ESAB Multipower 460 Pulse DC Welding Power Sources Instruction manual

Multipower 460PULSE

DC WELDING POWER SOURCES

INSTRUCTION MANUAL

ESAB ITEM NO. 0558002877, Multipower 460PULSE - 230/460/575 vac, 3 ph., 60 Hz

F-15-721-A 05/2003

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

2.1 Description .........................................................................................................................................13

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

SECTION 4 OPERATION ....................................................................................................................................... 23

SECTION 5 MAINTENANCE..................................................................................................................................39

5.0 Cleaning .............................................................................................................................................. 39

SECTION 6 TROUBLESHOOTING ........................................................................................................................ 41

6.0 Troubleshooting..................................................................................................................................41

SECTION 7 REPLACEMENT PARTS.................................................................................................................... 47

Schematic Diagrams ..........................................................................................................................42

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 Pro-

--

cesses", available from the National Fire Protection Asso­ciation, Batterymarch Park, Quincy, MA 02269.

ELECTRICAL SHOCK -- Contact with live
electrical parts and ground can cause
severe injury or death. DO NOT use AC
welding current in damp areas, if move­ment is confined, or if there is danger of
falling.

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

2. Connect the workpiece to a good electrical ground.

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

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

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

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

and from ground.

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

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

9. Turn off the power before removing your gloves.

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

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

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

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

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

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

cables. Route cables on the same side of your body.
D. Connect the work cable to the workpiece as close as

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

from your body as possible.

5

10/98

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

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.

6

SP98-10

SECTION 1 PRECAUCION DE SEGURIDAD

ADVERTENCIA: Estas Precauciones de

Seguridad son para su protección. Ellas hacen
resumen de información proveniente de las
referencias listadas en la sección "Información

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

PROTEJASE USTED Y A LOS DEMAS-­Algunos procesos de soldadura, corte y
ranurado son ruidosos y requiren protección
para los oídos. El arco, como el sol , emite
rayos ultravioleta (UV) y otras radiaciones

que pueden dañar la piel y los ojos. El metal
caliente causa quemaduras. EL entrenamiento en el uso
propio de los equipos y sus procesos es esencial para
prevenir accidentes. Por lo tanto:

1. Utilice gafas de seguridad con protección a los lados siempre

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

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

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

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

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

4. Chispas y partículas de metal caliente puede alojarse en las

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

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

1. Remueva todo material combustible lejos del área de trabajo

o cubra los materiales con una cobija a prueba de fuego.
Materiales combustibles incluyen madera, ropa, líquidos y
gases flamables, solventes, pinturas, papel, etc.

2. Chispas y partículas de metal pueden introducirse en las

grietas y agujeros de pisos y paredes causando fuegos
escondidos en otros niveles o espacios. Asegúrese de que
toda grieta y agujero esté cubierto para proteger lugares
adyacentes contra fuegos.

3. No corte, suelde o haga cualquier otro trabajo relacionado

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

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

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

6. Después de termirar la operación del equipo, 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 §25249.5 et seq.)

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

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

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

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

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

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.

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

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

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

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

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."

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 pe

rsona.

8

SECTION 1 PRÉCAUTIONS DE SÉCURITÉ

A VERTISSEMENT: 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 combus-

tibles du secteur où l’on exécute des soudures ou des
coupes à l’arc, à moins de les recouvrir complètement
d’une bâche non-inflammable. Ce type de matériaux
comprend notamment le bois, les vêtements, la sciure,
l’essence, le kérosène, les peintures, les solvants, le
gaz naturel, l’acétylène, le propane et autres sub­stances combustibles semblables.

b. Les étincelles ou les projections de métal incandes-

cent peuvent tomber dans des fissures du plancher ou
dans des ouvertures des murs et y déclencher une
ignition lente cachée. Veiller à protéger ces ouvertures
des étincelles et des projections de métal.

c. N’exécutez pas de soudures, de coupes, d’opérations

de gougeage ou autres travaux à chaud à la surface
de barils, bidons, réservoirs ou autres contenants
usagés, avant de les avoir nettoyés de toute trace de
substance susceptible de produire des vapeurs
inflammables ou toxiques.

d. En vue d’assurer la prévention des incendies, il

convient de disposer d’un matériel d’extinction prêt à
servir immédiatement, tel qu’un tuyau d’arrosage, un
seau à eau, un seau de sable ou un extincteur portatif.

e. Une fois le travail à l’arc terminé, inspectez le secteur

de façon à vous assurer qu’aucune étincelle ou projec­tion de métal incandescent ne risque de provoquer
ultérieurement un feu.

3. CHOC ÉLECTRIQUE-- Le gougeage à l’arc et à l’arc
au plasma exige l’emploi de tensions à vide
relativement importantes; or, celles-ci risquent de
causer des dommages corporels graves et même
mortels en cas d’utilisation inadéquate. La gravité du
choc électrique reçu dépend du chemin suivi par le
courant à travers le corps humain et de son intensité.

a. Ne laissez jamais de surfaces métalliques sous ten-

sion venir au contact direct de la peau ou de
vêtements humides. Veillez à porter des gants bien
secs.

b. Si vous devez effectuer un travail sur une surface

métallique ou dans un secteur humide, veillez à assu­rer votre isolation corporelle en portant des gants secs
et des chaussures à semelles de caoutchouc et en
vous tenant sur une planche ou une plate-forme
sèche.

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

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

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

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

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

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

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

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

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. Arrêtez­vous de travailler afin de prendre les mesures néces­saires à l’amélioration de la ventilation. Ne poursuivez
pas l’opération entreprise si le malaise persiste.

d. Certaines commandes comportent des canalisations

où circule de l’hydrogène. L’armoire de commande est
munie d’un ventilateur destiné à empêcher la forma­tion de poches d’hydrogène, lesquelles présentent un
danger d’explosion; ce ventilateur ne fonctionne que
si l’interrupteur correspondant du panneau avant se
trouve placé en position ON (Marche). Veillez à
manœuvrer cette commande en vérifiant si le
couvercle est bien en place, de façon à assurer
l’efficacité de la ventilation ainsi réalisée. Ne jamais
débrancher le ventilateur.

e. Les fumées produites par l’opération de soudage ou

de coupage peuvent s’avérer toxiques. Aussi est-il
nécessaire de disposer en permanence d’un dispositif
adéquat de ventilation de type aspirant, afin d’élimi­ner du voisinage de l’opérateur tout dégagement de
fumée visible.

f. Consultez les recommandations particulières en

matière de ventilation indiquées à l’alinéa 6 de la
norme Z49.1 de l’AWS.

