Esp-600c Plasma Power Supply F-15-656

F-15-656
Jun., 2005
Installation, Operation, and Maintenance for the
ESP-600C
Plasma Power Source
The equipment described in this manual is
potentially hazardous. Use caution when installing,
operating and maintaining this equipment.
Purchaser is solely responsible for the safe

operation and use of all products purchased,
including compliance with OSHA and other
government standards. ESAB Cutting
Systems has no liability for personal injury or
other damage arising out of the use of any
product manufactured or sold by ESAB. See
standard ESAB terms and conditions of sale
for a specific statement of ESAB’s
responsibilities and limitations on its liability.
ESAB Cutting Systems first priority is total

customer satisfaction. We constantly look for
ways to improve our products, service and
documentation. As a result, we make
enhancements and/or design changes as
required. ESAB makes every possible effort to
ensure our documentation is current. We
cannot guarantee that each piece of
documentation received by our customers
reflects the latest design enhancements.
Therefore, the information contained in this
document is subject to change without notice.
This manual is ESAB Part Number F15656
This manual is for the convenience and use of the

cutting machine purchaser. It is not a contract or
other obligation on the part of ESAB Cutting
Systems.
© ESAB Cutting Systems, 2000
Printed in U.S.A.
ESP-600C Plasma Power Source Table of Contents
Page
Section 1 Safety
1.1 Introduction 1
1.2 Safety Notations And Symbols 1
1.3 General Safety Information 2
1.4 Installation Precautions 3
1.5 Electrical Grounding 4
1.6 Operating A Plasma Cutting Machine 4-7
1.7 Service Precautions 8
1.8 Safety References 9
Section 2 Description
2.1 General 1
2.2 General Specifications 1
2.3 Dimensions and Weight 2
Section 3 Installation
3.1 General 1
3.2 Unpacking 1
3.3 Placement 2
3.4 Input Power Connections 2-5
3.4.1 Primary Power 3
3.4.2 Input Conductors 4
3.4.3 Input Connection Procedure 4-5
3.5 Output Connections 5-6
3.5.1 Output Cables 5
3.5.2 Output Connection Procedure 5
3.6 Parallel Installation 6-7
3.7 System Interconnecting Block Diagram with Smart Flow II 8
3.8 System Interconnecting Block Diagram without Smart Flow II 9
Section 4 Operation
4.1 Introduction 1
4.2 Control Panel 1-3
4.3 Sequence of Operation 4
4.4 Arc Initiation Settings 4-7
4.4.1 Enable/Disable Arc Initiation Timer 6
4.4.2 Adjusting Arc Initiation Timer 6
4.4.3 Arc Initiation Controls 7
4.4.4 Start Current and Up-slope Timer 7
4.5 V-I Curve 8
i
Section 5 Maintenance
5.1 General 1
5.2 Cleaning 1
5.3 Fan Lubrication 2
Section 6 Troubleshooting
6.1 General 1
6.2 Fault Indicators 1-3
6.3 Fault Isolation (Diagnostics) 4-10
6.3.1 Fans 4
6.3.2 Power not on or Low Voltage 4
6.3.3 Fault Light Illumination 5-8
6.3.4 Torch will not Fire 9
6.3.5 Fuses 1 and 2 Blown 10
6.3.6 Intermittent, interrupted or Partial Operation 10-12
6.4 Testing and Replacing Components 13
6.4.1 Power Rectifiers 14
Negative Plate 14
Positive Plate 15
Electrode Plate 15
6.4.2 Freewheeling Diodes and IGBTs 16-18
6.4.3 Power Shunt Installation 18
6.4.4 Procedure for Verifying Calibration of Digital Meters 19
6.5 ESP-600C Schematic Diagrams 20-27
6.6 Wiring Diagrams 28-35
6.7 PC Controller Board (PCB1 - P/N 38032) Schematics 36-40
6.8 PCB Digital Meter Board (PCB4 – P/N 38139) Schematics 41-43
6.9 IGBT Driver Board (PCB2,3 – P/N 38030) Schematics 44-46
ii
Section 7 Replacement Parts

7.1 General 1
7.2 Ordering 1
7.3 Outside View - Front and Back 2-3
7.4 Front View With PCBs Exposed 4-5
7.5 Right Side View 6-7
7.6 Left Side View 8-9
7.7 Top View 10-11
7.8 Back Inside View 12-13
7.9 Middle Cross Section 14-15
7.10 Front Cross Section – Behind Front Panel 16-17
Customer/Technical Information Back Manual Cover
iii
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iv
SECTION 1 SAFETY
1.1 Introduction
The process of cutting metals with plasma equipment
provides industry with a valuable and versatile tool.
ESAB cutting machines are designed to provide both
operation safety and efficiency. However, as with any
machine tool, sensible attention to operating
procedures, precautions, and safe practices is
necessary to achieve a full measure of usefulness.
Whether an individual is involved with operation,
servicing, or as an observer, compliance with
established precautions and safe practices must be
accomplished. Failure to observe certain precautions
could result in serious personnel injury or severe
equipment damage. The following precautions are
general guidelines applicable when working with
cutting machines. More explicit precautions pertaining
to the basic machine and accessories are found in the
instruction literature. For a wide scope of safety
information on the field of cutting and welding
apparatus, obtain and read the publications listed in
the Recommended References.
1.2 Safety Notations And Symbols The following words and symbols are used throughout
this manual. They indicate different levels of required
safety involvement.
ALERT or ATTENTION. Your safety is involved

! or potential equipment failure exists. Used with
other symbols and information.
Used to call attention to immediate hazards

! DANGER which, if not avoided, will result in serious
personal injury or loss of life.
Used to call attention to potential hazards

! WARNING that could result in personal injury or loss of
life.
Used to call attention to hazards that could

! CAUTION result in minor personal injury or equipment
damage.
Used to call attention to minor hazards to

CAUTION equipment.
Used to call attention to important

installation, operation or maintenance
NOTICE information not directly related to safety
hazards.
ESP-600Clasma Power Source 1-1
SECTION 1 SAFETY
1.3 General Safety Information
Machinery often starts automatically.

! WARNING
This equipment moves in various directions and
speeds.
• Moving machinery can crush.

• Only qualified personnel should operate or service
this power source.
• Keep all personnel, materials, and equipment not
involved in production process clear of entire
system area.
• Fence off entire work cell to prevent personnel
from passing through area or standing in the
working envelope of the equipment.
• Post appropriate WARNING signs at every work
cell entrance.
• Follow lockout procedure before servicing any
equipment.
Failure to follow operating instructions

! WARNING could result in death or serious injury.
Read and understand this operator’s manual before

using machine.
• Read entire procedure before operating or

performing any system maintenance.
• Special attention must be given to all hazard

warnings that provide essential information
regarding personnel safety and/or possible
equipment damage.
• All safety precautions relevant to electrical

equipment and process operations must be
strictly observed by all having system
responsibility or access.
• Read all safety publications made available by

your company.
1-2 ESP-600Clasma Power Source

SECTION 1 SAFETY
Failure to follow safety warning label

! WARNING instructions could result in death or
serious injury.
Read and understand all safety warning labels on

machine.
Refer to operator’s manual for additional safety

information.
1.4 Installation Precautions
! WARNING Improperly Installed Equipment Can Cause

Injury Or Death.
Follow these guidelines while installing machine:
• Contact your ESAB representative before

installation. He can suggest certain precautions
regarding piping installation and machine lifting,
etc. to ensure maximum security.
• Never attempt any machine modifications or

apparatus additions without first consulting a
qualified ESAB representative.
• Observe machine clearance requirements for

proper operation and personnel safety.
• Always have qualified personnel perform

installation, troubleshooting and maintenance of
this equipment.
• Provide a wall mounted disconnect switch with

proper fuse sizes close to the power supply.

SECTION 1 SAFETY
1.5 Electrical Grounding
Electrical grounding is imperative for proper machine
operation and SAFETY. Refer to this manual’s
Installation section for detailed grounding instructions.
Electric shock hazard.

! WARNING
Improper grounding can cause severe injury or death.
Machine must be properly grounded before put into

service.
1.6 Operating A Plasma Cutting Machine
! WARNING Flying debris and loud noise hazards.

• Hot spatter can burn and injure eyes. Wear
goggles to protect eyes from burns and flying
debris generated during operation.
• Chipped slag may be hot and fly far. Bystanders
should also wear goggles and safety glasses.
• Noise from plasma arc can damage hearing. Wear

correct ear protection when cutting above water.
! WARNING Burn hazard.

Hot metal can burn.
• Do not touch metal plate or parts immediately after

cutting. Allow metal time to cool, or douse with
water.
• Do not touch plasma torch immediately after
cutting. Allow torch time to cool.

SECTION 1 SAFETY
! WARNING Hazardous voltages. Electric shock

can kill.
• Do NOT touch plasma torch, cutting table or cable
connections during plasma cutting process.
• Always turn power off to plasma power supplies
before touching or servicing plasma torch.
before servicing any system component.
• Do not touch live electrical parts.
• Keep all panels and covers in place when machine
is connected to power source.
• Wear insulating gloves, shoes and clothing to
insulate yourself from workpiece and electrical
ground.
• Keep gloves, shoes, clothing, work area, and
equipment dry.
• Replace worn or damaged cables.
Fume hazard.
! WARNING
Fumes and gases generated by the plasma cutting
process can be hazardous to your health.
• Do NOT breathe fumes.

• Do not operate plasma torch without fume removal
system operating properly.
• Use additional ventilation to remove fumes if
necessary.
• Use approved respirator if ventilation is not

adequate.
• Provide positive mechanical ventilation when

cutting galvanized steel, stainless steel, copper,
zinc, beryllium, or cadmium. Do not breathe these
fumes.
• Do not operate near degreasing and spraying

operations. Heat or arc rays can react with
chlorinated hydrocarbon vapors to form phosgene,
a highly toxic gas and other irritant gases.

SECTION 1 SAFETY
Radiation hazard.
! WARNING
Arc rays can injure eyes and burn skin.
• Wear correct eye and body protection.
• Wear dark safety glasses or goggles with side
shields. Refer to following chart for recommended
lens shades for plasma cutting:
Arc Current Lens Shade
Up to 100 Amps Shade No. 8
100-200 Amps
AmpsShade
Shade No. 10
200-400 Amps
AmpsShade
Shade No. 12
Over 400 Amps Shade No. 14
• Replace glasses/goggles when lenses are pitted or
broken
• Warn others in area not to look directly at the arc
unless wearing appropriate safety glasses.
• Prepare cutting area to reduce reflection and
transmission of ultraviolet light.
§ Use special paint on walls to absorb UV
light.
§ Install protective screens or curtains to
reduce ultraviolet transmission.
! WARNING Burn Hazard.

Heat, spatter, and sparks cause fire and burns.
• Do not cut near combustible material.

• Do not have on your person any combustibles (e.g.
butane lighter).
• Pilot arc can cause burns. Keep torch nozzle
away from yourself and others when activating
plasma process.
• Wear correct eye and body protection.
• Wear gauntlet gloves, safety shoes and hat.
• Wear flame-retardant clothing covering all exposed
areas.
• Wear cuffless trousers to prevent entry of sparks
and slag.
• Have fire extinguishing equipment available for use.

SECTION 1 SAFETY
! WARNING Explosion hazard.

• Certain molten aluminum-lithium (Al-
(Al-Li)
Li) alloys can
cause explosions when plasma cut OVER water.
§ These alloys should only be dry cut on a dry
table.
§ DO NOT dry cut over water.
§ Contact your aluminum supplier for
additional safety information regarding
hazards associated with these alloys.
• Do not cut in atmospheres containing explosive
dust or vapors.
• Do not carry any combustibles on your person

(e.g. butane lighter)
• Do not cut containers that have held combustibles.

SECTION 1 SAFETY
1.7 Service Precautions
! WARNING Hazardous voltages. Electric shock

can kill.
• Do NOT touch plasma torch, cutting table or cable
connections during plasma cutting process.
before touching or servicing plasma torch.
before removing covers or panels to service any
system component.
• Do not touch live electrical parts.
• Keep all panels and covers in place when machine
is connected to power source.
• Keep gloves, shoes, clothing, work area, and
equipment dry.
• Inspect power and ground leads cables for wear or
cracking. Replace worn or damaged cables. Do
not use if damaged.
• Never bypass safety interlocks.
• Follow lock-out procedures.
Establish and adhere to preventive maintenance. A

CAUTION composite program can be established from
recommended schedules.
Avoid leaving test equipment or hand tools on

machine. Severe electrical or mechanical damage
could occur to equipment or machine.
! CAUTION Extreme caution should be used when probing

circuitry with an oscilloscope or voltmeter. Integrated
circuits are susceptible to over voltage damage.
Power off before using test probes to prevent
accidental shorting of components.
All circuit boards securely seated in sockets, all cables

properly connected, all cabinets closed and locked, all
guards and covers replaced before power is turned
on.

SECTION 1 SAFETY
1.8 Safety References
The following nationally recognized publications on safety in welding
and cutting operations are recommended. These publications have
been prepared to protect persons from injury or illness and to protect
property from damage, which could result from unsafe practices.
Although some of these publications are not related specifically to this
type of industrial cutting apparatus, the principles of safety apply
equally.
• “Precautions and Safe Practices in Welding and Cutting with
Oxygen-Fuel Gas Equipment,” Form 2035. ESAB Cutting
Systems.
• “Precautions and Safe Practices for Electric Welding and Cutting,”
Form 52-529. ESAB Cutting Systems.
• “Safety in Welding and Cutting” - ANSI Z 49.1, American Welding
Society, 2501 NW 7th Street, Miami, Florida, 33125.
• “Recommended Safe Practices for Shielded Gases for Welding and
Plasma Arc Cutting” - AWS C5.10-94, American Welding Society.
• “Recommended Practices for Plasma Arc Welding” - AWS C5.1,
American Welding Society.
• “Recommended Practices for Arc Cutting” - AWS C5.2, American
Welding Society.
• “Safe Practices” - AWS SP, American Welding Society.
• “Standard for Fire Protection in Use of Cutting and Welding
Procedures” - NFPA 51B, National Fire Protection Association, 60
Batterymarch Street, Boston, Massachusetts, 02110.
• “Standard for Installation and Operation of Oxygen - Fuel Gas
Systems for Welding and Cutting” - NFPA 51, National Fire
Protection Association.
• “Safety Precautions for Oxygen, Nitrogen, Argon, Helium, Carbon
Dioxide, Hydrogen, and Acetylene,” Form 3499. ESAB Cutting
Systems. Obtainable through your ESAB representative or local
distributor.
• "Design and Installation of Oxygen Piping Systems," Form 5110.
ESAB Cutting Systems.
• “Precautions for Safe Handling of Compressed Gases in
Cylinders”, CGA Standard P-1, Compressed Gas Association.
Literature applicable to safe practices in welding and cutting with
gaseous materials is also available from the Compressed Gas
Association, Inc., 500 Fifth Ave., New York, NY 10036.

SECTION 1 SAFETY

SECTION 2 Description
2.1 Introduction
The ESP power Source is designed for high speed
plasma mechanized cutting applications. It can be
used with other ESAB products such as the PT-15
and PT-600 torches along with the Smart Flow II, a
computerized gas regulation and switching system.
• 50 to 600 Amperes cutting current range
• Forced air cooled
• Solid state DC power
• Input voltage protection
• Local or remote front panel control
• Thermal switch protection for main transformer

and power semiconductor components
• Top lifting rings or base forklift clearance for

transport
• Parallel secondary power source capabilities to

extend current output range.
2.2 General Specifications

ESP-600C 400V, ESP-600C 460V, ESP-600C 575V,
50Hz 60Hz 60Hz
Color Scheme Black Yel-gry Black Yel-gry Black Yel-gry
Part Number 35879 35610 35878 35609 35880 35611
Voltage 200 V dc
Current range
50A to 600A
OUTPUT (100 DC
% duty cycle) Power 120KW
Open Circuit
427 V dc
Voltage (OCV)
Voltage
400 V 460 V 575 V
(3-phase)
Current
206 A RMS 179 A RMS 143 A RMS
(3- phase)
Frequency 50/60 HZ 60 Hz 60 Hz
INPUT
KVA 142.7 KVA 142.6 KVA 142.4 KVA
Power 129.9 KW 129.8 KW 129.6 KW
Power Factor 91 %
Fuse Recom. 250A 250A 200A
ESP 600C Plasma Power Source 2-1

SECTION 2 Description
2.3 Dimensions and Weight
Front View
400
300 500
OUTPUT
200 600
MAX
AMPS
100
50
MIN
0 MAIN
CURRENT POWER
VOLTS
PILOT HIGH PANEL
ARC
ACTUAL AMPS LOW REMOTE

OVER
TEMP 600C
CONTACTOR
ON
PRESET AMPS
FAULT
POWER
RESET
FAULT
40.25"
(102.24cm)
37.25"
(94.62cm) Side View
Weight = 2040 lbs.

