ESAB MultiPower 460 Pulse Bedienerhandbuch

0558004964 10/2005MultiPower 460 PulseDC Welding Power Source (Shipyard Model)INSTRUCTION MANUALESAB ITEM NO. 0558004922, MultiPower 460 Pulse - (2

10SECTION 1 SEGURIDAD 1. Asegúrese de que el chasis de la fuente de poder esté conectado a tierra através del sistema de electricidad prima

11SECTION 1 SEGURIDAD5. ADVERTENCIA-- Este producto cuando se uti-liza para soldaduras o cortes, produce humos o gases, los cuales contien

12SECTION 1 SEGURIDADSIGNIFICADO DE LOS SIMBOLOS -- Según usted avanza en la lectura de este folleto: Los Símbolos Sig-nifican ¡Atención! ¡Esté Alerta

13SECTION 1 SÉCURITÉ1.3 Safety - FrenchINCENDIES ET EXPLOSIONS -- La chaleur provenant des flammes ou de l'arc peut provoquer un incendie.

14SECTION 1 SÉCURITÉ3. Les soudeurs doivent suivre les procédures suivantes pour minimiser l'exposition aux champs électriques et magnétiques :

15SECTION 1 SÉCURITÉ1. Efforcez-vous de toujours confier les tâches d'installation, de dépannage et d'entretien à un personnel

16SECTION 1 SÉCURITÉSIGNIFICATION DES SYMBOLESCe symbole, utilisé partout dans ce manuel, signifie "Attention" ! Soyez vigilant ! Votre sécu

17SECTION 2 DESCRIPTION2.0. DescriptionThis manual has been prepared for use by an experienced operator. It provides information to familiarize t

18SECTION 2 DESCRIPTIONThe MultiPower 460 Pulse is a multi-process power source designed for Mig short circuiting, spray and pulse spray transfer (GM

19SECTION 2 DESCRIPTIONFigure 2-2. Control PanelC. Control Panel Description (Refer To Figures 2-2 & 2-3)1. Fault Lamp The RED fault light on th

This equipment will perform in conformity with the description thereof contained in this manual and accompa-nying labels and/or inserts when installed

20.045.040.0351/16.052WIRE TYPEWIRE DIAMETERPULSE SELECTIONEN-625 ERNiCrMo-3STAINLESSAL-4000AL-5000EN-60 ERNiCu-7METAL CORESTEELSTEELEN-67 ERCuNi05432

217. Preset ButtonPreset push button is used in conjunction with the VOLTAGE/CURRENT/TRIM knob to set the desired voltage / current. Pre-set switch is

22.045.040.0351/16.052WIRETYPEWIREDIAMETERPULSESELECTIONEN-625ERNiCrMo-3STAINLESSAL-4000AL-5000EN-60ERNiCu-7METALCORESTEELSTEELEN-67ERCuNi0549876Volta

23Figure 2-5. Remote Control PendantE. Optional Accessories1. Remote Control Pendant (P/N - 0558002871)This pendant (Figure 2-5) provides remote out

24SECTION 2 DESCRIPTION

25SECTION 3 INSTALLATION3.0. Installation A. LocationA proper installation site is necessary for the power source to provide dependable service.

26 ELECTRIC SHOCK CAN KILL! BEFORE MAKING ELECTRICAL INPUT CONNECTIONS TO THE POWER SOURCE, "MACHINERY LOCKOUT PROCEDU

27SECTION 3 INSTALLATIONThe primary power leads must be insulated copper conductors. Three power leads and one ground wire are re-quired. Either rub

28SECTION 3 INSTALLATIONELECTRIC SHOCK CAN KILL! BEFORE MAKING ELECTRICAL INPUT CONNECTIONS TO THE POWER SOURCE, "MACHINERY LOCKOUT

29SECTION 3 INSTALLATIONCHECK THE VOLTAGE LINKS FOR PROPER VOLTAGE ON THE INPUT TERMINAL BOARD BEFORE APPLYING PRIMARY POWER.Figure 3-4. In

