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.
You can get extra copies through your supplier.
ESAB Welding &
Cutting Products
F-15-237
October, 1995
INSTRUCTION MANUAL
ESP-600C
Cutting Power Source
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
0
100
200
300
400
500
600
D-C AMPERES
0
10
20
30
40
50
D-C VOLTS
HIGH
LOW
PANEL
REMOTE
CURRENT
OVER
TEMP
CONTACTOR
ON
FAULT
POWER
RESET
FAULT
MAIN
POWER
PILOT
ARC
A
V
5
6
7
8
4
3
9
MAX
MIN
V
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
3
WARNING: These Safety Precautions are for
your protection. They summarize precaution-
ary information from the references listed in
Additional Safety Information section. Before
performing any installation or operating procedures, be
sure to read and follow the safety precautions listed below
as well as all other manuals, material safety data sheets,
labels, etc. Failure to observe Safety Precautions can result
in injury or death.
PROTECT YOURSELF AND OTHERS --
Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation and
can injure skin and eyes. Hot metal can cause burns.
Training in the proper use of the processes and equip-
ment is essential to prevent accidents. Therefore:
1. Always wear safety glasses with side shields in any work
area, even if welding helmets, face shields, and goggles
are also required.
2. Use a face shield fitted with the correct filter and cover
plates to protect your eyes, face, neck, and ears from
sparks and rays of the arc when operating or observing
operations. Warn bystanders not to watch the arc and
not to expose themselves to the rays of the electric-arc
or hot metal.
3. Wear flameproof gauntlet type gloves, heavy long-sleeve
shirt, cuffless trousers, high-topped shoes, and a weld-
ing helmet or cap for hair protection, to protect against
arc rays and hot sparks or hot metal. A flameproof apron
may also be desirable as protection against radiated
heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cuffs, or pockets. Sleeves and collars should be
kept buttoned, and open pockets eliminated from the
front of clothing
5. Protect other personnel from arc rays and hot sparks
with a suitable non-flammable partition or curtains.
6. Use goggles over safety glasses when chipping slag or
grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety glasses.
FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot slag
or sparks can also cause fires and ex-
plosions. Therefore:
1. Remove all combustible materials well away from the
work area or cover the materials with a protective non-
flammable covering. Combustible materials include wood,
cloth, sawdust, liquid and gas fuels, solvents, paints and
coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or
crevices in floors or wall openings and cause a hidden
smoldering fire or fires on the floor below. Make certain
that such openings are protected from hot sparks and
metal.“
3. Do not weld, cut or perform other hot work until the
workpiece has been completely cleaned so that there
are no substances on the workpiece which might pro-
duce flammable or toxic vapors. Do not do hot work on
closed containers. They may explode.
4. Have fire extinguishing equipment handy for instant use,
such as a garden hose, water pail, sand bucket, or
portable fire extinguisher. Be sure you are trained in its
use.
SAFETY PRECAUTIONS
11/95
5. Do not use equipment beyond its ratings. For example,
overloaded welding cable can overheat and create a fire
hazard.
6. After completing operations, inspect the work area to
make certain there are no hot sparks or hot metal which
could cause a later fire. Use fire watchers when neces-
sary.
7. For additional information, refer to NFPA Standard 51B,
"Fire Prevention in Use of Cutting and Welding Pro-
cesses", available from the National Fire Protection Asso-
ciation, Batterymarch Park, Quincy, MA 02269.
ELECTRICAL SHOCK -- Contact with live
electrical parts and ground can cause
severe injury or death. DO NOT use AC
welding current in damp areas, if move-
ment is confined, or if there is danger of
falling.
1. Be sure the power source frame (chassis) is connected
to the ground system of the input power.
2. Connect the workpiece to a good electrical ground.
3. Connect the work cable to the workpiece. A poor or
missing connection can expose you or others to a fatal
shock.
4. Use well-maintained equipment. Replace worn or dam-
aged cables.
5. Keep everything dry, including clothing, work area, cables,
torch/electrode holder, and power source.
6. Make sure that all parts of your body are insulated from
work and from ground.