(925.34 kg.)
45.00"
(114.3cm)
2-2 ESP 600C Plasma Power Source

SECTION 3 Installation
3.1 General
Failure To Follow Instructions Could
! WARNING Lead To Death, Injury Or Damaged
Property
Follow these instructions to prevent injury

or property damage.
You must comply with local, state and

national electrical and safety codes.
3.2 Unpacking
Using One Lifting Eye Will Damage
CAUTION Sheet Metal And Frame
Use both lifting eyes when transporting

with overhead method.
Unit weighs over 2000 lbs. Use approved

6 0 0 C
straps or cables in good condition.
• Inspect for transit damage immediately upon

receipt.
• Remove all components from shipping
container and check for loose parts in container.
• Inspect louvers for air obstructions.
ESP-600C Plasma Power Source 3-1

3.3 Placement
Note: Use both lifting eyes when transporting
from overhead.
• A minimum of 2 ft. clearance on front and back
for cooling air flow.
Power • Plan for top panel and side panels having to be

Source removed for maintenance, cleaning and
inspection.
• Locate the ESP-600C relatively close to a
properly fused electrical power supply.
• Keep area beneath power source clear for
cooling air flow.
• Environment should be relatively free of dust,
fumes and excessive heat. These factors will
affect cooling efficiency.
Conductive Dust And Dirt Inside

CAUTION Power Source May Cause Arc Flash-
Over
Equipment damage may occur. Electrical
shorting may occur if dust is allowed to build-up
inside power source. See maintenance section.
3.4 Input Power Connection

Electric Shock Can Kill!
! WARNING
Provide maximum protection against
electrical shock.
Before any connections are made inside

the machine, open the line wall disconnect
switch to turn power off.
3-2 ESP-600C Plasma Power Source

3.4.1 Primary Power
ESP-600C is a 3-phase unit. Input power must be
provided from a line (wall) disconnect switch that
contains fuses or circuit breakers in accordance to
local or state regulations.
Recommended input conductor and line fuse sizes:

Rated Load Input and Time delay
Ground Fuse size
Volts Amperes conductor* (amperes)
CU/AWG
400 206 4/0 250
460 179 3/0 250**
575 143 1/0 200
*Sizes per National Electrical Code for a 90 °C rated
copper conductors @ 40 °C ambient. Not more than
three conductors in raceway or cable. Local codes
should be followed if they specify sizes other than those
listed above.
**During heavy duty cutting at 600A, input current can

momentarily rise above 200A and cause nuisance
blowing of 200A fuses. When cutting currents are below
500A, 200A fuses are sufficient.
Dedicated power line may be necessary.

NOTICE ESP-600C is equipped with line voltage
compensation but to avoid impaired performance
due to an overloaded circuit, a dedicated power
line may be required.

3.4.2 Input Conductors
• Customer supplied
• May consist either of heavy rubber covered
copper conductors (three power and one
ground) or run in solid or flexible conduit.
• Sized according to the chart.
Input conductors must be terminated with

NOTICE ring terminals.
Input conductors must be terminated with ring

terminals sized for ½" hardware before being
attached to the ESP-600C.
3.4.3 Input Connection Procedure
1. Remove left side panel of the ESP-600C

2. Thread cables through the access opening in
the rear panel.
3. Secure cables with a strain relief or conduit
coupling (not supplied) at the access opening.
Primary
Terminals 4. Connect the ground lead to the stud on the
chassis base.
5. Connect the power lead ring terminals to the
Power Input Cable primary terminals with supplied bolts, washers
Access opening Chassis Ground and nuts.
(rear panel)
6. Connect the input conductors to the line (wall)
disconnect.


! WARNING
Ring terminals must have clearance between
side panel and main transformer. Clearance
must be sufficient to prevent possible arcing
Make sure cables do not interfere with cooling

fan rotation.
Improper Grounding Can Result In

! WARNING Death or Injury.
Chassis must be connected to an approved
electrical ground.
Be sure ground lead is NOT connected to any

primary terminal.
3.5 Output Connections
Electric Shock Can Kill! Dangerous

! WARNING Voltage And Current!
Any time working around a plasma power
source with covers removed:
• Disconnect power source at the line(wall)

disconnect.
• Have a qualified person check the output

bus bars (positive and negative) with a
voltmeter.
3.5.1 Output Cables (customer supplied)

Choose plasma cutting output cables (customer
supplied) on the basis of one 4/0 AWG, 600 volt
insulated copper cable for each 400 amps of output
current.
Note: Do not use 100 volt insulated welding

cable.

3.5.2 Output Connection Procedure
Access Panel
1. Remove access panel on the lower front of the

power source.
2. Thread output cables through the openings at
the bottom of the front panel or at the bottom of
the power source immediately behind the front
panel.
3. Connect cables to designated terminals
mounted inside the power source using UL
listed pressure wire connectors.
4. Replace panel removed during the first step.
3.6 Parallel Installation

Two power sources may be connected together to
extend the output current range.
Parallel power source start currents

CAUTION exceed recommended amounts when
cutting below 100A.
Use Only One Power Source For Currents

Below 100A.
We recommend disconnecting the negative

lead from the secondary power source when
changing to currents below 100 amperes.
This lead should be safely terminated
(insulated) to protect against electric shock.

Note: Primary power source has the electrode
Connections for Parallel Installation (-) conductor jumpered. The secondary power
of 2 Power sources source has the work (+) jumpered.
Secondary Power Primary Power 1. Connect the negative (-) output cables to the
Source Source plumbing box (high frequency generator).
work electrode work electrode
(+) (-) (+) pilot arc (-)
2. Connect the positive (+) output cables to the
workpiece.
3. Connect the positive (+) and negative (-)
conductors between the power sources.
4. Connect the pilot arc cable to the pilot arc
terminal in the primary power source. The pilot
arc connection in the secondary power source
is not used. The pilot arc circuit is not run in
3 - 4/0 600V 4/0 600V Cable 1 - 14 AWG 600V 3 - 4/0 600V
positive leads to jumpers lead to pilot negative leads parallel.
workpiece between units arc connection to plumbing box
in plumbing box (h.f. generator) 5. Set the Pilot Arc HIGH/LOW switch on the
(h.f. generator) secondary power source to “LOW”.
6. Set the Pilot Arc HIGH/LOW switch on the
primary power source to “HIGH”.

! WARNING
Exposed Electrical Conductors Can
Be Hazardous!
Do not leave electrically “hot “ conductors

exposed. When disconnecting the
secondary power source from the primary,
Secondary Power Primary Power
verify the correct cables were
Source Source disconnected. Insulate the disconnected
work
(+)
electrode work
(+)
electrode
(-)
ends.
(-)
When using only one power source in a

parallel configuration, the negative
electrode conductor must be disconnected
from the secondary power source and the
plumbing box. Failure to do this will leave
the secondary electrically “hot”.
Disconnect
negative
3 - 4/0 600V connection from 3 - 4/0 600V
positive leads to secondary power source negative leads
workpiece and insulate to to plumbing box
convert from two (high freq.
to one power generator)
sources

3.7 System Interconnecting Block Diagram with Smart Flow II
3 phase
w/ground
Remote to
CNC ESP C
CNC -
Fron 600C -600
t vie ESP view
w Back
600C
CNC I/O to
Smart Flow II
On/Off
N2 O2 Air H-35 Control
Torch (-)
Pilot Arc
Work (+)
Smart
Flow II
WC-7
Water
Cut Water
Cooler
Pump
(for PT-15) Cooling Water
To Torch
Cooling Water
From Torch Voltage
Height
Control
Plasma Torch
Bundle and
Torch
Earth Ground

3.8 System Interconnecting Block Diagram with Manual Flow Control
(+) Return
Wall Lead
Gas Box (-) Cut
Regulators Input
Power Source Current
power
Pilot Arc
O2 Cut gas
Coolant On-
Off Coolant Return
Cooler Coolant Output
N2 Start (WC-7)
Gas
Cut Start Gas Solenoid

Water
Cut gas Solenoid
Pump
High Freq. On-Off
on-off
Interlocks
Injection Water
Start Gas
Flow Control Cut Gas

Plumbing Box
Volt-Feedback
Work piece
voltage
Process E-
OK stop
Interlocks Height
Process on-off
Current Ref
Control
Gas
Pilot arc High Freq

Cutting Machine
TORCH injection water
Control Height Ref. PT-15 OR PT-600 Coolant to
Current to
Coolant From
Work Piece


SECTION 4 Operation
4.1 Introduction
The ESP-600C does not have an ON/OFF switch.
The main power is controlled through the line(wall)
disconnect switch.
Do not operate the ESP-600C with

! WARNING Covers Removed.
High voltage components are exposed
increasing shock hazard.
Internal component may be damaged

because cooling fans will lose efficiency.
4.2 Control Panel
Main Power
Indicator illuminates when input power is applied to

the power source.
Over Temp
Indicator illuminates when power source has

overheated.
Contactor On
Indicator illuminates when the main contactor is

energized.

SECTION 4 Operation
Fault
Indicator illuminates when there are abnormalities in

the cutting process or when the input line voltage
falls outside of the required nominal value by ±10%.
Power Reset Fault
Indicator illuminates when a serious fault is

detected. Input power must be disconnected for at
least 5 seconds and then reapplied.
Current Dial (Potentiometer)
ESP-600C dial shown. ESP-600C has a range of

50 to 600 A. Used only in panel mode.
Panel Remote Switch
Controls the location of current control.

• Place in the PANEL position for control using
the current potentiometer.
• Place in REMOTE position for control from an
external signal (CNC).
Remote Connection
Amphenol 19 pin plug for connecting power source

to CNC.
Pilot Arc HIGH/LOW Switch
Used to select amount of pilot arc current desired.

As a general rule, for 100 amperes and below, a
setting of LOW is used. This can vary depending
on gas, material and torch used. High/Low settings
are specified in cutting data included in the torch
manual.

SECTION 4 Operation
Meters
Displays voltage and amperage when cutting. The

ammeter can be activated when not cutting to view
an estimation of the cutting current before cutting
begins.
Actual/Preset Switch
Spring return toggle switch defaults to ACTUAL

position. When pressed down, the AMMETER
displays an estimate of the actual current. This
permits the operator to preset the cutting current
close to the desired current using the current
potentiometer.
Final adjustment is made after the torch has started

cutting to achieve a more precise current.
Dangerous Voltages and Current!

! WARNING
Before operation, ensure installation and
grounding procedures have been followed.
Do not operate this equipment with covers

removed.

SECTION 4 Operation
4.3 Sequence of Operation
1. Apply power by closing the line (wall) switch.

Apply Power
(The ESP-600C does not have an on/off
switch). The main power light will illuminate
and the fault light will flash and then go out.
PANEL
2. Select the Panel/Remote setting.
3. Set pilot arc High/Low switch. (Refer to cutting
REMOTE data in the torch manual.)
4. If using panel mode, view preset amps with the
PILOT HIGH
ACTUAL/PRESET AMPS switch. Adjust current
ARC until the approximate desired value is shown on
the ammeter.
LOW 5. Begin plasma cutting operation. This may
include manually setting up other options,
depending on the total plasma package.
ACTUAL AMPS
6. If using panel mode, after cutting has begun,
adjust current to desired amount.
PRESET AMPS
7. Check for fault light. If a fault light illuminates,
refer to troubleshooting section.
Begin Note: The fault light flashes when the contactor is

Cutting first turned on signifying the DC Bus powered up
normally.
4.4 Arc Initiation Settings

The time to achieve full current can be adjusted to
suit your particular system. This feature uses 50%
of the cutting current to start, dwell and then
gradually (less than a second) achieve full current.
The ESP-600C is factory shipped with this feature
enabled. The default settings are:
Minimum Start Current 40A
Start Current 50% of cut current
Timing to achieve full current 800 msec
Dwell Time 50 msec

SECTION 4 Operation
Start Current Waveform With Arc These timing functions can be disabled or adjusted
DC Output Current Initiation Timer OFF to suit individual system requirements.
Cut Current
1OUT = 80 VREF
approx. 2 msec time to

full current
Time
Start Current Waveform With Arc

Initiation Timer ON
DC Output Current
Cut Current
1OUT = 80 VREF
Start Current
Dwell Time to
full current
800 msec
Time

! WARNING
Shut off power at the line (wall) disconnect
before removing any covers or making any
adjustments to the power source.

SECTION 4 Operation
4.4.1 Enable/Disable Arc Initiation Timer
Factory default setting shown.
1 2
1. Remove access panel on the upper-right corner
of the front panel. Be sure to replace this panel
ON after adjustments have been made.
2. Locate SW1 and PCB1 and push both rocker
switches down to disable. To enable push both
OFF
switches up. (If one switch is up and the other
is down, arc initiation time is considered on.)
SW1
4.4.2 Adjusting Arc Initiation Timer

Minimum Start Current
Controlled by selection of positions 5 through 8 of

SW2. When a switch is pushed on, its value is
added to the factory set minimum value of 40A.
Switch #5 = 80A min. start current

Factory default settings shown Switch #7 = 20A min. start current
1 2 3 4 5 6 7 8
Default setting is with all switches off. = 40A
ON
Dwell Time
OFF
SW2
Controlled by selections of positions 1 through 4 of
SW2 on PCB1. When a switch is pushed on, its
value is added to the minimum dwell time of 10
msec.
Switch #1 = 10 msec dwell time

The default setting is with switch #3 on. 40 msec +

10 msec (minimum) = 50 msec

SECTION 4 Operation
4.4.3 Arc Initiation Controls
Start Current Pot UP-Slope Timer
SW1
SW2
4.4.4 Start Current and Up-Slope Timer

Starting Curent (%) and Pot Setting
90% Relationship
Start Current
80% Set using potentiometer located above and to the
70%
left of center of PCB1. Factory default setting is 7.
Percentage (%) of Cutting Current
60%
50%
Up-Slope Timer
40% Three position switch located next to the start
current potentiometer. Time is from start current
30%
(after dwell ends) to full current. Factory default =
20% 800 msec.
10%
Left position = 250 msec
0% Center position = 800 msec
0 1 2 3 4 5 6 7 8 9 10 MAX Right Position = 1200 msec
Start Current Pot Setting

SECTION 4 Operation
4.5 ESP-600C V-I Curves
ESP-600C V-I CURVES

IOUT = (80) x (VREF)
450 427V Open Circuit (460V & 575V Models)
410V Open Circuit (400V Model)
400
Output of Boost/Start Circuit

OUTPUT VOLTAGE (Volts)
350
Max Output Voltage
@ Nominal Line
300
250
INTERNAL CURRENT LIMIT

200
MAX RATING
VREF = 7.500V
RATING
VREF = 0.625V
VREF = 2.000V
150 VREF = 5.000V

VREF = 4.000V
VREF = 6.000V
VREF = 1.000V
VREF = 3.000V
VREF = 7.000V
100
MIN
50
0
0 100 200 300 400 500 600 700
OUTPUT CURRENT (Amperes)

SECTION 5 Maintenance
5.1 General

! WARNING
Shut off power at the line (wall) disconnect
before attempting any maintenance.
Eye Hazard When Using

! WARNING Compressed Air To Clean.
• Wear approved eye protection with side

shields when cleaning the power
source.
• Use only low pressure air.
Maintenance On This Equipment

! CAUTION Should Only Be Performed By
Trained Personnel.
5.2 Cleaning
Regularly scheduled cleaning of the power source is
required to help keep the unit running trouble free.
The frequency of cleaning depends on environment
and use.
1. Turn power off at wall disconnect.

2. Remove side panels.
3. Use low pressure compressed dry air, remove
dust from all air passages and components.
Pay particular attention to heat sinks in the front
of the unit. Dust insulates, reducing heat
dissipation. Be sure to wear eye protection.

SECTION 5 Maintenance
Air Restrictions May Cause ESP-

CAUTION 600C To Over Heat.
Thermal Switches may be activated
causing interruption of function.
Do not use air filters on this unit.
Keep air passages clear of dust and other

obstructions.
5.3 Lubrication
• Some units are equipped with oil tubes on the

fans. These fans should be oiled after 1 year of
service.
• All other ESP-600Cs have fan motors that are

permanently lubricated and require no regular
maintenance.
Electric Shock Hazard!

! WARNING
Be sure to replace any covers removed
during cleaning before turning power back
on.

