ESAB THE 430, THE 650 Instruction manual / Spare parts list (Replacement parts)

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Instruction Book and Spare Parts List

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THE 430 and THE 650

CONTENTS	Page
Part Numbers	1
THE 430 and THE 650 hand
operated	2
THE 650 motorized	3
Circuit Diagram THE 430 and
THE 650	4
Circuit Diagram THE 650
motorized	5—6
Voltage limiter	7
Technical Data	8—9
Maintenance and Service	10
Spare Parts List	11—20

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THE 430 and THE 650 are single operator handwelding transformers. They are robust but easy to handle and have first class welding properties. The welding current is steplessly adjustable by varying the magnetic field with a leakage core. This can be done manually but in the case of THE 650 a motorized version is also available. The transformers are available for two input voltage ranges:

1. 380/500 V, 50 Hz 440/550 V, 60 Hz
2. 220/380/440 V, 50—60 Hz.

The following shows the different versions available.

NOTE! When phase compensation is required the transformers are supplied with built-in condensers. The unit for limiting the open circuit voltage can be ordered separately.

THE 430 Manually controlled

380/500 V - 50 Hz 440/550 V - 60 Hz	220/380/440 V 50—60 Hz	Condensers 5 kVAr	Part No.
х	x	x	161 840-001
	х	х	161 840-002
			161 840-006

THE 650

380/500 V - 50 Hz 440/550 V - 60 Hz	220/380/440 V 50—60 Hz	Condensers 7 kVAr	Manual control	Motorized with remote control	Part No.
x		х		x	161 841-001
	х	х		х	161 841-002
х		х	х		161 841-003
	х	х	х		161 841-004
	х		x		161 841-006
			•	•	•

Voltage limiter for THE 430 and 650 For transformers connected to 380/440/500/550 V 50-60 Hz Part No. For transformers connected to 380/440/500/550 V 50-60 Hz Part No. 161 842.00

For tran	and with built-in conde	161 842-001
	Ditto	220 V 50—60 Hz	161 842-002

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Fig. 1 THE 430 Hand operated

HAND OPERATED VERION

1. HAND-OPERATED-VERSION=

THE 430 and THE 650 hand operated. Scefig: 1 and the circuits, figs: 5 and 6. Both THE 430 and 650 are built from components which are easily accessible for servicing and connecting up. The transformers are single phase and are connected across two input phases. The mains cable is connected to the primary terminal block which can be wired to suit different input voltages. From the terminal block the input voltage is fed via a mains isolation switch to the primary side of the main transformer,

From the secondary side of the main transformer the welding current is led to the welding current terminals.

The welding current is steplessly adjustable throughout the range by means of a moveable leakage core. Depending on the position of the core in the magnetic field the leakage is greater or less which in turn affects the strength of the magnetic field on the secondary side and thus also the welding current. The leakage core can be moved by a screw which is attached to a wheel on the front of the transformer cabinet, fig. 1. The welding current can be read

off a clear scale above the current setting wheel (fig. 1). The transformer is housed in a robust steel cabinet. Two solid rubber-tyred wheels and two handles facilitate movement of the unit

Fig I shows the appearance, fig 586 the circuits

They are built from components which are easily accessible for servicing and connecting up

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THE 650 Motorised Version

Fig. 2 THE 650 Motorised

Fig. 4 Control rod for remote control

2. MOTORIZED VERSION

The motorized version of THE 650 is shown in figs 2 3 and 4 and the circuits figs. 7 and 8. In this version the leakage core (and therefore the welding current) are set by means of a servomotor. The auxiliary transformer supplies a control voltage of 100 V. By means of the push buttons marked increase and decrease located on the front panel of the transformer cabinet, the servomotor is activated and via a worm gear moves the leakage core. The direction of rotation of the motor and hence the movement of the core depends upon which button is pressed. Limit switches disconnect the supply to the servomotor when the leakage core reaches either of its end positions.

One advantage of this arrangement is that the welding current can be set or adjusted at the welding bench.

The motorized transformers have a built-in unit (see fig. 3) which enables the welding current to be set via the welding cables. A control rod (see fig. 4) which is held between the electrode tip and the workpiece operates the servomotor and thus changes the weld-

ing current. The control rod is marked "+" (plus) and "—" (minus) and the welding current is increased or decreased according to the way the rod is placed between the electrode and the workpiece.

