LG Electronics 453cc Welding System User Manual
Contents
1. sa 45277 4 L eel oo 0 0 0 Li il 0 WO 0 0 1 FTT UD us LL 453cc 553cc View 2 Panel LEGEND e 21 REPLACEMENT PARTS SECTION 6 2 2 453cc 553cc View 3 Angled Front LEGEND 6 22 SECTION 6 REPLACEMENT PARTS D 5 266 2 OM e 28 453 553 4 LEGEND e 23 REPLACEMENT PARTS SECTION 6 BACK VIEW OF POWER SWITCH CONNECTED TO FRONT PANEL W ROUTING OF PRIMARY WIRES AND HEATSHRINK 4 WIN D 230 460 575V ONLY Gs QE Be 220 400 CE ONLY 453cc 553cc View 5 Internal Rear View LEGEND 24 REPLACEMENT PARTS SECTION 6 5 9 2 REF 40 GFI 18 43 GND gt lt ANNE AMIS y AA 7 PAN q SNA ae SS x Q N TS1 453cc 553cc View 6 Internal Front View LEGEND 25 REPLACEMENT PARTS SECTION 6 LSNW 09 WALI OYL OL WALI 6120668 WALI 982729 SWALI SLIM 3HIM 30 LHVd ATIVNLOV 3HV SONIMVHO 3S3Hl NO NMOHS G3T1IVO NIV LH3O 12NVd 10HLNO9 NO NMOHS LY 38 OL NOILISOd WNNININ OL ASIMMOOTOYSLNNOD2. ee 15 Mig Spray Arc and Flux Cored 15 MAINTENANCE oboe uero qid eios 16 RT 16 Cleaning emm 16 Inspection sand deed 16 Fan MOTOT 16 TTD 16 16 Over Temperature Protection Do sm Ende 16 Digital Voltmeter Ammeter 16 FROUBEESHOOTIN G z tutes 2 rigole ten dat nan UE dd 17 esce 17 Testing and Replacing Bridge Assembly Components 17 POB isiieca ge O 17 Troubleshooting Information Table Re ec 18 PARTS P 19 19 6 xe ueste E MAL I DM M IL S 19 sarety precautions WARNING These Safety Precautions are for A your protection They summarize precaution ary information from the references listed in Additional Safety
3. 15 591 February 2001 INSTRUCTION MANUAL 453 amp 553cc DC WELDING POWER SOURCES i amp M mE 00 oo V 9 don Pm 620 PPP m Um 0 e 5 qu p omm mae th 7 x 3 This manual provides complete instructions for the following power sources 453cc 553cc Item No Item No ESAB 230 460 vac 3 ph 60 Hz 453cc 0558001274 553cc 0558001278 ESAB 230 460 575 vac 3ph 60 Hz 453cc 0558001275 553cc 0558001279 ESAB 220 400 vac 3 ph 50 Hz 453cc 0558001276 553cc 0558001280 ESAB 220 400 vac 3 ph 50 Hz CE 453cc 0558001277 553cc 0558001281 A FIXES These INSTRUCTIONS are for experienced operators If you are not fully familiar with the principles of operation and safe practices for arc welding equipment we urge you to read our booklet Precautions and Safe Practices for Arc Welding Cutting and Gouging Form 52 529 Do NOT permit untrained persons to install operate or maintain this equipment Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions If you do notfully understand these instructions contact your supplier for further information Be sure to read the Safety Precautions before installing or operating this equipment Be sure this information reaches the operator IE
4. 991 WALI 79 268 9 69 WALI 22902 72 SLOd ONIIGWASSV 3H0d38 NOLLISOd NI YOL OVdVO 9L WALI 76229008 HOLOIN TIVLSNI WALI SO60S6 SNOLSV4 TIVLSNI HOLON OL OL SAGVAT 9 WALI SNOLLO3NNOO OL 334405 OL YaddOO OL H3ddOO 1 OL WALI 7991919373 40 STSNNVE 31V 1nSNI OL WALI 20229806 ZZL 20269806 92 WALI 20029806 MNIMHS LVSH SSN SHOLIOVdVO 9541714 AYNOAS OL WALI 22200212 ASN GAYINOAY SV 3HIM 35001 ANIANOO OL 971 WLI 89M08L WALI 99M08L 051 WALI 81611966 Lb WALI 0919 SdVYMAL ASN S LNIOd NOLLO3NNOO 11 OL 43434 75569068 YOLOW NVA LNO SALON gt ZH 09 06 226 66 2266 04 La lt 7 014 9 17 gt lt 8 014 9 1f gt lt 9 014 1 lt 1 014 8 10 gt lt 8 0 6 7 lt 6 014 01 1 01 014 1 10 41 0 21 91 014 1 lt 1 014 61 10 61 019 91 10 91 04 PAOL 6 97 0 000400 9 1 4 NOLO 038 cas QN9 LNINJINOI M ZH 09 3SVHd 6 90 1 494 9 80 Xn 9 84 1 84 8 84 X zm Lu 6 84 gt 01 92 0 6 MI NOSS Y QV
5. Table 52 provides troubleshooting information 2 5 4 115V Circuit Breaker CB2 The 115V resettable circuit breaker CB2 protects the 115 volt auxiliary receptacle and control circuitry against over current Table 5 2 provides troubleshooting infor mation SECTION 2 INSTALLATION Figure 2 3 CONTROL CONNECTIONS SW POWER SWITCH 63A 600V CKT BREAKERS 10A 32VDC 250VAC aw ig 4 Jo ahd bodad Pn 4 4 4 mn 1 2 M IMs T Xe PEN TUE 4 229 Ve Cn ice a gt gt t T Ye 1 7 o _ e H 2 4 OUTPUT RECEPTACLE 2 4 13 SECTION 3 AF Never operate the power source with the cover re moved In addition to the safety hazards Improper cooling may cause damage to the components Keep side panels closed when unit is energized Welding helmet gloves and other personal protec tion should always be worn when welding 3 1 CONTROLS See Figure 3 1 3 1 1 PowerSwitch ON OFF I O The power switch is located on the front panel of the power source In the OFF 0 position the unit is shutdown however power is still present at the switch itself To totally shut down the power source power must be disconnected at the line disconnect switch or the fuse box With the switch in the ON I position power is provided to the main transformer and the low voltage
6. leaving the cooling fan on After the power source has cooled to a safe level the thermal protection will auto matically reset While deenerigized the contactor can not be operated 4 3 5 Digital Voltmeter Ammeter Calibration To verify the accuracy of the digital voltmeter ammeter combination the following procedure can be performed periodically 1 Place the Panel Remote switch in Panel position 2 Disconnectcables from the outputterminals then connect an accurate DC voltmeter to the output terminals 3 Openthe front control panel by removing the two mounting screws from the upper corners Lo cate the J9 jumper plug on the control pc board and remove the plug The J9 jumper plug is located just left of the meter pc board ribbon cable connection plug J10 4 Place the Contactor switch in the On position 5 Withthe primary input power on turn the Current control knob until you get 25V on the DC voltme ter Compare the reading with the reading on the digital voltmeter on the front panel 6 If there is a difference in the voltage readings remove meter board from its four mounting posts and adjustthe trimpot R13 on the meter board with a small screwdriver until the digital meter reading matches the DC voltmeter read ing When satisfied reassemble meter board reconnecting J9 jumper plug and reassemble front control panel SECTION 5 5 1 GENERAL Amuma DISCONNECT primary power at wall switch or cir
7. s crispins une tunique paisse manches longues des pantalons sans rebord des chaussures embout d acier et un casque de soudage ou une calotte de protection afin d viter d exposer la peau au rayonnement de l arc lectrique ou du m tal incandescent est galement souhaitable d utiliser un tablier ininflammable de facon se prot ger des tincelles et du rayonnement thermique c Les tincelles ou les projections de m tal incandes cent risquent de se loger dans des manches retrouss es des bords relev s de pantalons ou dans des poches Aussi convient il de garder boutonn s le col et les manches et de porter des v tements sans poches l avant d Prot gez des tincelles et du rayonnement de l arc lectrique les autres personnes travaillant proximit l aide d un cran ininflammable ad quat e Ne jamais omettre de porter des lunettes de s curit lorsque vous vous trouvez dans un secteur l on effectue des op rations de soudage ou de coupage l arc Utilisez des lunettes de s curit crans ou verres lat raux pour piquer ou me ler le laitier Les piquetures incandescentes de laitier peuvent tre projet es des distances consid rables Les personnes se trouvant proximit doivent galement porter des lunettes de protection f Le gougeage l arc et le soudage l arc au plasma produisent un niveau de bruit extr mement lev de 100 114 dB et exigent par cons quent l
