ESAB MultiPower 460 DC Welding Power Source (Shipyard Model) Instruction manual

MultiPower 460

DC WELDING POWER SOURCE

(Shipyard Model)

INSTRUCTION MANUAL

ESAB ITEM NO. 0558003401, MultiPower 460 - 230/460/575 vac, 3 ph., 60 Hz

0558004302 10 / 2004

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

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

SECTION 1 SAFETY ..............................................................................................................................................5

SECTION 2 DESCRIPTION .................................................................................................................................... 11

2.0 General ...............................................................................................................................................11

2.1 Description .........................................................................................................................................11

SECTION 3 INSTALLATION .................................................................................................................................19

3.0 Installation ...........................................................................................................................................19

SECTION 4 OPERATION ....................................................................................................................................... 25

4.0 Operation............................................................................................................................................ 25

SECTION 5 MAINTENANCE.................................................................................................................................. 31

5.0 Maintenance and Troubleshooting..................................................................................................... 31

SECTION 6 REPLACEMENT PARTS................................................................................................................... 39

Schematic Diagrams ..........................................................................................................................33

3

TABLE OF CONTENTS

4

SECTION 1 SAFETY PRECAUTIONS

WARNING:

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.

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 nonflammable partition or curtains.

6. Use goggles over safety glasses when chipping slag or

grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot slag
or sparks can also cause fires and ex­plosions. Therefore:

1. Remove all combustible materials well away from the

work area or cover the materials with a protective non­flammable covering. Combustible materials include
wood, cloth, sawdust, liquid and gas fuels, solvents,
paints and coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or

crevices in floors or wall openings and cause a hidden
smoldering fire or fires on the floor below. Make certain
that such openings are protected from hot sparks and
metal.“

3. Do not weld, cut or perform other hot work until the

workpiece has been completely cleaned so that there
are no substances on the workpiece which might pro­duce flammable or toxic vapors. Do not do hot work on
closed containers. They may explode.

4. Have fire extinguishing equipment handy for instant use,

such as a garden hose, water pail, sand bucket, or
portable fire extinguisher. Be sure you are trained in its
use.

These Safety Precautions are for

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

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.

1. Be sure the power source frame (chassis) is connected
to the ground system of the input power.

2. Connect the workpiece to a good electrical ground.

3. Connect the work cable to the workpiece. A poor or
missing connection can expose you or others to a fatal
shock.

4. Use well-maintained equipment. Replace worn or dam­aged cables.

5. Keep everything dry, including clothing, work area,
cables, torch/electrode holder, and power source.

6. Make sure that all parts of your body are insulated from
work

and from ground.

7. Do not stand directly on metal or the earth while working
in tight quarters or a damp area; stand on dry boards or
an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

9. Turn off the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)
for specific grounding recommendations. Do not mis­take the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS — May be
dangerous. Electric current flowing through
any conductor causes localized Electric and
Magnetic Fields (EMF). Welding and cutting
current creates EMF around welding cables
and welding machines. Therefore:

1. Welders having pacemakers should consult their physi­cian before welding. EMF may interfere with some pace­makers.

2. Exposure to EMF may have other health effects which are
unknown.

3. Welders should use the following procedures to minimize
exposure to EMF:
A. Route the electrode and work cables together. Secure

them with tape when possible.
B. Never coil the torch or work cable around your body.
C. Do not place your body between the torch and work

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

D. Connect the work cable to the workpiece as close as

possible to the area being welded.
E. Keep welding power source and cables as far away

from your body as possible.

5

SECTION 1 SAFETY PRECAUTIONS

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

1. Always provide adequate ventilation in the work area by
natural or mechanical means. Do not weld, cut, or gouge
on materials such as galvanized steel, stainless steel,
copper, zinc, lead, beryllium, or cadmium unless posi­tive mechanical ventilation is provided. Do not breathe
fumes from these materials.

2. Do not operate near degreasing and spraying opera­tions. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly toxic
gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat irritation
while operating, this is an indication that ventilation is
not adequate. Stop work and take necessary steps to
improve ventilation in the work area. Do not continue to
operate if physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specific ventilation recommendations.

5. WARNING: This product, when used for welding or

cutting, produces fumes or gases which
contain chemicals known to the State of
California to cause birth defects and, in
some cases, cancer. (California Health &

Safety Code §25249.5 et seq.)

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

ing", Form 52-529.

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

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 Goug-

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.

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.

6

SECTION 1 PRECAUCION DE SEGURIDAD

ADVERTENCIA:

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

Estas Precauciones de Seguridad

.

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 chispas

calientes con una cortina adecuada no-flamable como división.

6. Use careta protectora además de sus gafas de seguridad

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 -- El calor de las
flamas y el arco pueden ocacionar
fuegos. Escoria caliente y las chispas
pueden causar fuegos y explosiones.
Por lo tanto:

Remueva todo material combustible lejos del área de trabajo o

1.

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, inspeccione 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 y tierra
puede causar daño severo o muerte. NO
use soldadura de corriente alterna (AC) en
áreas húmedas, de movimiento confinado
en lugares estrechos o si hay
posibilidad de caer al suelo.

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 condiciones. 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 procedimientos 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.

7

SECTION 1 PRECAUCION DE SEGURIDAD

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 substancias
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.

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

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 cilindros.

4. Localize los cilindros lejos del calor, chispas, y flamas.
Nunca establezca un arco en el cilindro.

5. Para información adicional, haga referencia a la publicación
CGA Standard P-1, "Precautions for Safe Handling of Com­pressed Gases in Cylinders", disponible através del Com­pressed Gas Association, 1235 Jefferson Davis Highway,
Arlington, VA 22202.

§25249.5 et seq.)