5. ENTRETIEN DE L’ÉQUIPEMENT-- Un équipement
entretenu de façon défectueuse ou inadéquate risque
non seulement de réaliser un travail de mauvaise
qualité mais, chose plus grave encore, d’entraîner des

dommages corporels graves, voire mortels en
déclenchant des incendies ou des chocs électriques.
Observez par conséquent les précautions suivantes:

a. Efforcez-vous de toujours confier à un personnel qua-

lifié l’installation, le dépannage et l’entretien du poste
de soudage et de coupage. N’effectuez aucune
réparation électrique sur l’équipement à moins d’être
qua-lifié à cet effet.

b. Ne procédez jamais à une tâche d’entretien

quelconque à l’intérieur du poste de soudage/
coupage, avant d’avoir débranché l’alimentation
électrique.

c. Maintenez en bon état de fonctionnement les câbles,

le câble de masse, les branchements, le cordon
d’alimentation et le poste de soudage/coupage.
N’utilisez jamais le poste ou l’équipement s’il présente
une défectuosité quelconque.

d. Prenez soin du poste de soudage et de coupage et

des équipements accessoires. Gardez-les à l’écart
des sources de charleur, notamment des fours, de
l’humidité, des flaques d’eau maintenez-les à l’abri des
traces d’huile ou de graisse, des atmosphères corro­sives et des intempéries.

e. Laissez en place tous les dispositifs de sécurité et tous

les panneaux de l’armoire de commande en veillant à
les garder en bon état.

f. Utilisez le poste de soudage/coupage conformément à

son usage prévu et n’effectuez aucune modification.

6. INFORMATIONS COMPLÉMENTAIRES RELATIVES
À LA SÉCURITÉ--

Pour obtenir des informations complémentaires sur les

règles de sécurité à observer pour le montage et
l’utilisation d’équipements de soudage et de coupage
électriques et sur les méthodes de travail
recommandées, demandez un exemplaire du livret N°
52529 “Precautions and Safe Practices for Arc Weld­ing, Cutting and Gouging” publié par ESAB. Nous
conseillons également de consulter les publications
sui-vantes, tenues à votre disposition par l’American
Welding Society, 550 N.W. LeJuene Road, Miami, FL
32126:

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

Welding “AWS A6. 1.

c. “Safe Practices for Welding and Cutting Containers

That Have Held Combustibles” AWS-A6.0.

d. “Recommended Safe Practices for Plasma Arc Cut-

ting” 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.

10

9/97

SECTION 2 DESCRIPTION

■

Multi-process, three phase power source de­signed for heavy duty Industrial DC welding
applications.

■

Use for High Performance Mig, Pulse Mig, Flux
Cored wire, Stick electrode welding, Tig and Air
Carbon Arc Gouging

■

SuperSwitch T echnology design, provides superior
inverter like performance in the welding arc while
providing SCR like reliability.

■

Variable inductance for fine tuning of the arc
characteristics in short arc welding.

■

Built-in arc force control for superior stick electrode
performance.

■

Digital preset of voltage/amperage on all process at
the front panel.

■

Sheet metal parts and hardware made of stainless
steel. T op and side panel made of Kydex polymer
for superior durability in harsh environments.

■

Auto Fan feature standard in the unit for energy
savings. Automatically turns the fan motor on and
off when needed.

■

Energy and power efficient, the best in its class
with a 92% efficiency figure. Saves energy and
reduces power costs. Uses up to 50% less
current than conventional SCR machines. See
chart, next page.

■

Convenient 115Vac auxiliary power receptacle.

■

Synergic / Non-Synergic Mig Pulse welding
capability with the intelligence built into the power
source (Standard on pulse unit, optional in the
standard unit) Allows you to do Pulse Mig with
almost any wire feeder.

■

100% Solid State, no mechanical contactor

■

Compatible with DuraDrive 4-30 and DuraDrive 4­48 wire feeders.

Specifications:

Rated DC Output @ 100% Duty Cycle

50/60Hz, cv or cc .............................. .450 amps 38 vdc

Rated DC Output @ 60% Duty Cycle

50/60Hz, cv or cc ............................... 500 amps 39 vdc

Welding Range .................................. 10A/12V to 500A/40V

Open Circuit Voltage Max. .......................................... 80vdc

Primary Input Voltage and Current @ 100% Duty Cycle

230/460/575Vac, 60Hz 3ph ...................66/33/26 amps

Power Factor at Rated Output ...................................... 89%

Efficiency at Rated Output ............................................ 92%

Auxiliary Output Power .............. 115Vac 50/60Hz, 10 amps

Physical Dimensions:

WxLxH ........... 18.8”(483mm), 32.5” (819mm), 25”(622mm)

Net Weight .................................................322 lbs.(146 Kg)

Shipping Weight......................................... 375 lbs. (170Kg)

How to Order:

Multipower 460PULSE 230/460/575Vac

50/60 Hz 3ph .........................................0558002877

11

SECTION 2 DESCRIPTION

Options & Accessories:

Remote Hand Control...........................0558002871

This pendant 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 460PULSE control panel must be placed in the RE­MOTE position when using this accessory. The pendant has
the capability to change weld processes and is designed to
work with wire feeders without remote voltage control.

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

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

Wire Feeder Swivel Mount Kit......................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.

Remote Hand Control

Primary Line Current Draw (amps)

B

ESA

45
40
35
30
25
20
15
10

3

5
0

50

1/16" Cored Wire Comparison

welding @ 300a 28v - 40% du ty cy cle

0i

cv

5

Mpi

-4

I

353

B

E

B 453cv

A

S

ESAB 452cvcc

ESAB 653cvcc

lle

ltiPower 460 Pulse

i

u

M

M

Dimension

r

SV

ESA

Primary Line Current Draw Power Factor

TR-29 Truck Kit

90%
80%
70%
60%
50%
40%
30%
20%

Power Factor

10%
0%

0

452

40

C

ln D

o

c

n

Li

Multipower 460 Better than the Competition

12

SECTION 2 DESCRIPTION

2.0. GENERAL

Before the Multipower 460PULSE 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 460PULSE 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 460PULSE

OPEN CIRCUIT VOLTAGE (U2) 80V DC Max.

