ESAB ESP-600C Cutting Power Source User manual

Brand: ESAB

Model: ESP-600C Cutting Power Source

Category: Welding System

Type: User manual

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

100

200

300

400

500

600

D-C AMPERES

D-C VOLTS

HIGH

LOW

PANEL

REMOTE

CURRENT

OVER

TEMP

CONTACTOR

FAULT

POWER

RESET

FAULT

MAIN

POWER

PILOT

ARC

MAX

MIN

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

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.

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

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

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

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

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

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

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

Work

SECTION 3 OPERATION

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

800

D-C AMPERES

200

400

5000

100

300

D-C VOLTS

CURRENT

PANEL

REMOTE

HIGH

LOW

CONTACTOR

OVER

TEMP

FAULT

POWER

RESET

FAULT

MAIN

POWER

600

500

400

300

200

100

PILOT

ARC

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

REF

= 8.00 V

MAX. CURRENT RATING V

REF

= 7.50 V

700

REF

= 7.00 V

600

REF

= 6.00 V

500

MAX. OUTPUT VOLTAGE AT NOMINAL LINE

REF

= 5.00 V

400

REF

= 4.00 V

DC OUTPUT CURRENT (AMPERES)

300

REF

= 3.00 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

REF

= 1.00 V

100

450

400

300

THRESHOLD

OF CURRENT

DETECTOR

200

100

DC OUTPUT VOLTAGE (VOLTS)

OUT

= 80 V

REF

Figure 3-2. Volt-Ampere Curves

SECTION 3 OPERATION

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

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

OUT = 80 VREF

Start Current Waveform vs. Time with Soft-Start ON

Start

Current

Dwell Time

Upslope Time

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

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

1 2

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%

(MIN)

23456

(MAX)

START CURRENT SETTING

PERCENTAGE (%) OF CUTTING CURRENT

SECTION 4 MAINTENANCE

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

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

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

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

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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ESAB ESP-600C Cutting Power Source User manual

Brand: ESAB

Model: ESP-600C Cutting Power Source

Category: Welding System

Type: User manual

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ESAB ESP-600C Cutting Power Source User manual

ESAB ESP-600C Cutting Power Source User manual

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