TAFA 652cv & 782cv Power Sources Instruction manual

INSTRUCTION MANUAL

652CV & 782CV

POWER SOURCES

F-15-477

July, 1998

This manual provides complete instructions for the following power sources starting with Serial No. M0RI827001:

652CVCC - 230/460 vac, 3 ph., 60 Hz ........................... 37501

652CVCC - 230/460/575 vac, 3 ph., 60 Hz .................... 37502

782CVCC - 220/400 vac, 3 ph., 50 Hz, CE .................... 37503

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 Welding, Cutting, and Gouging," Form 52-529. Do NOT permit untrained persons to install, operate, or
maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully
understand these instructions. If you do not fully understand these instructions, contact your supplier for
further information. Be sure to read the Safety Precautions before installing or operating this equipment.

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

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/
or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment
must be checked periodically. Malfunctioning 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 ................................................................................................................................... 7

1.1 General ............................................................................................................................................... 7

1.2 Receiving-Handling ............................................................................................................................ 7

1.3 Description .......................................................................................................................................... 7

1.3.1 Power Source ..................................................................................................................................... 7

1.3.2 Volt-Ampere Characteristics ............................................................................................................... 7

1.4 Safety ................................................................................................................................................. 8

SECTION 2 INSTALLATION ................................................................................................................................. 9

2.1 Location .............................................................................................................................................. 9

2.2 Receiving, Unpacking and Placement ............................................................................................... 9

2.3 Primary (Input) Electrical Connection ................................................................................................ 9

2.4 Secondary (Output)Connections ........................................................................................................ 11

2.5 Control Connections ........................................................................................................................... 11

2.5.1 Console Control .................................................................................................................................. 11

2.5.2 Auxiliary 115 V ac Receptacle ........................................................................................................... 11

2.5.3 42 V Circuit Breaker ........................................................................................................................... 11

2.5.4 115 V Circuit Breaker ......................................................................................................................... 11

SECTION 3 OPERATION ...................................................................................................................................... 13

3.1 Controls .............................................................................................................................................. 13

3.1.1 Power Switch (ON-OFF) .................................................................................................................... 13

3.1.2 Over Temperature Indicator ............................................................................................................... 13

3.1.3 Fault Indicator ..................................................................................................................................... 13

3.1.4 Over Current Protection ..................................................................................................................... 13

3.1.5 High & Low Inductance Receptacles ................................................................................................. 13

SECTION 4 MAINTENANCE ................................................................................................................................. 14

4.1 General ............................................................................................................................................... 14

4.2 Cleaning - Preventive Maintenance ................................................................................................... 14

4.3 Inspection and Service ....................................................................................................................... 14

4.3.1 Fan Motor ........................................................................................................................................... 14

4.3.2 Transformer ........................................................................................................................................ 14

4.3.3 Wire Feeder and Control Circuits ....................................................................................................... 14

4.3.4 Over Temperature Protection ............................................................................................................. 14

SECTION 5 TROUBLESHOOTING ....................................................................................................................... 15

5.1 General ............................................................................................................................................... 15

5.2 Testing and Replacing Bridge Assembly Components ...................................................................... 15

SECTION 6 PARTS ................................................................................................................................................ 21

6.1 General ............................................................................................................................................... 21

2

SAFETY PRECAUTIONS

WARNING: These Safety Precautions are for
your protection. They summarize precaution­ary information from the references listed in

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

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

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

1. Always wear safety glasses with side shields in any work

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

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

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

3. Wear flameproof gauntlet type gloves, heavy long-sleeve

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

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

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

5. Protect other personnel from arc rays and hot sparks

with a suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag or

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

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

1. Remove all combustible materials well away from the

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

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

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

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

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

4. Have fire extinguishing equipment handy for instant use,

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

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

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

2. Connect the workpiece to a good electrical ground.

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

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

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

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

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

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

9. Turn off the power before removing your gloves.

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

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

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

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

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

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

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

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

from your body as possible.

TAFA -11/97

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.

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
wire arc spraying, please refer to safety sec­tion in owners manual.

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:

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

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

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

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

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.

