ESAB SVI 450i cvcc Power Source Instruction manual

INSTRUCTION MANUAL

SVI 450i cvcc

Power Source

F15-071-D

December, 2003

This manual provides installation and operation / maintenance and troubleshooting instructions for the following units:

ESAB P/N 31950 - 208/230/460 V ac, 1 or 3 Phase, 60 Hz
ESAB P/N 31955 - 575 V ac, 3 Phase, 60 Hz (Refer to Supplement F-15-072.)
ESAB P/N 31960 - 220/380/415 V ac, 3 Phase, 50 Hz (Refer to Supplement F-15-073.)
L-TEC P/N 35618 - 220/380/415 V ac, 3 Phase, 50 Hz (Refer to Supplement F-15-073.)

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

Be sure this information reaches the operator.
You can get extra copies through your supplier.

ESAB Welding &
Cutting Products

USER RESPONSIBILITY

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

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

TABLE OF CONTENTS

SECTION TITLE PAGE

PARAGRAPH

SECTION 1 DESCRIPTION ................................................................................................. 5

1.1 Introduction ....................................................................................................... 5

1.2 Optional Accessories......................................................................................... 5

SECTION 2 INSTALLATION ................................................................................................ 6

2.1 General ............................................................................................................. 6

2.2 Unpacking and Placement ................................................................................ 6

2.3 Input Power Connections .................................................................................. 6

2.4 Output Welding Connections............................................................................. 8

2.5 MIG Control (J1) Interconnection ...................................................................... 9

2.6 Additional Remote Control (J2) Interconnection ................................................ 10

SECTION 3 OPERATION ..................................................................................................... 11

3.1 Introduction ....................................................................................................... 11

3.2 Duty Cycle ......................................................................................................... 11

3.3 Volt-Ampere (Slope) Characteristics ................................................................. 11

3.4 Power Source Welding Controls ....................................................................... 11

3.5 Sequence of Operation ..................................................................................... 12

SECTION 4 MAINTENANCE ................................................................................................ 15

4.1 General ............................................................................................................. 15

4.2 Cleaning ............................................................................................................ 15

4.3 Lubrication ........................................................................................................ 15

SECTION 5 TROUBLESHOOTING ..................................................................................... 16

5.1 Troubleshooting ................................................................................................ 16

SECTION 6 REPLACEMENT PARTS .................................................................................. 27

6.1 General ............................................................................................................. 27

6.2 Ordering ............................................................................................................ 27

2

WARNING: T hese Safety Precautions are for your

protection. They summarize precautionary infor-

mation from the references listed in Additional
Safety Information paragraph. 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 ultravio-

let (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-sleeved

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

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

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

5. Protect other personnel from arc rays and hot sparks with a

suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag or

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

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

1. Remove all combustible materials well away from the work

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

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

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

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

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

4. Have fire extinguishing equipment handy for instant use,

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

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

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

7. For additional information, refer to NFPA Standard 51B,
"Fire Prevention in Use of Cutting and Welding Processes,"
available from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.

ELECTRICAL SHOCK — Contact can
cause severe injury or death. Do NOT use
AC output in damp areas, if movement is
confined, or if danger of falling exists. Put
on dry, hole-free gloves before turning on
the power. Also:

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 the operator 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. Fix water leaks
immediately.

6. Make sure that you are well insulated, especially when
standing on metal or working in tight quarters or in a damp
area. Wear rubber-soled shoes and stand on a dry board or
insulating platform.

7. Turn off the power before removing your gloves.

8. Refer to ANSI/ASC Standard Z49.1 (see listing below) for
specific grounding recommendations. Do not mistake the
work lead for a ground cable.

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

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

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

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

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

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

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

your body as possible.

3

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.

8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held Haz­ardous Substances."

This symbol appearing throughout this manual
means Attention! Be Alert! Your safety is

involved.

The following definitions apply to DANGER, WARNING,
CAUTION found throughout this manual:

Used to call attention to immediate hazards
which, if not avoided, will result in immedi­ate, serious personal injury or loss of life.

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

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

4

Used to call attention to potential hazards
which could result in personal injury or loss
of life.

Used to call attention to hazards which
could result in minor personal injury.

SECTION 1 DESCRIPTION

1.1 INTRODUCTION

The SVI 450i cvcc is a high performance constant voltage
(cv)/constant current (cc) 450-ampere industrial inverter
power source that is designed with adjustable output
(voltage or current), slope, and inductance. Exclusive
power MOSFET inverter technology combined with solid
state electronics provides state-of-the-art, multi-process
welding performance including MIG (short arc, spray arc,
cored wire), Stick, TIG, and air carbon arc gouging. The
SVI 450i cvcc offers all this versatility and performance in
one compact power source.

The power source is designed to operate in the cv mode
for outstanding MIG short arc performance as well as MIG
spray-arc and cored wire welding. It is compatible with
ESAB's full line of digital and conventional wire feeders for
unmatched accuracy and performance.

The constant current mode for Stick, TIG (scratch-start),
and air carbon arc gouging applications is provided by
connecting one of the remote control devices and select­ing the cc process mode.

The power source's electronic output (voltage or current)
adjustment provides full-range regulation either locally
from the front panel or from a remote control. A conve­nient panel-mounted digital meter provides selectable
output voltage or current readings for welding accuracy.
The panel-mounted 3-step slope selector and variable

inductance control allows the operator to select the opti­mum cv slope/curve characteristic and/or inductance
condition required for your MIG welding application. Refer
to table 1-1 for specifications.

1.2 OPTIONAL ACCESSORIES

A. To avoid duplication of MIG accessories which

may or may not be required for the various MIG
systems, please refer to the individual wire feeder
or control instruction booklets provided for your
system.

B. For applicable Stick/TIG accessories, refer to

figure 2-3 and/or the following:

1. TC-2B Torch Controls (30 ft lg), P/N 33839

2. FC-5B Foot Control (30 ft lg), P/N 33646

3. FC-5B EHD (Extra Heavy Duty) Foot Control
(30 ft lg), P/N 33841

4. HC-3B Hand Control (30 ft lg), P/N 33838

5. HC-4B Hand Control w/Arc Force (30 ft lg),
P/N 33840

6. Ultra-Pulse 450i Mig Pulse Pendant Control,
P/N 34946. Easy to use synergic pulse control
automatically provides precise parameters
for pulsed MIG welding. Must be used with
Mig 4HD wire feeder. (Control cable (8 ft
lg) included.)

7. Cart, P/N 31700. Provides complete mobility
for power source, wire feeder, gas cylinder(s)/
water cooler (vertical).

Table 1-1. SVI 450i cvcc Specifications

Input Voltage

Input Current @ Rated Load 80 A 65 A 40 A

Open Circuit Voltage

Rated Output @ 60% Duty Cycle

Dimensions

width
length
height

Shipping Weight

Net Weight

208 V ac, 1 or 3 phase, 60 Hz 230 V ac, 1 or 3 phase, 60 Hz 460 V ac, 3 phase, 60 Hz

72 V dc

450 A @ 38 V dc, 3 phase
275 A @ 31 V dc, 1 phase

15.75" (400 mm) + 2" (51 mm) for handle

450 A @ 38 V dc, 3 phase
275 A @ 31 V dc, 1 phase

15.25" (385 mm)

24.25" (616 mm)

172 lbs (78 kg)

161 lbs (74 kg)

450 A @ 38 V dc, 3 phase
275 A @ 31 V dc, 1 phase

5

SECTION 2 INSTALLATION

2.1 GENERAL

Proper installation will contribute to safe, satisfactory, and
trouble-free operation of the welding setup. It is sug­gested that each step in this section be studied carefully
and followed as closely as possible.

2.2 UNPACKING AND PLACEMENT

A. Immediately upon receipt of the equipment, in-

spect for damage which may have occurred in
transit. Notify the carrier of any defects or dam­age at once.

B. After removing the components from the ship-

ping container(s), check the container(s) for any
loose parts. Remove all packing materials.

C. Check air passages of power source for any

packing materials that may obstruct air flow
through the power source.

D. If the equipment is not to be installed immedi-

ately, store it in a clean, dry, well-ventilated area.

E. The location of the power source should be

carefully selected to ensure satisfactory and de­pendable service. Choose a location relatively
close to a properly fused supply of electrical
power.

2.3 INPUT POWER CONNECTIONS

The SVI 450i power source must be connected to a
"clean-unloaded" supply power line. An unloaded line is
essential for good performance and lessens the chance
of nuisance (fault) tripping or damage due to transients
caused by other equipment loads such as resistance
welders, punch presses, large electric motors, etc.

If nuisance tripping caused by transients becomes a
problem, ESAB has a "primary line conditioner" (P/
N 15983) which may be added to filter out transient
voltages . Contact your distributor for details. Please note
that the conditioner will not correct for sustained line
voltages which exceed the limits of its rated voltage
inputs.

The power source is designed to provide line voltage
compensation within 10 percent of the rated 208/230/
460-volt input to maintain its rated output and protect its
power electronics. If these limits are exceeded, serious
damage to the power source could occur. Therefore,
prior to installation, it is suggested that the proposed line
circuit be checked with a meter at two or three different
time periods of the day to make sure the power load does
not exceed the power source's input limits. If input power
cannot be maintained within the 10 percent limits, consult
your local power company or call ESAB for possible
solutions.

