LG Electronics Welding System 453cc User Manual

F-15-591-A  
February, 2001  
INSTRUCTION MANUAL  
453cc & 553cc  
DC WELDING POWER SOURCES  
This manual provides complete instructions for the following power sources:  
453cc  
553cc  
Item No.  
Item No.  
ESAB 230/460 vac, 3 ph., 60 Hz  
ESAB 230/460/575 vac, 3ph., 60 Hz  
ESAB 220/400 vac, 3 ph., 50 Hz  
453cc - 0558001274  
453cc - 0558001275  
453cc - 0558001276  
553cc - 0558001278  
553cc - 0558001279  
553cc - 0558001280  
553cc - 0558001281  
ESAB 220/400 vac, 3 ph., 50 Hz, CE 453cc - 0558001277  
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. DoNOTpermit untrainedpersonstoinstall, operate, ormaintainthisequipment. DoNOT  
attempt to install or operate this equipment until you have read and fully understand these  
instructions. Ifyoudonotfullyunderstandtheseinstructions,contactyoursupplierforfurther  
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.  
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TABLE OF CONTENTS  
SECTION  
PARAGRAPH  
TITLE  
PAGE  
SAFETY  
ENGLISH  
FRENCH  
SAFETY PRECAUTIONS ................................................................................................................ 4, 5  
SAFETY PRECAUTIONS ................................................................................................................ 6, 7  
SECTION 1  
1.1  
DESCRIPTION..................................................................................................................................... 8  
General ................................................................................................................................................ 8  
Receiving-Handling.............................................................................................................................. 8  
Description ........................................................................................................................................... 8  
Power Source ...................................................................................................................................... 8  
Volt-Ampere Characteristics ................................................................................................................ 9  
Optional Accessories ........................................................................................................................... 9  
Safety ................................................................................................................................................... 9  
1.2  
1.3  
1.3.1  
1.3.2  
1.4  
1.5  
SECTION 2  
INSTALLATION ...................................................................................................................................10  
Location ...............................................................................................................................................10  
Receiving, Unpacking and Placement .................................................................................................10  
Primary (Input) Electrical Connection ..................................................................................................10  
Secondary (Output) Welding Connections ..........................................................................................12  
Control Connections ............................................................................................................................12  
2.1  
2.2  
2.3  
2.4  
2.5  
SECTION 3  
3.1  
OPERATION ........................................................................................................................................14  
Controls................................................................................................................................................14  
Power Switch (ON-OFF) .....................................................................................................................14  
Arc Force Control ................................................................................................................................14  
Contactor Or/Remote Switch ...............................................................................................................14  
Current Panel/Remote Switch .............................................................................................................14  
Current Control ....................................................................................................................................14  
Over Temperature Indicator .................................................................................................................15  
Voltmeter and Ammeter .......................................................................................................................15  
Fault indicator ......................................................................................................................................15  
Operation Set-Up .................................................................................................................................15  
Stick Welding, Arc Gouging, Tig Welding ............................................................................................15  
Mig Spray Arc and Flux Cored Welding ...............................................................................................15  
3.1.1  
3.1.2  
3.1.3  
3.1.4  
3.1.5  
3.1.6  
3.1.7  
3.1.8  
3.2  
3.2.1  
3.2.2  
SECTION 4  
4.1  
MAINTENANCE...................................................................................................................................16  
General ................................................................................................................................................16  
Cleaning ...............................................................................................................................................16  
Inspection .and Service .......................................................................................................................16  
Fan Motor.............................................................................................................................................16  
Transformer..........................................................................................................................................16  
Control Circuit ......................................................................................................................................16  
Over Temperature Protection ...............................................................................................................16  
Digital Voltmeter/Ammeter Calibration.................................................................................................16  
4.2  
4.3  
4.3.1  
4.3.2  
4.3.3  
4.3.4  
4.3.5  
SECTION 5  
TROUBLESHOOTING.........................................................................................................................17  
General ................................................................................................................................................17  
Testing and Replacing Bridge Assembly Components ........................................................................17  
PCB Voltage Test .................................................................................................................................17  
Troubleshooting Information Table.......................................................................................................18  
5.1  
5.2  
5.3  
5.6  
SECTION 6  
PARTS .................................................................................................................................................19  
General ................................................................................................................................................19  
Ordering ...............................................................................................................................................19  
6.1  
6.2  
3
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SAFETY PRECAUTIONS  
WARNING: These Safety Precautions are for  
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 neces-  
sary.  
7. For additional information, refer to NFPA Standard 51B,  
"Fire Prevention in Use of Cutting and Welding Pro-  
cesses", available from the National Fire Protection Asso-  
ciation, Batterymarch Park, Quincy, MA 02269.  
your protection. They summarize precaution-  
ary 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  
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 move-  
ment is confined, or if there is danger of  
falling.  
can injure skin and eyes. Hot metal can cause burns.  
Training in the proper use of the processes and equip-  
ment 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.  
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 dam-  
aged cables.  
3. Wearflameproofgauntlettypegloves,heavylong-sleeve  
shirt, cuffless trousers, high-topped shoes, and a weld-  
ing 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.  
Bystandersshouldalsoweargogglesoversafetyglasses.  
5. Keepeverythingdry,includingclothing,workarea,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 mis-  
take the work lead for a ground cable.  
ELECTRIC AND MAGNETIC FIELDS —  
Maybedangerous.Electriccurrentflow-  
ing through any conductor causes lo-  
calized Electric and Magnetic Fields  
(EMF). Welding and cutting current cre-  
ates EMF around welding cables and  
welding machines. Therefore:  
FIRES AND EXPLOSIONS -- Heat from  
flames and arcs can start fires. Hot slag  
or sparks can also cause fires and ex-  
plosions. Therefore:  
1. Remove all combustible materials well away from the  
work area or cover the materials with a protective non-  
flammablecovering.Combustiblematerialsincludewood,  
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 pro-  
duce 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.  
1. Welders having pacemakers should consult their physi-  
cian before welding. EMF may interfere with some pace-  
makers.  
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.  
10/98  
4
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SAFETY PRECAUTIONS  
EQUIPMENT MAINTENANCE -- Faulty or  
improperly maintained equipment can  
cause injury or death. Therefore:  
FUMES AND GASES -- Fumes and  
gases,cancausediscomfortorharm,  
particularly in confined spaces. Do  
notbreathefumesandgases. Shield-  
ing gases can cause asphyxiation.  
Therefore:  
1. Always have qualified personnel perform the installa-  
tion, troubleshooting, and maintenance work. Do not  
perform any electrical work unless you are qualified to  
perform such work.  
