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

Download

MultiPower 460 Pulse

.045

.040

.035

1/16

.052

WIRE

TYPE

WIRE

DIAMETER

PULSE

SELECTION

EN-625

ERNiCrMo-3

AINLESS

AL-400

AL-500

EN-60

ERNiCu-

L CORE

STEEL

EN-67

CuNi

lta

(CV)

Cur

ent

(CC)

rim

(Pulse)

TEMP

BLINKING

WIRE

SPEED

OUT

RANGE

STEAD

OGRAM

PRESET

LIFT

STICK

REMO

ANEL

AND

ARD

MIG

PULSE

Auto

Fan

ill

cycle

automatically

Multipower 460PULSE

WFS-IP

AMPS

DC Welding Power Source (Shipyard Model)

INSTRUCTION MANUAL

ESAB ITEM NO. 0558004922, MultiPower 460 Pulse - (208)230/460 vac, 3 ph., 60 Hz, Serial Number: MxxJ432xxx

0558004964 10/2005

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

CAUTION

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.

TABLE OF CONTENTS

Section / Title Page

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

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

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

1.3 Safety - French

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

2.0 Description

3.0 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.0 Operation

5.0 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

6.0 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

6.1 General

6.2 Ordering

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS

1.0 Safety Precautions

WARNING: These Safety Precautions are

for your protection. They summarize precautionary information from the references

listed in Additional Safety Information section. Before performing any installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.

PROTECT YOURSELF AND OTHERS -Some welding, cutting, and gouging processes are noisy and require ear protection. The arc, like the sun, emits

ultraviolet (UV) and other radiation and can injure skin and eyes. Hot metal can cause burns. Training in the proper use of the processes and equipment is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any

work area, even if welding helmets, face shields, and goggles are also required.

2. Use a face shield ﬁtted with the correct ﬁlter and

cover plates to protect your eyes, face, neck, and ears from sparks and rays of the arc when operating or observing operations. Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric-arc or hot metal.

3. Wear ﬂameproof gauntlet type gloves, heavy long-

sleeve shirt, cuﬄess trousers, high-topped shoes, and a welding helmet or cap for hair protection, to protect against arc rays and hot sparks or hot metal. A ﬂameproof apron may also be desirable as protection against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cuﬀs, or pockets. Sleeves and collars should be kept buttoned, and open pockets eliminated from the front of clothing.

5. Protect other personnel from arc rays and hot

sparks with a suitable non-ﬂammable partition or curtains.

6. Use goggles over safety glasses when chipping slag

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

1.1 Safety - English

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

1. Remove all combustible materials well away from the work area or cover the materials with a protective non-ﬂammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc.

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

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

4. Have ﬁre extinguishing equipment handy for instant use, such as a garden hose, water pail, sand bucket, or portable ﬁre extinguisher. Be sure you are trained in its use.

5. Do not use equipment beyond its ratings. For ex ample, overloaded welding cable can overheat and create a ﬁre hazard.

6. After completing operations, inspect the work area to make certain there are no hot sparks or hot metal which could cause a later ﬁre. Use ﬁre watchers when necessary.

7. For additional information, refer to NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", available from the National Fire Protection Association, Batterymarch Park, Quincy, MA

02269.

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

Heat from

SECTION 1 SAFETY PRECAUTIONS

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

2. Connect the workpiece to a good electrical ground.

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

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

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

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

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

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

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

A. Route the electrode and work cables together.

Secure them with tape when possible.

B. Never coil the torch or work cable around your

body.

C. Do not place your body between the torch and

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

D. Connect the work cable to the workpiece as close

as possible to the area being welded.

E. Keep welding power source and cables as far

away from your body as possible.

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

Therefore:

9. Turn oﬀ the power before removing your gloves.

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

ELECTRIC AND MAGNETIC FIELDS — May be dangerous. Electric current ﬂowing through any conductor causes localized Electric and

Magnetic Fields (EMF). Welding and cutting current creates EMF around welding cables and welding machines. Therefore:

1. Welders having pacemakers should consult their

physician before welding. EMF may interfere with some pacemakers.

2. Exposure to EMF may have other health eﬀects which

are unknown.

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

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

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

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

SECTION 1 SAFETY PRECAUTIONS

5. WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code

§25249.5 et seq.)

CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release gas. Sudden rupture of cylinder, valve, or relief device can injure or kill. Therefore:

1. Use the proper gas for the process and use the

proper pressure reducing regulator designed to operate from the compressed gas cylinder. Do not use adaptors. Maintain hoses and ﬁttings in good condition. Follow manufacturer's operating instructions for mounting regulator to a compressed gas cylinder.

1. Always have qualiﬁed personnel perform the instal lation, troubleshooting, and maintenance work. Do not perform any electrical work unless you are qualiﬁed to perform such work.

2. Before performing any maintenance work inside a power source, disconnect the power source from the incoming electrical power.

3. Maintain cables, grounding wire, connections, power cord, and power supply in safe working order. Do not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such as furnaces, wet conditions such as water puddles, oil or grease, corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position and in good repair.

6. Use equipment only for its intended purpose. Do not modify it in any manner.

2. Always secure cylinders in an upright position by chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure cylinders to work tables or ﬁxtures where they may become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and ﬂames. Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", which is available from Compressed Gas Association, 1235 Jeﬀerson Davis Highway, Arlington, VA 22202.

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

ADDITIONAL SAFETY INFORMATION -- For

more information on safe practices for electric arc welding and cutting equipment, ask your supplier for a copy of "Precautions and Safe Practices for Arc Welding, Cutting and Gouging", Form 52-529.

The following publications, which are available from the American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are recommended to you:

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

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

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

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

SECTION 1 SAFETY PRECAUTIONS

5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal Arc Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Hand book.

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.

SECTION 1 SEGURIDAD

1.2 Safety - Spanish

ADVERTENCIA: Estas Precauciones de Se-

guridad son para su protección. Ellas hacen

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

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

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

1. Utilice gafas de seguridad con protección a los lados

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

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

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

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

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

4. Chispas y partículas de metal caliente puede alojarse

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

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

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

6. Use careta protectora además de sus gafas de segu

ridad cuando esté removiendo escoria o puliendo.

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

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

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

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

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

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

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

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

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

CHOQUE ELECTRICO -- El contacto con las partes eléctricas energizadas

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

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

El calor de

SECTION 1 SEGURIDAD

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

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

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

4. Use el equipo solamente si está en buenas 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 proced imientos para minimizar exponerse al EMF:

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

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

B. Nunca envuelva los cables de soldar alrededor

de su cuerpo.

C. Nunca ubique su cuerpo entre la antorcha y el

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

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

lo más cercano posible al área de la soldadura.

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

lo más lejos posible de su cuerpo.

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

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

1. Siempre provea ventilación adecuada en el área

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

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

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

3. Si momentáneamente desarrolla inrritación de

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

4. Haga referencia a la publicación ANSI/ASC Standard

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

SECTION 1 SEGURIDAD

5. ADVERTENCIA-- Este producto cuando se utiliza para soldaduras o cortes, produce humos o gases, los cuales contienen químicos conocidos por el Estado de Cali fornia 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 romp erse y liberar violentamente gases. Rotura repentina del cilindro, válvula, o válvula de escape puede causar daño o muerte. Por lo tanto:

1. Utilize el gas apropiado para el proceso y utilize

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

2. Asegure siempre los cilindros en posición vertical

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

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

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

1. Siempre tenga personal cualiﬁcado para 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"

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

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

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

SECTION 1 SEGURIDAD

SIGNIFICADO DE LOS SIMBOLOS

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

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

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

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

SECTION 1 SÉCURITÉ

1.3 Safety - French

AVERTISSEMENT :

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

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

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

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

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

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

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

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

3. Portez des gants ignifugiés à crispin, une chemise

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

4. Les étincelles et les projections de métal incandescent

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

5. Protégez toute personne se trouvant à proximité des

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

6. Portez des lunettes étanches par dessus vos lunettes

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

Ces règles de sécurité

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

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

peuvent également provoquer un

incendie ou une explosion. Par conséquent :

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

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

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

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

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

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

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

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

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

SECTION 1 SÉCURITÉ

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

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

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

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

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

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

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

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

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

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

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

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

1. Un soudeur ayant un stimulateur cardiaque doit

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

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

tiques peut avoir des eﬀets néfastes inconnus pour la santé.

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

A. Acheminez l'électrode et les câbles de masse

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

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

autour de votre corps.

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

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

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

plus près possible de la section à souder.

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

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

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

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

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

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

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

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

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

SECTION 1 SÉCURITÉ

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

MANIPULATION DES CYLINDRES --

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

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

1. Utilisez toujours le gaz prévu pour une opération

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

2. Fixez les cylindres dans une position verticale, à

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

3. Lorsque les cylindres ne servent pas, gardez les

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

4. Placez les cylindres à une distance appropriée

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

5. Pour de l'information supplémentaire, consultez

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

ENTRETIEN DE L'ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou inadéquate peut causer des blessures

1. Efforcez-vous de toujours confier les tâches

2. Avant de procéder à une tâche d'entretien à

3. Maintenez les câbles, les ﬁls de mise à la terre, les

4. N'utilisez pas l'équipement de façon abusive. Gardez

5. Laissez en place tous les dispositifs de sécurité et

6. Utilisez l'équipement conformément à son usage

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

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

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

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

4. AWS C5.3 - "Recommended Practices for Air Carbon

graves ou mortelles. Par conséquent :

d'installation, de dépannage et d'entretien à un personnel qualiﬁé. N'eﬀectuez aucune réparation électrique à moins d'être qualiﬁé à cet eﬀet.

l'intérieur de la source d'alimentation, débranchez l'alimentation électrique.

branchements, le cordon d'alimentation et la source d'alimentation en bon état. N'utilisez jamais un équipement s'il présente une défectuosité quelconque.

l'équipement à l'écart de toute source de chaleur, notamment des fours, de l'humidité, des ﬂaques d'eau, de l'huile ou de la graisse, des atmosphères corrosives et des intempéries.

tous les panneaux de la console et maintenez-les en bon état.

prévu et n'eﬀectuez aucune modiﬁcation.