SECTION 6 Troubleshooting
6.1 General

! WARNING
Do not permit untrained persons to inspect
or repair this equipment.
Electrical work must be performed by an

experienced electrician.
Stop Work Immediately If Power

! CAUTION Source Does Not Work Properly.
Have only trained personnel investigate
the cause.
Use only recommended replacement parts.
6.2 Fault Indicators

Fault indicators are found on the front panel
Used with the LEDs on PCB1 (located behind
400
OUTPUT
AMPS
200
300 500
600
MAX
the cover with the ESP label) problems can be
100
50
MIN
0 MAIN
diagnosed.
NOTE: Momentary lighting (flashing) is normal
CURRENT POWER
VOLTS
PILOT PANEL
HIGH
6 0 0 C
ARC OVER
TEMP
ACTUAL AMPS LOW REMOTE
PRESET AMPS
CONTACTOR
ON
FAULT
and does not indicated a fault.
POWER
RESET
FAULT
Fault Indicator used with:

LED 3
Front Panel Fault Indicators LED 4
PCB1 Located LED 5
behind this panel. LED 7
LED 8
Power Reset Fault Indicator used with:

LED 6
LED 9
LED 10
LED 11
LED 12
LED 13
ESP 400C and 600C Plasma Power Sources 6-1

Fault Indicator (Front Panel)
Illuminates when there are abnormalities in the

cutting process or when the input voltage falls
±10% outside the normal value. Momentary
illumination is normal. If continuously lit, check
LEDs 3, 4, 5, 7, and 8 on PCB1 for further
diagnosis.
LED 3 – (amber) Bus Ripple Fault -

Momentarily illuminates at the beginning of each
cut. Continuously lit during single-phasing or
imbalanced line-to-line voltages of the three phase
input line.(Excessive Ripple) Power Source is shut
down.
LED 4 – (amber) High Bus Fault – Illuminates

when input line voltage is too high for proper
operation (approx. 20% above nominal line voltage
rating). Power source is shut down.
LED 5 – (amber) Low Bus Fault – Illuminates

when input line voltage is approx. 20% below
nominal line voltage rating. PS is shut down.
LED 7 – (amber) Arc Voltage Saturation Fault

– Illuminates when the cutting arc voltage is too
high and cutting current drops below preset level.
LED will extinguish after voltage decreases and
current rises.
LED 8 – (amber) Arc Voltage Cutoff Fault –

Illuminates when arc voltage increases over the
preset value. PS is shut down.
6-2 ESP 400C and 600C Plasma Power Sources

Power Reset Fault Indicator (on front panel)
Illuminates when a serious fault is detected. Input

power must be disconnected for a least 5 seconds
to clear this fault. Check PCB1 Red LEDs 6, 9, 10,
11, 12, and 13 if this fault is illuminated for further
diagnosis.
LED 6 – (red) Right Overcurrent Fault –

Illuminates when the current out of the right side
chopper is too high (300 amps). This current is
measured by the right-side hall sensor. The power
source is shut down.
LED 9 – (red) Left Overcurrent Fault –

Illuminates when the current from the left side
chopper is too high (300 amps). Measured by the
left hall sensor. Power source is shut down.
LED 10 _ (red) Left IGBT Unsaturated Fault –

Illuminates when left IGBT is not fully conducting.
PS (PS) is shut down.
LED 11 – (red) Right IGBT Unsaturated Fault –

Illuminates when right IGBT is not fully conducting.
Power Source (PS) is shut down.
LED 12 – (red) Left -(neg) 12V Bias Supply

Fault – Illuminates when negative 12 V bias supply
to the left side IGBT gate drive circuit (located on
PWM-drive board PCB2) is missing. PS is shut
down.
LED 13 – (red) Right –(neg) 12V Bias Supply

Fault - Illuminates when negative 12 V bias supply
to the right side IGBT gate drive circuit (located on
PWM-drive board PCB3) is missing. PS is shut
down.

6.3 Fault Isolation
Many of the most common problems are listed by
symptom.
6.3.1 Fans not working
6.3.2 Power not on
6.3.3 Fault Light Illumination
6.3.4 Torch won’t fire
6.3.5 Fusses Blown F1 and F2
6.3.6 Intermittent, Interrupted or Partial Operation
6.3.1 Fans Not Working

Problem Possible Cause Action
All Three fans do not run This is normal when not cutting. None
Fans run only when “Contactor On”
signal is received.
One or two fans do not run. Broken or disconnected wire in fan Repair wire.
motor circuit.
Faulty fan(s) Replace fans
6.3.2 Power Not On or LOW Voltage

Power source inoperable: Missing 3-phase input voltage Restore all 3 phases of input voltage
Main Power lamp is off. to within ±10% of nominal line.
Restore all 3 phases of input voltage

Missing 1 of 3-phase input voltage to within ±10% of nominal line.
Low Open Circuit Voltage Fuse F3 blown Replace F3
Pilot arc Contactor (K4) faulty Replace K4
Faulty Control PCB1 Replace Control PCB1 (P/N 38032)

6.3.3 Fault Light Illumination
Fault light illuminates at the end of Normal condition caused by Reprogram cutting process to
cut but goes off at the start of the terminating the arc by running the ensure arc is terminated only by
next. torch off the work or the arc being removing the “Contactor On” signal.
attached to a part that falls away.
LED 3 – (amber) Bus Ripple Imbalance of 3-phase input power Maintain phase voltage imbalance of
less than 5%.
Momentary loss of one phase of
input power Restore and maintain input power
within ±10% nominal
Faulty control PCB1
Replace PCB1 P/N 38032
LED 4 – (amber) High Bus One or more phases of input voltage Restore and maintain line voltage
exceed nominal line voltage by more within ±10%
than 20%.
Faulty control PCB1 Replace PCB1 P/N 38032
One or more shorted diode rectifiers Replace shorted diode rectifiers

(D25-D28) on the “Electrode Plate”
LED 5 – (amber) Low Bus One or more phases of input voltage Restore and maintain with in ±10%
are lower than nominal by more than of nominal
15%.
Blown F1 and F2 fuses See F1 and F2 in Blown Fuses

Section
Over temp Light comes on. See over temp in Fault Light Section
Imbalanced 3-phase input power Maintain phase voltage imbalance of

less than 5%
Momentary loss of one phase of Restore and maintain within ±10% of

input power nominal
Faulty Main Contactor (K1) Replace K1
FAULTY Control PCB1 Replace PCB1 P/N 30832

LED 6 – (red) Right Over Current Output current of the right side Turn the output current down to
exceeds 200A because of operating 400A
the power source over 400A.
Note:
Cutting at over 250A with a faulty See faulty left or right side
If operation at 250A or less is
left side (left side output = 0)
possible, then the LEFT side is
not working. Right current transducer connector Secure connections
loose or unplugged. PCB loose.
Loose or unplugged connector at Secure connection

right PWM/Drive Printed circuit
board.
P2 at left of PWM/Drive PCB loose or Secure connection

unplugged.
Check voltage between P7-6 and Replace right current transducer

P7-7. A voltage in either polarity of (TD2)
greater than 0.01 V indicates a faulty
right current transducer (TD2).
Faulty PCB1 Replace PCB1 P/N 30832
Faulty right PWM/Drive PCB Replace right PWM/Drive PCB P/N

38030
LED 6 – (red) Left Over Current Output current of the left side Turn the output current down to
exceeds 250A because of operating 400A
the power source over 400.
Note:
Cutting at over 250A with a faulty See faulty right side
If operation at 250A or less is
right side (right side output = 0)
possible, then the Right side is
not working. Left current transducer connector Secure connections
loose or unplugged. PCB loose.
Loose or unplugged connector at left Secure connection

PWM/Drive Printed circuit board.
P2 at right of PWM/Drive PCB loose Secure connection

or unplugged.
Check voltage between P7-2 and Replace left current transducer (TD1)
P7-3. A voltage in either polarity of
greater than 0.01 V indicates a faulty
left current transducer (TD1).
Faulty left PWM/Drive PCB Replace left PWM/Drive PCB P/N

38030

Very high Output current Shorted IGBT Replace the pair of IGBTs containing
accompanied by either a left or the shorted IGBT
right over current (LED 6) Current pot set too high Lower the current setting
Faulty left PWM/Drive PCB Replace left PWM/Drive PCB
High remote current signal Decrease remote current signal

LED 10 - (red) Left IGBT Black wire connecting IGBT (Q4) Secure connector
Unsaturated collector to P3 of the left PWM/Drive
PCB (PCB2) is disconnected.
Shorted Freewheeling Diode(s) Replace freewheeling diode(s)
Loose or unplugged P1 connector at Secure P1

the left PWM/Drive PCB
Loose or unplugged P10 connector Secure P10

at PCB1
Faulty left PWM/Drive PCB Replace PCB2 P/N 38030
LED 11 - (red) Right IGBT Black wire connecting IGBT (Q4) Secure connector
Unsaturated collector to P3 of the right
PWM/Drive PCB (PCB3) is
disconnected.
Shorted Freewheeling Diode(s) Replace freewheeling diode(s)
Loose or unplugged P1 connector at Secure P1

the left PWM/Drive PCB
Loose or unplugged P10 connector Secure P11

at PCB1
Faulty right PWM/Drive PCB Replace PCB3 P/N 38030

LED 12 – (red) Left –12V Loose or unplugged P1 connector at Secure P1 connector
Missing the left PWM/Drive PCB
Loose or unplugged P10 connector Secure P10 connector

at PCB1
Faulty left PWM/Drive PCB Replace left PWM/Drive PCB P/N

38030
LED 12 – (red) Right –12V Loose or unplugged P1 connector at Secure P1 connector
Missing the right PWM/Drive PCB
Loose or unplugged P11 connector Secure P11 connector

at PCB1
Faulty right PWM/Drive PCB Replace right PWM/Drive PCB P/N

38030
Very high Output current Shorted IGBT Replace the pair of IGBTs containing
accompanied by either a left or the shorted IGBT
right over current (LED 6)
Current pot set too high Lower the current setting
Faulty left PWM/Drive PCB Replace left PWM/Drive PCB
High remote current signal Decrease remote current signal

Over Temp Lamp illuminates One or more fans inoperable Repair or replace fan(s)
Broken wire or unplugged connector Repair broken wires and unplugged

at thermal switch. connector
Obstruction to air flow closer than 2 Allow 2 ft. minimum between the rear
feet to rear of power source. of the power source and any object
that may restrict air flow.
Excessive dirt restricting cooling air Clean out excessive dirt, especially in
flow the extrusions for the IGBTs and
freewheeling diodes, the POS, NEG
and Electrode Plates, the main
transformer (T1) and the filter
inductors (L1 and L2).
Obstructed air intake Check and clear any obstructions

from the bottom, front, and top rear
of the Power Source.

6.3.4 Torch Will Not Fire
Main Arc Transfers to the work Panel/Remote switch in “Remote” Place Panel/Remote switch in
with a short “pop”, placing only a with no remote control of the “Panel” position
small dimple in the work. current
Remote current control present Check for current reference signal

but signal missing. at TB1-4(+) and TB1-5(-). See
Signal vs. Output Current Curve
this section.
Current pot set too low. Increase current pot setting.
Start current pot, located behind Increase the start current post
the cover for the control PCB is setting to “7”.
set too low.
Arc does not start. There is no Open connection between the Repair connection
arc at the torch. Open circuit power source positive output and
voltage is OK at 400 –460V the work.
Fuse F6 in the Pilot arc circuit is Replace F6

blown.
Fuse F7 in the pilot arc circuit is Replace F7

blown.
Pilot arc High/Low switch is in the Change Pilot arc to “High”

”LOW” position when using position. (Refer to process data
consumables for 100A or higher included in torch manuals)
(Refer to process data included in
torch manuals)
Pilot arc contactor (K4) faulty. Replace K4

6.3.5 Fuses F1 and F2 Blown
Fuses F1 and F2 blown. Process controller ignites pilot arc Process controller must allow at
too soon after providing the least 300MS to lapse between
“Contactor On” signal the application of the “Contactor
On” signal and the ignition of the
pilot arc. Fix process controller
logic and replace diodes.
Faulty negative (Electrode) output Repair cable

cable shorting to earth ground.
Shorted freewheeling diode. Replace shorted freewheeling

diode and F1-F2
One or more shorted diode Replace all diode rectifiers on the

rectifiers (D13-D18) on “POS “POS Plate”.
Plate”.
One or more shorted diode Replace all diode rectifiers on the

rectifiers (D7-D12) on “NEG “NEG Plate”.
Plate”.
6.3.6 Intermittent, Interrupted or Partial Operation

Works OK at 250A or less- Over Loose or unplugged connector at Secure connector
current – Faulty Left Side left PWM/Drive PCB (PCB2)
Faulty left PWM/Drive PCB Replace right PWM/Drive PCB

P/N 38030
Check voltage between P5-1 and Replace control transformer T5

P5-2 at the left PWM/Drive PCB
(PCB2). Should be 20V AC.
Between P5-1 and P5-3 should
be 40V AC. If not the control
transformer (T5) is faulty.

Works OK at 250A or less- Over Loose or unplugged connector at Secure connector
current – Faulty Right Side Right PWM/Drive PCB (PCB3)
Faulty Right PWM/Drive PCB Replace right PWM/Drive PCB

P/N 38030
Check voltage between P5-1 and Replace control transformer T7

P5-2 at the right PWM/Drive PCB
(PCB3). Should be 20V AC.
Between P5-1 and P5-3 should
be 40V AC. If not the control
transformer (T7) is faulty.
Power Supply turns off “Contactor On” signal is removed Power source is OK. Trouble
prematurely in the middle of the from unit. shoot process controller.
cut.
Momentary loss of primary input Restore and maintain input
power. voltage within ±10% of nominal.
Faulty condition, indicated by Remove control PCB (PCB1)

illumination of the fault lamp. access panel to determine the
fault causing the shutdown.
Refer to fault light illumination
section.
Faulty condition, indicated by the Remove control PCB (PCB1)

illumination of the power reset access panel to determine the
fault lamp. fault causing the shutdown.
Refer to fault light illumination
section.
Current setting too low. Increase current setting
Remote current signal removed Fix remote current signal

during cut.

Output current is unstable and Place the PANEL/REMOTE Fix the remote current control
drifts above or below the setting. switch in the “PANEL” position. signal to operate the
Adjust current control pot. If PANEL/REMOTE switch in the
current no longer drifts, the “PANEL” position.
remote current control signal is
faulty.
Select “PANEL” on the Replace the current control pot.

PANEL/REMOTE switch and
adjust the current control pot.
The current still drifts, measure
the current reference signal at
TB1-4 (+) and TB1-5 (-). If the Replace the control PCB (PCB1)
signal drifts, the current control P/N 38032
pot is faulty. If the signal does
not drift, the Control PCB (PCB1)
is faulty.

6.4 Testing and Replacing Components
• Replace a PC board only until a problem was

NOTICE isolated to that board.
• Always disconnect power before removing or
installing a PC board.
• Do not grasp or pull on board components.
• Always place a removed board on a static free
surface.
• If a PC board is found to be a problem, check
with your ESAB distributor for a replacement.
Provide the distributor with the part number of
the board as well as the serial number of the
power source.
• Do not attempt to repair the board yourself.
Warranty will be voided if repaired by the
customer or an unauthorized repair shop.
Power Semiconductor Components

Three categories of power semiconductors include;
• Power Rectifiers
• Freewheeling Diodes
• IGBTs

6.4.1 Power Rectifiers
Power Rectifiers – Procedure to access behind the
front panel
1. Remove top cover and side panels

2. Locate and disconnect plug in rear of ammeter
(white plug with one red and one black wire)
3. Remove pilot arc switch
4. Disconnect voltmeter
5. Disconnect orange and yellow wires from relay
K4.
6. Remove two bolts holding the left side of the
front panel to the base.
7. Remove three bolts holding across the center
base of the front panel. These are accessed
Power Rectifiers located from underneath.
behind the front panel.
8. Remove one of the bolts holding the right side
of the front panel to the base. Loosen the
second bolt. Of these two bolts, remove the
bolt on the left and loosen the bolt on the right.
9. Swing the front panel out to gain access to
power rectifier components.
Troubleshooting Procedures –Negative Plate
Location of Neg. Plate
1. Visually inspect fuses F8 and F9. Replace if

they show signs of being blown or melted.
Inspect diodes. If ruptured or burned, replace
Location of fuses F8 and F9 all diodes on the NEG Plate. If diodes appear to
be OK, proceed to next step.

1. Check ohms between NEG Plate and BR “A”
NEG Plate
Diode Rectifier Bus. A reading of 2 ohms or less indicates one
or more shorted diodes. Replace all Diodes on
NEG Plate.
“C” bus
“A” bus 2. If fuses F8 and/or F9 were open in the first step,
“B” bus
make two more ohmmeter readings.
A. Measure resistance between the NEG Plate

and BR “B” bus.
POS Plate B. Measure between NEG Plate and BR “C”

Electrode Plate
bus.
If resistance is 2 ohms or less in either case, replace

all the diodes on the NEG Plate.
Troubleshooting POS Plate

1. Check ohms between POS Plate and BR “A”
Bus. A reading of 2 ohms or less indicates one
or more shorted diodes. Replace all Diodes on
POS Plate.
Location of Positive Plate
2. If fuses F8 and/or F9 were open in the first step,
make two more ohmmeter readings.
Fuses F8 and F9 A. Measure resistance between the POS Plate

and BR “B” bus.
B. Measure between POS Plate and BR “C” bus.
If resistance is 2 ohms or less in either case, replace

all the diodes on the POS Plate.
Troubleshooting Electrode Plate

1. Visually inspect for ruptured or burned diodes.
D25,26 D27,28
Replace only those damaged.
2. Check resistance between Electrode Plate and
the parallel pig tails (cathode leads) of D25 and
D26. If reading is 2 ohms or less, disconnect
leads from bus and check each diode. Replace
Bus only shorted diodes.
Cathode
Leads
Repeat procedure for D27 and D28. Replace only
shorted diodes.

6.4.2 Troubleshooting Freewheeling Diode and IGBTs
Freewheeling Diodes and IGBTs
1. Remove top cover.

2. Remove “incoming” bus bars.
3. Remove PCB2 and PCB3 from IGBTs. (PC
boards are held in place by four screws each.)
After PCB2 and/or PCB3 have been

CAUTION removed, protect against electrostatic
damage. The emitter and the gate of each
affected IGBT must be jumpered together
to prevent electrostatic damage.
Emitter
Gate
Electrostatic Discharge Hazard

CAUTION
Electrostatic discharge may damage these
components.
• Damage is accumulative and may only
appear as shortened component life
and not as a catastrophic failure.
• Wear a protective ground strap when
handling to prevent damage to PCB
components.
• Always place a pc board in a static-free
bag when not installed.

