ESAB 653 cvcc DC Welding Power Source Instruction manual

653 cvcc

DC Welding Power Source

Instruction Manual

This manual provides complete instructions for the following power sources starting with Serial No. M0RI603036, January 1996:

ESAB ITEM NO. 37830 - 653cvcc - 230/460/575 vac, 3 ph., 60 Hz
ESAB ITEM NO. 37832 - 653cvcc - 220/400 vac, 3 ph., 50 Hz CE

F15-572-H 02/2006

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

CAUTION

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding and cutting 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.

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.

2

TABLE OF CONTENTS

Section / Title Page

1.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.1 Safety - English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.2 Safety - Spanish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

1.3 Safety - French

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

2.0 Description

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

2.2 Receiving-Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

2.3 Description

2.4 Optional Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

2.5 Safety

3.0 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

3.1 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

3.2 Receiving, Unpacking & Placement

3.3 Primary (input) Electrical Connection

3.4 Output Welding Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.5 Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.0 Operation

4.1 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.2 Sequence of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

5.0 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

5.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

5.2 Cleaning

5.3 Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

6.0 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

6.1 General

6.2

Testing and Replacing Bridge Assembly Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

7.0 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

7.2 Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

3

TABLE OF CONTENTS

4

SECTION 1 SAFETY PRECAUTIONS

1.0 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.

1.1 Safety - English

FIRES AND EXPLOSIONS -­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 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
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
Processes", 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.

Heat from

5

SECTION 1 SAFETY PRECAUTIONS

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.

3. Welders should use the following procedures to
minimize exposure to EMF:

A. Route the electrode and work cables together.

Secure them with tape when possible.

B. Never coil the torch or work cable around your

body.

C. Do not place your body between the torch and

work cables. Route cables on the same side of
your body.

D. Connect the work cable to the workpiece as close

as possible to the area being welded.

E. Keep welding power source and cables as far

away from your body as possible.

FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shield­ing gases can cause asphyxiation.

Therefore:

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.

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.

6

SECTION 1 SAFETY PRECAUTIONS

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

§25249.5 et seq.)

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.

1. Always have qualified personnel perform the instal
lation, 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.

-

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.

EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:

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"

7

SECTION 1 SAFETY PRECAUTIONS

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.

8

SECTION 1 SEGURIDAD

1.2 Safety - Spanish

ADVERTENCIA: Estas Precauciones de Se-

guridad son para su protección. Ellas hacen

resumen de información proveniente de las
referencias listadas en la sección "Información Adi­cional Sobre La Seguridad". Antes de hacer cualquier
instalación o procedimiento de operación , asegúrese
de leer y seguir las precauciones de seguridad listadas
a continuación así como también todo manual, hoja
de datos de seguridad del material, calcomanias, etc.
El no observar las Precauciones de Seguridad puede
resultar en daño a la persona o muerte.

PROTEJASE USTED Y A LOS DEMAS-­Algunos procesos de soldadura, corte
y ranurado son ruidosos y requiren
protección para los oídos. El arco,

como el sol , emite rayos ultravioleta
(UV) y otras radiaciones que pueden dañar la piel
y los ojos. El metal caliente causa quemaduras. EL
entrenamiento en el uso propio de los equipos y
sus procesos es esencial para prevenir accidentes.
Por lo tanto:

1. Utilice gafas de seguridad con protección a los lados

siempre que esté en el área de trabajo, aún cuando
esté usando careta de soldar, protector para su cara
u otro tipo de protección.

2. Use una careta que tenga el filtro correcto y lente

para proteger sus ojos, cara, cuello, y oídos de las
chispas y rayos del arco cuando se esté operando y
observando las operaciones. Alerte a todas las per­sonas cercanas de no mirar el arco y no exponerse
a los rayos del arco eléctrico o el metal fundido.

3. Use guantes de cuero a prueba de fuego, camisa

pesada de mangas largas, pantalón de ruedo liso,
zapato alto al tobillo, y careta de soldar con capucha
para el pelo, para proteger el cuerpo de los rayos y
chispas calientes provenientes del metal fundido.
En ocaciones un delantal a prueba de fuego es
necesario para protegerse del calor radiado y las
chispas.

4. Chispas y partículas de metal caliente puede alojarse

en las mangas enrolladas de la camisa , el ruedo del
pantalón o los bolsillos. Mangas y cuellos deberán
mantenerse abotonados, bolsillos al frente de la
camisa deberán ser cerrados o eliminados.

5. Proteja a otras personas de los rayos del arco y chis

pas calientes con una cortina adecuada no-flamable
como división.

6. Use careta protectora además de sus gafas de segu

ridad cuando esté removiendo escoria o puliendo.

La escoria puede estar caliente y desprenderse con
velocidad. Personas cercanas deberán usar gafas
de seguridad y careta protectora.

FUEGO Y EXPLOSIONES -­las flamas y el arco pueden ocacionar
fuegos. Escoria caliente y las chispas
pueden causar fuegos y explosiones.
Por lo tanto:

1. Remueva todo material combustible lejos del área
de trabajo o cubra los materiales con una cobija a
prueba de fuego. Materiales combustibles incluyen
madera, ropa, líquidos y gases flamables, solventes,
pinturas, papel, etc.

2. Chispas y partículas de metal pueden introducirse en
las grietas y agujeros de pisos y paredes causando
fuegos escondidos en otros niveles o espacios.
Asegúrese de que toda grieta y agujero esté cubierto
para proteger lugares adyacentes contra fuegos.

3. No corte, suelde o haga cualquier otro trabajo
relacionado hasta que la pieza de trabajo esté to­talmente limpia y libre de substancias que puedan
producir gases inflamables o vapores tóxicos. No
trabaje dentro o fuera de contenedores o tanques
cerrados. Estos pueden explotar si contienen vapores
inflamables.

4. Tenga siempre a la mano equipo extintor de fuego
para uso instantáneo, como por ejemplo una
manguera con agua, cubeta con agua, cubeta con
arena, o extintor portátil. Asegúrese que usted esta
entrenado para su uso.

5. No use el equipo fuera de su rango de operación. Por
ejemplo, el calor causado por cable sobrecarga en
los cables de soldar pueden ocasionar un fuego.

6. Después de termirar la operación del equipo, inspec
cione el área de trabajo para cerciorarse de que las
chispas o metal caliente ocasionen un fuego más
tarde. Tenga personal asignado para vigilar si es
necesario.

7. Para información adicional , haga referencia a la
publicación NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible
a través de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.

CHOQUE ELECTRICO -- El contacto
con las partes eléctricas energizadas

-

-

de movimiento confinado en lugares estrechos o
si hay posibilidad de caer al suelo.

9

y tierra puede causar daño severo o
muerte. NO use soldadura de corri­ente alterna (AC) en áreas húmedas,

El calor de

-

SECTION 1 SEGURIDAD

1. Asegúrese de que el chasis de la fuente de poder
esté conectado a tierra através del sistema de
electricidad primario.

2. Conecte la pieza de trabajo a un buen sistema de
tierra física.

3. Conecte el cable de retorno a la pieza de trabajo.
Cables y conductores expuestos o con malas
conexiones pueden exponer al operador u otras
personas a un choque eléctrico fatal.

4. Use el equipo solamente si está en buenas condi
ciones. Reemplaze cables rotos, dañados o con
conductores expuestos.

5. Mantenga todo seco, incluyendo su ropa, el área de
trabajo, los cables, antorchas, pinza del electrodo,
y la fuente de poder.

6. Asegúrese que todas las partes de su cuerpo están
insuladas de ambos, la pieza de trabajo y tierra.

7. No se pare directamente sobre metal o tierra mien­tras trabaja en lugares estrechos o áreas húmedas;
trabaje sobre un pedazo de madera seco o una
plataforma insulada y use zapatos con suela de
goma.

8. Use guantes secos y sin agujeros antes de energizar
el equipo.

9. Apage el equipo antes de quitarse sus guantes.

10. Use como referencia la publicación ANSI/ASC
Standard Z49.1 (listado en la próxima página) para
recomendaciones específicas de como conectar el
equipo a tierra. No confunda el cable de soldar a
la pieza de trabajo con el cable a tierra.