This version has a built in remote control unit

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Circuit diagram for THE 430 and THE 650. 380/500 V 50 Hz 440/550 V 60 Hz with condensers. Hand operated

Circuit diagram for THE 430 and THE 650, 220/380/440 V 50-60 Hz without condensers. Hand operated

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Page 8

Circuit Diagram

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Fig. 7 Voltage limiter

VOLTAGE LIMITER

When welding in cramped, warm or damp places where voltages exceeding 50 V are considered dangerous and safety regulations are in force to protect the welder, a voltage limiter (see fig. 9) should be used.

The voltage limiter automatically reduces the open circuit voltage of the transformer to 22 V without affecting its welding characteristics. The regulations also require the incorporation of a device to show whether the voltage limiter is working. This is provided by a signal lamp which lights up during welding and goes out when the arc is broken. If the lamp lights under open circuit conditions there is a fault in the voltage limiter. With this system the welder can always check the operation of the voltage limiter. For part no. see page 1.

Phase Compensation Condensers

The transformers can be supplied with phase compensation condensers (see table 1)

a) if the electricity supplier requires the power factor (cos φ) to exceed a certain value
b) to reduce the size of the cables and fuses.

The effect of the condensers on cable area, fuse size and power factor can be seen from the tables of mains connections given under the heading Technical Data.

Changing the Input Voltage Connections

The transformers can be connected to different mains input voltages.

Check that the connection block is wired for the mains voltage used. The correct connections are given in figs. 5 - 6 - 7 - 8.

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Technical Data

THE 650

TECHNICAL DATA

Input voltages: 1) 380/500 V, 50 Hz - 440/550 V, 60 Hz 2) 220/380/440 V, 50 and 60 Hz

Current range: 60 A, 22 V - 430 A, 37 V

Permitted loading: 100 % duty cycle 250 A, 30 V 60 % duty cycle 350 A, 33 V 35 % duty cycle 430 A, 37 V

Open circuit voltage: 66—73 V at 50 Hz

No load power: 310 W

Efficiency $\eta = 0.86$

Dimensions: Height mm = 1010 Width mm = 635 Depth mm = 765 with handles

Weight approx: 190 kg Area of welding and earth cables: 50 mm²

TECHNICAL DATA

Input voltages: 1) 380/500 V, 50 Hz - 440/550 V, 60 Hz 2) 220/380/440 V, 50 and 60 Hz

Current range: 80 A, 23 V - 650 A, 44 V

Permitted loading: 100 % duty cycle, 390 A, 36 V 60 % duty cycle, 500 A, 40 V 35 % duty cycle, 650 A, 44 V

Open circuit voltage: 66—75 V at 50 Hz

No-load power: 390 W

Efficiency $\eta = 0.92$

Dimensions: Height mm = 1010 Width mm = 635 Depth mm = 765 without handles

Weight approx: 240 kg Arca of welding and earth cables: 70 mm²

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THE 430 Mains Connections

Voltage Range A		With Co	ndensers
Frequency, Hz		50	6	i0
Voltage, V	380	500	440	550
Current, A	45	34	41	32
Fuse, slow-blow, A	50	35	50	35
Cable area, mm ²	3×16	3×10	3×16	3×10
Power Factor, Cos ø	0	.54	0.	52
Rating, kVA	····	17		.8

Voltage Range B	Witho	Without CondensersWith Condensers50-6050		ndensers	ndensers
Frequency, Hz		Without CondensersWith Condensers50-6050		50		60
Voltage, V Current, A Fuse, slow-blow, A Cable area, mm ²	220 91 100 3×35	380 53 50 3×16	440 46 50 3×16	220 74 80 3×25	380 43 50 3×16	440 37 35 3×10	220 66 63 3×16	380 38 35 3×10	440 33 35 3×10
Power Factor, Cos q		0.46	•		0.57			0.62
Rating, kVA		20		16.5		14.5

THE 650 Mains Connections

Voltage Range A		With Co	ndensers
Frequency, Hz	5	50	6	60
Voltage, V	380	500	440	550
Current, A	70	53	66	53
Fuse, slow-blow, A	63	50	63	50
Cable area, mm ²	3×16	3×16	3×16	3×16
Power Factor, Cos 9	0.	.59	0.	.57
Rating, kVA	20	6.5	2	29