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

Welding"

Cutting"

Arc Gouging and Cutting"

SECTION 1 SÉCURITÉ

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

DANGER

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

AVERTISSEMENT

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

ATTENTION

Signiﬁe un danger qui peut entraîner des blessures corporelles mineures.

SECTION 2 DESCRIPTION

2.0. Description

This manual has been prepared for use by an experienced operator. It provides information to familiarize the operator with the design, installation and operation of the MultiPower 460 Pulse 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.

Table 2-1. Speciﬁcations for MultiPower 460 Pulse

OPEN CIRCUIT VOLTAGE (U2) 80 VDC Max.

DUTY CYCLE

RATED OUTPUT

Current (I

Voltage (U

RATED INPUT 3 Phase 60 Hz

Power Factor at Rated Output

Welding Range 10 A/12 V - 500 A/40 V

Auxiliary Power 115 V ac @ 10 A, 60 Hz

Height 32.4” (82.3 cm)

Width 18.8” (48.3 cm)

Depth 34.5” (87.6 cm)

Net Weight 322lbs (146 kg)

Shipping Weight 375lbs (170 kg)

) 500 A 450 A

) 40 V 38 V

Volts(U1)

Current (I1) Flat Current (I1) Flat

208/230 V 76 A 66 A

460 V 38 A 33 A

PHYSICAL SPECIFICATIONS

60% 100%

89%

SECTION 2 DESCRIPTION

V/I (Volt / Ampere) Response of MultiPower 460

0 100 200 300 400 500 600

Amps

Open Circuit Voltage

Maximum CC Curve

Maximum CV Curve

Minimum CV Curve

Minimum CC Curve

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

A. Power Source

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

Features

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

• Stainless steel frame for envirornmental durability.

• Durable composite side and top panels will not corrode.

• 100% duty cycle output at 450 amps.

• Designed for “Oﬀ the Arc” 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

SECTION 2 DESCRIPTION

.045

.040

.035

1/16

.052

WIRE TYPE

WIRE DIAMETER

PULSE SELECTION

EN-625 ERNiCrMo-3

STAINLESS

AL-4000

AL-5000

EN-60 ERNiCu-7

METAL CORE STEEL

STEEL

EN-67 ERCuNi

Voltage (CV) Current (CC) Trim (Pulse)

TEMP

POWER

BLINKING

WIRE SPEED

OUT OF RANGE

STEADY

NO PROGRAM

PRESET

MIG

LIFT

START

TIG

STICK

REMOTE

PANEL

STANDARD

MIG PULSE

Auto Fan

Fan will cycle automatically

Multipower 460PULSE

WFS-IPM

AMPS

VOLTS

C. Control Panel Description (Refer To Figures 2-2 & 2-3)

1. Fault Lamp

The RED fault light on the MultiPower 460 Pulse front panel indicates a problem with set-up parameters. A "Steady-On" light 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 460 Pulse 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 during MIG PULSE preset and welding current (amps) during TIG and STICK preset. The bottom display reads power source open circuit voltage during STANDARD Mig preset. Each display indicates average welding current or average welding voltage, respectively, during welding.

Digital Meter

Volts

Digital Meter

Amps/WFS

Power “ON”

Lamp

Temperature

Lamp

Fault

Lamp

WFS - IPM

Lamp

Figure 2-2. Control Panel

Amps Lamp

Weld Process

Switch

.045

.040

.035

1/16

.052

WIRE TYPE

WIRE DIAMETER

PULSE SELECTION

EN-625 ERNiCrMo-3

STAINLESS

AL-4000

AL-5000

EN-60 ERNiCu-7

METAL CORE STEEL

STEEL

EN-67 ERCuNi

Voltage (CV) Current (CC) Trim (Pulse)

TEMP

POWER

BLINKING

WIRE SPEED

OUT OF RANGE

STEADY

NO PROGRAM

PRESET

MIG

LIFT

START

TIG

STICK

REMOTE

PANEL

STANDARD

MIG PULSE

Auto Fan

Fan will cycle automatically

Multipower 460PULSE

WFS-IPM

AMPS

VOLTS

SECTION 2 DESCRIPTION

5. Voltage / Current / Trim

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

The weld 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 welding power to the electrode is trimmed by turning the knob clockwise to increase pulse power or counterclockwise to decrease pulse power.

6. Panel/Remote Switch

With this switch in the PANEL position, the output voltage in the CV mode and the output current in the CC mode is 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 hand or foot control.

Mode

Switch

Figure 2-3. Control Panel

Preset

Button

Voltage/

Current/Trim

Material Selection

Panel/ Remote

(Pulse)

Weld Process

Switch

Wire Diameter

Selector (Pulse)

SECTION 2 DESCRIPTION

7. Preset Button

Preset push button is used in conjunction with the VOLTAGE/CURRENT/TRIM knob to set the desired voltage / current. Preset switch is also used in the Pulse Mig mode to preset the pulse parameters by using preset wire feed speed as the intial

setting for the “Oﬀ the Arc” feeder.

8. Standard / MIG Pulse Switch

This switch enables the Mig pulse mode. When this switch is in the MIG PULSE position, the pulse parameters are determined by the WIRE TYPE and WIRE DIAMETER position on the PULSE SELECTION switches.

9. Pulse Selection Switches

WIRE TYPE

Use this switch to select the WIRE TYPE used by 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 being used. The position of this switch and the WIRE TYPE switch selects the pulse parameters during welding in the Mig pulse mode.

.045

.040

.035

1/16

.052

WIRE

TYPE

WIRE

DIAMETER

PULSE

SELECTION

EN-625

ERNiCrMo-3

AINLESS

AL-400

AL-500

EN-60

ERNiCu-

L CORE

STEEL

EN-67

CuNi

lta

(CV)

Cur

ent

(CC)

rim

(Pulse)

TEMP

BLINKING WIRE

SPEED

OUT

RANGE

STEAD

PR OGRAM

PRESET

LIFT

STICK

REMO

P ANEL

AND

ARD

MIG

PULSE

Auto

Fan

ill

cycle

automatically

Multipower 460PULSE

WFS-IP

AMPS

SECTION 2 DESCRIPTION

D. Power Source Front View Description (Refer To Figure 2-4)

1. Power On/oﬀ Switch & Lamp

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

2. Remote Control Receptacle

This receptacle (J8) 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.

3. 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). Turn to ON position when using an "Oﬀ the Arc" wire feeder with secondary contactor is being operated in the CV mode.

4. Auxiliary 115 Vac Receptacle

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

5. 42 Vac (CB-2) & 115 Vac Circuit Breaker (CB-1)

These resettable 10 amp circuit breakers (CB-1 & CB-2) protect the 42 volt wire feeder/control and 115 volt auxiliary receptacle circuitry against over current. (Table 5-1 provides troubleshooting information).

Control Panel

Circuit Breakers

CB1 & 2

CV Contactor On/Oﬀ

Switch

Remote Control Pendant

Connection

115 Vac

10 Amps

Receptacle

Output

Connections

Main Power

On/Oﬀ Switch

Figure 2-4. MultiPower 460

SECTION 2 DESCRIPTION

E. Optional Accessories

1. Remote Control Pendant (P/N - 0558002871)

This pendant (Figure 2-5) provides remote output control and a MIG contactor closure switch to close the contactor making the output terminals “hot”. The PANEL/REMOTE switch on the MultiPower 460 Pulse control panel must be placed in the REMOTE position when using this accessory.

Figure 2-5. Remote Control Pendant

2. Remote Control Options

The options below (Figure 2-6) provide remote output control. The PANEL/REMOTE switch on the MultiPower 460 Pulse control panel must be placed in the REMOTE position when using these accessories.

FC-5B Foot Control - 30 ft. (9.1 m) ....................................................................................................................................................... P/N 33646

FC-5B EHD Foot Control - 30 ft. (9.1 m) .............................................................................................................................................. P/N 33841

TC-2B Torch Control - 25 ft. (7.6 m) ...................................................................................................................................................... P/N 33839

HC-3B Hand Control - 30 ft. (9.1 m) .................................................................................................................................................... P/N 33838

FC-5B Foot Control - P/N 33646 FC-5B EHD Foot Control - P/N 33646

Remote Contactor / Current Control

TC-3A Torch Button Control HW-9, 17, 20, 20A & 24 - P/N 35783 HW-18 &26R - P/N-36680

TC-2B Hand Current Control - P/N 33839

Figure 2-6. Remote Control Options

SECTION 2 DESCRIPTION

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.

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

CAUTION

B. Receiving, Unpacking And Placement

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.

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

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

• parts. Check air passages at front and rear of cabinet, making sure that packing material has not obstructed air ﬂow

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

• by using the lifting bail 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.

SECTION 3 INSTALLATION

Rated Input

@ 100% Duty Cycle

Input &

GND

Conductor*

CU/AWG

Fuse

Size

Amps

Volts Amps

220 230 400 460 575

68 66 37 33 26

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

No. 10

100 100

60 60 50

C. Primary (Input) Electrical Connection

This power source is a three-phase unit and must be connected to a three-phase AC primary power. It is recommended that the unit be operated on a dedicated circuit to prevent impairment of weld performance due to an overloaded circuit.