7. Do not stand directly on metal or the earth while working
in tight quarters or a damp area; stand on dry boards or
an insulating platform and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)
for specific grounding recommendations. Do not mistake
the work lead for a ground cable.
ELECTRIC AND MAGNETIC FIELDS —
May be dangerous. Electric current flow-
ing through any conductor causes lo-
calized Electric and Magnetic Fields
(EMF). Welding and cutting current cre-
ates EMF around welding cables and
welding machines. Therefore:
1. Welders having pacemakers should consult their physi-
cian before welding. EMF may interfere with some pace-
makers.
2. Exposure to EMF may have other health effects which are
unknown.
3. Welders should use the following procedures to minimize
exposure to EMF:
A. Route the electrode and work cables together. Secure
them with tape when possible.
B. Never coil the torch or work cable around your body.
C. Do not place your body between the torch and work
cables. Route cables on the same side of your body.
D. Connect the work cable to the workpiece as close as
possible to the area being welded.
E. Keep welding power source and cables as far away
from your body as possible.
4
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shield-
ing gases can cause asphyxiation.
Therefore:
1. Always provide adequate ventilation in the work area by
natural or mechanical means. Do not weld, cut, or gouge
on materials such as galvanized steel, stainless steel,
copper, zinc, lead, beryllium, or cadmium unless positive
mechanical ventilation is provided. Do not breathe fumes
from these materials.
2. Do not operate near degreasing and spraying opera-
tions. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly toxic
gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat irritation
while operating, this is an indication that ventilation is not
adequate. Stop work and take necessary steps to im-
prove ventilation in the work area. Do not continue to
operate if physical discomfort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specific ventilation recommendations.
CYLINDER HANDLING -- Cylinders, if
mishandled, can rupture and violently
release gas. Sudden rupture of cylin-
der, valve, or relief device can injure or
kill. Therefore:
1. Use the proper gas for the process and use the proper
pressure reducing regulator designed to operate from
the compressed gas cylinder. Do not use adaptors.
Maintain hoses and fittings in good condition. Follow
manufacturer's operating instructions for mounting regu-
lator to a compressed gas cylinder.
2. Always secure cylinders in an upright position by chain
or strap to suitable hand trucks, undercarriages, benches,
walls, post, or racks. Never secure cylinders to work
tables or fixtures where they may become part of an
electrical circuit.
3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not con-
nected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases in
Cylinders", which is available from Compressed Gas
Association, 1235 Jefferson Davis Highway, Arlington,
VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or im-
properly maintained equipment can cause
injury or death. Therefore:
1. Always have qualified personnel perform the installa-
tion, troubleshooting, and maintenance work. Do not
perform any electrical work unless you are qualified to
perform such work.
2. Before performing any maintenance work inside a power
source, disconnect the power source from the incoming
electrical power.
3. Maintain cables, grounding wire, connections, power cord,
and power supply in safe working order. Do not operate
any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces, wet
conditions such as water puddles, oil or grease, corrosive
atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position and
in good repair.
6. Use equipment only for its intended purpose. Do not
modify it in any manner.
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for elec-
tric arc welding and cutting equipment, ask
your supplier for a copy of "Precautions and
Safe Practices for Arc Welding, Cutting and
Gouging", Form 52-529.
The following publications, which are available from the
American Welding Society, 550 N.W. LeJuene Road, Miami,
FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon Arc
Gouging and Cutting"
5. AWS C5.5 - "Recommended Practices for Gas Tungsten
Arc Welding“
6. AWS C5.6 - "Recommended Practices for Gas Metal Arc
Welding"“
7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, "Recommended Safe Practices for Weld-
ing and Cutting of Containers That Have Held Hazardous
Substances."
This symbol appearing throughout this manual
means Attention! Be Alert! Your safety is
involved.
The following definitions apply to DANGER, WARNING,
CAUTION found throughout this manual:
Used to call attention to immediate haz-
ards which, if not avoided, will result in
immediate, serious personal injury or loss
of life.
Used to call attention to potential haz-
ards which could result in personal injury
or loss of life.