1. Siempre tenga personal cualificado para efectuar 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.

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"

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."

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

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.

SIGNIFICADO DE LOS SIMBOLOS -- Según
usted avanza en la lectura de este folleto:
Los Símbolos Significan ¡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.

8

SECTION 1 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 assu­rer votre isolation corporelle en portant des gants secs
et des chaussures à semelles de caoutchouc et en
vous tenant sur une planche ou une plate-forme sèche.

c. Mettez toujours à la terre le poste de soudage/coupage

en le reliant par un câble à une bonne prise de terre.

d. N’utilisez jamais de câbles usés ou endommagés. Ne

surchargez jamais le câble. Utilisez toujours un
équipement correctement entretenu.

e. Mettez l’équipement hors tension lorsqu’il n’est pas en

service. une mise à la masse accidentelle peut en effet
provoquer une surchauffe de l’équipement et un danger
d’incendie. Ne pas enrouler ou passer le câble autour
d’une partie quelconque du corps.

f. Vérifiez si le câble de masse est bien relié à la pièce en

un point aussi proche que possible de la zone de travail.
Le branchement des câbles de masse à l’ossature du
bâtiment ou en un point éloigné de la zone de travail
augmente en effet le risque de passage d’un courant de
sortie par des chaînes de

9

9/97

SECTION 1 PRÉCAUTIONS DE SÉCURITÉ

levage, des câbles de grue ou divers chemins
électriques.

g. Empêchez l’apparition de toute humidité, notamment

sur vos vêtements, à la surface de l’emplacement de
travail, des câbles, du porte-électrode et du poste de
soudage/coupage. Réparez immédiatement toute
fuite d’eau.

4. VENTILATION-- La respiration prolongée des fumées
résultant des opérations de soudage/coupage, à
l’intérieur, d’un local clos, peut provoquer des mal­aises et des dommages corporels. Aussi convient-il
d’observer les précautions suivantes:

a. Assurez en permanence une aération adéquate de

l’emplacement de travail en maintenant une ventila­tion naturelle ou à l’aide de moyens mécaniques.
N’effectuez jamais de travaux de soudage ou de
coupage sur des matériaux de zinc, de plomb, de
beryllium ou de cadmium en l’absence de moyens
mécaniques de ventilation capables d’empêcher
l’inhalation des fumées dégagées par ces matériaux.

b. N’effectuez jamais de travaux de soudage ou de

coupage à proximité de vapeurs d’hydrocarbure
chloré résultant d’opérations voisines de
dégraissage ou de pulvérisation. La chaleur dégagée
ou le rayonnement de l’arc peut déclencher la
formation de phosgène -- gaz particulièrement
toxique -- et d’autres gaz irritants, à partir des
vapeurs de solvant.

c. Une irritation momentanée des yeux, du nez ou de la

gorge constatée au cours de l’utilisation de
l’équipement dénote un défaut de ventilation.
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 sui-vantes, tenues à votre disposition par
l’American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 32126:

a. “Safety in Welding and Cutting” AWS Z49.1
b. “Recommended Safe Practices for Gas-Shielded Arc

Welding “AWS A6. 1.

c. “Safe Practices for Welding and Cutting Containers

That Have Held Combustibles” AWS-A6.0.

d. “Recommended Safe Practices for Plasma Arc

Cutting” AWS-A6. 3.

e. “Recommended Safe Practices for Plasma Arc

Welding” 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.

10

9/97

SECTION 2

DESCRIPTION

2.0. GENERAL

Before the MultiPower 460 power source 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 below:

are described at the end of the Safety Section in the front of this manual —

read them and their specific text references carefully.

2.1. DESCRIPTION

This manual has been prepared for use by an experienced operator. It
provides information to familiarize the operator with the design, installation
and operation of the MultiPower 460 power source. DO NOT attempt to install
or operate this equipment until you have read and fully understood these
instructions. The information presented here should be given careful consid­eration to ensure proper installation and optimum weld performance of this
equipment.

RATED

OUTPUT

RATED

INPUT

Table 2-1. Specifications for MultiPower 460

OPEN CIRCUIT VOLTAGE (U2) 80V DC Max.

DUTY CYCLE 60% 100%

Current (I

Voltage (U

60 Hz

3 Phase

50 Hz

Power Factor at Rated Output 89%

Welding Range 10 A/12 V - 500 A/40 V
Auxiliary Power 115 V ac @ 10 A, 60 Hz

PHYSICAL SPECIF ICATIONS

Height (without lift eye) 25.0" (62.2 cm)

Width 18.8" (48.3 cm)

)500 A450 A

2

) 40 V 38 V

2

Volt s ( U

208/230 V 76 A 66 A

) Current (I1) Flat Current (I1) Flat

1

460 V 38 A 33 A
575 V 31 A 26 A

220 V 79 A 68 A
400 V 43 A 37 A

Depth 32.5" (81.9 cm)

Net Weight 322lbs (146 kg)

Shipping Weight 3 75l bs (17 0 kg)

11

SECTION 2

DESCRIPTION

The MultiPower 460 is a multi-process power source designed for Mig short
circuiting, spray transfer (GMAW), flux core (FCAW), Tig (GTAW), and stick
(SMAW) welding and air carbon arc cutting/gouging (CAC-A) applications.
Table 2-1 outlines the electrical and physical specifications.

A. POWER SOURCE

The power source is a constant current (CC) and constant voltage (CV), three
phase, secondary chopper dc design with solid state contactor and control
circuitry. It provides the volt-ampere characteristics desired for conventional
MIG and flux core arc welding in the CV (constant voltage) mode or stick
welding, Tig (GTAW) and arc gouging in the CC (constant current) mode.