DUTY CYCLE 60% 100%

Current (I

Voltage (U

60 Hz

3 Phase

50 Hz

Power F acto r a t Rated Outp ut 89 %

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

PHYSICAL SPECIFICATIONS

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 375lbs (170 kg)

13

SECTION 2 DESCRIPTION

The Multipower 460PULSE is a multi-process power source designed for Mig
short circuiting, spray and pulse spray transfer (GMAW), flux core (FCAW), Tig
(GTAW), and stick (SMAW) welding and air carbon arc cutting/gouging (CAC­A) 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 460PULSE 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 2-1 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 2-1 - Multipower 460 Volt-Ampere Curves

14

SECTION 2 DESCRIPTION

C. CONTROL PANEL DESCRIPTION

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

1. FAULT LAMP

The RED fault light on the Multipower 460PULSE front panel indicates a
problem with set-up parameters. A "Steady" light "On" indicates there is no
program for the material and wire diameter selected. A "Blinking" light
indicates the wire feed speed is out of the recommended range.

2. TEMPERATURE LAMP

The TEMP lamp illuminates if an over temperature condition occurs within the
Multipower 460PULSE 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.
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
feeder is rotated. The WFS LED beside the top display meter will light when
the display is showing wire feed speed.

wire

Power “ON”

Lamp

Temperature

Lamp

Fault

Lamp

Digital Meter

Volts

Digital Meter

Amps/WFS

Figure 2-3. Pulse Control Panel

15

WFS - IPM

Lamp

Amps
Lamp

SECTION 2 DESCRIPTION

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.

For MIG PULSE welding, the arc length (arc voltage) is controlled with this
knob. The WELD PROCESS switch is placed in the MIG position and the
MIG MODE switch is placed in the PULSE position. The TRIM PRESET knob
should be place at the 12 o'clock position as the synergic preset for the wire
feed speed, WIRE TYPE and WIRE DIAMETER chosen by the operator using

A DuraDrive Wire Feeder is required to

NOTE:

preset wire feed speed.

the PULSE SELECTION switches. The arc length can then be adjusted by
turning the knob clockwise to increase the arc length or counterclockwise to
decrease the arc.

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.

7. INDUCTANCE TRIM

This control is used only in the MIG process mode and is deactivated in the
TIG, STICK and MIG PULSE 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

Preset
Button

Current
Voltage

Mig Mode

Switch

Panel/
Remote

Material Selection

(Pulse)

Weld Process

Switch

Inductance

Figure 2-4. Pulse Control Panel

16

Wire Diameter

Selector (Pulse)

SECTION 2 DESCRIPTION

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.

8. MODE SWITCH

This switch enables the Mig pulse or standard operation mode. When this
switch is in the PULSE position, the pulse parameters are determined by the
WIRE TYPE and WIRE DIAMETER position on the PULSE SELECTION
switches. Use the STANDARD position for CV MIG, TIG and STICK welding.
The Multipower 460 will default to minimum voltage if trying to TIG or STICK weld
in the PULSE position.

9. PULSE SELECTION SWITCHES

WIRE TYPE

Use this switch to select the WIRE TYPE installed on the wire feeder. The
position of this switch and the WIRE DIAMETER switch selects the pulse
parameters to be used during welding in the Mig pulse mode.

WIRE DIAMETER

Use this switch to select the WIRE DIAMETER installed on the wire feeder.
The position of this switch and the WIRE TYPE switch selects the pulse
parameters to be used during welding in the Mig pulse mode.

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. (Refer to Figure 2-1)

Main Power

Control Panel

Circuit Breakers

CB1 & 2

Wire Feeder

Connector

Contactor On/Off

Switch

Remote Pendant

Connection

On/Off Switch

115 Vac

10 Amps

Receptacle

Connections

Output

Figure 2-5. Multipower 460

17

SECTION 2 DESCRIPTION

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.

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.

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 CO
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 6-1 provides troubleshooting information).

regulator, or small hand tools. The receptacle is

2

18

SECTION 3 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

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.

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

1. 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.

2. Remove the power source from the container. Remove all packing
materials. Check the container for any loose parts.

3. Check air passages at front and rear of cabinet, making sure that
packing material has not obstructed air flow through the power source.

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

5. 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 three­phase 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 listed above.

68
66
37
33
26

Input &

GND

Conductor*

CU/AWG

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

No. 10

Fuse

Size

Amps

100
100

60
60
50

19

SECTION 3 INSTALLATION

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.

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.

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 through 3-6.

3. When using the provided strain relief, refer to Figure 3-2 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.

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 Primary Power Leads

L1, L2, L3 & Ground

(3) PRIMARY

INPUT

CONDUCTORS

24"

Green

Figure 3-2 Recommended Cable Strip Lengths

20

SECTION 3 INSTALLATION

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.

230 Vac Input 460 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

575 Vac Input

*

*

*

220 Vac Input

Figure 3-5 Input T erminal Board Configuration 220/

400 Model (factory supplied in the 400 configuration)

21

400 Vac Input

SECTION 3 INSTALLATION

D. OUTPUT WELDING CONNECTIONS

(SECONDARY)

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.

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 460PULSE. The secondary output cable connects
(in most cases) between the positive output lug of the Multipower 460PULSE
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 460PULSE 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 Length (Feet) of

Welding

Current

50 100 150 200 250

Cable in Weld Circuit*

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.

2/0

3/0

6

4

3

2

1

1/0

2/0

3/0

3/0

4

3

1

1/0

2/0

3/0

4/0

4/0

3

1

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

22

SECTION 4 OPERATION

4.0. OPERATION

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.

NOTE

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

A. WIRE FEEDER COMPATIBILITY

The Multipower 460PULSE 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 feeder control

Table 4-1. Wire Feeder Compatibility

MIG MODE SWITCH*

STAN DARD

(Mul tiPower 460 )

Wire Feeder

Mig 4HD

DuraDriv e 4-30 Feeder X X Optional
DuraDriv e 4-48

Mig 2E Feeder X N/A

Mig 5XL

(Mongoose)

MobileMaster IV

(Off the Ar c)

Mini 8

(Off the Ar c)

N/A - N ot Availabl e
* - Process switc h M US T be in the MIG pos i t ion.
** - See Sy nergic/NonSynergic des cription section for configuration information

Arc Trim Location

from:

MP-460 Panel X X Optional

Remote Pendant X X Optional

MP-460 Panel X X Optional

Feeder X N/A N/A X

Remote Pendant X N/A X

MP-460 Panel X N/A X

PANEL REMOTE Synergic

(Applies to Multipower 460PULSE only)

PULSE

(Mul tiPower 4 60 P u lse)

Non-

Synergic**

The digital wire feed speed meter on the

NOTE

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 approxi­mately 75 Vdc even if the OCV (Open
Circuit Voltage) is higher. The Multipower
460 has the following OCV"s:

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

panel. To see the preset wire feed speed, press the PRESET button on the
Multipower 460PULSE 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 460PULSE 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 460PULSE 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”.