2. Before performing any maintenance work inside a power  
source, disconnect the power source from the incoming  
electrical power.  
3. Maintain cables, grounding wire, connections, power  
cord, and power supply in safe working order. Do not  
operate any equipment in faulty condition.  
4. Do not abuse any equipment or accessories. Keep  
equipment away from heat sources such as furnaces,  
wet conditions such as water puddles, oil or grease,  
corrosive atmospheres and inclement weather.  
5. Keep all safety devices and cabinet covers in position  
and in good repair.  
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 posi-  
tive mechanical ventilation is provided. Do not breathe  
fumes from these materials.  
2. Do not operate near degreasing and spraying opera-  
tions. 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 im-  
prove ventilation in the work area. Do not continue to  
operate if physical discomfort persists.  
6. Use equipment only for its intended purpose. Do not  
modify it in any manner.  
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)  
for specific ventilation recommendations.  
5. WARNING: This product, when used for welding or  
cutting, produces fumes or gases which  
ADDITIONAL SAFETY INFORMATION -- For  
more information on safe practices for elec-  
tric 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.  
contain chemicals known to the State of  
California to cause birth defects and, in  
some cases, cancer. (California Health &  
Safety Code §25249.5 et seq.)  
The following publications, which are available from the  
American Welding Society, 550 N.W. LeJuene Road, Mi-  
ami, 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"  
CYLINDER HANDLING -- Cylinders, if  
mishandled, can rupture and violently  
release gas. Sudden rupture of cylin-  
der, valve, or relief device can injure or  
kill. Therefore:  
3. AWS C5.2 - "Recommended Practices for Plasma Arc  
Cutting"  
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 regu-  
lator to a compressed gas cylinder.  
2. Always secure cylinders in an upright position by chain  
orstraptosuitablehandtrucks,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 con-  
nected. 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.  
4. AWS C5.3 - "Recommended Practices for Air Carbon  
Arc Gouging and Cutting"  
5. AWS C5.5 - "Recommended Practices for Gas Tung-  
sten Arc Welding“  
6. AWS C5.6 - "Recommended Practices for Gas Metal Arc  
Welding"“  
7. AWS SP - "Safe Practices" - Reprint, Welding Hand-  
book.  
8. ANSI/AWS F4.1, "Recommended Safe Practices for  
Welding and Cutting of Containers That Have Held  
Hazardous Substances."  
MEANING OF SYMBOLS - As used through-  
out this manual: Means Attention! Be Alert!  
Your safety is involved.  
Means immediate hazards which, if  
not avoided, will result in immediate,  
serious personal injury or loss of life.  
Means potential hazards which could  
result in personal injury or loss of life.  
Means hazards which could result in  
minor personal injury.  
SP98-10  
5
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P RÉCAUTIONS DE S ÉCURITÉ  
coupes à l’arc, à moins de les recouvrir complètement  
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.  
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 sub-  
stances 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 projec-  
tion 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.  
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  
b. Si vous devez effectuer un travail sur une surface  
métallique ou dans un secteur humide, veillez à assu-  
rer 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 dan-  
ger 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 pas-  
sage d’un courant de sortie par des chaînes de  
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  
9/97  
6
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P RÉCAUTIONS DE S ÉCURITÉ  
déclenchant des incendies ou des chocs électriques.  
levage, des câbles de grue ou divers chemins  
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.  
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.  
b. Ne procédez jamais  
à
une tâche d’entretien  
4. VENTILATION-- La respiration prolongée des fumées  
résultant des opérations de soudage/coupage, à  
l’intérieur, d’un local clos, peut provoquer des mal-  
aises et des dommages corporels. Aussi convient-il  
d’observer les précautions suivantes:  
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 corro-  
sives 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.  
6. INFORMATIONS COMPLÉMENTAIRES RELATIVES  
À LA SÉCURITÉ--  
a. Assurez en permanence une aération adéquate de  
l’emplacement de travail en maintenant une ventila-  
tion 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. Arrêtez-  
vous de travailler afin de prendre les mesures néces-  
saires 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 forma-  
tion 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  
manœuvrer 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.  
Pour obtenir des informations complémentaires sur les  
règles de sécurité à observer pour le montage et  
l’utilisation d’équipements de soudage et de coupage  
électriques et sur les méthodes de travail  
recommandées, demandez un exemplaire du livret N°  
52529 “Precautions and Safe Practices for Arc Weld-  
ing, Cutting and Gouging” publié par ESAB. Nous  
conseillons également de consulter les publications  
sui-vantes, tenues à votre disposition par l’American  
Welding Society, 550 N.W. LeJuene Road, Miami, FL  
32126:  
a. “Safety in Welding and Cutting” AWS Z49.1  
b. “Recommended Safe Practices for Gas-Shielded Arc  
Welding “AWS A6. 1.  
c. “Safe Practices for Welding and Cutting Containers  
That Have Held Combustibles” AWS-A6.0.  
d. “Recommended Safe Practices for Plasma Arc Cutting”  
AWS-A6. 3.  
e. “Recommended Safe Practices for Plasma Arc Weld-  
ing” AWS-C5. 1.  
f. “Recommended Safe Practices for Air Carbon Arc  
Gouging and Cutting” AWS-C5. 3.  
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.  
g. “Code For Safety in Welding and Cutting”  
CSA-Standard W117. 2.  
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  
7
9/97  
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SECTION 1  
DESCRIPTION  
1.1 GENERAL  
When requesting information concerning this equip-  
ment, it is essential that Item number, Serial number  
and Model number of the equipment be supplied.  
This manual has been prepared for use by an experi-  
enced operator. It provides information to familiarize  
the operator with the design, installation and operation  
ofthe482ccand582ccmodelpowersources.DONOT  
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.  
1.3 DESCRIPTION  
These power sources are designed for constant cur-  
rent Stick welding (SMAW), air carbon arc gouging  
(ACAG), and scratch start tig (GTAW). It can also be  
used for Mig spray arc (GMAW) and flux cored wire  
(FCAW) welding with an “off the arc”wire feeder. Table  
1-1outlinestheelectricalandphysicalspecificationsof  
the available models.  
1.2 RECEIVING-HANDLING  
Uponreceipt,removeallpackingmaterialandcarefully  
inspect for any damage that may have occurred during  
shipment.Anyclaimsforlossordamagethatmayhave  
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.  
1.3.1 POWER SOURCE  
The power source is a constant current, Silicon Con-  
trolled Rectifier (SCR), three phase, star-connected  
transformer/rectifiertypedcunitwithsolidstatecontactor  
and control circuitry. It provides the volt-ampere char-  
acteristics desired for conventional Stick welding.  