Features

• Auto Fan - The MultiPower 460 fan will run when the power source is first
powered up and will continue running for 6 minutes, then shut down. The
fan will start again when welding begins and at current levels above 50
amps. The fan will remain running for 6 minutes after welding stops and
then shut down automatically.

• Stainless steel frame for environmental durability.

• Durable composite side and top panels will not corrode.

• 100% duty cycle output at 450 amps.

• Compatible with all ESAB 42 vac wire feeders.

B. VOLT - AMPERE CHARACTERISTICS

The curves shown in Figure 2-2 represent the static volt-ampere 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/current control.

Figure 2-2 - MultiPower 460 Volt-Ampere Curves

12

SECTION 2 DESCRIPTION

C. CONTROL PANEL DESCRIPTION

(Refer to Figures 2-3 and 2-4)

1. FAULT LAMP

The RED fault light on the MultiPower 460 front panel indicates a prob­ lem with set-up parameters.

2. TEMPERATURE LAMP

The TEMP lamp illuminates if an over temperature condition occurs within the
MultiPower 460 power source. This condition may be caused by excessive
duty cycle or over-current conditions. When an over temperature condition
occurs, the welding output is turned off and the unit must be allowed to cool.
The machine will automatically reset when the temperature falls to a safe
level.

3. PROCESS SELECTOR SWITCH

The three position process selector switch is located in the upper right-hand
corner of the control panel. The process selector switch position provides the
visual indication of which weld process (Mig, Tig or stick) has been selected.

4. DIGITAL DISPLAY/METERS (WFS, AMPS & VOLTS)

The digital displays located on the left side of the control panel are
multifunctional depending on the welding process being used. The top
display reads wire feed speed in inches per minute in the MIG PRESET mode
and welding current (amps) in the TIG and STICK PRESET mode. During
welding both displays indicate average welding current and average welding
voltage.

Power “ON”

Lamp

Temperature

Lamp

Fault

Lamp

Digital Meter

Volts

Digital Meter

Amps/WFS

Figure 2-3. Control Panel

WFS - IPM

Lamp

Amps
Lamp

13

SECTION 2

DESCRIPTION

When using a DuraDrive 4-30 or DuraDrive 4-48 Wire Feeder, the wire feed
speed is displayed in inches per minute (IPM) in the top display when the
PRESET button is pressed and the wire speed adjustment knob on the wire
feeder is rotated. The WFS LED beside the top display meter will light when
the display is showing wire feed speed.

5. VOLTAGE / CURRENT / TRIM

The arc voltage is controlled with this knob when the WELD PROCESS
selector switch is in the MIG position. The Mig arc voltage can be preset
by pressing the PRESET button and reading the arc volts in the bottom
digital display while rotating this knob.

The arc current is controlled with this knob when the WELD PROCESS
SWITCH is in the TIG or STICK position. The welding current can be preset
in amperes by pressing the PRESET button and reading the current (amps)
in the top digital display while rotating this knob. The average weld current
will be displayed during welding.

A DuraDrive Wire Feeder is required to

NOTE:

preset wire feed speed.

6. PANEL/REMOTE SWITCH

With this switch in the PANEL position, output voltage in the CV mode and
the output current in the CC mode are controlled by adjusting the VOLTAGE/
CURRENT/TRIM knob on the power source control panel to the desired
output. In the REMOTE position, output is controlled using a remote control
device such as a wire feeder, hand control or foot control.

Panel/
Remote

Preset
Button

Weld Process

Switch

Current
Voltage

Figure 2-4. Control Panel

14

Inductance

SECTION 2

DESCRIPTION

7. INDUCTANCE TRIM

This control is deactivated in the TIG and STICK modes.
Inductance is used to optimize short circuiting arc performance by changing

the current rise and fall time of each short circuit. This results in improved
spatter control, weld bead wetting and arc stability. The short circuiting Mig
arc performance will change from a high short circuit frequency, fast reacting
arc, to a lower short circuit frequency, soft and less spattering arc as the dial
is turned clockwise. The optimized arc performance will vary depending on
shielding gas, wire type and wire diameter. The operator can adjust this
control to optimize welding characteristics.

D. POWER SOURCE FRONT PANEL DESCRIPTION

(Refer to Figure 2-5)

1. POWER ON/OFF SWITCH & LAMP

The main power switch is located on the right front panel of the power source.
This switch energizes the main transformer, control circuitry and illuminates
the Power “ON” lamp.

2. WIRE FEEDER CONTROL RECEPTACLE

This 19-pin receptacle (J1) accepts the control cable from the wire feeder and
handles all the control signals needed to operate a 42 Vac wire feeder.

19-pin Receptacle

Contactor On/Off

Switch

Remote Pendant

Connection

115 Vac

10 Amps

Receptacle

3. REMOTE CONTROL RECEPTACLE

This receptacle (J2) is provided for an optional 14-pin control cable from the
optional remote pendant, Tig torch control or foot control . This receptacle
is operative only if the PANEL/REMOTE switch on the power source front
panel is in the "REMOTE" position.

Control Panel

Circuit
Breakers
CB1 & 2

Main Power

On/Off Switch

Output

Connections

Figure 2-5. MultiPower 460

15

SECTION 2

DESCRIPTION

4. CONTACTOR "ON/OFF" SWITCH

This switch provides manual control of the welding contactor when the
PROCESS switch on the control panel is in the MIG position (CV welding).
An example of when to use this switch is when CV carbon arc gouging is
needed or an "Off the Arc" wire feeder with secondary contactor is operated
in the CV mode.

5. AUXILIARY 115 VAC 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 with a floating neutral.

6. 42VAC AND 115 VAC CIRCUIT BREAKER (CB1 & CB2)

These resetable 10 amp circuit breakers (CB1 & CB2) protect the 42 volt
wire feeder/control and 115 volt auxiliary receptacle circuitry against over
current. (Table 5-1 provides troubleshooting information).