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,

23

SECTION 4 OPERATION

the display will show average welding current and volts in the top and bottom
display, respectively. After welding stops, the current display will again 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
460PULSE 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 460PULSE and set PANEL/RE-

MOTE switch to REMOTE position.
Step 2. Set the MIG MODE switch to the STANDARD position.
Step 3. Place the WELD PROCESS switch in the MIG (center) position.

"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 4. Press and release the PRESET button then turn the

trol on the wire feeder to the desired speed shown on the top digital

display window of the Multipower 460PULSE.
Step 5. Turn the VOL TAGE knob

age in the bottom digital display window of the Multipower

460PULSE.

4

Figure 4-1 Standard Mig Setup Procedure

on the wire feeder to the desired arc volt-

2

1

wire speed con-

3

Step 6. 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 ad-

justment knob on the Flowmeter.

Step 7. 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 .

24

SECTION 4 OPERATION

F. TIG WELDING

When the PROCESS switch is placed in the TIG position, the Multipower
460PULSE 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 connecting

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. Place MIG MODE PULSE switch in the STANDARD position.
Step 5. While depressing the PRESET button, turn the VOLTAGE/CURRENT

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
Curent knob to the maximum desired
weld current. The remote device will then
control the current between minimum and
the maximum setting preset.

Step 6. Set the shielding gas flow rate to 20 cfh by adjusting the control knob on

Step 7. Touch the tungsten electrode to the workpiece momentarily then lift

knob to the desired weld current as displayed on the top digital display

window.

the flowmeter.

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

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

5

Figure 4-2 Standard Tig Setup Procedure

G. STICK WELDING

When the PROCESS switch is placed in the STICK position, the Multipower
460PULSE 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.

4

3

2

25

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. Place MIG MODE PULSE switch in the STANDARD position.
Step 5. While holding the PRESET button, turn the VOL T AGE/CURRENT knob

to the desired weld current in the top digital display window .
Step 6. Strike the electrode on the workpiece and start welding. Trim the

welding current as needed for the desired weld pool control.

5

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.

4

3

2

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.

Step 4. Place MIG MODE PULSE switch in the STANDARD position.

26

SECTION 4 OPERATION

Step 5. 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.

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

touching or scratch starting the electrode.

3

4

1

2

5

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

NOTE:

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

Figure 4-4 Carbon Arc Setup Procedure

Figure 4-5 Contactor Switch

for Carbon Arc Setup

5

CV

Carbon Arc

Gouging

ONLY!!!!!!!

I. MIG PULSE WELDING

The Multipower 460PULSE is designed to provide simple to use, high quality,
preprogrammed synergic and non-synergic pulsed Mig welding. Synergic pulsed
Mig welding means that pulse parameters (such as pulse height, pulse width,
background current and pulse frequency) are automatically adjusted by the
Multipower 460PULSE as the wire feed speed is changed by the operator.

A unique non-synergic Mig pulse mode is also offered for welding applications
and wire feeder combinations that cannot use the preprogrammed synergic pulse
data.

27

SECTION 4 OPERATION

The preprogrammed wire types, wire diameters and shielding gases are
listed in Table 4-2.

The TRIM allows the operator to fine tune the pulse arc length and optimize the
welding. When the PROCESS switch is placed in the MIG position and the MIG
MODE switch is placed in the PULSE position, the Multipower 460PULSE is set
for CC over CC (constant current) pulse welding. The power source will output
open circuit voltage (OCV) when the Mig Gun trigger is depressed. The
Multipower 460PULSE provides a TRIM from either the wire feeder or power
source depending on the position of the PANEL/REMOTE switch characteris­tics. The TRIM adjustment is calibrated such that the preprogrammed synergic
pulse data is approximately at the 12 o'clock position of the TRIM knob. The
operator should preset the voltage control on the wire feeder to the 12 o'clock
position and adjust for best arc characteristics.

The operator can change to STANDARD MIG (CV) by simply moving the MIG
MODE switch to the STANDARD position.

Table 4-2. Wire Types, Diameter and Shield Gases

Material Type Diameters

Carbon Steel

Stainless St eel

4000 & 5000

Al um i num

Meta l Co re

Carbon Steel

Meta l Co re

Stainless St eel

.035, .040, .045,

.052, .062

.035, .040, .045,

.062

.035, .040, 3/64,

.062

.035, .040, .045,

.052, .062

.045, .062

Shielding Gas

(AW S D esignation)

Ar - 5% CO2 (SG-AC-5)
Ar - 8% CO2 (SG-AC-8)

Ar - 10% CO2 (SG-AC-10)

Ar - 2% O2 (SG-AO-2)

Ar - 8% CO2 - 2% O2 (SG-AC O-8/2)

Ar -2% CO2 (SG-AC-2)

Ar - 8% CO2 (SG-AC-8)

Ar - 2% O2 (SG-AO-2)

Ar - 8% CO2 - 2% O2 (SG-AC O-8/2)

Ar - He

Ar ( SG- A)
Ar - He 25% (SG-AHe-25)
Ar - He 50% (SG-Ahe- 50)

Ar - 5% CO2 (SG-AC-5)
Ar - 8% CO2 (SG-AC-8)

Ar - 10% CO2 (SG-AC-10)

Ar - 2% O2 (SG-AO-2)

Ar - 8% CO2 - 2% O2 (SG-AC O-8/2)

Ar - 2% CO2 (SG-AC-2)
Ar - 8% CO2 (SG-AC-8)
Ar - 1% CO2 (SG-AC-1)

Ar - He 50% - 2% CO2 (SG-AHeC-50/2)

28

SECTION 4 OPERATION

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. See
Table 4-2 for the recommended shielding gases for each wire alloy type. Set the
flowrate at 30 to 40 cfh for argon mixtures.

A. PULSE MIG SETUP

Step 1. Place the WELD PROCESS switch in the MIG (center) position
Step 2. Set the MIG MODE switch to the PULSE position.
Step 3. Set the PANEL/REMOTE switch to the REMOTE position.
Step 4 Set the PULSE SELECTION switches to the WIRE TYPE and WIRE

DIAMETER installed on the wire feeder .