Table 1-1. Specifications for 453cc and 553cc  
453cc  
55 Vdc  
553cc  
OPEN CIRCUIT VOLTAGE (Uo)  
57 Vdc  
DUTY CYCLE  
Current (12)  
Voltage (U2)  
Volts (U 1)  
60.00%  
450 A  
100.00%  
350 A  
60.00%  
550 A  
100.00%  
450 A  
RATED  
OUTPUT  
38 Vdc  
Current (11  
70 A  
34 Vdc  
Current (11  
58 A  
42 Vdc  
Current (11  
86 A  
38 Vdc  
Current (11)  
74 A  
60 Hz  
(208)230 Vac  
460 Vac  
RATED  
INPUT  
3
35A  
29 A  
43 A  
37 A  
Phase  
575 Vac  
28A  
23 A  
34 A  
30 A  
50 Hz  
220/400  
73/40 (42-39) A  
61/33 (35-30) A  
90/49 (52-47) A  
77/43 (45--41) A  
(380-415) Vac  
Pow er Factor at Rated Output  
Welding Range  
83.00%  
83.00%  
20A/20V to 450A/38Vdc  
115 V ac @ 10 A, 60 Hz  
20A/20V to 550A/42Vdc  
115 V ac @ 10 A, 60 Hz  
Auxiliary Pow er  
PHYSICAL SPECIFICATIONS  
Height (w ithout lifting eyebolt)  
Width  
60 Hz.  
50 Hz.  
60 Hz.  
50 Hz.  
25.0" (62.2 cm)  
25.0" (62.2 cm)  
18.8" (48.3 cm)  
32.5" (81.9 cm)  
18.8" (48.3 cm)  
32.5" (81.9 cm)  
Depth  
Net Weight  
339lbs(154kg)  
349 lbs (158 kg)  
379lbs(172kg)  
363 lbs (165 kg)  
373 lbs (170 kg)  
400 lbs (181 kg)  
410 lbs (186 kg)  
Shipping Weight  
389 lbs (177 kg)  
NOTE: The 453cc and 553cc may also operate from a 200 (208)- volt a.c. primary input using the 230 volt change over connections. However,  
when connected to this source (200-volt), the output is derated to 36 volts @ 400 amps (453cc) and to 38 volts @ 500 amps (553cc).  
The 453cc and 553cc 50 Hz may operate from 380 vac or 415 vac primary input when using the 400 vac change over connection. When using  
this connection, the output voltage is derated from 38 v to 36 v (453cc) and 42 v to 38 v (553cc).  
8
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SECTION 1  
DESCRIPTION  
These controls provide remote output current control  
and contactor operation. Each control is equipped with  
30 ft. (9.1 m) cable/plug assembly that mates with the  
optional Remote Control Kit described above. The  
current adjustment is limited to the range as set by the  
currentcontrolonthepowersource. Thecontactorand  
current panel/remote switches on the power source  
must be in remote position when operating with any of  
the remote controls.  
1.3.2 Volt-Ampere Characteristics  
The curves shown in Figure 1-1 represent the volt-  
ampere static characteristics for the power source.  
These curves show the output voltage available at any  
givenoutputcurrentfromtheminimumtothemaximum  
setting of the current control.  
Figure 1.1 Volt/Ampere Curves  
TR-29 Truck Kit (37924)  
This truck kit provides complete mobility of the power  
source. The kit consists of front castors, rear cylinder  
rack and wheels, gas cylinder bracket, cylinder chain,  
and pull handle.  
553CC  
MAX. OUTPUT  
MIN. OUTPUT  
453CC  
Automatic Fan Kit (36707)  
MAX. OUTPUT  
With this kit installed, the fan will start to operate when  
the welding arc is initiated and will continue to run for 5  
minutes after the arc has been extinguished.  
NOTE: This optional kit can only be installed in units  
manufactured after Serial No. MX-I709000 in  
which the large R5 resistor was moved from  
top center of the "A" frame to the base in front  
of the fan bracket.  
1.4 OPTIONAL ACCESSORIES  
Stick Electrode Holder Assembly (21226)  
1.5 SAFETY  
Includes holder, 15-ft. cable, and twist lock connector.  
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.  
Work Cable Assembly, 10-ft. (32995)  
Includes ground clamp and twist lock connector.  
Remote Control Receptacle (0558001436)  
The definitions relating to the:  
This Remote Control Kit consists of a 14 pin and 19 pin  
amphenol receptacle and assembly that permits the  
useoftheHC-3BRemoteControl,FC-5BRemoteFoot  
Control , or TC-2B Torch Control, as described below  
for tig welding. The Remote Control Kit also provides a  
115 vac 10Amp Receptacle for auxiliary power tools.  
HC-3B Remote Hand Control (33838)  
FC-5B Remote Foot Control (33646)  
TC-2B Remote Torch Control (33839)  
safety notations are described at the end of the Safety  
Sectioninthefrontofthismanual-readthemandtheir  
specific text references carefully.  
9
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SECTION 2  
INSTALLATION  
2.1 LOCATION  
2.3 PRIMARY (INPUT) ELECTRICAL CONNEC-  
TION  
A proper installation site is necessary for the power  
source to provide dependable service. A proper instal-  
lationsitepermitsfreedomofairmovementthroughthe  
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. Also, the  
undersideofthepowersourcemustbekeptcompletely  
free of obstructions.  
This power source is a three-phase unit and must be  
connected to a three-phase power supply. It is recom-  
mendedthattheunitbeoperatedonadedicatedcircuit  
to prevent impairment of performance due to an over-  
loaded circuit.  
Theselectedsiteshouldalsoalloweasyremovalofthe  
power source outer enclosure for maintenance. See  
Table 1.1 for overall dimensions of the unit.  
ELECTRIC SHOCK CAN KILL! Before making elec-  
trical input connections to the power source, "Ma-  
chineryLockoutProcedures"shouldbeemployed.  
If the connections are to be made from a line  
disconnect switch, place the switch in the off posi-  
tion and padlock it to prevent inadvertent tripping.  
If the connection is made from a fusebox, remove  
thecorrespondingfusesandpadlocktheboxcover.  
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.  
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 dam-  
age.  
B. Remove the power source from the container.  
Remove all packing materials. Check the con-  
tainer for any loose parts.  
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.  
Table2-1providesrecommendedinputconduc-  
tors and line fuse sizes.  
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.  
D. Installtheliftingeyeboltfurnishedwiththepower  
source into the top of the unit.  
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.  
For lifting purposes and for keeping dust, mois-  
ture, and other foreign material from entering the  
power source, the lifting eyebolt must be fully  
tightened with a tool.  