Voltage Range B	With	Without Condensers With Condensers			ndensers
Frequency, Hz		50-60		50			60
Voltage, V Current, A Fuse, slow-blow, A Cable area, mm ²	220 39 160 3×70	380 80 80 3×25	440 69 63 3×16	220 116 125 3×50	380 67 63 3×16	440 58 63 3×16	220 110 125 3×50	380 64 63 3×16	440 55 63 3×16
Power Factor, Cos φ Rating, kVA		0.51 30.5			0.61	·		0.65

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Fig. 14

5 MAINTENANCE AND SERVICE

5.1 MAINTENANCE

Once a year:

1. Blow the inside of the unit clean with compressed air.
In the case of THE 650 motorized version, check the brushes in the servomotor for wear.

5.2 Service

THE 430 and THE 650 are designed for hard use and are very reliable They have no moving parts which are subject to heavy wear. For this reason they need very little service. If spare parts are required these can be ordered from the nearest ESAB sales office or representative. The part number which is given in the spare parts list and the serial number of the transformer which is stamped on the rating plate, should always be quoted when ordering spares. In this way delivery is quicker and the possibility of receiving the wrong part is minimised. The remote control unit is positioned and fixed in such a way that it can easily be changed if necessary, see fig. 14. After the lower part of the front plate, which is fastened

by four screws, has been removed the remote control box containing the electrical components is exposed. The electrical connections consist of two 8-pole plugs and a single 4-pole plug. When these have been pulled out the box can be removed by unscrewing the two screws connecting it to the chassis.

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Spare Parts List

Reservdelsförteckning Ersatzteilverzeichnis Liste de pièces détachées

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Fig. Nr	Beskrivning Description Beschreibung Désignation	Best.nr., P Teil Nr., Y THE 430	art No., No. de réf. THE 650	Antai, 1 Anzahi, THE 430	Jumber, Quantité THE 650
1	Lock Top cover Deckel Couvercle	161 981-006	161 981-006	1	v
2	Hölje kompl. Housing compl. Gehäuse kompl. Plaque compl.	161 981-007	161 981-007	1	ł
3	Frontskylt Front plate Frontschild Plaquette indicatrice	161 981-003	161 981-004	1	1
4	Handtag kompl. Transport handle compl. Schubstange kompl. Brancard compl.	161 981-001	161 981-001	2	2
5	Ratt kompl. Handwheel compl. Handrad kompl. Volant compl.	161 981-002	161 981-002	1	I
6	Maskinkontakt Cable connectors Kabelanschluß Prises de courant pour câbles	160 362-881	160 362-881	2	2
	Kabelkoppling Cable coupling Kabelkupplung Connecteur pour câble de soudage	160 360-881	160 360-882	2	2
7	Hjul Wheel Rad Roue	161 981-005	161 981-005	2	2
8	Lucka kompl. Cover compl. Deckel kompl. Couvercle compl.	161 981-008	161 981-008	1	1
9	Kabelintag Cable entry Kabelzugentlastung Entrée de câble	216 6101-80	216 6101-80	I	1

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Fig. Nr	Beskrivning Description Beschreibung Désignation	Best.nr., Pa Teil Nr., Na THE 430	rt No., o. de réf. THE 650	Antal, N Anzahl, THE 430	lumber, Quantité THE 650
10	Nätfrånskiljare Mains switch Netzschalter Interrupteur	161 982-015	161 982-015	1	1
11	Primärspolar kompl. Primary coils compl. Primärspulen kompl. Enroulements primaires compl. 380/500 V 50 Hz 440/550 V 60 Hz	161 982-009	161 982-010	1	1
11	Primärspolar kompl. Primary coils compl. Primärspulen kompl. Enroulements primaires compl. 220/380/440 V 50-60 Hz	161 982-011	161 982-012	1	1
12	Sekundärspolar kompl. Secondary coils compl. Sekundärspulen kompl. Enroulements secondaires compl.	161 982-013	161 982-014	1	1
13	Mikrobrytare Microswitch Mikroschalter Microinterrupteur		161 982-029	_	2
14	Inställningsindikering kompl. Current indicator compl. Einstellungsindikator kompl. Indicatrice de mise au point compl.	161 982-024	161 982-024	1	1
15	Tryckknappspanel kompl. Push-button panel compl. Druckknopfplatte kompl. Bouton-poussoir compl.	_	161 982-016		1
16	Transduktor Transductor Transduktor Transducteur	_	161 982-017		1
17	Rörlig kärna Iron core Streukern Bras de noyau	161 982-018	161 982-019	1	ł
18	Nylonhjul (litet) Nylon wheel (small) Nylonrad (kleines) Roue de nylon (petite)	161 982-027	161 982-028	ì	1
19	Nylonhjul (stort) Nylon wheel (big) Nylonrad (großes) Roue de nylon (grande)	161 982-025	161 982-026	J	1
20	Skruv kompl. Screw compl. Schraube kompl. Vis compl.	161 982-022	161 982-023	I	j

