INSTRUCTION MANUAL
Digipulse 450i
Power Source
F-15-014-F
June, 2003
This manual provides installation and operation instructions for the following Digipulse 450i cutting package:
ESAB P/N 31120 - 208/230/460 V ac, 1 or 3 phase
ESAB P/N 31238 - 575 V ac, 3 phase, 60 Hz (refer to supplement F-15-015)
ESAB P/N 31690 - 220/380/415 V ac, 3 phase, 50 Hz (refer to supplement F-15-039)
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and
safe practices for electric 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.
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. Defective 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 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.
TABLE OF CONTENTS
SECTION TITLE PAGE
PARAGRAPH
SECTION 1 DESCRIPTION ................................................................................................. 5
1.1 Introduction ....................................................................................................... 5
1.2 Specifications.................................................................................................... 5
SECTION 2 INSTALLATION................................................................................................ 6
2.1 General ............................................................................................................. 6
2.2 Unpacking and Placement ................................................................................ 6
2.3 Primary (Input) Connections.............................................................................. 6
2.4 Secondary (Output) Welding Connections ........................................................ 7
2.5 Control Interconnection ..................................................................................... 9
2.6 Optional Accessories ........................................................................................ 9
SECTION 3 OPERATION..................................................................................................... 11
3.1 Introduction ....................................................................................................... 11
3.2 Duty Cycle......................................................................................................... 11
3.3 Power Source Welding Controls ....................................................................... 11
3.4 Sequence of Operation ..................................................................................... 12
SECTION 4 MAINTENANCE ............................................................................................... 13
4.1 General ............................................................................................................. 13
4.2 Cleaning ............................................................................................................ 13
4.3 Lubrication ........................................................................................................ 13
SECTION 5 TROUBLESHOOTING ..................................................................................... 14
5.1 Troubleshooting ................................................................................................ 14
5.2 Calibration Procedure ....................................................................................... 20
SECTION 6 REPLACEMENT PARTS ................................................................................. 25
6.1 General ............................................................................................................. 25
6.2 Ordering ............................................................................................................ 25
2
SAFETY PRECAUTIONS
WARNING: These Safety Precautions are for
your protection. They summarize precautionary
information from the references listed in Addi-
tional 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:
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 con-
fined, 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:
away from the work area or cover the materials with a
1.Remove all combustible materials well
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.
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.
3
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.
4
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 incandescent
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 combustibles
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 incandescent
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 tension
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 assu-rer
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
5
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. Arrêtez-vous de travailler
afin de prendre les mesures néces- saires 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’élimi-ner
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 suivantes, 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.
6
SECTION 1
DESCRIPTION
1.1 INTRODUCTION
The Digpulse 450i is a CV/CC inverter-type power
source specifically designed and dedicated for use with
a Digipulse wire feeder or Digipulse mechanized/robotic
control. When combined, these components work together to provide a pulsed MIG system that self-adjusts
while welding to give optimum arc performance. The
Digipulse system is also designed to provide non-pulsed
digital logic needed for convenient MIG short and spray
arc welding applications.
When operated in its Constant Current (CC) setting, the
Power Source can be used for a wide range of dc Stick,
scratch-start TIG, and air-carbon arc gouging applications.
1.2 SPECIFICATIONS
Rated Output @:
....60% Duty .......................... 450 amps @ 38 V dc
....100% Duty ......................... 350 amps @ 34 V dc
Open Circuit Voltage (Max.) ......................... 72 V dc
Input Voltage ................... 230/460 V ac, 3 ph. 60 Hz
Input Current @ Rated Load ... 80 amps @ 230 V ac
................................................................................
............................................... 40 amps @ 460 V ac
Dimensions
................. 15.25" (387 mm) w x 23.0" (584 mm) d x
...................................................... 15.5" (394 mm)h
Weight .............................................. 166 lbs (70 kg)
Figure 1-1. MIG Mode - VA Curves
Figure 1-2. Duty Cycle Rating Chart
7
SECTION 2
INSTALLATION
2.1 GENERAL
Proper installation will contribute to safe, satisfactory, and trouble-free operation of the welding setup.