E. OPTIONAL ACCESSORIES

1. REMOTE HAND CONTROL (PN - 0558002871)

This pendant (Figure 2-6) provides remote output control and a contactor
closure switch to close the contactor making the output terminals “hot”.
The PANEL/REMOTE switch on the MultiPower 460 control panel must be
placed in the REMOTE position when using this accessory. The pendant
has the capability to change weld processes as well as adapt to digital and
analog wire feeders.

2. TR-29 TRUCK KIT (PN - 37924)

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

3. SWIVEL MOUNT KIT (PN - 36172)

This kit allows the wire feeder to be placed on an insulated swivel post on
top of the power source. The feeder can freely rotate, relieving potential wire
feed problems caused by sharp bends in the gun cable while, at the same
time, increasing the radius of the working area.

4. PULSE MIG UPGRADE KIT (PN - 0558002671)

This kit adds pulse gas metal arc welding capability to the MultiPower 460
and includes and new control front panel.

16

SECTION 2

DESCRIPTION

The FC-5B foot control or TC-2B hand

NOTE

control must be used with the MP-460 for
remote current Tig current control.

NOTE

If a Foot Control or Remote Hand Control
is used for continuous current control,
place the PANEL/REMOTE switch in the
PANEL POSITION and set the Panel Cur­rent knob to the maximum desired weld
current. The remote device will then con­trol the current between minimum and the
maximum setting preset (proportional
current control). Maximum Tig weld cur­rent is 525 amps.

NOTE

If the MP-460 PANEL/REMOTE switch
is left in the REMOTE position when Tig
welding while using a remote current
control device, the current range will
be full scale or 10 to 400 Amps.
Limiting the the Maximum weld current
on the MP-460 front panel is defeated.

Figure 2-6. Remote Control Pendant

When using a DuraDrive wire feeder

NOTE

(or any wire feeder with Remote
Voltage control from the feeder front
panel) connected simultaneously with
a remote current control Tig device
(FC-5B or TC-2B), proportional control
of the TIG remote current will be
controlled by the position of the feeder
voltage control knob when the PANEL/
REMOTE switch is in the REMOTE
position. When in the PANEL position
the maximum current of the remote
device is controlled by the MP-460
front panel current control preset.

5. TIG REMOTE CONTROLS

The following Remote controls are available for the Tig welding:

FC-5B EHD Foot Control 33841
FC-5B Foot Control 33838
TC-2B Torch Mount Control 33839
TC-3A Torch Mount On/Off only:
(HW-9, 17, 20, 20A & 24) 35783
(HW-18 & 26R) 36680

17

SECTION 2

DESCRIPTION

18

SECTION 3

For lifting purposes and for keeping
dust, moisture, and other foreign ma­terial from entering the power source,
the lifting eyebolt must be fully tight­ened with a tool.

Do not use filters on this unit as they
would restrict the volume of intake air
required for proper cooling. Output
ratings on this unit are based on an
unobstructed supply of cooling air
drawn over its internal components.
Warranty is void if any type of filtering
device is used.

INSTALLATION

3.0. INSTALLATION

A. 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.

B. RECEIVING, UNPACKING AND PLACEMENT

When requesting information concerning this equipment, it is essential that
Item number, Serial number and Model number of the equipment be supplied.

a. 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.

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

packing material has not obstructed air flow through the power source.

d. Install the lifting bolt furnished with the power sources into the top of the

unit.

e. After selecting an installation site, place the power source in the

desired location. The unit may be lifted either by using the lifting bolt
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.

C. 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.

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

68
66
37
33
26

Input &

GND

Conductor*

CU/AWG

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

No. 10

listed above.

Fuse

Size

Amps

100
100

60
60
50

19

SECTION 3

ELECTRIC SHOCK CAN KILL! Before
making electrical input connections
to the power source, "Machinery
Lockout Procedures" should be em­ployed. If the connections are to be
made from a line disconnect switch,
place the switch in the off position
and padlock it to prevent inadvert­ent tripping. If the connection is
made from a fuse box, 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.

INSTALLATION

Typical Installation - User Supplied
3 Phase Fused Power Disconnect
Box with Receptacle and Plug

The chassis must be connected to
an approved electrical ground. Fail­ure to do so may result in electrical
shock, severe burns or death.

1. 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.

2. Remove the top cover. Identify primary power input connection block,
chassis ground lug on the frame, and primary input terminal board.
Refer to Figures 3-1 and 3-2.

20

SECTION 3

ELECTRIC SHOCK CAN KILL! Before
making electrical input connections to
the power source, "Machinery Lock­out Procedures" should be employed.
If the connections are to be made from
a line disconnect switch, place the
switch in the off position and padlock
it to prevent inadvertent tripping. If the
connection is made from a fuse box,
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.

INSTALLATION

3. When using the provided strain relief, refer to Figure 3-1 for proper cable
strip lengths. It is important to follow the cable strip guide to ensure that
if the primary input cable is ever pulled from the strain relief, the input
conductors will be pulled from the Terminal Block before the ground
lead is pulled from the ground lug. Once stripped, thread the input and
ground conductors through the large strain-relief in the rear panel of the
power source. Connect the ground wire to the terminal lug located on
the "A" frame support. Connect the primary power leads to terminals
L1, L2, and L3 on the input power block. Secure the strain relief on the
input cable.

4. Check all connections for proper tightness. Ensure all connections are
correct and well-insulated.

(3) PRIMARY

INPUT

CONDUCTORS

5"

The chassis must be connected to an
approved electrical ground. Failure to
do so may result in electrical shock,
severe burns or death.