Used to call attention to hazards which
could result in minor personal injury.
SECTION 1 DESCRIPTION
5
1.1 INTRODUCTION
The ESP-600C cutting power source is designed for high
speed plasma cutting applications. It is normally used
with equipment such as the ESAB ESP Mechanized
Plasma System. For cutting currents beyond the rating of
the ESP-600C, two power sources may be connected in
parallel. The ESP-600C may also be operated in parallel
with the Ultralife-300 or ESP-400 power sources. Refer to
figure 1-1 for technical specifications.
1.2 DESCRIPTION
The ESP-600C is a solid state dc power source capable
of producing 100 to 600 amperes of cutting current at
100% duty (no cool-down period required). Cutting cur-
rent is regulated either locally from the power source's
front panel or remotely from a precision 0-10 volt refer-
ence (VREF) signal.
The ESP-600C uses a ripple cancellation technique to
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.
Internal components are maintained at proper operating
temperatures by forced air drawn through the power
source. This cooling air is generated by three internal
fans. If the flow of cooling air is inadequate, the ESP-600C
may overheat. If the power source does overheat, ther-
mal switches provide protection for the main transformer
and power semiconductor components. These switches
automatically reset when the components have cooled to
their normal operating temperature.
Solid state circuitry maintains constant-current output
independent of component heating and line voltage varia-
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.
Nuisance tripping is reduced by an excitation circuit that
practically eliminates high input currents to the main
transformer.
The ESP-600C is designed for ease of moving and
handling. Sufficient clearance at its base permits lifting
with a forklift truck. The power source may also be raised
with a crane or hoist using the lifting rings protruding
through the top cover.
Use both lifting rings when using a hoist or crane.
Using only one ring may distort and damage the
sheet metal parts.
SECTION 1 DESCRIPTION
6
Table 1-1. ESP-600C Specifications
ESP-600C
460 V, 60 Hz
(P/N 35609)
ESP-600C
400 V, 50 Hz
(P/N 35610)
ESP-600C
575 V, 60 Hz
(P/N 35611)
OUTPUT
(100% DUTY)
Voltage
200 V dc
Current Range DC
100 A to 600 A
Power
120 KW
Open Circuit
Voltage (OCV)
427 V dc
INPUT
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
KVA
142.6 KVA 142.7 KVA 142.4 KVA
Power
129.8 KW 129.9 KW 129.6 KW
Power Factor
91%
DIMENSIONS
(without skids)
Height
Width
Depth
40.25 in (102.24 cm)
37.25 in (94.62 cm)
45.00 in (114.3 cm)
NET WEIGHT
2040 lbs (925.34 kg)
SECTION 1 DESCRIPTION
7
Figure 1-1. ESP-600C Functional Block Diagram
8
SECTION 2 INSTALLATION
2.1 GENERAL
Proper installation will contribute to safe, satisfactory, and
trouble-free operation of the ESP-600C. This section
should be studied carefully and closely followed.
2.2 UNPACKING AND PLACEMENT
CAUTION
Use the two lifting eyes whenever lifting the unit. Do
not use just one of the lifting eyes.
A. Immediately upon receipt of the equipment, in-
spect for damage which may have occurred in
transit. Notify the carrier of any defects or dam-
age at once.
B. After removing the components from the ship-
ping container(s), check the container(s) for any
loose parts. Remove all packing materials.
C. Check air passages of the ESP-600C for any
packing materials that may obstruct air flow
through the power source.
D. If the equipment is not to be installed immedi-
ately, store it in a clean, dry, well-ventilated area.
E. The location of the power source should be
relatively close to a properly fused supply of
electrical power.
F. Locate the ESP-600C in an open area where air
can circulate freely. If space is at a premium,
leave at least 2 feet of clearance between the
nearest obstruction and the front and rear of the
power source. Also, keep the area beneath the
power source free of equipment and debris. The
area around the power source should be rela-
tively free of dust, fumes, and excessive heat. It
is also suggested to locate the power source so
the top cover and side panels can be removed
easily for cleaning and maintenance.