It is suggested that each step in this section be
studied carefully and followed as closely as possible.
2.2 UNPACKING AND PLACEMENT
A. Immediately upon receipt of the equipment,
inspect for damage which may have occurred
in transit. Notify the carrier of any defects or
damage at once.
B. After removing the components from the ship-
ping container(s), check the containers for any
loose parts. Remove all packing materials.
C. Check air passages of Power Source for any
packing materials that may obstruct air flow
through the Power Source.
D. If the equipment is not to be installed immedi-
ately, store it in a clean, dry, well-ventilated
area.
chance of nuisance (fault) tripping or damage due to
transients caused by other equipment loads such as
resistance welders, punch presses, large electric
motors, etc.
If nuisance tripping caused by transients becomes a
problem, ESAB has a "primary line conditioner" (P/
N 31102) which may be added to filter out transient
voltages . Contact your distributor for details.
Please note that the conditioner will not correct for
sustained line voltages which exceed the limits of
its rated voltage inputs.
The Power Source is designed to provide line
voltage compensation within 10 percent of the rated
230/460 volt input to maintain its rated output and
protect its power electronics. If these limits are
exceeded, serious damage to the unit could occur.
Therefore, prior to installation, it is suggested that
the proposed line circuit be checked (with a meter)
at two or three different time periods of the day to
make sure the power load does not exceed the
Power Source's input limits. If input power cannot
be maintained within the 10 percent limits, consult
your local power company or call ESAB for possible solutions.
E. The location of the welding equipment should be
carefully selected to ensure satisfactory and
dependable service. Choose a location relatively close to a properly fused supply of electrical power.
F. The Power Source components are maintained
at proper operating temperatures by forced air
drawn through the cabinet by the fan unit on the
rear panel. For this reason, it is important the
machine be located in an open area where air
can circulate freely at the front and rear openings. If space is at a premium, leave at least 1
foot of clearance between the rear of the Power
Source and wall or other obstruction. The area
around the unit should be relatively free of dust,
fumes, and excessive heat. It is also desirable
to locate the unit so the cover can be removed
easily for cleaning and maintenance.
2.3 PRIMARY (INPUT) CONNECTIONS
The Digipulse 450i Power Source is a 3-phase unit
and must be connected to a "clean-unloaded" 3phase supply power line. An unloaded line is
essential for good performance and lessens the
ELECTRIC SHOCK CAN KILL! PRECAUTIONARY MEASURES SHOULD BE TAKEN TO PROVIDE MAXIMUM PROTECTION AGAINST ELECTRICAL SHOCK. BE SURE THAT ALL POWER IS
OFF BY OPENING THE LINE (WALL) DISCONNECT SWITCH WHEN PRIMARY ELECTRICAL
CONNECTIONS ARE MADE TO THE POWER
SOURCE. TO BE DOUBLY SAFE, CHECK YOUR
INPUT LEADS WITH A VOLTMETER TO MAKE
SURE THAT ALL POWER IS OFF.
A. A line (wall) disconnect switch, with fuses or
circuit breakers, should be provided at the main
power panel (see Figure 2-2). The customer
can either use the factory-supplied input power
cable (No. 6 AWG, 4/c, type SO (90 °C), 12-ft
lg) or provide his own input power leads. The
primary power leads should be insulated copper
conductors and include a 3-phase power lead
with one ground wire. The wires may be heavy
rubber covered cable or run in a solid or flexible
conduit. Refer to Table 2-1 for recommended
input conductors and line fuse sizes.
8
SECTION 2
Table 2-1. Recommended Sizes for
Input Conductors and Line Fuses
INSTALLATION
Rated Load
Volts Amps
230
460
*Sizes per National Electric Code for 90°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 above.