F. The power source components are maintained

at proper operating temperatures by forced air
drawn through the cabinet by the fan unit on the
rear panel. For this reason, it is important to
locate the power source in an open area where
air can circulate freely at the front and rear
openings. If space is at a premium, leave at least
1 foot of clearance between the rear of the power
source and wall or other obstruction. The area
around the power source should be relatively
free of dust, fumes, and excessive heat. It is also
desirable to locate the power source so the cover
can be removed easily for cleaning and mainte­nance.

Electric shock can kill! Precautionary measures
should be taken to provide maximum protection
against electrical shock. Be sure that all power is off
by opening the line (wall) disconnect switch when
primary electrical connections are made to the power
source. To be doubly safe, check your input leads
with a voltmeter to make sure all power is off.

A. A line (wall) disconnect switch, with fuses or

circuit breakers, should be provided at the main
power panel (see Figure 2-1). The customer may
either use the factory-supplied input power cable
(No. 6 AWG, 4/c, type SO (90 °C), 12-ft lg) or
provide his own input power leads. The primary
power leads should be insulated copper conduc­tors and include two (1 phase) or three (3 phase)
power leads and one ground wire. The wires may
be heavy rubber-covered cable or run in a solid or
flexible conduit. Refer to table 2-1 for recom­mended input conductors and line fuse sizes.

6

SECTION 2 INSTALLATION

208

208

208208

DOUBLE LINKS

230460230

230460230

i
l
i

g
n

Customer's Fused Line Disconnect Switch

Make sure all input power is disconnected

before performing any operation inside the power source.

No. 6 AWG, 4/c, type SO, 12-ft lg

nput power cable factory installed to
ine switch (LS) or customer may
nstall own 4-conductor (3 phase) or

3-conductor (1 phase) cable and

round (see paragraph 2.3) and con­ect to Line Switch as shown.

1ø Hookup

2

4

3ø Hookup

Line Switch (LS) Rear View

Figure 2-1. Input Power and MIG Interconnection Diagram

19-pin MIG
Receptacle J1

6

Ground
Stud

POSITIVE (+)

OUTPUT

For interconnecting control cable(s) part number(s) and
hookup, refer to appropriate system instruction booklets and
paragraph 2.5.

Approved
Earth Ground

To Work

-

+

NEGATIVE (-)
OUTPUT

To Wire Feeder/
Plumbing Box/Torch.
See appropriate in­struction booklet.

WELDING CABLES (customer
supplied, see Table 2-1) are set
up for DCRP (negative to work)
operation. See paragraph 2.4.

MALE CONNECTOR
(supplied w/power source)

Table 2-1. Recommended Sizes for Input

Conductors and Line Fuses

switch through the strain relief hole in the rear
panel. Connect the primary leads to the Line
Switch (LS) for either single- or 3-phase input

Rated Load

Volts Amps

208
230
460

* Sizes per National Electric Code for 90 °C rated copper conductors
@ 30 °C ambient. Not more than three conductors in raceway or
cable. Local codes should be followed if they specify sizes other
than those listed above.

80
65
40

Input &
Gnd.
Conductor*
CU/AWG

6
6
8

Time-Delay
Fuse Size
Amps

90
80
60

and the ground lead (green) to the stud on the
base of the unit as shown in figure 2-1. After
making sure the connections are secured, tighten
the strain relief coupling to secure the input
cable.

It is of the utmost importance that the chassis be
connected to an approved electrical ground to pre­vent accidental shock. Take care not to connect the
ground wire to any of the primary leads.

B. As shipped, the power source is set up for 460-

volt input power. If using 208- or 230-volt input,
two links on the input terminal board (located
inside the power source) must be repositioned as
marked on the plate (see Figure 2-2). The input
terminal board connections will be visible after
removing the top cover.

D. Recheck all connections to make sure they are

tight, well insulated, and properly connected.

C. The factory-supplied input power cable is con-

nected to the power source ON-OFF switch.
However, if customers wish to connect their own
input power leads, proceed as follows: With the
top cover and left side panel removed, thread the
input conductor cable from the wall disconnect

Figure 2-2. Input Voltage Terminal Board

(TB) Connections

7

SECTION 2 INSTALLATION

2.4 OUTPUT WELDING CONNECTIONS

Before making any connections to the power source
output terminals, make sure that all primary input
power to the power source is deenergized (off) at the
customer's disconnect switch.

A. MIG Setup (see Figure 2-1). This power source

is designed to provide MIG welding operating
characteristics only when the J2 control recep­tacle is "vacant" (meaning no accessories are
plugged in) or, if the remote HC-3B or HC-4B
hand control is plugged in. The process switch
must be set in the CV-MIG position for conven­tional wire feeders or in the DIGITAL-MIG (cen­ter) position for Digimig/Digimatic controls. Ad­ditionally, proper operation of the power source
depends on the use of copper output cables that
are insulated, of adequate size, in good condi­tion, and properly connected to the machine
using the jack plug connectors provided with the
power source. It is recommended that only 4/0
welding output cable be used, regardless of
length and current, and that these cables be kept
as short as possible. (Total length including work
and electrode leads should not exceed 100 feet.
Beyond this distance, there will be performance
deterioration. Consult with the factory if you have
an application of this nature.)

To ensure good torch performance, periodically
replace the water-cooled power cable.

The welding output receptacles are located on
the front panel; one negative (-) and one positive
(+) receptacle. Two male plug connectors (P/N

950693) are supplied with the power source for

attachment to customer supplied 4/0 welding
cables (see Table 2-1 and Figure 2-1). This
power source is designed for conventional and
digital MIG applications using Direct Current
Reverse Polarity (DCRP) setup. In a DCRP
setup, the torch or electrode is positive (+), and
the workpiece is negative (-).

B. Stick/Scratch-Start TIG/ Arc Gouging Setup

(see Figure 2-3). These processes require

constant current (cc) type curve characteristics
for proper operation. These characteristics are
only provided when one of the remote accesso­ries (FC-5B, TC-2B) is plugged into the J2 recep­tacle or when the remote HC-3B or HC-4B hand
control is connected to J2 and its process switch
is set in the CC-TIG/Stick position. Select the
desired welding mode, accessories, and polarity
as shown in figure 2-3. The output cables may be
connected for DCRP or DCSP; meaning that for
a DCRP setup, the electrode holder/torch is POS
(+) and the work is NEG (-); whereas for a
DCSP setup, the electrode holder/torch is NEG (­) and the work is POS (+).

Pay particular attention to high resistance in the
welding circuit; specifically, the work cable/circuit
and water-cooled torch cable. It is recommended
that the power source/wire feeder and workpiece
be placed as close together as possible to limit
resistance in the welding circuit. High resistance
in the welding circuit can cause performance
deterioration (loss of "heat" input, popping of
weld puddle, bushy arcs, etc.). Ensure the work
cable is large enough, kept as short as possible,
properly insulated, securely connected to the
workpiece, and that all connections are clean
and tightly secured. If a separate work circuit is
used (such as in mechanical fixturing, shipbuild­ing, robot fixturing, etc.), make sure the work
circuit is secure and presents a low resistance
path to the flow of welding current. Also, the
power cable on a water-cooled torch is normally
subject to gradual deterioration and increased
resistance due to corrosion. This leads to poor
performance as described above.

8

Regardless of your secondary welding cable setup
(DCRP or DCSP), in order to prevent electrical shock,
it is necessary that you connect the workpiece to an
approved electrical (earth) ground. The work cable
lead is not a ground lead. It is used to complete the
welding circuit between the power source and the
workpiece. This connection (at the workpiece) must
be made to a clean, exposed metal surface that is free
of paint, rust, mill scale, etc. A separate connection
is required to ground the workpiece to an approved
earth ground. The work cable should be the same
rating as the torch/electrode cable lead.

Proper operation of the power source depends to a great
extent on the use of copper output cables that are
insulated, adequately sized, in good condition and prop­erly connected to the machine using the jack plug connec­tors provided. It is recommended that the output cables
be kept as short as possible, placed close together, and
be of adequate current carrying capacity. The resistance

SECTION 2 INSTALLATION

NOTE: For cc operation, either of these remote acces­sories (FC-5B or TC-2B) must be plugged in. However,
for MIG operations, these particular controls must be
unplugged in order to provide constant voltage.

FC-5B Foot Control

TC-2B Torch Control

HC-3B or HC-4B Hand Control

Gas Supply/Hose

TIG Torch Adaptor (Insulate from ground by taping.)

TIG Torch w/Gas Valve

NOTE: To provide cc operation with the HC-3B or HC-4B plugged in,
simply place its process switch in the CC-TIG/STICK position. Constant
voltage is provided in the CV-MIG position for "non-digital" conventional
MIG operations and in the DIGITAL-MIG (center position) for "digital­microprocessor" MIG operations.

(2) Male Connector for #2 thru #40 AWG
(supplied w/power source).

POWER CABLE/CONNECTION

STICK

+

J1
J2

-

WORK DCRP (-)

Connect Work to Approved Earth Ground

Figure 2-3. Stick/Scratch-Start TIG/Carbon Arc Gouging Interconnection Diagram

of the output cables and connections cause a voltage
drop which is added to the voltage of the arc. Excessive
cable resistance can reduce the maximum current output
of the power source. Refer to table 2-2 to select the
recommended output cable size.