4. Remove bus bars between capacitor banks,
IGBTs and freewheeling diodes.
View of freewheeling diodes and capacitor banks

with bus bars removed. (PCB2 and PCB3 are
PCB2 PCB3
shown still in place)
Failure To Route Leads Properly Can Lead To

CAUTION Failure Of Freewheeling Diodes.
Dressing Of Freewheeling Diode Snubber

1 2 3
Leads.
1 2 3 Snubber Capacitor
(ex.C18) Red wire of snubber resistor must be routed under
capacitor self lead. Red wire terminal must have a
Freewheeling Diode
3 2 1
(ex. D6) minimum 1/8" clearance from the bus bar on diode
Snubber Resistor
(ex. R9)
terminal #2.
Note: Bus bar connecting terminal no. 3 is not

shown for terminal clarity.
Red Wire
The red snubber leads are numbered as viewed

from the rear of the power source:
D1 - Left D4 - Right
D2 - Right D5 - Left
D3 - Left D6 - Right
Cover snubber capacitor self leads with sleeving

P/N 95193486

Some power sources may contain snubber
NOTICE resistors and capacitors in a molded module similar
in size and mounting to the free wheeling diode
modules. These snubber modules utilize two
conductive straps. One strap attaches to the free
wheeling diode terminal #1 and the other to terminal
#3. Strap to #3 is sandwitched between the free
wheeling diode and the stamped copper bus. The
strap to #1 is mounted on top of the copper bus
under the mounting hardware and in direct contact
with the copper bus.
6.4.3 Power Shunt Installation
Instability Or Oscillation In Cutting Current

CAUTION Can Be Caused By Improper Dressing Of
Shunt Pick-Up Leads.
Poor torch consumable life will be the

result.
There are two cables that attach to the shunt pick-

up points:
a two conductor cable drives the ammeter
a three conductor which provides the current
feedback signal to PCB1 (control PCB).
Dressing of the 2 conductor cable is not critical.
The following is the dressing procedure for the 3

conductor cable.
• The breakout point should be physically at the

middle of the shunt. The breakout point is the
place where the conductors exit from the outer
insulation jacket.
Terminals • The black and clear insulated wires must be

parallel to kept next to the shunt and under the cable ties.
bus bars
• The wire terminals for the black and clear

insulated wires should be oriented in parallel
with bus bars as shown.

Clear Insulation
• It is important to have the barrels of the black

and clear insulated wires, from the three lead
cable, be pointing in opposite directions.
Three Leads Two Leads
• The third wire attaches to the bus bar on the left

with the shunt mounting hardware. Orientation
of this wire is not critical.
6.4.4 Procedure For Verifying Calibration Of Digital Meters.

Voltmeter
1. Connect a digital meter known to be calibrated

to the positive and negative output bus bars.
2. Compare the power source voltmeter reading to
the calibrated meter reading. Readings should
match within ± 0.75%
Ammeter
1. External to the power source, connect a

precision shunt in series with the work lead(s).
The best shunt is one with a value of 100 µΩ
(50mV/500A or 100mV/1000A) and a calibrated
tolerance of ± 0.25%.
2. Use a calibrated 4 ½ digit meter to measure the
output of the shunt. The amperage indicated
with the external shunt and meter should match
power source ammeter to within ± 0.75%.

6.5 ESP-400C Schematic Diagrams - Drawing 1 - Part1
1a
2a
3a
4a
5a
6a
7a
8a
9a
GRY
BLK
GRY BLK
LOC SYM Descrip LOC SYM Descrip LOC SYM Descrip

1 M1,2 Motor ,fan 1/3 hp 1 C14-16 Capacitor .033uf 630v 2 C24 Capacitor 5uf 600vdc
1 M3 Motor, fan 230v 50/60hz 1 D19,20,23 Module diode rectifier 630v 2 C13,15,17 Capacitor .033uf 630v
1 T1 Transformer main 1 R12,13 Resistor 8ohm 300w 2 K2 Contactor 3 pole 90A
1 T2 Transformer control 1 D2,4 Module diode Red 2 K4 Contactor 3 pole 40A
1 T5-8 Transformer 117/12/12/24ct 1 R5,7 Resistor 10ohm 50w 2 PL1 Lamp neon wht
1 K1A,B,C Contactor 3pole 90A 1 R53,54 Resistor 2ohm 25w 2 PL2 Lamp neon wht
1 PCB2 PC board circuit IGBT Driver 2 TD1,2 Transducer Current 2 PL3 Lamp indicator Amber
1 Q1-2 Module IGBT 600A 600V 2 PCB3 PC board IGBT driver 2 TS4,5,6 Switch thermal 176 deg.F
1 C19,20 Capacitor 27uf 1200vdc 2 Q3,4 Module IGBT 600A 600v 2 TS7 Switch thermal 194 deg.F
1 C23 Capacitor 5uf 800vdc 2 C21,22 Capacitor 27uf 1200vdc 2 TS1,2,3 Switch thermal 176 deg.F

Schematic Diagram - Drawing 1 – Part2
1b
2b
3b 4b
5b
6b
7b
8b
9b
2 C18 Capacitor .033uf 630v 2 C41-43,44 Capacitor .01uf 125vdc 3 R44 Resistor 10k 8w
2 R4,6,8,9 Resistor 10ohm 50w 2 D29,30 Rectifier silicone reverse 85A 3 C30 Capacitor 60uf 370v
2 D1,3,5,6 Module diode dual 100A 600V 2 D31,32 Rectifier silicone forward 85A 3 C39,40 Capacitor .01uf 125vdc
2 D21,22,24 Module dual diode rectifier 630V 2 F3 Fuse slo-blo 15A 600v 3 D27,28 Diode rect reverse 800v 300A
2 R14,15 Resistor 8ohm 300w 2 F6 Fuse n-t delay 15A 3 D33,35 Rectifier silicone reverse 85A
2 L1,2 Inductor Assy 2 R23 Resistor 1 ohm 300w 3 D34 Rectifier silicone forward 85A
2 D25,26 Resistor 10ohm 300w 2 R24 Resistor 8 ohm 300w 3 R25,26 Resistor 10 ohm
2 C37,38 Capacitor .01uf 125vdc 2 FN1,FN2 Filter PC board 3 R39,40 Resistor 10k 8w
2 R30 Resistor 1k 100w 3 PCB4 PC board digital meter 3 R34,35,36 Resistor 220k 1w
2 R16,17 Resistor 8ohm 300w 3 SH1 Shunt 100mV 800A 3 R29 Resistor 1k 100w
2 S1 Switch toggle 3pst 2 pos 3 R31 Resistor 1k 100w 3 R21,22 Resistor 10ohm 300w
2 R41-43 Resistor 10k 8w 3 R18,19,20 Resistor 4 ohm 300w 3 R27 Resistor 10ohm 300w
2 C27,28,29 Capacitor 2900uf 450w 3 R38 Resistor 220k 1w

LOC SYM Descrip LOC SYM Descrip LOC SYM Descrip

C32,33 Capacitor 1900uf 450v 4 C25 Capacitor 10uf 370v 4 K6 Relay 3pdt
C34,35,36 Capacitor 10uf 370vac 4 R32 Resistor 220k 4 TD1 Transducer Current
R1,2,3 Resistor 1 ohm 300w 4 FN4 Filter RFI 4 TD2 Transducer Current
F1,2 Fuse 15A 4 R37 Resistor 10ohm 1w 4 R46-48 Resistor 133k 1/2w
TB4,5,6 Terminal Assy 4 C31 Capacitor 1uf 600v 4 R52 Resistor 4.7k ohms 2w 10%
4 K3,5-7 Relay 3pdt brkt mt 4 R51 Pot 10k 2w 4 PL4,5 Lamp LED red 12v

LOC SYM DESCRIPTION LOC SYM DESCRIPTION LOC SYM DESCRIPTION
4 T3,4 XMFR 117/12/12/24ct 5 C45,46 Capacitor .01uf 125vdc 5 S3 Switch toggle DPDT 3 pos
5 R50 Pot 15k 2w 5 R45 Resistor 10k 8w 5%
5 S2 Switch toggle DPDT 2 pos 5 FN3 Filter EMI

Schematic Diagram - Drawing 3

Schematic Diagram - Drawing 4



6.6 Wiring Diagrams – 460V 60Hz Drawing 1 – Part1 (P/N 35878)
C47 D7,D8 C48 D9,D10 C49 D11,

ELECTRODE BUS BLK D12
YEL BLU WORK BUS BLU BR "C" BUS

BR"A" BUS BR "B" BUS
D13 D15, D17,
D14 C50 D16 C51 D18 C52
TB10 C37 TB9-21 BLK TS3-1 WHT C39
FN1 FN2 D25, TS7 D27,
WHT C38 D28
D26 1 2 C40
WHT
WHT WHT
3 3
"B" COIL "B" COIL

GND4 GRN K4-T1 YEL X1 X1
GND4 GRN
Section A-A
L1 L2
PCB4 P1-1 GRN
"A" COIL "A" COIL
X1 X1
TB1-10 BLK
H1 PCB4 P1-2 GRN/YEL
T9 X3 YEL
TB1-12 BLK TB11-3 YEL
H2
TB11-2 YEL
PCB4 P1-3 GRN
X4 YEL
Ammeter Voltmeter
PCB4 P1-11 VIO
1 7 8 2 1 7 8 2
Section B-B
WHT
GRN
RED
BLK
BRN
ORN
BLU
YEL
PCB4 P1-12 GRY

B
S4
1 J1 GND 1
3
P2-1
P2-2
P2-3
P2-4
P2-5
P2-6
P2-7
P2-8
2 A TB1-1 BRN
B TB1-2 YEL K3-4 RED
X2 TS4-1 WHT
PCB4 B C C TB1-4 ORN BR "A"
A D X3
N
P E
R D TB1-5 BLU BUS
K4-L1 BLK S1 K1A-T1.2.3 BLK
U
V S F E TB1-9 RED X4 2 H1
5 6 R24-2 BRN M T G F5-1 BLU
L F TB1-7 BLK X5 TS1 H2
3 4 POS PLATE RED K J H
1
R19-2 ORN G TB1-8 WHT X6 "A"
1 2 TB1-5 BLU R23-1 BRN
R17-1 YEL H GND 5 GRN L1 X7
D29/30 BUS WHT PCB1 P8-1 GRY J TB1-13 GRY
TB1 6 X8
K TB1-14 VIO
GRY
R50-3 GRY
WORK BUS
S2-6 GRY S2
4 5 6 K1B-T1.2.3 BLK
FN2-2 BLU
3 S2-3 RED 1 2 3 M3-2 RED
R50 2
1 TB1-3 VIO
R50-2 RED PCB4 P1-4 BLU A M2-2 RED
PCB1 P8-2 VIO M1-2 RED X2
TB1-4 ORN
BR "B" X3 T1
BUS
X4 2
TB1-12 H1
F5-2 BLU X5 TS2 "B"
WHT TB1-18 BRN H2
FN4-3 BLK TB1-11 WHT X6 1
TB9-24 YEL F3-1 BRN
ELECTRODE BUS
TB1-10-A BLK TB9-24 YEL X7

CB1
X8
T2-X2 PL1 PL2 PL3 PL4 PL5
BLU PCB1 P9-11 VIO FN1-1 BLK
A
K1C-T1.2.3 BLK
TB1-9 RED PCB1 P9-5 GRY
PCB4 P3-1 BLK
TB1-10-B BLK TB9-21 BLK
BR "C"
FN1-3 GRN GND 4 BUS X2
R51 M3-1 WHT
FN2-3 GRN L2 X3
PCB1 P7-10 GRY 123 M2-1 WHT
PCB1 P7-12 VIO X4 2
M1-1 WHT "C" H1
PCB1 P7-11 BLK X5 TS3
F4-1 BRN H2
PCB1 P7-15 WHT S3 X6 1
D33 BUS GRY
36 X7
PCB1 P7-14 BRN TS7-2 WHT
X8
25
PCB1 P7-13 RED
14
B
PCB4
Note: From ESP-400C/600C//460V
P1 P3 Drawing No. 35719, sheet 1 of 5
1 T9-GRN 1 ELECTRODE BUS-BLK Rev E
2 T9-GRN/YEL
3 T9-GRN
4 WORK BUS-BLU
5 TB1-15 RED
6 TB1-16 BLK
7 SH1 +
8 TB9-2 WHT
9 TB9-1 ORN
PCB4 P1-10 BLK ESP-400C
10 PCB4 P1-9 BLK
11 S4-1 VIO
12 S4-2 GRY

6.6 Wiring Diagrams – 460V 60Hz Drawing 1 – Part2 (P/N 35878)
M1-3 GRN
M2-3 GRN
F2-1 ORN K2-L1 BLK

T1-CX4 WHT
1 GND-2 GRN 2
3
R3 1
M1 R1
2
2 1
K2-L3 RED TB4 BLU
T1-BX2 RED
1 R2 2
F1-1 VIO K2-L2 WHT
ELECTRODE PLATE GRY D35-C VIO

2 R21 1
K4-T2 WHT F7-2 ORN
F7-1 BRN 2 R18 1 TD2 (SPLICE) BLK

C32 (-) BLU TD1 (SPLICE) BLK
T1-CX4 WHT
1 1 GND-2 GRN 2 2
3
R22 1
R19 M2 R16 R17
2
FN4-4 WHT
K1B-L1 YEL GND 3 GRN 2 2 1 1

H1 T1-BX2 RED
X1 F4-2 BLK S1-1 YEL
H2 CB1-1 BLU
H3 T2 X2 ORN
WHT H4 TB8-15 YEL S1-3 ORN C27(-) WHT
X3 1 R20 2
H5 TB8-16 RED
K1C-L1 BLK H6 X4 POS PLATE BLU
1 R23 2
T1-AX7 BRN K4-L3 RED

Drawing No. 35719, sheet 1 of 5
Rev E

6.6 Wiring Diagrams – 460V 60Hz Drawing 2 – Part 1 (P/N 35878)
SEE VIEW K-K
K1A K1B K1C

K2-B WHT
TB1-11 WHT
1
R33
C26 K7-9 ORN
2
K4-B ORN
K2-A ORN
1
R32
C25 K1C-B GRY
2
K7-7 GRY
R2-1 VIO K1C-A ORN

F1
K2 R3-1 ORN
K3-7 ORN NEG PLATE
F2 TB5 GRY S1-4 RED
TB6 BRN
TB4 TB5 TB6 C33(+) RED
R26-2 RED
C34-2 BLK
D34
POS PLATE
BLK
D33
T1-CX7 GRY
R25-2 GRY
ELECTRODE PLATE
SEE VIEW L-L R28-2 YEL
TB5 BLK T2-H1 YEL
K1A-A/K1C-A ORN TB5 BLK

TB5 BLK
K1B-B GRY
K1A-B/K1C-B GRY
TB4 BLK
K1B-A/C25-1 ORN
TB4 BLK
TB6 BLK
TB4 BLK T2-H6 BLK
TB6 BLK
TB6 BLK
L1 L2 L3 L1 L2 L3 L1 L2 L3
C23-2 VIO C24-1 VIO
K1B-A ORN C4(+) WHT C10(+) WHT
K1-B/C25-2 GRY
A K1A B A K1B B A K1C B
T1-AH1 BLK
T1 T2 T3 T1 T2 T3 T1 T2 T3
C R54
G
R53
C8(+) BLU
T1-AH1 BLK C2(+) BLU 1 2 1 2
K2-T3 RED C2(-) YEL C8(-) YEL
T1-AH1 BLK
K2-T2 WHT 1 R10 2 1 R11 2
K2-T1 BLK T1-BH2/CH1 BLK
T1-AH2/BH1 BLK
T1-BH2/CH1 BLK T1-CX4 WHT
R3-2 RED T1-AH2/BH1 BLK
T1-BX2 RED
T1-BH2/CH1 BLK
R2-2 WHT T1-AH2/BH1 BLK
M3
R1-2 BLK
C26-1 ORN C26-2 WHT

VIEW K-K
G
K1A-T3 BLK
K1B-T3 WHT
K1C-T3 RED K1B-L1 BLK
K1B-L2 BLK
K1B-L3 BLK C
K1C-L1 BLK
K1A-L3 BLK
K1C-L2 BLK
"A" "C"
K1A-L2 BLK K1C-L3 BLK "B"
K1A-L1 BLK
TB4 TB5 TB6

R1-1 BLU F2-2 GRN
X1
X1 X1
F8 F9
K7-4 BLK
F1-2 GRY
C60 C61 C62
400V 50HZ
UNITS ONLY
R55 R57
R56
VIEW L-L

C23-2 VIO C24-1 VIO
C4(+) WHT C10(+) WHT
C R53 R54
G
1 2 C8(+) BLU
C2(+) BLU 1 2
C8(-) YEL
C2(-) YEL
1 R10 2 1 R11 2
T1-CX4 WHT
T1-BX2 RED
M3
C
"A" "C"
"B"
X1
X1 X1
F8 F9
K7-4 BLK
SECTION D-D
K5-9 RED
VIEW G-G
R45
R52
TB7 1 2 3 4 5 6 7 8 9 10 11 12 13
PCB1 P4-1 WHT
PCB1 P6-1 ORN

