPEED C2 C11 12.4K TO VREF 1K 100K 7 SOFT START 6
R7 C1 R35
- C21 .01 C22 METER TP9
C24 R113 C37 ON/OFF IC6
.47 .47 100 10A .01 7
P8-3 200K .01 .47 OFF +
R14 P5-2 .01 200K 8 R69 5
D3 S # T TP6 R109 T
STANDARD IC1 - 40A SW1 10K T
R1 R8 2 T P5-3 R40 6 49.9K
7 1
- P8-1 - 9 TP7 IC3 TP17
150K 49.9K 6 15 12.4K 7 ON C40 R71 -
34001 7 R20 2 D8 +
R39 -15T 22.1K 9
R2 R9 + R5
IC2
10K
- (-)
TO START C25 5 .01 IC6
+ 4 C8 16 8 CUR METER 100 T - D11 8
P8-2 0.0 C3 0.0 3 1K IC3 .47 2 10
10 3 1 R72 +
.47 2 START CURRENT REF (+) R65 IC6
.47 R10 CCW + R66 3 1 (-) 2.74K TP12
0.0 C9 C12 P5-4
C5 POT1 T + T
C4 .47 10K 10K
.47 1K .47 R64 20K -15T
.47 T ICUT REF (-) T
D2 R11 R13 R19 R63 10K C35 .01 TP14