2.3 INPUT POWER CONNECTIONS
Electric shock can kill! Take precau-
tionary measures to provide maximum
protection against electrical shock. Before making
electrical connections between the power source
and the line (wall) disconnect switch, be sure that all
power is off by opening the line (wall) disconnect
switch.
A. Primary Power
The ESP-600C is a 3-phase unit and must be
connected to a 3-phase power line. Input power
must be provided from a line (wall) disconnect
switch that contains fuses or circuit breakers
sized in accordance with figure 2-1. Although
equipped with line voltage compensation, it is
suggested that the ESP-600C be connected to a
dedicated power line to prevent impaired perfor-
mance due to an overloaded circuit.
B. Input Conductors (not supplied)
Primary power is applied to the ESP-600C through
four insulated copper conductors (three power
leads and one ground lead) sized in accordance
with table 2-1. The leads may consist of a heavy
rubber covered cable or may be run in a solid or
flexible conduit.
NOTE
Input conductors must be terminated with ring terminals
sized for ½-inch hardware before being attached to the
ESP-600C.
1. Remove the left side panel of the ESP-600C.
2. Thread the conductor cables through the access
opening in the rear panel of the ESP-600C.
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.
SECTION 2 INSTALLATION
9
4. Connect the ground lead to the stud on the
chassis base below the primary terminals as
shown in figure 2-1.
It is of the utmost importance that the chassis be
connected to an approved electrical ground to pre-
vent accidental shock. Be sure the ground lead is
NOT connected to any primary terminal.
5. Connect the power lead ring terminals to the
primary terminals with the supplied bolts, wash-
ers, and nuts as shown in figure 2-1.
6. Connect the input conductors to the line (wall)
disconnecth.
Figure 2-1. Interconnection Diagram
2.4 OUTPUT CONNECTIONS
Before making any connections to
the power source output bus bars,
make sure the power source is
deenergized by opening the line (wall)
disconnect switch. To be doubly safe,
have a qualified person check the output bus bars
(positive and negative) with a voltmeter to be sure all
power is off.
A. Output Cables (not supplied)
Select plasma cutting output cables on the basis
of one 4/0 AWG, 600-volt insulated copper cable
for each 400 amps of output current. Do NOT use
ordinary 100-volt insulated welding cable.
1. Remove the access panel on the lower-front
panel of the power source.
2. Thread the output cables through the openings at
the bottom of the front panel or at the bottom of
the power supply immediately behind the front
panel.
3. Connect cables to the designated terminals
mounted inside the power source using UL listed
pressure wire connectors.
Rated Load
Volts Amps
Input &
Gnd.
Conductor*
CU/AWG
Time-Delay
Fuse Size
Amps
400
460
575
206
179
143
4/0
3/0
1/0
250
250**
200
* Sizes per National Electric Code for 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 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
10
SECTION 2 INSTALLATION
-
+
-
+
NOTE
Each bus bar terminal is labeled with a polarity mark to
help facilitate a standard plasma hookup (negative bus to
torch electrode and positive bus to the workpiece). For
parallel operation connections, refer to paragraph 2.5.
4. Attach access panel removed in step 1.
5. Complete the plasma system installation in
accordance with the appropriate instructional
literature.
2.5 PARALLEL INSTALLATION
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
For cutting currents below 200 A, use only one power
source.
A. Connect the negative (-) output cables to the
power receptacles located on the plumbing box
(high frequency generator) used in the cutting
setup.
B. Connect the positive (+) output cables to the
workpiece.
C. Connect the positive (+) and negative (-) connec-
tions between the power sources as shown in
figure 2-2.
D. Connect the pilot arc cable to the "appropriate
place in power source "No. 1."
E. Set the PILOT ARC HIGH/LOW switch in power
source "No. 2" to LOW.
F. Set PILOT ARC HIGH/LOW switch in power
source "No. 1" to HIGH.
Whenever power source "No. 1" is used
by itself in a parallel installation, the
negative output from power source "No.
2" must be disconnected from power
source "No. 1." Failure to disconnect
will make power source "No. 2" electrically "hot"
when power source "No. 1" is energized.
