ESAB MultiPower 460 Pulse Bedienerhandbuch

F-15-721-A 05/2003Multipower 460PULSEDC WELDING POWER SOURCESINSTRUCTION MANUALESAB ITEM NO. 0558002877, Multipower 460PULSE - 230/460/575 vac, 3 ph.,

10levage, des câbles de grue ou divers cheminsélectriques.g. Empêchez l’apparition de toute humidité, notammentsur vos vêtements, à la surface de l’em

11 Multi-process, three phase power source de-signed for heavy duty Industrial DC weldingapplications. Use for High Performance Mig, Pulse Mig, FluxCo

12Options & Accessories:Remote Hand Control...0558002871This pendant provides remote output control and a contactorclosure

13Table 2-1. Specifications for Multipower 460PULSE2.0. GENERALBefore the Multipower 460PULSE power source is put into operation, thesafety section a

14The Multipower 460PULSE is a multi-process power source designed for Migshort circuiting, spray and pulse spray transfer (GMAW), flux core (FCAW), T

15Figure 2-3. Pulse Control PanelC. CONTROL PANEL DESCRIPTION (Refer to Figure 2-3 and 2-4)1. FAULT LAMPThe RED fault light on the Multipower 460PUL

165. VOLTAGE/CURRENT TRIMThe arc voltage is controlled with this knob when the WELD PROCESSselector switch is in the MIG position. The Mig arc voltag

17Figure 2-5. Multipower 460Main PowerOn/Off SwitchOutputConnectionsWire FeederConnectorRemote PendantConnectionContactor On/OffSwitchCircuit Breaker

182. WIRE FEEDER CONTROL RECEPTACLEThis 19-pin receptacle (J1) accepts the control cable from the wire feederand handles all the control signals neede

19Table 3-1. Recommended Sizes for InputConductors and Line Fuses*Sized per National Code for 80 °C rated copper conductors @ 30 °C ambient. Notmore

2These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principlesof operation and safe practices for arc welding a

201. The primary power leads must be insulated copper conductors. Threepower leads and one ground wire are required. Either rubber coveredcable or co

21SECTION 3 INSTALLATION5. Figures 3-3, 3-4 and 3-5 illustrate the input voltage terminal boards and the input voltage linkconnections. The particular

22Table 3-2. Output Cable Sizes (Secondary)* Total cable length includes work and electrode cables. Cable size is based on directcurrent, insulated c

234.0. OPERATIONA. WIRE FEEDER COMPATIBILITYThe Multipower 460PULSE power source can be used with several ESAB 42 voltwire feeders. The model wire

24NOTE"OFF THE ARC" Wire Feeders can useeither MIG (CV) or STICK (CC) ProcessSelection. Place the contactor toggleswitch on the accesssory p

25F. TIG WELDINGWhen the PROCESS switch is placed in the TIG position, the Multipower460PULSE is automatically set for CC (constant current) welding

26When the WELD PROCESS switch ismoved to the TIG or STICK position,electrode becomes electrically“HOT”. Do not allow the electrode tocontact ground

27When the WELD PROCESS switch ismoved to the TIG or STICK position,electrode becomes electrically“HOT”. Do not allow the electrodeto contact groun

28The preprogrammed wire types, wire diameters and shielding gases arelisted in Table 4-2.The TRIM allows the operator to fine tune the pulse arc leng

29The following procedure assumes the wire feed and voltage adjustments will bemade from the wire feeder front panel and wire and gas have been instal

3TABLE OF CONTENTSSECTION TITLE PAGESECTION 1 SAFETY ...

30B. PULSE PROCESS CONTROL1. Use a tip-to-work distance (TTW) of 3/8" to 5/8". This refers to thedistance between the end of the Mig gun co

31The selectable pulse parameters are any combination of WIRE TYPE or WIREDIAMETER selected using the PULSE SELECTION switches. Not all combina-tions

32F. PULSE PARAMETERSTables 4-3 through 4-8 list the approximate pulse weld parameters for each materialand diameter available. These are provided fo

33Table 4-3 Multipower 460PULSE Carbon Steel Data Table.035 Steel .040 SteelWFS Range (IPM)Pulse Peak (Amps)Pulse Width (ms)Pulse Back-ground (Amp

34Table 4-4 Multipower 460PULSE Stainless Steel Data TableWFS Range (IPM)Pulse Peak (Amps)Pulse Width (ms)Pulse Back-ground (Amps)Pulse Frequency