8. Do not weld cut or gouge on materials such as galvanized steel stainless steel copper zinc lead beryllium or cadmium unless posi tive mechanical ventilation is provided Do not breathe fumes from these materials 2 Do not operate near degreasing and spraying opera tions The heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene a highly toxic gas and other irritant gases If you develop momentary eye nose or throat irritation while operating this is an indication that ventilation is not adequate Stop work and take necessary steps to im prove ventilation in the work area Do not continue to operate if physical discomfort persists 4 Refer to ANSI ASC Standard 249 1 see listing below for specific ventilation recommendations 5 WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code 25249 5 et seq CYLINDER HANDLING Cylinders if mishandled can rupture and violently release gas Sudden rupture of cylin der valve or relief device can injure or kill Therefore 1 Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder Do not use adaptors Maintain hoses and fittings in good condition Follow manufacturer s operating instructions
9. ESAB ESAB Welding amp copies tnrou our suppliier id E Cutting Products USER RESPONSIBILITY This equipment will perform in conformity with the description thereof contained in this manual and accompa nying labels and or inserts when installed operated maintained and repaired in accordance with the instruc tions provided This equipment must be checked periodically Malfunctioning or poorly maintained equipment should not be used Parts that are broken missing worn distorted or contaminated should be replaced immediately Should such repair or replacement become necessary the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was pur chased This equipment or any of its parts should not be altered without the prior written approval of the manufacturer The user of this equipment shall have the sole responsibility for any malfunction which results from improper use faulty maintenance damage improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer PREFACE The purpose of this manual is to provide the operator with information required to install and operate the power source Some technical reference material is also provided to assist in basic troubleshooting the power source If itis determined that the power source is not operating properly the opera
10. Figure 3 1 Control Locations 453cc illustrated 14 SECTION 3 3 1 6 Over Temperature Indicator Temp This amber light will indicate when an internal overheat ing condition has occurred and one of the thermal switches has opened User control of the solid state contactor will be interrupted and power source output will shut down to protect critical components Once cooled to a safe temperature the thermal switch will automatically reset and output control will be restored 3 1 7 Voltmeter and Ammeter A digital voltmeter and ammeter provides an accurate indication of dc output voltage and current 3 1 8 Fault Indicator Ifan optional External Ground Conductor Protection Kit was installed this red light when lit will indicate that current was flowing through the external ground con ductor The power source output termirals are deenergized and the fault must be corrected before resuming operation 3 2 OPERATION SET UP Prior to performing the steps below open the wall disconnect switch or remove the fuse from the fuse box to electrically isolate the power source Amuma ELECTRIC SHOCK CAN KILL Machinery Lockout Procedures should be employed If it is not pos sible to use padlocks attach a red tag to the line disconnect switch or fuse box warning others that the circuit is being worked on 3 2 1 Stick Welding SMAW Air Carbon Arc Goug ing ACAG and Scratch Start Tig Welding GTAW A If stick welding or
11. Information section Before performing any installation or operating procedures be sure to read and follow the safety precautions listed below as well as all other manuals material safety data sheets labels etc Failure to observe Safety Precautions can result injury or death PROTECT YOURSELF AND OTHERS Some welding cutting and gouging processes are noisy and require ear protection The arc like the sun emits SZ ultraviolet UV and other radiation and can injure skin and eyes Hot metal can cause burns Training in the proper use of the processes and equip ment is essential to prevent accidents Therefore 1 Always wear safety glasses with side shields in any work area even if welding helmets face shields and goggles are also required 2 Use a face shield fitted with the correct filter and cover plates to protect your eyes face neck and ears from sparks and rays of the arc when operating or observing operations Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric arc or hot metal Wear flameproof gauntlet type gloves heavy long sleeve shirt cuffless trousers high topped shoes and a weld ing helmet or cap for hair protection to protect against arc rays and hot sparks or hot metal A flameproof apron may also be desirable as protection against radiated heat and sparks 4 Hot sparks or metal can lodge in rolled up sleeves trouser cuffs or pockets Slee
12. P6 1 SCR6 Varies with setting of VCP R1 3 V dc with contactor on SECTION 5 TROUBLESHOOTING CONDITION ACTION Unit Inoperative A No input power Check main line user s switch fuses replace if needed B Poor or improper input terminal board connections C Defective on off switch on front panel replace D Main transformer overheating Also check for proper cooling proper primary hookup or shorted turn on secondary E Fan motor not operating check motor and leads F Gound fault indicator ON Check for cause and correct Turn power switch OFF then ON to reset 5 Loss of primary phase Check that LED on control PCB is lit If not find amp replace defective fuse No Output Fan A Poor or improper electrical input check input connections TB Running Poor connections at output terminals work station check tighten or replace C Main transformer overheating thermal switches tripped due to restricted cooling air Temperature light on front panel will be lit Let unit cool down D Solid state breaker tripped due to current overload E PC board defective or loose PC board connector s if loose reinsert if defective replace Limited Output or Low A Input voltage jumper links on terminal board improperly set check for proper voltage Open Circuit Voltage Poor output connections Take apart clean and reassemble B Unitmaybe single phasing check incoming power for three phases C
13. Panel Remote switch in Remote position and remote voltage pot disabled Erratic Weld Current A Welding cable size too small use correct cables B Loose welding cable connection will usually get hot tighten all connections C Improper wire feeder setup D Defective SCR in bridge rectifier E PC board defective replace High Output No A PC board defective or loose reset and or replace board Voltage Control No 115 Voltac Output A Circuit breaker tripped Check 42V CB1 and 115V CB2 Reset Line Fuse Blows When A Shorted SCR in Main Bridge replace Power Source is First Turned On SECTION 6 6 1 GENERAL Always provide the series or serial number of the unit on which the parts will be used The serial number is stamped on the unit nameplate 6 2 ORDERING assure 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 Replacement parts may be ordered from your ESAB distributor For a list of Authorized Distributors in your area contact ESAB at 1 800 ESAB 123 For your convenience an ESAB Communication Guide listing important contact phone numbers has been printed on the rear cover of this book SECTION 6 REPLACEMENT PARTS OO 3 3 P3 4 7 29 2 CB1 2 453cc 553cc View 1 Front LEGEND P 20 SECTION 6 REPLACEMENT PARTS