Figure 3-1

24"

Green

(Earth Ground)

Recommended Cable Strip Lengths

Figure 3-2 Primary Power Leads

L1,L2, L3 & Ground

21

SECTION 3

5. Figures 3-3, 3-4 and 3-5 illustrate the input voltage terminal boards 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 (575VAC).
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 silk-screened
voltage designations for the desired voltage.

INSTALLATION

230 Vac Input 460 Vac Input 575 Vac Input

Figure 3-3. Input T erminal Board Configuration for 230/460/575 Model

(factory supplied in the 575 configuration)

230 Vac Input

Figure 3-4 Input T erminal Board Configuration 230/

460 Model (factory supplied in the 460 configuration)

460 Vac Input

*

*

*

220 Vac Input

Figure 3-5 Input T erminal Board Configuration 220/

400 Model (factory supplied in the 400 configuration)

400 Vac Input

22

SECTION 3

Check the voltage links for proper volt­age on the Input Terminal board before
applying primary power.

Before making any connections to the
power source output terminals make
sure that all primary input power to the
machine is off.

INSTALLATION

D. OUTPUT WELDING CONNECTIONS

(SECONDARY)

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

1. CONNECTIONS FROM THE WIRE FEEDER

The wire feeder control cable connects to the 19 pin J1 receptacle on
the lower front left of the MultiPower 460. The secondary output cable
connects (in most cases) between the positive output lug of the
MultiPower 460 and the power connection block of the wire feeder. See
the wire feeder installation instructions for other connections such as
shield gas, water, remote controls, Mig guns and wire feeder operation.

2. CONNECTIONS FOR STICK AND TIG WELDING

The Tig torch and stick electrode holder connect directly to the
appropriate MultiPower 460 output lugs on the lower front panel. The
choice of the Positive or Negative terminal depends on the welding
process and electrode type being used. In most cases the Tig torch
will connect to the negative lug and work cable will connect to the
positive lug. The stick electrode holder usually connects to the positive
lug and the work cable to the negative lug.

Table 3-2. Output Cable Sizes (Secondary)

Total Len g th (F eet) of

Welding

Current

50 100 150 200 250

100

150
200
250
300
400
500

* 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.

6
4
3
2

1
2/0
3/0

Cable in W e ld C ir cu it*

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

2-2/0

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

4/0
2-2/0
2-3/0

23

INSTALLATIONSECTION 3

24

SECTION 4 OPERATION

(

)

4.0. OPERATION

A. WIRE FEEDER COMPATIBILITY

Never operate the power source with
the covers removed. In addition to the
safety hazards, improper cooling may
cause damage to the components.
Keep side panels and top closed when
unit is energized. Welding helmet,
gloves, and other personal protection
should always be worn when welding.

NOTE

Wire Feeders with 115VAC contactor
control circuitry cannot be connected to
the MultiPower 460.

The MultiPower 460 power source can be used with several ESAB 42 volt wire
feeders. The model wire feeder being used will determine the setup method
and operator interface. The position of the REMOTE/PANEL switch deter­mines the location of the voltage preset and TRIM locations. The wire feed
speed is always set from the wire feeder using the wire speed knob on the

Table 4-1. Wire Feeder Compatibility

MIG MODE SWITCH*

STANDARD

(Mul tiPo wer 460 )

Wire Feeder

Mig 4HD Feeder X X Optional

DuraDri v e 4-30 MP-460 Panel X X Optional
DuraDri v e 4-48

Mig 2E Feeder X N/A

Mig 5XL

(Mongoose)

Arc Trim Location

from:

Remote Pendant X X Opt i onal

MP-460 Panel X X Optional

PANEL REMOTE Synergic

PULSE

(MultiPow er 460 P ulse)

Non-

Synergic**

Wire Feeders with remote voltage control

NOTE

must be disconnected before Tig & Stick
current can be controlled by the remote
control pendant.

NOTE

The digital wire feed speed meter on the
MultiPower front panel reads a maximum
of 760 ipm. Some wire feeders have
speed ranges that exceed this maximum
limit of the digital meter. Wire feed speeds
above 760 ipm will be displayed at 760
ipm.

NOTE

The digital volt meter on the MultiPower
front panel reads a maximum of of ap­proximately 75 Vdc even if the OCV (Open
Circuit Voltage) is higher. The MultiP­ower 460 has the following OCV"s:

MobileMaster IV

(Off the Ar c)

Mini 8

Off the Ar c

N/A - No t A vailab le
* - Proces s switch MUST be in the MIG posi tion.
** - See Sy nergic / NonS y nergic description sect i on for configuration informati on
(Applies to Mult i P ower 460 Pulse only)

Feeder X N/A N/A X

Remote Pendant X N/A X

MP-460 Panel X N/A X

feeder control panel. To see the preset wire feed speed, press the PRESET
button on the MultiPower 460 control panel. Use Table 4-1 to determine the
switch position of operator preference. In most Mig welding applications, the
switch will be in the REMOTE position and the wire feed speed and voltage will
be adjusted from the wire feed front panel.

B. DIGITAL DISPLAY METERS

The digital displays located on the left side of the control panel are multifunc­tional depending on the welding process being used. The MultiPower 460
digital display meters permit preset of the wire feed speed on wire feeders
without digital displays. A Mig 2E, 4HD or DuraDrive 4-30 or 4-48 will not need
digital meters to preset the wire feed speed. The wire feed speed can be
displayed on the MultiPower 460 panel meter.