Step 5. Press and release the PRESET button. Turn the wire speed knob on

the wire feeder to the desired speed in the top digital display win­dow of the Multipower 460PULSE.

Step 6. 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 7. Set the voltage knob on the wire feeder to the "5" or center 12 o'clock

position.

Step 8. Connect the work cable to the workpiece and pull the gun trigger to

start welding.

5

Figure 4-6 Synergic Pulse MIG Setup

2

3

1

4

Step 9. The volt age knob on the wire feeder becomes the ARC TRIM and is

used to fine tune the arc length for best arc performance. Turn the
knob clockwise to increase the arc length or counterclockwise to de­crease the arc. Trim the wire speed and volts as needed for the de­sired arc characteristics and weld quality .

29

SECTION 4 OPERATION

B. PULSE PROCESS CONTROL

1. Use a tip-to-work distance (TTW) of 3/8" to 5/8". This refers to the
distance between the end of the Mig gun contact tip and the work­piece or weld puddle. The tip-to-work distance can also be used to
adjust the stability of the arc. Changes in distance will cause the arc to
shorten or lengthen as desired for best results. Excessive tip to work
movement can cause arc instability . Maint aining a constant TTW will
insure the best arc stability and consistency .

2. For the best arc stability , keep the arc on the front edge of the molten
puddle and use a 5 to 10 degree gun angle from the vertical.

3. If the arc is "crackling" or if spatter is excessive lengthen the arc. If the
arc is "fluttering" or difficult to control then shorten the arc length.

C. PULSE MIG ARC STABILITY

Many variables can affect the arc stability of pulse MIG
welding. Some examples are:

Differences in shielding gas compositions
Differences in weld wire chemistry
Water vs. air cooled guns
Base metal surface condition
Tip-to work distance
Variations on wire feed speed
Wire feedability
Long welding cables
High resistance cables and connections

When adverse conditions are present, the pulse arc stability is sometimes less
than desirable. The arc will "crackle" and produce higher than normal spatter
levels. This occurs when high resistances in the welding circuit cause changes
pulse waveform and average current levels or the wire feed rate is varying
excessively. The TRIM knob adjusts the pulse frequency to accommodate
small changes in the welding equipment set-up and base material variations to
achieve a stable pulse welding condition.

D. SHIELDING GASES

Table 4-2 lists the types of shielding gas mixtures that can be used with the
Multipower 460PULSE. The wire burn-off rate and synergic operation can vary
with changes in shielding gas. The TRIM knob is used to compensate for small
changes in shield gas composition.

E. NON-SYNERGIC PULSE OPERATION

The Multipower 460PULSE has the unique ability to Pulse MIG weld in the NON­SYNERGIC mode. Non-synergic operation means the pulse parameters can
be selected by choosing the WIRE TYPE, WIRE DIAMETER, and presetting a
WIRE FEED SPEED on the Multipower 460PULSE panel. The pulse frequency
or arc length (TRIM) is controlled by the TRIM knob. The TRIM knob is
adjustable from the minimum to maximum pulse frequency. By using a
combination of adjusting the wire feed speed on the wire feeder and TRIM setting
on the Multipower 460PULSE, the pulse Mig welding arc can be tuned in and
stabilized.

30

SECTION 4 OPERATION

The selectable pulse parameters are any combination of WIRE TYPE or WIRE
DIAMETER selected using the PULSE SELECTION switches. Not all combina­tions will produce acceptable pulse characteristics but by using the pulse tables
provided in this manual, reasonable pulse combinations can be selected for trial.
This will take some trial and error but the added flexibility and expanded pulse
range of the non-synergic mode can be beneficial for many welding applications.

There are several unique advantages to Non Synergic pulse mig welding. The
Non -Synergic mode of operation permits pulse welding when:

1. A wire feeder without tachometer feedback is used.

2. An "Off the Arc" wire feeder is used

3. The Mig wire type or diameter installed on the wire feeder does not have
a pulse synergic line available..

4. Pulse arc characteristics other than those preprogrammed are desired.

To take advantage of the Multipower 460 Pulse Non-Synergic mode, it is
necessary to reposition a jumper plug and/or connector in the main control panel
wiring harness. Remove the Multipower 460 control panel and locate the jumper
plug in the wiring harness in the PC board compartment.

Jumper Plug Installed (Factory Shipped)
Synergic Mode - Pulse circuitry is looking for a 1 volt per 100 inches per minute

signal to determine the pulse parameters required to make the weld.

Figure 4-7 Jumper Plug Installed (Factory Shipped)

Jumper Plug Removed and Harness connected
Non-Synergic Mode - The pulse parameters are determined by the position of

the pulse selection switches, the Multipower 460PULSE TRIM knob and Wire
Feed Speed set on the wire feeder.

Figure 4-8 Jumper Plug Removed and Harness Connected

31

SECTION 4 OPERATION

F. PULSE PARAMETERS

Tables 4-3 through 4-8 list the approximate pulse weld parameters for each material
and diameter available. These are provided for general reference only. Actual pulse
parameters can vary with the equipment set-up, welding application and shielding
gases being used. The wire feed speed ranges shown in the tables are the same
as programmed into the Multipower 460 Micro. Attempting to weld outside of the
suggested speed ranges will result in a "blinking" warning light on the Multipower
460 front panel. A "steady" light on the panel indicates the wire material and
diameter combination selected does not have any pulse data programmed.