Table 2-2. Recommended Welding Cable Sizes

Welding Total Length (Feet) of Cable in Weld Circuit*

Current 50 100 150 200 250

100
150
200
250
300
400
500

* Total cable length includes work and electrode cables. Cable size
is based on direct current, insulated copper conductors, 100% duty
cycle, and a voltage drop of 4 or less volts. The welding cable
insulation must have a voltage rating that is high enough to
withstand the open circuit voltage of the machine.

** Cam-Lock jack plug connectors will not accept smaller than No. 2
gauge cable. Also, remember that for MIG-Pulse conditions we
recommend only 4/0 cable be used due to pulse-peak currents.

6**
4**
3**
2
1
2/0
3/0

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

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

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

--

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

--

--

STICK

WORK DCSP (+)

2.5 MIG CONTROL (J1)
INTERCONNECTION

IMPORTANT

In order to provide MIG welding (cv) operating char­acteristics, make sure that the J2 Remote Control
receptacle is either "vacant" (meaning no remote
accessories are plugged-in) or, if the HC-3B or HC­4B hand control is plugged in, its process switch
must be set in the CV-MIG position for conventional
non-digital wire feeders or in the DIGITAL-MIG (cen­ter) position for digital-microprocessor type feeder/
controls.

Please note that all control cable functions for MIG
operations must be connected through control receptacle
J1 (19-pin amphenol) on the rear panel (see Figure 2-1).
Additionally, if remote voltage control for "non-digital"
conventional feeder/controls (only) is desired, you can
also plug in the HC-3B or HC-4B hand control accessory
to Remote Control receptacle J2 to provide this function
(see paragraph 2.6).

To make the control interconnections for various MIG
equipment controls, select from the appropriate cable
assemblies listed on table 2-3.

9

SECTION 2 INSTALLATION

Table 2-3. Control Interconnection Cables

Wire Feeders

Digimig, Digimig Dual,

Cable Lengths

6-ft (1.8 m) P/N 31829 -- P/N 30686

30-ft (9.1 m) P/N 31830 P/N 34378 P/N 30780

60-ft (18.3 m) P/N 31831 P/N 34377 P/N 30781

Mig 35 Mig 2E and Mig 4HD

and Digimatic II

2.6 ADDITIONAL REMOTE CONTROL (J2)
INTERCONNECTION

A. For non-digital conventional MIG operations. This

8-pin remote control receptacle (J2) can be used
to provide full-range remote voltage regulation
from the HC-3B or HC-4B hand control. Note that
the power source’s Panel/Remote switch must
be set to REMOTE to provide this feature. When
connected, the HC-3B's or HC-4B’s process
switch must be set to its CV-MIG position to
provide constant voltage (cv) operation and volt­age regulation from its potentiometer. Also re­member that the contactor switch is nonfunc­tional for this process — contactor control is
provided by the torch switch through receptacle
J1.

B. For Stick, TIG, or Arc Gouging operations (see

Figure 2-3). These processes require constant
current (cc) characteristics for proper operation,
and this is only provided when one of the remote
control accessories (FC-5B or TC-2B) is con­nected to receptacle J2, or when the HC-3B or
HC-4B hand control is connected to J2 and its
process switch is set in the CC-TIG/STICK posi­tion. Note that the power source’s Panel/Remote
switch must be set to REMOTE to provide cur­rent regulation and/or contactor control at the
welding location. When the FC-5B foot or TC-2B
torch accessory is connected, full-range current
regulation and contactor control are available
from the remote accessory.

When the HC-3B hand control is connected, the
process switch must placed in the CC-TIG/STICK
position to set up the power source for constant
current operation. Remote current regulation is
provided from the CURRENT potentiometer. The
CONTACTOR control switch must be placed in
the ON position to provide welding power to the
torch/electrode.

If the HC-4B hand control is connected, you must
place its Process switch in the CC position to set
up the power source for constant current opera­tion. Remote current regulation (up to full range)
is provided from the CURRENT control potenti­ometer. The CONTACTOR control switch must
be placed in the ON position to provide welding
output current to the torch/electrode. The HC-4B
also incorporates two additional control features;
a TIG/Stick selector and an Arc Force potentiom­eter that functionally operates in the STICK mode.
The TIG and Stick modes provide the same cc
type volt-ampere curve characteristic; however,
the slope of the STICK curves can be further
adjusted by regulating the Arc Force control pot.
The lower Arc Force settings provide less short
circuit current and a softer, more stable arc;
whereas the high settings provide more short
circuit current and a forceful, more penetrating
arc.

10

SECTION 3 OPERATION

3.1 INTRODUCTION

This section is intended to familiarize personnel with the
operational procedures applicable to the SVI 450i cvcc
power source. Information contained in this section should
be read carefully before operation of the power source.

Never, under any circumstances, operate the power
source with the cover or side panels removed. In
addition to the safety hazard, improper cooling may
cause damage to internal components. Also make
sure you are adequately protected before welding.
Welding helmet, gloves, safety glasses, and ear pro­tection should always be worn.

3.2 DUTY CYCLE

Duty cycle is defined as the ratio of load time to total time.
Standard current ratings are based on a 10-minute cycle.
The SVI 450i cvcc power source has a 60% duty cycle
rating which allows 450 amperes @ 38 V dc (see Figure
3-1). The 60% duty cycle rating means that the 450­ampere rated load can be applied for a total of 6 minutes
and shut off for a total of 4 minutes in a 10-minute period.
If the welding current is decreased, the duty cycle can be
increased. Conversely, if the welding current is increased,
the duty cycle must be decreased.

Important Digimig/Digimatic Operational Note
All ESAB microprocessor-type wire feeder/controls
are designed to provide good arc starts with power
supplies that utilize a FLAT-SLOPE volt-ampere curve
characteristic. Since this power supply also allows
you to select a MEDIUM or STEEP slope characteris­tic, you may have to readjust the microprocessor’s
factory-set "starting" characteristics to provide the
best arc-starts possible using the "steeper" volt­ampere curves. The procedures required to recalibrate
the microprocessor "hot-start" characteristics are
provided in all of the appropriate Digimig/Digimatic
instruction booklets.

3.4 POWER SOURCE WELDING

CONTROLS

A. On-Off Line Switch (LS). Placed in the ON

position, this switch (located on the rear panel)
provides primary input power to start the cooling
fan motor and energize the secondary control
circuitry. Power light (PL1) on the front panel
should illuminate.

B. Digital Voltmeter/Ammeter (DPM) and Selec-

tor (SW2). This instrument provides direct digital

reading of open-circuit or welding, or welding
current depending on the position of the VOLT/
AMP selector switch.

C. Troubleshooting Lights.

3.3 VOLT-AMPERE (SLOPE)
CHARACTERISTICS

The curves shown in figure 3-2 represent the volt-ampere
static characteristics for the power supply in the MIG (cv)
and TIG (cc) modes. The slant of these curves is referred
to as the ‘slope’ and is generally defined as the ‘voltage
drop per 100 amperes of current rise.’ These curves show
the output voltage available at any given output current
between the minimum and maximum settings of the
voltage/current control. Typical curves are shown for
other settings between the minimum and maximum curves.
Because the volt-ampere slope is fixed, it is possible to
select optimum welding conditions by approximating the
open-circuit voltage required for a particular load current.

If you require greater slope (shown as dotted curves at
maximum setting) for your MIG welding applications, you
may change the slope switch position located on the front
panel. The static volt-ampere slope is not affected by the
inductor rheostat setting. For welding aluminum or stain­less steel, the steeper slope settings are recommended.

1. Temperature (PL2). This will light if compo­nents in the power source overheat. The contactor
will then deenergize. Allow the power source to
cool with the line switch in the ON position (the
fan will help cool the power source) before con­tinuing welding operations when light goes off.

2. Fault (PL3). This light functions as a visual
detector for two specific fault conditions:
overcurrent or over/undervoltage indication. In
either case, if a fault is detected in the inverter
bridge, the contactor will deenergize and the
power source will stop welding. If an overcurrent
condition caused the problem, the fault light will
energize and remain "steady-on." Do not attempt
to restart welding (refer to Section 5). If an over
or undervoltage condition occurs, the fault light
will flash. Since this can often be caused by a
transient, retry the torch switch to resume weld­ing. If tripping continues, stop and refer to section

5.

11

SECTION 3 OPERATION

D. Voltage Control Potentiometer (VCP). This

control sets and regulates the desired amount of
welding voltage required for your operation. The
panel-faced dial surrounding the control knob
provides a convenient reference for resetting
prior welding conditions. Note that the Panel/
Remote switch must be in the PANEL position
when this control (VCP) is used.

E. Panel/Remote Control Switch (SW1). This

switch determines the location from which weld­ing voltage will be regulated. In the PANEL posi­tion, full-range voltage is controlled by setting the
Voltage Control Potentiometer (VCP) on the
power supply — if desired, this position may be
used for non-digital (conventional) wire feeder
voltage control. In the REMOTE position, full
range voltage control is regulated either from the
J1 receptacle for mechanized controls or digital­microprocessor type (Digimig/Digimatic) feeder
controls, or from the J2 receptacle for non-digital
(conventional) feeder controls using the remote
accessory hand or torch controls.