TABLE OF CONTENTS1.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30SECTION 3 INSTALLATIONBEFORE MAKING ANY CONNECTIONS TO THE POWER SOURCE OUTPUT TERMINALS MAKE SURE THAT ALL PRIMARY INPUT POWER TO THE MACHINE IS

31SECTION 4 OPERATIONNever operate the power source with the covers removed. In addition to the safety hazards, improper cooling may cause da

32C. Tig Welding (Lift Start Tig)When the PROCESS switch is placed in the LIFT START TIG position, the MultiPower 460 Pulse is automatically set for

33Figure 4-2 Standard Stick Setup ProcedureBe sure to set the polarity to DCEP (Electrode Positive) by placing the Electrode Holder cable in the Posi

34SECTION 4 OPERATIONNOTEDue to the "Built-In" Arc Force in the stick mode, the actual current may be greater than the preset value. See R

35SECTION 4 OPERATIONFigure 4-5 Standard Mig Setup Procedure1324.045.040.0351/16.052WIRE TYPEWIRE DIAMETERPULSE SELECTIONEN-625 ERNiCrMo-3STAINLESSA

36.045.040.0351/16.052WIRE TYPEWIRE DIAMETERPULSE SELECTIONEN-625 ERNiCrMo-3STAINLESSAL-4000AL-5000EN-60 ERNiCu-7METAL CORESTEELSTEELEN-67 ERCuNi05432

37SECTION 4 OPERATIONTable 4-1. Wire Types, Diameter and Shield Gases for Pulse MigMaterial Type DiametersShielding Gas (AWS D

38SECTION 4 OPERATION1. Pulse Mig Arc StabilityMany variables can affect the arc stability of pulse MIG welding. Some examples are:Differences in shi

39SECTION 5 MAINTENANCEF. Over Temperature ProtectionIf the power source reaches an abnormally high internal temperature, the thermal protection will

4TABLE OF CONTENTS

40SECTION 5 MAINTENANCEWhat is ESD?A sudden transfer or discharge of static electricity from one object to another. ESD stands for Electrostatic Dis

41SECTION 5 MAINTENANCESince IGBT gates are insulated from any other conducting region, care should be taken to prevent static build up, which could

42SECTION 5 MAINTENANCEC2 E1E2C1G2E2Set the VOM to ohms then check for continuity between all the legs of the IGBT. No continuity should be measured

43SECTION 5 MAINTENANCEOnce the IGBT is turned on, remove the power source and the unit should stay on.C2 E1E2C1G2E2Short the gate leads (you can use

44SECTION 5 MAINTENANCEI. TroubleshootingIf the power source is operating improperly, the following troubleshooting information may be used to locate

45SECTION 5 MAINTENANCETable 5-1. Troubleshooting GuideCONDITION ACTIONUnit Inoperative No input power. Check main line (user’s) sw

46SECTION 5 MAINTENANCEFigure 5-2. READY/ON Light OFF Figure 5-3. Fan Does Not Run NOTE:Schematics and Wiring Diagrams on 11" x 17" paper a

47SECTION 5 MAINTENANCEFigure 5-4. No Weld Power (STICK Position)Figure 5-5. Meter Display is BlankNo weld power(Stick position)Power Light is OnVeri

48SECTION 5 MAINTENANCEFigure 5-7. Ammeter Displays 760AFigure 5-6. PRESET Does Not FunctionPreset does not function(unit welds)Does preset work when

49SECTION 5 MAINTENANCEFigure 5-8. Over Temperature Light is ONOver Templight is on Was the Duty Cycle exceeded?Allow time for machineto coolReplace

5SECTION 1 SAFETY PRECAUTIONS1.0 Safety Precautions1.1 Safety - EnglishWARNING: These Safety Precautions are for your protection. They summariz

50SECTION 5 MAINTENANCE

51SECTION 6 REPLACEMENT PARTS6.1 GeneralAlways provide the serial number of the unit on which the parts will be used. The serial number is stamped o