32

-

-

-

-

SECTION 4 OPERATION

Table 4-3 Multipower 460PULSE Carbon Steel Data Table

.035 Steel .040 Steel

WFS

Range

(IPM)

75 312 1.70 19 52 75 304 2.40 25 42
125 318 1.70 26 70 125 318 2.40 34 58
175 325 1.70 32 87 175 332 2.40 44 75
225 331 1.70 39 105 225 346 2.40 53 92
275 337 1.70 46 123 275 360 2.40 62 108
325 343 1.70 52 141 325 374 2.40 71 125
375 350 1.70 59 158 375 388 2.40 80 141
425
475 362 1.70 72 194 475 416 2.40 98 174
525 368 1.70 79 212 525 430 2.40 107 191
575 375 1.70 85 229 575 444 2.40 116 207
625 381 1.70 92 247 625 458 2.40 125 224
675 387 1.70 98 265 675 472 2.40 135 241
725 394 1.70 105 283 725 486 2.40 144 257

Pulse

Peak

(Amps)

356 1.70 65 176

Pulse

Width

(ms)

Pulse Back

ground
(Amps)

Pulse

Frequency

(Hz)

WFS

Range

(IPM)

425

Pulse Peak

(Amps)

402 2.40 89 158

Pulse
Width

(ms)

Pulse Back

ground
(Amps)

Pulse

Frequency

.045 Steel .052 Steel

WFS

Range

(IPM)

125 441 2.20 45 64 100 400 2.50 80 56
175 451 2.20 56 85 175 400 2.50 80 93
225
275 471 2.20 79 128 325 400 2.50 80 169
325
375 491 2.20 101 171 475 400 2.50 80 244
425 501 2.20 113 192 550 400 2.50 80 282
475 511 2.20 124 213 625 400 2.50 80 320
525 521 2.20 135 235 700 400 2.50 80 358
575

Pulse

Peak

(Amps)

461 2.20 68 106

481 2.20 90 149

531 2.20 146 256

Pulse
Width

(ms)

Pulse Back

ground
(Amps)

Pulse

Frequency

(Hz)

WFS

Range

(IPM)

250

400

Pulse Peak

(Amps)

400 2.50 80 131

400 2.50 80 207

Pulse
Width

(ms)

Pulse Back

ground
(Amps)

Pulse

Frequency

(Hz)

(Hz)

1/16 Steel

WFS

Range

(IPM)

50

100 524 2.50 80 71
150 529 2.50 114 103
200 534 2.50 148 134
250 540 2.50 182 166
300 545 2.50 216 197
350 550 2.50 250 228
400

Pulse

Peak

(Amps)

518 2.50 45 40

556 2.50 284 260

Pulse
Width

(ms)

Pulse

Back-
ground
(Amps)

33

Pulse

Frequency

(Hz)

-

-

-

-

SECTION 4 OPERATION

Table 4-4 Multipower 460PULSE Stainless Steel Data Table

.035 Stainless .040 Stainless

WFS

Range

(IPM)

100
150
200
250
300
350
400
450
500
550
600
650
700

WFS

Range

(IPM)

125
175
225
275
325
375
425
475
525
575
625

Pulse

Peak

(Amps)

300 1.64
300 1.71
300 1.78
300 1.86
300 1.93
300 2.00
300 2.07
300 2.14
300 2.21
300 2.28
300 2.35
300 2.42
300 2.49

Pulse
Width

(ms)

Pulse Back

ground
(Amps)

20
24
27
31
35
39
42
46
50
53
57
61
65

Pulse

Frequency

(Hz)

55
71

88
104
120
136
153
169
185
201
218
234
250

WFS

Range

(IPM)

100
150
200
250
300
350
400
450
500
550
600
650
700

Pulse Peak

(Amps)

234 2.80
244 2.80
255 2.80
265 2.80
275 2.80
285 2.80
296 2.80
306 2.80
316 2.80
327 2.80
337 2.80
347 2.80
358 2.80

Pulse
Width

(ms)

.045 Stainless .052 Stainless

Pulse

Peak

(Amps)

305 2.70
325 2.70
345 2.70
365 2.70
385 2.70
405 2.70
426 2.70
446 2.70
466 2.70
486 2.70
506 2.70

Pulse
Width

(ms)

Pulse Back

ground
(Amps)

58
65
71
77
84
90

97
103
110
116
122

Pulse

Frequency

(Hz)

81
100
119
138
157
176
195
214
233
252
271

WFS

Range

(IPM)

Pulse Peak

(Amps)

Pulse
Width

(ms)

NO PROGRAM

Pulse Back

ground
(Amps)

19
45
71

97
123
148
174
200
226
252
277
303
329

Pulse Back

ground
(Amps)

Pulse

Frequency

(Hz)

47
62
78

93
108
124
139
155
170
185
201
216
231

Pulse

Frequency

(Hz)

1/16 Stainless

Pulse

Back-
ground
(Amps)

Pulse

Frequency

(Hz)

WFS Range

(IPM)

50
100
150
200
250
300
350
400
450
500

Pulse

Peak

(Amps)

428 2.00 47 72
453 2.00 84 10 5
478 2.00 122 137
503 2.00 160 170
528 2.00 197 202
553 2.00 235 235
578 2.00 272 267
603 2.00 310 300
627 2.00 347 333
652 2.00 385 365

Pulse

Width

(ms)

34

-

-

SECTION 4 OPERATION

Table 4-5 Multipower 460PULSE 4000 Aluminum

.035 4043 AIuminum .040 4043 Aluminum

WFS

Range

(IPM)

200
250
300
350
400
450
500
550
600
650

WFS

Range

(IPM)

150
200
250
300
350
400
450
500
550
600

Pulse

Peak

(Amps)

239 1.80 32 89
246 1.80
253 1.80
260 1.80
266 1.80 79 152
273 1.80
280 1.80
287 1.80 113 200
294 1.80
301 1.80

Pulse

Peak

(Amps)

206 2.20 22 138
226 2.20
246 2.20
267 2.20 98 192
287 2.20
307 2.20
327 2.20 174 245
347 2.20
367 2.20
387 2.20 250 299

Pulse
Width

(ms)

Pulse
Width

(ms)

Pulse Back-

ground
(Amps)

44
56
67

90

102

125
137

Pulse Back-

ground
(Amps)

47
73

123
149

199
225

Frequency

Frequency

Pulse

(Hz)

105
121
137

168
184

216
231

Pulse

(Hz)

156
174

210
228

263
281

WFS

Range

(IPM)

150
200
250
300
350
400
450
500
550
600
650

WFS

Range

(IPM)

Pulse Peak

(Amps)

218 1.80 33 70
232 1.80
246 1.80
259 1.80
273 1.80 78 1 46
287 1.80
300 1.80
314 1.80 111 203
328 1.80
341 1.80
355 1.80 145 261

Pulse
Width

(ms)

Pulse Back

ground
(Amps)

45
56
67

89

100

123
134

.052 4043 Aluminum3/64 4043 Aluminum

Pulse Peak

(Amps)

Pulse
Width

(ms)

Pulse Back

ground
(Amps)

NO PROGRAM

Pulse

Frequency

(Hz)

89
108
127

165
184

222
242

Pulse

Frequency

(Hz)

1/16 4043 Aluminum

Pulse

Back-
ground
(Amps)

WFS Range

(IPM)