The REMOTE position is also required to provide
full range "current" control from the J2 receptacle
using the remote accessory hand, foot or torch
controls for the Stick/TIG/Gouging processes.

F. Slope Control Switch (SW3). This 3-position

switch sets the slope of the volt-ampere curve
characteristic in the MIG (cv) mode — this control
feature is bypassed in the TIG/Stick (cc) mode.
Slope positions (top-to-bottom) are as shown in
table 3-1.

to minimum for all pulse and standard spray arc
welding applications.

H. Digital MIG Control Receptacle (J1). This 19-

pin remote control receptacle receives a mating
connector from the MIG/Digimig wire feeder or
other mechanized MIG controls (see Figure
2-1).

I. TIG/Stick Control Receptacle (J2). This 8-pin

remote control receptacle, located on the rear
panel, receives a mating connector from the
remote control accessories (see Figure 2-3).

J. Reset Circuit Breaker (CB). A 10-ampere cir-

cuit breaker (on the rear panel) provides protec­tion to the 115-volt control circuit. If an overload
occurs, the breaker will trip and suspend all
operation. To restore service, depress the breaker
button to reset the circuit.

K. Auxiliary 115 Volt Receptacle (J3). This recep-

tacle supplies 5 amperes of 115-volt power for
auxiliary equipment.

L. Welding Output Receptacles. Two output re-

ceptacles are located on the front panel — one
negative (-) and one positive (+). Refer to figures
2-1 and 2-3.

3.5 SEQUENCE OF OPERATION

Table 3-1. Slope Positions

Switch Position Process/Material Slope

MEDIUM
STEEP
FLAT

Short Arc/MS/AL
Short Arc/MS,AL,SS
Spray Arc

3 V/100 A
6 V/100 A
1 V/100 A

G. Inductance Control Potentiometer (ICP). This

control allows the operator to set and regulate the
desired amount of inductance required for stan­dard MIG short arc welding operations. Variable
control allows the operator to fine tune the induc­tance needed to make the weld puddle more fluid
and minimize the weld spatter produced during
MIG short arc applications. When short arc
welding stainless steel, high values of induc­tance should be used with A1025 helium rich
shielding gas. This potentiometer should be set

12

Never, under any circumstances, operate the power
source with the cover or side panels removed. In
addition to the safety hazard, improper cooling may
cause damage to internal components. Also make
sure you are adequately protected before welding.
Welding helmet, gloves, safety glasses, and ear pro­tection should always be worn.

A. MIG Welding

1. Make all secondary output connections to the
power source output receptacles as described in
section 2 (see Figure 2-2) and as shown in the
appropriate wire feeder and/or control instruction
booklets.

2. Make the necessary control connections to re­ceptacle J1 as described in section 2 (see Figure
2-2) and J2, if necessary. Make sure that FC-5B

SECTION 3 OPERATION

or TC-2B is unplugged from J2, or if HC-3B or
HC-4B is plugged in, the process switch is in the
DIGITAL-MIG (center) position.

3. After the primary input connections have been
made in accordance with section 2, close the
main wall disconnect switch or circuit breaker.

4. Place the power source ON-OFF line switch (on
rear panel) to the ON position. This will start the
cooling fan and apply power to the control cir­cuitry as indicated by the illuminated POWER
pilot light on the front panel.

5. Set the Voltage Control Potentiometer (VCP) for
the approximate desired welding voltage de­pending on the position of the Panel-Remote
voltage control switch (see step 6).

6. Set the Panel-Remote switch (SW-1) to the de­sired position from which full-range welding volt­age will be regulated — PANEL position for
operation from the power supply front panel
(typical for non-digital conventional MIG feed­ers), or REMOTE position for operation from
remote wire feeders/controls for digital-micro­processor MIG equipment, or for conventional
MIG using the HC-3B or HC-4B hand control.

B. Stick/Scratch-Start TIG Welding

1. Depending on the process being used, make all
secondary output connections to the power source
output receptacles (see Figure 2-3).

2. Connect appropriate control accessories to re­ceptacle J2 (see Figure 2-3).

3. After the primary input connections have been
made, close the main wall disconnect switch

or circuit breaker.

4. Place the power source ON-OFF line switch (on
the rear panel) to the ON position. This will start
the cooling fan and apply power to the control
circuitry as indicated by the illuminated POWER
pilot light on the front panel.

Ensure the contactor control switch on the TC-2B
torch control, HC-3B or HC-4B hand control, or the
Stick control pendant is in its OFF position (until
you're ready to weld); otherwise, the electrode will be
energized and may cause a short or electrical shock.

7. Set the variable inductance control (on the front
panel) to provide the amount of inductance de­sired for MIG short arc welding. For MIG spray

arc and pulsed MIG welding, this control
should be set at MINIMUM.

8. Set the Slope Control Switch (SW3) to provide
the desired slope characteristic (FLAT, MEDIUM
or STEEP) required for your MIG process/mate­rial and feeder/control.

9. For remaining wire feeder or control operations,
refer to the appropriate instruction booklet sup­plied for your particular system.

Operational Note For Digimig Series Wire Feeders
Due to the high open-circuit voltage of this power
supply, it is possible that some Digimig controls may
"abort" if the torch switch is energized for 2 seconds
without striking a welding arc. This will most likely
occur if you use the torch switch to thread new wire
in the torch liner or for wire inching operations. (It will
not occur if you use the recommended cold wire
inching controls, provided on the feeder, for these
functions.) If an "abort" does occur, simply "reset"
the control as described in the appropriate wire
feeder instruction booklet.

5. The variable inductance control need not be set
for these processes because it is isolated from
this circuit.

6. Full range current control is provided and regu­lated by the potentiometer on the selected re­mote controls. If the HC-3B or HC-4B is con­nected, ensure it is set for CC-TIG/STICK opera­tion.

7. To establish the welding arc, position the torch/
electrode near the workpiece. Close the remote
torch/foot control or turn the pendant on. This will
energize the solid-state contactor and provide
welding power to the torch/electrode. Com­mence welding by touch or scratch starting.

8. If necessary, readjust the remote current poten­tiometer until the exact condition desired is ob­tained.

13

SECTION 3 OPERATION

80
70
60
50
40

VOLTS

30
20
10

CV MODE

MIN

0

0

100 200 300 400 500 600

AMPERES

80
70
60
50
40

VOLTS DC

30
20

MINIMUM CURRENT

10

0

MAX

STICK CC MODE

MIN. AF

AMPERES DC

MAX. AF

80
70
60
50
40

VOLTS DC

30
20
10

0

0700

MIN

200100

ARC FORCE RANGE
@ A MEDIUM
CURRENT SETTING

AF=ARC FORCE SETTING

MAXIMUM CURRENT

TIG CC MODE

AMPERES DC

MAX

600500400300

700

7006005004003002001000

120
110
100

90
80
70

DUTY CYCLE BASED ON

60

10-MINUTE PERIOD AND
MAX. AMBIENT OF 40

50

% DUTY CYCLE

40
30
20
10

0

Figure 3-1. Volt-Ampere Curves

O

C.

MAX SHORT CIRCUIT

2001000

400300

OUTPUT CURRENT

Figure 3-2. Duty Cycle Rating Chart

DUTY CYCLE-3ø

DUTY CYCLE-1ø

500

600

14

SECTION 4 MAINTENANCE

4.1 GENERAL

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

Electric shock can kill! Ensure the wall disconnect
switch or circuit breaker is open before attempting
any inspection or work on the inside of the power
source. Always wear safety goggles with side shields
when blowing out the power source with low pres­sure air.

4.2 CLEANING

Since there are no moving parts (other than the fan) in the
power source, maintenance consists mainly of keeping
the interior of the cabinet clean. Periodically, remove the
cover from the cabinet and, wearing proper eye protec­tion, blow accumulated dust and dirt from the air pas­sages and the interior components using clean low pres­sure air. It is imperative that the air passages to the
interior of the unit be kept free of dirt accumulation to
ensure adequate circulation of cooling air; especially,
over the rectifier bridge plates. The length of time be­tween cleaning will depend on the location of the unit and
the amount of dust in the atmosphere.

4.3 LUBRICATION

Fan motors with oil tubes located on the side of the motor
require lubrication after 1 year of service. Motors without
oil tubes are permanently lubricated for life and should not
require any attention.

15

SECTION 5 TROUBLESHOOTING

5.1 TROUBLESHOOTING

Electric shock can kill! Ensure all primary power to
the power source has been externally disconnected.
Open wall disconnect switch or circuit breaker be­fore attempting inspection of work inside of the
power source.

Capacitors can explode causing personal injury. To
avoid injury, carefully read and do the following:

The subject warning concerns the four power filter­ing capacitors mounted behind Power Board No. 1
and No. 2. (For location, see figure 6-3.)

This potential hazard exists when the side panels are removed
and power is ON. This should only occur when troubleshooting
the power source.

Safe troubleshooting practice requires a systematic procedure as
follows:

1. Disconnect primary input power to power source.

2. Remove panels and perform visual inspection for obvi­ous problems; loose wiring and plug connections, dam­aged or discolored components, etc.