TB1-9 RED
F7-1 BRN
K6-9 RED
TB7
PRA1 YEL NEGATIVE PLATE

PCB1 P7-9 BLU
NEG PLATE YEL

C28(+) BLU PRA1
ELECTRODE PLATE GRY
R20-2 BLU
PCB1 P5-9 BLK
F3-2 BLK K4-T3 ORN
D31 D32
POS
C43 C44 PLATE
BLK ORN
C41 C42
D29 D30
C27(-) WHT
S1-2 WHT
ELECTRODE PLATE
PRA1 GRY
C29(-) GRY
R21-2 GRY
TD2 (SPLICE) GRY
TD1 (SPLICE) GRY

6.6 Wiring Diagrams – 460V 60Hz Drawing 3 (P/N 35878)
TB11
SHT BUS POS BLU
1
BLK
2 PCB1 P9-12 YEL
R59
L2-X4 YEL
3 L2-X3 YEL
4 PCB1 P9-13 YEL

R63
7
R58
8
RIGHT COLLECTOR BUS RED Note: Wires on shunt
PCB1 P1-1 CLR (TP)

TB1-16 BLK(TP)
(+) and (-) must be
dressed in location and
PCB1 P1-3 SHLD

direction shown.
(-) SH1 (+)

TD1 TD2
P1 1 2 3 4 P1 1 2 3 4
PCB1 P1-2 BLK(TP)
TB1-15 RED(TP)
P1 P1
PCB4 P1-4 BLU
1 PCB1 P7-5 BLK
TB11-1 BLU
1 PCB1 P7-1 BLK
2 PCB1 P7-8 RED
2 PCB1 P7-4 RED
3 PCB1 P7-6 GRN
Note1: 3
4
PCB1 P7-2
PCB1 P7-3
GRN
WHT
4 PCB1 P7-7 WHT
Splice must pass through

transducers TD1 and TD2 in
direction shown.
R16-2 (SPLICE) BLK
(-) SH1 (+)

3
R17-2 (SPLICE) BLK
D20-2 BRN
TD1 TD2
1 R13 2 1 R15 2
D20-1 ORN
D19-1 ORN
ELECTRODE PLATE (SPLICE) GRY
1 R12 2 1 R14 2
D19-2 BRN D22-1 ORN
ELECTRODE PLATE (SPLICE) GRY D21-1 ORN

D22-2 BRN
D21-2 BRN
T1-CX5 BRN R22-2 BLK TB11-8 RED
S1-6 BRN
F6-1 VIO C29(-) GRY T1-BX7 BRN
D31-A BLK
F4 ELECTRODE PLATE GRY

C32(-) BLU 1 1 2
2 F3 R31-2 GRY
D33 BUS GRY
R21-1 VIO D29/D30 BUS WHT
POS PLATE RED
D35
D35-C VIO R27-2 VIO GRY 2 R16-1 WHT

1 F5 2 2
R37
L3 B T3
D34-A BLK 2
R41
1 F6
R43
L2 K4 T2 2 C27
C31
C29
R34
BLK
R25-1 YEL C34 2 2 2 2 2

L1 A T1 + +
F7
R40
1 C32 1 2
BLK
R31 R30
+
2
R27 R26 R25 R29 R28
BLK
R35
1
PCB1 P2-5 YEL
C35
R38
R42
R26-1 BRN C30 C28

R19-1 BRN
TB7-5 BRN
C26-1 ORN
R18-2 WHT
R23-2 RED
D32-A ORN
C30-2 WHT
C30-1 YEL
R24-1 VIO
2
TB10 YEL
S1-5 BLK
+
T1-AX5 BLU
1
R39
1 1
C33 R44 POS PLATE BLU
1 1 RED 1
+ R30-1 BLU
1 1
2
C32(-) BLU
J J
R36
R27-1 ORN C36

POS PLATE RED
1
R29-1 RED
C36-2 BLU
R29-2 BLU
R22-1 BLU
ELECTRODE PLATE YEL
C36-1 ORN
C35-1 BRN
C34-1 YEL
R18-1 ORN
C28 (+) BLU

T1-BX5 BLU
C29(+) VIO
C29 (+) VIO
K4-T2 WHT
C33(+) RED
K4-T1 YEL
R31-1 VIO
F6-2 VIO
H
H
VIEW E-E

35719, sheet 3 of 5
Rev E

PCB2 PCB3
P1 P2 P1 P2
1 PCB1 P10-1 BLK 1 PCB2 P2-3 YEL 1 PCB1 P11-1 BLK 1
2 PCB1 P10-2 WHT 2 PCB3 P2-2 CLR(TP) 2 PCB1 P11-2 WHT 2 PCB2 P2-2 CLR(TP)
3 PCB1 P10-3 GRN 3 PCB2 P2-1 YEL 3 PCB1 P11-3 GRN 3 PCB2 P2-5 BLK(TP)
4 PCB1 P10-4 RED 4 PCB3 P2-4 SHLD 4 PCB1 P11-4 RED 4 PCB2 P2-4 SHLD(TP)
5 PCB1 P10-7 BLU 5 PCB3 P2-3 BLK(TP) 5 PCB1 P11-7 BLU 5
6 PCB1 P10-8 ORN 6 6 PCB1 P11-8 ORN 6
7 PCB1 P10-9 YEL 7 PCB1 P11-9 YEL
8 PCB1 P10-10 BRN
P5 P5
8 PCB1 P11-10 BRN
9 PCB1 P10-5 GRY 1 T5-X1 BRN 1 T7-X1 BRN
9 PCB1 P11-5 GRY
10 PCB1 P10-6 VIO 2 T5-X4 GRN/YEL 2 T7-X4 GRN/YEL
10 PCB1 P11-6 VIO
3 T5-X7 RED 3 T7-X7 RED
P6 P6
1 T6-X1 BRN 1 T8-X1 BRN
2 T6-X4 GRN/YEL 2 T8-X4 GRN/YEL
PCB2 P5-1 BRN

G
R
Y
TB2-1 BLK PCB3 P6-1 BRN

GR X2X1 H1
PCB2 P5-2 GRN/YEL N X3 T5
G
X4
R
TB2-2 BLK
Y
L
YE X5 H2 TB3-1 BLK
X6
X7 GR X2X1 H1
U PCB3 P6-2 GRN/YEL N X3 T8
L X4
PCB2 P5-3 RED B L TB3-2 BLK
YE X5 X6 H2
X7
LU
PCB3 P6-3 RED B
T5-H1 BLK TB3 TB2-1 BLK

TB2 T8-H1 BLK
T6-H1 BLK TB3-1 BLK T7-H1 BLK TB9-20 BLK
1 1
T5-H2 BLK TB3-2 WHT T8-H2 BLK TB2-2 WHT
2 2
T6-H2 WHT T7-H2 WHT TB9-15 WHT
C6 + C12
+
R13-1 BRN
R15-2 ORN
R13-2 ORN
R15-1 BRN
R52-1 VIO
PCB3 P3 BLK
TB2 TB3
C20 C11 C22

C5 +
T5 T8
D20 D22
+ 2
1 Q4-C BLK
P5 P6 P3
E C Q4 C E
C4 + C10
P2 +
2 2
C3 + C9 P1
PCB2 PCB3
D23
D24
C23 C24
P1 +
1 1
C2 + C8 P2
K2
+
E C Q1 Q3 C E
P3 P5
Q1-C BLK P6
C1 + C7 1 2
D19 D21
T6 T7
C19 + C21
PCB2 P3 BLK
R12-2 ORN
R54-2 WHT
R12-1 BRN
R11-1 BLU
R10-1 YEL
R10-2 BLU
R53-2 WHT
R11-2 YEL
R14-1 BRN
PCB2 P6-3 RED

R14-2 ORN
R54-1 VIO
LU
B
TB2-2 WHT X7
H2 X6 L
X5 YE PCB2 P6-2 GRN/YEL
T6 X4
TB2-1 BLK X3 GR PCB3 P5-3 RED
H1 X2 N
X1
LU
B
G
R
TB3-2 WHT X7
Y
PCB2 P6-1 BRN H2 X6 L

VIEW F-F (WITH BUS BARS) TB3-1 BLK
H1
T7
X5
X4
YE PCB3 P5-2 GRN/YEL
X3 GR
N
X2
X1
G
R
Y
PCB3 P5-1 BRN

35719, sheet 4 of 5
Rev E

PCB1
P1 P6
1
P9
1 SH1(+) CLR(TP) 1 TB7-9 ORN GRY
2
2 SH1(-) BLK(TP) 2 PCB1 P3-3 WHT GRY
3
3 TB1-6 GRY 3 TB9-11 GRY GRY
4
SH1-3 SHLD 4 TB9-10 BLU GRY
5
P2 5 TB9-9 BLK
PL4(+) GRY
1 6
6
VIO
2 TB8-4 ORN 7
3 TB8-3 BLK P7 8
VIO
1 TD1 P1-1 BLK VIO
4 9
2 TD1 P1-3 GRN VIO
5 K4-A YEL 10
3 TD1 P1-4 WHT VIO
6 TB9-14 WHT 11
PCB P3-3 WHT 4 TD1 P1-2 RED PL5(+) VIO
7 FN3-4 ORN 5 TD2 P1-1 BLK 12 TB11-2 YEL
8 FN3-3 GRY 6 TD2 P1-3 GRN 13 TB11-4 YEL
7 TD2 P1-4 WHT 14
P3 8 TD2 P1-2 RED
1 9 PRA1- BLU P10
2 K6-A BLU 10 R51-1 GRY 1 PCB3 P1-1 BLK
3 PCB1 P2-6 WHT 11 R51-2 BLK 2 PCB3 P1-2 WHT
TB1 PCB1 P6-2 WHT 12 R51-3 VIO 3 PCB3 P1-3 GRN
TS6-2 BRN 4 PCB3 P1-4 RED
13 S3-1 RED
PL3-2 BRN 18
K7-A BRN
P4 14 S3-2 BRN 5 PCB3 P1-9 GRY
17
1 TB7-7 WHT 15 S3-3 WHT 6 PCB3 P1-10 VIO
2 TB1-6 GRY 7 PCB3 P1-5 BLU
PCB4 P1-6 BLK SH1(-) BLK(TP)
16 3 P8 8 PCB3 P1-6 ORN
PCB4 P1-5 RED
15
SH1(+) RED(TP) 4 TB8-5 VIO 9 PCB3 P1-7 YEL
5 TB8-6 YEL 1 S2-5 GRY 10 PCB3 P1-8 BRN
J1-K VIO
14 2 S2-2 VIO 11
T9-H2 WHT
J1-J GRY
13 T4-H2 BLK
P5 3 12
PL1-2 WHT TB9-14 WHT 4 T4-X1 BRN
C26-2 WHT
1 TB9-1 RED 5 T4-X4 GRN/YEL
12
PL2-2 WHT WHT FN4-4 WHT 2 TB9-2 WHT 6 T4-X7 RED P11
PL1-1 BLK
11 T4-H1 BLK 3 TB9-3 BRN 1 PCB2 P1-1 BLK
TB9-20 BLK
CB1-2 BLK
10
4 TB9-4 VIO 2 PCB2 P1-2 WHT
T9-H1 BLK
PL2-1 RED
TB7-8 RED
5 TB9-5 GRY 3 PCB2 P1-3 GRN
J1-E RED 9
TB8-8 RED 6 TB9-6 ORN 4 PCB2 P1-4 RED
J1-G WHT
8
FN4-2 WHT 7 TB9-7 YEL 5 PCB2 P1-9 GRY
FN4-1 BLK
8 TB9-8 VIO 6 PCB2 P1-10 VIO
J1-F BLK
TB8-7 BLK
7
PCB1 P1-3 GRY 9 PRA1-BLK 7 PCB2 P1-5 BLU
S2-6 GRY
6
PCB1 P4-2 GRY C45 10 T3-X1 BRN 8 PCB2 P1-6 ORN
S2-4 BLU
J1-D BLU TB8-12 BLU J1-H GRN
11 TB9-24 YEL 9 PCB2 P1-7 YEL
5 T3-X4 GRN/YEL
J1-C ORN 10 PCB2 P1-8 BRN
GND 5
S2-1 ORN TB8-11 ORN 12 T3-X7 RED
4 C46 11
R50-1 VIO
3
PCB1 P5-8 VIO 12
J1-B YEL FN3-2 YEL
2
J1-A BRN FN3-1 BRN
1
P7 P6
PCB1 P8-6 RED P8
PCB1 P5-10 BRN
LU T4 T3
B PCB1
G
R
TB1-12 BLK X7 P5
Y
H2 X6 L X1
X5 YEPCB1 P8-5 GRN/YEL TB1 P9 GR X2 TB9-20 BLK
TB1-10 BLK
T4 X4
GR
PCB1 P5-11 GRN/YEL N X3
X4 T3
X3
H1 X2 N P10 P11 L
X1 P1 P2 P3 P4 YE X5 TB9-15 WHT
GND5 X6
G
X7
RY
PCB1 P8-4 BRN LU

B
FN4 PCB1 P5-12 RED
TB9 FN3
VIEW H-H
TB1-1 BRN PCB1 P2-8 GRY

1 3
PCB1 P2-8 WHT
PCB1 P5-3 BRN
PCB4 P1-9 ORN
PCB1 P5-5 GRY

PCB1 P5-2 WHT
TB1-12 WHT
PCB1 P5-11 YEL

PCB1 P5-4 VIO
PCB1 P5-6 ORN
PCB1 P6-3 GRY

PCB4 P1-8 WHT
PCB1 P5-1 RED
PCB1 P5-7 YEL
PCB1 P6-5 BLK
PCB1 P6-4 BLU
T3-H2 WHT
TB3-2 WHT
TB8-17 WHT
K7-B WHT
K5-6 BLK
PL3-1 BLK
K3-6 BLK
K3-B WHT
FN3
TS7-1 BLK
TB1-10 BLK
TB3-1 BLK
(LINE) (LOAD)
TB1-2 YEL PCB1 P2-7 ORN
2 4
TB9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
1
TB1-7 BLK CB1-2 BLK

BLK 1 3
PL5(-) YEL
JUMPER
JUMPER
JUMPER
JUMPER
JUMPER
FN4
T3-H1 BLK
PL4(-) YEL
(LINE) (LOAD)
K6-B BLK
TB1-8 WHT T2-X1 WHT

2 4
TB1-11 WHT

35719, sheet 5 of 5
Rev E

K7 K6 K6 K3
1 2 3 1 2 3 1 2 3 1 2 3
4 5 6 4 5 6 4 5 6 4 5 6
7 8 9 7 8 9 7 8 9 7 8 9
A B A B A B A B
TB1-18 BRN
C25-2 GRY
T1-AX1 BLK
T1-AX2 RED
PCB1 P3-2 BLU
TB9-22 BLK
C25-1 ORN
TB8-19 BLU
TB8-18 VIO
TB9-16 WHT
TB9-22 BLK
TB9-22 BLK
K3-9 YEL
TB9-16 WHT
TB8-9 GRY
C26-1 ORN
TB8-10 BRN
TB7-8 RED
TB8-2 WHT
TB7-8 RED
TB8-1 BLU
K7-6 YEL
C54 C53
TB8
TB8
20
K3-A BLU
K7 K6 K5 K3 19
K6-6 VIO JUMPER
18
TB9-17 WHT
17
T2-X4 RED
16
T2-X3 YEL
15
14
13
TB1-5 BLU
12
TB1-4 ORN
11
K6-7 BRN
10
K6-1 GRY
9
TB1-9 RED
8
TB1-7 BLK
7
PCB1 P4-5 YEL
6
PCB1 P4-4 VIO
5
PCB1 P2-2 ORN
4
VIEW J-J PCB1 P2-3 BLK
3
K5-B WHT
2
K5-A BLU
1
TS5-2 WHT
VIEW F-F
TB1-18 BRN
(WITHOUT BUS BARS)
1 TS6
C1 C2 C1
C3 C4 C5 C6
D1 RED D2 RED D3 RED D4 RED D5 RED D6 RED
1 3 1 3 1 3
TS5
TS5-1 WHT
C17
C15
C18
C13
C14
C16
R5
R4
R8
R7
1 2
R6
R9
2 2 2 2 2 2
TS1-2 WHT
3 1 3 1 3 1
C7 C8 C9 C10 C11 C12
TS4
1 2
TS5-1 WHT
TS1-2 WHT
35719, sheet 5 of 5
Rev E

C47 D7,D8 C48 D9,D10 C49 D11,


D13 D15, D17,
D14 C50 D16 C51 D18 C52
FN1 FN2 D25, TS7 D27,
WHT C38 D28
D26 1 2 C40
WHT
WHT WHT
3 3
"B" COIL "B" COIL

GND4 GRN
Section A-A
L1 L2
PCB4 P1-1 GRN
"A" COIL "A" COIL
X1 X1
TB1-10 BLK
H1 PCB4 P1-2 GRN/YEL
T9 X3 YEL
TB1-12 BLK TB11-3 YEL
H2
TB11-2 YEL
PCB4 P1-3 GRN
X4 YEL
Ammeter Voltmeter
PCB4 P1-11 VIO
1 7 8 2 1 7 8 2
Section B-B
WHT
GRN
RED
BLK
BRN
ORN
BLU
YEL
PCB4 P1-12 GRY