R4 22 TP8 (+) RAMP TIME R56 1M
S 22 2K 22 6 (+) TP15
R16 # R30 - APPROX 15.4K POT5 6 IC4
332 R62 10K R58 CW
-15S IC5
R17 R31 (ICUT - ISTART) 7 4 5
# + - 10K 10K
-15T 1K C17 5 2 R59 TP67
P7-10 R25 C33 D9
C10 .01 (-) .47 IC5 1 C31
R32 R61 10K .01 +
1KV T 10K (+) UPSLOPE TIME + 10
S T 15K C15 C29 1K 3 (-)
.01 T 13 - R55
R29 R26
I (1) 10K
-
.47 IC5
14 9 - (+)
+15T SW2 10K 1K 9 D7 49.9K
P7-11 + IC5
+15T C18 IC3 P7-13 12 10 8
1 2 3 4 8
R93 .47 +
+ .25S DN R50 27.4K
20K 10 R27 20K .8S
T
R23 R52 CURRENT RAMP
R91 CTR
R94 R22 470 R49
20K D21 (1,0) P7-12 T
49.9K C32
100K R96 150K C14 1/2W 1K P7-14 4.99K
T
DWL UP
-15T 1.2S R51 .47
49.9K TP65 RATIO ISTART/ICUT R53
R95 R98 D6 13
- .01
DEFAULT = .40
R97 R24 12 MISSING:
100K 12.1K IC3 Q1 P7-15 6.81K
24.9K 10K +15T
+ 14 T 13
11
12 R21 P10-1
R33 C20 IC22
TP68 100 8
10K .01 MIN
1 V
R92 665 C13 Q2 + C19 D5 T P10-3 TO LEFT ~4.5V 10 +15T
C122 9
.01 IC4 .47 PWM/GATE IC22
2 -15T R224
R34 10 DRIVE BOARD T
T
10K P10-4 - 1
MAX 2
22 IC17
TP63 H11F1 TP29 C70 .001 R57 P10-2 ~-.5V IC21
DWELL TIMER
T L ERROR +15T 3 1 2 H11F1
1K R225 SIGNAL +
IC17 R125 .022 TP32 P11-1
4 6 TP30 T I MIN 1K
C28 .01 R263 T
CW POT4 49.9K C64 1K (1) R304 R305
C71 .001 R133 R ERROR R300
(1) C63 .1 I REF R47 R124 SAT 1.21K 1.21K
2 10K I MIN 1K SIGNAL TO RIGHT 10K
IFB R118 - (+) 1M 499K TP13 T
P11-2 PWM/GATE
13 R121 1 D27 CW POT7 .022 C72 -
33.2K
- 14 4.99K
IC11
-15T R132 R129 DRIVE BOARD 9 (1) R301
3 10K IC21 DWL Q29
(1) IC11 + 1M 49.9K C69 .01 10 8 10K
R117 R306 CW D28 P11-3 + D106
+ POT3 R48 R128
12 665 IC11 R302
CRS 2K I MAX
9
- T
.47
C143 T T
(1) IX Q6 C67 10K 20K 8 R126 R127 499K I
R116 10K R122 D29 10K
L R131 P11-4 (2)
.47 D63 R46 10K 1.30K 4.75K 1.30K
PD +15T 100K + +15T
10 ERROR AMP -15T R264 22 D97
(1) D24 R119
D30
K1 13 -
TP10 IC11 R130
T 6 - IC21
14
P7-1 20K 4.75K 12
(-) R42 4.99K
T
IFB R 7
+
5
(1) + T
P7-2 4.99K R43 R303
R259 R260 ERROR AMP -15T C145 49.9
.1 C26 +15V 100
T
L 22 C138 .47 1
P7-3 R261 R266 .47 P2-4 P2-5 P2-6
T IC24
R296 10K P5-5 TO OUTPUT H11A1
10K 12.4K 2 I I
D96 CURRENT METER
P7-4 LEFT HALL SENSOR (2X) P5-6 I P2-1 P2-2 P2-3
-15T C140 .01 +15T
(1,0) IX
Q25
I C106
+15T
TP11 - T
R279
C151 R275 R276 I I SPARE CURRENT DETECTOR
P1-2 R270 R272 2 TP55 499K .001 4.99K 4.99K K2-1 K2-2 R285
7 I .10
P7-5
49.9 49.9
- 6 R273 Q24 100
(-) R44 R45 OP07 (0,1) (2,0) .01 P2-9
IC20 - I T 150V DC MAX PEAK
P1-1 R269 R271 10K 6 R280 1 K1-1 K1-2
P7-6 4.99K 4.99K 5 TP56 1 50mA MAX C155
+ 4 C149 IC21 IC23 P2-7
49.9 49.9 3 7 1M 3 R283
C156
.1 C27 .47 + 2 4 H11D2 IC24 5
R + C149 .47 5 IC22 6 2 D99
P7-7
SHUNT
R278 IC22 C154 IC23 5
D100
* 22 + .47
C142 C141 C153 H11D2 6
R297
T 100mV
10K
CURRENT
.01 .01 R277 4 *
800A .01 .47 DETECTOR 6 4 R284
.01 .10 121 1M C107 C157 P2-10
P7-8 10K P1-3 C150 .47 C152 COMPARATOR LED14 MOV1
1M
T .01
-15T Q26 .01 V130L20
R262 C148 R281 1KV
RIGHT HALL SENSOR R265 22 D98 R282
T 10K
1K
P7-2 & P7-6 = -7.5V WITH K2 -15T -
RESPECTIVE HALL SENSOR UNPLUGGED. -15T MPSA42
P2-8
47
+15T +15T +15T +15T +15T +15T

