Page 1
INSTRUCTION MANUAL
453cc & 553cc
DC WELDING POWER SOURCES
F-15-591-A
February, 2001
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
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding equipment, we urge you to read our
booklet, "Precautions and Safe Practices for Arc Welding, Cutting, and Gouging," Form 52-
529. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT
attempt to install or operate this equipment until you have read and fully understand these
instructions. If you do not fully understand these instructions, contact your supplier for further
information. Be sure to read the Safety Precautions before installing or operating this
equipment.
Be sure this information reaches the operator.
You can get extra copies through your supplier.
Page 2
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. 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 purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a
service facility designated by the manufacturer.
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 it is determined that the power source is not operating properly, the operator should
contact ESAB at (843) 664-4416 for assistance.
The following is a list of terms/acronyms used throughout this manual.
CC Constant Current
CV Constant Voltage
GMAW Gas Metal Arc Welding, CV mode (same as MIG)
GMAW-P Gas Metal Arc Welding - Pulsed, CV mode (same as pulsed MIG)
GTAW Gas Tungsten Arc Welding, CC mode (same as TIG)
MIG Metal Inert Gas, CV mode (same as GMAW)
SMAW Shielded Metal Arc Welding, CC mode (same as Stick)
Stick Stick Welding, CC mode (same as SMAW)
TIG Tungsten Inert Gas, CC mode (same as GTAW)
2
Page 3
TABLE OF CONTENTS
SECTION
PARAGRAPH TITLE PAGE
SAFETY
ENGLISH SAFETY PRECAUTIONS ................................................................................................................ 4, 5
FRENCH SAFETY PRECAUTIONS ................................................................................................................ 6, 7
SECTION 1 DESCRIPTION..................................................................................................................................... 8
1.1 General ................................................................................................................................................ 8
1.2 Receiving-Handling .............................................................................................................................. 8
1.3 Description ........................................................................................................................................... 8
1.3.1 Power Source ...................................................................................................................................... 8
1.3.2 Volt-Ampere Characteristics ................................................................................................................ 9
1.4 Optional Accessories ........................................................................................................................... 9
1.5 Safety ................................................................................................................................................... 9
SECTION 2 INSTALLATION ................................................................................................................................... 10
2.1 Location ............................................................................................................................................... 10
2.2 Receiving, Unpacking and Placement .................................................................................................10
2.3 Primary (Input) Electrical Connection ..................................................................................................10
2.4 Secondary (Output) Welding Connections ..........................................................................................12
2.5 Control Connections ............................................................................................................................12
SECTION 3 OPERATION ........................................................................................................................................14
3.1 Controls................................................................................................................................................ 14
3.1.1 Power Switch (ON-OFF) .....................................................................................................................14
3.1.2 Arc Force Control ................................................................................................................................14
3.1.3 Contactor Or/Remote Switch ...............................................................................................................14
3.1.4 Current Panel/Remote Switch .............................................................................................................14
3.1.5 Current Control ....................................................................................................................................14
3.1.6 Over Temperature Indicator .................................................................................................................15
3.1.7 Voltmeter and Ammeter .......................................................................................................................15
3.1.8 Fault indicator ......................................................................................................................................15
3.2 Operation Set-Up ................................................................................................................................. 15
3.2.1 Stick Welding, Arc Gouging, Tig Welding ............................................................................................15
3.2.2 Mig Spray Arc and Flux Cored Welding ...............................................................................................15
SECTION 4 MAINTENANCE ................................................................................................................................... 16
4.1 General ................................................................................................................................................16
4.2 Cleaning ...............................................................................................................................................16
4.3 Inspection .and Service ....................................................................................................................... 16
4.3.1 Fan Motor.............................................................................................................................................16
4.3.2 Transformer .......................................................................................................................................... 16
4.3.3 Control Circuit ......................................................................................................................................16
4.3.4 Over Temperature Protection ...............................................................................................................16
4.3.5 Digital Voltmeter/Ammeter Calibration ................................................................................................. 16
SECTION 5 TROUBLESHOOTING ......................................................................................................................... 17
5.1 General ................................................................................................................................................17
5.2 Testing and Replacing Bridge Assembly Components ........................................................................17
5.3 PCB Voltage Test .................................................................................................................................17
5.6 Troubleshooting Information Table ....................................................................................................... 18
SECTION 6 PARTS ................................................................................................................................................. 19
6.1 General ................................................................................................................................................19
6.2 Ordering ...............................................................................................................................................19
3
Page 4
SAFETY PRECAUTIONS
WARNING: These Safety Precautions are for
your protection. They summarize precautionary information from the references listed in
Additional Safety Information section. Before
performing any installation or operating procedures, be
sure to read and follow the safety precautions listed below
as well as all other manuals, material safety data sheets,
labels, etc. Failure to observe Safety Precautions can result
in injury or death.
PROTECT YOURSELF AND OTHERS
Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation and
can injure skin and eyes. Hot metal can cause burns.
Training in the proper use of the processes and equipment is essential to prevent accidents. Therefore:
1. Always wear safety glasses with side shields in any work
area, even if welding helmets, face shields, and goggles
are also required.
2. Use a face shield fitted with the correct filter and cover
plates to protect your eyes, face, neck, and ears from
sparks and rays of the arc when operating or observing
operations. Warn bystanders not to watch the arc and
not to expose themselves to the rays of the electric-arc
or hot metal.