C. MIG WELDING

In the MIG process mode, the digital displays will read preset wire feed speed
in inches per minute and preset arc volts when the PRESET button is pressed.
Once welding begins, the displays will show average welding current and
volts in the top and bottom display, respectively. The displays have a “HOLD”
circuit that retains the welding conditions. After welding stops, the display will
continue to show the last average welding current and voltage sampled for 10
seconds, then returns to “0”.

STICK 75 to 80 Vdc
TIG - 38 to 42 Vdc
MIG - 11 to 44 Vdc

D. TIG and STICK WELDING

In the TIG and STICK process mode, you must depress and "HOLD" the
PRESET button while presetting the welding current in the top display.
Releasing the preset button causes the display to return to zero. Once welding
begins, the display will show average welding current and volts in the top and
bottom display, respectively. After welding stops, the current display will again

25

SECTION 4 OPERATION

return to zero. There is no “HOLD” circuit for the display meters when using the
TIG and STICK process modes.

E. MIG WELDING PRESET PROCEDURE

When the PROCESS switch is placed in the MIG position, the MultiPower 460
is set for CV (constant voltage) welding. The power source will output open
circuit voltage (OCV) when the Mig Gun trigger is depressed. The following
procedure assumes the wire feed and voltage adjustments will be made from
the wire feeder front panel and wire and gas have been installed.

Step 1. Connect wire feeder to MultiPower 460 and set PANEL/REMOTE

switch to REMOTE position.
Step 2. Place the WELD PROCESS switch in the MIG (center) position.
Step 3. Press and release the PRESET button then turn the wire speed

control on the wire feeder to the desired speed shown on the top

digital display window of the MultiPower 460.
Step 4. Turn the VOLTAGE knob on the wire feeder to the desired arc

voltage in the bottom digital display window of the

MultiPower 460.

"OFF THE ARC" Wire Feeders can use

NOTE

either MIG (CV) or STICK (CC) Process
Selection. Place the contactor toggle
switch on the accesssory panel (see
Figure 2-5) to the "ON" position.

Step 5. Set the shielding gas flow rate to 35 cfh by activating the gas purge

switch on the wire feeder or pulling the gun trigger and turning the

adjustment knob on the Flowmeter.

Step 1

Step 3

Step 2

Figure 4-1 Standard Mig Setup Procedure

Step 6. Connect the work cable to the part to be welded and pull the gun

trigger to start welding. Trim the wire speed and volts as needed for

the desired arc characteristics and weld quality .

26

SECTION 4

OPERATION

The FC-5B foot control or TC-2B hand

NOTE

control must be used with the MP-460 for
remote current Tig current control.

NOTE

When using a DuraDrive wire feeder
(or any wire feeder with Remote
Voltage control from the feeder front
panel) connected simultaneously with
a remote current control Tig device
(FC-5B or TC-2B), proportional control
of the TIG remote current will be
controlled by the position of the feeder
voltage control knob when the PANEL/
REMOTE switch is in the REMOTE
position. When in the PANEL position
the maximum current of the remote
device is controlled by the MP-460
front panel current control preset.

F. TIG WELDING

When the PROCESS switch is placed in the TIG position, the MultiPower 460

is automatically set for CC (constant current) welding using the ESAB Touch

TIG starting method. The voltage and current at the output lugs is maintained

at low values until the tungsten electrode is shorted to the workpiece.

Step 1. Be sure to set the polarity to DCEN (Electrode Negative) by con-

necting the Tig torch to the negative terminal lug on the front of the

power source.
Step 2. Place the WELD PROCESS switch in the TIG position.
Step 3. Place the PANEL/REMOTE switch in the PANEL position.
Step 4. While depressing the PRESET button, turn the VOLT AGE/CURRENT

knob to the desired weld current as displayed on the top digital dis-

play window.
Step 5. Set the shielding gas flow rate to 20 cfh by adjusting the control knob

on the flowmeter.
Step 6. Touch the tungsten electrode to the workpiece moment arily then lift

1/16" off the workpiece to establish the welding arc. Trim the weld

current as desired by turning the VOL T AGE/CURRENT knob.

Step 3 Step 2

If a Foot Control or Remote Hand Control

NOTE

is used for continuous current control,
place the PANEL/REMOTE switch in the
PANEL POSITION and set the Panel Cur­rent knob to the maximum desired weld
current. The remote device will then con­trol the current between minimum and the
maximum setting preset (proportional
current control). Maximum Tig weld cur­rent is 525 amps.

NOTE

If the MP-460 PANEL/REMOTE switch
is left in the REMOTE position when Tig
welding while using a remote current
control device, the current range will
be full scale or 10 to 400 Amps.
Limiting the the maximum weld current
(proportional current control) using the
currnet control on the MP-460 front

panel is defeated.

Step 4

Figure 4-2 Standard Tig Setup Procedure

G. STICK WELDING

When the PROCESS switch is placed in the STICK position, the MultiPower
460 establishes open circuit voltage (OCV) and output power is immediately
available for welding. This means that the STICK electrode holder is “HOT”, and
an arc will strike when the electrode comes in contact with the workpiece or
any other object at ground potential.

27

SECTION 4

OPERATION

Arc Force is automatically enabled when the WELD PROCESS switch is set
to the STICK position. The level of Arc Force is automatically adjusted by the
current preset being used.

When the WELD PROCESS switch is
moved to the TIG or STICK position,
electrode becomes electrically
“HOT”. Do not allow the electrode to
contact ground potential until you are
ready to make a weld.

Step 1. Be sure to set the polarity to DCEP (Electrode Positive) by placing

the Electrode Holder cable in the Positive connection lug on the front

of the power source.
Step 2. Place the WELD PROCESS switch in the STICK position.
Step 3. Place the PANEL/REMOTE switch in the PANEL position.
Step 4. While holding the PRESET button, turn the VOLTAGE/CURRENT

knob to the desired weld current in the top digital display window.
Step 5. Strike the electrode on the workpiece and start welding. Trim the

welding current as needed for the desired weld pool control.