CAMPOS ELECTRICOS Y MAGNETI­COS - Son peligrosos. La corriente
eléctrica fluye através de cualquier
conductor causando a nivel local

Campos Eléctricos y Magnéticos
(EMF). Las corrientes en el área de corte y soldadura,
crean EMF alrrededor de los cables de soldar y las
maquinas. Por lo tanto:

1. Soldadores u Operadores que use marca-pasos para

el corazón deberán consultar a su médico antes de
soldar. El Campo Electromagnético (EMF) puede
interferir con algunos marca-pasos.

2. Exponerse a campos electromagnéticos (EMF) puede

causar otros efectos de salud aún desconocidos.

3. Los soldadores deberán usar los siguientes proced
imientos para minimizar exponerse al EMF:

A. Mantenga el electrodo y el cable a la pieza de

trabajo juntos, hasta llegar a la pieza que usted
quiere soldar. Asegúrelos uno junto al otro con
cinta adhesiva cuando sea posible.

B. Nunca envuelva los cables de soldar alrededor

de su cuerpo.

-

C. Nunca ubique su cuerpo entre la antorcha y el

cable, a la pieza de trabajo. Mantega los cables a
un sólo lado de su cuerpo.

D. Conecte el cable de trabajo a la pieza de trabajo

lo más cercano posible al área de la soldadura.

E. Mantenga la fuente de poder y los cables de soldar

lo más lejos posible de su cuerpo.

HUMO Y GASES -- El humo y los
gases, pueden causar malestar o
daño, particularmente en espacios
sin ventilación. No inhale el humo

o gases. El gas de protección puede
causar falta de oxígeno.
Por lo tanto:

1. Siempre provea ventilación adecuada en el área

de trabajo por medio natural o mecánico. No solde,
corte, o ranure materiales con hierro galvanizado,
acero inoxidable, cobre, zinc, plomo, berílio, o cad­mio a menos que provea ventilación mecánica
positiva . No respire los gases producidos por
estos materiales.

2. No opere cerca de lugares donde se aplique sub-

stancias químicas en aerosol. El calor de los rayos
del arco pueden reaccionar con los vapores de
hidrocarburo clorinado para formar un fosfógeno,
o gas tóxico, y otros irritant es.

3. Si momentáneamente desarrolla inrritación de

ojos, nariz o garganta mientras est á operando, es
indicación de que la ventilación no es apropiada.
Pare de trabajar y tome las medidas necesarias
para mejorar la ventilación en el área de trabajo.
No continúe operando si el malestar físico per­siste.

4. Haga referencia a la publicación ANSI/ASC Standard

Z49.1 (Vea la lista a continuación) para recomen­daciones específicas en la ventilación.

-

10

SECTION 1 SEGURIDAD

5. ADVERTENCIA-- Este producto cuando se uti­liza para soldaduras o cortes,
produce humos o gases, los
cuales contienen químicos
conocidos por el Estado de Cali­fornia de causar defectos en el
nacimiento, o en algunos casos,
Cancer. (California Health &
Safety Code §25249.5 et seq.)

MANEJO DE CILINDROS-- Los

cilindros, si no son manejados
correctamente, pueden romp­erse y liberar violentamente
gases. Rotura repentina del
cilindro, válvula, o válvula de
escape puede causar daño o
muerte. Por lo tanto:

1. Utilize el gas apropiado para el proceso y utilize

un regulador diseñado para operar y reducir la
presión del cilindro de gas . No utilice adapta­dores. Mantenga las mangueras y las conexiones
en buenas condiciones. Observe las instrucciones
de operación del manufacturero para montar el
regulador en el cilindro de gas comprimido.

2. Asegure siempre los cilindros en posición vertical

y amárrelos con una correa o cadena adecuada
para asegurar el cilindro al carro, transportes, tab­lilleros, paredes, postes, o armazón. Nunca asegure
los cilindros a la mesa de trabajo o las piezas que
son parte del circuito de soldadura . Este puede ser
parte del circuito elélectrico.

3. Cuando el cilindro no está en uso, mantenga la

válvula del cilindro cerrada. Ponga el capote de
protección sobre la válvula si el regulador no
está conectado. Asegure y mueva los cilindros
utilizando un carro o transporte adecuado. Evite
el manejo brusco de los

1. Siempre tenga personal cualificado para efec
tuar l a instalación, diagnóstico, y mantenimiento
del equipo. No ejecute ningún trabajo eléctrico a
menos que usted esté cualificado para hacer el
trabajo.

2. Antes de dar mantenimiento en el interior de la
fuente de poder, desconecte la fuente de poder
del suministro de electricidad primaria.

3. Mantenga los cables, cable a tierra, conexciones,
cable primario, y cualquier otra fuente de poder
en buen estado operacional. No opere ningún
equipo en malas condiciones.

4. No abuse del equipo y sus accesorios. Mantenga
el equipo lejos de cosas que generen calor como
hornos, también lugares húmedos como charcos
de agua , aceite o grasa, atmósferas corrosivas y
las inclemencias del tiempo.

5. Mantenga todos los artículos de seguridad y
coverturas del equipo en su posición y en buenas
condiciones.

6. Use el equipo sólo para el propósito que fue
diseñado. No modifique el equipo en ninguna
manera.

INFORMACION ADICIONAL DE SEGU­RIDAD -- Para más información sobre las
prácticas de seguridad de los equipos de
arco eléctrico para soldar y cortar, pregunte
a su suplidor por una copia de "Precautions
and Safe Practices for Arc Welding, Cutting
and Gouging-Form 52-529.

Las siguientes publicaciones, disponibles através de
la American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, son recomendadas para usted:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"

-

MANTENIMIENTO DEL EQUIPO -- Equipo
defectuoso o mal mantenido puede cau­sar daño o muerte. Por lo tanto:

3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"

11

SECTION 1 SEGURIDAD

SIGNIFICADO DE LOS SIMBOLOS

-- Según usted avanza en la lectura
de este folleto: Los Símbolos Sig
nifican ¡Atención! ¡Esté Alerta! Se
trata de su seguridad.

Significa riesgo inmediato que,
de no ser evadido, puede resultar
inmediatamente en serio daño
personal o la muerte.

Significa el riesgo de un peligro
potencial que puede resultar en
serio daño personal o la muerte.

Significa el posible riesgo que
puede resultar en menores daños
a la persona.

-

12

SECTION 1 SÉCURITÉ

1.3 Safety - French

AVERTISSEMENT : Ces règles de sécurité

ont pour but d'assurer votre protection. Ils
récapitulent les informations de précaution

provenant des références dans la section
des Informations de sécurité supplémentaires. Avant de
procéder à l'installation ou d'utiliser l'unité, assurez-vous
de lire et de suivre les précautions de sécurité ci-des­sous, dans les manuels, les fiches d'information sur la
sécurité du matériel et sur les étiquettes, etc. Tout défaut
d'observer ces précautions de sécurité peut entraîner
des blessures graves ou mortelles.

PROTÉGEZ-VOUS -- Les processus de
soudage, de coupage et de gougeage

produisent un niveau de bruit élevé et
exige l'emploi d'une protection auditive. L'arc, tout
comme le soleil, émet des rayons ultraviolets en plus
d'autre rayons qui peuvent causer des blessures à la
peau et les yeux. Le métal incandescent peut causer
des brûlures. Une formation reliée à l'usage des
processus et de l'équipement est essentielle pour
prévenir les accidents. Par conséquent:

1. Portez des lunettes protectrices munies d'écrans la-

téraux lorsque vous êtes dans l'aire de travail, même
si vous devez porter un casque de soudeur, un écran
facial ou des lunettes étanches.

2. Portez un écran facial muni de verres filtrants et de

plaques protectrices appropriées afin de protéger
vos yeux, votre visage, votre cou et vos oreilles des
étincelles et des rayons de l'arc lors d'une opération
ou lorsque vous observez une opération. Avertissez
les personnes se trouvant à proximité de ne pas re­garder l'arc et de ne pas s'exposer aux rayons de l'arc
électrique ou le métal incandescent.