Table 3-1. Recommended Sizes for Input

Conductors and Line Fuses

*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.

ELECTRIC SHOCK CAN KILL! BEFORE MAKING ELECTRICAL INPUT

WARNING

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.

SECTION 3 INSTALLATION

THE CHASSIS MUST BE CONNECTED TO AN APPROVED ELECTRICAL

WARNING

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

REAR PANEL VIEW

Figure 3-1. Typical Installation -

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

The primary power leads must be insulated copper conductors. Three power leads and one ground wire are re-

1. quired. Either rubber covered cable or conduit (ﬂexible or solid) may be used. Table 3-1 provides recommended input conductors and line fuse sizes. Remove the top cover. Identify primary power input connection block, chassis ground lug, and primary input

2. terminal board. Refer to Figures 3-3 and 3-4. When using the provided strain relief, refer to Figure 3-2 for proper cable strip lengths. It is important to follow

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

SECTION 3 INSTALLATION

ELECTRIC SHOCK CAN KILL! BEFORE MAKING ELECTRICAL INPUT CONNECTIONS TO THE POWER SOURCE, "MACHINERY LOCKOUT PROCEDURES" SHOULD BE EMPLOYED. IF THE CONNECTIONS ARE TO BE MADE FROM A LINE DISCONNECT SWITCH, PLACE THE SWITCH

WARNING

IN THE OFF POSITION AND PADLOCK IT TO PREVENT INADVERTENT TRIPPING. IF THE CONNECTION IS MADE FROM A 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.

(3) PRIMARY

INPUT

CONDUCTORS

WARNING

Primary Input

Connection Block

Chassis Ground Lug

24"

Green

(Earth Ground)

Figure 3-2. Recommended Cable Strip Lengths

THE CHASSIS MUST BE CONNECTED TO AN APPROVED ELECTRICAL GROUND. FAILURE TO DO SO MAY RESULT IN ELECTRICAL SHOCK, SEVERE BURNS OR DEATH.

Primary Input

Terminal Board

Figure 3-3. Primary Power Leads L1,L2, L3 & Ground

SECTION 3 INSTALLATION

Figure 3-4 illustrates the input voltage terminal boards and the input voltage link connections. The particular

5. 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 (460 VAC). 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.

CHECK THE VOLTAGE LINKS FOR PROPER VOLTAGE ON THE INPUT

WARNING

TERMINAL BOARD BEFORE APPLYING PRIMARY POWER.

(208)230 Vac Input

Note: For 208 vac use 230 vac linking

460 Vac Input

Figure 3-4. Input Terminal Board Conﬁguration for 230/460 Model

SECTION 3 INSTALLATION

Welding

Current

Total Length (Feet) of Cable in Weld Circuit*

50 100 150 200 250

100

150

200

250

300

400

500

2/0

3/0

1/0

2/0

3/0

1/0

2/0

3/0

4/0

1/0

2/0

3/0

4/0

2-2/0

1/0

2/0

3/0

4/0

2-2/0

2-3/0

D. Output Welding Connections (Secondary)

The output connections are located on the front panel (Figure 2-4). 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 secondary output cable connects (in most cases) between the positive output lug of the MultiPower 460 Pulse and the power connection block of the wire feeder. See the wire feeder installation instructions for other connections such as shield gas, water, remote controls, Mig guns and wire feeder operation.

2. Connections For Stick And Tig Welding

The Tig torch and stick electrode holder connect directly to the appropriate MultiPower 460 Pulse 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 cable length includes work and electrode cables. Cable size is based on direct current, insulated copper conductors, 100-per-

cent 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.

WARNING

BEFORE MAKING ANY CONNECTIONS TO THE POWER SOURCE OUT PUT TERMINALS MAKE SURE THAT ALL PRIMARY INPUT POWER TO THE MACHINE IS OFF.

SECTION 4 OPERATION

4.0. Operation

A. Wire Feeder Compatibility

The MultiPower 460 Pulse power source is designed for use with “Oﬀ the Arc” or “Voltage Controlled” wire feeders. These types of wire feeders can be operated in either the CV (MIG) or CC (Stick) mode. The wire feed speed is always controlled from the wire feeder using the wire speed knob on the feeder control panel. The MP-460 Pulse can output either CV or CC power. Use the PANEL/REMOTE switch in the PANEL position to set the power source open circuit voltage (OCV) for the CV mode or the welding current for the CC mode. Use the REMOTE position when using a remote control device.

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

CAUTION

B. Digital Display Preset Mode

The digital displays located on the left side of the control panel are multifunctional depending on the welding process being used. The MultiPower 460 Pulse digital display meters permit preset of the wire feed speed on wire feeders without digital displays.

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

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

above 760 ipm will be displayed at 760 ipm.

1. Preset 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”.

2. Preset Tig And Stick Welding

In the TIG and STICK process mode, you must depress and "HOLD" the PRESET button while presetting the welding current in the top display. Releasing the preset button causes the display to return to zero. Once welding begins, the display will show average welding current and volts in the top and bottom display, respectively. After welding stops, the current display will again return to zero. There is no “HOLD” circuit for the display meters when using the TIG and STICK process modes.

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.

SECTION 4 OPERATION

.045

.040

.035

1/16

.052

WIRE TYPE

WIRE DIAMETER

PULSE SELECTION

EN-625 ERNiCrMo-3

STAINLESS

AL-4000

AL-5000

EN-60 ERNiCu-7

METAL CORE STEEL

STEEL

EN-67 ERCuNi

Voltage (CV) Current (CC) Trim (Pulse)

TEMP

POWER

BLINKING

WIRE SPEED

OUT OF RANGE

STEADY

NO PROGRAM

PRESET

MIG

LIFT

START

TIG

STICK

REMOTE

PANEL

STANDARD

MIG PULSE

Auto Fan

Fan will cycle automatically

Multipower 460PULSE

WFS-IPM

AMPS

VOLTS

When the WELD PROCESS switch is moved to the TIG or STICK position,

CAUTION

C. Tig Welding (Lift Start Tig)

When the PROCESS switch is placed in the LIFT START TIG position, the MultiPower 460 Pulse is automatically set for CC (constant current) welding using the ESAB Lift Start TIG starting method. The voltage and current at the output terminals are maintained at low values until the electrode is shorted to the workpiece then “lifted” to create the welding arc.

Be sure to set the polarity to DCEN (Electrode Negative) by connecting the Tig torch to the negative terminal lug

1. on the front of the power source. Place the WELD PROCESS switch in the LIFT START TIG position.

2. Place the PANEL/REMOTE switch in the PANEL position.

3. Place STANDARD/MIG PULSE switch in the STANDARD position.

4. While depressing the PRESET button, turn the VOLTAGE/CURRENT knob to the desired weld current as displayed

5. on the top digital display window. Set the shielding gas ﬂow rate to a desired ﬂow by adjusting the adjustment knob on the ﬂowmeter. (20 cfh is

6. typically recommended) Touch the tungsten electrode to the workpiece momentarily then lift the electrode 1/16" oﬀ the workpiece to

7. establish the welding arc. Trim the weld current as desired by turning the VOLTAGE/CURRENT knob.

electrode becomes electrically “HOT”. Do not allow the electrode to contact ground potential until you are ready to make a weld.

When using a remote current device with the MP-460 Pulse, the STANDARD/MIG PULSE switch must be in the STANDARD position for proportional current control. Set the current knob on the MP-460 Pulse front panel to the maximum desired weld current using the procedure above. The remote device will then control the current proportionally between the minimum current setting of 5 amps and maximum set on

the MP-460 front panel. The maximum Tig welding current is 525 amps.

If the MP-460 PANEL/REMOTE switch is left in the REMOTE position while using a remote control option device, the current range will be full scale or 10 to 400 amps on the remote device. Adjustment of the

maximum current on the MP-460 Pulse front panel is defeated.

Figure 4-1 Standard Tig Setup Procedure

NOTE

SECTION 4 OPERATION

.045

.040

.035

1/16

.052

WIRE TYPE

WIRE DIAMETER

PULSE SELECTION

EN-625 ERNiCrMo-3

STAINLESS

AL-4000

AL-5000

EN-60 ERNiCu-7

METAL CORE STEEL

STEEL

EN-67 ERCuNi

Voltage (CV) Current (CC) Trim (Pulse)

TEMP

POWER

BLINKING

WIRE SPEED

OUT OF RANGE

STEADY

NO PROGRAM

PRESET

MIG

LIFT

START

TIG

STICK

REMOTE

PANEL

STANDARD

MIG PULSE

Auto Fan

Fan will cycle automatically

Multipower 460PULSE

WFS-IPM

AMPS

VOLTS

When the WELD PROCESS switch is moved to the TIG or STICK position,

CAUTION

D. Stick Welding

When the PROCESS switch is placed in the STICK position, the MultiPower 460 Pulse 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.

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. Due to the "Built-In" Arc Force in the stick mode, the actual current may be greater than the preset value.

Be sure to set the polarity to DCEP (Electrode Positive) by placing the Electrode Holder cable in the Positive con-

1. nection lug on the front of the power source. Place the WELD PROCESS switch in the STICK position.

2. Place the PANEL/REMOTE switch in the PANEL position.

3. Place STANDARD/MIG PULSE switch in the STANDARD position.

4. While holding the PRESET button, turn the VOLTAGE/CURRENT knob to the desired weld current displayed in the

5. top digital display window for the stick electrode type and size being used . Strike the electrode on the workpiece and start welding. Trim the welding current as needed for the desired

6. weld pool control.