Step 3

Step 2

Step 4

Figure 4-3 Standard Stick Setup Procedure

H. AIR CARBON ARC GOUGING (CAC-A)

1. CONSTANT CURRENT and CONSTANT VOLTAGE GOUGING

Step 1. Place the Output PANEL/REMOTE switch into PANEL position if

output current is regulated from the VOLTAGE/CURRENT knob on the
power source front panel, or in REMOTE position if output current is

regulated from the optional Hand Control.
Step 2. Place the Process Control switch in the STICK position.
Step 3. Press and hold the PRESET button and set the VOLT AGE/CURRENT

knob to gouging current.

28

SECTION 4

When the WELD PROCESS switch is
moved to the TIG or STICK position,
electrode becomes electrically “HOT”.
Do not allow the electrode to contact
ground potential until you are ready
to make a weld.

OPERATION

Step 4. CV-Carbon Arc Gouging Only - Place the Process Switch in the

MIG position and the Contactor Toggle switch to the "ON" position.
See Figures 4-4 and 4-5.

Step 5. Turn the air on the gouging electrode holder "ON and start gouging by

touching or scratch starting the electrode.

Due to the "Built-In" Arc Force in the stick

NOTE

mode, the actual current may be greater
than the preset value.

Step 1

Step 3

Figure 4-4 Carbon Arc Setup Procedure

Step 2

Figure 4-5 Contactor Switch

for Carbon Arc Setup

29

Step 4

For CV Carbon Arc
Gouging and "Off the
Arc" wire feeders
ONLY!!!!!!!

SECTION 4

OPERATION

30

SECTION 5

MAINTENANCE

5.0 MAINTENANCE AND TROUBLESHOOTING

A. CLEANING

Periodically, remove the cover from the power source and blow accumulated

dust and dirt from the air passages and interior components by using clean low

pressure air. The frequency of cleaning required depends upon the environment

in which the power source is used.

It is imperative that all air passages be kept as clean as possible in order to allow

adequate air flow to provide proper cooling.

After cleaning with low pressure air, check for and tighten any loose hardware,

including all electrical connections. Check for frayed and/or cracked insulation

on all power cables and replace if necessary.

B. 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.

C. FAN MOTOR

Keep the fan motor free of accumulated dust and lint.

D. 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.

E. WIRE FEEDER 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.

F. 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.

G. TROUBLESHOOTING

If the power source is operating improperly, the following troubleshooting

information may be used to locate the source of the trouble.

Check the problem against the symptoms in the following troubleshooting guide

(Table 5-1.) 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.

31

g

SECTION 5

CONDITION ACTION

MAINTENANCE

Table 5-1 Troubleshooting Guide

Unit Inoperative A.

B.
C.
D.

E.

No Output -- Fan
Runn ing

Limited Output or Low
Open-Circuit Voltage

Erratic W e ld Current A.

A.
B.
C.

D.

A.
B.

C.

B.
C.
D.

No input power. Check main line (user's) switch fuses -- replace if needed.
Poor or improper input (terminal board) connections.
Defective on/off switch -- replace.
Thermal light on. Main transformer overheating. Also check for proper cooling,
proper primary hookup, or shorted turn on secondary.
Loss of primary phase. Find & replace defective fuse.

Poor or improper electrical input -- check input connections on TB.
Poor connections at output terminals/work station -- check, tighten or replace.
Main transformer overheating -- thermal switches tripped due to restricted cooling
air. Temperature light on front panel will be lit. Let unit cool down.
PC board defective or loose PC board connector(s) -- if loose, reinsert; if
defective, replace.

Input voltage jumper links on terminal board improperly set -- check for proper
voltage.
Poor output connections. Take apart, clean, and reassemble.
Panel-Remote switch in Remote position and remote voltage pot disabled.

Welding cable size too small -- use correct cables.
Loose welding cable connection (will usually get hot) -- t ighten all connections.
Improper wire feeder setup.
PC board defective -- replace.

Hig h Output, No
Voltage Control

No 115 Volt ac Output

Line Fuse Blows
When Power Source
is First Turned On

Wire Feeder is
Inoperative

A.B.PC board defective or loose -- reset and/or replace board.

Shorted I.G.B.T. - Replace I.G.B.T. and check driver PCB.

A. Circuit breaker tripped. Check 115V CB2 -- Reset.

A.B.Shorted DIODE in Main Bridge -- replace.

Shorted capacitor in Capacitor Bank.

A.B.Loose feeder control cable -- Check and tighten all connections.

A Circuit Breaker tripped -- Check 42V CB 1-- Reset.

32

0558003034-B

Schematic Diagram - MultiPower 460 - 230/460/575V

33

0558003034-B

Schematic Diagram (Continued) - MultiPower 460 - 230/460/575V

34

0558003064-D

Wiring Diagram Section 1 - MultiPower 460 - 230/460/575V

35

0558003064-D

Wiring Diagram Section 2 - MultiPower 460 - 230/460/575V

36

0558003064-D

Wiring Diagram Section 3 - MultiPower 460 - 230/460/575V

37

SECTION 5

MAINTENANCE

38

SECTION 6 REPLACEMENT PARTS

A. REPLACEMENT P ARTS

Replacement Parts are illustrated on the following figures. When ordering replacement parts, order by part number and
part name, as illustrated on the figure. Always provide the series or serial number of the unit on which the p arts will be
used. The serial number is stamped on the unit nameplate.