14. SONS S sense visas eee dessu teen cie 9 9 INSTALLATION mU CE P 10 BOCATION see M 10 Receiving Unpacking and 10 Primary Input Electrical Connection iii 10 Secondary Output Welding Connections 480 12 EI de 12 OPERATION rece ra ro net RE er ND 14 COMOL satu eee cas 14 POWER Switch ON OFF T 14 Force babet reso _ 14 Contactor Or emole 9WIECDI 14 Current Panel Remote Switch iii 14 CO NO MEE mE 14 Over Temp rature reeled hs cae 15 Vomer and in 15 8 15 oe RUD PP 15 Suck Welding Arc Gouging VVeldihg
15. current from the minimum to the maximum setting of the current control Figure 1 1 Volt Ampere Curves ii L me MIN OUTPUT 453CC MAX OUTPUT ALL 100 200 250 300 350 400 450 500 550 600 650 5 40 VOLTS 20 1 4 OPTIONAL ACCESSORIES Stick Electrode Holder Assembly 21226 Includes holder 15 ft cable and twist lock connector Work Cable Assembly 10 ft 32995 Includes ground clamp and twist lock connector Remote Control Receptacle 0558001436 This Remote Control Kit consists of a 14 pin and 19 pin amphenol receptacle and assembly that permits the use of the HC 3B Remote Control FC 5B Remote Foot Control or TC 2B Torch Control as described below for tig welding The Remote Control Kit also provides a 115 vac 10Amp Receptacle for auxiliary power tools HC 3B Remote Hand Control 33838 FC 5B Remote Foot Control 33646 TC 2B Remote Torch Control 33839 DESCRIPTION These controls provide remote output current control and contactor operation Each control is equipped with 30 ft 9 1 m cable plug assembly that mates with the optional Remote Control Kit described above The current adjustment is limited to the range as set by the current control on the power source The contactor and current panel remote switches on the power source must be in remote position when operating with any of the remote controls TR 29 Truck Kit 37924 T
16. emploi de dispositifs appropri s de protection auditive 2 PREVENTION DES INCENDES Les projections de laitier incandescent ou detincelles peuvent provoquer de graves incendies au contact de mat riaux combustibles solides liquides ou gazeux Aussi faut il observer les pr cautions suivantes a loigner suffisamment tous les mat riaux combus tibles du secteur ou l on execute des soudures ou des coupes l arc moins de les recouvrir compl tement d une b che non inflammable Ce type de mat riaux comprend notamment le bois les v tements la sciure l essence le kerosene les peintures les solvants le gaz naturel l ac tyl ne le propane et autres sub stances combustibles semblables Les tincelles ou les projections de m tal incandes cent peuvent tomber dans des fissures du plancher ou dans des ouvertures des murs et y d clencher une ignition lente cach e Veiller prot ger ces ouvertures des tincelles et des projections de m tal N ex cutez pas de soudures de coupes d op rations de gougeage ou autres travaux chaud la surface de barils bidons r servoirs ou autres contenants usag s avant de les avoir nettoy s de toute trace de substance susceptible de produire des vapeurs inflammables ou toxiques En vue d assurer la pr vention des incendies il convient de disposer d un mat riel d extinction pr t servir imm diatement tel qu un tuyau d arrosage un seau eau un seau de sable ou
17. off the power before removing your gloves 10 Refer to ANSI ASC Standard Z49 1 listed on next page for specific grounding recommendations Do not mis take the work lead for a ground cable ELECTRIC AND MAGNETIC FIELDS be dangerous Electric current flow ing through any conductor causes lo calized Electric and Magnetic Fields S EMF Welding and cutting current cre ates EMF around welding cables and welding machines Therefore 1 Welders having pacemakers should consult their physi cian before welding EMF may interfere with some pace makers Exposure to EMF may have other health effects which are unknown Welders should use the following procedures to minimize exposure to EMF A Route the electrode and work cables together Secure them with tape when possible B Never coil the torch or work cable around your body C Do not place your body between the torch and work cables Route cables on the same side of your body D Connect the work cable to the workpiece as close as possible to the area being welded E Keep welding power source and cables as far away from your body as possible 10 98 EIUS FUMES AND GASES Fumes and gases can cause discomfort or harm particularly confined spaces Do not breathe fumes and gases Shield ing gases can cause asphyxiation Therefore 1 Always provide adequate ventilation in the work area by natural or mechanical means
18. operator with the design installation and operation of the 482cc and 582cc model power sources DO NOT attempt to install or operate this equipment until you have read and fully understood these instructions The information presented here should be given careful consideration to ensure optimum performance of this equipment 1 2 RECEIVING HANDLING Upon receipt remove all packing material and carefully inspect for any damage that may have occurred during shipment Any claims for loss or damage that may have occurred in transit must be filed by the purchaser with the carrier A copy of the bill of lading and freight bill will be furnished by the carrier on request Table 1 1 Specifications for 453cc and 553cc DUTY CYCLE Current 12 Voltage U2 Pow er Factor at Rated Output Welding Range Auxiliary Pow er PHY SICAL SPECIFICA TIONS Height w ithout lifting eyebolt Width Depth Net Weight REEL RATED 3 INPUT Phase 50 Hz 220 400 73 40 42 39 A 61 33 35 30 A 90 49 52 47 A 77 43 45 41 A 380 415 Vac 25 0 62 2 cm 18 8 48 3 cm 32 5 81 9 cm 339lbs 154kg 379lbs 172kg 363 Ibs 165 kg 400 Ibs 181 kg shipping Weight 349 Ibs 158 389 lbs 177 kg 373 Ibs 170 kg 410 Ibs 186 kg DESCRIPTION When requesting information concerning this equip ment it is essential that Item number Serial number and Model number of the equipment be
19. un extincteur portatif Une fois le travail l arc termin inspectez le secteur de facon vous assurer qu aucune tincelle ou projec tion de m tal incandescent ne risque de provoquer ult rieurement un feu CHOC LECTRIQUE Le gougeage l arc et l arc au plasma exige l emploi de tensions vide relativement importantes or celles ci risquent de causer des dommages corporels graves et m me mortels en cas d utilisation inad quate La gravit du choc lectrique recu d pend du chemin suivi par le courant travers le corps humain et de son intensit Ne laissez jamais de surfaces m talliques sous ten sion venir au contact direct de la peau ou de v tements humides Veillez porter des gants bien Secs Si vous devez effectuer un travail sur une surface m tallique ou dans un secteur humide veillez assu rer votre isolation corporelle en portant des gants secs et des chaussures semelles de caoutchouc et en vous tenant sur une planche ou une plate forme seche Mettez toujours a la terre le poste de soudage coupage en le reliant par un cable a une bonne prise de terre N utilisez jamais de cables us s ou endommag s Ne surchargez jamais le c ble Utilisez toujours un quipement correctement entretenu Mettez l quipement hors tension lorsqu il n est pas en service une mise la masse accidentelle peut en effet provoquer une surchauffe de l quipement et un dan ger d incen
