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.
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 2
INSTALLATION
Figure 2.3 CONTROL CONNECTIONS
SW
POWER
SWITCH
63A
CKT. BREAKERS,
10A 32VDC, 250VAC
600V
-
+
OUTPUT RECEPTACLE 2.4
13
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
thefrontaccesspanelopenandthepowerswitch“ON”.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 6
REPLACEMENT PARTS
453cc-553cc View 1 - Front
20
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 6
REPLACEMENT PARTS
453cc-553cc View 2 - Top Panel
21
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 6
REPLACEMENT PARTS
453cc-553cc View 3 - Angled Front
22
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 6
REPLACEMENT PARTS
453cc-553cc View 4 - Rear
23
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 6
REPLACEMENT PARTS
453cc-553cc View 5 - Internal Rear View
24
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 6
REPLACEMENT PARTS
453cc-553cc View 6 - Internal Front View
25
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 6
REPLACEMENT PARTS
26
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 6
REPLACEMENT PARTS
27
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 6
REPLACEMENT PARTS
28
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
Download from Www.Somanuals.com. All Manuals Search And Download.
|