3. Wear flameproof gauntlet type gloves, heavy long-sleeve
shirt, cuffless trousers, high-topped shoes, and a welding helmet or cap for hair protection, to protect against
arc rays and hot sparks or hot metal. A flameproof apron
may also be desirable as protection against radiated
heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cuffs, or pockets. Sleeves and collars should be
kept buttoned, and open pockets eliminated from the
front of clothing
5. Protect other personnel from arc rays and hot sparks
with a suitable non-flammable partition or curtains.
6. Use goggles over safety glasses when chipping slag or
grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety glasses.
FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot slag
or sparks can also cause fires and explosions. Therefore:
1. Remove all combustible materials well away from the
work area or cover the materials with a protective nonflammable 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 produce flammable or toxic vapors. Do not do hot work on
closed containers. They may explode.
4. Have fire extinguishing equipment handy for instant use,
such as a garden hose, water pail, sand bucket, or
portable fire extinguisher. Be sure you are trained in its
use.
5. Do not use equipment beyond its ratings. For example,
overloaded welding cable can overheat and create a fire
hazard.
6. After completing operations, inspect the work area to
make certain there are no hot sparks or hot metal which
could cause a later fire. Use fire watchers when necessary.
7. For additional information, refer to NFPA Standard 51B,
"Fire Prevention in Use of Cutting and Welding Pro-
--
cesses", available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
ELECTRICAL SHOCK -- Contact with live
electrical parts and ground can cause
severe injury or death. DO NOT use AC
welding current in damp areas, if movement 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 damaged cables.
5. Keep everything dry, including clothing, work area, cables,
torch/electrode holder, and power source.
6. Make sure that all parts of your body are insulated from
work and from ground.
7. Do not stand directly on metal or the earth while working
in tight quarters or a damp area; stand on dry boards or
an insulating platform and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)
for specific grounding recommendations. Do not mistake the work lead for a ground cable.
ELECTRIC AND MAGNETIC FIELDS —
May be dangerous. Electric current flowing through any conductor causes localized Electric and Magnetic Fields
(EMF). Welding and cutting current creates EMF around welding cables and
welding machines. Therefore:
1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.
2. Exposure to EMF may have other health effects which are
unknown.
3. Welders should use the following procedures to minimize
exposure to EMF:
A. Route the electrode and work cables together. Secure
them with tape when possible.
B. Never coil the torch or work cable around your body.
C. Do not place your body between the torch and work
cables. Route cables on the same side of your body.
D. Connect the work cable to the workpiece as close as
possible to the area being welded.
E. Keep welding power source and cables as far away
from your body as possible.
4
10/98
Page 5
SAFETY PRECAUTIONS
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shielding gases can cause asphyxiation.
Therefore:
1. Always provide adequate ventilation in the work area by
natural or mechanical means. Do not weld, cut, or gouge
on materials such as galvanized steel, stainless steel,
copper, zinc, lead, beryllium, or cadmium unless positive mechanical ventilation is provided. Do not breathe
fumes from these materials.
2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly toxic
gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat irritation
while operating, this is an indication that ventilation is not
adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not continue to
operate if physical discomfort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specific ventilation recommendations.
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 &
Safety Code
CYLINDER HANDLING -- Cylinders, if
mishandled, can rupture and violently
release gas. Sudden rupture of cylinder, valve, or relief device can injure or
kill. Therefore:
1. Use the proper gas for the process and use the proper
pressure reducing regulator designed to operate from
the compressed gas cylinder. Do not use adaptors.
Maintain hoses and fittings in good condition. Follow
manufacturer's operating instructions for mounting regulator to a compressed gas cylinder.
2. Always secure cylinders in an upright position by chain
or strap to suitable hand trucks, undercarriages, benches,
walls, post, or racks. Never secure cylinders to work
tables or fixtures where they may become part of an
electrical circuit.
3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not connected. 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.
§25249.5 et seq.)
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do not
perform any electrical work unless you are qualified to
perform such work.
2. Before performing any maintenance work inside a power
source, disconnect the power source from the incoming
electrical power.
3. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do not
operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position
and in good repair.
6. Use equipment only for its intended purpose. Do not
modify it in any manner.
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for electric arc welding and cutting equipment, ask
your supplier for a copy of "Precautions and
Safe Practices for Arc Welding, Cutting and
Gouging", Form 52-529.
The following publications, which are available from the
American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding“
6. AWS C5.6 - "Recommended Practices for Gas Metal Arc
Welding"“
7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."
MEANING OF SYMBOLS - As used throughout this manual: Means Attention! Be Alert!
Your safety is involved.
Means immediate hazards which, if
not avoided, will result in immediate,
serious personal injury or loss of life.
Means potential hazards which could
result in personal injury or loss of life.
Means hazards which could result in
minor personal injury.
5
SP98-10
Page 6
PRÉCAUTIONS DE SÉCURITÉ
AVERTISSEMENT: Ces règles de sécurité ont pour objet
d’ assurer votre protection. Veillez à lire et à observer les
précautions énoncées ci-dessous avant de monter l’
équipement ou de commercer à l’utiliser. Tout défaut
d’observation de ces précautions risque d’entraîner des
blessures graves ou mortelles.
1. PROTECTION INDIVIDUELLE-- Les brûlures de la
peau et des yeux dues au rayonnement de l’arc
électrique ou du métal incandescent, lors du soudage
au plasma ou à l’électrode ou lors du gougeage à
l’arc, peuvent s’avérer plus graves que celles
résultant d’une exposition prolongée au soleil. Aussi
convient-il d’observer les précautions suivantes:
a. Portez un écran facial adéquat muni des plaques
protectrices et des verres filtrants appropriés afin de
vous protéger les yeux, le visage, le cou et les oreilles
des étincelles et du rayonnement de l’arc électrique
lorsque vous effectuez des soudures ou des coupes
ou lorsque vous en observez l’exécution.