20. 4857 954858 954859 954860 954912 2091514 2091558 13730632 13730763 13731781 13732431 13732733 13734588 13735311 13735312 13735508 17300020 22993477 61212092 65509506 71200732 73585980 79900317 90863007 90863202 90863203 99510047 99511578 REPLACEMENT PARTS Bill of Materials 453cc 553 DC Welding Power Source ITEM PART OR NO CODE NO DESCRIPTION SYMBOL 310 TYWRAP MEDIUM TAB GND1 LUG TERMINAL 2 8 WIRE 1 4 STUD BOLT EYE 75 10 X 2 00 GROMMET RUB 1 12 ID X 1 50 GD X 06 W TERM IL M 250 TS X 14 16 AWG J5 PLUG HOUSING 15 POS CONNECTOR 20 AWG 3 PIN 1 MTA 156 COVER 3 PIN CONNECTOR 20 AWC 7 PIN 5 156 CONNECTOR 20 AWG 12 PIN P3 4 7 TERM BLOCK 12 POS TB2 CONNECTOR 20 AWG 10 PIN P8 PLASTIC MARKER 1 12 PALLET 42 00 TAG WARRANTY ESAB LABEL ISO 9002 OVERLAY 453CC OVERLAY 553CC LABEL RATING 453CC 230 460 LABEL RATING 553CC 230 460 LABEL RATING 453CC 230 460 575 LABEL RATING 553CC 230 460 575 LABEL RATING 453CC 220 400 LABEL RATING 553CC 220 400 LABEL SCHEM 230 460V amp 220 400 amp 575 LABEL WARNING WELD AND CUT LABEL GND BLK 50 X 1 38 POT LIN 10K 2W 88L R1 NAME PLATE CODE SERIAL STOCK MTA 156 COVER 10 PIN MTA 156 COVER 12 PIN LABEL FOR INSTALL USE COPPER WIRE ONLY LOGO ESAB CLEAR CONNECTOR 20 AWG 6 PIN P6 MTA 156 COVER 6 PIN SHROUD FAN RES RW FIXD ST 300W 10 20 00 R5 RUBBER 188 X 500 BO
21. ASLZ HOD QVASLE 0 A MO WHO ou 6 84 RS WHO WI 2 RS 4 NYO B AINO SUNN 30 303 chauve 810 310 83 Mq 6 97 m 10 82 H X01 p 10 15 8 97 qms 1 60 OSL 01 001 Fl ASIL 1 67 NE TK Wy 01 4 89 O w QN9 ZH 09 3SVHd 097 0 Z V 89S1008SS0 d 26 REPLACEMENT PARTS SECTION 6 959 66 09 0 007 000 097 0 7 69S1008SS0 d ZH 09 06 22 66 2266 034 2 151 01 85 2 8 qu HHS OF 0 94 1894 6 ma or 6 9 6 8 alo 8 8 97 9 L ES 8 Mig 2 85 Z L OIA 1 281 1 1 L a ARE mum oa me Pam A8 8 74 18 OIA 2 25 M S 07 7 t ae 21 57 IHM p sse 9 IHM 2 5 449 7 7 Z 2 65 052 9 12 Z aad zS me or 17 2824 91 1 18 1 2 0349 4951 NYO 1 19 1 0389 1 139 41899 Old gd Ld 9d Gd d td ld 1939 REPLACEMENT PARTS SECTION 6 ____ LJ ma 9d ldody sae N ANS CSL XNISIV3H o 1 11 30 N
22. LT LAG 1 4 20 X 1 50 LG RIV BLD AL 1 8 GRIP 251 312 ADH SI RBR CLEAR CNPD ELEC JOINT ALCOA 2 EJC INSULATOR SEALING 3 75 X 125 TUBING HEAT SHRINK 250 ID BLK TUBING HEAT SHRINK 3 4 ID CLEAR TUBING HEAT SHRINK 5 8 ID CLEAR VINYL SLEEVING 7 8 SNAP IN TIE BASE 218 30 SECTION 6 REPLACEMENT PARTS Bill of Materials 453cc 553cc DC Welding Power Source PART OR DESCRIPTION SYMBOL 99512240 LABEL CAUTION LIFT EYE 99512558 BRACKET RESISTOR 18 0558001010 TERMINAL BLOCK 3 POS 055800101 1 BOX PCB GRAY 0558001012 PLUG HOUSING 2 POS 0558001014 SEAL WIRE 2 POS 0558001015 SEAL INTER 0558001016 CAP 9 POS 0558001018 INSULATOR STAND OFF 0558001019 KNOB 1 57 DIA 0558001032GY PANEL FRONT TOP 0558001038 INSULATOR 180W66 TYWRAP LARGE 180W68 TYWRAP SMALL 36043GY BRACKET FAN 36048GY LEG AFRAME 36049GY BAIL LIFTING 36070GY BRACKET TERMINAL BOARD MTG 36642GY BAFFLE 36140GY BAFFLE 3 902GY BLANKING PLATE 0558001818 KNOB 01 37 3 866YL PANEL TOP 90861100 TUBING INSULATING VINYL 105 C RATING 9 LG 90863005 TUBING HEAT SHRINKABLE 6 LG 838100 CE FILTER ASSY 952223 STAND OFF 1 4 20 X 75 0558001331G HINGE ACCESS 0558001332G PANEL ACCESS GRAY A 954864 LABEL THREE PHASE A 892W64 POT LIN 100K 2W 10981006 SOLDER 60 40 ROSIN 2 A ESAB Welding amp Cutting Products Florence SC Welding Equipment COMMUNICATION GUIDE CUSTOMER SERVICES A CUSTOMER SERVICE QUESTIONS Order Entry Product Availability Pricing De
23. Not more than three conductors in a raceway or cable Local codes should be followed if they specify sizes other than those listed above Double Link Provided Connections for 50 Hz Figure 2 2 Input Terminal Board 230 460 220 400 V illustrated with voltage links in the factory supplied 460 volt configuration 11 SECTION 2 D Check all connections for proper tightness En sure all connections are correct and well insu lated E Figure 2 2 illustrates the input voltage terminal board and the input voltage link connections The particular voltages from which this power source may be operated are stated on the rating plate The voltage links were factory set for highest voltage stated on the rating plate If the power source is to be operated on another stated input voltage the links must be reset for that particular input voltage Always verify the input voltage and check the link arrangement regardless of factory setting The voltage links are set up by re configuring the copper link bars to the silk screened voltage designations for the desired voltage 2 4 OUTPUT WELDING CONNECTIONS SECONDARY Amuma Before making any connections to the power source output terminals make sure that all primary input power to the machine is off The output terminals are located on the front panel Figure 2 3 Two output terminals are provided One NEGATIVE terminal is located at the bottom right hand corner and the PO
24. O SI ISL C INS SHL SIAM 0340100 TW NEN 8 D KO 94 1804 LT A 9d 189d GY 9 4 189d A 8 lt lt 4 1824 ks IX8 11 t d 189d M8 Sd 189d Z Sd 182d 133 1 94 _ T qas 299 1929 6 14 1804 THM INNHS 4 4 LXO INDHS 4 HS 30 39 01 14 1804 INNHS 01 7 b kg 7 1d 180d IHM 11 281 Da R He 1 lt 8 5 1 282 12 B i 199 80 E Ems H ON HOH BIO R P IRA INNS 8 8 67 INHS TE HA C 910 34 lt 5 03 9 _ Tak 1d 180d 1 L O 7 18 10 Yid RON 6 97 4 9 ANNONS Jl LJ V 02S1008SS0 d 28 SECTION 6 453 553 DC Welding Power Source REPLACEMENT PARTS Bill of Materials ITEM PART OR NO CODE NO QTY DESCRIPTION SYMBOL 36 0558001568 37 0558001569 38 0558001570 39 0558001329 0558001879 40 0558001330 SCHEMATIC DIAG 453CC 553CC 50 60HZ WIRING DIAG PRI 3 PH AFRAME 453CC 553CC WIRING DIAG SECONDARY 453CC 553CC 50 60HZ KIT WIRE PRI 453CC KIT WIRE PRIMARY 553CC KIT WIRE SEC 453CC 553CC 1 954838 1 LABEL SUBARC STICK 2 954839 1 LABEL MIG 3 836121 1 PCB DIGITAL METER PCB2 4 836173 1 BLADE FAN 14 5 838127 1 CONTROL PCB1 838128 1 CONTROL PCB 6 8634515 2 SW TGGL SPDT 2 POS 15A 125
25. SITIVE terminal is located atthe bottom left corner The output cable connections will depend on the materials and welding process desired Table 2 2 provides the recommended cable output sizes Table 2 2 Output Cable Sizes Secondary Welding Total Length Feet of Cable In Weld Circuit Current 50 100 150 200 250 100 0 Total cable length includes work and electrode cables Cable size is based on direct current insulated copper conductors 100 percent duty cycle and a voltage drop of 4 or less volts The welding cable insulator must have a voltage rating that is high enough to withstand the open circuit voltage of the machine INSTALLATION 2 5 CONTROL CONNECTIONS Refer to Figure 2 3 2 5 1 Remote Control Optional This function is provided by an optional 14 pin recep tacle J2 located on the front panel directly below connector J1 It mates with a plug from any optional remote control device see 1 4 2 This receptacle is operative only if the panel remote switches on the power source front panel are in the Remote position 2 5 2 Auxiliary 115 V AC Receptacle Option A 115 Vac receptacle is provided to supply power to accessories such as a water cooler heated 02 regu lator or small hand tools The receptacle is rated 115 Vac 10 amps 2 5 3 A2V Circuit Breaker CB1 The 42V resettable circuit breaker CB1 protects the 42 volt control circuitry against over current
26. V 52 3 7 8672065 6 STRAP TERMINAL 8 8678025 2 TERM AY 9 8950122 2 CKT BREAKER 10A 32VDC 250VAC CB1 2 10 8950219 1 RELIEF STRAIN 2 00 11 8950711 2 SW THERMAL 194F 151 3 12 8950768 1 DIODE FWD 300V 300A D1 13 836107 1 SW PWR DISC 63A 600V S1 8950945 1 SW PWR DISC 100A 600V S1 14 8951474 2 SW SEAL BLACK 15 8954008 1 LABEL DANGER HIGH VOLTAGE 16 82062334 1 MOTOR FAN 1 3 HP 1625RPM M1 17 80558001024 3 SCR ASSY SCR1 6 18 34149 1 CLIP ANNEALED 19 34916 3 BUSBAR TAB 20 36091 1 BOARD INPUT TERMINAL 230 460V 1 136110 1 BOARD INPUT TERMINAL 230 460 575 TB1 32236 1 BOARD INPUT TERMINAL 220 400V TB1 21 36092 1 CABLE DIGITAL METER PCB P10 22 36635 4 CLIP SKID 23 3 861GY 1 BASE 24 3 862GY 1 PANEL FRONT BOTTOM 25 3 863YL 1 PANEL RIGHT SIDE 26 3 864YL 1 PANEL LEFT SIDE 27 37865 1 CONTROL PANEL 28 37867 1 PANEL REAR 29 37868 1 BRIDGE BUSBAR 30 3 869 1 HIGH TAP INDUCTOR BUSBAR 31 37870 1 LOW TAP INDUCTOR BUSBAR 32 0558001037 1 SHUNT SH 33 37872 2 INSULATOR KYDEX 34 836430 1 XFMR MAIN 230 460 453CC T1 836626 1 XFMR MAIN 230 460 575V 453CC T1 836622 1 XFMR MAIN 220 400 453CC T1 836610 1 XFMR MAIN 230 460 553CC T1 836684 1 XFMR MAIN 230 460 575V 553CC1T1 836687 1 XFMR MAIN 220 400 553CC1T1 35 836426 1 INDUCTOR L1 1 1 1 1 1 1 29 SECTION 6 a 43 44 45 46 631507 634220 647361 672786 950167 950905 951504 952067 952068 952070 952071 952072 952073 952081 952155 952243 954046 954506 954911 954910 954855 954856 95