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
negative output cable of the power source 2 at both ends
(power source 2 and at the plumbing box). Insulate both
ends with electrical tape.
Second
Unit
4/0, 600 Volt
Cable Jumpers
Between Units
3-4/0, 600 Volt Neg.
Leads to Plumbing
Box (Hi-Freq Gen)
Power Receipts
First
Unit
Figure 2-2. Parallel Configuration Diagram
3-4/0, 600 Volts
Pos. Leads to
Workplace
Electrode
Electrode
Work
Work
SECTION 3 OPERATION
11
3.1 INTRODUCTION
This section is intended to familiarize personnel with the
operational procedures applicable to the ESP-600C cut-
ting power source. Read carefully before operating the
power source.
Never operate the ESP-600C with the top cover or
side panels removed. In addition to the safety hazard,
improper cooling may cause damage to internal com-
ponents.
3.2 CONTROL PANEL (FIGURE 3-1)
A. MAIN POWER indicator illuminates when input
power is applied to the power source.
B. OVER TEMP indicator illuminates when the power
source has overheated.
C. CONTACTOR ON indicator illuminates when
the main contactor is energized.
D. FAULT indicator illuminates when there are ab-
normalities in the cutting process or when the
input line voltage falls outside of the required
nominal value by ±10%.
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.
F. PANEL/REMOTE switch controls the location of
current control. Place in the PANEL position for
control from the power source (CURRENT po-
tentiometer). Place in the REMOTE position for
control from an external signal (CNC).
G. PILOT ARC HIGH/LOW switch allows selection
for either high pilot arc and low pilot arc.
H. Voltmeter displays arc voltage when cutting.
I. Ammeter displays current while cutting.
Figure 3-1. ESP-600C Control Panel
200
400
600
0
800
D-C AMPERES
200
400
5000
100
300
D-C VOLTS
CURRENT
PANEL
REMOTE
HIGH
LOW
CONTACTOR
ON
OVER
TEMP
FAULT
POWER
RESET
FAULT
MAIN
POWER
0
V
600
500
400
300
200
100
+
-
PILOT
ARC
A
V
12
SECTION 3 OPERATION
3.3 VOLT-AMPERE (SLOPE)
CHARACTERISTICS
The curves shown in figure 3-2 represent the volt-ampere
static characteristics of the ESP-600C. These curves
show the output voltage available at any given output
current between the minimum and maximum settings of
the "current control pot." Values for other settings fall
between the minimum and maximum curves. The output
curve is regulated with precision to within 1% of full output
by the 0-10 volt reference signal (VREF) from the CNC
control.
3.4 SEQUENCE OF OPERATION
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.
B. Select the location from which welding current
will be regulated on the PANEL/REMOTE switch,
either locally from the front panel or from a
precision remote reference.
C. Set PILOT ARC HIGH/LOW switch to HIGH for
cutting currents 250 A or higher. Set switch to
LOW for cutting currents below 250 A.
D. Commence plasma cutting operation in accor-
dance with the appropriate system instruction
manuals.
E. If a fault light illuminates, refer to section 5 for
troubleshooting information.
INTERNAL MAX. CURRENT LIMIT
V
REF
= 8.00 V
MAX. CURRENT RATING V
REF
= 7.50 V
700
V
REF
= 7.00 V
600
V
REF
= 6.00 V
500
MAX. OUTPUT VOLTAGE AT NOMINAL LINE
V
REF
= 5.00 V
400
V
REF
= 4.00 V
DC OUTPUT CURRENT (AMPERES)
300
V
REF
= 3.00 V
V
REF
= 2.00 V
200
427 V - OPEN CIRCUIT
THIS OUTPUT IS FROM
THE BOOST/START CIRCUIT
MIN. CURRENT RATING V
REF
= 1.25 V
V
REF
= 1.00 V
100
450
400
300
THRESHOLD
OF CURRENT
DETECTOR
200
100
DC OUTPUT VOLTAGE (VOLTS)
0
0
I
OUT
= 80 V
REF
Figure 3-2. Volt-Ampere Curves
SECTION 3 OPERATION
13
Figure 3-3. Start Current Waveforms
3.5 ARC INITIATION SETTINGS
The ESP-600C is equipped with an arc initiation feature
called Soft-Start. This feature uses a percentage of the
cutting current (start current) to ignite the arc and then
"ramps up" to the full cutting currrent. Figure 3-3 shows
the relationship between start current, dwell time, and up-
slope time. The ESP-600C is factory shipped with Soft-
Start enabled and with the default settings shown in table
3-1. In order to change these default settings to suit your
particular system, internal modifications (see paragraphs
A. - D. below) must be made to the power source. To
make these modifications, the access panel on the upper-
right corner of the front panel must be removed. After the
settings are changed, make sure the access panel is
replaced.