When using the MP-460 Pulse with an Optional Remote Pendent Control , the STANDARD/MIG PULSE switch must be in the STANDARD position for proportional current control. Set the current knob on the MP-460 Pulse front panel to the maximum desired weld current level. The remote device will then control the current proportionally between the minimum current setting of 5 amps and the maximum

current set on the MP-460 Pulse front panel. The maximum Stick welding current is 525 amps.

electrode becomes electrically “HOT”. Do not allow the electrode to contact ground potential until you are ready to make a weld.

NOTE

If the MP-460 PANEL/REMOTE switch is left in the REMOTE position while using a Remote Pendant Control option, the current range will be full scale or 10 to 400 amps on the remote device. Adjustment of the

maximum current on the MP-460 Pulse front panel is defeated.

Figure 4-2 Standard Stick Setup Procedure

SECTION 4 OPERATION

.045

.040

.035

1/16

.052

WIRE TYPE

WIRE DIAMETER

PULSE SELECTION

EN-625 ERNiCrMo-3

STAINLESS

AL-4000

AL-5000

EN-60 ERNiCu-7

METAL CORE STEEL

STEEL

EN-67 ERCuNi

Voltage (CV) Current (CC) Trim (Pulse)

TEMP

POWER

BLINKING

WIRE SPEED

OUT OF RANGE

STEADY

NO PROGRAM

PRESET

MIG

LIFT

START

TIG

STICK

REMOTE

PANEL

STANDARD

MIG PULSE

Auto Fan

Fan will cycle automatically

Multipower 460PULSE

WFS-IPM

AMPS

VOLTS

When the WELD PROCESS switch is moved to the TIG or STICK position,

CAUTION

E. Air Carbon Arc Gouging (CAC-A) - Constant Current

Be sure the CONTACTOR “ON/OFF” switch on the lower left auxiliary panel is in the OFF position.

1. Place the Output PANEL/REMOTE switch into PANEL position if output current is regulated from the VOLTAGE/

2. CURRENT knob on the power source front panel, or in REMOTE position if output current is regulated from the optional MP-460 Remote Pendant Control. Place the Process Control switch in the STICK position.

3. Press and hold the PRESET button and set the VOLTAGE/CURRENT knob to gouging current.

4. Place STANDARD/MIG PULSE switch in the STANDARD position.

5. Turn the air on the gouging electrode holder "ON and start gouging by touching or scratch starting the elec-

6. trode.

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

actual current may be greater than the preset value.

See Remote Pendant Control Device operation notes

under STICK welding on previous page.

Arc gouging with the “Oﬀ the Arc” contactor switch in the “ON” position (CV Mode) is not recommended as standard practice or the best method for carbon arc

electrode becomes electrically “HOT”. Do not allow the electrode to contact ground potential until you are ready to make a weld.

NOTE

Figure 4-3

Contactor Switch for "Oﬀ the

WARNING

gouging .

Arc" wire feeders ONLY

Figure 4-4 Carbon Arc Setup Procedure

SECTION 4 OPERATION

.045

.040

.035

1/16

.052

WIRE TYPE

WIRE DIAMETER

PULSE SELECTION

EN-625 ERNiCrMo-3

STAINLESS

AL-4000

AL-5000

EN-60 ERNiCu-7

METAL CORE STEEL

STEEL

EN-67 ERCuNi

Voltage (CV) Current (CC) Trim (Pulse)

TEMP

POWER

BLINKING

WIRE SPEED

OUT OF RANGE

STEADY

NO PROGRAM

PRESET

MIG

LIFT

START

TIG

STICK

REMOTE

PANEL

STANDARD

MIG PULSE

Auto Fan

Fan will cycle automatically

Multipower 460PULSE

WFS-IPM

AMPS

VOLTS

When the CONTACTOR switch is moved to the “ON” position, MP-460

CAUTION

F. Mig & Flux Core Welding Preset Procedure

When the PROCESS switch is placed in the MIG position, the MultiPower 460 Pulse is set for CV (constant voltage) welding for use with “Oﬀ the Arc” or “Arc Voltage “ type wire feeders. With these feeders, power to run the wire feed motor and accessories is suppied by the MP-460 Pulse output voltage. There is no contactor “ON” signal from the wire feeder to tell the power source to turn “ON”. Therfore, the contatctor is turned “ON” manually to supply power to the wire feeder. When the Mig gun trigger is pulled, wire feed begins and power is supplied to the gun through the secondary contactor in the wire feeder unit. The following procedure assumes that the wire and gas have been installed.

Connect wire feeder to MultiPower 460 Pulse and set PANEL/REMOTE switch to PANEL position.

1. Set the STANDARD/MIG PULSE switch to the STANDARD position.

2. Place the WELD PROCESS switch in the MIG (center) position.

3. Press and release the PRESET button then turn the VOLTAGE to the approximate welding voltage needed for the

4. wire type and size to be used. If the MIG CONTACTOR is in the “ON” position the PRESET button must be held down to preset the wire feed speed. Flip the CONTACTOR switch on the MP-460 auxiliary panel to the “ON” position. See Fig. 4-6.

5. Turn the wire speed knob on the wire feeder to the desired wire feed speed.

6. Connect the work cable from the MP-460 and the voltage pick-up lead from the wire feeder to the part to be

7. welded. Activate the gas purge switch if the wire feeder has this feature. If not, release the pressure roll so wire does not

8. feed. Pull the gun trigger and set the shielding gas ﬂow rate by turning the adjustment knob on the shield gas ﬂowmeter to the recommended gas ﬂow (typically 35 cfh). Engage the drive stand pressure roll and begin welding by pulling the gun trigger. Trim the wire speed and volts

9. as needed for the desired arc characteristics and weld quality.

Pulse output terminals and the cables connected to them become electrically “HOT”. Do not allow the cable to contact ground potential.

Figure 4-5 Standard Mig Setup Procedure

.045

.040

.035

1/16

.052

WIRE TYPE

WIRE DIAMETER

PULSE SELECTION

EN-625 ERNiCrMo-3

STAINLESS

AL-4000

AL-5000

EN-60 ERNiCu-7

METAL CORE STEEL

STEEL

EN-67 ERCuNi

Voltage (CV) Current (CC) Trim (Pulse)

TEMP

POWER

BLINKING

WIRE SPEED

OUT OF RANGE

STEADY

NO PROGRAM

PRESET

MIG

LIFT

START

TIG

STICK

REMOTE

PANEL

STANDARD

MIG PULSE

Auto Fan

Fan will cycle automatically

Multipower 460PULSE

WFS-IPM

AMPS

VOLTS

SECTION 4 OPERATION

NOTE

When using the MP-460 Remote Pendant Control, place the PANEL/REMOTE switch in the REMOTE position. This will defeat the MP-460 front panel voltage control. Voltage can then

be adjusted from the remote pendant

Figure 4-6

Contactor Switch for "Oﬀ the

Arc" wire feeders

G. Pulse Mig Setup

Connect wire feeder to MultiPower 460 Pulse and set PANEL/REMOTE switch to PANEL position.

1. Set the STANDARD/MIG PULSE switch to the MIG PULSE position.

2. Place the WELD PROCESS switch in the MIG (center) position.

3. Set the PULSE SELECTION switches to the WIRE TYPE and DIAMETER installed on the wire feeder.

4. Press and release the PRESET button then turn the TRIM knob to the approximate welding wire feed speed

5. needed for the wire type and size to be used. If the MIG CONTACTOR is in the “ON” position the PRESET button must be held down to preset the wire feed speed. Flip the CONTACTOR switch on the MP-460 auxiliary panel to the “ON” position. See Fig. 4-6.

6. Turn the wire speed knob on the wire feeder to the desired wire feed speed.

7. Connect the work cable from the MP-460 and the voltage pick-up lead from the wire feeder to the part to be

8. welded. Activate the gas purge switch if the wire feeder has this feature. If not, release the pressure roll so wire does not

9. feed. Pull the gun trigger and set the shielding gas ﬂow rate by turning the adjustment knob on the shield gas ﬂowmeter to the recommended gas ﬂow (typically 35 cfh). Engage the drive stand pressure roll and begin welding by pulling the gun trigger. Trim the arc length using the

10. wire speed control knob on the wire feeder. Adjust the heat content of the arc by increasing or decreasing the Trim knob on the MP-460 Pulse front panel.

Figure 4-7 Synergic Pulse MIG Setup

SECTION 4 OPERATION

Material Type Diameters

Shielding Gas

(AWS Designation)

Carbon Steel

.035, .040, .045,

.052, .062

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-ACO-8/2)

Stainless Steel

.035, .040, .045,

.062

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

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

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

Ar - 8% CO2 - 2% O2 (SG-ACO-8/2)

Ar - He

4000 & 5000

Aluminum

.035, .040, 3/64,

.062

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

Metal Core

Carbon Steel

.035, .040, .045,

.052, .062

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-ACO-8/2)

EN-67

ERCuNi

.035 100% Ar (SG-A)

EN-60

ERNiCu-7

.035 He - 25% Ar (SG-HeA-25)

EN-625

ERNiCrMo-3

.035, .045 Ar - 35% He (SG-AHe-35)

H. Pulse Mig Welding using “Oﬀ the Arc” Wire Feeders

The MultiPower 460 Pulse is designed to provide simple to use, high quality, preprogrammed pulsed Mig welding. The pulse parameters, such as pulse height, pulse width, background current and pulse frequency, are automatically adjusted by the MultiPower 460 Pulse depending on the WIRE TYPE and DIAMETER selected.