B. ORDERING

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

Replacement parts may be ordered from your ESAB distributor or from:

ESAB Welding & Cutting Products
Attn: Customer Service Dept.
P.O. Box 100545, 411 S. Ebenezer Road
Florence, SC 29501-0545

Be sure to indicate any special shipping instructions when ordering replacement parts.
T o order p arts by phone, contact ESAB at 1-843-664-5540. Orders may also be faxed to 1-800-634-7548. Be sure to

indicate any special shipping instructions when ordering replacement parts.
Refer to the Communication Guide located on the last page of this manual for a list of customer service phone numbers.

39

SECTION 6 REPLACEMENT PARTS

12, 13

10

8,9

7

20, 21

4, 5

11

14

15

16

17

18

19

3

2

1

QTY . ITEM CIRCUIT

NO. REQ. NO. DESCRIPTION SYMBOL

1 2 678025 Terminal Assembly
2 1 952219 Outlet 110V (Square)
3 1 951916 Connection Box Rcpt. 14FS X-ROT
4 2 634515 SW TGGL SPDT 2 Pos 14A 125V Q/D S3, 5
5 3 951474 Switch Seal Black
6
7 2 950122 Ckt Breaker 10A 32VDC/250VAC CB1, 2
8 2 0558001019 Knob 1.31 Dia.
9 2 13730632 Pot Lin *10.0K 2.00W 0.88L (A & B) R1, R2

10 1 952895 Switch PB Normally Open S4

11 1 38196 PCB Display Assembly PCB2
12 2 634515 SW TGGL SPDT 2 POS 14A 125V Q/D S3, 5
13 3 951474 Switch Seal Black
14 1 2091514 Label Warning Arc Welding & Cutting
15 1 954008 Danger High Voltage
16 1 636702 SW TGGL SPDT 3 POS 10A 250V SCR S2

3 951474 Switch Seal Black
17 1 9512240 Label Caution Lifting Eye
18 1 0558002969 Panel Right Side
19 1 950945 SW Pwr Disc 100A 600V S1
20 1 952209 Recpt., Panel, 19-pin F (Shell)
21 1 0558003003 Connector Plate MP-460

40

SECTION 6 REPLACEMENT PARTS

3

2

5

1

6

4

7

QTY . ITEM

NO. REQ. NO. DESCRIPTION SYMBOL

1 3 99511916 Diode Fwd 200V 250A
2 3 99511915 Diode Rev 200V 250A
3 1 954864 Label 3 Phase
4 1 2062334 Fan Motor 1/3 HP 1625 RPM
5 1 954699 Label Warning Fan Hazard
6 1 36173 Blade Fan 14" 5(or)6 Fin
7 1 33939 Inductor 7 Turn
8 1 38186 PCB Assy Driver MM 260

41

SECTION 6 REPLACEMENT PARTS

6

2

1

4

42

SECTION 6 REPLACEMENT PARTS

2

1

3

4

QTY . ITEM

NO. REQ. NO. DESCRIPTION SYMBOL

1 2 17280110 Res WW Fix'd ST 100W 5% 100.00 R3, R4
2 1 0558002712 Transformer 230/460/575V T1
3 12 672065 Strap Terminal
4 1 36110 Board Input Terminal 230/460/575V

43

SECTION 6 REPLACEMENT PARTS

2

3

4

1

5

QTY . ITEM CIRCUIT

NO. REQ. NO. DESCRIPTION SYMBOL

1 1 1312733 Label for Install Use COP Wire
2 1 950219 Relief Strain 2" (Non-enclosed)
3 1 0558001371 Panel Top Kydex Env
4 1 0558001370 Panel Left Side Kydex Env
5 2 0558003490 Foot Skid (Shipyard model Only)

44

SECTION 6 REPLACEMENT PARTS

3

4

2

5

1

6

QTY . ITEM

NO. REQ. NO. DESCRIPTION SYMBOL

1 1 952938 SCR 480V 18A Panel MNT
2 1 951997 Transducer Current SH1
3 1 951085 SW THML D/T 176 15A 120V Q/D TS6
4 3 0558002557 IGBT 600V/300A Q1, 2, 3
5 1 951940 Capacitor 1.0uf 600VDC 10% C4
6 3 0558002844 Capacitor 35000 UF 100VDC
7 1 38186 PCB Driver Assy

45

SECTION 6 REPLACEMENT PARTS

2

1

7

3

4

5

46

6

REVISION HISTORY

Original release of this manual - 05/2003.
Revision A (05SEP03) - Added 19-pin receptacle to illustrations on cover and Pages 15, 29 and 40. Also added

Items 20 and 21 to illustration and replacements parts table per Mike Palumbo red-lines. Also updated schematics
on Pages 34 thru 37.

10 / 2004 revision - Updated wiring diagram (0558003064) per CN# 043141.

47

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

A . CUSTOMER SERVICE QUESTIONS:

Order Entry Product Availability Pricing Delivery
Order Changes Saleable Goods Returns Shipping Information

Telephone: [phone] / Fax: [phone]

Telephone: [phone] / Fax: [phone]

Telephone: [phone]/ Fax: [phone]

B. ENGINEERING SERVICE: Telephone: [phone] / Fax : [phone]

Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations

C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: [phone]

Part Numbers Technical Applications Hours: 8:00 AM to 5:00 PM EST
Performance Features Technical Specifications Equipment Recommendations

D. LITERATURE REQUESTS: Telephone: [phone] / Fax: [phone]

E. WELDING EQUIPMENT REPAIRS: Telephone: [phone] / Fax: [phone]

Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST

F. WELDING EQUIPMENT TRAINING:

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

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

Eastern Distribution Center

Central Distribution Center

Western Distribution Center

Hours: 7:30 AM to 4:00 PM EST

0558004302 10 / 2004

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123/ Fax: [phone]/ Web:http://www.esab.com

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