3. Portez des gants ignifugiés à crispin, une chemise

épaisse à manches longues, des pantalons sans
rebord et des chaussures montantes afin de vous
protéger des rayons de l'arc, des étincelles et du métal
incandescent, en plus d'un casque de soudeur ou
casquette pour protéger vos cheveux. Il est également
recommandé de porter un tablier ininflammable afin
de vous protéger des étincelles et de la chaleur par
rayonnement.

4. Les étincelles et les projections de métal incandescent

risquent de se loger dans les manches retroussées,
les rebords de pantalons ou les poches. Il est recom­mandé de garder boutonnés le col et les manches et
de porter des vêtements sans poches en avant.

5. Protégez toute personne se trouvant à proximité des

étincelles et des rayons de l'arc à l'aide d'un rideau ou
d'une cloison ininflammable.

6. Portez des lunettes étanches par dessus vos lunettes

de sécurité lors des opérations d'écaillage ou de
meulage du laitier. Les écailles de laitier incandescent
peuvent être projetées à des distances considérables.
Les personnes se trouvant à proximité doivent égale­ment porter des lunettes étanches par dessus leur
lunettes de sécurité.

INCENDIES ET EXPLOSIONS -- La
chaleur provenant des flammes ou de

l'arc peut provoquer un incendie. Le
laitier incandescent ou les étincelles

peuvent également provoquer un

incendie ou une explosion. Par conséquent :

1. Éloignez suffisamment tous les matériaux combus
tibles de l'aire de travail et recouvrez les matériaux
avec un revêtement protecteur ininflammable. Les
matériaux combustibles incluent le bois, les vête­ments, la sciure, le gaz et les liquides combustibles,
les solvants, les peintures et les revêtements, le
papier, etc.

2. Les étincelles et les projections de métal incan
descent peuvent tomber dans les fissures dans
les planchers ou dans les ouvertures des murs et
déclencher un incendie couvant à l'étage inférieur
Assurez-vous que ces ouvertures sont bien protégées
des étincelles et du métal incandescent.

3. N'exécutez pas de soudure, de coupe ou autre tra
vail à chaud avant d'avoir complètement nettoyé la
surface de la pièce à traiter de façon à ce qu'il n'ait
aucune substance présente qui pourrait produire
des vapeurs inflammables ou toxiques. N'exécutez
pas de travail à chaud sur des contenants fermés
car ces derniers pourraient exploser.

4. Assurez-vous qu'un équipement d'extinction
d'incendie est disponible et prêt à servir, tel qu'un
tuyau d'arrosage, un seau d'eau, un seau de sable
ou un extincteur portatif. Assurez-vous d'être bien
instruit par rapport à l'usage de cet équipement.

5. Assurez-vous de ne pas excéder la capacité de
l'équipement. Par exemple, un câble de soudage
surchargé peut surchauffer et provoquer un in­cendie.

6. Une fois les opérations terminées, inspectez l'aire de
travail pour assurer qu'aucune étincelle ou projec­tion de métal incandescent ne risque de provoquer
un incendie ultérieurement. Employez des guetteurs
d'incendie au besoin.

7. Pour obtenir des informations supplémentaires,
consultez le NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible au
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.

CHOC ÉLECTRIQUE -- Le contact avec
des pièces électriques ou les pièces
de mise à la terre sous tension peut
causer des blessures graves ou mor-

telles. NE PAS utiliser un courant de
soudage c.a. dans un endroit humide, en espace
restreint ou si un danger de chute se pose.

13

-

-

-

SECTION 1 SÉCURITÉ

1. Assurez-vous que le châssis de la source
d'alimentation est branché au système de mise à
la terre de l'alimentation d'entrée.

2. Branchez la pièce à traiter à une bonne mise de
terre électrique.

3. Branchez le câble de masse à la pièce à traiter et
assurez une bonne connexion afin d'éviter le risque
de choc électrique mortel.

4. Utilisez toujours un équipement correctement
entretenu. Remplacez les câbles usés ou endom­magés.

5. Veillez à garder votre environnement sec, incluant
les vêtements, l'aire de travail, les câbles, le porte­électrode/torche et la source d'alimentation.

6. Assurez-vous que tout votre corps est bien isolé
de la pièce à traiter et des pièces de la mise à la
terre.

7. Si vous devez effectuer votre travail dans un espace
restreint ou humide, ne tenez vous pas directe­ment sur le métal ou sur la terre; tenez-vous sur
des planches sèches ou une plate-forme isolée et
portez des chaussures à semelles de caoutchouc.

8. Avant de mettre l'équipement sous tension, isolez
vos mains avec des gants secs et sans trous.

9. Mettez l'équipement hors tension avant d'enlever
vos gants.

10. Consultez ANSI/ASC Standard Z49.1 (listé à
la page suivante) pour des recommandations
spécifiques concernant les procédures de mise à
la terre. Ne pas confondre le câble de masse avec
le câble de mise à la terre.

CHAMPS ÉLECTRIQUES ET MAGNÉ­TIQUES — comportent un risque
de danger. Le courant électrique
qui passe dans n'importe quel con-

ducteur produit des champs élec­triques et magnétiques localisés. Le soudage et le
courant de coupage créent des champs électriques
et magnétiques autour des câbles de soudage et
l'équipement. Par conséquent :

1. Un soudeur ayant un stimulateur cardiaque doit

consulter son médecin avant d'entreprendre une
opération de soudage. Les champs électriques et
magnétiques peuvent causer des ennuis pour cer­tains stimulateurs cardiaques.

2. L'exposition à des champs électriques et magné-

tiques peut avoir des effets néfastes inconnus pour
la santé.

3. Les soudeurs doivent suivre les procédures suivantes
pour minimiser l'exposition aux champs électriques
et magnétiques :

A. Acheminez l'électrode et les câbles de masse

ensemble. Fixez-les à l'aide d'une bande adhésive
lorsque possible.

B. Ne jamais enrouler la torche ou le câble de masse

autour de votre corps.

C. Ne jamais vous placer entre la torche et les câbles

de masse. Acheminez tous les câbles sur le même
côté de votre corps.

D. Branchez le câble de masse à la pièce à traiter le

plus près possible de la section à souder.

E. Veillez à garder la source d'alimentation pour le

soudage et les câbles à une distance appropriée
de votre corps.

LES VAPEURS ET LES GAZ -- peuvent
causer un malaise ou des dommages
corporels, plus particulièrement
dans les espaces restreints. Ne re­spirez pas les vapeurs et les gaz. Le
gaz de protection risque de causer
l'asphyxie. Par conséquent :

1. Assurez en permanence une ventilation adéquate
dans l'aire de travail en maintenant une ventila­tion naturelle ou à l'aide de moyens mécanique.
N'effectuez jamais de travaux de soudage, de coup­age ou de gougeage sur des matériaux tels que
l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc,
le plomb, le berylliym ou le cadmium en l'absence
de moyens mécaniques de ventilation efficaces. Ne
respirez pas les vapeurs de ces matériaux.

2. N'effectuez jamais de travaux à proximité d'une
opération de dégraissage ou de pulvérisation.
Lorsque la chaleur

ou le rayonnement de l'arc entre en contact avec les

vapeurs d'hydrocarbure chloré, ceci peut déclencher
la formation de phosgène ou d'autres gaz irritants,
tous extrêmement toxiques.

3. Une irritation momentanée des yeux, du nez ou de la
gorge au cours d'une opération indique que la ven­tilation n'est pas adéquate. Cessez votre travail afin
de prendre les mesures nécessaires pour améliorer
la ventilation dans l'aire de travail. Ne poursuivez
pas l'opération si le malaise persiste.

4. Consultez ANSI/ASC Standard Z49.1 (à la page
suivante) pour des recommandations spécifiques
concernant la ventilation.

14

SECTION 1 SÉCURITÉ

5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé
dans une opération de soudage ou de
coupage, dégage des vapeurs ou des
gaz contenant des chimiques consi­déres par l'état de la Californie comme
étant une cause des malformations
congénitales et dans certains cas, du
cancer. (California Health & Safety
Code §25249.5 et seq.)