B. As shipped, the Power Source is set up for 460
volt input power. If using a 230 volt input, two
links on the input terminal board (located inside
the unit) must be repositioned as marked on the
plate (see Figure 2-1). The input terminal board
connections will be visible after removing the top
cover.
C. The factory-supplied input power cable is con-
nected to the Power Source ON-OFF switch.
However, if the customer wishes to connect his
own input power leads, proceed as follows:
With the top cover and left side panel removed,
thread the input conductor cable from the wall
disconnect switch through the strain relief hole
in the rear panel. Connect the primary leads to
the Line Switch (LS) for either single- or 3phase input and the ground lead (green) to the
stud on the base of the unit as shown in Figure
2-2. After making sure the connections are
secured, tighten the strain relief coupling to
secure the input cable.
IT IS OF THE UTMOST IMPORTANCE THAT
THE CHASSIS BE CONNECTED TO AN APPROVED ELECTRICAL GROUND TO PREVENT
ACCIDENTAL SHOCK. TAKE CARE NOT TO
CONNECT THE GROUND WIRE TO ANY OF
THE PRIMARY LEADS.
80
40
Input &
Gnd.
Conductor*
CU/AWG
6
8
Time-Delay
Fuse Size
Amps
100
50
Figure 2-1. Input Voltage Terminal Board
(TB) Connections
D. Recheck all connections to make sure they are
tight, well insulated, and properly connected.
2.4 SECONDARY (OUTPUT) WELDING
CONNECTIONS
BEFORE MAKING ANY CONNECTIONS TO THE
POWER SOURCE OUTPUT TERMINALS, MAKE
SURE THAT ALL PRIMARY INPUT POWER TO
THE UNIT IS DEENERGIZED (OFF) AT THE
CUSTOMER'S DISCONNECT SWITCH.
A. Digipulse MIG Setup (see Figure 2-2). This
Power Source is designed to provide MIG
welding operating characteristics only when the
J2 control receptacle is "vacant" (meaning no
accessories are plugged in) or, if the remote
HC-3B Hand Control (P/N 33838) is plugged in.
The Process Switch must be set in the DigitalMIG (center) position for Digipulse controls.
Additionally, proper operation of the Power
Source depends on the use of copper output
cables that are insulated, of adequate size, in
good condition, and properly connected to the
machine using the jack plug connectors provided with the Power Source. It is recommended
only 4/0 welding output cable be used regardless of length and current to be used, and that
these cables be kept as short as possible (Total
length including work and electrode leads should
not exceed 100 feet. Beyond this distance,
there will be performance deterioration. Consult
with the factory if you have an application of this
nature.)
Particular attention should be paid to high
resistance in the welding circuit; specifically,
the work cable/circuit and water-cooled torch
cable. It is recommended that the Power
9
SECTION 2
INSTALLATION
Source/Wire Feeder and workpiece be placed
as close together as possible to limit resistance
in the welding circuit. High resistance in the
welding circuit can cause performance deterioration (loss of "heat" input, popping of weld
puddle, bushy arcs, etc.). Ensure the work
cable is large enough (refer to Table 2-2), kept
as short as possible, properly insulated, securely connected to the workpiece, and that all
connections are clean and tightly secured. If a
separate work circuit is used (such as in
mechanical fixturing, shipbuilding, robot
fixturing, etc.), make sure the work circuit is
secure and presents a low resistance path to the
flow of welding current. Also, the power cable
on a water-cooled torch is normally subject to
gradual deterioration and increased resistance
due to corrosion. This leads to poor performance as described above. To assure good
torch performance, the water-cooled power
cable should be replaced periodically.