3. Perform resistance checks described in the following
tables.

4. With input power deenergized and side panels re­moved, locate the Input Bridge Module (IBR) (see Fig­ures 5-1 and 6-5). Using the existing wiring diagram
(Figure 5-5), disconnect and tape the large gray leads
attached to terminals IBR (+) and IBR (-). This will
prevent high voltage input to power boards No. 1 and
No. 2, eliminating the potential hazard while performing
the low voltage checks in step 5.

7. With the side panels in place, reapply input power to the
power source and perform high voltage checks (desig-

nated by ) listed in the following tables.

A. Wire Feeder or Control

If it is determined that the wire feeder is operating
improperly, refer to the troubleshooting information
located in the instruction booklet.

B. Power Source

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

Check the problem using the following troubleshoot­ing guide (Figure 5-1). The potential problems are
listed in "most probable" order, and the remedy may
be quite simple. If the cause cannot be located
quickly, open the power source and perform a simple
visual inspection of all components and wiring. Check
for secure terminal and plug connections, loose or
burned wiring or components, bulged or leaking
capacitors, or any other sign of damage or discolora­tion. Always follow this general rule — Do not replace
a printed circuit (PC) board until you have made all of
the checks listed in the following guide. Always put
the power switch in its OFF position before removing
or installing a PC board. Take great care not to grasp
or pull on components when removing a PC board
and always place a removed board on a static-free
surface. If a PC board is found to be the problem,
check with your ESAB supplier for a replacement.
Provide the distributor with the part number of the
board, as well as the serial number of the power
source. Do not attempt to repair the board your-

self. Warranty on a PC board will be null and void
if repaired by customer or any unauthorized re­pair shop.

NOTE

High voltage checks, listed in the following tables, must be
performed with the side panels installed and IBR leads con­nected. To distinguish the high voltage checks (from low voltage)
we have indicated these readings with the symbol. H.V.

5. Apply input power to the power source, and perform the
low voltage checks described in the following tables.

6. After the low voltage checks are completed, disconnect
input power to power source and reconnect IBR (+) and
(-) leads to module, and reinstall the unit's side panels.

16

SECTION 5 TROUBLESHOOTING

Table 5-1. Troubleshooting Guide (Sheet 1 of 2)

PROBLEM POSSIBLE CAUSE CIRCUIT CHECKS

Unit inoperative - fan
does not run

Blows input line fuses Defective Input Bridge (IBR)

No open circuit voltage 115 V ac circuit breaker tripped

Incorrect primary condition or blown line
fuse

Incorrect linkages on voltage changeover
board

Defective Line Switch (LS)

Incorrect linkages on voltage changeover
board

Defective PB1/PB2

MIG mode operation

1. Stick pendant/control plugged into J2

2. No contactor signal from wire
feeder/control

STICK mode operation

1. No contactor signal from
pendant/control

Check incoming power to unit

Check links on voltage changeover
terminal board

Perform continuity check on Line Switch

See IBR Troubleshooting

Check links on voltage changeover
terminal board

See PB1/PB2 Troubleshooting

Check circuit breaker and reset if tripped

Check J2 and disconnect pendant/foot
control

Check MIG contactor signal - see ICB
troubleshooting

Check STICK contactor signal - see ICB
troubleshooting

No open circuit voltage Defective SCR1/R1

Missing bias voltage to Inverter Control
Board (ICB)

False thermal indication to ICB

Defective ICB

Excessive open circuit
voltage

Thermal overload Exceeding duty cycle rating

Flashing fault indicator Input voltage not within +15% and -10% of

Defective resistor/capacitor across Output
Bridge (OBR)

Exceeding max. rated ambient temperature

rated requirements

Excessive line impedance

Defective Inverter Control Board (ICB)

See SCR1 troubleshooting

See ICB troubleshooting

See ICB troubleshooting

Replace ICB

Check components R4, C7, R5, C8

See duty cycle rating chart

40 °C (104 °F)

Check incoming voltage to unit - all three
phases

Check voltage TB-1 (+) to TB-4(-). See
IBR troubleshooting

Replace ICB

17

SECTION 5 TROUBLESHOOTING

Table 5-1. Troubleshooting Guide (Sheet 2 of 2)

PROBLEM POSSIBLE CAUSE CIRCUIT CHECKS

Flashing fault indicator Input voltage not within +15% and -10% of

rated requirements

Excessive line impedance

Defective Inverter Control Board (ICB)

Continuous fault
indicator

Low welding output Single-phase operation

Defective PB1/PB2

Defective Output Bridge Module (OBR1-4)

CT1/CT2 lead open

Missing shunt signal to Inverter Control
Board (ICB)

Defective ICB

Incorrect slope setting for application

Check incoming voltage to unit - all three
phases

Check voltage TB-1 (+) to TB-4(-). See
IBR troubleshooting

Replace ICB

See PB1/PB2 troubleshooting

See OBR troubleshooting

Disconnect P4 connector to inverter
control and make continuity check P4-1 to
P4-2/P4-4 to P4-5

See ICB troubleshooting

Replace ICB

Check incoming power to unit - all three
phases

Reference VA curves and change slope
according to required output (volts and
amps)

Excessive welding
output

Volt/Amp Meter blank
or reads incorrect

Excessive welding cable length

Welding cable size too small

High resistance torch power cable

Inverter Control Board (ICB) calibration

Defective ICB

Missing arc voltage feedback to Inverter
Control Board (ICB)

ICB calibration

Defective ICB

Missing +5 V at Inverter Control Board
(ICB)

Shunt calibration

Recommend max cable length (work and
torch) of 100 ft

Recommend 4/0 cable for MIG
applications

Replace torch if defective/use torch with
voltage pickup lead

See ICB troubleshooting

Replace ICB

See ICB troubleshooting

See ICB troubleshooting

See ICB troubleshooting

See ICB troubleshooting

Check millivolt drop across shunt - should
read 10±0.3 mV per 100 amps output

18

Defective ICB

Defective meter

Replace ICB

Replace meter

SECTION 5 TROUBLESHOOTING

C. Power Boards, PB1/PB2, Troubleshooting (See

Figures 5-1 and 5-2)

Make sure input power is disconnected (OFF) and
voltage between T1 and T2 is zero.

Resistance Checks

(+)Probe (-)Probe Measurement

Drain-1 Source-1 5k ohms nominal*
Source-1 Drain-1 diode forward drop**
Gate-1 Source-1 1k ohms nominal*

Drain-2 Source-2 5k ohms nominal*
Source-2 Drain-2 diode forward drop**
Gate-2 Source-2 1k ohms nominal*

* Using meter high impedance diode scale.
** Using meter low impedance diode scale.

Voltage Checks (T.S. deenergized)

(+) Probe (-) Probe Measurement

TB-1(+) TB-3(-) 324 V dc
TB-2(+) TB-4(-) 325 V dc

Gate-1 Source-1 -12 V dc

Gate-2 Source-2 -12 V dc

P1-1 P1-3 24 V ac
P1-1 P1-2 12 V ac
P1-2 P1-3 12 V ac

P1-8 P1-10 24 V ac
P1-8 P1-9 12 V ac
P1-9 P1-10 12 V ac

D. Input Bridge, IBR, Troubleshooting

(See Figure 5-1)

Resistance Checks

(+) Probe (-) Probe Measurement

IBR-1,2,3 IBR (+) diode forward drop**
IBR (+) IBR-1,2,3 open*

IBR (-) IBR-1,2,3 diode forward drop**
IBR-1,2,3 IBR (-) open *

Voltage Checks

*Using meter high impedance diode scale.
**Using meter low impedance diode scale.

TB-1(+) 375-290 V dc @ 230 V ac

(+15%/-10%)

TB-4(-) 750-580 V dc @ 460 V ac

(+15%/-10%)

E. Output Bridge, OBR, Troubleshooting

(See Figure 5-2)

Resistance Checks

(+) Probe (-) Probe Measurement

Anode-1 Cathode diode forward drop**
Anode-2 Cathode diode forward drop**

Cathode Anode-1 open*
Cathode Anode-2 open*

*Using meter high impedance diode scale.
**Using meter low impedance diode scale.

NOTE

If any of the above readings are incorrect, remove the
busbars and check modules OBR1-4 individually. Re­place modules which are defective.

19

SECTION 5 TROUBLESHOOTING

F. SCR1 Troubleshooting (See Figure 5-1)

Resistance Checks

SCR1-A SCR1-K 5 ohms If reads open, then replace R1

If reads short, then replace SCR-1

SCR1-G SCR1-K diode forward drop (low impedance using diode scale)

Gate Lead from Inverter Control should be disconnected

Voltage Checks

SCR1-G SCR1-K 0 V dc Torch switch deenergized

0.6 V dc Torch switch energized - if missing, check Inverter Control

20

SECTION 5 TROUBLESHOOTING

P1 CONTROL PLUS

* To replace Power Boards (PB-1 & PB-2), disconnect cables form T1-T4, disconnect control
plug P1, loosen capacitor mounting brackets behind board, remove and retain transistor mounting
screws and two mounting screws at bottom of board. NEVER, UNDER ANY CIRCUMSTANCES,
REMOVE OR LOOSEN ISOBARS ATTACHED TO HEAT SINK!