AVERTISSEZ les personnes se trouvant à proximité
de façon à ce qu’elles ne regardent pas l’arc et à ce
qu’elles ne s’exposent pas à son rayonnement, ni à
celui du métal incandescent.
b. Portez des gants ignifugés à crispins, une tunique
épaisse à manches longues, des pantalons sans
rebord, des chaussures à embout d’acier et un
casque de soudage ou une calotte de protection, afin
d’éviter d’exposer la peau au rayonnement de l’arc
électrique ou du métal incandescent. ll est également
souhaitable d’utiliser un tablier ininflammable de
façon à se protéger des étincelles et du rayonnement
thermique.
c. Les étincelles ou les projections de métal incandes-
cent risquent de se loger dans des manches
retroussées, des bords relevés de pantalons ou dans
des poches. Aussi convient-il de garder boutonnés le
col et les manches et de porter des vêtements sans
poches à l’avant.
d. Protégez des étincelles et du rayonnement de l’arc
électrique les autres personnes travaillant à proximité
à l’aide d’un écran ininflammable adéquat.
e. Ne jamais omettre de porter des lunettes de sécurité
lorsque vous vous trouvez dans un secteur où l’on
effectue des opérations de soudage ou de coupage à
l’arc. Utilisez des lunettes de sécurité à écrans ou
verres latéraux pour piquer ou meûler le laitier. Les
piquetures incandescentes de laitier peuvent être
projetées à des distances considérables. Les
personnes se trouvant à proximité doivent également
porter des lunettes de protection.
f. Le gougeage à l’arc et le soudage à l’arc au plasma
produisent un niveau de bruit extrêmement élevé (de
100 à 114 dB) et exigent par conséquent l’emploi de
dispositifs appropriés de protection auditive.
2. PRÉVENTION DES INCENDES-- Les projections de
laitier incandescent ou d’étincelles peuvent
provoquer de graves incendies au contact de
matériaux combustibles solides, liquides ou gazeux.
Aussi faut-il observer les précautions suivantes:
a. Éloigner suffisamment tous les matériaux combus-
tibles du secteur où l’on exécute des soudures ou des
coupes à l’arc, à moins de les recouvrir complètement
d’une bâche non-inflammable. Ce type de matériaux
comprend notamment le bois, les vêtements, la sciure,
l’essence, le kérosène, les peintures, les solvants, le
gaz naturel, l’acétylène, le propane et autres substances combustibles semblables.
b. Les étincelles ou les projections de métal incandes-
cent peuvent tomber dans des fissures du plancher ou
dans des ouvertures des murs et y déclencher une
ignition lente cachée. Veiller à protéger ces ouvertures
des étincelles et des projections de métal.
c. N’exécutez pas de soudures, de coupes, d’opérations
de gougeage ou autres travaux à chaud à la surface
de barils, bidons, réservoirs ou autres contenants
usagés, avant de les avoir nettoyés de toute trace de
substance susceptible de produire des vapeurs
inflammables ou toxiques.
d. En vue d’assurer la prévention des incendies, il
convient de disposer d’un matériel d’extinction prêt à
servir immédiatement, tel qu’un tuyau d’arrosage, un
seau à eau, un seau de sable ou un extincteur portatif.
e. Une fois le travail à l’arc terminé, inspectez le secteur
de façon à vous assurer qu’aucune étincelle ou projection de métal incandescent ne risque de provoquer
ultérieurement un feu.
3. CHOC ÉLECTRIQUE-- Le gougeage à l’arc et à l’arc
au plasma exige l’emploi de tensions à vide
relativement importantes; or, celles-ci risquent de
causer des dommages corporels graves et même
mortels en cas d’utilisation inadéquate. La gravité du
choc électrique reçu dépend du chemin suivi par le
courant à travers le corps humain et de son intensité.
a. Ne laissez jamais de surfaces métalliques sous ten-
sion venir au contact direct de la peau ou de
vêtements humides. Veillez à porter des gants bien
secs.
b. Si vous devez effectuer un travail sur une surface
métallique ou dans un secteur humide, veillez à assurer votre isolation corporelle en portant des gants secs
et des chaussures à semelles de caoutchouc et en
vous tenant sur une planche ou une plate-forme
sèche.
c. Mettez toujours à la terre le poste de soudage/coupage
en le reliant par un câble à une bonne prise de terre.
d. N’utilisez jamais de câbles usés ou endommagés. Ne
surchargez jamais le câble. Utilisez toujours un
équipement correctement entretenu.
e. Mettez l’équipement hors tension lorsqu’il n’est pas en
service. une mise à la masse accidentelle peut en effet
provoquer une surchauffe de l’équipement et un danger d’incendie. Ne pas enrouler ou passer le câble
autour d’une partie quelconque du corps.
f. Vérifiez si le câble de masse est bien relié à la pièce en
un point aussi proche que possible de la zone de
travail. Le branchement des câbles de masse à
l’ossature du bâtiment ou en un point éloigné de la
zone de travail augmente en effet le risque de passage d’un courant de sortie par des chaînes de
6
9/97
Page 7
PRÉCAUTIONS DE SÉCURITÉ
levage, des câbles de grue ou divers chemins
électriques.
g. Empêchez l’apparition de toute humidité, notamment
sur vos vêtements, à la surface de l’emplacement de
travail, des câbles, du porte-électrode et du poste de
soudage/coupage. Réparez immédiatement toute
fuite d’eau.