C. When using the provided strain relief, refer to  
Figure 2.1 for proper cable strip lengths. It is  
important to follow the cable strip guide to en-  
sure that if the primary input cable is ever pulled  
fromthestrainrelief, theinputconductorswillbe  
pulledfromtheON/OFFpowerswitchbeforethe  
ground lead is pulled from the ground lug. Once  
stripped, thread the input and ground conduc-  
tors through the large strain relief in the rear  
panel of the power source. Connect the ground  
wire to the terminal lug located on the right rear  
A-frame leg inside the power source. Connect  
the primary power leads to terminals L1, L2, and  
L3 on the input power switch. Secure the strain  
relief on the input cable.  
E. After selecting an installation site (see para-  
graph2.1),placethepowersourceinthedesired  
location. The unit may be lifted either by using  
the lifting eyebolt 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  
thevolumeofintakeairrequiredforpropercooling.  
Output ratings on this unit are based on an unob-  
structed supply of cooling air drawn over its inter-  
nal components. Warranty is void if any type of  
filtering device is used.  
The chassis must be connected to an approved  
electrical ground. Failure to do so may result in  
electrical shock, severe burns or death.  
10  
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SECTION 2  
INSTALLATION  
Recommended Cable Strip Lengths  
Rear Panel (Inside View)  
Strain Relief  
5"  
Ground Fault  
Switch*  
10"  
TB3 Located on  
Fan Bracket  
SWITCH  
GROUND LUG  
NUT  
HORSESHOE  
Figure 2.1 Connecting Primary Power Leads  
Table 2.1 Recommended Input Conductor Size and  
Line Fuses  
Rated Input  
Input &  
GND  
100% Duty Cycle Rating  
Fuse Size  
Amps  
Conductor*  
CU/AWG  
No. 6  
Volts  
Am ps  
208  
220  
230  
400  
460  
575  
208  
220  
230  
400  
460  
575  
64  
61  
58  
33  
29  
23  
82  
77  
74  
43  
37  
30  
90  
80  
No. 6  
No. 6  
80  
453CC  
No. 10  
No. 10  
No. 12  
No. 4  
40  
40  
30  
120  
120  
120  
70  
No. 4  
No. 4  
553CC  
No. 8  
No. 8  
60  
No. 10  
50  
* Sized per National Code for 75o C rated copper conductors @ 40o  
Not more than three conductors in a raceway or cable. Local codes  
C
should be followed if they specify sizes other than those listed above.  
*
Double Link Provided  
( ) Connections for 50 Hz  
Figure 2.2 Input Terminal Board  
230/460 (220/400)V illustrated with voltage links in  
the factory supplied 460 volt configuration.  
11  
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SECTION 2  
INSTALLATION  
2.5 CONTROL CONNECTIONS  
D. Check all connections for proper tightness. En-  
sure all connections are correct and well insu-  
lated.  
Refer to Figure 2-3.  
2.5.1 Remote Control (Optional)  
E. Figure 2-2 illustrates the input voltage terminal  
board and the input voltage link connections.  
The particular voltages from which this power  
source may be operated are stated on the rating  
plate. The voltage links were factory set for  
highest voltage stated on the rating plate. If the  
power source is to be operated on another  
stated input voltage, the links must be reset for  
that particular input voltage. Always verify the  
input voltage and check the link arrangement  
regardless of factory setting. The voltage links  
are set up by re-configuring the copper link bars  
to the silk screened voltage designations for the  
desired voltage.  
This function is provided by an optional 14-pin recep-  
tacle (J2) located on the front panel directly below  
connector J1. It mates with a plug from any optional  
remote control device (see 1.4.2). This receptacle is  
operative only if the panel remote switches on the  
power source front panel are in the "Remote" position.  
2.5.2 Auxiliary 115 V AC Receptacle (Option)  
A 115 Vac receptacle is provided to supply power to  
accessories such as a water cooler, heated C02 regu-  
lator, or small hand tools. The receptacle is rated 115  
Vac / 10 amps.  
2.5.3 - 42V Circuit Breaker (CB1)  
2.4 OUTPUT WELDING CONNECTIONS  
(SECONDARY)  
The 42V resettable circuit breaker (CB1) protects the  
42 volt control circuitry against over current. (Table 52  
provides troubleshooting information).  
2.5.4 - 115V Circuit Breaker (CB2)  
Beforemakinganyconnectionstothepowersource  
output terminals, make sure that all primary input  
power to the machine is off.  
The 115V resettable circuit breaker (CB2) protects the  
115voltauxiliaryreceptacleandcontrolcircuitryagainst  
overcurrent.(Table5-2providestroubleshootinginfor-  
mation).  
The output terminals are located on the front panel  
(Figure 2.3). Two output terminals are provided. One  
NEGATIVE (-) terminal is located at the bottom right  
hand corner and the POSITIVE (+) terminal is located  
at the bottom left corner. The output cable connections  
will depend on the materials and welding process  
desired. Table 2-2 provides the recommended cable  
output sizes.  
Table 2-2. Output Cable Sizes (Secondary)  
Total Length (Feet) of Cable In Weld Circuit*  
Welding  
Current  
100  
50  
6
100  
4
150  
3
200  
2
250  
1/0  
150  
4
3
1
1/0  
2/0  
3/0  
4/0  
4/0  
2-2/0  
2/0  
200  
3
1
1/0  
2/0  
3/0  
4/0  
4/0  
3/0  
250  
2
1/0  
2/0  
3/0  
3/0  
4/0  
300  
1/0  
2/0  
3/0  
4/0  
400  
2-2/0  
2-3/0  
500  
*Total cable length includes work and electrode cables. Cable size is based on direct  
current, insulated copper conductors, 100 percent duty cycle and a voltage drop of 4 or  
less volts. The welding cable insulator must have a voltage rating that is high enough  
to withstand the open circuit voltage of the machine.  
12  
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SECTION 2  
INSTALLATION  
Figure 2.3 CONTROL CONNECTIONS  
SW  
POWER  
SWITCH  
63A  
CKT. BREAKERS,  
10A 32VDC, 250VAC  
600V  
-
+
OUTPUT RECEPTACLE 2.4  
13  
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SECTION 3  
OPERATION  
3.1.2 Arc Force Control.  
This control is used for stick welding only.The lower  
settings provide less short circuit current and a softer,  
morestablearc.Thehighersettingsprovidemoreshort  
circuit current and a forceful, more penetrating arc. For  
most Stick welding, set the knob at 3 or 4 and readjust  
up (forceful) or down (softer) as desired.  
Never operate the power source with the cover re  
moved. In addition to the safety hazards, lmproper  
cooling may cause damage to the components.  