T1, T2, POWER CABLE CONNECTIONS*

Torque Specifications

IBR
Case to Heatsink - 40 lb. in.
Terminals - 25 lb. in.

SCR1
Case to Heatsink - 25 lb. in.
Terminals - 25 lb. in.

PA1 - Transistors

Case to Isobar - 10 lb. in.

(TYP.) TRANSISTOR MOUNTING -

SCREW (TOTAL-16)

When replacing the
components, make
sure mounting surfaces
are clean. Coat surfaces
with Dow-Corning #340
silicon heat sink
compound or equivalent.
All hardware must be
torqued to above
specifications

ISOBAR, TYPICAL EACH SIDE*

P.C. BOARD MOUNTING
SCREW, TYPICAL EACH SIDE*

Figure 5-1. Left Side Power/Control Components (PB-1, SCR1, IBR, R1)

CAPACITOR MOUNTING BRACKETS

(BEHIND BOARD)

P1 CONTROL PLUS

CAPACITOR MOUNTING BRACKETS

(BEHIND BOARD)

T3, T4, POWER CABLE CONNECTIONS*

T3, T4, POWER CABLE CONNECTIONS*

Figure 5-2. Right Side Power/Control Components (PB-2, OBR-1,2,3,4)

* To replace Power Boards (PB-1 & PB-2), disconnect cables form T1-T4, disconnect control
plug P1, loosen capacitor mounting brackets behind board, remove and retain transistor mounting
screws and two mounting screws at bottom of board. NEVER, UNDER ANY CIRCUMSTANCES,
REMOVE OR LOOSEN ISOBARS ATTACHED TO HEAT SINK!

T1, T2, POWER CABLE CONNECTIONS*

(TYP.) TRANSISTOR MOUNTING -

SCREW (TOTAL-16)

Torque Specifications

IBR
Case to Heatsink - 40 lb. in.
Terminals - 20 lb. in.

PA2 - Transistors

Case to Isobar - 10 lb. in.

When replacing the
components, make
sure mounting surfaces
are clean. Coat surfaces
with Dow-Corning #340
silicon heat sink
compound or equivalent.
All hardware must be
torqued to above
specifications

ISOBAR, TYPICAL EACH SIDE*

P.C. BOARD MOUNTING SCREW, TYPICAL EACH SIDE*

21

SECTION 5 TROUBLESHOOTING

G. Inverter Control Board, ICB, Troubleshooting (See Figure 5-3)

Voltage Checks

(+) Probe (-) Probe Measurements

P5-8 P5-9 18 V ac AC Bias
P5-8 P5-10 36 V ac AC Bias

P5-6 P2-9 12 V dc DC Bias
P5-5 P2-9 -12 V dc DC Bias
P5-3 P1-6 5 V dc Digital Meter Bias
P5-1 P2-9 10 V dc DC Bias

P4-7 P4-8 115 V ac MIG Contactor Signal
P4-9 P4-10 24 V ac Stick Contactor Signal

P2-10 P3-1 72 V dc Arc Voltage - open circuit

P1-1 P1-2 10 ±0.3 mV Shunt Signal/100 amps
P1-4 P1-5 10 ±0.3 mV Meter Signal/100 amps

P3-3 P2-2 12 V dc MIG Mode Select

0 V dc Stick Mode Select

P3-9 P3-10 0 V dc Thermal-Normal

12 V dc Thermal-Overload

P2-5 P2-2 0 V dc Steep Slope

5 V dc Medium Slope
12 V dc Flat Slope

22

SECTION 5 TROUBLESHOOTING

TP1

TP2

Figure 5-3. Inverter Control Board (ICB) (Top View Layout)

23

SECTION 5 TROUBLESHOOTING

PB2 - POWER BOARD #2

PB1 - POWER BOARD #1

LS - LINE SWITCH

IBR - INPUT BRIDGE MODULE

5

3

4

1

2

12

3

J3

CTR2

PL1

H2

TB-5

B

WHITE

115 VAC

X4

X3

2

H2

2

X2

H3

TB-7

6

T1-4

T1-2

TB-8

H4

WELD

K2

X6

X5
9

T1-3

P4-7

X3

13

D

C

CONTACTOR

SAFETY GROUND

2

TS2

1
2

1

TS1

P3-9

P4-8

P5-8

P5-9

X4

H5

1

TB-10

FM

14

U

T

B

K2

A

2

CB1

10A

1

X18

P3-10

ICB

INVERTER

P5-10

X5

H6

2

TB-6

11

J1

A

BLACK

115 VAC

X2

L1

X1

1

T1-1

H1
2

10A

1

CB2

1

T1-5

X1

230/460/3 PH 60 HZ W/EQUIP GND

CTR1

H1

TB-9

-

1

2

6

4

LS

3

2

5

1

3

IBR

C11

1000V

0.22UF

+

P6-5

G

K

A

SCR1

SH - SHUNT

CTR1 - CONTROL TRANSFORMER #1

CT1 - CURRENT TRANSFORMER #1

MTR - MAIN TRANSFORMER

CT2 - CURRENT TRANSFORMER #2

6

7

CB2 - CIRCUIT BREAKER

IND - INDUCTOR

OBR - OUTPUT BRIDGE MODULE

9

8

10

11

15

J

H

F

V

E

G

-12 VDC

+12 VDC

COMMON

CONTROL (MIG)

CTR1

X19

2

PL2

1

P3-6

P5-5

P5-6

P2-9

BOARD

CONTROL

P6-4

P6-6

P6-5

SCR-G

TB-1

TB-4

P6-6

SCR-K

R7

20K, 12W

TB-2

460V

TB-3

R6

20K, 12W

R10

PB1-P1-7

T2
(-)

(+)

T1

CTR1

T2
(-)

(+)
T1

Ω

100

1/2W

P1-1

X12

X6

P1-1

P6-3

PB1-P1-6

D

P1-2

X13

X7

P1-2

D

G

L1 - COMMON MODE CHOKE

CTR2 - CONTROL TRANSFORMER #2

J3 - 115V RECEPTACLE

PL1 - POWER LIGHT

12

TS1 - THERMAL SWITCH - POWER ASSEMBLY

J1 - DIGIMIG INTER-CONNECT RECEPTACLE

13

14

16

L

M

N

P1-10

P6-7

P1-4

G

S

P1-4

K

POS-OTB

P3-2

P6-8

P1-5

P1-7

P1-8

P1-3

X15

X14

X8

X9

P1-3

P1-8

PB1

S

P1-5

TORCH

P2-10

P6-10

G

S

PB2

P1-9

X16

X10

P1-9

G

P1-6

P1-7

WORK

P3-1

P6-9

X11

S

SH +

P5-2

P6-1

R9

PB1-P1-4

P1-6

D

P1-10

X17

P1-10

D

P

SH -

P5-6

FLAT

1

P5-4

Ω

1/2W

100

T4

C6

R3

T3

T4

R2

T3

PL2 - THERMAL OVERLOAD LIGHT

FM - FAN MOTOR

ICB - INVERTER CONTROL BOARD

CB1 - CIRCUIT BREAKER

TS2 - THERMAL SWITCH - INDUCTOR

K

G

COMMON

P5-3

STEEP

MED

3

2

SW3

P2-5

P6-2

P4-4

T2-3

T2-4

PB1-P1-5

X2

X1

.05UF

CT2

10,

100W

P4-1

T2-1

T2-2

X2

X1

C5

.05UF

CT1

10,

100W

K2 - RELAY

F

E

+10 VDC

CONTROL (STICK)

P2-2

P5-1

P2-1

P4-1

P4-5

T2-1

H2

"B"

H1

P4-2

H2

"A"

H1

MTR

15

D

CP/CC SELECT

P4-2

T2-2

X3

X2

X1

J2 - WIRE FEEDER RECEPTACLE

16

A

CONTACTOR

P3-3

PL3 - VOLTAGE/FAULT LIGHT

DPM - DIGITAL PANEL METER

ICP - INDUCTANCE CONTROL POTENTIOMETER

VCP - VOLTAGE CONTROL POTENTIOMETER

19

18

17

17

P4-9

P3-7

H

B

CONTACTOR

SAFETY GROUND

T1-7

X3

X1

T1-6

P4-10

1

2

PL3

R5

5.25W

C8

.05UF

C7

.05UF

R4

5.25W

18

J

P2-2

CTR2

ARC DETECTOR

ARC DETECTOR

P3-4

P3-5

P2-3

P3-8

2

3

1

1

2

3

3

OBR2

OBR1

C

T1-8

CW

10K

REMOTE

3

2

1

ICP

2

SW1

P2-4

OBR3

P2-8

J2

+10V

PANEL
1

P1-3

1

2

3

P1-7

P5-1
3

VCP

P1-2

1

3

OBR4

19

P2-2

2

1

10K

SW2

1

2

VOLTS

AMPS

C12

P1-1

0.22UF @ 16V

P1-9
P1-8
P5-3

P1-6
P1-5

P1-4

SH

-

J1-N

J1-P

2

IND

X2

X1

ROH

10

RFH

D3 ­V (+)
TST

IN LO
IN HI

DPM

9

RFL

8

COM

5

.01UF

C10

NEG

11

1

4
6

7

+

Figure 5-4. SVI 450i Schematic Diagram - 230/460 V, 3 Phase, 60 Hz

C9

.01UF

POS

31951
D-

24

50W

R1

5,

2

1

3

ICB-P6-4

ICB-P6-2

ICB-P6-3

ICB-P6-1

5

4

6

7

8

9

10

SECTION 5 TROUBLESHOOTING

GRN

ORN

YEL

WHT

BRN

BLK

RED

GRY

GRY

GRY

TB-6

TB-8

L1-X2

A

IBR-1

IBR-2

IBR-3

BLK

BLK

2

1

3

4

LS

6

5

1

P5-10

CB1-1

ICB

BLU

TB-9

PB1

P1-3

P1-8

J1-V

BRN

YEL

BLU

X5

X19

X18

H2

H1

H3

X9

X10

X7

X8

X6

BLK

PB1

RED

PB1

BLK

PB1

BRN

P1-9

YEL

PB1

PB1

BRN

P1-10

MTR X2

X1

X2

"A" COIL

GND 1

GRY

ORN

BRN

TB-7

TB-5

TB-8

P1-1

P1-2

VIEW "A"