To disable Soft-Start, locate SW1 on PCB1 (refer to table
3-2) and push both rockers down. To enable Soft-Start
again, push both rockers up. Do not leave the rockers in
different positions.
Minimum Start Current
80 A
Start Current
50% of cut current
Up-Slope Time
800 msec
Dwell Time
50 msec
Table 3-1. Factory Default Settings
Electric shock can kill! Take precau-
tionary measures to provide maximum
protection against electrical shock. Be-
fore making electrical connections be-
tween the power source and the line (wall) discon-
nect switch, be sure that all power is off by opening
the line (wall) disconnect switch.
A. Minimum Start Current is controlled by the
selection of positions 5 thru 8 of SW2 on PCB1
(refer to figure 3-4). When a rocker is pushed on,
its value (refer to table 3-2) is added to the factory
set threshold of 40 A.
B. Start Current. Start current is set using the
START CURRENT potentiometer located for-
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
next to the START CURRENT knob is used to
change up-slope time.
D. Dwell Time. Dwell time is controlled by the
selection of positions 1 thru 4 of SW2 on PCB1.
When a position rocker is pushed on, its value is
added to the minimum dwell time of 10 msec.
Refer to table 3-2 for positional values.
DC OUTPUT CURRENT
TIME
Cut Current
I
OUT = 80 VREF
approximately 2 msec
rise time
Start Current Waveform vs. Time with Soft-Start OFF (Bang Start)
DC OUTPUT CURRENT
TIME
Cut Current
I
OUT = 80 VREF
Start Current Waveform vs. Time with Soft-Start ON
Start
Current
Dwell Time
Upslope Time
14
SECTION 3 OPERATION
SW2 SW1
Figure 3-4. PCB1 Switch Locations
FACTORY DEFAULT POSITIONS SHOWN
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.
1 2 3 4 5 6 7 8
ON
OFF
#1 - 10 mS DWELL TIME *
#2 - 20 mS DWELL TIME *
#3 - 40 mS DWELL TIME *
#4 - 80 mS DWELL TIME *
#5 - 80 A MIN START CURRENT
#6 - 40 A MIN START CURRENT
#7 - 20 A MIN START CURRENT
#8 - 10 A MIN START CURRENT
Table 3-2. Switch 2 (SW2) Settings on Control PCB
SECTION 3 OPERATION
15
1 2
ON
OFF
BOTH SWITCHES "ON" - SOFT START
BOTH SWITCHES "OFF" - BANG START
FACTORY DEFAULT POSITIONS SHOWN
Table 3-3. (SW1) Settings on Control PCB
Figure 3-5. Start Current Settings
80.0%
90.0%
10.0%
70.0%
60.0%
50.0%
40.0%
30.0%
20.0%
0.0%
1
0
(MIN)
23456
7
89
10
(MAX)
START CURRENT SETTING
PERCENTAGE (%) OF CUTTING CURRENT
SECTION 4 MAINTENANCE
16
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
ensure adequate circulation of cooling air, especially over
the heat sink extrusions and aluminum heat sinks in the
front of the power source. This power source is NOT
designed to be used with air filters of any kind. Any
obstruction to the free flow of cooling air may damage the
machine and void the warranty. The length of time be-
tween cleaning will depend on the location of the unit and
the amount of dust in the atmosphere.
4.3 LUBRICATION
Fan motors with oil tubes located on the side of the motor
require lubrication after 1 year of service. Motors without
oil tubes are permanently lubricated for life and should not
require any attention.