Keep side panels closed when unit is energized.  
Weldinghelmet,gloves,andotherpersonalprotec-  
tion should always be worn when welding.  
3.1.3 Contactor, On/Remote Switch  
3.1 CONTROLS (See Figure 3.1)  
3.1.1 PowerSwitch(ON-OFF)/(I-O)  
The Contactor Control switch is located on the front  
panel of the power source. In the ON position, the solid  
state contactor is energized and output power is avail-  
able at the output terminals. The REMOTE position  
allows the solid state contactor to be controlled from a  
remote control.  
The power switch is located on the front panel of the  
power source. In the OFF ("0") position, the unit is  
shutdown however, power is still present at the switch  
itself. To totally shut down the power source, power  
must be disconnected at the line disconnect switch or  
the fuse box.  
3.1.4 Current Panel/Remote Switch  
With this switch in the PANEL position, output current  
iscontrolledbyadjustingthepotentiometeronthefront  
panel to the desired output. In the REMOTE position,  
outputiscontrolledusinganoptionalremotecontrolvia  
receptacle J2.  
With the switch in the ON ("I") position, power is  
provided to the main transformer and the low voltage  
control circuitry.  
3.1.1.1 Power Indicator  
3.1.5 Current Control  
This white light will indicate that the power switch is in  
theONpositionandpowerhasbeenappliedtothemain  
transformer and low voltage circuitry.  
This control allows the operator to adjust the output  
current. Placing the Panel/Remote switch in the RE-  
MOTE position disables the current control on the front  
panel.  
3.1.5  
3.1.1.1  
3.1.6  
3.1.2  
3.1.8  
3.1.3  
3.1.4  
3.1.7  
3.1.1  
Figure 3.1 Control Locations (453cc illustrated)  
14  
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SECTION 3  
OPERATION  
3.1.6 Over Temperature Indicator (Temp)  
B. Place the Power ON-OFF switch to the ON  
position or close the main(wall) disconnect  
switch.  
Thisamberlightwillindicatewhenaninternaloverheat-  
ing condition has occurred and one of the thermal  
switches has opened. User control of the solid state  
contactor will be interrupted and power source output  
will shut down to protect critical components. Once  
cooled to a safe temperature, the thermal switch will  
automatically reset and output control will be restored.  
C. Adjust the current control on the power source  
to the approximate desired welding current.  
D. If stick welding, set the Arc Force control at 3 or  
4onthedialandreadjustasnecessarytoobtain  
a softer or harder welding arc.  
3.1.7 Voltmeter and Ammeter  
For air gouging or Tig welding, set Arc Force  
control at zero (0).  
A digital voltmeter and ammeter provides an accurate  
indication of dc output voltage and current.  
E. If using a remote current control, such as HC-  
3B, place current and contactor switches in  
REMOTE positions. Notethatthecurrentrange  
will be limited to the maximum setting on the  
power source's current control dial.  
3.1.8 Fault Indicator  
IfanoptionalExternalGroundConductorProtectionKit  
was installed, this red light, when lit, will indicate that  
current was flowing through the external ground con-  
ductor. The power source output termirals are  
deenergized and the fault must be corrected before  
resuming operation.  
Ifnotusingremotecurrentcontrol,placecurrent  
switch to PANEL and contactor switch to ON.  
F. Place the Power ON-OFF switch to the ON  
position.  
3.2 OPERATION SET-UP  
G. To preset the approximate welding current, pro-  
ceed as follows:  
Prior to performing the steps below, open the wall  
disconnectswitchorremovethefusefromthefusebox  
to electrically isolate the power source.  
1. Connect the electrode holder to the  
workpiece to create short.  
2. Place the contactor switch to the ON posi-  
tion.  
ELECTRICSHOCKCANKILL!"MachineryLockout  
Procedures" should be employed. If it is not pos-  
sible to use padlocks, attach a red tag to the line  
disconnect switch (or fuse box) warning others  
that the circuit is being worked on.  
3. Set the Arc Force control to the minimum  
position.  
4. Place the Power On-Off switch to the ON  
position.  
5. By observing the digital ammeter,adjust  
Current Control to the desired current set-  
ting.  
3.2.1 Stick Welding (SMAW) Air Carbon Arc Goug-  
ing (ACAG) and Scratch Start Tig Welding  
(GTAW)  
A. If stick welding or arc gouging, connect work  
cable to the workpiece and to the negative (-)  
terminal of the power source. Connect torch  
cable to the positive (+) terminal of the power  
source.  
6. Place Power On-Off switch back to OFF  
7. Then remove the holder from the work-  
place.  
H. After setting the desired current and if using  
remote, turn switch back to REMOTE.  
If Tig welding, connect work cable to the  
workpiece and to the positive (+) terminal of the  
power source. Connect Tig torch cable to the  
negative(-) terminal of the power source.  
I. You are now ready to begin welding.  
3.2.2 Mig Spray Am (GMAW) and Flux Cored  
(FCAW) Welding with "Off the Are" Wire  
Feeder.  
Refer to wire feeder instruction manual for set-up and  
operating procedures.  
15  
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SECTION 4  
MAINTENANCE  
4.1 GENERAL  
4.3.1 Fan Motor  
Keep the fan motor free of accumulated dust and dirt.  
4.3.2 Transformer  
If this power source does not operate properly,  
stopworkimmediatelyandinvestigatethecauseof  
the malfunction. Maintenance work must be per-  
formed by an experienced person, and electrical  
work by a trained electrician. Do not permit un-  
trained persons to inspect, clean, or repair this  
power source. Use only recommended replace-  
ment parts.  
Other than periodically cleaning the dust and dirt from  
the transformer, no maintenance is required. Ensure  
that only clean, dry, low pressure air is used.  
4.3.3 Control Circuits  
These circuits are protected by two 10 amp circuit  
breakers mounted in the front panel. If these open, the  
contactor will not operate.  
4.3.4 Over Temperature Protection  
Ifthepowersourcereachesanabnormallyhighinternal  
temperature,thethermalprotectionwilldeenergizethe  
contactor circuit, shutting down the power source but  
leaving the cooling fan on. After the power source has  
cooled to a safe level, the thermal protection will auto-  
matically reset. While deenerigized, the contactor can  
not be operated.  
ELECTRICSHOCKCANKILL!"MachineryLockout  
Procedures" should be employed. If it is not pos-  
sible to use padlocks, attach a red tag to the line  
disconnect switch (or fuse box) warning others  
that the circuit is being worked on. Placing the  
powerswitchintheoffpositiondoesnotremoveall  
power from inside the power source.  