OBR-BUS #1

OBR-BUS #2

GRY

GRY

IND-BX1

GRY

PB1-T3

WHT

C5-2

IND-AX1

"A"

T2

GRY

PB1-T4

X2

X3

X1

C9

GND 2

ICB-P2-10 GRY

IND AX2. BX2 GRY

J2-K GRY

"B"

MTR

H1

H1

H2

H2

2

4

3

1

GRY

PB2-T4

WHT

C6-2

GRY

PB2-T3

WHT

R3-1

BLU

GRY

YEL

ORN

P4-5

P4-2

P4-4

P4-1

ICB

ICB

ICB

ICB

2

1

3

4

T2

WHT

R2-1

P5-9

ICB

RED

L1-X4

2

FM

X4

H4

P2-9

P3-2

P5-6

P5-5

P1-10

GND4

ICB

ICB

ICB

T1-8

L1-X6

ICB

ICB

D

G

E

F

T1-5

BLK

X1

X14

1
2

TS2

"B" COIL

GRY

K

H

J

J1-B

J1-A

L1

T1-2

T1-1

CB2

J3

T1-1

BLK

H6

X17

X15

X16

BLU

GRY

ORN

P1-2

P1-1

GRY

MTR X2

WHT

WHT

B

C

P5-8

T1-4

ICB

WHT

ORN

X2

X3

H5

CTR1

X12

X13

X11

X1

IND

X2

GRY

BLU

(TP)

RED

P2-10

P3-1

SH+

ICB

ICB

N

L

M

J1

J2

X2

X4

X6

X1

X3

X5

2
1

3

2

1

GND 4

TB-6

VIO

TB-10

YEL

BLU

P1-9

WHT

P1-8

PB2

P1-3

PB2

PB2

TS1-2

PL2-2

POS OUTPUT

SH (+)

(TP)

BLK

SH­P

T1-3

P1-10

PB2

GND 3

T1-2

WHT

GRY

CB1-2

T

T1-1

BLK

PB2

PB2

BRN

K2-B

U

J2-H

GRN

J1-C

YEL

CTR1-X19

V

J2

T1-5

BLK

J1-D

GRN

C10

BLK

P4-9

ICB
A

VIEW "B"

RED

T1-7

B

CB1

BRN

VIO

T1-8

P3-3

ICB

C

D

GRY

J1-T

2
1

BRN

CTR1-X18

GRY

K2-A

YEL

P5-1

ICB
E

GRN

BLU

ORN

ORN

GRY

P2-1

P2-2

P2-2

GND4

ICB

ICB

ICB

POS-OTB

H

F

J

G

K

INDICATES CONNECTOR USING IN-LINE

INDICATES SELF LEADS

INDICATES 600V WIRE

TWISTED PAIR

QUICK DISCONNECT

SHIELDED PAIR

TP

SP

31952
D-

BRN ICB P5-3

GRY ICB P2-5

3
2
1

SW3

WHT ICB P5-6

BRN T1-8

3
2
1

SW1

VIO ICB P2-8

GRY VCP-2

POS

(+)

SW3

PL1

2

BLK T1-5

WHT T1-4

PL2

212

1

WHT TS2-2

BLU ICB P3-6 (+)

WHT ICB P3-10

P2-2

SW2-2

ICB

SW1

ORN

ORN

PL3

1

BRN ICB P3-7 (+)

ORN ICB P3-8

1

SW1-1

GRY

2

VCP

P5-1

NEG

(-)

Figure 5-5. SVI 450i Wiring Diagram - 230/460 V, 3 Phase, 60 Hz (Sheet 1 of 2)

P2-4

P2-3

ICB

ICB

ICB

RED

BLK

YEL

1

4

2

1

3

13

3

ICP

SW2

C 12

DPM

P1-9

ICB

GRY
1

P1-6

P1-4

P1-5

ICB

ICB

ICB P1-8

DPM-5

DPM-8

DPM-10

ICB

DPM-9

CLR

SHLD

BLK

3

4

5

2

ORN

BLK

BLK

BLK

BLK

7

11

8

12

9

6

P1

13

10

ORN VCP-1

WHT ICB P1-7

3
2

1

SW2

25

SECTION 5 TROUBLESHOOTING

BLU

J1-H

WHT

CTR1-X2

T1-7

BLU

X3

2

H2

WHT

R5-1

PB2

BLK

J1-P

(TP)

PB1

WHT

PL1-2

4

WHT

P4-7

ICB

T1-2

BLK

(-)

BLK

(SP)

BLK

CB2-1

BLK

CTR1-X1

1

1

2

3

OBR2

P1-2

ICB

5

BLK

PL1-1

SH

BLU

CTR2-X1

6

BRN

P4-10
ICB

TS1

1

2

3

OBR3

2

1

CTR2-X3

7

RED

J2-B

T

1

GRY

P3-9

ICB

CLR

P1-1

ICB

(SP)

BRN

8

BRN

J2-C

1

2

3

OBR4

WHT

TS2-1

(+)

RED

J1-N

NEG. OUTPUT

(TP)

MTR-AH1

GRY

BRN

SW1-3

GRY

MTR-X3

T3

OBR (-)

T3

T1

8

2

R4

1

T4

BUS

MTR-AH2

GRY

T4

C7

SHUNT (-)

C7-1

2
1

BUS

R4-2

VIEW "B"

BH2

MTR

BH1

GRY

MTR

GRY

& VCP-3

P5-4

P1-9 & BRN SW3-3

ICB

J2-E

ICB

GRY

YEL

VIO2VIO

3

1

YEL

ICB P2-9 &

J1-K

J1-M

YEL

BLU

2

1

NEG OUTPUT (SP)

SH (-) (SP)

SH (+) (SP)

BLK

SHLD

CLR

3

1

2

P5-2

& SW3-1

ICB

CTR1-X3

J1-F

J1-E

ORN

BLK

WHT
6

8

5

4

P5

PL3-1

J2-D

PL3-2

PL2-1

BRN

VIO

ORN

BLU

6

7

3

8

P3

DPM P1-4 (SP)

DPM P1-6 (SP)

SW2-1

DPM P1-7 (SP)

BLK

SHLD

WHT

CLR

7

6

5

4

P1

CTR1-X5

CTR1-X4

BLU

RED
9

10

TS1-1

PL2-2

GRY

WHT

9

10

DPM P1-1 & ICB P5-3

J1-J

DPM P1-11

RED

ORN

GRY
9

8

10

P4

P5

ICB

1

1

P6

(TP) & R9-2

(TP) & R10-1

(TP) & R9-1

P1-5

P1-6

P1-4

PB1

PB1

PB1

BLK

RED

RED

2

3

1

T2-2

T2-3

T2-1

GRY

ORN

YEL

2

4

& VCP-1 &

J2-G

J2-J

J2-F

ORN

BLU

2

(TP) & R10-2

(TP)

P1-7

PB1

SCR-G

BLK

RED

4

5

P6

T2-4

T1-4

BLU

WHT

7

5

P4

ICP-2

ICP-1

BLK

RED

3

4

P2

P3

P2

P1

(TP)

SCR (+)

BLK
6

T1-3

VIO

9

8

SW3-2

SW1-2

GRY

VIO

5

8

(TP)

P1-4

PB2

RED
7

J2-A

BLK

& P3-2

9

(TP)

(TP)

P1-5

P1-6

PB2

PB2

BLK

RED

8

9

T1-6

BRN
10

& POS-OTB

J1-L

J1-G

GRY

ORN

10

(TP)

P1-7

PB2

BLK
10

VIEW "C"

WHT

BH1

MTR

WHT

AH1

MTR

BLK

BLK

K2-6

BLK

GRY

VIO

BRN

K-2

T1-1

CB1-2

T1-3

J1-U

6

A

9

B

VIEW "C"

BLU

BLU

RED (TP)

RED (TP)

ORN

GRY

WHT

BH2

MTR

2

C6

1

R3

1

R2

2

C5

WHT

AH2

MTR

GRY

PB2-P-1

CTR1-X13

CTR1-X14

CTR1-X12

2

3

1

1

WHT

2

2

WHT

1

RED

BLK

BLK

PB1-P-1

CTR1-X7

CTR1-X8

CTR1-X6

2

3

1

BLK (TP)