27. arc gouging connect work cable to the workpiece and to the negative terminal of the power source Connect torch cable to the positive terminal of the power source lf Tig welding connect work cable to the workpiece and to the positive terminal of the power source Connect Tig torch cable to the negative terminal of the power source OPERATION B Place the Power ON OFF switch to the ON position or close the main wall disconnect switch C Adjust the current control on the power source to the approximate desired welding current D Ifstick welding set the Arc Force control at 3 or 4 on the dial and readjust as necessary to obtain a softer or harder welding arc For air gouging or Tig welding set Arc Force control at zero 0 E lf using a remote current control such as HC 3B place current and contactor switches in REMOTE positions Note thatthe current range will be limited to the maximum setting on the power source s current control dial If notusing remote current control place current switch to PANEL and contactor switch to ON F Place the Power ON OFF switch to the ON position G Topresetthe approximate welding current pro ceed as follows 1 Connect the electrode holder to the workpiece to create short 2 Place the contactor switch to the ON posi tion 3 Set the Arc Force control to the minimum position 4 Place the Power On Off switch to the ON position 5 By observing t
28. away from heat sources such as furnaces wet conditions such as water puddles oil or grease corrosive atmospheres and inclement weather 5 Keep all safety devices and cabinet covers in position and in good repair 6 Use equipment only for its intended purpose Do not modify it in any manner ADDITIONAL SAFETY INFORMATION For more information on safe practices for elec A tric arc welding and cutting equipment ask your supplier for a copy of Precautions and Safe Practices for Arc Welding Cutting and Gouging Form 52 529 The following publications which are available from the American Welding Society 550 N W LeJuene Road Mi ami FL 33126 are recommended to you 1 ANSI ASC 249 1 Safety in Welding and Cutting 2 AWS C5 1 Recommended Practices for Plasma Arc Welding AWS C52 Recommended Practices for Plasma Arc Cutting 4 AWS 5 3 Recommended Practices for Air Carbon Arc Gouging and Cutting 5 AWS C5 5 Recommended Practices for Gas Tung sten Arc Welding 6 AWS C5 6 Recommended Practices for Gas Metal Arc Welding 7 AWS SP Safe Practices Reprint Welding Hand book 8 ANSI AWS F4 1 Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances MEANING OF SYMBOLS As used through out this manual Means Attention Be Alert Your safety is involved Means immediate hazards which if not avoided will result in immed
29. control circuitry 3 1 1 1 Power Indicator This white light will indicate that the power switch is in the ON position and power has been applied to the main transformer and low voltage circuitry CURRENT OPERATION 3 1 2 Arc Force Control This control is used for stick welding only The lower settings provide less short circuit current and a softer more stable arc The higher settings provide more short circuit current and a forceful more penetrating arc For most Stick welding set the knob at 3 or 4 and readjust up forceful or down softer as desired 3 1 3 Contactor On Remote Switch The Contactor Control switch is located on the front panel of the power source In the ON position the solid state contactor is energized and output power is avail able at the output terminals The REMOTE position allows the solid state contactor to be controlled from a remote control 3 1 4 Current Panel Remote Switch With this switch in the PANEL position output current is controlled by adjusting the potentiometer on the front panel to the desired output In the REMOTE position outputis controlled using an optional remote control via receptacle J2 3 1 5 Current Control This control allows the operator to adjust the output current Placing the Panel Remote switch in the RE MOTE position disables the current control on the front panel 3 1 5 3 1 2 ARC FORCE 70 Z 7 3 1 3 3 1 1
30. cuit breaker before attempting inspection or work inside the power source If the power source is operating improperly the follow ing troubleshooting information may be used to locate the source of the trouble Check the problem against the symptoms in the follow ing troubleshooting guide Table 5 2 The remedy for the problem may be quite simple If the cause cannotbe quickly located open up the unit and perform a simple visual inspection of all the components and wiring Check for proper terminal connections loose or burned wiring or components blown fuses bulged or leaking capacitors or any other sign of damage or discolora tion 5 2 TESTING AND REPLACING BRIDGE ASSEM BLY COMPONENTS The SCRs used in the power source are devices which allow currentto flow in only one direction The SCRs are designed to provide long trouble free operation how ever should a failure occur they may require replace ment A Testing SCRs 1 Remove top and right side panel from the power source 2 Locate the main rectifier assembly containing the SCRs 3 Electrically isolate main bridge assembly by disconnecting resistor 5 4 With the ohmmeter on RX1 scale place the positive lead on the anode end of SCR with screw threads and the negative lead on the cathode positive output terminal on the front panel The meter should read minimum of 5 megohms 5 Reverse leads and check each SCR All read ings should again sho
31. die Ne pas enrouler ou passer le cable autour d une partie quelconque du corps V rifiez si le c ble de masse est bien reli la pi ce en un point aussi proche que possible de la zone de travail Le branchement des c bles de masse l ossature du b timent ou en un point loign de la zone de travail augmente en effet le risque de pas sage d un courant de sortie par des chaines de 9 97 PRECAUTIONS DE SECURITE levage des cables de grue ou divers chemins lectriques Emp chez l apparition de toute humidit notamment sur vos v tements la surface de l emplacement de travail des c bles du porte lectrode et du poste de soudage coupage R parez imm diatement toute fuite d eau VENTILATION La respiration prolong e des fum es r sultant des op rations de soudage coupage l int rieur d un local clos peut provoquer des mal aises et des dommages corporels Aussi convient il d observer les pr cautions suivantes Assurez en permanence une a ration ad quate de l emplacement de travail en maintenant une ventila tion naturele ou l aide de moyens m caniques N effectuez jamais de travaux de soudage ou de coupage sur des mat riaux de zinc de plomb de beryllium ou de cadmium en l absence de moyens m caniques de ventilation capables d emp cher l inhalation des fum es d gag es par ces mat riaux N effectuez jamais de travaux de soudage ou de coupage proximit de vapeurs d hydrocarbur