MANIPULATION DES CYLINDRES --

La manipulation d'un cylindre, sans
observer les précautions nécessaires,
peut produire des fissures et un

échappement dangereux des gaz.
Une brisure soudaine du cylindre, de la soupape ou
du dispositif de surpression peut causer des bles­sures graves ou mortelles. Par conséquent :

1. Utilisez toujours le gaz prévu pour une opération

et le détendeur approprié conçu pour utilisation
sur les cylindres de gaz comprimé. N'utilisez jamais
d'adaptateur. Maintenez en bon état les tuyaux et
les raccords. Observez les instructions d'opération
du fabricant pour assembler le détendeur sur un
cylindre de gaz comprimé.

2. Fixez les cylindres dans une position verticale, à

l'aide d'une chaîne ou une sangle, sur un chariot
manuel, un châssis de roulement, un banc, un mur,
une colonne ou un support convenable. Ne fixez
jamais un cylindre à un poste de travail ou toute autre
dispositif faisant partie d'un circuit électrique.

3. Lorsque les cylindres ne servent pas, gardez les

soupapes fermées. Si le détendeur n'est pas bran­ché, assurez-vous que le bouchon de protection de
la soupape est bien en place. Fixez et déplacez les
cylindres à l'aide d'un chariot manuel approprié.
Toujours manipuler les cylindres avec soin.

4. Placez les cylindres à une distance appropriée

de toute source de chaleur, des étincelles et des
flammes. Ne jamais amorcer l'arc sur un cylindre.

5. Pour de l'information supplémentaire, consultez

CGA Standard P-1, "Precautions for Safe Handling
of Compressed Gases in Cylinders", mis à votre dis­position par le Compressed Gas Association, 1235
Jefferson Davis Highway, Arlington, VA 22202.

ENTRETIEN DE L'ÉQUIPEMENT -- Un équipe­ment entretenu de façon défectueuse ou
inadéquate peut causer des blessures
graves ou mortelles. Par conséquent :

1. Efforcez-vous de toujours confier les tâches
d'installation, de dépannage et d'entretien à un
personnel qualifié. N'effectuez aucune réparation
électrique à moins d'être qualifié à cet effet.

2. Avant de procéder à une tâche d'entretien à
l'intérieur de la source d'alimentation, débranchez
l'alimentation électrique.

3. Maintenez les câbles, les fils de mise à la terre, les
branchements, le cordon d'alimentation et la source
d'alimentation en bon état. N'utilisez jamais un
équipement s'il présente une défectuosité quel­conque.

4. N'utilisez pas l'équipement de façon abusive. Gardez
l'équipement à l'écart de toute source de chaleur,
notamment des fours, de l'humidité, des flaques
d'eau, de l'huile ou de la graisse, des atmosphères
corrosives et des intempéries.

5. Laissez en place tous les dispositifs de sécurité et
tous les panneaux de la console et maintenez-les
en bon état.

6. Utilisez l'équipement conformément à son usage
prévu et n'effectuez aucune modification.

INFORMATIONS SUPPLÉMENTAIRES RELA­TIVES À LA SÉCURITÉ -- Pour obtenir de
l'information supplémentaire sur les règles
de sécurité à observer pour l'équipement
de soudage à l'arc électrique et le coupage,
demandez un exemplaire du livret "Precau­tions and Safe Practices for Arc Welding,
Cutting and Gouging", Form 52-529.

Les publications suivantes sont également recomman­dées et mises à votre disposition par l'American Welding
Society, 550 N.W. LeJuene Road, Miami, FL 33126 :

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"

15

SECTION 1 SÉCURITÉ

SIGNIFICATION DES SYMBOLES
Ce symbole, utilisé partout dans ce manuel,
signifie "Attention" ! Soyez vigilant ! Votre
sécurité est en jeu.

DANGER

Signifie un danger immédiat. La situation peut
entraîner des blessures graves ou mortelles.

AVERTISSEMENT

Signifie un danger potentiel qui peut entraîner des
blessures graves ou mortelles.

ATTENTION

Signifie un danger qui peut entraîner des blessures
corporelles mineures.

16

SECTION 2 DESCRIPTION

ESAB 653cvcc

Multi-process, three phase power sources de-

•
signed for heavy duty industrial DC welding ap­plications
Use for Mig, flux cored wire, submerged arc and

•
stick electrode welding or air carbon arc gouging
Compatible with 42v wire feeders: MobileMaster IV,

•
2E, 4HD, 4HD Dual and with 115v wire feeders/
controls: Mig 35, Digimig, Digimig Dual, Digimatic
II,

UEC-8, DuraDrive 4-30 and DuraDrive 4-48

115 vac outlet for water circulator or tools

•
Control electronics are protected from dirt and dust

•
in an easy-access compartment
Optional wire feed adaptor kits for Miller and Lin-

•
coln wire feeders

Ordering Information

ESAB Power Sources

653cvcc, 230/460/575 vac, 3 ph, 60 Hz .................................................... 37830

653cvcc, 220/400 (380-415) vac, 3 ph, 50 Hz CE ...................................37832

ESAB 653cvcc Migmaster Packages

The follow ing package includes an ESAB DC power source, wire
feede r, 8 ft. (2.4m) control cabl e, 8 ft. (2.4m) gas hose, .035/.0 45
in. (.9/1.2mm) feed roll, - 15 ft. (4.5m) GunMaster gas-cooled gun,
15f t. work cabl e with clamp, 15 ft. wire fee der weld cable and
R-33-FM-580 regulator with adjustable flowmeter.

Migmaster 653cvcc, Mig 4HD, GM- 400cc,

230/460/575 vac .........................................................................................36234

Options & Accessories

HC-3B Hand Control, 30 ft. (9.1m) cable

(requires 0558001436) ..........................................................................33838

Mini Boom for Mig 4HD (requires Swivel Post) ..................................34322

Swivel Post, use with Mig 4HD or Mig 2E wire feeders .....................36172

Auto Fan™ Kit ....................................................................................................36707

TR-29 Truck Kit .................................................................................................. 37924

Remote Control Kit ............................................................................0558001436

Miller Wire Feeder Adaptor Kit (24 vac only) .........................0558001415

Lincoln Wire Feeder Adaptor Kit ................................................0558001416

Work Cable with Clamp (15 ft.) ..................................................... 0558001440

Feeder Cable with Lug (15 ft.) ........................................................0558001441

Shown with optional DuraDrive 4®-48 wire feeder,

GM-400 Mig welding torch, TR-29 Truck kit,

15 ft. work cable and welding wire

Specifications

Rated DC Output* @ 100% duty cycle,

50/60 Hz, cv or cc 653cvcc .........................................650 amps @ 44 vdc

Rated DC Output* @ 60% duty cycle,

50/60 Hz, cv or cc 653cvcc .........................................750 amps @ 44 vdc

Open Circuit Voltage, 50/60 Hz 653cvcc ...................54 vdc (cv)/59 vdc (cc)

Primary Input Voltage & Current @ rated 100% duty cycle load

653cvcc, 230/460 vac, 60 Hz, 3 ph ......................................108/54 amps

653cvcc, 230/460/575 vac, 60 Hz, 3 ph .......................108/54/43 amps

653cvcc, 220/400 (380-415) vac, 50 Hz, 3 ph ...........................................

...........................................................................................102/56 (59-54) amps

Power Factor @ rated load .................................................................................83%

Auxiliary Output Power (receptacle) ....................115 vac, 50/60 Hz, 10 amps

W x L x H ..........................18.75 in. (46 cm) x 32.5 in. (83 cm) x 25 in. (64 cm)

Net Weight,** 60 Hz 653cvcc ...................................................... 493 lb. (224 kg)

Shipping Weight** (approximate), 60 Hz 653cvcc .................503 lb. (229 kg)

* For 208 vac, 60 Hz and 380 vac, 50 Hz service, derate output current

rating 10%.
** For 50 Hz models, add 40 lb. (18kg)

17

SECTION 2 DESCRIPTION

2.1 GENERAL

This manual provides information to familiarize the operator with the design, installation and operation of the 653cvcc
model power source. DO NOT attempt to install or operate this equipment until you have read and fully understand
these instructions. The information presented here should be given careful consideration to ensure optimum perfor­mance of this equipment.