4. VENTILATION-- La respiration prolongée des fumées
résultant des opérations de soudage/coupage, à
l’intérieur, d’un local clos, peut provoquer des malaises et des dommages corporels. Aussi convient-il
d’observer les précautions suivantes:
a. Assurez en permanence une aération adéquate de
l’emplacement de travail en maintenant une ventilation naturelle ou à l’aide de moyens mécaniques.
N’effectuez jamais de travaux de soudage ou de
coupage sur des matériaux de zinc, de plomb, de
beryllium ou de cadmium en l’absence de moyens
mécaniques de ventilation capables d’empêcher
l’inhalation des fumées dégagées par ces matériaux.
b. N’effectuez jamais de travaux de soudage ou de
coupage à proximité de vapeurs d’hydrocarbure
chloré résultant d’opérations voisines de dégraissage
ou de pulvérisation. La chaleur dégagée ou le
rayonnement de l’arc peut déclencher la formation de
phosgène -- gaz particulièrement toxique -- et d’autres
gaz irritants, à partir des vapeurs de solvant.
c. Une irritation momentanée des yeux, du nez ou de la
gorge constatée au cours de l’utilisation de
l’équipement dénote un défaut de ventilation. Arrêtezvous de travailler afin de prendre les mesures nécessaires à l’amélioration de la ventilation. Ne poursuivez
pas l’opération entreprise si le malaise persiste.
d. Certaines commandes comportent des canalisations
où circule de l’hydrogène. L’armoire de commande est
munie d’un ventilateur destiné à empêcher la formation de poches d’hydrogène, lesquelles présentent un
danger d’explosion; ce ventilateur ne fonctionne que
si l’interrupteur correspondant du panneau avant se
trouve placé en position ON (Marche). Veillez à
manœuvrer cette commande en vérifiant si le
couvercle est bien en place, de façon à assurer
l’efficacité de la ventilation ainsi réalisée. Ne jamais
débrancher le ventilateur.
e. Les fumées produites par l’opération de soudage ou
de coupage peuvent s’avérer toxiques. Aussi est-il
nécessaire de disposer en permanence d’un dispositif
adéquat de ventilation de type aspirant, afin d’éliminer du voisinage de l’opérateur tout dégagement de
fumée visible.
f. Consultez les recommandations particulières en
matière de ventilation indiquées à l’alinéa 6 de la
norme Z49.1 de l’AWS.
5. ENTRETIEN DE L’ÉQUIPEMENT-- Un équipement
entretenu de façon défectueuse ou inadéquate risque
non seulement de réaliser un travail de mauvaise
qualité mais, chose plus grave encore, d’entraîner des
dommages corporels graves, voire mortels en
déclenchant des incendies ou des chocs électriques.
Observez par conséquent les précautions suivantes:
a. Efforcez-vous de toujours confier à un personnel qua-
lifié l’installation, le dépannage et l’entretien du poste
de soudage et de coupage. N’effectuez aucune
réparation électrique sur l’équipement à moins d’être
qua-lifié à cet effet.
b. Ne procédez jamais à une tâche d’entretien
quelconque à l’intérieur du poste de soudage/
coupage, avant d’avoir débranché l’alimentation
électrique.
c. Maintenez en bon état de fonctionnement les câbles,
le câble de masse, les branchements, le cordon
d’alimentation et le poste de soudage/coupage.
N’utilisez jamais le poste ou l’équipement s’il présente
une défectuosité quelconque.
d. Prenez soin du poste de soudage et de coupage et des
équipements accessoires. Gardez-les à l’écart des
sources de charleur, notamment des fours, de
l’humidité, des flaques d’eau maintenez-les à l’abri des
traces d’huile ou de graisse, des atmosphères corrosives et des intempéries.
e. Laissez en place tous les dispositifs de sécurité et tous
les panneaux de l’armoire de commande en veillant à
les garder en bon état.
f. Utilisez le poste de soudage/coupage conformément à
son usage prévu et n’effectuez aucune modification.
6. INFORMATIONS COMPLÉMENTAIRES RELATIVES
À LA SÉCURITÉ--
Pour obtenir des informations complémentaires sur les
règles de sécurité à observer pour le montage et
l’utilisation d’équipements de soudage et de coupage
électriques et sur les méthodes de travail
recommandées, demandez un exemplaire du livret N°
52529 “Precautions and Safe Practices for Arc Welding, Cutting and Gouging” publié par ESAB. Nous
conseillons également de consulter les publications
sui-vantes, tenues à votre disposition par l’American
Welding Society, 550 N.W. LeJuene Road, Miami, FL
32126:
a. “Safety in Welding and Cutting” AWS Z49.1
b. “Recommended Safe Practices for Gas-Shielded Arc
Welding “AWS A6. 1.
c. “Safe Practices for Welding and Cutting Containers
That Have Held Combustibles” AWS-A6.0.
d. “Recommended Safe Practices for Plasma Arc Cutting”
AWS-A6. 3.
e. “Recommended Safe Practices for Plasma Arc Weld-
ing” AWS-C5. 1.
f. “Recommended Safe Practices for Air Carbon Arc
Gouging and Cutting” AWS-C5. 3.
g. “Code For Safety in Welding and Cutting”
CSA-Standard W117. 2.
7
9/97
Page 8
SECTION 1 DESCRIPTION
1.1 GENERAL
This manual has been prepared for use by an experienced operator. It provides information to familiarize
the 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.
When requesting information concerning this equipment, it is essential that Item number, Serial number
and Model number of the equipment be supplied.