175
225
275
325
375
425
475
525

Pulse Peak

(Amps)

376 2 .30 89 117
407 2 .30 119 142
437 2 .30 149 167
468 2 .30 179 191
499 2 .30 209 216
530 2 .30 239 240
561 2 .30 269 265
592 2 .30 299 289

Pulse
Width

(ms)

35

Pulse

Frequency

(Hz)

SECTION 4 OPERATION

Table 4-6 Multipower 460PULSE 5000 Aluminuml Data Table

.035 5356 Aluminum .040 5356 Aluminum

WFS

Range

(IPM)

200
250
300
350
400
450
500
550
600
650

Pulse

Peak

(Amps)

260 1.70
264 1.70
268 1.70
272 1.70
276 1.70
280 1.70
284 1.70
288 1.70
292 1.70
296 1.70

Pulse
Width

(ms)

Pulse Back-

ground
(Amps)

14
20
26
31
37
43
48
54
60
66

Pulse

Frequency

(Hz)

66
81

97
112
127
142
157
173
188
203

WFS

Range

(IPM)

150
200
250
300
350
400
450
500
550
600
650
700

Pulse Peak

(Amps)

236 1.70
245 1.70
254 1.70
263 1.70
272 1.70
281 1.70
290 1.70
299 1.70
308 1.70
317 1.70
326 1.70
335 1.70

Pulse
Width

(ms)

Pulse

Back-
ground
(Amps)

26
33
40
47
54
61
68
75
82
89
96

103

Pulse

Frequency

(Hz)

53
70

86
103
119
135
152
168
185
201
218
234

WFS

Range

(IPM)

150
200
250
300
350
400
450
500

Pulse

Peak

(Amps)

206 2.20
226 2.20
246 2.20
267 2.20
287 2.20
307 2.20
327 2.20
347 2.20

Pulse
Width

(ms)

Pulse Back-

ground
(Amps)

22
47
73

98
123
149
174
199

WFS Range

(IPM)

175
225
275
325
375
425
475
525

Pulse

Frequency

(Hz)

138
156
174
192
210
228
245
263

WFS

Range

(IPM)

1/16 5356 Aluminum

Pulse

Peak

(Amps)

376 2.30 68 96
407 2.30 78 116
438 2.30 88 135
469 2.30 99 155
499 2.30 109 175
530 2.30 119 194
561 2.30 129 214
592 2.30 139 234

Pulse

Width

(ms)

Pulse

Back-
ground
(Amps)

.052 5356 Aluminum3/64 5356 Aluminum

Pulse Peak

(Amps)

Pulse
Width

(ms)

NO PROGRAM

Pulse

Frequency

(Hz)

Pulse

Back-
ground
(Amps)

Pulse

Frequency

(Hz)

36

SECTION 4 OPERATION

Table 4-7 Multipower 460PULSE Metal Core Carbon Steel Data Table

.035 Metal Core CS .040 Metal Core CS

WFS

Range

(IPM)

300 300 2.50 39 129
350 306 2.50 49 143
400
450 320 2.50 68 171
500 326 2.50 77 185
550
600 340 2.50 96 213

Pulse

Peak

(Amps)

313 2.50 58 157

333 2.50 86 199

Pulse

Width

(ms)

Pulse

Back-
ground
(Amps)

Frequency

Pulse

(Hz)

WFS

Range

(IPM)

Pulse Peak

(Amps)

Pulse

Width

(ms)

NO PROGRAM

Pulse

Back-
ground
(Amps)

Pulse

Frequency

(Hz)

.045 Metal Core CS .052 Metal Core CS

WFS

Range

(IPM)

100 334 2.50 21 74 75 357 2.70 18 76
175
250 388 2.50 70 117 175 410 2.70 77 111
325 415 2.50 95 138 225 437 2.70 106 129
400
475 468 2.50 144 180 325 491 2.70 165 164
550 495 2.50 168 201 375 518 2.70 194 182
625
700 549 2.50 217 244 475 572 2.70 253 217

Pulse

Peak

(Amps)

361 2.50 46 95

442 2.50 119 159

522 2.50 193 223

Pulse

Width

(ms)

Pulse

Back-
ground
(Amps)

Pulse

Frequency

(Hz)

WFS

Range

(IPM)

Pulse Peak

(Amps)

125

275

425

525 599 2.70 283 235

384 2.70 47 93

464 2.70 136 147

545 2.70 224 200

Pulse

Width

(ms)

Pulse

Back-
ground
(Amps)

Frequency

1/16 Metal Core CS

WFS

Range

(IPM)

75 388 3.20 9 86
125 411 3.20 53 106
175 435 3.20 97 127
225 459 3.20 141 148
275 483 3.20 186 168
325 507 3.20 230 189
375
425 555 3.20 318 230
475 579 3.20 363 251
525

Pulse

Peak

(Amps)

531 3.20 274 210

603 3.20 407 272

Pulse
Width

(ms)

Pulse
Back-

ground

(Amps)

Pulse

Frequency

(Hz)

Pulse

(Hz)

37

SECTION 4 OPERATION

Table 4-8 Multipower 460PULSE Metal Core Stainless Steel Data Table

.035 Metal Core SS .040 Metal Core SS

Pulse

Back-
ground
(Amps)

Pulse

Frequency

(Hz)

WFS Range

(IPM)

Pulse

Peak

(Amps)

Pulse
Width

(ms)

Pulse

Back-
ground
(Amps)

Pulse

Frequency

(Hz)

WFS

Range

(IPM)

Pulse Peak

(Amps)

Pulse
Width

(ms)

NO PROGRAM

.045 Metal Core SS .052 Metal Core SS

WFS Range

(IPM)

125 343 1.90 32 70
200 357 1.90 52 101
275 370 1.90 72 133
350 384 1.90 92 164
425 397 1.90 112 195
500
575 425 1.90 153 258
650 438 1.90 173 289
725 452 1.90 193 320

Pulse

Peak

(Amps)

411 1.90 133 226

Pulse
Width

(ms)

Pulse

Back-
ground
(Amps)

Pulse

Frequency

(Hz)

WFS

Range

(IPM)

NO PROGRAM

Pulse Peak

(Amps)

Pulse
Width

(ms)

NO PROGRAM

Pulse

Back-
ground
(Amps)

Pulse

Frequency

(Hz)

1/16 Metal Core SS

WFS

Range

(IPM)

150 434 2.80 57 143
200 443 2.80 69 167
250 452 2.80 81 191
300
350 470 2.80 105 238
400 479 2.80 117 262

Pulse

Peak

(Amps)

461 2.80 93 214

Pulse
Width

(ms)

38

Pulse
Back-

ground

(Amps)

Frequency

Pulse

(Hz)

SECTION 5

MAINTENANCE

5.0. CLEANING

If this power source does not op­erate properly, stop work imme­diately and investigate the cause
of the malfunction. Maintenance
work must be performed by an
experienced person, and electri­cal work by a trained electrician.
Do not permit untrained persons
to inspect, clean, or repair this
power source. Use only recom­mended replacement parts.