The welding output receptacles are located on
the front panel; one negative (-) and one positive
(+) receptacle. Two male plug connectors (P/
N 950693) are supplied with the Power Source
for attachment to customer supplied 4/0 welding
cables (see Figure 2-2). This Power Source is
designed for conventional and pulsed MIG
spray arc applications using Direct Current
Reverse Polarity (DCRP) setup. In a DCRP
setup, the torch or electrode is positive (+), and
the workpiece is negative (-).
B. Stick/Scratch-Start TIG/ Arc Gouging Setup
(see Figure 2-3). These processes require
Figure 2-2. MIG Interconnection Diagram
10
SECTION 2
constant current (CC) type curve characteristics for proper operation. These characteristics
are only provided when one of the remote
accessories (FC-5, TC-2) is plugged into the J2
receptacle or when the remote HC-3 Hand
Control is connected to J2 and its Process
Switch is set in the CC-TIG/Stick position.
Select the desired welding mode, accessories,
and polarity as shown in figure 2-3. The output
cables can be connected for DCRP or DCSP :
meaning that for a DCRP setup, the electrode
holder/torch is POS (+) and the work is NEG (); whereas for a DCSP setup, the electrode
holder/torch is NEG (-) and the work is POS (+).
regardless of your secondary welding cable setup
(dcrp or dcsp), in order to prevent electrical shock,
it is necessary that you connect the workpiece to an
approved electrical (earth) ground. The work cable
lead is not a ground lead. it is used to complete the
welding circuit between the Power Source and the
workpiece. this connection (at the workpiece) must
be made to a clean, exposed metal surface that is
free of paint, rust, mill scale, etc. a separate
connection is required to ground the workpiece to
an approved earth ground. the work cable should
be the same rating as the torch/electrode cable
lead.
INSTALLATION
Table 2-2. Recommended Welding Cable Sizes
Welding Total Length (Feet) of Cable in Weld Circuit*
Current 50 100 150 200 250
100
150
200
250
300
400
500
* Total cable length includes work and electrode cables. Cable
** Cam-Lock jack plug connectors will not accept smaller than #2
2.5 CONTROL INTERCONNECTION
Ensure all TIG/Stick remote control accessories are
physically disconnected from receptacle J2 when
making a Digipulse setup.
6**
4**
3**
2
1
2/0
3/0
size is based on direct current, insulated copper conductors,
100% duty cycle, and a voltage drop of 4 or less volts. The welding
cable insulation must have a voltage rating that is high enough to
withstand the open circuit voltage of the machine.
gauge cable. Also, remember that for MIG-Pulse conditions we
recommend only 4/0 cable be used due to pulse-peak currents.
4**
3**
1
1/0
2/0
3/0
3/0
3**
1
1/0
2/0
3/0
4/0
4/0
2
1/0
2/0
3/0
4/0
4/0
--
1
2/0
3/0
4/0
4/0
--
--
Proper operation of the Power Source depends to a
great extent on the use of copper output cables that
are insulated, adequately sized, in good condition
and properly connected to the machine using the
jack plug connectors provided. It is recommended
that the output cables be kept as short as possible,
placed close together, and be of adequate current
carrying capacity. The resistance of the output
cables and connections cause a voltage drop which
is added to the voltage of the arc. Excessive cable
resistance can reduce the maximum current output
of the Power Source. Refer to table 2-2 to select
the recommended output cable size.
Because the Digipulse 450i is only dedicated for
use with Digipulse type Wire Feeders and mechanized/Robotic Controls, the specific hookup and
interconnecting control cable(s) part numbers will
only be covered in the instructional booklets for
those Controls/Wire Feeders as follows:
F-15-012 Digipulse Wire Feeder
F-15-013 Teach Mode Operating Instructions
for Teach Option
2.6 OPTIONAL ACCESSORIES
To avoid duplication of MIG accessories which may
or may not be required for the various Digipulse
systems, please refer to the individual Digipulse
Wire Feeder/Control instruction booklets provided
for your system. For applicable Stick/TIG accessories, refer to figure 2-3.
11
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