1.3 DESCRIPTION
These power sources are designed for constant current 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 -1 outlines the electrical and physical specifications of
the available models.
1.3.1 POWER SOURCE
The power source is a constant current, Silicon Controlled Rectifier (SCR), three phase, star-connected
transformer/rectifier type dc unit with solid state contactor
and control circuitry. It provides the volt-ampere characteristics desired for conventional Stick welding.
Table 1-1. Specifications for 453cc and 553cc
453cc 553cc
55 Vdc 57 VdcOPEN CIRCUIT V OLTA GE (Uo)
DUTY CY CLE
RATED 450 A 350 A 550 A 450 A
OUTPUT 38 Vdc 34 Vdc 42 Vdc 38 Vdc
RATED 3 460 Vac 35A 29 A 43 A 37 A
INPUT Phase 575 Vac 28A 23 A 34 A 30 A
Pow er Factor at Rated Output
PHYSICAL SPECIFICATIONS
Height (w ithout lifting eyebolt)
Current (12)
Voltage (U2)
Volts (U 1) Current (11 Current (11 Current (11 Current (11)
60 Hz (208)230 Vac 70 A 58 A 86 A 74 A
50 Hz 220/400
(380-415) Vac
Welding Range
Auxiliary Pow er
Width
Dept h
Net Weight
Shipping Weight
60.00% 100.00% 60.00% 100.00%
73/40 (42-39) A 61/33 (35-30) A 90/49 (52-47) A 77/43 (45--41) A
83.00% 83.00%
20A/20V to 450A/38Vdc
115 V ac @ 10 A, 60 Hz
60 Hz. 50 Hz. 60 Hz. 50 Hz.
25.0" (62.2 cm)
18.8" (48.3 cm)
32.5" (81.9 cm)
339lbs(154kg) 379lbs(172kg) 363 lbs (165 kg) 400 lbs (181 kg)
349 lbs (158 kg) 389 lbs (177 kg) 373 lbs (170 kg) 410 lbs (186 kg)
20A/20V to 550A/42Vdc
115 V ac @ 10 A, 60 Hz
25.0" (62.2 c m)
18.8" (48.3 c m)
32.5" (81.9 c m)
NOTE: The 453cc and 553cc may also operate from a 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).
8
Page 9
SECTION 1 DESCRIPTION
1.3.2 Volt-Ampere Characteristics
The curves shown in Figure 1-1 represent the voltampere static characteristics for the power source.
These curves show the output voltage available at any
given output current from the minimum to the maximum
setting of the current control.
Figure 1.1 Volt/Ampere Curves
553CC
MAX. OUTPUT
MIN. OUTPUT
453CC
MAX. OUTPUT
1.4 OPTIONAL ACCESSORIES
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)
This 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-I709000 in
which the large R5 resistor was moved from
top center of the "A" frame to the base in front
of the fan bracket.
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)
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:
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.
9
Page 10
SECTION 2 INSTALLATION
2.1 LOCATION
A proper installation site is necessary for the power
source to provide dependable service. A proper installation site permits freedom of air movement through 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 of the power source must be kept completely
free 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 damage.
B. Remove the power source from the container.
Remove all packing materials. Check the container for any loose parts.
C. Check air 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 eyebolt furnished with the power
source into the top of the unit.
2.3 PRIMARY (INPUT) ELECTRICAL CONNECTION
This power source is a three-phase unit and must be
connected to a three-phase power supply. It is recommended that the unit be operated on a dedicated circuit
to prevent impairment of performance due to an overloaded circuit.
ELECTRIC SHOCK CAN KILL! Before making electrical input connections to the power source, "Machinery Lockout Procedures" should be employed.
If the connections are to be made from a line
disconnect switch, place the switch in the off position 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 it is 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 conductors 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.
For lifting purposes and for keeping dust, moisture, 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 unit as they would restrict
the volume of intake air required for proper cooling.
Output ratings on this unit are based on an unobstructed supply of cooling air drawn over its internal components. Warranty is void if any type of
filtering device is used.
C. When using the provided strain relief, refer to
Figure 2.1 for proper cable strip lengths. It is
important to follow the cable strip guide to ensure 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 conductors 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.
The chassis must be connected to an approved
electrical ground. Failure to do so may result in
electrical shock, severe burns or death.
10
Page 11
f
SECTION 2 INSTALLATION
Rear Panel (Inside View)
Ground Fault
Switch*
SWITCH
HORSESHOE
Recommended Cable Strip Lengths
Strain Relief
5"
10"
TB3 Located on
Fan Bracket
GROUND LUG
NUT
Figure 2.1 Connecting Primary Power Leads
Table 2.1 Recommended Input Conductor Size and
Line Fuses
Rated Input
100% Duty Cycle Rating
Volts Am ps
208 64 No. 6 90
220 61 No. 6 80
230 58 No. 6 80
482cc 400 33 No. 10 40
453CC
460 29 No. 10 40
575 23 No. 12 30
208 82 No. 4 120
220 77 No. 4 120
230 74 No. 4 120
553CC
582cc 400 43 No. 8 70
460 37 No. 8 60
575 30 No. 10 50
* Sized per National Code for 75o C rated copper conductors @ 40o C
Not more than three conductors in a raceway or cable. Local codes
should be
ollowed if they specify sizes other than those listed above.
Input &
GND Fuse Size
Conductor* Amps
CU/AWG
* 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
Page 12
SECTION 2 INSTALLATION
D. Check all connections for proper tightness. En-
sure all connections are correct and well insulated.
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)
2.5 CONTROL CONNECTIONS
Refer to Figure 2-3.