TAFA -11/97

4

PRÉCAUTIONS DE SÉCURITÉ

AVERTISSEMENT: Ces règles de sécurité ont pour objet
d assurer votre protection. Veillez à lire et à observer les
précautions énoncées ci-dessous avant de monter l
équipement ou de commercer à lutiliser. Tout défaut
dobservation de ces précautions risque dentraîner des
blessures graves ou mortelles.

1. PROTECTION INDIVIDUELLE-- Les brûlures de la
peau et des yeux dues au rayonnement de larc
électrique ou du métal incandescent, lors du soudage
au plasma ou à lélectrode ou lors du gougeage à
larc, peuvent savérer plus graves que celles
résultant dune exposition prolongée au soleil. Aussi
convient-il dobserver les précautions suivantes:

a. Portez un écran facial adéquat muni des plaques

protectrices et des verres filtrants appropriés afin de
vous protéger les yeux, le visage, le cou et les oreilles
des étincelles et du rayonnement de larc électrique
lorsque vous effectuez des soudures ou des coupes
ou lorsque vous en observez lexécution.

AVERTISSEZ les personnes se trouvant à proximité

de façon à ce quelles ne regardent pas larc et à ce
quelles ne sexposent pas à son rayonnement, ni à
celui du métal incandescent.

b. Portez des gants ignifugés à crispins, une tunique

épaisse à manches longues, des pantalons sans
rebord, des chaussures à embout dacier et un
casque de soudage ou une calotte de protection, afin
déviter dexposer la peau au rayonnement de larc
électrique ou du métal incandescent. ll est également
souhaitable dutiliser un tablier ininflammable de
façon à se protéger des étincelles et du rayonnement
thermique.

c. Les étincelles ou les projections de métal incandes-

cent risquent de se loger dans des manches
retroussées, des bords relevés de pantalons ou dans
des poches. Aussi convient-il de garder boutonnés le
col et les manches et de porter des vêtements sans
poches à lavant.

d. Protégez des étincelles et du rayonnement de larc

électrique les autres personnes travaillant à proximité
à laide dun écran ininflammable adéquat.

e. Ne jamais omettre de porter des lunettes de sécurité

lorsque vous vous trouvez dans un secteur où lon
effectue des opérations de soudage ou de coupage à
larc. Utilisez des lunettes de sécurité à écrans ou
verres latéraux pour piquer ou meûler le laitier. Les
piquetures incandescentes de laitier peuvent être
projetées à des distances considérables. Les
personnes se trouvant à proximité doivent également
porter des lunettes de protection.

f. Le gougeage à larc et le soudage à larc au plasma

produisent un niveau de bruit extrêmement élevé (de
100 à 114 dB) et exigent par conséquent lemploi de
dispositifs appropriés de protection auditive.

2. PRÉVENTION DES INCENDES-- Les projections de
laitier incandescent ou détincelles peuvent
provoquer de graves incendies au contact de
matériaux combustibles solides, liquides ou gazeux.
Aussi faut-il observer les précautions suivantes:

a. Éloigner suffisamment tous les matériaux combus-

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

b. Les étincelles ou les projections de métal incandes-

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

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

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

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

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

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

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

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

a. Ne laissez jamais de surfaces métalliques sous ten-

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

b. Si vous devez effectuer un travail sur une surface

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

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

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

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

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

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

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

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

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

5

9/97

levage, des câbles de grue ou divers chemins
électriques.

g. Empêchez lapparition de toute humidité, notamment

sur vos vêtements, à la surface de lemplacement de
travail, des câbles, du porte-électrode et du poste de
soudage/coupage. Réparez immédiatement toute
fuite deau.