32. e chlor r sultant d op rations voisines de d graissage ou de pulv risation La chaleur d gag e ou le rayonnement de l arc peut d clencher la formation de phosgene gaz particuli rement toxique et d autres gaz irritants partir des vapeurs de solvant Une irritation momentan e des yeux du nez ou de la gorge constat e au cours de l utilisation de l quipement d note un d faut de ventilation Arr tez vous de travailler afin de prendre les mesures n ces saires l am lioration de la ventilation Ne poursuivez pas l op ration entreprise si le malaise persiste Certaines commandes comportent des canalisations circule de l hydrog ne L armoire de commande est munie d un ventilateur destin emp cher la forma tion de poches d hydrog ne lesquelles pr sentent un danger d explosion ce ventilateur ne fonctionne que si l interrupteur correspondant du panneau avant se trouve plac en position ON Marche Veillez manoeuvrer cette commande v rifiant si le couvercle est bien en place de fa on assurer l efficacit de la ventilation ainsi r alis e Ne jamais d brancher le ventilateur Les fum es produites par l op ration de soudage ou de coupage peuvent s av rer toxiques Aussi est il n cessaire de disposer en permanence d un dispositif ad quat de ventilation de type aspirant afin d limi ner du voisinage de l op rateur tout d gagement de fum e visible Consultez les recommandati
33. for mounting regu lator to a compressed gas cylinder 2 Always secure cylinders in an upright position by chain orstrapto suitable hand trucks undercarriages benches walls post or racks Never secure cylinders to work tables or fixtures where they may become part of an electrical circuit 3 When not in use keep cylinder valves closed Have valve protection cap in place if regulator is not con nected Secure and move cylinders by using suitable hand trucks Avoid rough handling of cylinders 4 Locate cylinders away from heat sparks and flames Never strike an arc on a cylinder 5 For additional information refer to CGA Standard P 1 Precautions for Safe Handling of Compressed Gases in Cylinders which is available from Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 EQUIPMENT MAINTENANCE Faulty or improperly maintained equipment can cause injury or death Therefore 1 Always have qualified personnel perform the installa tion troubleshooting and maintenance work Do not perform any electrical work unless you are qualified to perform such work 2 Before performing any maintenance work inside a power source disconnect the power source from the incoming electrical power 3 Maintain cables grounding wire connections power cord and power supply in safe working order Do not operate any equipment in faulty condition 4 Do not abuse any equipment or accessories Keep equipment
34. he digital ammeter adjust Current Control to the desired current set ting 6 Place Power On Off switch back to OFF T Then remove the holder from the work place H After setting the desired current and if using remote turn switch back to REMOTE You are now ready to begin welding 3 2 2 Mig Spray Am GMAW and Flux Cored FCAW Welding with Off the Are Wire Feeder Refer to wire feeder instruction manual for set up and operating procedures SECTION 4 4 1 GENERAL ANE If this power source does not operate properly stop workimmediately and investigate the cause of the malfunction Maintenance work must be per formed by an experienced person and electrical work by a trained electrician Do not permit un trained persons to inspect clean or repair this power source Use only recommended replace ment parts Amema ELECTRIC SHOCK CAN KILL Machinery Lockout Procedures should be employed If it is not pos sible to use padlocks attach a red tag to the line disconnect switch or fuse box warning others that the circuit is being worked on Placing the power switch in the off position does not remove all power from inside the power source 4 2 CLEANING Periodically remove the cover from the power source and blow accumulated dust and dirt from the air pas sages and interior components by using clean low pressure air The frequency cleaning is required de pends upon the environmentin which the power so
35. his truck kit provides complete mobility of the power source The kit consists of front castors rear cylinder rack and wheels gas cylinder bracket cylinder chain and pull handle Automatic Fan Kit 36707 With this kit installed the fan will start to operate when the welding arc is initiated and will continue to run for 5 minutes after the arc has been extinguished NOTE This optional kit can only be installed in units manufactured after Serial No MX 1709000 in which the large R5 resistor was moved from top center of the A frame to the base in front of the fan bracket 1 5 SAFETY Before the equipment is put into operation the safety section at the front of this manual should be read completely This will help avoid possible injury due to misuse or improper installation The definitions relating to the ACNE ATTEN AS safety notations are described at the end of the Safety Section in the front of this manual read them and their specific text references carefully SECTION 2 2 1 LOCATION A proper installation site is necessary for the power source to provide dependable service A proper instal lation site permits freedom of air movementthrough the unit while minimizing exposure to dust dirt moisture and corrosive vapors A minimum of 18 inches 46 cm is required between the side and rear panels of the power source and the nearest obstruction Also the underside ofthe power source must be kept completely f
36. iate serious personal injury or loss of life EI Means potential hazards which could WARNIN result in personal injury or loss of life CAUTION Means hazards which could result in U minor personal injury SP98 10 PRECAUTIONS DE SECURITE AVERTISSEMENT Ces r gles de s curit ont pour objet d assurer votre protection Veillez lire et observer les pr cautions nonc es ci dessous avant de monter quipement ou de commercer l utiliser Tout d faut d observation de ces pr cautions risque d entrainer des blessures graves ou mortelles 1 PROTECTION INDIVIDUELLE Les br lures de la peau et des yeux dues au rayonnement de l arc lectrique ou du m tal incandescent lors du soudage au plasma ou l lectrode ou lors du gougeage l arc peuvent s av rer plus graves que celles r sultant d une exposition prolong e au soleil Aussi convient il d observer les pr cautions suivantes a Portez un cran facial ad quat muni des plaques protectrices et des verres filtrants appropri s afin de vous prot ger les yeux le visage le cou et les oreilles des tincelles et du rayonnement de l arc lectrique lorsque vous effectuez des soudures ou des coupes ou lorsque vous en observez l ex cution AVERTISSEZ les personnes se trouvant proximit de facon ce qu elles ne regardent pas l arc et ce qu elles ne s exposent pas son rayonnement ni celui du m tal incandescent b Portez des gants ignifug
37. livery Order Changes Saleable Goods Returns Shipping Information Eastern Distribution Center Telephone 800 362 7080 Fax 800 634 7548 Central Distribution Center Telephone 800 783 5360 Fax 800 783 5362 Western Distribution Center Telephone 800 235 401 2 Fax 888 586 4670 ENGINEERING SERVICE Telephone 843 664 4416 Fax 800 446 5693 Welding Equipment Troubleshooting Hours 7 30 AM to 5 00 PM EST Warranty Returns Authorized Repair Stations C TECHNICAL SERVICE Telephone 800 ESAB 123 Fax 843 664 4452 Part Numbers Technical Applications Hours 8 00 AM to 5 00 PM EST Performance Features Technical Specifications Equipment Recommendations D LITERATURE REQUESTS Telephone 843 664 5562 Fax 843 664 5548 Hours 7 30 AM to 4 00 PM EST E WELDING EQUIPMENT REPAIRS Telephone 843 664 4487 Fax 843 664 5557 Repair Estimates Repair Status Hours 7 30 AM to 3 30 PM EST F WELDING EQUIPMENT TRAINING Telephone 843 664 4428 Fax 843 679 5864 Training School Information and Registrations Hours 7 30 AM to 4 00 PM EST G WELDING PROCESS ASSISTANCE Telephone 800 ESAB 123 Fax 843 664 4454 Hours 7 30 AM to 4 00 PM EST H TECHNICAL ASST CONSUMABLES Telephone 800 933 7070 Hours 7 30 AM to 5 00 PM EST IF YOU DO NOT KNOW WHOM TO CALL Telephone 800 ESAB 123 Fax 843 664 4452 Web http www esab com Hours 7 30 AM to 5 00 PM EST ESAB Welding amp Cutting Prod