When the PROCESS switch is placed in the MIG position and the STANDARD / MIG PULSE switch is placed in the MIG PULSE position, the MultiPower 460 Pulse is set for pulse Mig welding. The TRIM Knob on the MP-460 Pulse front panel allows the operator to preset the wire feed speed and optimize the heat content of the welding arc. An initial wire feed speed setting using the TRIM Knob will determine the pulse parameters to be used. Use this knob to increase (clockwise) or decrease (counterclockwise) the welding arc heat content to achieve the required electrode wire burn oﬀ rate and weld depth of fusion. Fine tuning of the arc length is accomplished at the wire feeder by adjusting the wire feed speed knob.

The MultiPower 460 Pulse preprogammed WIRE TYPES, WIRE DIAMETERS and shielding gases are listed in Table 4-1.

Table 4-1. Wire Types, Diameter and Shield Gases for Pulse Mig

SECTION 4 OPERATION

1. 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 can occur when high resistances in the welding circuit cause changes in pulse waveform aﬀecting average current levels. The MP-460 TRIM knob and wire feeder speed control knob should be used to adjust the pulse parameters to accommodate small changes in the welding equipment set-up, base material variations and maintain a stable pulse welding condition. Mechanical wire feeding inconsistencies will signiﬁcantly aﬀect pulse arc stability that require correction before ﬁne tuning trim setting .

2. Shielding Gases

Table 4-1 lists the types of shielding gas mixtures that can be used with the MultiPower 460 Pulse. The wire burn-oﬀ rate and pulse operation can vary with changes in shielding gas. Use the wire feed speed to compensate for small changes in shield gas composition.

3. Mig Pulsing with Wire Alloys Not Preprogrammed

The MultiPower 460 Pulse permits pulse welding when the Mig wire type or diameter installed on the wire feeder does not have speciﬁc pulse parameters available through panel selection. By using a combination of wire feed speed and MP-460 Pulse front panel TRIM setting, the pulse Mig welding arc can be ﬁne tuned and stabilized for many diﬀerent wire types and diameters. The selectable pulse parameters can be any combination of WIRE TYPE or WIRE DIAMETER selected using the PULSE SELECTION switches. Not all combinations will produce acceptable pulse characteristics but, in many cases, reasonable pulse arc welding stability can be achieved. This process will take some trial and error but the added ﬂexibility and expanded pulse range might be beneﬁcial for specialty or rare welding applications.

SECTION 5 MAINTENANCE

5.0. Maintenance And Troubleshooting

A. Cleaning

Periodically, remove the cover from the power source and blow accumulated dust and dirt from the air passages and interior components by using clean low pressure air. The frequency of cleaning required depends upon the environment in which the power source is used.

It is imperative that all air passages be kept as clean as possible in order to allow adequate air ﬂow to provide proper cooling.

After cleaning with low pressure air, check for and tighten any loose hardware, including all electrical connections. Check for frayed and/or cracked insulation on all power cables and replace if necessary.

B. Inspection And Service

Keep the power source dry, free of oil and grease, and protected at all times from damage by hot metal and sparks.

C. Fan Motor

Keep the fan motor free of accumulated dust and lint.

D. Transformer

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

E. Wire Feeder Control Circuits

These circuits are protected by one 10 amp circuit breaker mounted in the front panel. If it is open, the contactor and wirefeeder will not operate.

F. Over Temperature Protection

If the power source reaches an abnormally high internal temperature, the thermal protection will deenergize the contactor circuit, shutting down the power source but leaving the cooling fan on. After the power source has cooled to a safe level, the thermal protection will automatically reset.

SECTION 5 MAINTENANCE

G. IGBT Handling and Replacement

STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS AND ELECTRONIC

WARNING

What is ESD?

A sudden transfer or discharge of static electricity from one object to another. ESD stands for Electrostatic Discharge.

COMPONENTS.

•

OBSERVE PRECAUTIONS FOR HANDLING ELECTROSTATIC SENSITIVE DEVICES. USE PROPER STATICPROOF BAGS AND BOXES.

•

How does ESD damage occur?

ESD can cause damage to sensitive electrical components, but is not dangerous to people. ESD damage occurs when an ungrounded person or object with a static charge comes into contact with a component or assembly that is grounded. A rapid discharge can occur, causing damage. This damage can take the form of immediate failure, but it is more likely that system performance will be aﬀected and the component will fail prematurely.

How do we prevent ESD damage?

ESD damage can be prevented by awareness. If static electricity is prevented from building up on you or on anything at your work station, then there cannot be any static discharges. Nonconductive materials (e.g. fabrics), or insulators (e.g. plastics) generate and hold static charge, so you should not bring unnecessary nonconductive items into the work area. It is obviously diﬃcult to avoid all such items, so various means are used to drain oﬀ any static discharge from persons to prevent the risk of ESD damage. This is done by simple devices: wrist straps, connected to ground, and conductive shoes.

Other handling precautions that should also be observed are as follows:

Work surfaces, carts and containers must be conductive and grounded, use only antistatic packaging materials. Over-

• all, handling of ESD--sensitive devices should be minimized to prevent damage. Never install devices into systems with power connected to the system.

• Use soldering irons with grounded tips when soldering to gate terminals.

•

SECTION 5 MAINTENANCE

G. IGBT Handling and Replacement (continued)

Since IGBT gates are insulated from any other conducting region, care should be taken to prevent static build up, which could possibly damage gate oxides. All IGBT modules are shipped from the factory with conductive foam contacting the gate and emmiter sense pins.

When mounting IGBT modules on a heatsink, certain precautions should be taken to prevent any damage against a sudden torque. If a sudden torque (“onesided tightening”) is applied at only one mounting terminal the ceramic insulation plate or silicon chip inside the module may get damaged. The mounting screws are to be fastened in the order shown in Figure 5-1. Also, care must be taken to achieve maximum contact (i.e. minimum contact thermal resistance) for the best heat dissipation. Application of a thermal pad on the contact surface improves it thermal conductivity. See Replacement Parts section for the required pad. A torque wrench should be used. Tighten mounting screws to 28 in-lbs (3.2 m-n); wire connecting screws to 19 in-lbs (2.1 m-n). If torque is too heavy, the device can damage like the above “one-sided tightening”.

Figure 5-1 Mounting Screw Installation

SECTION 5 MAINTENANCE

G. IGBT Handling and Replacement (continued)

Insulated Gate Bipolar Transistor (IGBT)

C2 E1

G2 E2

Set the VOM to ohms then check for continuity between all the legs of the IGBT. No continuity should be measured. Place the red probe to the Collector (C1) and the black probe to the Emitter ( E1). The VOM should read very high resistance or an open circuit. No shorts (continuity) should be measured. Repeat the steps on the second IGBT pair (C2 E2). This ensures

the IGBT is turned oﬀ.

C2 E1

NOTE

The power source should be more the 6 volts and less than 20. A 9 volt bat-

tery is common and works quite well.

Place a DC power source (9 v battery) on the gate leads of the same IGBT. First the negative source on the gate with the positive source on the emitter. This should not change the meter reading. Next place the positive source on the gate and the negative source on the emitter. This should turn on the IGBT.

SECTION 5 MAINTENANCE

G. IGBT Handling and Replacement (continued)

C2 E1

Once the IGBT is turned on, remove the power source and the unit should stay on.

NOTE

The power source should be more the 6 volts and less than 20. A 9 volt bat-

tery is common and works quite well.

C2 E1

Short the gate leads (you can use your ﬁnger) to turn the unit oﬀ. This demonstrates the correct functioning of the unit.

SECTION 5 MAINTENANCE

H. Procedure for Checking Diodes

Inspect the diode to determine if it is of the “ straight polarity “ or “reverse polarity” type. Refer to the following ﬁgure for typical marking of diode polarity. It is essential that a replacement diode be of the same polarity as the one removed.

Reverse Polarity

Diode

Anode

Stud

Positive side

of bridge

A = Anode

K = Cathode

Negative side

of bridge

Negative side

of bridge

Pigtail

Straight

Polarity

Diode

Cathode

Positive side

of bridge

Stud

Usually when a diode fails, it becomes a short circuit. A simple diode test uses the resistance circuits of a multimeter; the diode should show better conductivity in one direction than in the other.

TEST AS FOLLOWS:

Set the mulitmeter on the low resistance range.

1. Connect one lead to the stud and one lead to the pigtail. Read the Resistance.

2. Reverse the leads and read the resistance. It should show a higher resistance in the “blocking” direction than in

3. the “conducting” direction. If it shows a very low, resistance (or zero resistance) in both directions, the diode is shorted. If it does not show continuity in either direction, the diode is open.

As stated above, it is essential that a replacement diode must be of the same size, type, and polarity as the one it replaces.

I. Troubleshooting

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

Check the problem against the symptoms in the following troubleshooting guide (Table 5-1.) The remedy for the problem may be quite simple. If the cause cannot be quickly located, open up the unit and perform a simple visual inspection of all the components and wiring. Check for proper terminal connections, loose or burned wiring or components, blown fuses, bulged or leaking capacitors, or any other sign of damage or discoloration.

SECTION 5 MAINTENANCE

Table 5-1. Troubleshooting Guide

CONDITION ACTION

Unit Inoperative

No input power. Check main line (user’s) switch fuses -- replace if

needed. Poor or improper input (terminal board) connections.

Defective on/oﬀ switch -- replace.