52SECTION 6 REPLACEMENT PARTS123,4568(behind control panel)7 QTY. ITEM CIRCUIT NO. REQ. NO. DESCRIPTION SYMBOL 1 1 952219 Outle

53 SECTION 6 REPLACEMENT PARTS QTY. ITEM CIRCUIT NO. REQ. NO. DESCRIPTION SYMBOL 1 1 2091514 Label Warning Arc Welding & Cu

54SECTION 6 REPLACEMENT PARTS62 1,5 QTY. ITEM CIRCUIT NO. REQ. NO. DESCRIPTION SYMBOL 1 1 634519 Switch Toggle 4PDT S6 2 1 055

55SECTION 6 REPLACEMENT PARTS12345 QTY. ITEM CIRCUIT NO. REQ. NO. DESCRIPTION SYMBOL 1 1 13732733 Label for Install Use COP Wir

56SECTION 6 REPLACEMENT PARTS QTY. ITEM NO. REQ. NO. DESCRIPTION SYMBOL 1 3 99511916 Diode Fwd 200V 250A D1, D3, D5

57SECTION 6 REPLACEMENT PARTS12543 QTY. ITEM NO. REQ. NO. DESCRIPTION SYMBOL 1 1 952938 SCR 480V 18A Panel MNT SSR1 2 1 951997

58SECTION 6 REPLACEMENT PARTS123, 4 QTY. ITEM NO. REQ. NO. DESCRIPTION SYMBOL 1 2 17280110 Res WW Fix'd ST 100W 5% 100.00 R

59REVISION HISTORYPreliminary release - 08/2004Released - 09/2004Added IGBT and diode test data in Section 5 and updated schematic package - 12 / 2004

6SECTION 1 SAFETY PRECAUTIONS 1. Be sure the power source frame (chassis) is con-nected to the ground system of the input power. 2. Connect the

0558004964 10/2005A. CUSTOMER SERVICE QUESTIONS: Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST Order Entry P

M2M3ESAB ASY 38211REV.12345612345678910123412345671357911131516141210864219168++++++++++14796328+++15V-15VCOMMON(+)VREF.(+)Earc/10WIRE SPEED REF.VOLTS

12645+DSGDGS.1.01H11AA1H11AA1100uf1K1KCT5RT6INV15REF14NIV16COMP3INV2NIV1DT4O.C.13C113C18E18E19GNDVcc712+1uf+1uf68.1K68.1K174K174K1.3K1.3K10K10K1uf+1K.

4.99KR164DO NOT LOAD : R164R164DO NOT LOAD : R164(-)E arc(-)E arc(+)E arc(+)E arcMAX.INDUCTANCEPRE-SETCURRENT SENSORCURRENT SENSORTO FAN RELAYTO FAN R

RA2RA2RA3RA3RA4RA4MCLRMCLRVSSVSSRBORBORB1RB1RB2RB2RB3RB3RA1RA1RA0RA0OSC1OSC1OSC2OSC2VDDVDDRB7RB7RB6RB6RB5RB5RB4RB4U1U1PIC16C711PIC16C711(99513603)(995

C11000uF+U3HPCL-22318VCCOUT7GND5+IN1-IN3C2220uF+R8R24.02KD11N4007J1-1D218VJ1-2D318VJ1-3D418VJ1-4D518VJ1-5J1-6U1MC7815CTIN1OUT3GND2R55.0D81N4148D91N414

7SECTION 1 SAFETY PRECAUTIONS5. WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known t

8SECTION 1 SAFETY PRECAUTIONS5. AWS C5.5 - "Recommended Practices for Gas Tung-sten Arc Welding“6. AWS C5.6 - "Recommended Practices for

9SECTION 1 SEGURIDAD1.2 Safety - SpanishADVERTENCIA: Estas Precauciones de Se-guridad son para su protección. Ellas hacen resumen de información pro