35Table 4-5 Multipower 460PULSE 4000 AluminumWFS Range (IPM)Pulse Peak (Amps)Pulse Width (ms)Pulse Back- ground (Amps)Pulse Frequency (Hz)WFS Range

36Table 4-6 Multipower 460PULSE 5000 Aluminuml Data TableWFS Range (IPM)Pulse Peak (Amps)Pulse Width (ms)Pulse Back- ground (Amps)Pulse Frequency (

37Table 4-7 Multipower 460PULSE Metal Core Carbon Steel Data Table.035 Metal Core CS .040 Metal Core CSWFS Range (IPM)Pulse Peak (Amps)Pulse Width (

38Table 4-8 Multipower 460PULSE Metal Core Stainless Steel Data Table.035 Metal Core SS .040 Metal Core SSWFS Range (IPM)Pulse Peak (Amps)Pulse Widt

39SECTION 5MAINTENANCEIf this power source does not op-erate properly, stop work imme-diately and investigate the causeof the malfunction. Maintenanc

4TABLE OF CONTENTS

40SECTION 5MAINTENANCE

41TROUBLESHOOTINGSECTION 6DISCONNECT primary power at wallswitch, or circuit breaker, before at-tempting inspection or work inside thepower source.6.0

42Multipower 460PULSE Wiring Diagram0558003034-BSECTION 6 TROUBLESHOOTING

43Multipower 460PULSE Schematic Diagram (Sheet 1 of 3)0558003064-ASECTION 6 TROUBLESHOOTING

44Multipower 460PULSE Schematic Diagram (Sheet 2 of 3)0558003064-ASECTION 6 TROUBLESHOOTING

45Multipower 460PULSE Schematic Diagram (Sheet 3 of 3)0558003064-ASECTION 6 TROUBLESHOOTING

46SECTION 6 TROUBLESHOOTING

47A. REPLACEMENT PARTSReplacement Parts are illustrated on the following figures. When ordering re-placement parts, order by part number and part nam

48124, 5678, 9151112, 131714Figure 7-1 - Front View, Multipower 460PULSE310161819SECTION 7 REPLACEMENT PARTS

49SECTION 7 REPLACEMENT PARTSQTY. ITEM CIRCUITNO. REQ. NO. DESCRIPTION SYMBOL1 2 678025 Terminal Assembly2 1 952219 Outlet 110V (Square)3 1 952937 Co

5WARNING: These Safety Precautions are foryour protection. They summarize precaution-ary information from the references listed inAdditional Safety In

50123457QTY. ITEMNO. REQ. NO. DESCRIPTION SYMBOL1 3 99511916 Diode Fwd 200V 250A2 3 99511915 Diode Rev 200V 250A3 1 954864 Label 3 Pha

514621SECTION 7 REPLACEMENT PARTS

521234QTY. ITEMNO. REQ. NO. DESCRIPTION SYMBOL1 2 17280110 Res WW Fix'd ST 100W 5% 100.00 R3, R42 1 0558002712 Transformer 230/460/575V T13 12 6

531234QTY. ITEM CIRCUITNO. REQ. NO. DESCRIPTION SYMBOL1 1 1312733 Label for Install Use COP Wire2 1 950219 Relief Strain 2" (Non-enclosed)3 1 672

54126543QTY. ITEMNO. REQ. NO. DESCRIPTION SYMBOL1 1 952938 SCR 480V 18A Panel MNT2 1 951997 Transducer Current SH13 1 951085 SW THML D/T 176 15A 120V

551265437SECTION 7 REPLACEMENT PARTS

56 NOTES

57 NOTES

58 NOTES

59 REVISION HISTORY1. 05/2003 - General editorial changes.

6FUMES AND GASES -- Fumes andgases, can cause discomfort or harm,particularly in confined spaces. Donot breathe fumes and gases. Shield-ing gases can

F-15-721-A 05/2003IF YOU DO NOT KNOW WHOM TO CALLTelephone: (800) ESAB-123/ Fax: (843) 664-4452/ Web:http://www.esab.comHours: 7:30 AM to 5:00 PM ESTA

7ADVERTENCIA: Estas Precauciones deSeguridad son para su protección. Ellas hacenresumen de información proveniente de lasreferencias listadas en la se

8HUMO Y GASES -- El humo y los gases,pueden causar malestar o daño,particularmente en espacios sin ventilación.No inhale el humo o gases. El gas de

9a. Éloigner suffisamment tous les matériaux combus-tibles du secteur où l’on exécute des soudures ou descoupes à l’arc, à moins de les recouvrir com