Thermal light on. Main transformer overheating. Also check for prop-

er cooling, proper primary hookup, or shorted turn on secondary. Loss of primary phase. Find & replace defective fuse.

READY/ ON Light is OFF See Figure 5-2 Fan Does Not Run See Figure 5-3 (READY Light is ON) No Output -- Fan Running

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

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

or replace. Main transformer overheating -- thermal switches tripped due to re-

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

if defective, replace.

No Output - STICK Position See Figure 5-4 Meter Display is Blank See Figure 5-5 Preset Does Not Function See Figure 5-6 Ammeter Displays 760 Amps See Figure 5-7 Limited Output or Low Open-Circuit Voltage

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

for proper voltage. Poor output connections. Take apart, clean, and reassemble.

Panel-Remote switch in Remote position and remote voltage pot dis-

abled.

Over Temperature Light is ON See Figure 5-8 Erratic Weld Current

Welding cable size too small -- use correct cables.

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

connections. Improper wire feeder setup.

PC board defective -- replace.

High Output, No Voltage Control

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

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

No 115 Volt ac Output

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

Line Fuse Blows When Power Source is First Turned On

Shorted DIODE in Main Bridge -- replace.

Shorted capacitor in Capacitor Bank.

SECTION 5 MAINTENANCE

Ready-On

light is off

Replace Meter

Board (PCB2)

Is Voltage at

(PCB1)

P1-7 to P7-2

=28 VDC

Check and

repair wiring

Is Voltage at

(PCB1

P1-3 to P1-4

= 20VAC

Is voltage at

(PCB2)

P1-1 to P1-2

= to 28 VDC

Replace Main

Control board

(PCB1)

Yes

Check and

repair wiring

Fan does not run

(Ready-On light is

on)

Check and repair

wiring

Is Voltage at

fan motor

220 VAC?

P1-14 to P1-9 =

Is Voltage at

15 VDC?

Is voltage at

P1-15 to P1-9=

to 15 VDC?

Yes

Replace SSR1

Yes

Check and repair

wiring

Yes

Replace Main

Control board

(PCB1)

Yes

Replace Fan

Motor

Is Voltage at

P1-3 and P1-4 =

to 20 VAC?

NOTE:

Schematics and Wiring Diagrams on 11" x 17" paper are included

inside the back cover of this manual.

Figure 5-2. READY/ON Light OFF Figure 5-3. Fan Does Not Run

SECTION 5 MAINTENANCE

No weld power

(Stick position)

Power Light is On

Verify

Weld process in “Stick”

Panel-remote in “Panel”

Standard-Pulse in “Standard

Is voltage at

OTB+ to OTB- =

75 to 80 VDC

IS voltage at

C1 + to C1 -

= 80 VDC

Check external

connections and

components

D1,2,3,4,5,6,

good?

Replace if failed

(See Para. 5.H)

Check and repair

wiring

Replace failed

diodes

Is Q1,Q2,Q3

good?

Replace if failed

(See Para. 5.G)

Is gating signal

(15 VAC) available

at P1-6 to P1-5

(PCB3)?

Yes

Replace Main

Control Board

PCB1

Is gating signal

(15 VAC) available

at P6-3 to P6-2

(PCB3)?

Meter Display is

blank

Replace Meter

Board (PCB2)

Is the Power

LED on

Check and repair

wiring

Is voltage at

(PCB1

P1-7 to P7-2

= 28VDC

Is voltage at

(PCB2)

P1-1 to P1-2

= 28VDC

Check and repair

wiring

Is voltage at

(PCB1)

P1-3 to P1-4

= 20 VAC

Replace Main

Board (PCB1)

Replace Meter

Board (PCB2)

Yes

Yes Yes

Yes

Figure 5-5. Meter Display is Blank

(STICK Position)

Figure 5-4. No Weld Power

SECTION 5 MAINTENANCE

Preset does

not function

(unit welds)

Does preset work when

P2-11 and P216

(PCB1) are jumpered?

Replace

Switch S4

Replace

PCB1

Yes

1-Unit is in Stick Mode

2-CCP is set to minimum

4-Output leads are not shorted

3- Panel/Remote is in "Panel"

Ammeter

Displays

760 amps

Verify

Is voltage at

OTB + to OTB - =

to 80 VDC

Is Voltage at

(PCB1)

P1-7 to P1-2 = > 7

VDC

Is Voltage at

(PCB-1)

P3-2 to P3-4 =

> 7VDC

Is Voltage at

(SH-1)

3 to 4 =

> 7VDC

Replace SH-1

Check Wiring

Replace

PCB-1

OTB- + to OTB -

shorted

Repair short

circuit

Yes

Figure 5-7. Ammeter Displays 760A

Figure 5-6. PRESET Does Not Function

SECTION 5 MAINTENANCE

Over Temp

light is on

Was the Duty Cycle

exceeded?

Allow time

for machine

to cool

Replace PCB1

Does voltage at

P1-12 to P1-13 (PCB1)

= 8VDC ?

Check resistance

TS1

TS2 (Main

Tranformer)

TS3 (Inductor)

TS4

Replace if

switch is open

If OK, check

and repair

wiring

open

Yes

Figure 5-8. Over Temperature Light is ON

SECTION 5 MAINTENANCE

SECTION 6 REPLACEMENT PARTS

6.0 Replacement Parts

6.1 General

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

6.2 Ordering

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

Replacement parts may be ordered from your ESAB Distributor.

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

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

Note

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

Hardware items should be available through local sources.

SECTION 6 REPLACEMENT PARTS

8 (behind control panel)

9 (behind control

3,4

panel)

QTY. ITEM CIRCUIT NO. REQ. NO. DESCRIPTION SYMBOL

1 1 952219 Outlet 110V (Square) J3

2 1 951916 Connection Box Rcpt. 14FS X-ROT J8 3 1 634515 SW TGGL SPDT 2 Pos 14A 125V Q/D S3, 5 4 1 951474 Switch Seal Black 5 1 32385 Contactor Plate (ShipYard Model) 6 2 950122 Circuit Breaker 10A 32VDC/250VAC CB1, 2 7 1 0558004931 Lift Bail 8 1 951835 Thermal Switch N/O TS4 9 1 38246 PCB Pulse Shipyard PCB4 10 1 38211 Control PCB PCB1 11 1 0558005655 Cap Metal Protection

SECTION 6 REPLACEMENT PARTS

QTY. ITEM CIRCUIT NO. REQ. NO. DESCRIPTION SYMBOL

1 1 2091514 Label Warning Arc Welding & Cutting 2 1 954008 Label Danger High Voltage 3 1 99512240 Label Caution Lifting Eye 4 1 0558004927 Panel Right Side 5 1 950945 SW Pwr Disc 100A 600V S1 6 1 0558001363 Panel Front 7 2 678025 Terminal Assembly

SECTION 6 REPLACEMENT PARTS

.045

.040

.035

1/16

.052

WIRE TYPE

WIRE DIAMETER

PULSE SELECTION

EN-625 ERNiCrMo-3

STAINLESS

AL-4000

AL-5000

EN-60 ERNiCu-7

METAL CORE STEEL

STEEL

EN-67 ERCuNi

Voltage (CV) Current (CC) Trim (Pulse)

TEMP

POWER

BLINKING

WIRE SPEED

OUT OF RANGE

STEADY

NO PROGRAM

PRESET

MIG

LIFT

START

TIG

STICK

REMOTE

PANEL

STANDARD

MIG PULSE

Auto Fan

Fan will cycle automatically

Multipower 460PULSE

WFS-IPM

AMPS

VOLTS

2 1,5

4,5

7,53,5

9,10

QTY. ITEM CIRCUIT NO. REQ. NO. DESCRIPTION SYMBOL

1 1 634519 Switch Toggle 4PDT S6 2 1 0558001818 Knob 1.31 Dia 1 0558001176 Pot Lin *10.0K 2.00W 0.88L (A & B) R1 3 1 952895 Switch PB Normally Open S4 4 1 634515 Switch TGGL SPDT 2 POS 14A 124V Q/D S3 5 4 951474 Switch Seal, Black 6 1 0558004923 Panel, Front (Silkscreened) 7 1 636702 Switch Toggle 3PDT S2 8 1 38196 PCB Display Assembly PCB2 9 2 0558001595 Knob Ribbed Body 1/8 Hole 10 2 38222 PCB Pulse Switch PCB5

SECTION 6 REPLACEMENT PARTS

QTY. ITEM CIRCUIT NO. REQ. NO. DESCRIPTION SYMBOL

1 1 13732733 Label for Install Use COP Wire

2 1 950219 Relief Strain 2" (Non-enclosed) 3 1 0558004926 Panel Top Kydex Env 4 1 0558004925 Panel Left Side Kydex Env 5 2 0558003490 Foot Skid 6 1 0558001364 Panel Rear 16 GA ENV

SECTION 6 REPLACEMENT PARTS

QTY. ITEM NO. REQ. NO. DESCRIPTION SYMBOL

1 3 99511916 Diode Fwd 200V 250A D1, D3, D5

2 3 99511915 Diode Rev 200V 250A D2, D4, D6 3 1 954864 Label 3 Phase 4 1 2062334 Fan Motor 1/3 HP 1625 RPM M1 5 1 954699 Label Warning Fan Hazard 6 1 36173 Blade Fan 14" 5(or)6 Fin 7 1 33939 Inductor 7 Turn L1 8 1 38186 Driver PCB PCB3

SECTION 6 REPLACEMENT PARTS

QTY. ITEM NO. REQ. NO. DESCRIPTION SYMBOL

1 1 952938 SCR 480V 18A Panel MNT SSR1

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 1.0 uf 600 VDC 10% C4 6 3 0558002844 Capacitor 35000 uf 100 VDC C1,C2,C3

SECTION 6 REPLACEMENT PARTS

3, 4

QTY. ITEM NO. REQ. NO. DESCRIPTION SYMBOL

1 2 17280110 Res WW Fix'd ST 100W 5% 100.00 R3, R4

2 1 0558005169 Transformer 230/460V T1 3 6 672065 Strap Terminal 4 1 36091 Board Input Terminal 230/460V TB1

REVISION HISTORY

Preliminary release - 08/2004

1. Released - 09/2004

2. Added IGBT and diode test data in Section 5 and updated schematic package - 12 / 2004

3. Updated schematic package - 07 / 2005, del modiﬁed schematic 0558004922 made by J. Devito and replaced by

4. schematic from smartteam per R. Eldridge & D. Griﬃn on 7/11/05. The 10/2005 revision updates the replacement parts section by adding p/n 0558005655, item 11, metal cap pro-

5. tection and illustration to the front view.