4. VENTILATION-- La respiration prolongée des fumées
résultant des opérations de soudage/coupage, à
lintérieur, dun local clos, peut provoquer des mal­aises et des dommages corporels. Aussi convient-il
dobserver les précautions suivantes:

a. Assurez en permanence une aération adéquate de

lemplacement de travail en maintenant une ventila­tion naturelle ou à laide de moyens mécaniques.
Neffectuez jamais de travaux de soudage ou de
coupage sur des matériaux de zinc, de plomb, de
beryllium ou de cadmium en labsence de moyens
mécaniques de ventilation capables dempêcher
linhalation des fumées dégagées par ces matériaux.

b. Neffectuez jamais de travaux de soudage ou de

coupage à proximité de vapeurs dhydrocarbure
chloré résultant dopérations voisines de dégraissage
ou de pulvérisation. La chaleur dégagée ou le
rayonnement de larc peut déclencher la formation de
phosgène -- gaz particulièrement toxique -- et dautres
gaz irritants, à partir des vapeurs de solvant.

c. Une irritation momentanée des yeux, du nez ou de la

gorge constatée au cours de lutilisation de
léquipement dénote un défaut de ventilation. Arrêtez­vous de travailler afin de prendre les mesures néces­saires à lamélioration de la ventilation. Ne poursuivez
pas lopération entreprise si le malaise persiste.

d. Certaines commandes comportent des canalisations

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

lefficacité de la ventilation ainsi réalisée. Ne jamais
débrancher le ventilateur.

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

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

f. Consultez les recommandations particulières en

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

5. ENTRETIEN DE LÉQUIPEMENT-- Un équipement
entretenu de façon défectueuse ou inadéquate risque
non seulement de réaliser un travail de mauvaise
qualité mais, chose plus grave encore, dentraîner des
dommages corporels graves, voire mortels en
déclenchant des incendies ou des chocs électriques.
Observez par conséquent les précautions suivantes:

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

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

b. Ne procédez jamais à une tâche dentretien

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

c. Maintenez en bon état de fonctionnement les câbles,

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

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

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

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

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

f. Utilisez le poste de soudage/coupage conformément à

son usage prévu et neffectuez aucune modification.

9/97

6

SECTION 1

1.1 GENERAL

This manual has been prepared for use by an expe­rienced operator. It provides information to familiar­ize the operator with the design, installation and
operation of the TAFA 652CV & 782CV model power
sources. DO NOT attempt to install or operate this
equipment until you have read and fully understood
these instructions. The information presented here
should be given careful consideration to ensure opti­mum performance of this equipment.

1.2 RECEIVING-HANDLING

Upon receipt, remove all packing material and care­fully inspect for any damage that may have occurred
during shipment. Any claims for loss or damage that
may have occurred in transit must be filed by the
purchaser with the carrier. A copy of the bill of lading
and freight bill will be furnished by the carrier on
request.

DESCRIPTION

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

1.3 DESCRIPTION

1.3.1 Power Source

The power source is a constant voltage, Silicon
Controlled Rectifier (SCR), three phase, star-con­nected transformer/rectifier type dc unit with solid
state contactor and control circuitry. It provides the
volt-ampere characteristics desired for conventional
constant voltage output.

1.3.2 Volt-Ampere Characteristics

The curves shown in Figure 1-1 represent the volt­ampere static characteristics for the power source.
The slant of these curves is referred to as the "slope"
and is generally defined as the "voltage drop per 100

Table 1-1. Specifications for 652CV and 782CV

OPEN CIRCUIT VOLTAGE (U0) 54 vdc (cv)

RATED DUTY CYCLE 60% 100%

OUTPUT Current (I2) 750 A 650 A (60Hz)/600 A (50Hz)

Voltage (U2) 44 V 44 V

RATED 3 Phase 60 Hz Volts (U1) Current (I1) Flat Current (I1) Flat

INPUT 230 V 124 A 108 A

460 V 62 A 54 A

575 V 50 A 43 A

50 Hz 220 V 127 A 102 A

400 V 70 A 56 A

Power Factor at Rated Output 83%

Welding Range 750 A/44 V - 50 A/14 V

Auxiliary Power 115 V ac @ 10 A, 60 Hz

PHYSICAL SPECIFICATIONS 60 Hz. 50 Hz.

Height (without lift eye) 25.0 (62.2 cm)

Width 18.8 (48.3 cm)

Depth 32.5 (81.9 cm)

Net Weight 493 lbs (224 kg) 528 lbs (240 kg)

Shipping Weight 503 lbs (228 kg) 538 lbs (244 kg)

NOTE: The 652cv/782cv may also operate from a 200 (208)-volt a.c. primary input using the 230-volt changeover connections. However,

when connected to this source (200-volt), the output voltage is derated from 44-volts to 40-volts @ 600 amps.