2.5.1 Remote Control (Optional)
This function is provided by an optional 14-pin receptacle (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 C02 regulator, or small hand tools. The receptacle is rated 115
Vac / 10 amps.
2.5.3 - 42V Circuit Breaker (CB1)
The 42V resettable circuit breaker (CB1) protects the
42 volt control circuitry against over current. (Table 52
provides troubleshooting information).
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 POSITIVE (+) terminal is located
at the 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)
We lding
Cur rent 50 100 150 200 250
10064321/0
150 4 3 1 1/0 2/0
200 3 1 1/0 2/0 3/0
250 2 1/0 2/0 3/0 4/0
300 1/0 2/0 3/0 4/0 4/0
400 2/0 3/0 4/0 4/0 2-2/0
500 3/0 3/0 4/0 2-2/0 2-3/0
*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.
Total Length (Feet) of Cable In Weld Circuit*
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 information).
12
Page 13
SECTION 2 INSTALLATION
Figure 2.3 CONTROL CONNECTIONS
CKT. BREAKERS,
10A 32VDC, 250VAC
+
SW
POWER
SWITCH
63A
600V
-
OUTPUT RECEPTACLE 2.4
13
Page 14
SECTION 3 OPERATION
3.1.2 Arc Force Control.
This control is used for stick welding only.The lower
Never operate the power source with the cover re
moved. In addition to the safety hazards, lmproper
cooling may cause damage to the components.
Keep side panels closed when unit is energized.
Welding helmet, gloves, and other personal protection 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
control circuitry.
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 available 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,
output is controlled using an optional remote control via
receptacle J2.
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.
3.1.1.1
3.1.6
3.1.8
3.1.7
3.1.5 Current Control
This control allows the operator to adjust the output
current. Placing the Panel/Remote switch in the REMOTE position disables the current control on the front
panel.
3.1.5
3.1.2
3.1.3
3.1.4
3.1.1
Figure 3.1 Control Locations (453cc illustrated)
14
Page 15
SECTION 3 OPERATION
3.1.6 Over Temperature Indicator (Temp)
This amber light will indicate when an internal overheating 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
If an optional External Ground Conductor Protection Kit
was installed, this red light, when lit, will indicate that
current was flowing through the external ground conductor. 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.
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. If stick 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. If using a remote current control, such as HC-
3B, place current and contactor switches in
REMOTE positions. Note that the current range
will be limited to the maximum setting on the
power source's current control dial.
If not using 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. To preset the approximate welding current, pro-
ceed as follows:
1. Connect the electrode holder to the
workpiece to create short.
ELECTRIC SHOCK CAN KILL! "Machinery Lockout
Procedures" should be employed. If it is 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.
3.2.1 Stick Welding (SMAW) Air Carbon Arc Gouging (ACAG) and Scratch Start Tig Welding
(GTAW)
A. If stick welding or 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.
If 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.
2. Place the contactor switch to the ON position.
3. Set the Arc Force control to the minimum
position.
4. Place the Power On-Off switch to the ON
position.
5. By observing the digital ammeter,adjust
Current Control to the desired current setting.
6. Place Power On-Off switch back to OFF
7. Then remove the holder from the workplace.
H. After setting the desired current and if using
remote, turn switch back to REMOTE.
I. 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.
15
Page 16
SECTION 4 MAINTENANCE
4.1 GENERAL
If this power source does not operate properly,
stop work immediately and investigate the cause of
the malfunction. Maintenance work must be performed by an experienced person, and electrical
work by a trained electrician. Do not permit untrained persons to inspect, clean, or repair this
power source. Use only recommended replacement parts.
ELECTRIC SHOCK CAN KILL! "Machinery Lockout
Procedures" should be employed. If it is 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. 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 passages and interior components by using clean low
pressure air. The frequency cleaning is required depends upon the environment in which the power source
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 insulation on all power cables and replace if necessary.
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
If the power source reaches an abnormally high internal
temperature, the thermal protection will deenergize the
contactor circuit, shutting down the power source but
leaving the cooling fan on. After the power source has
cooled to a safe level, the thermal protection will automatically 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. Disconnect cables from the output terminals and
then connect an accurate DC voltmeter to the
output terminals.
3. Open the front control panel by removing the two
mounting screws from the upper corners. Locate 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
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 serious 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.
5. With the primary input power on, turn the Current
control knob until you get 25V on the DC voltmeter. 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 adjust the trimpot (R13) on the meter
board with a small screwdriver until the digital
meter reading matches the DC voltmeter reading. When satisfied, reassemble meter board,
reconnecting J9 jumper plug, and reassemble
front control panel.
16
Page 17
SECTION 5 TROUBLESHOOTING
5.1 GENERAL
DISCONNECT primary power at wall switch, or
circuit breaker, before attempting inspection or
work inside the power source.
If the power source is operating improperly, the following troubleshooting information may be used to locate
the source of the trouble.
Check the problem against the symptoms in the following troubleshooting guide (Table 5-2.) The remedy for
the problem may be quite simple. If the cause cannot be
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 discoloration.
5.2 TESTING AND REPLACING BRIDGE ASSEMBLY COMPONENTS
The SCRs used in the power source are devices which
allow current to flow in only one direction. The SCRs are
designed to provide long trouble-free operation; however, should a failure occur, they may require replacement.
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.
Place the clamp in position with the bolts through
the holes in the heatsinks and proceed as follows:
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 alternating between the bolts noting that the nuts are not
rotating.
5.3 PCB VOLTAGE TESTS
Electrical service and repair should be attempted
only by a trained electrician.
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 R5.
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 readings should again show 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.