R38 R60 R67 R123 R192 R142
NOTES:
10 10 10 10 10 10
C23 C34 C41 C68 C103 C82

4 4 4 4 4 4
- .47 - .47 - .47 - .47 - .47 - .47
3403 3403 3403 3403 3403 3403
+ + + + + + # LEAVE OFF BOARD.
11 T 11 T 11 T 11 T 11 T 11 T
C16 C30 C38 C65 C59 C78 CRS CURRENT REFERENCE SIGNAL. ANALOG, 0-10V=0-800A. PRECISION INPUT TO
IC3 .47 IC5 .47 IC6 .47 IC11 .47 IC10 .47 IC12 .47
R28 R54 R70 R120 R106 R295 OUTER SERVO. INCLUDES INITIAL CURRENT AND RAMP UP.
10 10 10 10 10 10
+15T +15T +15T +15T +15T +15T DWL DWELL. HI (+14) HOLDS CRS AT INITIAL CURRENT LEVEL. LO (-14)
-15T -15T -15T -15T -15T -15T
PERMITS CRS RAMP UP.
R99 R148 R155 R108 R235 R248
10 10 10 10 10 10 E ERROR NOT. HI WHEN NO ERROR EXISTS.
14 14 14 14 14 14
4093 4093 4093 4093 4093 4093
C55
IC9
.47 IC13 .47
IC14 .47 IC16 .47 IC18 .47 IC19 EINH ERROR INHIBIT. FIRST ERROR CREATES HI WHICH PREVENTS
.47 7 C81 7 C86 7 C62 7 C125 7 C133 7
MULTIPLE ERRORS.
T T T T T T
I CURRENT. HI WHEN MAIN ARC CURRENT THROUGH SHUNT > 23.6A.
P5-10 R217
TP61 TP62 TP48
1.0 D73 I CURRENT NOT. HI WHEN MAIN ARC CURRENT THROUGH THE SHUNT < 23.6A.
C115 D102
20V 2W .10
* +15T +10T
*
T R215 P5-8 IFB CURRENT FEEDBACK. +10V=800A.
IN REG5 OUT IN REG3 OUT
20V
1 7815 3 499 2 AD581J 3
1.0 2W BR3 R216
D78 2 D77 C117 + 1K 1 D74 C111 + IX CURRENT X NOT. CURRENT DETECTOR COMPARATOR HI (+14) WHEN MAIN ARC
P5-12 R218 C110
+ C114
3.3 .47 3.3
CURRENT < 23.6A, LO (-14) WHEN > 23.5A.
P5-11 .10 C116 1000 * * *
LED16 MC MAIN CONTACTOR. HI WHEN K3 RELAY COIL IN POWER SUPPLY IS ON.
R214
+ C113 D76 D75 C112 +
1K T
1000 FUBAR 3.3 TP49 TP60 TP64
MC MAIN CONTACTOR NOT. LO WHEN K3 RELAY COIL IN POWER SUPPLY IS ON.
* 2 * LED15
1 7915 3
IN REG4 OUT +15T +15T MCR MAIN CONTACTOR RESET NOT. LO PULSE ACTS AS ERROR RESET.
-15T
TP57 D101 TP59
R268 R166
P8-4 R87 10 10
* PR POWER RESET NOT. LO PULSE ON POWER UP RESETS ALL ERRORS.
1.0 C51 TP3 D14 TP4
C147 C89
20V 2W .10 4 4
* - .47 - .47 RESET RESET NOT. CONNECT P6-6 TO "T" COMMON TO RESET ALL ERRORS.
3403 3403
S +15S
+ +
PERFORMS SAME FUNCTION AS PR (POWER RESET NOT).
IN REG1 OUT
20V 11 T 11 T
P8-6 1 7815 3 C144 C46
R88 BR2 R89 IC21 .47 IC7 .47 VSAT VOLTAGE SATURATION. HI WHEN IGBT'S REACH 100% ON TIME AND WITH
D15 2 D16 C53 + 1K ARC CURRENT OVER 23.6A.
1.0 R267 R83
+ C6 TP5 10 10
2W 3.3 LED1
P8-5 .10 C52 1000
* * +15T +15T PD PULL DOWN NOT. LO EXISTS WHEN VSAT EXISTS. LO PULLS DOWN CRS
-15T -15T
R274 R167 TO MINIMIZE CURRENT OVERSHOOT WHEN COMING OUT OF SATURATION.
R90
+ C7 D18 D17 C54 + 1K S 10 10
14 14
1000 FUBAR 2 3.3 4093 4093
* * LED2
1 7915 3 IC22 IC15
REG2 .47 7 .47 7
IN OUT C146 C90
-15S
D19
T T
TP2 * TP24
48
10
P1-1 METER POS