4.1 GENERAL
Electric shock can kill! Ensure the line
(wall) disconnect switch or circuit
breaker is open before attempting any
inspection or work on the inside of the power source.
Always wear safety goggles with side shields when
blowing out the power source with low pressure air.
Maintenance work must be performed by an experienced
person. Do not permit untrained persons to inspect,
clean, or lubricate this equipment.
4.2 CLEANING
Since there are no moving parts (other than the internal
fans) in the power source, maintenance consists mainly
of keeping the interior of the cabinet clean. Periodically,
SECTION 5 TROUBLESHOOTING
17
5.1 GENERAL
Electric shock can kill! Open wall (line)
disconnect switch or circuit breaker
before attempting inspection or work
inside of the power source.
If the power source does not operate properly, stop work
immediately and investigate the cause of the malfunction.
Troubleshooting work must be performed by an experi-
enced person, and electrical work by a trained electrician.
Do not permit untrained personnel to inspect or repair this
equipment. Use only recommended replacement parts.
5.2 INDICATORS
A. The 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%. If any of the LEDs listed below are illuminated,
then the FAULT indicator will also illuminate.
LEDs on PCB1 (refer to Figure 5-1)
1. LED 3 (Amber) - Bus Ripple Fault illuminates
when input power is first applied to the power
source and when single-phasing. When single-
phasing, an increased ripple in the bus voltage is
detected and the power source is shut down.
2. LED 4 (Amber) - High Bus Fault illuminates
when input line voltage is too high for proper
operation (approx. 20% above nominal line volt-
age rating). The power source is shut down.
3. LED 5 (Amber) - Low Bus Fault illuminates
when input line voltage is too low for proper
operation (approx. 20% below nominal line volt-
age rating). The power source is shut down.
4. LED 7 (Amber) - Arc Voltage Saturation Fault
illuminates when the cutting arc voltage is too
high and cutting current is below the preset level.
LED will extinguish after voltage decreases and
current rises to the preset level.
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.
B. POWER RESET FAULT Indicator illuminates when a
serious fault is detected. Input power must be discon-
nected for at least 5 seconds and then reapplied to clear
this fault. If any of the LEDs listed below are illuminated,
then the power RESET fault indicator will also illuminate.
LEDs on PCB1 (refer to Figure 5-1)
1. LED 6 (Red) - Right Overcurrent Fault illumi-
nates when the current out of the right-side
chopper is too high (>375 amps). This current is
measured by the right-side hall sensor. The
power source is shut down.
2. LED 9 (Red) - Left Overcurrent Fault illumi-
nates when the current out of the left-side chop-
per is too high (>375 amps). This current is
measured by the left-side hall sensor. The power
source is shut down.
3. LED 10 (Red) - Left IGBT Unsaturated Fault
illuminates when the left IGBT is not fully satu-
rated during its conduction period. The power
source is shut down.
4. LED 11 (Red) - Right IGBT Unsaturated Fault
illuminates when the right IGBT is not fully con-
ducting. The power source is shut down.
5. LED 12 (Red) - Left -12 V Bias Supply Fault
illuminates when the negative (-) 12-volt bias
supply to the left-side IGBT gate drive circuit
(located on PWM-drive board PCB2) is missing.
The power source is shut down.
6. LED 13 (Red) - Right -12 V Bias Supply Fault
illuminates when the negative (-) 12-volt bias
supply to the right-side IGBT gate drive circuit
(located on PWM-drive board PCB3) is missing.
The power source is shut down.
SECTION 5 TROUBLESHOOTING
18
5.3 FAULT ISOLATION
Check the problem using the following troubleshooting
guide (Table 5-1). The potential problems are listed in
"most probable" order, and the remedy may be quite
simple.
Figure 5-1. LED Switch Locations
LED 9
LED 10 LED 11 LED 13LED 12
LED 3 LED 4 LED 5 LED 6 LED 7 LED 8
If the cause of the malfunction cannot be located quickly,
open the power source and perform a simple visual
inspection of all components and wiring. Check for secure
terminal and plug connections, loose or burned wiring or
components, bulged or leaking capacitors, or any other
sign of damage or discoloration.