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 TO READING
P8-5 OTB+ +10 V dc
P8-7 OTB+ 0-10 V dc*
P6-6 (SCRI)
P6-5 (SCR2)
P6-4 (SCR3)
P6-3 (SCR4) OTB+ .3 V dc with
P6-2 (SCR5) contactor on
P6-1 (SCR6)
* Varies with setting of VCP (R1)
17
Page 18
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.
G Loss of primary phase. Check that LED on control PCB is lit. If not, find & replace
defective fuse.
No Output - Fan A. Poor or improper electrical input -- check input connections on TB.
Running B. 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. Unit may be single phasing -- check incoming power for three phases.
C. 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 Volt ac 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
18
Page 19
SECTION 6 REPLACEMENT PARTS
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
To 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 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.
19
Page 20
SECTION 6 REPLACEMENT PARTS
453cc-553cc View 1 - Front
20
Page 21
SECTION 6 REPLACEMENT PARTS
453cc-553cc View 2 - Top Panel
21
Page 22
SECTION 6 REPLACEMENT PARTS
453cc-553cc View 3 - Angled Front
22
Page 23
SECTION 6 REPLACEMENT PARTS
453cc-553cc View 4 - Rear
23
Page 24
SECTION 6 REPLACEMENT PARTS
453cc-553cc View 5 - Internal Rear View
24
Page 25
SECTION 6 REPLACEMENT PARTS
453cc-553cc View 6 - Internal Front View
25
Page 26
SECTION 6 REPLACEMENT PARTS
POINTS.
180W66 (ITEM 145), 180W68 (ITEM 146). TO CONFINE
LOOSE WIRE AS REQUIRED. USE 71200732 (ITEM 123)
TO SECURE FILTER CAPACITORS. USE HEAT SHRINK
90863007 (ITEM 126), 90863202 (127) AND 90863203
(ITEM 128) TO INSULATE BARRELS OF TERMINALS.
ALL COPPER TO COPPER, ALUMINUM TO COPPER AND
ALUMINUM TO ALUMINUM CONNECTIONS.
FROM MOTOR AND INSTALL FASTONS 950905 (ITEM 46).
TOR IN UP POSITION.
892W64 (ITEM 166) COUNTERCLOCKWISE TO MINIMUM
POSITION. POINTER TO BE AT "MIN" DESIGNATION
SHOWN ON CONTROL PANEL.
DRAWINGS ARE ACTUALLY PART OF THE WIRE KITS.
NOTES:
1. REFER TO WIRING DIAGRAMS FOR ALL CONNECTION
2. USE TYWRAPS 631507 (ITEM 41), 99511578 (ITEM 130),
3. APPLY ELECTRICAL JOINT COMPOUND (ITEM 124) TO
4. CUT FAN MOTOR 82062334 (ITEM 16) LEADS TO 10"
5. INSTALL FAN MOTOR 82062334 (ITEM 16) WITH CAPACI-
6. BEFORE ASSEMBLING TURN POTS 13730632 (ITEM 69) &
(ITEM 60) MUST BE SHIPPED WITH MACHINE.
7. CERTAIN ITEMS CALLED FOR AND SHOWN ON THESE
8. ITEMS 672786 (ITEM 44), 8950219 (ITEM 10), AND TAG
D-0558001568-A
453cc-553cc Schematic Diagram- 50/60 HZ
26
Page 27
SECTION 6 REPLACEMENT PARTS
D-0558001569
453cc-553cc Wiring Diagram- Primary 3 PH
27
Page 28
SECTION 6 REPLACEMENT PARTS
D-0558001570-A
453cc-553cc Wiring Diagram Secondary - 50/60 HZ
28
Page 29
SECTION 6 REPLACEMENT PARTS
Bill of Materials
453cc/553cc DC Welding Power Source
ITEM PART OR
NO. CODE NO. QTY. DESCRIPTION SYMBOL
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 PCB CONTROL PCB1
838128 1 CONTROL PCB
6 8634515 2 SW TGGL SPDT 2 POS 15A 125V S2,3
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 TS1,3
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 TB1
136110 1 BOARD INPUT TERMINAL 230/460V/575 TB1
32236 1 BOARD INPUT TERMINAL 220/400V TB1
21 36092 1 CABLE DIGITAL METER PCB P10
22 36635 4 CLIP SKID
23 37861GY 1 BASE
24 37862GY 1 PANEL FRONT BOTTOM
25 37863YL 1 PANEL RIGHT SIDE
26 37864YL 1 PANEL LEFT SIDE
27 37865 1 CONTROL PANEL
28 37867GY 1 PANEL REAR
29 37868 1 BRIDGE BUSBAR
30 37869 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 C-836426 1 INDUCTOR L1
36 0558001568 1 SCHEMATIC DIAG 453CC/553CC 50/60HZ
37 0558001569 1 WIRING DIAG PRI 3 PH AFRAME 453CC/553CC
38 0558001570 1 WIRING DIAG SECONDARY 453CC/553CC 50/60HZ
39 0558001329 1 KIT WIRE PRI 453CC
0558001879 1 KIT WIRE PRIMARY 553CC
40 0558001330 1 KIT WIRE SEC 453CC/553CC
29
Page 30
SECTION 6 REPLACEMENT PARTS