7

DESCRIPTIONSECTION 1

amperes of current use". These curves show the
output voltage available at any given output current
from the minimum to the maximum setting of the
voltage control. Because the volt-ampere slope is
fixed, it is possible to select output conditions by
estimating the open-circuit voltage required for the
load current.

60
50
40
30

Volts

20
10

MIN.

0

100 200

0

300 400 600

D.C. OUTPUT CURRENT (AMPS)

AMPS

MAX.

700

900

800500

1.4 SAFETY

Before the equipment is put into operation, the safety
section at the front of this manual should be read
completely. This will help avoid possible injury due to
misuse or improper installation.

The definitions relating to the:

safety notations are described at the end of the Safety
Section in the front of this manual  read them and

their specific text references carefully.

8

SECTION 2 INSTALLATION

2.1 LOCATION

A proper installation site is necessary for the power
source to provide dependable service. A proper in­stallation site permits freedom of air movement
through the unit while minimizing exposure to dust,
dirt, moisture, and corrosive vapors. A minimum of 18
inches (46 cm) is required between the side and rear
panels of the power source and the nearest obstruc­tion. The selected site should also allow easy re­moval of the power source outer enclosure for main­tenance. See Table 1-1 for overall dimensions of the
unit.

2.2 RECEIVING, UNPACKING AND
PLACEMENT

A. Immediately upon receipt of the power

source, inspect for damage which may have
occurred in transit. Notify the carrier of any
defects or damage.

B. Remove the power source from the con-

tainer. Remove all packing materials. Check
the container for any loose parts.

C. Check air passages at front and rear of

cabinet, making sure that no packing mate­rials that may obstruct air flow through the
power source.

2.3 PRIMARY (INPUT) ELECTRICAL
CONNECTION

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

ELECTRIC SHOCK CAN KILL! Before making
electrical input connections to the power source,
"Machinery Lockout Procedures" should be em­ployed. If the connections are to be made from a
line disconnect switch, place the switch in the off
position and padlock it to prevent inadvertent
tripping . If the connection is made from a fusebox,
remove the corresponding fuses and padlock the
box cover. If it is not possible to use padlocks,
attach a red tag to the line disconnect switch (or
fuse box) warning others that the circuit is being
worked on.

A. The primary power leads must be insulated

copper conductors. Three power leads and
one ground wire are required. Either rubber
covered cable or conduit (flexible or solid)
may be used. Table 2-1 provides recom­mended input conductors and line fuse sizes.

D. Install the lifting ring furnished with the power

sources into the top of the unit.

For lifting purposes and for keeping dust,
moisture, and other foreign material from
entering the power source, the lifting eyebolt
must be fully tightened with a tool.

E. After selecting an installation site (see para-

graph 2.1), place the power source in the
desired location. The unit may be lifted either
by using the lifting ring or by forklift truck. If
a forklift is used for lifting the unit, be sure that
the lift forks are long enough to extend com­pletely under the base.

Do not use filters on this unit as they would
restrict the volume of intake air required for
proper cooling. Output ratings on this unit are
based on an unobstructed supply of cooling air
drawn over its internal components. Warranty is
void if any type of filtering device is used.

B. Remove the top cover. Identify primary power

input connections on the power switch, chas­sis ground lug on the "A" frame, and primary
input terminal board. Refer to Figures 2-1
and 2-2.

Table 2-1. Recommended Sizes for Input

Conductors and Line Fuses

Rated Input

@ 100% Duty Cycle

Volts Amps

220
230
400
460
575

* Sized per National Code for 80 °C rated copper conductors @ 30 °C

ambient. Not more than three conductors in raceway or cable. Local
codes should be followed if they specify sizes other than those listed
above.

** Wire per National Electric Code Table 310-16 using 90° C rated conduc-

tors (e.g. THW-2, THWN, THHN).

102
100

56
54
43

Input &

GND

Conductor*

CU/AWG

No. 2**
No. 2**

No. 6
No. 6
No. 8

Fuse Size

Amps

175
175

90
90
75

9