10
50 mV METER
P1-2 13 RESISTANCE
P1-3 METER NEG
Figure 5-6. ESP 600C Meter PCB
49
+15Z
+15Z +15Z POT 1 3.32K ON POSITION
P2-5 P2-6 P2-2 P2-4 FIRST RUN P5-1
CLOCK OSCILLATOR R80 R08
R29 TP12 TP07
20KHZ 1.0
TP05 10 +15Z 20K R11 C01 D03
14 10K D07 20V 2W
5 R24 .10
R23 10 POT6
R19 10 6
4 1K Z R10 10K + SPAN
* !!
+15Z
POT5 7 C14
10K C50 Z
10K IC04 CW 3.3 R16 POT2 10K IN REG1 OUT
.47 20V
C13 P5-3 7815
CW POT1 24.9K CW R09 BR1 R13
Z TP15
.47 P2-3 +15Z 10K Z TP02 D02 D01 C09 + 3.32K
P2-1 TP18 1.0
14 1 +15Z 2 + C07 TP08
R20 D08 - 6 2W 3.3 LED1
4 8 3.32K VDD Q
5
TP11 TP19 R25
IC01 P5-2 .10 C02 1000 * *
3 D 1K 12 R30 +
3 CLK 1 8 R32 C17 3 TP14
9 R22 R87 R12
4013 2 11 100 34001 + C08 D05 D04 C10 + Z
10 221 13 Q1
7 10 Q 2 3 1K 10K 9 560 IC04 R81 +15Z 3.32K
IC02 TP03 12=OPEN IC04 IC04 PF 10K 1000 !! 3.3
555 R21 11 13=OPEN C18 C03
R15 * * LED2
20K D09 10 7915
VSS R S TP06 .0015 TP17 .10 v RAMP
6 TP20 IN REG2 OUT
8 7 4 6 t -15Z
C05
7 D06
IC03 - .47
1 5 2 TP09
34001
Z +1.25V
C06 C11
TP04 R33 -5.0V + *
4 Z TP10
C12 .0015 10K C04
.47 .01 IC01
TP01 .47
+15Z
+15H R14 +15Z
MAX ERROR CW IC10 R01
10
MIN +4.5V R28
V R41 R34 POT4 2 1
2.2 1W
10
10K R02 G -15Z
# 100K R55 2.21K
# 2.2 POWER CONNECTIONS FOR IC1 C16
Z 1W ZD2 7
MAX -0.5V R39 +15Z 8 4 IGBT 1
R43
Q5 - .47
14 34001
10 & ZD1
P1-01 # R37 D50 D51 E +
R44 10
TP16 M57962L R05 4 Z
TP23 5 C15
1M C19 IC06 10 1W
C25 .47 D12 TP32 IC05 .47
R45 1 E
TP21 & REGION 3 R27
10K 15 9
P1-02 .47 D11 Q4 10
7 R36 D20 P3-1
C26 .01 IC07 D10 1
P1-03 TP13 680 @ -15Z
16 8
10 1/2W 13 # R04 POWER CONNECTIONS FOR IC5
2 R31 2 6
C20 Q2 ZD7
R46
C24 .47 R35 .47 10K
- 6 R26 2.2 1W G
P1-04 10 IC05
# 499 C23
10 + 2N4401 # R03
3 -12H ZD4
R40 34001 4.7 2.2 IGBT 2
1W #
ANALOG
-15Z R82 R83 10K #
ISOLATOR C22 C51 ZD3
TP24 R42 # 221 COMPARATOR TP22 4.7 .033 E
630V
T C54 Z OFF H R06 E
Q3
.01 +15Z TP31 2.2 1W
TP25 R38 ON
1KV
20K # R07 G
R47
P1-05 5 C21 2.2
1M R48 ZD6
IC08 .01 1W IGBT 3
100K 4
Q6 5 6 ZD5
IC10 SS CONTACTOR
C52 R85 IGBT SAT
4 LOSS E
1M Z R60
.01 P6-1
P1-06
1.0 E
TP26 C33
2W
20V .10 D14
TP27
H * TP33
R49 +15H
P1-07 IN OUT 3.32K
20V REG3
1M R50 7815
100K -12H P6-3 R59 BR2 R56 R57
R53
5 & C29 + IC09 1K 15K
Q7 6 -12V INDICATOR 1.0 D15
IC09 + C28 D16 LED4
2W
4 C53 R86 C32
1000
* * 1000 2 1
1M P6-2 .10 Q8
.01
P1-08 R54
R84 H
TP28 + C31 C30 + 3.32K R58
221 D19 D18
1000 1000 LED5 10K
&
TP29 D13 LED3 * *
P1-09 7912
R52
C27 * 1 IC08 IN REG4 OUT
-12H
SS CONTACTOR
10K .01 D17
R51 2 TP34
P1-10
221 *
TP30 REGION 2
# LEAVE OFF BOARD
REGION 1
Figure 5-7. ESP 600C PWM/DRIVE PCB
50
SECTION 6 REPLACEMENT PARTS
6.1 GENERAL Replacement parts may be ordered from your ESAB