4.3.5 Digital Voltmeter/Ammeter Calibration  
4.2 CLEANING  
To verify the accuracy of the digital voltmeter/ammeter  
combination,thefollowingprocedurecanbeperformed  
periodically:  
Periodically, remove the cover from the power source  
and blow accumulated dust and dirt from the air pas-  
sages and interior components by using clean low  
pressure air. The frequency cleaning is required de-  
pendsupontheenvironmentinwhichthepowersource  
is used.  
1 . Place the Panel/Remote switch in Panel position.  
2. Disconnectcablesfromtheoutputterminalsand  
then connect an accurate DC voltmeter to the  
output terminals.  
It is imperative that all air passages be kept as clean as  
possible in order to allow adequate air flow to provide  
proper cooling.  
3. Openthefrontcontrolpanelbyremovingthetwo  
mounting screws from the upper corners. Lo-  
cate the J9 jumper plug on the control pc board  
and remove the plug. The J9 jumper plug is  
located just left of the meter pc board ribbon  
cable connection plug J10.  
After cleaning with low pressure air, check for and  
tighten any loose hardware, including all electrical  
connections. Check for frayed and/or cracked insula-  
tion on all power cables and replace if necessary.  
4. Place the Contactor switch in the On position  
5. Withtheprimaryinputpoweron,turntheCurrent  
control knob until you get 25V on the DC voltme-  
ter. Comparethereadingwiththereadingonthe  
digital voltmeter on the front panel.  
Failure to replace worn or damaged cables may  
result in a bare cable touching a grounded object.  
The resulting electrical arc may injure unprotected  
eyes and will present a serious fire hazard. Body  
contact with a bare cable, connector, or conductor  
may result in severe electrical shock, causing seri-  
ous burns or death.  
6. If there is a difference in the voltage readings,  
remove meter board from its four mounting  
posts, and adjust the trimpot (R13) on the meter  
board with a small screwdriver until the digital  
meter reading matches the DC voltmeter read-  
ing. When satisfied, reassemble meter board,  
reconnecting J9 jumper plug, and reassemble  
front control panel.  
4.3 INSPECTION AND SERVICE  
Keep the power source dry, free of oil and grease, and  
protected at all times from damage by hot metal and  
sparks.  
16  
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SECTION 5  
TROUBLESHOOTING  
5.1 GENERAL  
Remove the jumper from the gate. The meter  
reading should increase (3050 ohms).  
B. Replacing the SCRs.  
DISCONNECT primary power at wall switch, or  
circuit breaker, before attempting inspection or  
work inside the power source.  
IMPORTANT  
1. When replacing SCR’s, make sure mounting  
surfaces are clean. Using Alcoa No. 2 EJC  
Electrical Joint Compound or an equivalent,  
apply a thin coat to the SCR mounting surface  
and positively locate in place on the heatsinks.  
Placetheclampinpositionwiththeboltsthrough  
the holes in the heatsinks and proceed as fol-  
lows:  
If the power source is operating improperly, the follow-  
ing troubleshooting information may be used to locate  
the source of the trouble.  
Checktheproblemagainstthesymptomsinthefollow-  
ing troubleshooting guide (Table 5-2.) The remedy for  
theproblemmaybequitesimple.Ifthecausecannotbe  
quickly located, open up the unit and perform a simple  
visual inspection of all the components and wiring.  
Checkforproperterminalconnections,looseorburned  
wiring or components, blown fuses, bulged or leaking  
capacitors, or any other sign of damage or discolora-  
tion.  
2. Tighten the bolts evenly until finger tight noting  
that the nuts are not rotating.  
3. Tighten the bolts 3/4 turn plus an 1/8 turn using  
a socket wrench on the bolt heads and rotating  
onlyin1/4turnincrementsplus1/8turnalternat-  
ingbetweentheboltsnotingthatthenutsarenot  
rotating.  
5.2 TESTING AND REPLACING BRIDGE ASSEM-  
BLY COMPONENTS  
5.3 PCB VOLTAGE TESTS  
The SCRs used in the power source are devices which  
allowcurrenttoflowinonlyonedirection.TheSCRsare  
designed to provide long trouble-free operation; how-  
ever, should a failure occur, they may require replace-  
ment.  
Electrical service and repair should be attempted  
only by a trained electrician.  
A. Testing SCRs.  
WhenmakingPCBvoltagemeasurements, refertothe  
schematic diagram. All voltage readings are taken with  
thefrontaccesspanelopenandthepowerswitchON”.  
1. Remove top and right side panel from the power  
source.  
2. Locate the main rectifier assembly containing  
the SCRs.  
Table 5.1 SCR Voltages (Output)  
3. Electrically isolate main bridge assembly by  
disconnecting resistor R5.  
FROM  
P8-5  
TO  
READING  
+10 V dc  
OTB+  
OTB+  
4. With the ohmmeter on RX1 scale, place the  
positive lead on the anode (end of SCR with  
screw threads) and the negative lead on the  
cathode (positive output terminal on the front  
panel). The meter should read minimum of 5  
megohms.  
P8-7  
0-10 V dc*  
P6-6 (SCRI)  
P6-5 (SCR2)  
P6-4 (SCR3)  
P6-3 (SCR4)  
P6-2 (SCR5)  
P6-1 (SCR6)  
5. Reverse leads and check each SCR. All read-  
ings should again show high resistance. The  
SCRs are bad if they show low resistance in  
either direction.  
OTB+  
.3 V dc with  
contactor on  
* Varies with setting of VCP (R1)  
6. Check the gate circuit on the SCRs by installing  
a jumper from the gate lead to the anode of the  
SCR. The meter should read less than 5 ohms.  
17  
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SECTION 5  
TROUBLESHOOTING  
CONDITION  
ACTION  
Unit Inoperative  
A. No input power. Check main line (user's) switch fuses -- replace if needed.  
B. Poor or improper input (terminal board) connections.  
C. Defective on/off switch on front panel -- replace.  
D. Main transformer overheating. Also check for proper cooling, proper primaryhookup,  
or shorted turn on secondary.  
E. Fan motor not operating -- check motor and leads.  
F. Gound fault indicator "ON". - Check for cause and correct. Turn power switch "OFF"  
then "ON" to reset.  
G
Loss of primaryphase. Check that LED on control PCB is lit. If not, find & replace  
defective fuse.  
No Output - Fan  
Running  
A. Poor or improper electrical input -- check input connections on TB.  
B. Poor connections at output terminals/work station -- check, tighten or replace.  
C. Main transformer overheating -- thermal switches tripped due to restricted cooling air.  
Temperature light on front panel will be lit. Let unit cool down,  
D. Solid-state breaker tripped due to current overload.  
E. PC board defective or loose PC board connector(s) -- if loose, reinsert; if defective,  
replace.  