Be sure that the branch circuit or
main disconnect switch is off, or
electrical input fuses are removed,
before attempting any inspection
or work inside the power source.
Placing the power switch in the off
position does not remove all power
from inside the power source.

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.

A. 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.

1. FAN MOTOR

Keep the fan motor free of accumulated dust and lint.

2. TRANSFORMER

Other than periodically cleaning the dust and dirt from the transformer, no
maintenance is required. Ensure that only clean, dry, low pressure air is
used.

Failure to replace worn or dam­aged cables may result in a bare
cable touching a grounded object.
The resulting electrical arc may
injure unprotected eyes and will
present a serious fire hazard.
Body contact with a bare cable,
connector, or conductor may re­sult in severe electrical shock,
causing serious burns or death.

3. 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.

4. OVER TEMPERATURE PROTECTION

If the power source reaches an abnormally high internal temperature, the
thermal protection will deenergize the contactor circuit, shutting down the
power source but leaving the cooling fan on. After the power source has
cooled to a safe level, the thermal protection will automatically reset. While
de-energized, the contactor and wire feeder cannot be operated.

39

SECTION 5

MAINTENANCE

40

SECTION 6

TROUBLESHOOTING

6.0. TROUBLESHOOTING

If the power source is operating improperly, the following troubleshooting
information may be used to locate the source of the trouble.

DISCONNECT primary power at wall
switch, or circuit breaker, before at­tempting inspection or work inside the
power source.

CONDITION ACTION

Unit Inoperative A.

No Output -- Fan
Running

No input power. Check mai n line (user's) switch fuses -- replace if needed.

B.

Poor or improper input (terminal board) connections.

C.

Defective on/off switch on rear panel -- replace.

D.

proper primary hookup, or shorted turn on secondary.

E.

Loss of primary phase. Find & replace defective fuse.

Poor or improper electrical input -- check input connections on TB.

A.

Poor connections at output terminals/work station -- check, tighten or replace.

B.

Main transformer overheating -- thermal switches tripped due to restricted cooling

C.

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

D.

defective, replace.

Check the problem against the symptoms in the following troubleshooting
guide (Table 6-1.) 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.

Table 6-1 Troubleshooting Table

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

Limited Output or Low
Open-Circuit Voltage

Erra tic We ld Current A.

Hig h Output, No
Voltage Control

No 115 Volt ac Output A. Circui t breaker tripped. Check 115V CB2 -- Reset.

Line Fuse Blows When
Power Source is First

Turned On

Wire Feeder is

Inoperative

Input voltage jumper links on terminal board improperly set -- check for proper

A.

voltage.

Poor output connections. Take apart, clean, and reassemble.

B.

Panel-Remote switch in Remote position and remote voltage pot di sabled.

C.

Welding cable size too small -- use correct cables.

Loose welding cable connection (will usually get hot) -- tighten all connections.

B.

Improper wire feeder setup.

C.

PC board defective -- replace.

D.

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.B.Shorted SCR 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.

41

SECTION 6 TROUBLESHOOTING

0558003034-B

Multipower 460PULSE Wiring Diagram

42

SECTION 6 TROUBLESHOOTING

0558003064-A

Multipower 460PULSE Schematic Diagram (Sheet 1 of 3)

43

SECTION 6 TROUBLESHOOTING

0558003064-A

Multipower 460PULSE Schematic Diagram (Sheet 2 of 3)

44

SECTION 6 TROUBLESHOOTING

0558003064-A

Multipower 460PULSE Schematic Diagram (Sheet 3 of 3)

45

SECTION 6 TROUBLESHOOTING

46

SECTION 7 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
parts will be used. The serial number is stamped on the unit nameplate.

B. ORDERING

T o assure proper operation, it is recommended that only genuine ESAB p arts
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.

To order parts 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.

47

SECTION 7 REPLACEMENT PARTS

16

14

12, 13

10

15

17

11

7

4, 5

18

19

8, 9

6

3

2

1

Figure 7-1 - Front View, Multipower 460PULSE

48

SECTION 7 REPLACEMENT PARTS

Figure 7-1 - Front View, Multipower 460PULSE

QTY . ITEM CIRCUIT

NO. REQ. NO. DESCRIPTION SYMBOL

1 2 678025 Terminal Assembly
2 1 952219 Outlet 110V (Square)
3 1 952937 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 1 952209 Recpt Panel 19 PIN F (Shell)
7 2 950122 Ckt Breaker 10A 32VDC/250V AC CB1, 2
8 2 0558001818 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 91514 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

49

SECTION 7 REPLACEMENT PARTS

3

2

5

1

6

4

7

Figure 7-2 - Inside Front View, Multipower 460PULSE

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 L2

50

SECTION 7 REPLACEMENT PARTS

6

2

1

4

51

SECTION 7 REPLACEMENT PARTS

2

1

3

4

Figure 7-3 - Inside Rear View, Multipower 460PULSE

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 2 0 36110 Board Input Terminal 230/460/575V

52

SECTION 7 REPLACEMENT PARTS

3

2

4

5

1

Figure 7-4 External Rear View, Multipower 460PULSE

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 672786 Bolt Eye
4 1 0558001371 Panel Top Kydex Env
5 1 0558001370 Panel Left Side Kydex

53

SECTION 7 REPLACEMENT PARTS

3

7

4

2

5

1

6

Figure 7-5 External Top View, Multipower 460

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, 35000UF 100VDC C1, 2, 3
7 1 38186 PCB Driver Assy. PCB3

54

SECTION 7 REPLACEMENT PARTS

2

1

7

3

4

5

55

6

NOTES

56

NOTES

57

NOTES

58

REVISION HISTORY

1. 05/2003 - General editorial changes.

59

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS: Telephone: [phone] / Fax: [phone]

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

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

Hours: 8:00 AM to 7:00 PM EST

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

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

F-15-721-A 05/2003