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS: Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST Order Entry Product Availability Pricing Order Information Returns

B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting

C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Hours: 8:00 AM to 5:00 PM EST Part Numbers Technical Applications Speciﬁcations Equipment Recommendations

D. LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4487 / Fax: (843) 664-5557 Hours: 7:30 AM to 3:30 PM EST Repair Estimates Repair Status

F. WELDING EQUIPMENT TRAINING Telephone: (843)664-4428 / Fax: (843) 679-5864 Hours: 7:30 AM to 4:00 PM EST Training School Information and Registrations

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

H. TECHNICAL ASST. CONSUMABLES: Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123

Fax: (843) 664-4452

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

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

The ESAB web site oﬀers

Comprehensive Product Information

Material Safety Data Sheets

Warranty Registration

Instruction Literature Download Library

Distributor Locator

Global Company Information

Press Releases

Customer Feedback & Support

0558004964 10/2005

C16

C17

C18

R64

R63

D15

D16

R71

D12

D39

R142

R141

R96

R95

D27

R88

R97

R84

R83

R80

R82

C57

R177

R81

R79

R178

C58

C39

C19

C48

R33

C52

R32

2 3 4 5 6

D17

D19

R75

R76

IC9

D20

D18

R70R73

R77

R143

D40

R145

R144

C40

D41

IC10

D42

D29

R116

C44

R115

D31

R114

IC11

D22

R87

C37

R86

R90

R93

R101

R91

D25

R89

R100

D23 D24

R92

C59

Q10

R60

R59

R48

R56

IC7

R183

R57

R58

R54

D10

R55

R128

R184

D11

R123

R126

R124

R121

R122

IC13

R125

R127

D36

R180

C53

D32

D30

R188

R189

C61

C45

D51

R181

R187

D34

D53

R94

R99

IC15

R179

C41

D26

R113

R112

D28

R109

R130

R108

R110

IC12

C46

D35

R111

R129

R107

R131

D43

C51

D38

R140

R155

C50

IC5

R152

VR3

D49

C56

R137

D50

R186

R138

R139

R148

R169

R135

VR4

R166

R168

IC16

R167

R174

R133

R134

WIRE SPEED REF.

R98

R132

TP4

VOLTS REF.

1V/10V

R36

R136

R34

TP6

T.S.

VR5

R35

R147

D21

R37

1 2 3 4 5 6 7 8 9 10

R146

R67

R65

C15

D14

D13

TP7

IC1

R3 D3

IC2

TP3

TP5

-15V

VREF.

(+)

HS1

R2 R1

HS4

TP8

(+)

R102 R104

R106

D48

Earc/10

R74

R72

R120

R119

C42

C43C38

C30 C35 C34 C29 C28 C27 C26

R103

R105

14 12 10 8 6 4 2

R118

R117

C22

R38

R40

IC19

C20

R39

M2M3

1 2 3 4 5 6 7

1516 13 11 9 7 5 3 1

C21

D46

R170

D47

R66

R68

1 2 3 4

R171

R160

R161

ESAB ASY 38211 REV.

R165

R164

R163

R162

R159

R158

R156

TP9

IC17

R154

R185

R157

C55

R153

R149

D44

IC14

R151

R176

R150

R175

D45

R69

R78

R62

IC18

R61

R182

TP2

+15V

C49

C33

C36

MultiPower 460 PULSE (Shipyard Model) Control PCB PN-(8)38211 Sheet 1 of 3

C11

C10

BR1

916

TP1

COMMON

TO METER BD.TO METER BD.

P1-1

TO SPOOLTO SPOOL

GUN POT. MAX.GUN POT. MAX.

WIRE

SPEED

10K

TO SPOOLTO SPOOL

GUN POT. MIN.GUN POT. MIN.

10K

V/AV/A

REM. V/A POT.REM. V/A POT.

MAX.

REM. V/A POT.

WIPER

1000 uf

C29

C30 .01

1N40041N4004

-15v

100 uf

D FS20FS20 UM6UM6

FS20FS20 UM6UM6

LM2907N-8

VR1

100K

C24

75K

IC7

IC8

-15v

+15v

1N4004

R22

IC6

TP3

TP1TP1

.01

R42

+15v

R183

680

1/2W

ZD1

1N5246

R23

.33

C25

R56R56

49.9K

100K R57R57

1N40041N4004

IC2

3 2

LM317

4.99K4.99K4.99K4.99K

R20

100 uf

R21

6.19K

R24

C12 .01

R43

+15v

R52

6.19K

R53

4.99K

C59

1uf

+15v+15v

TP2

IC3

H11AA1

.01

1MEG

1 MEG

2N4401

R60

R19

R190

R187R187

221K221K

100 uf

Q10

2N4401

R18

R44

6.19K

100K

R48

R179

10K

R180 20K

R181

4.99K

C61

1uf

R61 100K

100K R62

221

174K

+15v+15v

100K

R59

IC7

1.3K

10K

R10

R11

1.3K

R45

6.19K

SHORT CKT.SHORT CKT.

DETECT

D53

20K

R6 10K

174K

1uf

R172

68.1K 5

R173

C60

.47uf

TP4

IC6

174K

R12

R16

R17

IC7

+15v

68.1K

1uf

150K

R25

IC6

IC7

IC18

6,7,8

IC1

.01

MC7915

RL1

BR1

C10

4700uf

100v.

C11

812

.01

C23

.01

MYLARMYLAR

C26

100K

R49

680

1/2W

R50

R51

D48

826

100K

R54

D10

R55R55

R191R191

1MEG1 MEG

D11

R182

100K

-15v

10K

R58

P7-1

P1-1

P1-2

P1-3

P1-4

P7-3

P1-5

P1-6

P1-7

P1-8

P1-9

P2-1

P2-2

P2-3

MAX.

MIN.MIN.

P2-3

P2-4

P2-5

P2-6

P2-7

P2-8P2-8

P4-1

P4-2

P4-3

1N40041N4004

.01

826

10K

R41

.01

C27 .01

C28

.01

+15v

10K

R13

ZD2

1N4732

100K 100K

R46

IC6

WIRE SPEEDWIRE SPEED

REF.

D51

TP5

IC9

D52

4.99K

R14

R15

(+) V/A REF.(+) V/A REF.

+15v

10K

R33

100K

R32

+15v+15v

IC5

+15v

R38

4.99K

.01

C20

11 12

IC5

100

R65

R66

4.99K R67

IC9

STICK = HIGHSTICK = HIGH

IC9

1N4004

D19

+15v

RL1

100

R31

IC9

D18

IC5

TP6

D12

R64

D15

D16

100K

IC5

IC19

H11AA1

10K

R63

D13

2N4401

10K

D17

TIG = HIGHTIG = HIGH

+15v

Vcc

GND

O.C.

NIV

IC4

TL594

REF

INV

R47

INV

NIV

R26

COMP

R30 100

8E18

.01

C13

6.19K

R29

R28 10K

R27

.22

C14

10K

IC10

+15v

10K

R76

D20

+15v

C52 .01

+15v+15v

10K

499

R36

R39 680

1/2W

680

1/2W

R40

CONTACTOR HIGH = ON

HIGH = ON

100K100K

R70R71

100K

R73

100K100K

R77

R35

.01

C16

C17

.01

D21

R37 499

C18

.01

C19

.01

C21

.01

C22

1N4004

D14

+15v

10K

R68

10K

R69

C33 .01

+15v

10K

R72

C34

.01

+15v+15v

10K

R74

100K

R75

10K

+15v

C35

.01

R78

C36 .01

100K

R34

C15

+ 1uf

10K

P5-2P5-2

P5-3

P5-4

P5-5

P5-6

P5-1

P1-10

P1-11

P2-9

P7-8

P1-12

P1-13

P4-7

P2-10

P2-11

P2-12

P4-8

P4-9

TO PRE/POST FLOW OPT.TO PRE/POST FLOW OPT.

250K

BURNBACKBURNBACK

TO PRE/POST FLOW OPT.TO PRE/POST FLOW OPT.

TORCH SWITCH

MAIN

OVER TEMP. TO METER BOARD

TS1

TS2

TORCH SWITCH

REMOTE

STICK

MIG

TIG

24VAC

PANELPANEL

REMOTEREMOTE

MultiPower 460 PULSE (Shipyard Model) Control PCB PN-(8)38211 Sheet 2 of 3

CURRENT SENSORCURRENT SENSOR

INDUCTANCE

(-)E arc(-)E arc

(+)E arc(+)E arc

TO FAN RELAYTO FAN RELAY

MAX.