2.2 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 the Item number, Serial number and Model
number of the equipment be supplied.

2.3 DESCRIPTION

The 653cvcc is a multi-process power sources designed for Mig and spray transfer (GMAW), flux core (FCAW), and stick
(SMAW) welding as well as submerged arc welding (SAW) and air carbon arc cutting/gouging (CAC-A) applications. Table
2-1 outlines the electrical and physical specifications of the available models.

Table 2-1. Specifications for 653cvcc

OPEN CIRCUIT VOLTAGE (U0) 54 vdc (cv)/59 vdc (cc)

RATED DUTY CYCLE 60% 100%
OUTPUT Current (I2) 750 A 650 A (60Hz)/600 A (50Hz)
Voltage (U2) 44 V 44 V

RATED 3 Phase 60 Hz Volts (U1) Current (I1) Flat Current (I1) Flat
INPUT 230 V 124 A 108 A
460 V 62 A 54 A
575 V 50 A 43 A
50 Hz 220 V 127 A 102 A
400 V 70 A 56 A

Power Factor at Rated Output 83%
Welding Range 750 A/44 V - 50 A/14 V
Auxiliary Power 115 V ac @ 10 A, 60 Hz

PHYSICAL SPECIFICATIONS 60 Hz. 50 Hz.
Height (without lift eye) 25.0” (62.2 cm)
Width 18.8” (48.3 cm)
Depth 32.5” (81.9 cm)
Net Weight 493 lbs (224 kg) 528 lbs (240 kg)
Shipping Weight 503 lbs (228 kg) 538 lbs (244 kg)

NOTE: The 653cvcc may also operate from a 200 (208)-volt a.c. primary input using the 230-volt changeover connections. However, when connected to

this source (200-volt), the output voltage is derated 10%.

18

SECTION 2 DESCRIPTION

2.3.1 Power Source

The power source is a constant current/constant potential, 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 MIG, flux core and submerged arc welding in the CV mode or stick welding and arc gouging
in the CC mode.

2.3.2 Volt-Ampere Characteristics

The curves shown in Figure 2-1 represent the volt-ampere static characteristics for the power source. The slant of these
curves is referred to as the "slope" and is generally defined as the "voltage drop per 100 amperes of current use". These
curves show the output voltage available at any given output current from the minimum to the maximum setting of the
voltage control. Because the volt-ampere slope is fixed, it is possible to select welding conditions by estimating the open­circuit voltage required for the load current when operating in the CV mode.

60

50

40

30

Volts

20

10

MAX.

MIN.

0

100

200

0

300

400

500

AMPS

D.C. OUTPUT CURRENT (AMPS)

CV MODE FOR MIG/SUB ARC

600

700

800

900

60

50

40

30

MIN. MAX.

Volts

20

10

0

100

200

0

CC MODE FOR STICK/ARC GOUGING/SUB ARC

300

400

D.C. OUTPUT CURRENT (AMPS)

500

AMPS

600

700

800

900

1000

Figure 2-1. Volt-Ampere Curves

2.4 OPTIONAL ACCESSORIES

2.4.1 TR-29 Truck Kit (Item No. 37924)

This truck kit provides complete mobility of the power source. The kit consists of castors, rear cylinder rack and wheels,
gas cylinder bracket, cylinder chain, and pull handle.

2.4.2 Swivel Mount Kit (Item No. 36172)

This kit allows ESAB wire feeders with swivel base mounts to be mounted to the top of the power source on an insulated
swivel mount. This allows the feeder to freely rotate, relieving potential wire feed problems while increasing the working
area of the torch.

2.5 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 spe-

cific text references carefully.

19

SECTION 2 DESCRIPTION

20

SECTION 3 INSTALLATION

3.1 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.
The selected site should also allow easy removal of the power source outer enclosure for maintenance. See Table 2-1 for
overall dimensions of the unit.

3.2 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 ring furnished with the power sources into the top of the unit.

For lifting purposes and for keeping dust, moisture, and other for-

CAUTION

eign material from entering the power source, the lifting eyebolt
must be fully tightened with a tool.

E. After selecting an installation site, place the power source in the desired location. The unit may be lifted either

by using the lifting ring 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

CAUTION

based on an unobstructed supply of cooling air drawn over its internal
components. Warranty is void if any type of filtering device is used.

21

SECTION 3 INSTALLATION

3.3 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

WARNING

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 3-1 provides recommended input conduc­tors and line fuse sizes.

B. Remove the top cover. Identify primary power connections, TB3, and the ground lug located on the A-Frame bracket.

Refer to figure 3.1.

Table 3-1. Recommended Sizes for Input

Conductors and Line Fuses

Rated Input

@ 100% Duty Cycle

Volts Amps

220
230
400
460
575

* Sized per National Code for 80 °C rated copper conductors @ 30° C ambient. Not more than three conductors in raceway or cable. Local

codes should be followed if they specify sizes other than those listed

68
66
37
33
26

Input & GND

Conductor *

CU / AWG

No. 6
No. 6
No. 8
No. 8

No. 10

Fuse

Size

Amps

100
100

60
60
50

22

SECTION 3 INSTALLATION

THE CHASSIS MUST BE CONNECTED TO AN APPROVED ELECTRICAL

WARNING

GROUND. FAILURE TO DO SO MAY RESULT IN ELECTRICAL SHOCK,
SEVERE BURNS OR DEATH.

C. Thread the properly stripped input and ground conduc-

tors through the large strain relief in the rear panel of the
power source. Connect the three input conductors to the
three input terminals on TB3 (see figure 2-1). To connect
the ground conductor, thread the ground wire through the
ground fault switch bracket and connect to the ground lug
provided on the A-Frame.

D. Check all connections for proper tightness. Ensure all con-

nections are correct and well-insulated.

TB-3
L1, L2, L3
Connection

Primary Cable

(Supplied by
Customer)

Recommended Cable Strip Lengths

Ground Fault
Switch & Bracket

Ground
Connection

Figure 3-1. Connecting Primary Power Leads

23

SECTION 3 INSTALLATION

E. Figures 3-2, 3-3 & 3-4 illustrate 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 reconfiguring the copper link bars to the voltage designa­tions for the desired voltage.

230 Vac Input 460 Vac Input 575 Vac Input

Figure 3-2. Input Terminal Board Configuration for 230/460/575 Model

(factory supplied in the 575 configuration)

230 Vac Input

460 Vac Input

Figure 3-3. Input Terminal Board Configura­tion 230/460 Model (factory supplied in the

460 configuration)

*

*

220 Vac Input

Figure 3-4. Input Terminal Board Configura­tion 220/400 Model (factory supplied in the

400 configuration)

24

400 Vac Input

*

SECTION 3 INSTALLATION

3.4 OUTPUT WELDING CONNECTIONS (SECONDARY)

BEFORE MAKING ANY CONNECTIONS TO THE POWER SOURCE OUT

WARNING

The output connections are located on the front panel (Figure 3-5). The negative connection is located at the bottom right
corner and the positive (high inductance and low inductance) connections are located at the bottom left corner. Table 3-2
provides the recommended cable output sizes.

PUT TERMINALS, MAKE SURE THAT ALL PRIMARY INPUT POWER TO
THE MACHINE IS OFF.

Table 3-2. Output Cable Sizes (Secondary)

Welding

Current

50 100 150 20 250

Total Length (Feet) of Cable in Weld Circuit*

100 6 4 3 2 1/0
150 4 3 1 1/0 2/0
200
250
300

3 1 1/0 2/0 3/0
2 1/0 2/0 3/0 4/0

1 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 power source.

3.5 CONTROL CONNECTIONS

The wire feeder receptacle and 115 VAC Auxiliary control are mounted on a removable plate. This plate may be exchanged
for different applications.

Optional Available Plates:

• Blank (P/N 37902M)

• Terminal Block for Lincoln - 24vac & 115vac feeders - (P/N 0558001416)

• Miller 14 pin Receptacle for 24vac feeders only - (P/N 0558001415)

Refer to Figure 3-5.