distributor or from:
Always provide the series or serial number of the unit on
which the parts will be used. The serial number is ESAB Welding & Cutting Products
Attn: Customer Service Dept.
stamped on the unit nameplate.
PO Box 100545, Ebenezer Road
Florence, SC, 29501-0545
6.2 ORDERING
Be sure to indicate any special shipping instructions when
To assure proper operation, it is recommended that only ordering replacement parts.
genuine ESAB parts and products be used with this
equipment. The use of non-ESAB parts may void your To order parts by phone, contact ESAB at 1-803-664-
warranty. 5540 or 4460. Orders may also be faxed to 1-800-634-
7548. Be sure to indicate any special shipping instruc-
tions when ordering replacement parts.
29
11 10 9 8 7 6 5 4 3
12
13
2
14
15
1
16
Figure 6-1. ESP-600C Power Source
ITEM QTY PART CIRCUIT

NO. REQ. NO. DESCRIPTION SYMBOL
1 1 35749 BASE
2 1 35751 PANEL SIDE RIGHT
3 1 35753 COVER TOP
4 2 951032 LAMP LED RED 12 V PL4, PL5
5 1 2134926 LAMP INDICATOR AMBER PL3
6 2 951526 LAMP NEON WHT PL1, PL2
7 1 950122 CIRCUIT BREAKER 10 AMP CB1
8 1 950715 POTENTIOMETER 15K 2 W R50
9 1 2062170 KNOB R51
10 1 634518 SWITCH TOGL DPDT 2 POS S2
11 1 672508 SWITCH 10GL 3PST 2 POS S1
12 1 672671 AMMETER DC 0-800 AM
13 1 2062290 VOLTMETER 0-500 VDC VM
14 1 1006733 CONN BOX RECP 19P J1
15 1 35752 PANEL SIDE LEFT
16 1 35722 PANEL FRONT
30
4 3 2 1
9
9-(T4)
5 8
7
6
Figure 6-2. Front View

1 1 2062018 POTENTIOMETER 10K 2 W R51
2 1 951502 KNOB
3 1 950458 SWITCH TOGL DPDT 3 POS S3
4 1 38032 PC BOARD CONTROL PCB1
5 1 635568 TERMINAL BLOCK 18 POS TB1
6 1 951275 FILTER RFI FN4
7 1 995103 TERMINAL STRIP 24 POS TB9
8 1 950116 FILTER OMI FN3
9 2 995284 TRANSFORMER, CONTROL T3,4
31
6
4
3 8
9
2 7
10
1
Figure 6-3. Right Side View

1 1 35717 TRANSFORMER CONTROL T2
2 2 674969 PC BOARD FILTER FN1,2
3 2 950704 RECT SIL REV 85 A D29,30
4 2 950703 RECT SIL FOR 85 A D31,32
5 1 673168 TERMINAL STRIP 13 POS TB7
6 2 17300008 RESISTOR 8 OHM 300 W R17,16
7 1 17300001 RESISTOR 1 OHM 300 W R23,24
8 2 17300004 RESISTOR 4 OHM 300 W R20,19
9 1 35750 PANEL REAR
10 1 35710 INDUCTOR L2
32
3 4 5 6 7
2 8
10
Figure 6-4. Left Side View

1 3 678025 TERMINAL ASSY TB4,5,6
2 1 950173 CONTACTOR 3 POLE 210 AMP K1
3 1 673502 CONTACTOR 3 POLE 75 AMP K2
4 2 2046333 FUSE SLO-BLO 15.00A 600 V F1,2
5 2 951966 CAPACITOR 5.0 µF 800VDC C23,C24
6 2 672772 CAPACITOR 10 µF 370 V C25,26
7 2 17280210 RESISTOR 1K OHMS 100W R28,R29
8 3 17280010 RESISTOR 10 OHM 100W R25-27
9 1 950703 RECT SIL FOR 85 A D34
10 1 950704 RECT SIL REV 85 A D33
33
Figure 6-5. Rear View