P3-1

P3-2

P3-3

P3-4

P2-13

P2-14

P3-6

P3-7

P1-14

P1-15

-15v

C38

.0047 uf

R104

R103

15K 15K

R105 R106

.0047

C43

499

R117

499

R118

2N4401

+15v

C42

15K15K

(+) Earc/10(+) Earc/10

+15v

(+) V/A REF.(+) V/A REF.

20K

R79

150K

R80

R102

3.01K

+15v

IC12

3.01K

-15v

R107

R119

R120 10K

I ARCI ARC

(+)

1V/100A

R176

IC14

30.1K

D38

IC18

100

30.1K

C46

R174 R175

10K

R133

20K

R134

R132

1uf

68.1K

R131

D35

IC12

TIG = HIGHTIG = HIGH

R98

100K

33.2K

R81

.047

C37

R82

20K

+15v

IC11

20K

R90

10K R101

TP8

20K

R178 100

C58 .01

IC10

20K

6.19K

-15v

(-)1v/5v

20K

R83

R177

D24

20K

R91

IC11

D25

R108

40.2K

-15v R109

R110

1000uf C44

R121

R122

+15v-+15v

R123

100

20K

R100

D29

150K 150K

R115 R116

C57 .01

R89

D23

R92 499

R93

158

D28

IC12

100K

R111

IC13

10K

R84

IC11

D27

-15v

R184

40.2K

2N4401

68.1K

R94

R99

R112

R124

33.2K

90.9K

R125

SHORT CKT.SHORT CKT.

DETECT

TP7

VOLTS REF. 1v/10vVOLTS REF. 1v/10v

C39

1uf

C41

D26

IC12

100K

R113

R114

IC13

R126

150K

4.99K

R95

C53 1uf

100K

R87

D22

150K

R127

IC10

ARC DETECTARC DETECT = HIGH= HIGH

R189

10K

IC11

C40

IC15

D31

221K

R97

1uf

6.19K

-15v

D32

TIG = HIGHTIG = HIGH

R129

40.2K

R130

C45

1uf

D30

IC13

D36

D34

100K

R86

R96

10K

+15v

IC15

R188 100K

+15v

IC13

-15v

+15v

10K

4.99K

R168

I arc 1v/100AI arc 1v/100A

AMPS REF. 1v/100AAMPS REF. 1v/100A

WIRE SPEEDWIRE SPEED

REF.

E arc 1v/10vE arc 1v/10v

VOLTS REF. 1v/10vVOLTS REF. 1v/10v

C48

4.7uf

D45

C56

.01

CONTACTOR

HIGH = ON

STICK = HIGHSTICK = HIGH

D46

R160 100K

49.9K

R166

R167

D39 R141 100K

R142

100K

IC10

CONTACTOR

HIGH = ON

10K

R148

IC14

R186

100

R128

49.9K

Q6 Q7

R161

+15v

D47

IC14

-15v

150K

R169

30.1K

-15v

R156

100K

49.9K

R149

R140

10K

30.1K

R150

R157

100K

IC16

MC14052

VEE

100K 100K

R143

R144

D40

221K

R151

R185

10K

IC14

R152

30.1K

20K

C50

VR3

330pf

2N4401

R162

2N44012N4401

R163

DO NOT LOAD : R164

VSS

C49

D44

330pf

R153

R154

4.99K

R164

VDD

INH

IC10

D41

IC10

D43

C55

10K

TP9

10K

INV

R155 10K

COMP

R165

REF

INV

O.C.

.01

C51

IC15

R158

4.99K

R159 1K

4.99K4.99K

R137

100K

+15v

R135

20K

VR4

20K

VR5

D42

R147 100K

+15v

Vcc

IC17

TL594TL594

NIV

90.9K

R136R136

90.9K

R139

R138R138

10K

D49

D50

IC5

NIV

GND

R170

R171

P7-6

P7-2

P7-7

P2-15

P2-16

10K

P7-4

R145

10K

P7-5P7-5

1514

R146

100

P6-1P6-1

P6-2P6-2

100

P6-3P6-3

VOLTS REF. TO METERVOLTS REF. TO METER

COM. TO METERCOM. TO METER

AMPS/W.F.S. REF. TO METERAMPS/W.F.S. REF. TO METER

PRE-SET

HOLD SIGNAL TO METERHOLD SIGNAL TO METER

W.F.S. LED SIGNAL TO METERW.F.S. LED SIGNAL TO METER

TO DRIVER BOARDTO DRIVER BOARD

COM. TO DRIVER BOARDCOM. TO DRIVER BOARD

TO DRIVER BOARD

MultiPower 460 PULSE (Shipyard Model) Control PCB PN-(8)38211 Sheet 3 of 3

P1P1

7U67

+5v+5v

R4R4

3.9K3.9K

C8C8

.1uf.1uf

10K10K

R5R5

MCLRMCLR

1616

OSC1OSC1

1818

RA1RA1

1717

RA0RA0

1313

RB7RB7

RA2RA2

RA3RA3

RA4RA4

R12R12

10K10K

XY7X

C3C3 35pf35pf

R1R1

10K10K

R2R2

221K221K

R6R6

10K10K

R7R7

221K221K

R13R13

10K10K

R14R14 10K10K

C1C1 .1uf.1uf

C2C2

.1uf.1uf

+5v+5v

R15R15 10K10K

Q3Q3

2N44012N4401

R3R3

270270

R8R8

270270

PIC16C711PIC16C711

(99513603)(99513603)

74AL23874AL238

VDDVDD

U1U1

VSSVSS

U5U5

1414

6,166,16

4,5,84,5,8

RBORBO

RB1RB1

RB2RB2

RB3RB3

1010

RB4RB4

1111

RB5RB5

1212

RB6RB6

1515

OSC2OSC2

1111

Y4Y4

1010

Y5Y5

Y6Y6

1414

Y1Y1

1313

Y2Y2

1212

Y3Y3

1515

Y0Y0

+5v+5v

C5C5 .1uf.1uf

C4C4 .1uf.1uf

7x150 OHM7x150 OHM7x150 OHM

MC1413BPMC1413BP

4A4A

3A3A

2A2A

1A1A

6A6A

5A5A

RN1RN1

1414

1313

1212

1111

1010

U4U4

1313

4Y4Y

1414

3Y3Y

1515

2Y2Y

1616

1Y1Y

1111

6Y6Y

1212

5Y5Y

1010

7,87,8

25,21,1625,21,16

24,20,1524,20,15

4,8,134,8,13

2,7,112,7,11

1,6,101,6,10

27,23,1727,23,17

28,22,1228,22,12

+5v+5v

R9R9

270270

25,21,1625,21,16

24,20,1524,20,15

4,8,134,8,13

2,7,112,7,11

1,6,101,6,10

27,23,1727,23,17

28,22,1228,22,12

U2U2

DISPLAYDISPLAY

7SEG.x3DIG.7SEG.x3DIG.

AMPSAMPS

OROR

WIRE SPEEDWIRE SPEEDWIRE SPEED

CC1CC1 CC2CC2 CC3CC3

2626

1919

U3U3

DP2DP2

DISPLAYDISPLAY

7SEG.x3DIG.7SEG.x3DIG.

VOLTSVOLTS

CC1CC1 CC2CC2 CC3CC3

2626 1919 18

DP1DP1

DP2DP2

1414

DP3DP3

1818

DP1DP1

1414

DP3DP3

OVERTEMPOVERTEMP

D3D3

FAULTFAULT

D7D7

R10R10

1.8K1.8K 1/2W1/2W

R11R11

1.8K1.8K 1/2W1/2W

10K10K

R18R18

R16R16

806806

10K10K

R19R19

R17R17

1.8K1.8K

1/2W1/2W

AMPSAMPS

D5D5

Q1Q1

2N44012N4401

R20R20

10K10K

R21R21

WFSWFS

D4D4

Q2Q2

2N44012N4401

R22R22

1.8K1.8K

1/2W1/2W

D1D1

POWERPOWER

D6D6

R23R23

1.8K1.8K 1/2W1/2W

D2D2

1N40041N4004

LM317LM317

33 22

ININ

ADJ.ADJ.

C6C6 1uf1uf

R24R24 806806

+5v+5v

OUTOUT

R25R25

270270

C7C7

1uf1uf

1N40041N4004

MultiPower 460 PULSE (Shipyard Model) Display PCB PN-(8)38196

20V

J1-2

- +

BR1 W04G

1N4007J1-1

MC7815CT

OUT

+15V

TP2

J1-3

J1-5

TP4

J1-4

J1-6

TP5

1N4148

4.02K

TP3

4.02K

HPCL-2231

-IN 2

-IN

+IN

1000uF 35V

VCC

GND

OUT

GND

C2 220uF

35V

TP1

+15V

5.0

D2 18V

WIRE TO G1WIRE TO G1

WHT

TWISTED PAIR

TYP. 3 PLCS.TYP. 3 PLCS.

+15V

D3 18V

WIRE TO S1

BLK

4.02K

O/P

VDD

I/P

GND

VDD

GND

TC4422

O/P

TP6

5.0

D4 18V

WIRE TO G2

WHT

D5 18V

WIRE TO S2WIRE TO S2

TP5

6 1

TP4

TP3

R8 TP6

TP2

TP1

BR1

5.0

18V

D7 18V

MultiPower 460 PULSE (Shipyard Model) IGBT Driver PCB PN-(8)38186

BLK

WIRE TO G3

WHT

WIRE TO S3

BLK

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

Specifications and Main Features

Frequently Asked Questions

User Manual