25

SECTION 3 INSTALLATION

3.5.1 Wire Feeder Control

The Wire feeder control cable connection is provided by a 19-pin receptacle (J1) located on the left-hand side of the power
source front panel. This receptacle will operate all ESAB wire feeders with 19 pin control cables including the Mig 2E, Mig
4HD, Mig 4HD Dual, Mig 5XL, Mig 28A, Mig 35, Digimig, Digimig Dual as well as the UEC-8, Digimatic II and Analog Interface
mechanized controls.

3.5.2 Remote Control (Optional)

This function is provided by an optional 14-pin receptacle (J2) located on the front panel directly below connector J1. It
receives a mating plug from a Hand Control Assembly (optional). This receptacle is operative only if the panel remote switch
on the power source front panel is in the "Remote" position.

3.5.3 Auxiliary 115 V AC Receptacle

A 115 Vac receptacle is provided to supply power to accessories such as a water cooler, heated CO2 regulator, or small hand
tools. The receptacle is rated 115 Vac / 10 amps.

3.5.4 42V Circuit Breaker (CB1)

The 42V resettable circuit breaker (CB1) protects the 42 volt wire feeder/control circuitry against over current. (Table 6-2
provides troubleshooting information).

3.5.5 115V Circuit Breaker (CB2)

The 115V resettable circuit breaker (CB2) protects the 115 volt auxiliary receptacle and wire feeder/control circuitry against
over current. (Table 6-2 provides troubleshooting information).

3.5.6 External Grounding Conductor Protection

This feature will de-energize the power source output if current flow is detected in the external ground conductor. When this
happens, the Fault light on the front control panel will illuminate. It will remain lit until the fault is corrected or the power
source power switch (S1) is turned off.

26

SECTION 3 INSTALLATION

653cvcc

4.1.1

POWER "ON-OFF"

SWITCH

3.5.4
CB1

3.5.1

WIRE FEEDER

CONTROL

RECEPTACLE

REMOVABLE

PANEL

3.5.3

115V ac

AUXILIARY

RECEPTACLE

3.5.5
CB2

3.4, 4.1.7

High Inductance for

STICK WELDING (SMAW)

SUBMERGED ARC WELDING (SAW)

ARC CUTTING/GOUGING (CAC-A)

MIG WELDING (GMAW) optional

Positive Output

Receptacle

Figure 3-5. Connection Diagram

3.4

Negative

Output

Receptacle

3.4, 4.1.7

Low Inductance for

MIG WELDING (GMAW)

FLUX CORED WELDING (FCAW)

ARC GOUGING (CAC-A) optional

PosItive Output

Receptacle

27

SECTION 3 INSTALLATION

28

SECTION 4 OPERATION

Never operate the power source with the cover removed. In addition
to the safety hazards, improper cooling may cause damage to the

CAUTION

4.1 CONTROLS (See Figure 4-1)

4.1.1 Power Switch (ON-OFF)/(I-O)

The power switch is located on the front panel of the power source. In the "off" ("O") position, the unit is shut down; however,
power is still present in the unit. To fully 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.

4.1.1.1 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.

components. Keep side panels closed when unit is energized. Weld­ing helmet, gloves, and other personal protection should always be
worn when welding.

4.1.1.2 Fault Indicator

This red light will indicate that current was flowing through the external ground conductor. It will also illuminate if a short
occurs (momentary or permanent) between the +12 volt J1-E; the +10 volt (J2-E) and either the chassis ground or the nega­tive terminal of the power source. The power source output terminals are de-energized and the fault must be corrected
before resuming operation.

4.1.2 Output Panel/Remote Switch

With this switch in the “Panel” position, output voltage is controlled by adjusting the voltage potentiometer on the front
panel to the desired output. In the “Remote” position, output is controlled using an optional remote voltage control via
receptacle J2.

4.1.5

4.1.1.1

4.1.9

4.1.4

4.1.1.2

4.1.8

4.1.3

4.1.2

Figure 4-1. Control Locations

29

SECTION 4 OPERATION

4.1.3 Output Voltage/Current Control

This control allows the operator to adjust the output voltage in the CV mode and output current in the CC mode. Placing
the Panel/Remote switch in the “Remote” position disables the output control on the front panel. Calibration marks are to
provide a rough guide in setting voltage and current.

4.1.4 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.

4.1.5 Voltmeter and Ammeter

A digital voltmeter and ammeter provides an accurate indication of dc output voltage and current.

4.1.6 Over Current Protection

The 653cvcc incorporates automatic over current protection. If an over current condition occurs, the automatic circuitry will
“fold back” the output current to a level that will prevent damage to the power source. The power source will remain in this
low current “fold back” mode until the arc is broken, the torch trigger is released or the contactor switch is reset.

4.1.7 High & Low Inductance Receptacles

The 653cvcc provides high and low inductance output connections (see figure 3-5). Both are positive output terminals. The
high inductance terminal slows the power source dynamic response. This means the output current will build at a slower
rate compared to the low inductance terminals. The welding process and application will determine which terminal should
be used. The chart below provides suggested terminal connections.

Process Switch CC CV
Inductance High Low High Low
Mig Solid Wire (GMAW) X X

Flux Cored (FCAW) X X
Sub Arc (SAW) X X 2 X
Arc Gouging (CAC-A) X X 3 X

1. Small diameter wires (<1/16-inch) with argon mixtures.

2. <3/32-inch diameter wires.

3. Fast dynamic response (optional setting only).

1

X

4.1.8 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 Mig wire feeder or mechanized sub arc control.

4.1.9 Process Switch (CC-CV)

The process switch allows for selection of the output characteristics of the power source depending on the welding process
being used. The CV position produces a “Flat” volt-amp characteristic and is mostly used for the Mig (GMAW) and Submerged
Arc (SAW) welding processes and occasionally with Air Carbon Arc Cutting (CAC-A). The CC position produces a “Drooping”
characteristic most popular for Stick (SMAW), CAC-A and sometimes SAW.

30

SECTION 4 OPERATION

4.2 SEQUENCE OF OPERATION

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.

ELECTRIC SHOCK CAN KILL! "MACHINERY LOCKOUT PROCEDURES"
SHOULD BE EMPLOYED. IF IT IS NOT POSSIBLE TO USE PADLOCKS,

WARNING

4.2.1 General Procedures for the CV-MIG (GMAW), SUB ARC (SAW) and CC-STICK (SMAW), SUB
ARC (SAW) Processes

A. Make the secondary output connections to the positive and negative output receptacles. See paragraph 3.4 and

figure 3-5.

B. Make the control connections. Refer to the appropriate wire feeder, mechanized control, and/or torch instruction

booklets for additional process requirements or control connections.

ATTACH A RED TAG TO THE LINE DISCONNECT SWITCH OR FUSE BOX
WARNING OTHERS THAT THE CIRCUIT IS BEING WORKED ON.

C. If primary input connections have been made to the power switch, and on the input terminal board to match the

incoming voltage, close the main wall disconnect switch or reinstall fuses in the fuse box.

4.2.2 Specific Procedures for the CV-MIG (GMAW) and SUB ARC (SAW) Processes

A. Set the Output Panel/Remote switch to the desired setting.

B. Set the Process switch to the CV position.

C. Set the contactor switch to "Remote".

ELECTRIC SHOCK CAN KILL! WHEN THE CONTACTOR SWITCH IS IN
THE "ON" POSITION, OUTPUT POWER WILL BE PRESENT THROUGH

WARNING

OUT THE WELDING CIRCUIT; ie. CABLES, WIRE FEEDER, WIRE SPOOL,
DRIVE STAND, GUN, AND ELECTRODE. BE SURE ALL ARE CLEAR OF
THE WORKPIECE OR ARCING WILL RESULT.

D. Set the power switch on the rear panel to the "on" ("I") position. The fan will run for 30 seconds and stop automati

cally if welding current does not exceed 100 amps. The fan will automatically turn off after 6 minutes when the
contactor is "off" and the welding current is below 100 amps.