P6-7

P6-8

ICB

ICB

4

5

RED (TP)

BLK (TP)

P6-1

P6-2

ICB

ICB

4

5

BLK (TP)

P6-9

P6-10

ICB

ICB
7

6

RED (TP)

BLK (TP)

P6-3

P6-4

ICB

ICB

6

7

WHT

CTR1-X15

CTR1-X16

9

8

BRN

YEL

CTR1-X9

CTR1-X10

8

9

CTR1-X17

10

BRN

CTR1-X11

10

P1

T1

GRY

GRY

TB-2

TB-4

TB-1

TB-3

GRY

GRY

T1

P1

CB2-2

BLK

CTR2-H1

T2

T2

L1-X3

L1-X1

1

2

BLK

WHT

BLK

J3-1

J3-2

CTR2-H2

T1-1

BLK

K2

2

C8

1

2

R5

1

WHT

GRY

MTR-X1

OBR1 (+) BUS1

T1-6

BLU

VIO

K2-9

C

P4-8

X1

WHT

3

VIO

L1-X5

ICB

X2

T

R

H1

1

2

3

OBR1

SHLD

P1-3

ICB

(SP)

31952
D-

26

CTR1-H6

CTR1-H2

VIO

ORN

5

GRY

SCR (+)

FM-2

BLK

6

1

GRY

PB1-T1

IBR-3

VIO

CTR1-H3

GRY

7

R6

2

GRY

PB2-T1

CTR1-H4

BRN

8

3

GRY

PB1-T2

FM-1

BLK

CTR1-H1

BLU

R7

9

GRY

PB2-T2

IBR-2

BLU

CTR1-H5

YEL

4

GRY

IBR (-)

IBR (+)

GRY

WHT

SCR (-)

R1-1

WHT

P6-5(TP)

ICB

RED

1

SCR

G

(+)

(-)

1

R

TB-4

SCR (-)

GRY

C

11

GRY

LS-5

BLU

TB-9

GRY

-

+

IBR

1

2

3

GRY

LS-3

TB-6

LS-1

VIO

GRY

10

TB

(WIRING VIEW)

2

WHT

SCR (+)

P6-6 (TP)

ICB

TB-1

BLK

GRY

R1-2

WHT

Figure 5-5. SVI 450i Wiring Diagram - 230/460 V, 3 Phase, 60 Hz (Sheet 2 of 2)

VIEW "A"

SECTION 6 REPLACEMENT PARTS

6.1 GENERAL

Replacement Parts are illustrated in figures 6-1 thru 6-6.
When ordering replacement parts, order by part number
and part name, as illustrated on the figure. DO NOT
ORDER BY PART NUMBER ALONE.

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

6.2 ORDERING

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

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

ESAB Welding & Cutting Products

Attn: Customer Service Dept.
PO Box 100545, Ebenezer Road
Florence, SC, 29501-0545

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

To order parts by phone, contact ESAB at 1-803-664­5540 or 4460. Orders may also be faxed to 1-800-634-

7548. Be sure to indicate any special shipping instruc­tions when ordering replacement parts.

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

27

SECTION 6 REPLACEMENT PARTS

11

12

10

1

SVI 450i cvcc

+

2

3 (SW2)

4

5

3 (SW1)

-

6

7

ITEM

NO.

1
2
3
4
5

6
7
8

9
10
11
12

QTY

REQ.

1
2
2
1
2
2
1
2
1
1
1
1
1

9

Figure 6-1. SVI 450i cvcc (Front View)

PART

NO.

951526
951032
634515
951795

2062018

13730611

31129YL

13733935

32059GY

31128YL

672831

32057GY

31130YL

LAMP, WHITE
LAMP, RED
SWITCH, TOGGLE, SPDT
METER, DIGITAL
POTENTIOMETER, TRIM
KNOB (P/O ITEM NO. 5)
PANEL, RIGHT SIDE
CONNECTOR, FEMALE
PANEL, FRONT, SILKSCREENED
PANEL, LEFT SIDE
SWITCH, TOGGLE, SPDT
PANEL, CONTROL, SILKSCREENED
PANEL, TOP

DESCRIPTION

8

CIRCUIT

SYMBOL

PL1

PL2, PL3

SW1, SW2

DPM

ICP, VCP

SW3

28

SECTION 6 REPLACEMENT PARTS

1

REF: Matched set
of capacitors is part
of PB1 and PB2.

2

3

ITEM

NO.

1

2

3

QTY

REQ.

1

1

1

Figure 6-2. SVI 450i cvcc (Top View)

PART

NO.

31135

31133

31134

INDUCTOR (MOUNTED ON FRONT PART OF
CHASSIS BASE)

TRANSFORMER, MAIN (MOUNTED ON TOP
OF INDUCTOR)

TRANSFORMER, CONTROL (MOUNTED ON
CHASSIS BASE UNDER FAN MOTOR)

DESCRIPTION

CIRCUIT

SYMBOL

IND

MTR

CTR1

29

SECTION 6 REPLACEMENT PARTS

1

2

ITEM

NO.

1

2

QTY

REQ.

1
1

Figure 6-3. SVI 450i cvcc (Top View)

PART

NO. DESCRIPTION

31143
38082

TERMINAL BOARD, SCREEN PRINTED

PC BOARD ASSY, CONTROL

CIRCUIT
SYMBOL

TB

ICB

30

SECTION 6 REPLACEMENT PARTS

7

1

2,3

ITEM

NO.

1

2

3

4

5

6

7

QTY

REQ.

1
1
1
1
1
1
1

6

5

4

Figure 6-4. SVI 450i cvcc (Left Side View)

PART

NO.

674991

17282010

950516
950702
951023

17250005

951022

DESCRIPTION

PC BOARD ASSY, POWER
RESISTOR, 10 OHM, 100 W
CAPACITOR, 0.05 µF, 600 V
CAPACITOR, 0.01 µF, 125 V
MODULE, SCR
RESISTOR, 5 OHM, 50 W
INPUT BRIDGE MODULE

CIRCUIT

SYMBOL

PB1

R2
C5
C9

SCR1

R1

IBR

31

SECTION 6 REPLACEMENT PARTS

12

3,11

1

2 (R5), 3

4

5

6

7

10

ITEM

NO.

1

2

3

4

5

6

7

8

9
10
11
12

QTY

REQ.

1
2
3
1
1
1
1
4
1
1
1
1

9

8

Figure 6-5. SVI 450i cvcc (Right Side View)

PART

NO.

674991

17725005

950516

13735102

33938
993717
635686
951184
951085
950702

17282010

31132

PC BOARD ASSY, POWER
RESISTOR, 5 OHM, 25 W
CAPACITOR, 0.05 µF, 600 V
RELAY, 42 V, 3-POLE
CHOKE, COMMON MODE
TRANSFORMER
TERMINAL STRIP, 8-POSITION
DIODE, OUTPUT
SWITCH, THERMAL, 80 °C
CAPACITOR, 0.01 µF, 100 W
RESISTOR, 10 OHM, 100 W
SHUNT

DESCRIPTION

2 (R4), 3

CIRCUIT

SYMBOL

PB2

R4,5

C8
K2

L1

CTR2

T1

OBR1-4

TS1
C10

R3
SH

32

SECTION 6 REPLACEMENT PARTS

10

DIGITAL

CONTROL

OFF

ON

1

9

REMOTE

CONTROL

MAIN

POWER

2,3

8

7

115 AUX.

6

4

5

ITEM

NO.

1
2
3
4
5
6
7
8
9

10

QTY

REQ.

1
1
1
1
1
1
2
1
1
1

Figure 6-6. SVI 450i cvcc (Rear View)

PART

NO.

950822
680970

679384GY

950592
97W63
952219
950122

31126GY

951476
951475

SWITCH, ROTOR, 3PST
MOTOR, FAN
SHROUD, FAN
BLADE, FAN
CONNECTOR, CABLE GRIP
RECEPTACLE, 125 V, 15 A
CIRCUIT BREAKER, 10 A
REAR PANEL
RECEPTACLE, 14-PIN
RECEPTACLE, 19-PIN

DESCRIPTION

CIRCUIT

SYMBOL

LS
FM

J3

CB1,2

J2
J1

33

SECTION 6 REPLACEMENT PARTS

34

SECTION 6 REPLACEMENT PARTS

35

ESAB Welding & Cutting Products

PO Box 100545 Florence SC 29501-0545

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS:

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

Telephone: [phone] / Fax: [phone]

Telephone: [phone] / Fax: [phone]

Telephone: [phone]/ Fax: [phone]

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

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

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

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

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

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

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

F. WELDING EQUIPMENT TRAINING:

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

G. WELDING PROCESS ASSISTANCE:

Telephone: (800) ESAB-123 / Fax: [phone] Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES:

Telephone : [phone] Hours: 7:30 AM to 5:00 PM EST

Eastern Distribution Center

Central Distribution Center

Western Distribution Center

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

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

F15-071-D 12/2003 Printed in U.S.A.

IF YOU DO NOT KNOW WHOM TO CALL

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