Limited Output or Low  
Open-Circuit Voltage  
A. Input voltage jumper links on terminal board improperlyset -- check for proper voltage.  
Poor output connections. Take apart, clean, and reassemble.  
B. Unit may be single phasing -- check incoming power for three phases.  
C. Panel-Remote switch in Remote position and remote voltage pot disabled.  
A. Welding cable size too small -- use correct cables.  
Erratic Weld Current  
B. Loose welding cable connection (will usually get hot) -- tighten all connections.  
C. Improper wire feeder setup.  
D. Defective SCR in bridge rectifier.  
E. PC board defective -- replace.  
High Output, No  
A. PC board defective or loose -- reset and/or replace board.  
Voltage Control  
No 115 Volt ac Output  
A. Circuit breaker tripped. Check 42VCB1 and 115VCB2 -- Reset.  
Line Fuse Blows When A. Shorted SCR in Main Bridge -- replace.  
Power Source is First  
Turned On  
18  
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SECTION 6  
REPLACEMENT PARTS  
6.1 GENERAL  
Replacement parts may be ordered from your ESAB  
distributor. For a list of Authorized Distributors in your  
area, contact ESAB at 1-800-ESAB-123.  
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.  
ForyourconvenienceanESABCommunicationGuide  
listing important contact phone numbers has been  
printed on the rear cover of this book.  
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.  
19  
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SECTION 6  
REPLACEMENT PARTS  
453cc-553cc View 1 - Front  
20  
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SECTION 6  
REPLACEMENT PARTS  
453cc-553cc View 2 - Top Panel  
21  
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SECTION 6  
REPLACEMENT PARTS  
453cc-553cc View 3 - Angled Front  
22  
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SECTION 6  
REPLACEMENT PARTS  
453cc-553cc View 4 - Rear  
23  
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SECTION 6  
REPLACEMENT PARTS  
453cc-553cc View 5 - Internal Rear View  
24  
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SECTION 6  
REPLACEMENT PARTS  
453cc-553cc View 6 - Internal Front View  
25  
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SECTION 6  
REPLACEMENT PARTS  
26  
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SECTION 6  
REPLACEMENT PARTS  
27  
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SECTION 6  
REPLACEMENT PARTS  
28  
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SECTION 6  
REPLACEMENT PARTS  
Bill of Materials  
453cc/553cc DC Welding Power Source  
ITEM  
NO.  
PART OR  
CODE NO.  
QTY.  
DESCRIPTION  
SYMBOL  
1
2
3
4
5
954838  
954839  
836121  
836173  
838127  
1
1
1
1
1
1
2
6
2
2
1
2
1
1
1
2
1
1
3
1
3
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
LABEL SUBARC STICK  
LABEL MIG  
PCB DIGITAL METER  
BLADE FAN 14"  
PCB CONTROL  
CONTROL  
SW TGGL SPDT 2 POS 15A 125V  
STRAP TERMINAL  
TERM AY  
CKT BREAKER 10A 32VDC 250VAC  
RELIEF STRAIN 2.00  
PCB2  
PCB1  
PCB  
S2,3  
838128  
6
7
8
8634515  
8672065  
8678025  
8950122  
8950219  
8950711  
8950768  
836107  
9
CB1,2  
10  
11  
12  
13  
SW THERMAL 194F  
TS1,3  
D1  
S1  
DIODE FWD 300V 300A  
SW PWR DISC 63A 600V  
SW PWR DISC 100A 600V  
SW SEAL BLACK  
LABEL DANGER HIGH VOLTAGE  
MOTOR FAN 1/3 HP 1625RPM  
SCR ASSY  
8950945  
8951474  
8954008  
82062334  
80558001024  
34149  
34916  
36091  
136110  
32236  
36092  
36635  
37861GY  
37862GY  
37863YL  
37864YL  
37865  
37867GY  
37868  
37869  
S1  
14  
15  
16  
17  
18  
19  
20  
M1  
SCR1-6  
CLIP ANNEALED  
BUSBAR TAB  
BOARD INPUT TERMINAL 230/460V  
BOARD INPUT TERMINAL 230/460V/575  
BOARD INPUT TERMINAL 220/400V  
CABLE DIGITAL METER PCB  
CLIP SKID  
TB1  
TB1  
TB1  
P10  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
BASE  
PANEL FRONT BOTTOM  
PANEL RIGHT SIDE  
PANEL LEFT SIDE  
CONTROL PANEL  
PANEL REAR  
BRIDGE BUSBAR  
HIGH TAP INDUCTOR BUSBAR  
LOW TAP INDUCTOR BUSBAR  
SHUNT  
37870  
0558001037  
37872  
SH  
INSULATOR KYDEX  
836430  
836626  
836622  
836610  
836684  
836687  
XFMR MAIN 230/460 453CC  
XFMR MAIN 230/460/575V 453CC  
XFMR MAIN 220/400 453CC  
XFMR MAIN 230/460 553CC  
XFMR MAIN 230/460/575V 553CC1T1  
XFMR MAIN 220/400 553CC1T1  
INDUCTOR  
SCHEMATIC DIAG 453CC/553CC 50/60HZ  
WIRING DIAG PRI 3 PH AFRAME 453CC/553CC  
WIRING DIAG SECONDARY 453CC/553CC 50/60HZ  
KIT WIRE PRI 453CC  
T1  
T1  
T1  
T1  
35  
36  
37  
38  
39  
C-836426  
0558001568  
0558001569  
0558001570  
0558001329  
0558001879  
0558001330  
L1  
KIT WIRE PRIMARY 553CC  
KIT WIRE SEC 453CC/553CC  
40  
29  
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SECTION 6  
REPLACEMENT PARTS  
Bill of Materials  
453cc/553 DC Welding Power Source  
ITEM  
NO.  
PART OR  
CODE NO.  
QTY.  