-

E. To preset the approximate welding voltage, place the Contactor switch to the "on" position. This will energize the

power source output, allowing the voltage to be preset using the Output Voltage/Current Control dial and observ­ing the voltmeter.

31

SECTION 4 OPERATION

F. After setting the desired voltage condition, turn the contactor switch back to the “remote” position. This position

requires a remote start control in order to start the welding sequence.

NOTE:

A PCB and resistor pack discharges capacitor voltage to eliminate the electrode "sparking" or "arcing"

potential.

G. Begin welding. Observe the voltmeter, ammeter, and the weld. Readjust the voltage and wire feed speed settings

as necessary to obtain a satisfactory weld.

H. When welding is completed, release torch switch. (This action will de-energize the power source solid state contactor

and remove dc power from the output terminals.)

4.2.3 Specific Procedures for the CC-Stick Welding (SMAW) and Arc Gouging (CAC-A) Processes

A. Place the Output Panel/Remote switch into PANEL position if output current is regulated from the Output Voltage/

Current dial on the panel, or in REMOTE position if output current is regulated from the optional Hand Control.

B. Set the Output Voltage/Current Control to provide the approximate desired welding current using the control knob

as the reference. Example - set knob to “5” for approximately 450 amps output.

C. Set the Contactor switch to the ON position -- this will energize the solid-state contactor and all associated circuitry

up to the output terminals.

D. Place the Process Control switch in the CC position.

E. Commence welding by touch or scratch starting the electrode.

32

SECTION 5 MAINTENANCE

5.1 General

If this power source does not operate properly, stop work immedi­ately and investigate the cause of the malfunction. Maintenance

CAUTION

WARNING

5.2 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, dry low pressure air. The frequency of cleaning required depends upon the environment
in which the power source is used.

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.

BE SURE THAT THE BRANCH CIRCUIT OR MAIN DISCONNECT SWITCH
IS OFF, OR ELECTRICAL INPUT FUSES ARE REMOVED, BEFORE AT
TEMPTING ANY INSPECTION OR WORK INSIDE THE POWER SOURCE.
PLACING THE POWER SWITCH IN THE OFF POSITION DOES NOT RE
MOVE ALL POWER FROM INSIDE THE POWER SOURCE.



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.

FAILURE TO REPLACE WORN OR DAMAGED CABLES MAY RESULT IN
A BARE CABLE TOUCHING A GROUNDED OBJECT. THE RESULTING

WARNING

ELECTRICAL ARC MAY INJURE UNPROTECTED EYES AND WILL PRES
ENT A SERIOUS FIRE HAZARD. BODY CONTACT WITH A BARE CABLE,
CONNECTOR, OR CONDUCTOR MAY RESULT IN SEVERE ELECTRICAL
SHOCK, CAUSING SERIOUS BURNS OR DEATH.



33

SECTION 5 MAINTENANCE

5.3 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.

5.3.1 Fan Motor

Keep the fan motor free of accumulated dust and lint.

5.3.2 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.

5.3.3 Wire Feeder and Control Circuits

These circuits are protected by two 10 amp circuit breakers mounted in the front panel. If these open, the contactor and
wire feeder will not operate.

5.3.4 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 de-energized, the contactor and wire feeder cannot be operated.

5.3.5 Digital Voltmeter/Ammeter Calibration

To verify the accuracy of the digital volt/ammeter combination, the following calibration 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. Place the Contactor switch in the On position.

4. With the primary input power on, turn the Voltage control knob until you get 25V on the DC voltmeter. Compare the
reading with the reading on the digital voltmeter on the front panel.

5. If there is a difference in the voltage readings, open front control panel by removing the two mounting screws from
the upper corners, 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 and front control panel.

34

SECTION 6 TROUBLESHOOTING

6.1 General

DISCONNECT PRIMARY POWER AT WALL SWITCH, OR CIRCUIT

WARNING

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 6-2.) 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.

6.2 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.

A. Testing SCRs.

BREAKER, BEFORE ATTEMPTING INSPECTION OR WORK INSIDE THE
POWER SOURCE.

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 20
meg ohms.

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. Remove the jumper from the gate. The meter reading should increase (30-50 ohms).

IMPORTANT

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:

35

SECTION 6 TROUBLESHOOTING

ELECTRICAL SERVICE AND REPAIR SHOULD BE ATTEMPTED ONLY BY

WARNING

1. Tighten the bolts evenly until finger tight noting that the nuts are not rotating.

2. 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.

A TRAINED ELECTRICIAN.

Table 6-1. PCB Voltage Tests*

FROM TO READING

P8-5 OTB+ +10 V dc
P8-7 OTB+ 0-10 V dc**

P6-6 (SCR1)
P6-5 (SCR2)
P6-4 (SCR3)
P6-3 (SCR4)
P6-2 (SCR5)
P6-1 (SCR6)

* Refer to Schematic Diagram
** Varies with VCP (R1)

OTB+ .3 V dc with

contactor on

NOTE:

All voltage readings are taken with the front access panel open and the power switch "ON".

36

SECTION 6 TROUBLESHOOTING

Table 6-2. Troubleshooting Guide

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 — replace.
D. Thermal light on. Main transformer overheating. Also check for proper cooling,

proper primary hookup, or shorted turn on secondary.
E. Thermal light on. Fan motor not operating — check motor and leads.
F. External Ground Conductor 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 not lit. If lit, find & replace

defective fuse.

No Output — Fan Running A. Poor or improper electrical input — check input connections on TB.
B. Poor connections at output terminals/work station — check, tighten or replace.
C. Main transformer overheating — thermal switches tripped due to restricted cool

ing air. Temperature light on front panel will be lit. Let unit cool down.
D. PC board defective or loose PC board connector(s) — if loose, reinsert; if defective,

replace.

-

Limited Output or
Low Open-Circuit Voltage A. Input voltage jumper links on terminal board improperly set — check for proper

voltage.
B. Poor output connections. Take apart, clean, and tighten securely.
C. Panel-Remote switch in Remote position and remote voltage pot disabled.
D. Over current condition had occurred. Unit is in “fold back” mode. See Section

4.1.6.

Erratic Weld Current A. Welding cable size too small — use correct cables.
B. Loose welding cable connection (will usually get hot) — tighten connections.
C. Improper wire feeder setup.
D. Defective SCR in bridge rectifier.
E. PC board defective — replace.

High Output, No Voltage Control A. PC board defective or loose — reset and/or replace board.

No 115 Volt ac Output A. Circuit breaker tripped. Check 115V CB2 — Reset.

Line Fuse Blows When Power
Source is First Turned On A. Shorted SCR in Main Bridge — replace.
B. Shorted capacitor in Capacitor Bank.

Wire Feeder is Inoperative A. Loose feeder control cable — Check and tighten all connections.
B. A Circuit Breaker tripped — Check 42V CB1 and 115V CB2 — Reset.

37

SECTION 6 TROUBLESHOOTING

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38

SECTION 7 REPLACEMENT PARTS

7.0 Replacement Parts

7.1 General

Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on
the unit nameplate.

7.2 Ordering

To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this
equipment. The use of non-ESAB parts may void your warranty.

Replacement parts may be ordered from your ESAB Distributor.

Be sure to indicate any special shipping instructions when ordering replacement parts.

Refer to the Communications Guide located on the back page of this manual for a list of customer service phone
numbers.

Note

Bill of material items that have blank part numbers are provided for customer information only.

Hardware items should be available through local sources.