38. ons particuli res en mati re de ventilation indiqu es l alin a 6 de la norme Z49 1 de l AWS ENTRETIEN DE L QUIPEMENT Un quipement entretenu de facon d fectueuse ou inad quate risque non seulement de r aliser un travail de mauvaise qualit mais chose plus grave encore d entrainer des dommages corporels graves voire mortels en d clenchant des incendies ou des chocs lectriques Observez par cons quent les pr cautions suivantes Efforcez vous de toujours confier un personnel qua l installation le d pannage et l entretien du poste de soudage et de coupage N effectuez aucune r paration lectrique sur l quipement moins d tre qua lifi cet effet Ne proc dez jamais une t che d entretien quelconque l int rieur du poste de soudage coupage avant d avoir d branch l alimentation lectrique Maintenez bon tat de fonctionnement les cables le c ble de masse les branchements le cordon d alimentation et le poste de soudage coupage N utilisez jamais le poste ou l quipement s il pr sente une d fectuosit quelconque Prenez soin du poste de soudage et de coupage et des quipements accessoires Gardez les l cart des sources de charleur notamment des fours de l humidit des flaques d eau maintenez les l abri des traces d huile ou de graisse des atmospheres corro sives et des intemp ries Laissez en place tous les dispositifs de s curit e
39. ree of obstructions The selected site should also allow easy removal of the power source outer enclosure for maintenance See Table 1 1 for overall dimensions of the unit 2 2 RECEIVING UNPACKING AND PLACEMENT A Immediately upon receipt of the power source inspect for damage which may have occurred in transit Notify the carrier of any defects or dam age B Remove the power source from the container Remove all packing materials Check the con tainer for any loose parts C Checkair passages at front and rear of cabinet making sure that no packing materials that may obstruct air flow through the power source D Install the lifting eyeboltfurnished with the power source into the top of the unit ANE For lifting purposes and for keeping dust mois ture and other foreign material from entering the power source the lifting eyebolt must be fully tightened with a tool E After selecting an installation site see para graph 2 1 place the power source in the desired location The unit may be lifted either by using the lifting eyebolt or by forklift truck If a forklift is used for lifting the unit be sure that the lift forks are long enough to extend completely under the base Do not use filters on this unitas they would restrict the volume of intake air required for proper cooling Output ratings on this unit are based on an unob structed supply of cooling air drawn over its inter nal components Wa
40. rranty is void if any type of filtering device is used INSTALLATION 2 3 PRIMARY INPUT ELECTRICAL CONNEC TION This power source is a three phase unit and must be connected to a three phase power supply It is recom mended thatthe unit be operated on a dedicated circuit to prevent impairment of performance due to an over loaded circuit ATEN ELECTRIC SHOCK CAN KILL Before making elec trical input connections to the power source Ma chinery Lockout Procedures should be employed If the connections are to be made from a line disconnect switch place the switch in the off posi tion and padlock it to prevent inadvertent tripping If the connection is made from a fusebox remove the corresponding fuses and padlock the box cover If itis not possible to use padlocks attach a red tag to the line disconnect switch or fuse box warning others that the circuit is being worked on A The primary power leads must be insulated copper conductors Three power leads and one ground wire are required Either rubber covered cable or conduit flexible or solid may be used Table 2 1 provides recommended input conduc tors and line fuse sizes B Remove the top cover Identify primary power input connections on the power switch chassis ground lug on the A frame and primary input terminal board Refer to Figures 2 1 and 2 2 C When using the provided strain relief refer to Figure 2 1 for proper cable strip lengths It is impor
41. s ratings For example overloaded welding cable can overheat and create a fire hazard 6 After completing operations inspect the work area to make certain there are no hot sparks or hot metal which could cause a later fire Use fire watchers when neces Sary For additional information refer to NFPA Standard 51B Fire Prevention in Use of Cutting and Welding Pro cesses available from the National Fire Protection Asso ciation Batterymarch Park Quincy MA 02269 e ELECTRICAL SHOCK Contact with live electrical parts and ground can cause severe injury or death DO NOT use AC welding current in damp areas if move ment is confined or if there is danger of falling 1 Be sure the power source frame chassis is connected to the ground system of the input power 2 Connect the workpiece to a good electrical ground 3 Connect the work cable to the workpiece A poor or missing connection can expose you or others to a fatal shock 4 Use well maintained equipment Replace worn or dam aged cables 5 Keepeverything dry including clothing work area cables torch electrode holder and power source 6 Make sure that all parts of your body are insulated from work and from ground 7 Do not stand directly on metal or the earth while working in tight quarters or a damp area stand on dry boards or an insulating platform and wear rubber soled shoes 8 Puton dry hole free gloves before turning on the power 9 Turn
42. supplied 1 3 DESCRIPTION These power sources are designed for constant cur rent Stick welding SMAW air carbon arc gouging ACAG and scratch start tig GTAW It can also be used for Mig spray arc GMAW and flux cored wire FCAW welding with an off the arc wire feeder Table 1 10utlines the electrical and physical specifications of the available models 1 3 1 POWER SOURCE The power source is a constant current Silicon Con trolled Rectifier SCR three phase star connected transformer rectifier type dc unit with solid state contactor and control circuitry It provides the volt ampere char acteristics desired for conventional Stick welding 25 0 62 2 cm 18 8 48 3 cm 32 5 81 9 cm NOTE 453cc and 553cc may also operate from 200 208 volt a c primary input using the 230 volt change over connections However when connected to this source 200 volt the output is derated to 36 volts 400 amps 453cc and to 38 volts 500 amps 553cc The 453cc and 553cc 50 Hz may operate from 380 vac or 415 vac primary input when using the 400 vac change over connection When using this connection the output voltage is derated from 38 v to 36 v 453cc and 42 v to 38 v 553cc SECTION 1 1 3 2 Volt Ampere Characteristics The curves shown in Figure 1 1 represent the volt ampere static characteristics for the power source These curves show the output voltage available at any given output