DESCRIPTION  
SYMBOL  
41  
42  
43  
44  
45  
631507  
634220  
647361  
672786  
950167  
950905  
951504  
1
952068  
952070  
952071  
952072  
952073  
952081  
952155  
1
954046  
954506  
954911  
954910  
954855  
954856  
954857  
954858  
954859  
954860  
954912  
2091514  
2091558  
AR  
2
1
1
1
1
1
TYWRAP MEDIUM  
TAB  
GND1 LUG TERMINAL 2-8 WIRE 1/4 STUD  
BOLT EYE .75-10 X 2.00  
GROMMET RUB 1.12 ID X 1.50 GD X .06 W  
TERM IL/M .250 TS X 14-16 AWG  
J5 PLUG HOUSING 15 POS  
46  
47  
52046979  
50  
CONNECTOR  
20  
AWG  
3
PIN  
P1  
1
1
1
3
1
1
1
MTA-156 COVER 3 PIN  
CONNECTOR 20 AWC 7 PIN  
MTA-156 COVER 7 PIN  
CONNECTOR 20 AWG 12 PIN  
TERM BLOCK 12 POS  
CONNECTOR 20 AWG 10 PIN  
PLASTIC MARKER (1-12)  
42.00  
51  
52  
53  
54  
55  
56  
P5  
P3,4,7  
TB2  
P8  
52254939  
60  
PALLET  
1
1
1
1
1
1
1
1
1
1
1
1
1
TAG WARRANTY ESAB  
LABEL ISO 9002  
OVERLAY 453CC  
62  
63  
OVERLAY 553CC  
64  
LABEL RATING 453CC 230/460  
LABEL RATING 553CC 230/460  
LABEL RATING 453CC 230/460/575  
LABEL RATING 553CC 230/460/575  
LABEL RATING 453CC 220/400  
LABEL RATING 553CC 220/400  
LABEL SCHEM 230/460V & 220/400 & 575  
LABEL WARNING WELD AND CUT  
LABEL GND BLK .50 X 1.38  
65  
66  
67  
6913730632  
1
POT  
LIN  
10K  
2W  
.88L  
R1  
70  
71  
72  
73  
74  
75  
76  
77  
78  
13730763  
13731781  
13732431  
13732733  
13734588  
13735311  
13735312  
13735508  
17300020  
22993477  
61212092  
65509506  
71200732  
73585980  
79900317  
90863007  
90863202  
90863203  
99510047  
99511578  
1
1
3
1
2
1
1
1
1
AR  
AR  
AR  
AR  
AR  
AR  
AR  
AR  
AR  
AR  
AR  
NAME PLATE CODE SERIAL STOCK  
MTA-156 COVER 10 PIN  
MTA-156 COVER 12 PIN  
LABEL FOR INSTALL USE COPPER WIRE ONLY  
LOGO ESAB CLEAR  
CONNECTOR 20 AWG 6 PIN  
MTA-156 COVER 6 PIN  
SHROUD FAN  
RES RW FIXD ST 300W 10% 20.00  
RUBBER .188 X .500  
BOLT LAG 1/4-20 X 1.50 LG  
RIV BLD AL 1/8 GRIP .251-.312  
ADH SI-RBR CLEAR  
CNPD ELEC JOINT ALCOA 2 EJC  
INSULATOR SEALING 3.75 X .125  
TUBING HEAT SHRINK .250 ID BLK  
TUBING HEAT SHRINK 3/4 ID CLEAR  
TUBING HEAT SHRINK 5/8 ID CLEAR  
VINYL SLEEVING 7/8  
P6  
R5  
79  
80  
122  
123  
124  
125  
126  
127  
128  
129  
130  
SNAP IN TIE BASE .218  
30  
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SECTION 6  
REPLACEMENT PARTS  
Bill of Materials  
453cc/553cc DC Welding Power Source  
ITEM  
NO.  
PART OR  
CODE NO.  
QTY.  
DESCRIPTION  
SYMBOL  
133  
134  
135  
136  
137  
138  
139  
140  
141  
142  
99512240  
99512558  
1
2
1
1
3
3
3
1
1
LABEL CAUTION LIFT EYE  
BRACKET RESISTOR #18  
TERMINAL BLOCK 3 POS  
BOX PCB GRAY  
PLUG HOUSING 2 POS  
SEAL WIRE 2 POS  
SEAL INTER  
CAP 9 POS  
INSULATOR STAND OFF  
KNOB 1.57 DIA  
0558001010  
0558001011  
0558001012  
0558001014  
0558001015  
0558001016  
0558001018  
0558001019  
TB3  
J6  
1
143 0558001032GY  
1
1
AR  
AR  
1
4
1
1
1
1
1
1
1
AR  
AR  
1
3
1
PANEL FRONT TOP  
INSULATOR  
TYWRAP LARGE  
TYWRAP SMALL  
BRACKET FAN  
LEG AFRAME  
BAIL LIFTING  
BRACKET TERMINAL BOARD MTG  
BAFFLE  
BAFFLE  
BLANKING PLATE  
KNOB 01.37 A  
PANEL TOP  
TUBING INSULATING VINYL 105' C RATING 9" LG  
TUBING HEAT SHRINKABLE 6" LG  
CE FILTER ASSY  
STAND OFF 1/4-20 X .75  
HINGE ACCESS  
144  
145  
146  
147  
148  
149  
150  
151  
0558001038  
180W66  
180W68  
36043GY  
36048GY  
36049GY  
36070GY  
36642GY  
36140GY  
37902GY  
0558001818  
37866YL  
152  
153  
154  
155  
156  
157  
159  
160  
161  
162  
166  
167  
90861100  
90863005  
838100  
FN1  
R2  
952223  
0558001331G  
0558001332G  
A-954864  
A-892W64  
10981006  
1
1
1
AR  
PANEL ACCESS GRAY  
LABEL THREE PHASE  
POT LIN 100K 2W  
SOLDER 60/40 ROSIN  
31  
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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  
Eastern Distribution Center  
Telephone: (800)362-7080 / Fax: (800) 634-7548  
Central Distribution Center  
Telephone: (800)783-5360 / Fax: (800) 783-5362  
Western Distribution Center  
Telephone: (800) 235-4012/ Fax: (888) 586-4670  
B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693  
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: (843) 664-4452  
Part Numbers  
Performance Features Technical Specifications  
Technical Applications  
Hours: 8:00 AM to 5:00 PM EST  
Equipment Recommendations  
D. LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548  
Hours: 7:30 AM to 4:00 PM EST  
E. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4487 / Fax: (843) 664-5557  
Repair Estimates  
Repair Status  
Hours: 7:30 AM to 3:30 PM EST  
F. WELDING EQUIPMENT TRAINING:  
Telephone: (843)664-4428 / Fax: (843) 679-5864  
Training School Information and Registrations  
Hours: 7:30 AM to 4:00 PM EST  
Hours: 7:30 AM to 4:00 PM EST  
Hours: 7:30 AM to 5:00 PM EST  
G. WELDING PROCESS ASSISTANCE:  
Telephone: (800) ESAB-123 / Fax: (843) 664-4454  
H. TECHNICAL ASST. CONSUMABLES:  
Telephone : (800) 933-7070  
IF YOU DO NOT KNOW WHOM TO CALL  
Hours: 7:30 AM to 5:00 PM EST  
F-15-591-A  
2/2001 Printed in U.S.A.  
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