www.esabna.com
DATE: October 4, 2004 BULLETIN NO: P_04_016
TITLE/ PRODUCT NAME: PC-1250 & 1500 Output Diode Protection
RATING:
_
(Action is Required) (Potential Problem)
_
(Action is Optional) (Enhanced Product)
_
(Unrestricted) (Restricted Distribution)
PRODUCT SERIES/ MODEL:
PC-1250 and PC-1500 (60 Hz. only)
SERIAL NO:
Manufactured before serial number PX-J-441XXX (October 1, 2004)
SUMMARY:
In certain instances, normal reverse recovery of the output diodes can result in over voltage
transients beyond the capacity of the device. This event can vary substantially with the individual
characteristics of the component and is not limited to a particular batch. Certain events or
applications can aggravate this condition:
• units powered with high input voltage lines
• applications where the plasma arc frequently pops out (high voltage arcs that collapse)
• high duty cycle applications
OPERATIONAL IMPACT:
Improved reliability of output diodes
ACTION:
To insure output diode reliability, install 2 toroid filters between the main transformer and the output
diode bridge assembly during service repair. These filters absorb the energy of the transient to
better protect the diodes. We will add these toroid filters to all production PC-1250/1500 60 Hz.
units starting October 1, 2004 (before serial number PX-J-441XXX).
_ DIRECTIVE _ _ ALERT
X_ INFORMATION _ X _ PRODUCT IMPROVEMENT
X_ General Distribution _ _ Business Confidential
NOTE
Installation of these filters on older production consoles currently in
operation is not recommended due to the complexity of the installation
and risk of other failure modes occurring due to the disassembly of
the unit.
Installation of the toroid filter is recommended during a warranty repair
of the transformer or output diodes and should be completed by an
experienced service technician.
Output diode failures have occurred on:
PC-1250 208-230/460v Console 0558001935
PC-1250 208-230/460v Mechanized 0558004189
PC-1500 208/230v Console 0558003517
PC-1500 208-230/460v Console 0558003570
PC-1500 208-230/460v Mechanized 0558004195
Reference information:
Toroid part number: 0558005256 (2 required & provided at no charge)
The picture below shows the toroid filters installed in the leads between the main transformer and
the output diode.
Toroid Filter
CONTACT:
ESAB Welding & Cutting Products
Product & Service Information Group
843-664-4416 Phone
843-664-5539 FAX
Installing the Toroid Filters
Remove the power source left side panel and remove the X2 transformer leads going to the output
diode bridge assembly. Install the Toroid filters (2 each) being sure they are securely tie wrapped
to the X2 leads. Re-route the insulated X2 leads behind the left side and over the top of
transformer to the output diode as shown in the figure below.
Output Bridge Connection
Toroid Filter
Left Side of Power Source
Left Side of Power Source
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