B
S4
1 J1 GND 1
3
P2-1
P2-2
P2-3
P2-4
P2-5
P2-6
P2-7
P2-8
2 A TB1-1 BRN
X2 TS4-1 WHT X9
PCB4 B C C TB1-4 ORN BR "A"
A D X3
N
P E
R D TB1-5 BLU BUS
K4-L1 BLK S1 K1A-T1.2.3 BLK
U
5 6 R24-2 BRN M T G F5-1 BLU
L F TB1-7 BLK X5 TS1 H2
3 4 POS PLATE RED K J H
1
R19-2 ORN G TB1-8 WHT X6 "A"
1 2 TB1-5 BLU
R17-1 YEL H GND 5 GRN L1 R23-1 BRN X7
TB1 6 X8
K TB1-14 VIO
GRY
R50-3 GRY
WORK BUS
S2-6 GRY S2
4 5 6 K1B-T1.2.3 BLK
FN2-2 BLU
3 S2-3 RED 1 2 3 M3-2 RED
R50 2
1 TB1-3 VIO
PCB1 P8-2 VIO M1-2 RED X2 X9
TB1-4 ORN
BR "B" X3 T1
BUS X4 2
TB1-12 H1
F5-2 BLU X5 TS2 "B"
WHT TB1-18 BRN H2
TB9-24 YEL
ELECTRODE BUS
TB1-10-A BLK TB9-24 YEL X7

CB1 F3-1 BRN
X8
A
K1C-T1.2.3 BLK
PCB4 P3-1 BLK
BR "C"
FN1-3 GRN GND 4 BUS X2
R51 M3-1 WHT
FN2-3 GRN L2 X3
PCB1 P7-12 VIO X4 2
M1-1 WHT "C" H1
F4-1 BRN H2
36 X7
PCB1 P7-14 BRN D33 BUS GRY TS7-2 WHT X9
X8
25
PCB1 P7-13 RED
14
B
PCB4
P1 P3 Note: From ESP-400C/600C//400V
0558002859, sheet 1 of 5
1 T9-GRN 1 ELECTRODE BUS-BLK
2 T9-GRN/YEL
3 T9-GRN
4 WORK BUS-BLU
5 TB1-15 RED
6 TB1-16 BLK
7 SH1 +
8 TB9-2 WHT
9 TB9-1 ORN
PCB4 P1-10 BLK ESP-400C
10 PCB4 P1-9 BLK
11 S4-1 VIO
12 S4-2 GRY

6.7 Wiring Diagrams – Drawing 1 – Part 1 400V 50Hz (P/N 35879)
M1-3 GRN
M2-3 GRN
F2-1 ORN K2-L1 BLK

T1-CX4 WHT
1 GND-2 GRN 2
3
R3 1
M1 R1
2
2 1
K2-L3 RED TB4 BLU
T1-BX2 RED
1 R2 2
F1-1 VIO K2-L2 WHT

2 R21 1
K4-T2 WHT F7-2 ORN

T1-CX4 WHT
1 1 GND-2 GRN 2 2
3
R22 1
R19 M2 R16 R17
2
FN4-4 WHT
K1B-L1 YEL GND 3 GRN 2 2 1 1

H1 T1-BX2 RED
X1 F4-2 BLK S1-1 YEL
H2 CB1-1 BLU
WHT X2 ORN
H3 T2
H4 TB8-15 YEL S1-3 ORN C27(-) WHT
X3 1 R20 2
K1C-L1 BLK H5
X4 TB8-16 RED
H6 POS PLATE BLU
1 R23 2
Note: From ESP-400C/600C//400V,50 Hz

OR

SEE VIEW K-K
F F E E
K1A K1B K1C

K2-B WHT
TB1-11 WHT
1
R33
C26 K7-9 ORN
2
K4-B ORN
K2-A ORN
1
R32
C25 K1C-B GRY
2
K7-7 GRY
R2-1 VIO K1C-A ORN

F1
K2 R3-1 ORN
K3-7 ORN NEG PLATE
F2 TB5 GRY S1-4 RED
TB6 BRN
R26-2 RED
C34-2 BLK
D34
POS PLATE
BLK
D33
T1-CX7 GRY
SECTION C-C ELECTRODE PLATE

R25-2 GRY
SEE VIEW L-L

D R28-2 YEL
TB5 BLK T2-H1 YEL

K1B-L1 BLK
TB5 BLK
K1B-B GRY
K1A-B/K1C-B GRY K1B-L2 BLK
TB4 BLK
K1B-A/C25-1 ORN K1B-L3 BLK
TB4 BLK
TB6 BLK K1C-L1 BLK
K1A-L3 BLK
TB4 BLK T2-H6 BLK K1C-L2 BLK
K1A-L2 BLK K1C-L3 BLK
TB6 BLK
TB6 BLK K1A-L1 BLK
TB4 TB5 TB6

R1-1 BLU F2-2 GRN
L1 L2 L3 L1 L2 L3 L1 L2 L3
K1B-A ORN K1-B/C25-2 GRY

A K1A B A K1B B A K1C B F1-2 GRY
T1-AH1 BLK
T1 T2 T3 T1 T2 T3 T1 T2 T3
T1-AH1 BLK
K2-T3 RED
T1-AH1 BLK
K2-T2 WHT C60 C61 C62
T1-AH2/BH1 BLK
400V 50HZ
T1-BH2/CH1 BLK UNITS ONLY
T1-BH2/CH1 BLK
R2-2 WHT T1-AH2/BH1 BLK R57
R55
R56
R1-2 BLK L1 L2 L3 VIEW L-L
C26-1 ORN
A K2 B
C26-2 WHT
VIEW K-K
K1A-T3 BLK T1 T2 T3
K1B-T3 WHT
K1C-T3 RED
OR

C23-2 VIO C24-1 VIO
C R53 R54
G
C8(+) BLU
C2(+) BLU 1 2 1 2
C8(-) YEL
C2(-) YEL
1 R10 2 1 R11 2
T1-CX4 WHT
T1-BX2 RED
M3
C
T2
"A" "C"
"B"
X1
X1 X1
F8 F9
K7-4 BLK
SECTION D-D
K5-9 RED
VIEW G-G
R45
R52
TB7 1 2 3 4 5 6 7 8 9 10 11 12 13
PCB1 P4-1 WHT
PCB1 P6-1 ORN

TB1-9 RED
F7-1 BRN
K6-9 RED
TB7

PCB1 P7-9 BLU
NEG PLATE YEL

C28(+) BLU PRA1
ELECTRODE PLATE GRY
R20-2 BLU
PCB1 P5-9 BLK
F3-2 BLK K4-T3 ORN
D31 D32
POS
C43 C44 PLATE
BLK ORN
C41 C42
D29 D30
C27(-) WHT
S1-2 WHT
ELECTRODE PLATE
PRA1 GRY
C29(-) GRY Drawing No. 0558002859, sheet 2 of 5
R21-2 GRY OR
TD2 (SPLICE) GRY
TD1 (SPLICE) GRY

6.7 Wiring Diagrams – Drawing 3 400V 50Hz (P/N 35879)
TB11
SHT BUS POS BLU
1
BLK
2 PCB1 P9-12 YEL

R59
L2-X4 YEL
3 L2-X3 YEL
4 PCB1 P9-13 YEL

R63
7
R58
8
PCB1 P1-1 CLR (TP)

TB1-16 BLK(TP)
(+) and (-) must be
PCB1 P1-3 SHLD

direction shown.
(-) SH1 (+)

TD1 TD2
P1 1 2 3 4 P1 1 2 3 4
PCB1 P1-2 BLK(TP)
TB1-15 RED(TP)
P1 P1
PCB4 P1-4 BLU
1 PCB1 P7-5 BLK
TB11-1 BLU
1 PCB1 P7-1 BLK
2 PCB1 P7-8 RED
2 PCB1 P7-4 RED
3 PCB1 P7-6 GRN
Note1: 3
4
PCB1 P7-2
PCB1 P7-3
GRN
WHT
4 PCB1 P7-7 WHT

direction shown.
R16-2 (SPLICE) BLK
(-) SH1 (+)

3
R17-2 (SPLICE) BLK
D20-2 BRN
TD1 TD2
1 R13 2 1 R15 2
D20-1 ORN
D19-1 ORN
1 R12 2 1 R14 2
D19-2 BRN D22-1 ORN

D22-2 BRN
D21-2 BRN
S1-6 BRN
D31-A BLK

C32(-) BLU 1 1 2
2 F3 R31-2 GRY
D33 BUS GRY
POS PLATE RED
D35

1 F5 2 2
R37
L3 B T3
D34-A BLK 2
R41
1 F6
R43
L2 K4 T2 2 C27
C31
C29
R34
BLK
R25-1 YEL C34 2 2 2 2 2

L1 A T1 + +
1 F7 2
R40
1 C32
BLK
R31 R30
+
2
R27 R26 R25 R29 R28
BLK
R35
1
PCB1 P2-5 YEL
C35
R38
R42
R26-1 BRN C30 C28

R19-1 BRN
TB7-5 BRN
C26-1 ORN
R23-2 RED
R18-2 WHT
D32-A ORN
C30-2 WHT
C30-1 YEL
R24-1 VIO
2
S1-5 BLK
TB10 YEL
+
T1-AX5 BLU
1
R39
1 1
1 1 RED 1
+ R30-1 BLU
1 1
2
C32(-) BLU
J J
R36
R27-1 ORN C36

POS PLATE RED
1
R29-1 RED
C36-2 BLU
R29-2 BLU
R22-1 BLU
ELECTRODE PLATE YEL
C36-1 ORN
C35-1 BRN
C34-1 YEL
R18-1 ORN
T1-BX5 BLU
C28 (+) BLU

C29(+) VIO
C29 (+) VIO
K4-T2 WHT
C33(+) RED
K4-T1 YEL
R31-1 VIO
F6-2 VIO
H
H

VIEW E-E Drawing No. 0558002859, sheet 3 of 5
OR

6.7 Wiring Diagrams – Drawing 4 400V 50Hz (P/N 35879)
PCB2 PCB3
P1 P2 P1 P2
6 PCB1 P10-8 ORN 6 6 PCB1 P11-8 ORN 6
8 PCB1 P10-10 BRN P5 P5
8 PCB1 P11-10 BRN
9 PCB1 P11-5 GRY
10 PCB1 P11-6 VIO
P6 P6
PCB2 P5-1 BRN

G
RY

GR X2X1 H1
G
X4
R
TB2-2 BLK
Y
L X5 TB3-1 BLK
YE H2
X6
X7 GR X2X1 H1
LU X4
PCB2 P5-3 RED B L X5 TB3-2 BLK
YE X6 H2
X7
L U
PCB3 P6-3 RED B

TB2 T8-H1 BLK
1 1
2 2
C6 + C12
+
R13-1 BRN
R15-2 ORN
R13-2 ORN
R15-1 BRN
R52-1 VIO
PCB3 P3 BLK
TB2 TB3
C20 C11 C22

C5 +
T5 T8
D20 D22
+ 2
1 Q4-C BLK
P5 P6 P3
E C Q4 C E
C4 + C10
P2 +
2 2
C3 + C9 P1
PCB2 PCB3
D23
D24
C23 C24
P1 +
1 1
C2 + C8 P2
K2
+
E C Q1 Q3 C E
P3 P5
Q1-C BLK P6
C1 + C7 1 2
D19 D21
T6 T7
C19 + C21
PCB2 P3 BLK
R12-2 ORN
R54-2 WHT
R12-1 BRN
R11-1 BLU
R10-1 YEL
R10-2 BLU
R53-2 WHT
R11-2 YEL
R14-1 BRN
PCB2 P6-3 RED

R14-2 ORN
R54-1 VIO
LU
B
TB2-2 WHT X7
H2 X6 L
T6 X4
H1 X2 N
X1
LU
B
G
RY
TB3-2 WHT X7
H1
T7
X5
X4
X3 GR
X2 N
X1
G
R
Y
PCB3 P5-1 BRN

OR

PCB1
P1 P6
1
P9
2
3
4
5
P2 5 TB9-9 BLK
PL4(+) GRY
1 6
6
VIO
2 TB8-4 ORN 7
3 TB8-3 BLK P7 8
VIO
1 TD1 P1-1 BLK VIO
4 9
2 TD1 P1-3 GRN VIO
5 K4-A YEL 10
3 TD1 P1-4 WHT VIO
6 TB9-14 WHT 11
7 TD2 P1-4 WHT 14
P3 8 TD2 P1-2 RED
1 9 PRA1- BLU P10
13 S3-1 RED
PL3-2 BRN 18
K7-A BRN
17
16 3 P8 8 PCB3 P1-6 ORN
PCB4 P1-5 RED
15
J1-K VIO
14 2 S2-2 VIO 11
J1-J GRY
13
T9-H2 WHT
T4-H2 BLK
P5 3 12
C26-2 WHT
12
PL1-1 BLK
TB9-20 BLK
CB1-2 BLK
10
T9-H1 BLK
PL2-1 RED
TB7-8 RED
J1-E RED
9
J1-G WHT
8
FN4-1 BLK
J1-F BLK
TB8-7 BLK
7
S2-6 GRY
6
S2-4 BLU
5 T3-X4 GRN/YEL
GND 5
4 C46 11
R50-1 VIO
3
PCB1 P5-8 VIO 12
J1-B YEL FN3-2 YEL
2
J1-A BRN FN3-1 BRN
1
P7 P6
PCB1 P8-6 RED P8
PCB1 P5-10 BRN
LU T4 T3
B PCB1
G
R
TB1-12 BLK X7 P5
Y
H2 X6 L X1
TB1-10 BLK
T4 X4
GR
PCB1 P5-11 GRN/YEL N
X3
X4 T3
X3
H1 X2 N P10 P11 L
GND5 X6
G
X7
RY
PCB1 P8-4 BRN LU

B
FN4 PCB1 P5-12 RED
TB9 FN3
VIEW H-H

1 3
PCB1 P2-8 WHT
PCB1 P5-3 BRN
PCB4 P1-9 ORN
PCB1 P5-5 GRY

PCB1 P5-2 WHT
TB1-12 WHT
PCB1 P5-11 YEL

PCB1 P5-6 ORN
PCB1 P5-4 VIO
PCB1 P6-3 GRY

PCB4 P1-8 WHT
PCB1 P5-1 RED
PCB1 P5-7 YEL
PCB1 P6-5 BLK
PCB1 P6-4 BLU
TB3-2 WHT
T3-H2 WHT
TB8-17 WHT
K7-B WHT
K5-6 BLK
PL3-1 BLK
K3-6 BLK
K3-B WHT
FN3
TS7-1 BLK
TB1-10 BLK
TB3-1 BLK
(LINE) (LOAD)
2 4
TB9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
1
TB1-7 BLK CB1-2 BLK

BLK 1 3
PL5(-) YEL
JUMPER
JUMPER
JUMPER
JUMPER
JUMPER
FN4
T3-H1 BLK
PL4(-) YEL
(LINE) (LOAD)
K6-B BLK
TB1-8 WHT T2-X1 WHT

2 4
TB1-11 WHT

OR

K7 K6 K6 K3
1 2 3 1 2 3 1 2 3 1 2 3
4 5 6 4 5 6 4 5 6 4 5 6
7 8 9 7 8 9 7 8 9 7 8 9
A B A B A B A B
TB1-18 BRN
C25-2 GRY
T1-AX1 BLK
T1-AX2 RED
PCB1 P3-2 BLU
TB9-22 BLK
C25-1 ORN
TB8-19 BLU
TB8-18 VIO
TB9-16 WHT
TB9-22 BLK
TB9-16 WHT
K3-9 YEL
TB9-22 BLK
TB8-9 GRY
C26-1 ORN
TB8-10 BRN
TB7-8 RED
TB8-2 WHT
TB8-1 BLU
TB7-8 RED
K7-6 YEL
C54 C53
TB8
TB8
20
K3-A BLU
K7 K6 K5 K3 19
K6-6 VIO JUMPER
18
TB9-17 WHT
17
T2-X4 RED
16
T2-X3 YEL
15
14
13
TB1-5 BLU
12
TB1-4 ORN
11
K6-7 BRN
10
K6-1 GRY
9
TB1-9 RED
8
TB1-7 BLK
7
PCB1 P4-5 YEL
6
PCB1 P4-4 VIO
5
PCB1 P2-2 ORN
4
3
K5-B WHT
2
K5-A BLU
1
TS5-2 WHT
VIEW F-F
TB1-18 BRN
(WITHOUT BUS BARS)
1 TS6
C1 C2 C1
C3 C4 C5 C6
1 3 1 3 1 3
TS5
TS5-1 WHT
C17
C15
C18
C13
C14
C16
R5
R4
R8
R7
1 2
R6
R9
2 2 2 2 2 2
TS1-2 WHT
3 1 3 1 3 1
C7 C8 C9 C10 C11 C12
TS4
1 2
TS5-1 WHT
TS1-2 WHT
OR