Bill of Materials
453cc/553 DC Welding Power Source
ITEM PART OR
NO. CODE NO. QTY. DESCRIPTION SYMBOL
41 631507 AR TYWRAP MEDIUM
42 634220 2 TAB
43 647361 1 GND1 LUG TERMINAL 2-8 WIRE 1/4 STUD
44 672786 1 BOLT EYE .75-10 X 2.00
45 950167 1 GROMMET RUB 1.12 ID X 1.50 GD X .06 W
46 950905 1 TERM IL/M .250 TS X 14-16 AWG
47 951504 1 J5 PLUG HOUSING 15 POS
49 952067 1 CONNECTOR 20 AWG 3 PIN P1
50 952068 1 MTA-156 COVER 3 PIN
51 952070 1 CONNECTOR 20 AWC 7 PIN P5
52 952071 1 MTA-156 COVER 7 PIN
53 952072 3 CONNECTOR 20 AWG 12 PIN P3,4,7
54 952073 1 TERM BLOCK 12 POS TB2
55 952081 1 CONNECTOR 20 AWG 10 PIN P8
56 952155 1 PLASTIC MARKER (1-12)
59 952243 1 PALLET 42.00
60 954046 1 TAG WARRANTY ESAB
62 954506 1 LABEL ISO 9002
63 954911 1 OVERLAY 453CC
954910 1 OVERLAY 553CC
64 954855 1 LABEL RATING 453CC 230/460
954856 1 LABEL RATING 553CC 230/460
954857 1 LABEL RATING 453CC 230/460/575
954858 1 LABEL RATING 553CC 230/460/575
954859 1 LABEL RATING 453CC 220/400
954860 1 LABEL RATING 553CC 220/400
65 954912 1 LABEL SCHEM 230/460V & 220/400 & 575
66 2091514 1 LABEL WARNING WELD AND CUT
67 2091558 1 LABEL GND BLK .50 X 1.38
69 13730632 1 POT LIN 10K 2W .88L R1
70 13730763 1 NAME PLATE CODE SERIAL STOCK
71 13731781 1 MTA-156 COVER 10 PIN
72 13732431 3 MTA-156 COVER 12 PIN
73 13732733 1 LABEL FOR INSTALL USE COPPER WIRE ONLY
74 13734588 2 LOGO ESAB CLEAR
75 13735311 1 CONNECTOR 20 AWG 6 PIN P6
76 13735312 1 MTA-156 COVER 6 PIN
77 13735508 1 SHROUD FAN
78 17300020 1 RES RW FIXD ST 300W 10% 20.00 R5
79 22993477 AR RUBBER .188 X .500
80 61212092 AR BOLT LAG 1/4-20 X 1.50 LG
122 65509506 AR RIV BLD AL 1/8 GRIP .251-.312
123 71200732 AR ADH SI-RBR CLEAR
124 73585980 AR CNPD ELEC JOINT ALCOA 2 EJC
125 79900317 AR INSULATOR SEALING 3.75 X .125
126 90863007 AR TUBING HEAT SHRINK .250 ID BLK
127 90863202 AR TUBING HEAT SHRINK 3/4 ID CLEAR
128 90863203 AR TUBING HEAT SHRINK 5/8 ID CLEAR
129 99510047 AR VINYL SLEEVING 7/8
130 99511578 AR SNAP IN TIE BASE .218
30
Page 31
SECTION 6 REPLACEMENT PARTS
Bill of Materials
453cc/553cc DC Welding Power Source
ITEM PART OR
NO. CODE NO. QTY. DESCRIPTION SYMBOL
133 99512240 1 LABEL CAUTION LIFT EYE
134 99512558 2 BRACKET RESISTOR #18
135 0558001010 1 TERMINAL BLOCK 3 POS TB3
136 0558001011 1 BOX PCB GRAY
137 0558001012 3 PLUG HOUSING 2 POS
138 0558001014 3 SEAL WIRE 2 POS
139 0558001015 3 SEAL INTER
140 0558001016 1 CAP 9 POS J6
141 0558001018 1 INSULATOR STAND OFF
142 0558001019 1 KNOB 1.57 DIA
143 0558001032GY 1 PANEL FRONT TOP
144 0558001038 1 INSULATOR
145 180W66 AR TYWRAP LARGE
146 180W68 AR TYWRAP SMALL
147 36043GY 1 BRACKET FAN
148 36048GY 4 LEG AFRAME
149 36049GY 1 BAIL LIFTING
150 36070GY 1 BRACKET TERMINAL BOARD MTG
151 36642GY 1 BAFFLE
36140GY 1 BAFFLE
152 37902GY 1 BLANKING PLATE
153 0558001818 1 KNOB 01.37 A
154 37866YL 1 PANEL TOP
155 90861100 AR TUBING INSULATING VINYL 105' C RATING 9" LG
156 90863005 AR TUBING HEAT SHRINKABLE 6" LG
157 838100 1 CE FILTER ASSY FN1
159 952223 3 STAND OFF 1/4-20 X .75
160 0558001331G 1 HINGE ACCESS
161 0558001332G 1 PANEL ACCESS GRAY
162 A-954864 1 LABEL THREE PHASE
166 A-892W64 1 POT LIN 100K 2W R2
167 10981006 AR SOLDER 60/40 ROSIN
31
Page 32
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES
A. CUSTOMER SERVICE QUESTIONS:
Order Entry Product Availability Pricing Delivery
Order Changes Saleable Goods Returns Shipping Information
Telephone: (800)362-7080 / Fax: (800) 634-7548
Telephone: (800)783-5360 / Fax: (800) 783-5362
Telephone: (800) 235-4012/ Fax: (888) 586-4670
B. 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
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
Eastern Distribution Center
Central Distribution Center
Western Distribution Center
Hours: 7:30 AM to 4:00 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
F-15-591-A 2/2001 Printed in U.S.A.
Loading...