43. t tous les panneaux de l armoire de commande en veillant les garder en bon tat Utilisez le poste de soudage coupage conform ment son usage pr vu et n effectuez aucune modification INFORMATIONS COMPL MENTAIRES RELATIVES LA S CURIT Pour obtenir des informations compl mentaires sur les r gles de s curit observer pour le montage et l utilisation d quipements de soudage et de coupage lectriques et sur les m thodes de travail recommand es demandez un exemplaire du livret N 52529 Precautions and Safe Practices for Arc Weld ing Cutting and Gouging publi par ESAB Nous conseillons galement de consulter les publications sui vantes tenues votre disposition par l American Welding Society 550 N W LeJuene Road Miami FL 32126 Safety in Welding and Cutting AWS 249 1 Recommended Safe Practices for Gas Shielded Arc Welding AWS A6 1 Safe Practices for Welding and Cutting Containers That Have Held Combustibles AWS A6 0 Recommended Safe Practices for Plasma Arc Cutting AWS A6 Recommended Safe Practices for Plasma Arc Weld ing AWS C5 1 Recommended Safe Practices for Air Carbon Arc Gouging and Cutting AWS C5 3 Code For Safety in Welding Cutting CSA Standard W117 2 9 97 SECTION 1 1 1 GENERAL This manual has been prepared for use by enced operator It provides information to familiarize the
44. tant to follow the cable strip guide to en sure that if the primary input cable is ever pulled from the strain relief the input conductors will be pulled from the ON OFF power switch before the ground lead is pulled from the ground lug Once stripped thread the input and ground conduc tors through the large strain relief in the rear panel of the power source Connect the ground wire to the terminal lug located on the right rear A frame leg inside the power source Connect the primary power leads to terminals L1 L2 and L3 on the input power switch Secure the strain relief on the input cable ATEN The chassis must be connected to an approved electrical ground Failure to do so may result in electrical shock severe burns or death SECTION 2 Rear Panel Inside View Strain Relief Ground Fault Switch SWITCH 9 GROUND LUG dx NUT HORSESHOE INSTALLATION Recommended Cable Strip Lengths PRIMARY INPUT 3 PRIMARY INPUT CONDUCTORS 102 GREEN 1 41 0 cneEN YELLOW EARTH TB3 Located on Fan Bracket Figure 2 1 Connecting Primary Power Leads Table 2 1 Recommended Input Conductor Size and Line Fuses Rated Input Input amp 100 Duty Cycle Rating GND Volts Amps Conductor CU AWG 208 220 230 400 460 575 Fuse Size Amps 64 61 58 33 29 23 82 77 74 43 37 30 Sized per National Code for 75 Crated copper conductors 40 C
45. tor should contact ESAB at 843 664 4416 for assistance The following is a list of terms acronyms used throughout this manual CC CV GMAW GMAW P GTAW MIG SMAW Stick TIG Constant Current Constant Voltage Gas Metal Arc Welding CV mode same as MIG Gas Metal Arc Welding Pulsed CV mode same as pulsed MIG Gas Tungsten Arc Welding CC mode same as TIG Metal Inert Gas CV mode same as GMAW Shielded Metal Arc Welding CC mode same as Stick Stick Welding CC mode same as SMAW Tungsten Inert Gas CC mode same as GTAW SECTION PARAGRAPH SAFETY ENGLISH FRENCH SECTION 1 1 1 1 2 OR WW SECTION 2 2 1 2 2 2 3 2 4 2 5 SECTION 3 3 1 3 1 1 3 1 2 3 1 3 3 1 4 3 1 5 3 1 6 3 1 7 3 1 8 3 2 3 2 1 3 2 2 SECTION 4 4 1 4 2 4 3 4 3 1 4 3 2 4 3 3 4 3 4 4 3 5 SECTION 5 5 1 5 2 5 3 5 6 SECTION 6 6 1 6 2 TABLE OF CONTENTS TITLE PAGE SAFETY PRECAUTIONS 4 5 SAFETY PRECAUTIONS unions tan unten 6 7 DESCRIPTION TTE MEM due ou 8 GENEA 8 FRO CE 8 nr EU ACE E ee 8 8 Volt Ampere ChardeclerislleS ac alee 9 OOM AltACCES
46. ucts 15 591 2 2001 Printed U S A Box 100545 Florence SC 29501 0545
47. urce is used It is imperative that all air passages be kept as clean as possible in order to allow adequate air flow to provide proper cooling After cleaning with low pressure air check for and tighten any loose hardware including all electrical connections Check for frayed and or cracked insula tion on all power cables and replace if necessary Amema Failure to replace worn or damaged cables may result in a bare cable touching a grounded object The resulting electrical arc may injure unprotected eyes and will present a serious fire hazard Body contact with a bare cable connector or conductor may result in severe electrical shock causing seri ous burns or death 4 3 INSPECTION AND SERVICE Keep the power source dry free of oil and grease and protected at all times from damage by hot metal and sparks MAINTENANCE 4 3 1 Fan Motor Keep the fan motor free of accumulated dust and dirt 4 3 2 Transformer Other than periodically cleaning the dust and dirt from the transformer no maintenance is required Ensure that only clean dry low pressure air is used 4 3 3 Control Circuits These circuits are protected by two 10 amp circuit breakers mounted in the front panel If these open the contactor will not operate 4 3 4 Over Temperature Protection Ifthe power source reaches an abnormally high internal temperature the thermal protection will deenergize the contactor circuit shutting down the power source but
48. ves and collars should be kept buttoned and open pockets eliminated from the front of clothing 5 Protect other personnel from arc rays and hot sparks with a suitable non flammable partition or curtains 6 Use goggles over safety glasses when chipping slag or grinding Chipped slag may be hot and can fly far Bystanders should also wear goggles over safety glasses FIRES AND EXPLOSIONS Heat from flames and arcs start fires Hot slag sparks can also cause fires and plosions Therefore 1 Remove all combustible materials well away from the work area or cover the materials with a protective non flammable covering Combustible materials include wood cloth sawdust liquid and gas fuels solvents paints and coatings paper etc 2 Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hidden smoldering fire or fires on the floor below Make certain that such openings are protected from hot sparks and metal 3 Do not weld cut or perform other hot work until the workpiece has been completely cleaned so that there are no substances on the workpiece which might pro duce flammable or toxic vapors Do not do hot work on closed containers They may explode 4 Havefire extinguishing equipment handy for instant use such as a garden hose water pail sand bucket or portable fire extinguisher Be sure you are trained in its use 5 Do not use equipment beyond it
49. w high resistance The SCRs are bad if they show low resistance in either direction 6 Check the gate circuit on the SCRs by installing a jumper from the gate lead to the anode of the SCR The meter should read less than 5 ohms TROUBLESHOOTING Remove the jumper from the gate The meter reading should increase 3050 ohms B Replacing the SCRs IMPORTANT 1 When replacing SCR s make sure mounting surfaces are clean Using Alcoa No 2 EJC Electrical Joint Compound or an equivalent apply a thin coat to the SCR mounting surface and positively locate in place on the heatsinks Placethe clampin position with the bolts through the holes in the heatsinks and proceed as fol lows 2 Tighten the bolts evenly until finger tight noting that the nuts are not rotating 3 Tighten the bolts 3 4 turn plus an 1 8 turn using a socket wrench on the bolt heads and rotating only in 1 4 turn increments plus 1 8 turn alternat ing between the bolts noting thatthe nuts are not rotating 5 3 PCB VOLTAGE TESTS A TE Electrical service and repair should be attempted only by a trained electrician When making PCB voltage measurements refer to the schematic diagram All voltage readings are taken with the front access panel open and the power switch ON Table 5 1 SCR Voltages Output FROM Pes 10 V dc 0 10 V dc P6 6 SCRI P6 5 SCR2 P6 4 SCR3 P6 3 5 4 P6 2 SCR5
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