C47 D7,D8 C48 D9,D10 C49 D11,


D13 D15, D17,
D14 C50 D16 C51 D18 C52
FN1 FN2 D25, TS7 D27,
WHT C38 2 D28
D26 1 C40
WHT
WHT WHT
3 3
"B" COIL "B" COIL

GND4 GRN
Section A-A
L1 L2
PCB4 P1-1 GRN
"A" COIL "A" COIL
X1 X1
TB1-10 BLK
H1
PCB4 P1-2 GRN/YEL X3 YEL
T9
TB1-12 BLK H2 TB11-3 YEL
TB11-2 YEL
PCB4 P1-3 GRN
X4 YEL
Ammeter Voltmeter
PCB4 P1-11 VIO
1 7 8 2 1 7 8 2
Section B-B
WHT
GRN
RED
BLK
BRN
ORN
BLU
YEL
PCB4 P1-12 GRY

B
S4
J1 GND 1
1 3
P2-1
P2-2
P2-3
P2-4
P2-5
P2-6
P2-7
P2-8
2 A TB1-1 BRN
X2 TS4-1 WHT X9
PCB4 B C C TB1-4 ORN BR "A" K1A-T1.2.3 BLK
A D X3 H1
N
P E
R D TB1-5 BLU BUS
K4-L1 BLK S1
U
5 6 R24-2 BRN M T G F5-1 BLU
3 4 L F TB1-7 BLK X5 TS1
POS PLATE RED K J H
1 H3
R19-2 ORN G TB1-8 WHT R23-1 BRN X6 "A"
1 2 TB1-5 BLU
R17-1 YEL H GND 5 GRN H4
L1 X7
TB1 6 X8
K TB1-14 VIO
GRY
R50-3 GRY
WORK BUS
S2-6 GRY S2
4 5 6 M3-2 RED K1B-T1.2.3 BLK
FN2-2 BLU
3 S2-3 RED 1 2 3 M2-2 RED
R50 2
1 TB1-3 VIO
PCB1 P8-2 VIO X2 X9
TB1-4 ORN BR "B"
BUS X3 T1 H1
X4 2
TB1-12 F5-2 BLU H2
X5 TS2 "B"
WHT TB1-18 BRN H3
TB9-24 YEL F3-1 BRN
ELECTRODE BUS
TB1-10-A BLK X7 H4
CB1 TB9-24 YEL
X8
A
K1C-T1.2.3 BLK
PCB4 P3-1 BLK BR "C"
BUS
FN1-3 GRN GND 4 M3-1 WHT X2
R51 M2-1 WHT
FN2-3 GRN L2 X3 H1
PCB1 P7-12 VIO X4 2
F4-1 BRN "C" H2
D33 BUS GRY H3
X7 H4
PCB1 P7-14 BRN 36
X8
TS7-2 WHT X9
25
PCB1 P7-13 RED
14
B
PCB4
P1 P3 Note: From ESP-400C/600C//575V
1 T9-GRN 1 ELECTRODE BUS-BLK Drawing No. 0558002852, sheet 1 of 5
2 T9-GRN/YEL OR
3 T9-GRN
4 SHUNT 1-3 -BLU
5 TB1-15 RED (600C Only)
6 TB1-16 BLK
7 TB1-15 (400C Only)
8 TB9-2 WHT
9 TB9-1 ORN
PCB4 P1-10 ORN ESP-400C
10 PCB4 P1-9 ORN
11 S4-1 VIO
12 S4-2 GRY

M1-3 GRN
M2-3 GRN
F2-1 ORN K2-L1 BLK

T1-CX4 WHT
1 GND-2 GRN 2
3
R3 1
M1 R1
2
2 1
K2-L3 RED TB4 BLU
T1-BX2 RED
1 R2 2
F1-1 VIO K2-L2 WHT

2 R21 1
K4-T2 WHT F7-2 ORN

T1-CX4 WHT
1 1 GND-2 GRN 2 2
3
R22 1
R19 M2 R16 R17
2
FN4-4 WHT
K1B-L1 YEL
H1 GND 3 GRN 2 2 1 1
T1-BX2 RED
H2 X1 F4-2 BLK S1-1 YEL
H3 CB1-1 BLU
WHT T2 X2 ORN
H4 S1-3 ORN C27(-) WHT
X3 TB8-15 YEL 2
H5 1 R20
H6 X4 TB8-16 RED
K1C-L1 BLK POS PLATE BLU
H7
1 R23 2
GND 3

OR

SEE VIEW K-K
F F E E
K1A K1B K1C

K2-B WHT
TB1-11 WHT
1
R33
C26 K7-9 ORN
2
K4-B ORN
K2-A ORN
1
R32
C25 K1C-B GRY
2
K7-7 GRY
R2-1 VIO K1C-A ORN

F1
K2 R3-1 ORN
K3-7 ORN NEG PLATE
F2 TB5 GRY S1-4 RED
TB6 BRN
R26-2 RED
C34-2 BLK
D34
POS PLATE
BLK
D33
T1-CX7 GRY
SECTION C-C ELECTRODE PLATE

R25-2 GRY
SEE VIEW L-L

D R28-2 YEL
TB5 BLK T2-H1 YEL

K1B-L1 BLK
TB5 BLK
K1B-B GRY
K1A-B/K1C-B GRY K1B-L2 BLK
TB4 BLK
K1B-A/C25-1 ORN K1B-L3 BLK
TB4 BLK
TB6 BLK K1C-L1 BLK
K1A-L3 BLK
TB4 BLK T2-H6 BLK K1C-L2 BLK
K1A-L2 BLK K1C-L3 BLK
TB6 BLK
TB6 BLK K1A-L1 BLK
TB4 TB5 TB6

R1-1 BLU F2-2 GRN
L1 L2 L3 L1 L2 L3 L1 L2 L3
K1B-A ORN K1-B/C25-2 GRY

A K1A B A K1B B A K1C B F1-2 GRY
T1-AH1 BLK
T1 T2 T3 T1 T2 T3 T1 T2 T3
T1-AH1 BLK
K2-T3 RED
T1-AH1 BLK
K2-T2 WHT C60 C61 C62
T1-AH2/BH1 BLK
400V 50HZ
T1-BH2/CH1 BLK UNITS ONLY
T1-BH2/CH1 BLK
R2-2 WHT T1-AH2/BH1 BLK R57
R55
R56
R1-2 BLK L1 L2 L3 VIEW L-L

C26-1 ORN
A K2 B
C26-2 WHT
VIEW K-K
K1A-T3 BLK T1 T2 T3
K1B-T3 WHT
K1C-T3 RED
OR

C23-2 VIO C24-1 VIO
C R53 R54
G
C8(+) BLU
C2(+) BLU 1 2 1 2
C8(-) YEL
C2(-) YEL
1 R10 2 1 R11 2
T1-CX4 WHT
T1-BX2 RED
M3
C
T2
"A" "C"
"B"
X1
X1 X1
F8 F9
K7-4 BLK
SECTION D-D
K5-9 RED
VIEW G-G
R45
R52
TB7 1 2 3 4 5 6 7 8 9 10 11 12 13
PCB1 P4-1 WHT
PCB1 P6-1 ORN

TB1-9 RED
F7-1 BRN
K6-9 RED
TB7

PCB1 P7-9 BLU
NEG PLATE YEL

C28(+) BLU PRA1
ELECTRODE PLATE GRY
R20-2 BLU
PCB1 P5-9 BLK
F3-2 BLK K4-T3 ORN
D31 D32
POS
C43 C44 PLATE
BLK ORN
C41 C42
D29 D30
C27(-) WHT
S1-2 WHT
ELECTRODE PLATE
PRA1 GRY
C29(-) GRY
R21-2 GRY
TD2 (SPLICE) GRY
TD1 (SPLICE) GRY OR

TB11
SHT BUS POS BLU
1
BLK
2 PCB1 P9-12 YEL
R59
L2-X4 YEL
3 L2-X3 YEL
4 PCB1 P9-13 YEL

R63
7
R58
8
TB1-16 BLK(TP)
PCB1 P1-1 CLR (TP)

(+) and (-) must be
PCB1 P1-3 SHLD

direction shown.
(-) SH1 (+)

TD1 TD2
P1 1 2 3 4 P1 1 2 3 4
PCB1 P1-2 BLK(TP)
TB1-15 RED(TP)
P1 P1
PCB4 P1-4 BLU
1 PCB1 P7-5 BLK
TB11-1 BLU
1 PCB1 P7-1 BLK
2 PCB1 P7-8 RED
2 PCB1 P7-4 RED
3 PCB1 P7-6 GRN
Note1: 3
4
PCB1 P7-2
PCB1 P7-3
GRN
WHT
4 PCB1 P7-7 WHT

direction shown.
R16-2 (SPLICE) BLK
(-) SH1 (+)

3
R17-2 (SPLICE) BLK
D20-2 BRN
TD1 TD2
1 R13 2 1 R15 2
D20-1 ORN
D19-1 ORN
1 R12 2 1 R14 2
D19-2 BRN D22-1 ORN

D22-2 BRN
D21-2 BRN
S1-6 BRN
D31-A BLK

C32(-) BLU 1 1 2
2 F3 R31-2 GRY
D33 BUS GRY
POS PLATE RED
D35

1 F5 2 2
R37
L3 B T3
D34-A BLK 2
R41
1 F6
R43
L2 K4 T2 2 C27
C31
C29
R34
BLK
R25-1 YEL C34 2 2 2 2 2

L1 A T1 + +
1 F7 2
R40
1 C32
BLK
R31 R30
+
2
R27 R26 R25 R29 R28
BLK
R35
1
PCB1 P2-5 YEL
C35
R38
R42
R26-1 BRN C30 C28

R19-1 BRN
TB7-5 BRN
C26-1 ORN
D32-A ORN
R18-2 WHT
R23-2 RED
C30-2 WHT
C30-1 YEL
R24-1 VIO
2
TB10 YEL
S1-5 BLK
+
T1-AX5 BLU
1
R39
1 1
1 1 RED 1
+ R30-1 BLU
1 1
2
C32(-) BLU
J J
R36
R27-1 ORN C36

POS PLATE RED
1
R29-1 RED
C36-2 BLU
R29-2 BLU
R22-1 BLU
ELECTRODE PLATE YEL
C36-1 ORN
C35-1 BRN
C34-1 YEL
R18-1 ORN
C28 (+) BLU

T1-BX5 BLU
C29 (+) VIO

C29(+) VIO
K4-T2 WHT
C33(+) RED
K4-T1 YEL
R31-1 VIO
F6-2 VIO
H
H

VIEW E-E OR

PCB2 PCB3
P1 P2 P1 P2
6 PCB1 P10-8 ORN 6 6 PCB1 P11-8 ORN 6
8 PCB1 P10-10 BRN P5 P5
8 PCB1 P11-10 BRN
9 PCB1 P11-5 GRY
10 PCB1 P11-6 VIO
P6 P6
PCB2 P5-1 BRN

G
RY

GR X2X1 H1
G
X4
R
TB2-2 BLK
Y
L X5 TB3-1 BLK
YE H2
X6
X7 GR X2X1 H1
U PCB3 P6-2 GRN/YEL N X3 T8
L X4
PCB2 P5-3 RED B L TB3-2 BLK
YE X5 X6 H2
X7
LU
PCB3 P6-3 RED B

TB2 T8-H1 BLK
1 1
2 2
C6 + C12
+
R13-1 BRN
R15-2 ORN
R13-2 ORN
R15-1 BRN
R52-1 VIO
PCB3 P3 BLK
TB2 TB3
C20 C11 C22

C5 +
T5 T8
D20 D22
+ 2
1 Q4-C BLK
P5 P6 P3
E C Q4 C E
C4 + C10
P2 +
2 2
C3 + C9 P1
PCB2 PCB3
D23
D24
C23 C24
P1 +
1 1
C2 + C8 P2
K2
+
E C Q1 Q3 C E
P3 P5
Q1-C BLK P6
C1 + C7 1 2
D19 D21
T6 T7
C19 + C21
PCB2 P3 BLK
R12-2 ORN
R54-2 WHT
R12-1 BRN
R11-1 BLU
R10-1 YEL
R10-2 BLU
R53-2 WHT
R11-2 YEL
R14-1 BRN
PCB2 P6-3 RED

R14-2 ORN
R54-1 VIO
LU
B
TB2-2 WHT X7
H2 X6 L
T6 X4
H1 X2 N
X1
LU
B
G
RY
TB3-2 WHT X7
H1
T7
X5
X4
X3 GR
X2 N
X1
G
R
Y
PCB3 P5-1 BRN

OR

PCB1
P1 P6
1
P9
2
3
4
5
P2 5 TB9-9 BLK
PL4(+) GRY
1 6
6
VIO
2 TB8-4 ORN 7
3 TB8-3 BLK P7 8
VIO
1 TD1 P1-1 BLK VIO
4 9
2 TD1 P1-3 GRN VIO
5 K4-A YEL 10
3 TD1 P1-4 WHT VIO
6 TB9-14 WHT 11
7 TD2 P1-4 WHT 14
P3 8 TD2 P1-2 RED
1 9 PRA1- BLU
P10
13 S3-1 RED
PL3-2 BRN 18
K7-A BRN
17
16 3 P8 8 PCB3 P1-6 ORN
PCB4 P1-5 RED
15
J1-K VIO
14 2 S2-2 VIO 11
J1-J GRY
13
T9-H2 WHT
T4-H2 BLK
P5 3 12
C26-2 WHT
12
PL1-1 BLK
TB9-20 BLK
CB1-2 BLK
10
T9-H1 BLK
PL2-1 RED
TB7-8 RED
J1-E RED 9
J1-G WHT
8
FN4-1 BLK
J1-F BLK
TB8-7 BLK
7
S2-6 GRY
6
S2-4 BLU
5 T3-X4 GRN/YEL
GND 5
4 C46 11
R50-1 VIO
3
PCB1 P5-8 VIO 12
J1-B YEL FN3-2 YEL
2
J1-A BRN FN3-1 BRN
1
P7 P6
PCB1 P8-6 RED P8
PCB1 P5-10 BRN
LU T4 T3
B PCB1
G
R
TB1-12 BLK X7 P5
Y
H2 X6 L X1
TB1-10 BLK
T4 X4
GR
PCB1 P5-11 GRN/YEL N
X3
X4 T3
X3
H1 X2 N P10 P11 L
GND5 X6
G
X7
RY
PCB1 P8-4 BRN LU

B
FN4 PCB1 P5-12 RED
TB9 FN3
VIEW H-H

1 3
PCB1 P2-8 WHT
PCB1 P5-3 BRN
PCB4 P1-9 ORN
PCB1 P5-5 GRY

PCB1 P5-2 WHT
TB1-12 WHT
PCB1 P5-11 YEL

PCB1 P5-6 ORN
PCB1 P5-4 VIO
PCB1 P6-3 GRY

PCB4 P1-8 WHT
PCB1 P5-1 RED
PCB1 P5-7 YEL
PCB1 P6-5 BLK
PCB1 P6-4 BLU
TB3-2 WHT
T3-H2 WHT
TB8-17 WHT
K7-B WHT
K5-6 BLK
PL3-1 BLK
K3-6 BLK
K3-B WHT
FN3
TS7-1 BLK
TB1-10 BLK
TB3-1 BLK
(LINE) (LOAD)
2 4
TB9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
1
TB1-7 BLK CB1-2 BLK

BLK 1 3
PL5(-) YEL
JUMPER
JUMPER
JUMPER
JUMPER
JUMPER
FN4
T3-H1 BLK
PL4(-) YEL
(LINE) (LOAD)
K6-B BLK
TB1-8 WHT T2-X1 WHT

2 4
TB1-11 WHT

OR

K7 K6 K6 K3
1 2 3 1 2 3 1 2 3 1 2 3
4 5 6 4 5 6 4 5 6 4 5 6
7 8 9 7 8 9 7 8 9 7 8 9
A B A B A B A B
TB1-18 BRN
C25-2 GRY
T1-AX1 BLK
T1-AX2 RED
PCB1 P3-2 BLU
TB9-22 BLK
C25-1 ORN
TB8-19 BLU
TB8-18 VIO
TB9-16 WHT
TB9-22 BLK
K3-9 YEL
TB9-22 BLK
TB9-16 WHT
TB8-9 GRY
C26-1 ORN
TB8-10 BRN
TB7-8 RED
TB8-2 WHT
TB8-1 BLU
TB7-8 RED
K7-6 YEL
C54 C53
TB8
TB8
20
K3-A BLU
K7 K6 K5 K3 19
K6-6 VIO JUMPER
18
TB9-17 WHT
17
T2-X4 RED
16
T2-X3 YEL
15
14
13
TB1-5 BLU
12
TB1-4 ORN
11
K6-7 BRN
10
K6-1 GRY
9
TB1-9 RED
8
TB1-7 BLK
7
PCB1 P4-5 YEL
6
PCB1 P4-4 VIO
5
PCB1 P2-2 ORN
4
3
K5-B WHT
2
K5-A BLU
1
TS5-2 WHT
VIEW F-F
TB1-18 BRN
(WITHOUT BUS BARS)
2
TS6
1
C1 C2 C1
C3 C4 C5 C6
1 3 1 3 1 3
TS5
TS5-1 WHT
C17
C15
C18
C13
C14
C16
R5
R4
R8
R7
1 2
R6
R9
2 2 2 2 2 2
TS1-2 WHT
3 1 3 1 3 1
C7 C8 C9 C10 C11 C12
TS4
1 2
TS5-1 WHT
TS1-2 WHT
OR