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Fig. Nr	Description Beschreibung Désignation	g Best.nr., Part No., Teil Nr., No. de réf. THE 430 THE 65		Antal, Number, Anzahl, Quantit 0 THE 430 THE
21	Gejd kompl. Guide compl. Aufleiter kompl. Guide compl.	161 982-020	161 982-021	1	1
22	Motor kompl. med växellåda Motor compl. with gear box Motor kompl. mit Getriebekasten Moteur compl. avec carter d'engrenages	_	161 982-005	_	I
22a	Motor Motor Motor Moteur	_	161 982-006	_	1
22b	Elborstar Carbon-brushes Kohlenbürsten Balais de charbon		161 982-007	_	2
22c	Kuggdrev Gearing Zahnradantrieb Pignon	_	161 982-008	-	1
23	Kopplingsplint kompl. Connection terminal compl. Klemmbrett kompl. Plaque à bornes de couplage (380/500 V — 50 Hz) (440/550 V — 60 Hz)	161 982-003	161 982-003	I	I
23	Kopplingsplint kompl. Connection terminal compl. Klemmbrett kompl. Plaque à bornes de couplage (220/380/440 V 50-60 Hz)	161 982-004	161 982-004	1	I
24	Kondensator Capacitor Kondensator Condensateur	161 982-001	161 982-002	1	1

Reskrivning

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Fig. Nr	Beskrivning Description Beschreibung Désignation	Best.nr., Part No., Teil Nr., No. de réf.	Antal, Number, Anzahl, Quantité
25	Fjärrinställningsdon kompl. Remote control unit compl. Fernsteuergerät kompl. Régulateur à distance compl.	161 983-001	1
25a	Stiftpropp Plug Stecker Fiche pour prise	161 983-010	2
25Ь	Chassikontakt Socket Steckdose Socle de prise de courant	161 983-009	4
25¢	Relä Relay Relais Relais	161 983-003	2

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Fig. Nr	Beskrivning Description Beschreibung Désignation	Best.nr., Part No., Teil Nr., No. de réf.	Antal, Number, Anzahl, Quantité
25d	Likriktare Rectifier Gleichrichter Redresseur	161 983-012	2
25e	Elektrolytkondensator Electrolytic capacitor Elektrolytkondensator Condensateur électrolytique	161 983-011	2
25f	Manövertransformator Control transformer Steuertransformator Transformateur de commande	161 983-002	ł
25g	Chassikontakt Socket Steckdose Socle de prise de courant	161 983-016	1
25h	Stiftpropp med kabel Plug with cable Stecker mit Kabel Fiche pour prise avec câble	161 983-017	1
25i	Säkringssockel Fuse socket Sicherungssockel Porte-fusible	161 983-006	1
25k	Propphuv Fuse cap Sicherungshaube Capuchon	161 983-007	1
251	Smäitpropp Cartridge fuse Schmeltzsicherung Fusible	161 983-008	1
25m	Varistor Varistor Varistor Varistor	161 983-005	ł
25n	Varistor Varistor Varistor Varistor	161 983-004	1

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Fig. Nr	Beskrivning Description Beschreibung Désignation	Best.nr., Part No., Teil Nr., No. de réf. THE 430 THE 650	Antal, Number, Anzahl, Quantité THE 430 THE 650
26	Manöverstav kompl. Remote control rod compl. Fernsteuerstab kompl. Barre de commande compl.	161 983-013	1
26a	Diod Diode Diode Diode	161 983-014	1
26b	Motstånd Resistor Widerstand Résistance	161 983-015	1

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