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

Page 1

Instruction Book and Spare Parts List

Page 2

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
Page 3

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
Page 4

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

Page 5

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

Page 6

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

Page 7

Page 8

Circuit Diagram

Page 9

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.

Page 10

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

Page 11

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 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
Page 12

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.

Page 13

Spare Parts List

Reservdelsförteckning Ersatzteilverzeichnis Liste de pièces détachées

Page 14

Page 15
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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Page 17
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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Page 19
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

Page 20

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
Page 21
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
Page 22

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
Page 23
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BOX 8850 S-402 71 GÖTEBORG 8 SWEDEN Phone 22 80 20 Tgm Esabsales Telex 206 25

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