6.9 PC Controller Board (PCB1,P/N 38032, REV C) Schematics Drawing 1 Part 1

6.9 PC Controller Board (PCB1-P/N 38032) Schematics - Drawing 1 Part 2



6.9 PC Controller Board (PCB1-P/N 38032) Schematics - Drawing 3

6.10 PCB Digital Meter Board (PCB4-P/N 38139) Drawing 1

6.10 PCB Digital Meter Board (PCB4-P/N 38139) Drawing 2 Part
1

6.10 PCB Digital Meter Board (PCB4-P/N 38139) Drawing 2 Part 2

6.11 IGBT Driver Board (PCB2,3 – P/N 38030) Drawing 1 Part 1
+15Z +15Z POT1˜3.32K

CLOCK OSCILLATOR P2-5 P2-6 P2-2 P2-4
20KHZ R29 TP12
TP05 10 +15Z
R23 5 14 4 R24
R19 10 IC04 Z
10 POT5 C14 1K
6 7 .47
10K CW
C13
CW .47 Z POT1
P2-1 P2-3 TP18 10K
14 1 +15Z +15Z
R20 TP11 D08
4 8 3.32K VDD Q TP19 R25
3 CLK D 5 1K 12
3 8 R32 C17 1
9 4013 1
IC04 3
R22 R87 IC04 10 IC04
IC02 7 12=OPEN Q 2
10R 13=OPEN 2 1K 10K 9 221 560 13
555 TP03 PF
R21 11 C18
20K D09
6 SETVSS R S TP06 .0015 TP17
8 7 4 6 TP20 2
2 TP04 IC03 Z
1 5
C11 C12.0015 TP09 R33
C06
.01 3
.47 +15Z 10K
+15H
MAX ERROR IC10
V MIN ˜+4.5V R41 CW # 4
# R34 POT4 2 1
# 100K 10K R55
2.21K
+15Z
MAX˜-0.5V Z 8 4
R43 R39 14
10
P1-01 # R37 TP16 D50 D51
TP23 1M R44 10 M57962L 5 5
C25.47 C19 D12 IC06 TP32
R45 1 .47 TP21
10K 15 9 D11
P1-02
C26 .01 IC07 7 D10 R36 1 6
P1-03 8 C20 TP13 680
16
2 10 R31 2 1/2W 13
C24 .47 Q2 6 ZD7
R46 R35 .47 10K
-
IC05 6 499
R26
2N4401
P1-04 # 10 C23
10 +
3 34001 -12H
R40 4.7
ANALOG 7
-15Z R82 R83 10K C22
ISOLATOR
TP24 R42 221 TP22 4.7 8
COMPARATOR
#
T C54 Z OFF H
Q3
TP25 .01 R38 ON TP31
1KV +15Z
R47 20K
P1-05 C21
1M R48 IC08 .01
100K
Q6 IC10
C52 R85 IGBT SAT Z
.01 100K LOSS SS CONTACTOR P6-1 R60
P1-06
1.0
TP26 2W C33
20V
.10
TP27
R49 H
P1-07 20V
1M BR2 9
R50 -12H R59
+
P6-3
~
~
Q7 100K -12V INDICATOR 1.0 C32

+ C28
-
IC09 C53 R86 2W

.01 100K P6-2 .10 1000
P1-08 10
TP28 R84
221 + C31
TP29 1000
D13 LED3
P1-09 11
R52 C27 SS CONTACTOR
10K IC08
.01
R51
P1-10
TP30 221

6.11 IGBT Driver Board (PCB2,3 – P/N 38030) Drawing 1 Part 2
+15Z
POSITION P5-1
R80 R08 TP07
20K R11 2W 1.0 C01 D03
10K D07 20V
R10 POT6
10K
.10
10K
+ C50 POT2SPAN Z +15Z
3.3 R16 10K 20V IN REG1 OUT
22.1K CW P5-3 R09 BR1 7815 R13
+
TP15 D01 C09 + 3.32K
~
~
Z TP02 D02
2W 1.0 C07 TP08
-
2- TP14 + 1000 3.3 LED1
IC01 6 P5-2 .10 C02
1 R30 3 + 34001
+15Z R12
100 Q1 R81 + C08 D05 D04 C10 + 3.32K Z
10K 1000 3.3
C03 R15 LED2
10
.10 RAMP IN 7915 OUT
t C05 REG2
2 -15Z
7 .47 D06
-
˜+1.25V v 34001
˜-5.OV + C04
3 4 .47 Z
TP10
IC01 +15Z
TP01
R01 R14
4 10 R28
2.2 1W IGBT 1
10
# R02 G -15Z
2.2 1W ZD2 C16
POWER CONNECTIONS FOR IC1 7 .47
Q5 -
ZD1 34001
+ 4 C15
5 R05 E Z
.47
10 1W E
IC05
R27
Q4 10
6 D20
P3-1 -15Z
# R04 POWER CONNECTIONS FOR IC5
2.2 1W IGBT 2
# R03 G
2.2 1W
# ZD4
7
C51 # ZD3
.033
8 630V E
R06 E
2.2 1W IGBT 3
# R07 G
2.2 1W ZD6
ZD5
E
E
D14
TP33
9 IN OUT +15H
REG3
7815 R53
3.32K IC09 R56 R57
C29 + 1K 15K
D15 D16 LED4
1000 2 1
10 Q8
H R54
D19 D18 C30 + 3.32K R58
1000 LED5 10K
11 7912
IN REG4 OUT
-12H
D17 TP34
# LEAVE OFF BOARD

6.11 IGBT Driver Board (PCB2,3 – P/N 38030) Drawing 2

SECTION 7 Replacement Parts
7.1 General
Always provide the serial number of the unit on
which the parts will be used. The serial number is
stamped on the unit nameplate.
7.2 Ordering
To ensure proper operation, it is recommended
that only genuine ESAB parts and products be
used with this equipment. The use of non-ESAB
parts may void your warranty.
Replacement parts may be ordered from your

ESAB Distributor or from:
ESAB Welding and Cutting Products

ATTN: Customer Service Department
PO Box 100545 Ebenezer Road
Florence, SC USA 29501-0545
Phone (843) 664-4405
(800) ESAB-123 (372-3123)
ESAB Cutting Systems - Canada

6010 Tomken Road
Mississauga, Ontario, Canada L5T 1X9
Phone (905) 670-0220
Fax (905) 670-4879
ESAB Cutting Systems GmbH

Robert-Bosch-Strasse 20
Postfach 1128
D-61184 Karben 1
Germany
Phone 011 49 60 39 400
Fax 011 49 60 39 403 02
http://www.esab.de
Be sure to indicate any special shipping

instructions when ordering replacement parts.
Refer to the Communications Guide located on

the last page of this manual for a list of customer
service phone numbers.

7.3 Outside View – Front And Back
22
11 3
8 7 17 18
12 10 9 6 5 4
13
21
2
14
15
16 1
19
20

Item No Qty Part Number Description Circuit Symbol
1 1 35749 Base
2 1 35751 Panel Right Side
3 1 35753 Cover Top
4 2 951032 Lamp LED Red 12V PL4, PL5
5 1 2134926 Lamp Indicator Amber PL3
6 2 951526 Lamp Neon White PL1, PL2
7 1 950122 Circuit Breaker 10A CB1
8 1 950715 Potentiometer 15K 2W R50
9 1 2062170 Knob
10 1 634518 Switch Toggle DPDT 2 pos S2
11 1 672508 Switch 10GL 3pst 2 pos S1
12 1 951061 Meter LED 5VDC 200MN #dp-350 VM
13 1 951061 Meter LED 5VDC 200MN #dp-350 AM
14 1 1006733 Conn Box Recp 19P J1
15 1 35752 Panel Left Side
16 1 35722 Panel Front
17 1 954932 Label PC Box Cover –ESP-400C
32338GY,BK,D
18 1 Plate Cover ESP-400C
G
35822GY,BK,D
19 1 Access Door
G
20 5 993426 Grommet Rubber 1.5 ID
21 1 634516 Switch Toggle SPDT 2 pos 10A 250V Q/D S4
35750GY,BK,D
22 1 Rear Panel
G

7.4 Front View With PCBs Exposed
P2
P1
1
View with LED meter panel removed
10 5 3 10
4 2 (T-4)
7 8 9
6
View with PCB Cover Removed

1 1 38139 PCB Meter Digital PCB4
2 1 2062018 Potentiometer 10 K 2W R51
3 1 951502 Knob
4 1 950458 Switch Toggle DPDT 3 pos S3
5 1 38032 PC Board Control PCB1
6 1 635568 Terminal Block 18 pos TB1
7 1 951275 Filter RFI FN4
8 1 995103 Terminal Strip 24 pos TB9
9 1 950116 Filter OMI FN3
10 1 35779 Kit Wire 600C Control 460/575V

7.5 Right Side View
4 6
10
7
3
8
7
2
12 10 11
1

1 1 35717 Transformer Control T2
2 2 674969 PCB Filter FN1,2
3 4 950704 RECT SIL Reverse 85A D29,30,35
4 3 950703 RECT SIL Forward 85A D31,32,34
5 1 973168 Terminal Strip 13 pos TB7
6 7 17300008 Resistor 8 OHM 300W R12-17,24
7 6 17300001 Resistor 1 OHM 300W R1-3,21-23
8 3 17300004 Resistor 4 OHM 300W 18-20
9 1 35750 Panel Rear
10 1 35710 Inductor L2
11 1 0558002525 Potted Resistor Assembly PRA1
12 6 950631 PC Board Support

7.6 Left Side View
8
4
1
3 x4 5
5 7
10
11 6

C60,61,62,
1 3 35895 Kit Wire 600C 400V
R55-57
3 4 951491 Contactor 3 pole 90A K2,K1a,1b,1c
4 2 2046333 Fuse Slo-Blo 15A 600V F1,2
5 2 672772 Capacitor 10 µf 370V C25,26,34-36
6 2 17280210 Resistor 1K ohms 100W R10,11,28-31
7 3 17280010 Resistor 10 ohms 100W R25,26,27
8 1 950703 RECT SIL Forward 85A D34
9 1 950704 RECT SIL Reverse 85A D33
10 35710 Inductor (REF) L1,2
11 1 952002 Core, Saturable Amorphos

7.7 Top View

1 2 38030 PCB IGBT Driver PCB2,3
2 6 17750051 Resistor 10ohm 50W Noninductive R4-9
3 6 951828 Capacitor .033 µf 630V C13-18
4 15 951635 Capacitor 1900 µf 450V C1-12,29,32,33
5 3 951085 Switch Thermal 176 DEG F TS4-6
6 4 35779 Kit Wire ESP Control 460/575V
7 6 0558001020 Module Diode Dual 100A 600V D1-6
8 2 pr 951951 IGBT Matched Pair 600A 600V
9
10 4 950704 RECT SIL Reverse 85A
11 5 672772 Capacitor 10 µf 370V C25,26,34,35,36
12 5 17300008 Resistor 8 ohm 300W R12-15,24
13 2 0558002348 Transducer Current TD1,2
14 1 951282 Shunt 100mV 500A SH1
15 4 951998 Capacitor .27 µf 1200 VDC C19-22
16 4 951996 Module Dual Diode Rectifier 600V 30A D19,22
17 2 2046333 Fuse Slo-Blo 15A 600V F3,4
18
19 2 951802 Capacitor 2900 µf 450V C27,28
20 1 950255 Capacitor 60 µf 370V C30
21 2 2062357 Fuse Slo-Blo 30A 250V F5,7
22 1 951527 Fuse 15A F6
23 1 673458 Contactor 3 pole 40A K4
24 2 952103 Fuse holder 60A
25 4 951199 Core Saturable
26 6 952002 Core Saturable Amorphous
27 2 0558002435 Capacitor 3100 µf 450V C27,28

7.8 Back Inside View
4
2
2 3
1

1 2 2062334 Motor Fan 1/3 hP M1,2
2 6 17300001 Resistor 1 ohm 300W R1-3,21-23
3 3 17300004 Resistor 4 ohm 300W R18-20

7.9 Middle Cross Section
2 3 4 3
1 2
F8 F9

1 2 951997 Transducer Current (ref) TD1,2
2 2 17280210 Resistor 1K ohms 100W R10,11
3 2 23610413 Resistor 2 ohms 25W R53,54
4 1 951816 Fan 230 V 50/60 Hz M3
5 1 677298 Fuse Assembly F8,9

7.10 Front Cross Section –Behind Front Panel
3
1 4 4
5
6
7
7

1 6 17280210 Resistor 1k ohms 100W R10,11,28-31
2 4 2080196 Relay 3 pos brkt MT K3,5,6,7
3 1 0558004783 Terminal Block 18 pos TB8
4 10 13730638 Diode Rectifier Reverse 800V 300A D7-12,25-28
5 6 13730639 Diode Rectifier Forward 800V 300A D13-18
6 1 950711 Switch Thermal 194 DegF TS7
7 2 35710 Inductor L1,2


REVISION HISTORY
1. Revision – Oct., 2004 – Added “1 - 14 AWG 600V lead to pilot arc connection in plumbing box (h.f.
generator)” note to top diagram on page 3-7. Changed note 4 to read - “Connect the pilot arc cable to
the pilot arc terminal in the primary power source. The pilot arc connection in the secondary power
source is not used. The pilot arc circuit is not run in parallel” on page 3-7. Modiﬁed bottom diagram
and changed note to read – “Disconnect negative connection from secondary power source and insu-
late to convert from two to one power source” on page 3-7.
2. Revision - June, 2005 - Section 6, Replaced 6.7 wiring diagram - drawing 1 - part 1 400v 50Hz to show
new white wire connection from H2 to H4 on page 6-37.
Customer // Technical Support
(843) 664-4405
(800) ESAB-123 (372-2123)
ESAB Welding and Cutting Products

PO BOX 100545 Ebenezer Road
Florence, SC 29501-0545
http://www.esab.com
ESAB Cutting Systems – Canada

6010 Tomken Road
Mississauga, Ontario Canada L5T 1X9
Phone: (905) 670-0220
Fax: (905) 670-4879
ESAB-Hancock GmbH
Cutting Technologies
P.O Box 1128
D-61174 Karben
Robert-Bosch-Strasse 20
D-61184 Karben
Phone + 49 60 39 40-0
Fax + 49 60 39 40 301_302
http://www.esab.com
esab_info@compuserve.com
Printed in U.S.A

Esp-600c Plasma Power Supply F-15-656

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Esp-600c Plasma Power Supply F-15-656

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F-15-656

Installation, Operation, and Maintenance for the

Purchaser is solely responsible for the safe

ESAB Cutting Systems first priority is total

This manual is ESAB Part Number F15656

This manual is for the convenience and use of the

© ESAB Cutting Systems, 2000

Section 7 Replacement Parts

Customer/Technical Information Back Manual Cover

ALERT or ATTENTION. Your safety is involved

Used to call attention to immediate hazards

Used to call attention to potential hazards

Used to call attention to hazards that could

Used to call attention to minor hazards to

Used to call attention to important

Machinery often starts automatically.

• Moving machinery can crush.

Failure to follow operating instructions

Read and understand this operator’s manual before

• Read entire procedure before operating or

• Special attention must be given to all hazard

• All safety precautions relevant to electrical

• Read all safety publications made available by

1-2 ESP-600Clasma Power Source

Failure to follow safety warning label

Read and understand all safety warning labels on

Refer to operator’s manual for additional safety

1.4 Installation Precautions

! WARNING Improperly Installed Equipment Can Cause

Follow these guidelines while installing machine:

• Contact your ESAB representative before

• Never attempt any machine modifications or

• Observe machine clearance requirements for

• Always have qualified personnel perform

• Provide a wall mounted disconnect switch with

ESP-600Clasma Power Source 1-3

Electric shock hazard.

Machine must be properly grounded before put into

1.6 Operating A Plasma Cutting Machine

! WARNING Flying debris and loud noise hazards.

• Noise from plasma arc can damage hearing. Wear

! WARNING Burn hazard.

• Do not touch metal plate or parts immediately after

1-4 ESP-600Clasma Power Source

! WARNING Hazardous voltages. Electric shock

• Do NOT breathe fumes.

• Use approved respirator if ventilation is not

• Provide positive mechanical ventilation when

• Do not operate near degreasing and spraying

ESP-600Clasma Power Source 1-5

! WARNING Burn Hazard.

• Do not cut near combustible material.

1-6 ESP-600Clasma Power Source

! WARNING Explosion hazard.

• Do not carry any combustibles on your person

• Do not cut containers that have held combustibles.

ESP-600Clasma Power Source 1-7

! WARNING Hazardous voltages. Electric shock

Establish and adhere to preventive maintenance. A

Avoid leaving test equipment or hand tools on

! CAUTION Extreme caution should be used when probing

All circuit boards securely seated in sockets, all cables

1-8 ESP-600Clasma Power Source

ESP-600Clasma Power Source 1-9