39

SECTION 7 REPLACEMENT PARTS

195

653cvcc Front Panel View

40

SECTION 7 REPLACEMENT PARTS

653cvcc Front Isometric View

41

SECTION 7 REPLACEMENT PARTS

653cvcc Internal View

42

SECTION 7 REPLACEMENT PARTS

653cvcc Rear Isometric View

43

SECTION 7 REPLACEMENT PARTS

653cvcc Internal View

44

SECTION 7 REPLACEMENT PARTS

653cvcc Top Internal View

45

SECTION 7 REPLACEMENT PARTS

Bill of Materials

653cvcc 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 36121 1 PCB DIGITAL METER PCB2
4 36173 1 BLADE FAN 14"
5 38130 1 PCB CONTROL PCB1
6 634515 3 SW TGGL SPDT 2 POS 15A 125V S2,3,4
7 672065 6 STRAP TERMINAL, VOLTAGE CHANGELINE
8 678025 3 TERM AY OUTPUT
9 950122 2 CKT BREAKER 10A 32VDC 250VAC CB1,2
10 950219 1 RELIEF STRAIN 2.00
11 950711 3 SW THERMAL 194FT S2,3,4
12 950768 2 DIODE FWD 300V 300A D1,2
13 950945 1 SW PWR DISC 100A 600V S1
14 951474 3 SW SEAL BLACK
15 954008 1 LABEL DANGER HIGH VOLTAGE
16 2062334 1 MOTOR FAN 1/3 HP 1625RPM M1
17 0558001024 3 SCR ASSY
18 34149 1 CLIP ANNEALED
20 36110 1 BOARD INPUT TERMINAL 230/460V/575
21 36092 1 CABLE DIGITAL METER PCB P10
23 37861M 1 BASE
24 37862M 1 PANEL FRONT BOTTOM
25 0558001369 1 PANEL RIGHT SIDE ENV
26 0558001370 1 PANEL LEFT SIDE ENV
27 0558001378 1 CONTROL PANEL BLACK
28 37867M 1 PANEL REAR
30 37869 1 HIGH TAP INDUCTOR BUSBAR
31 37870 1 LOW TAP INDUCTOR BUSBAR
32 37871 1 SHUNT
33 37872 2 INSULATOR KYDEX
34 37890 1 XFMR MAIN 230/460/575V T1
35 0558006887 1 INDUCTOR L1
36 37907 1 SCHEMATIC DIAG 653 CVCC
37 37908 1 WIRING DIAG SEC 653 CVCC
38 0558001044 1 WIRING DIAG PRI 3 PH AFRAME
43 647361 1 TERMINAL LUG
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 PLUG HOUSING 15 POS J5
48 0558001013 1 CAP HOUSING 2 POSITION
49 952067 1 CONNECTOR 20 AWG 3 PIN P1
50 952068 1 MTA‑156 COVER 3 PIN
51 952070 1 CONNECTOR 20 AWG 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
57 952209 1 PANEL RECEPTACLE 19 PIN F J1

46

SECTION 7 REPLACEMENT PARTS

Bill of Materials

653cvcc DC Welding Power Source (Cont'd)

ITEM PART OR
NO. CODE NO. QTY. DESCRIPTION SYMBOL

58 952219 1 OUTLET 110V SQUARE J3
61 954425 1 LABEL LR-30071 CSA NRTL/C
62 954506 1 LABEL ISO 9002
63 954868 1 OVERLAY 653 CVCC BLK
64 954846 1 LABEL RATING 653 CVCC 230/460/575
65 954830 1 LABEL SCHEMATIC 653

66 2091514 1 LABEL WARNING WELD AND CUT
67 2091558 1 LABEL GND BILK .50 X 1.38
69 13730632 1 POT LIN 10K 2W .88L
71 13731781 1 MTA-156 COVER 10 PIN
72 13732431 3 MTA-156 COVER 12 PIN
73 13732733 1 LABEL FOR INSTALL USSE COP WIRE
74 13734588 1 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 17300016 1 RES RW FIXD ST 300W 10% 16.00
79 22993477 1 RUBBER .188 X .500
133 99512240 1 LABEL CAUTION LIFT EYE
134 99512558 1 BRACKET RESISTOR #18
135 0558001010 1 TERMINAL BLOCK 3 POS TB3
136 0558001033 1 BOX PCB BLACK
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 0558001032M 1 PANEL FRONT TOP
147 36043GY 1 BRACKET FAN
148 36048M 4 LEG AFRAME
149 36049M 1 BAIL LIFTING
152 37902M 1 BLANKING PLATE
153 37901M 1 19 AND 110V PANEL
154 0558001371 1 PANEL TOP ENV
155 37899 1 LOWER BAFFLE
156 13792157 LAMP WHITE 48V PL1
157 951754 1 LAMP LED YEL 12V PL2
158 952610 1 LAMP LED RED 12V PL3
161 38100 1 CE FILTER ASSY FN1
162 954565 1 LABEL CE
163 952223 3 STAND OFF 1/4-20 X .75
164 0558001337 HINGE ACCESS
166 954864 1 LABEL THREE PHASE
171 0558001407 2 SEAL WIRE 15 POS
172 0558001408 1 SEAL INTER 15 POS
173 0558001406 1 SEAL WIRE 9 POS
181 952938 1 RELAY SOLID STATE 660V 10

47

SECTION 7 REPLACEMENT PARTS

Bill of Materials

653cvcc DC Welding Power Source (Cont'd)

ITEM PART OR
NO. CODE NO. QTY. DESCRIPTION SYMBOL

182 0558003579 1 BRACKET MOUNTING
185 950466 1 CAP HOUSING 15 POS
186 2062348 1 PLUG HOUSING 9 POS
187 0558001409 1 CONNECTION INTERFACE SEAL 9
188 950125 1 CONTACT PIN
189 952609 1 CONN RECEPT 16 PIN TAFA P10
193 0558002417 1 BRACKET - GROUND FAULT
194 13730222 2 BUSHING - GROUND FAULT
195 0558005656 1 CAP METAL PROTECTION

48

SECTION 7 REPLACEMENT PARTS

49

NOTES

50

REVISION HISTORY

The "A" edition of this booklet includes a rewrite of the primary electrical connection.

The "B" edition of this booklet includes:

• Schematic and Wiring Diagrams

• Additional replacement parts

The "C" edition updated part numbers, edited graphics on pages 10 and 12 and removed references to 353cvcc Parts.

The "D" edition updated complete parts list.

The "E" edition covers the reinstallation of a Ground Fault Switch and Bracket and Ground Connection.

The "F" edition of this manual provides modifications requiring an updated display PCB, timer module, an additional PCB,
mounting brackets, resistor pack and associated wiring mounted to the "A" frame support near the output rectifier bridge.
These modifications are for a "fan on demand" feature. These modifications will affect serial no.'s M0RI603036 and above.
Replacement Parts listings have also been updated.See dneco# 023279 & service bulletin 03_01_001.

The "G" edition of this manual updated Section 2, Front Panel showing control locations. Section 3.1 has been reconfigured
to resemble the 353 & 453 manuals. Minor editorial changes have also been made. Front cover picture also updated.

The “H” revision updates the format and front cover picture (no records of the “G” revision being released, “E” revision was
currently on the web & “G” was in the folder but apparently never released). Added p/n 0558005656, item 195, metal cap
protection and illustration to replacement parts.

The “H” revision of 02/2006 made editorial change to reference Lincoln & Miller feeders in section 3.5.

51

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS:
Telephone: [phone] / Fax: [phone] Hours: 8:00 AM to 7:00 PM EST
Order Entry Product Availability Pricing Order Information Returns

B. ENGINEERING SERVICE:
Telephone: [phone] / Fax : [phone] Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting

C. TECHNICAL SERVICE:
Telephone: (800) ESAB-123/ Fax: [phone] Hours: 8:00 AM to 5:00 PM EST
Part Numbers Technical Applications Specifications Equipment Recommendations

D. LITERATURE REQUESTS:
Telephone: [phone] / Fax: [phone] Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS:
Telephone: [phone] / Fax: [phone] Hours: 7:30 AM to 3:30 PM EST
Repair Estimates Repair Status

F. WELDING EQUIPMENT TRAINING
Telephone: [phone] / Fax: [phone] Hours: 7:30 AM to 4:00 PM EST
Training School Information and Registrations

G. WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES:
Telephone : [phone] Hours: 7:30 AM to 5:00 PM EST

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123

Fax: [phone]

Hours: 7:30 AM to 5:00 PM EST

or

visit us on the web at http://www.esabna.com

The ESAB web site offers

Comprehensive Product Information

Material Safety Data Sheets

Warranty Registration

Instruction Literature Download Library

Distributor Locator

Global Company Information

Press Releases

Customer Feedback & Support

F15-572-H 02/2006