1 1 35750 PANEL REAR
34
13 7
6
13
5
6
4
4
3
3
9
2 10
1 12 11
Figure 6-6. Top View

1 1 950704 RECT SIL REV 85A D35
2 3 672772 CAPACITOR 10 µF 370 V C34-36
3 5 17300008 RESISTOR 8 OHM 300 W R12-15,24
4 2 951997 TRANSDUCER CURRENT TD1, TD2
5 1 951282 SHUNT 100 mV 800 A SH1
6 4 951998 CAPACITOR .27 3 1200 VDC C19-C22
7 4 951996 MODULE DUAL DIODE RECTIFIER 80CV 30A D19-D22
8 2 2046333 FUSE SLO-BLO 15.00 A 600 V F3,4
9 17 951635 CAPACITOR 1900 µF 450 V C1-12,29,32
10 1 950255 CAPACITOR 60 µF 370 V C30
11 2 2062357 FUSE SLO-BLO 30.00 A 250 V F5, F7
12 1 951527 FUSE 15 A F6
13 2 951966 CAPACITOR 5 µF, 800 VDC C23,24
35
Figure 6-7. Back View

1 2 2062334 MOTOR FAN 1/3 HP M1, M2
2 6 17300001 RESISTOR 1 OHM 300 W R1-3, R21-23
3 3 17300004 RESISTOR 4 OHM 300 W R18-R20
4 2 17300008 RESISTOR 8 OHM 300 W R16, 17
36
2 3
6 4 6
7
6 8 5 3 6
5 5
Figure 6-8. Top View

1 2 38030 PC BOARD IGBT DRIVER PCB2.3
2 6 17750051 RESISTOR 10 OHM 50W NONINDUCTIVE R4-R9
3 6 951828 CAPACITOR .033 µF 830 V C13-C18
4 12 951635 CAPACITOR 1900 µF 450 V C1-12
5 3 951085 SWITCH THERMAL 176 °F TS4-6
6 4 995284 TRANSFORMER CONTROL T6-8
7 6 951184 MODULE DIODE FRD D1-6
8 2 pr 951951 IGBT MATCHED PAIR 600 A, 600 V. --
37
3 3
4
2 2
Figure 6-9. Middle View

1 1 677298 FUSE ASSY F8, F9
2 2 17280210 RESISTOR 1K OHMS 100 W R10,11
3 2 23610413 RESISTOR 2 OHM 23 W R53,R54
4 1 951816 FAN 230 V 50/60 Hz M3
5 1 35714 XFMR MAIN 400/460 V T1
1 35716 XFMR MAIN 460/575 V 60 Hz T1
38
3
2 8
Figure 6-10. Back View

1 6 17280210 RESISTOR 1K OHMS 100 W R10,11,28-31
2 4 2080196 RELAY 3-POT BRKT MT K3, K5-7
3 1 2231002 TERMINAL BLOCK 18 POS TB8
4 10 99511894 DIODE RECT REVERSE 800 V 30 A D7-12, 25-28
5 6 99511787 DIODE RECT FORWARD 800 V 300 A D13-D18
6 1 950711 SWITCH TERMINAL 194 °F TS7
7 2 35710 INDUCTOR L1,2
8 1 38034 PC BOARD AMMETER PCB4
39
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATIONS GUIDE - CUSTOMER SERVICES
A. CUSTOMER SERVICE QUESTIONS: Telephone (803) 664-5540/Fax: (800) 634-7548

Order Entry Product Availability Pricing Hours: 8:30 AM to 5:00 PM EST
Order Changes Saleable Goods Returns Delivery
Shipping Information
B. ENGINEERING SERVICE: Telephone: (803) 664-4416 / Fax : (800) 446-5693

Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations
C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (803) 664-4452

Part Numbers Technical Applications Hours: 8:00 AM to 5:00 PM EST
Performance Features Technical Specifications Equipment Recommendations
D. LITERATURE REQUESTS: Telephone: (803) 664-5501 / Fax: (803) 664-5548

Hours: 7:30 AM to 4:00 PM EST
E. WELDING EQUIPMENT REPAIRS: Telephone: (803) 664-4469 / Fax: (803) 664-5557

Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST
F. WELDING EQUIPMENT TRAINING:

Telephone: (803)664-4428 / Fax: (803) 664-4476
Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST
G. WELDING PROCESS ASSISTANCE:

Telephone: (803) 664-4248 / Fax: (803) 664-4454 Hours: 7:30 AM to 4:00 PM EST
H. TECHNICAL ASST. CONSUMABLES:

Telephone: (800) 934-9353 Hours: 7:30 AM to 5:00 PM EST
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123/ Fax: (803) 664-4452/Web: http://www.esab.com
Hours: 7:30 AM to 5:00 PM EST
F-15-237 10/95

ESP-600C Cutting Power Source: Instruction Manual

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

ESP-600C Cutting Power Source: Instruction Manual

Uploaded by

Copyright:

Available Formats

F-15-237

ESAB P/N 35609 - 460 V ac, 60 Hz

Be sure this information reaches the operator. ESAB Welding &

SECTION 1 DESCRIPTION ................................................................................................. 5

SECTION 2 INSTALLATION ................................................................................................ 8

SECTION 3 OPERATION ..................................................................................................... 11

SECTION 4 MAINTENANCE ............................................................................................... 16

SECTION 5 TROUBLESHOOTING ..................................................................................... 17

SECTION 6 REPLACEMENT PARTS .................................................................................. 29

ESP-600C ESP-600C ESP-600C

Current Range DC 100 A to 600 A

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

Power 129.8 KW 129.9 KW 129.6 KW

Height 40.25 in (102.24 cm)

NET WEIGHT 2040 lbs (925.34 kg)

Table 1-1. ESP-600C Specifications

Figure 1-1. ESP-600C Functional Block Diagram

Proper installation will contribute to safe, satisfactory, and

Take precautionary measures to ensure ring termi-

Before making any connections to

Table 2-1. Recommended Input Conductor and

Figure 2-1. Interconnection Diagram

NOTE B. Connect the positive (+) output cables to the

NOTE Whenever power source "No. 1" is used

3-4/0, 600 Volt Neg.

Figure 2-2. Parallel Configuration Diagram

3.1 INTRODUCTION D. FAULT indicator illuminates when there are ab-

C. CONTACTOR ON indicator illuminates when

Figure 3-1. ESP-600C Control Panel

A. Apply power by closing the line (wall) disconnect

THE BOOST/START CIRCUIT

MAX. OUTPUT VOLTAGE AT NOMINAL LINE

MAX. CURRENT RATING VREF = 7.50 V

INTERNAL MAX. CURRENT LIMIT

Figure 3-2. Volt-Ampere Curves

Figure 3-3. Start Current Waveforms

A. Minimum Start Current is controlled by the

C. Up-Slope Time. A three-position switch located

Figure 3-4. PCB1 Switch Locations

FACTORY DEFAULT POSITIONS SHOWN

#5 - 80 A MIN START CURRENT

Table 3-2. Switch 2 (SW2) Settings on Control PCB

FACTORY DEFAULT POSITIONS SHOWN

OFF BOTH SWITCHES "OFF" - BANG START

Table 3-3. (SW1) Settings on Control PCB

Figure 3-5. Start Current Settings

5.1 GENERAL 5. LED 8 (Amber) - Arc Voltage Cutoff Fault

LED 3 LED 4 LED 5 LED 6 LED 7 LED 8

LED 9 LED 10 LED 11 LED 12 LED 13

Figure 5-1. LED Switch Locations

Table 5-1. Troubleshooting Guide (Sheet 1 of 7)

PROBLEM POSSIBLE CAUSE ACTION

Faulty Fan(s). Replace fan(s).

CURRENT Pot set too low. Increase CURRENT Pot setting.

Fault condition, indicated by the Remove Control PCB access panel to

Fault condition, indicated by the Remove Control PCB access panel to

Current setting too low. Increase the current setting.

Table 5-1. Troubleshooting Guide (Sheet 2 of 7)

One or more shorted diode rectifiers Replace shorted diode rectifiers.

Blown F1 and F2. See F1 and F2 Blown under the

Imbalanced 3-phase input power. Maintain phase voltage imbalance of

Faulty Main Contactor (K1). Replace K1.