SECTION 5 TROUBLESHOOTING
19
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
only when "CONTACTOR ON" signal is
received.
None.
One or two fans do not run. Broken or disconnected wire in fan motor
circuit.
Faulty Fan(s).
Repair wire.
Replace fan(s).
Power Supply inoperable:
MAIN POWER Lamp is off.
Missing 3-phase input voltage.
Missing one phase of 3-phase input
voltage.
Restore all three phases of input
voltage to within ±10% of nominal line.
Restore all three phases of input
voltage to within ±10% of nominal line.
Main Arc transfers to the
work with a short "pop"
placing only a small dimple
in the work.
PANEL/REMOTE switch in "REMOTE"
position with no remote control of current.
Remote Current Control present but
signal missing.
CURRENT Pot set too low.
Start Current Pot, located behind the
cover for the Control PCB, is set too low.
Place PANEL/REMOTE switch in
"PANEL" position.
Check for Current Reference Signal at
TB1-4(+) and TB1-5(-). See Figure 3-2
for the value of the Current Reference
Signal versus Output Current.
Increase CURRENT Pot setting.
Increase the Start Current Pot setting to
"7".
FAULT Light illuminates at
end of cut but goes off at
the start of the next.
This is a 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.
Reprogram cutting process to ensure
arc is terminated only by removing the
"Contactor On" signal from the unit.
Power Supply turns off
prematurely in the middle
of the cut.
"Contactor On" signal is removed from
unit.
Momentary loss of primary input power.
Fault condition, indicated by the
illumination of the FAULT lamp.
Fault condition, indicated by the
illumination of the POWER RESET
FAULT lamp.
Current setting too low.
Power Supply is OK. Troubleshoot
process controller.
Restore and maintain input voltage
within ±10% of nominal.
Remove Control PCB access panel to
determine the fault causing the
shutdown, and refer to the specfic fault
in the "Problem" column.
Remove Control PCB access panel to
determine the fault causing the
shutdown, and refer to the specific fault
in the "Problem" column.
Increase the current setting.
SECTION 5 TROUBLESHOOTING
20
Table 5-1. Troubleshooting Guide (Sheet 2 of 7)
PROBLEM POSSIBLE CAUSE ACTION
Power Supply turns off
prematurely in the middle
of the cut - (Cont)
Remote Current Signal removed during
cut.
Fix remote Current Signal or operate
the Power Supply with the
PANEL/REMOTE switch in the
"PANEL" position.
FAULT:BUS RIPPLE
(LED3 - amber)
Imbalanced 3-phase input power.
Momentary loss of one phase of input
power.
Faulty Control Printed Circuit Board
(PCB).
Maintain phase voltage imbalance of
less than 5%.
Restore and maintain input power
within ±10% of nominal voltage.
Replace Control PCB P/N 38032.
FAULT:HIGH BUS (LED4 -
amber)
One or more phases of input voltage
exceed nominal line voltage by more than
20%.
Faulty Control Printed Circuit Board
(PCB).
One or more shorted diode rectifiers
(D25-D28) on the "ELECTRODE
PLATE".
Restore and maintain input voltage
within ±10% of nominal.
Replace Control PCB P/N 38032.
Replace shorted diode rectifiers.
FAULT: LOW BUS
(LED5 - amber)
One or more phases of input voltage are
lower than nominal line voltage by more
than 15%.
Blown F1 and F2.
OVER TEMPerature Light comes on.
Imbalanced 3-phase input power.
Momentary loss of one phase of input
power.
Faulty Main Contactor (K1).
Faulty Control Printed Circuit Board
(PCB).
Restore and maintain input voltage
within ±10% of nominal.
See F1 and F2 Blown under the
PROBLEM column.
See "OVER TEMP Light Comes on"
under the PROBLEM column.
Maintain phase voltage imbalance of
less than 5%.
Restore and maintain input power
within ±10 of
Replace K1.
Replace Control PCB P/N 38032.
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