Multipower 460PULSE DC WELDING POWER SOURCES INSTRUCTION MANUAL ESAB ITEM NO. 0558002877, Multipower 460PULSE - 230/460/575 vac, 3 ph.
BE SURE THIS INFORMATION REACHES THE OPERATOR. YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER. These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, "Precautions and Safe Practices for Arc Welding, Cutting, and Gouging," Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this equipment.
TABLE OF CONTENTS SECTION TITLE PAGE SECTION 1 SAFETY .............................................................................................................................................. 5 SECTION 2 2.0 2.1 DESCRIPTION .................................................................................................................................... 11 General .....................................................................................................................................
TABLE OF CONTENTS 4
SECTION 1 WARNING: These Safety Precautions are for your protection. They summarize precautionary information from the references listed in Additional Safety Information section. Before performing any installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.
SECTION 1 SAFETY PRECAUTIONS EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death. Therefore: FUMES AND GASES -- Fumes and gases, can cause discomfort or harm, particularly in confined spaces. Do not breathe fumes and gases. Shielding gases can cause asphyxiation. Therefore: 1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do not perform any electrical work unless you are qualified to perform such work. 2.
SECTION 1 ADVERTENCIA: Estas Precauciones de Seguridad son para su protección. Ellas hacen resumen de información proveniente de las referencias listadas en la sección "Información Adicional Sobre La Seguridad". Antes de hacer cualquier instalación o procedimiento de operación , asegúrese de leer y seguir las precauciones de seguridad listadas a continuación así como también todo manual, hoja de datos de seguridad del material, calcomanias, etc.
SECTION 1 PRECAUCION DE SEGURIDAD HUMO 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 protección puede causar falta de oxígeno. Por lo tanto: 2. 3. 4. 5. 1. Siempre provea ventilación adecuada en el área de trabajo por medio natural o mecánico.
SECTION 1 PRÉCAUTIONS DE SÉCURITÉ a. Éloigner suffisamment tous les matériaux combustibles du secteur où l’on exécute des soudures ou des coupes à l’arc, à moins de les recouvrir complètement d’une bâche non-inflammable. Ce type de matériaux comprend notamment le bois, les vêtements, la sciure, l’essence, le kérosène, les peintures, les solvants, le gaz naturel, l’acétylène, le propane et autres substances combustibles semblables. b.
SECTION 1 g. 4. a. b. c. d. e. f. 5. PRÉCAUTIONS DE SÉCURITÉ levage, des câbles de grue ou divers chemins électriques. 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.
SECTION 2 DESCRIPTION ■ Multi-process, three phase power source designed for heavy duty Industrial DC welding applications. ■ Use for High Performance Mig, Pulse Mig, Flux Cored wire, Stick electrode welding, Tig and Air Carbon Arc Gouging ■ SuperSwitch Technology design, provides superior inverter like performance in the welding arc while providing SCR like reliability. ■ Variable inductance for fine tuning of the arc characteristics in short arc welding.
SECTION 2 DESCRIPTION Options & Accessories: Remote Hand Control...........................0558002871 This pendant provides remote output control and a contactor closure switch to close the contactor making the output terminals “hot”. The PANEL/REMOTE switch on the Multipower 460PULSE control panel must be placed in the REMOTE position when using this accessory. The pendant has the capability to change weld processes and is designed to work with wire feeders without remote voltage control. TR-29 Truck....
SECTION 2 DESCRIPTION 2.0. GENERAL Before the Multipower 460PULSE power source is put into operation, the safety section at the front of this manual should be read completely. This will help avoid possible injury due to misuse or improper installation. The definitions relating to the safety notations below: are described at the end of the Safety Section in the front of this manual — read them and their specific text references carefully. 2.1.
SECTION 2 DESCRIPTION The Multipower 460PULSE is a multi-process power source designed for Mig short circuiting, spray and pulse spray transfer (GMAW), flux core (FCAW), Tig (GTAW), and stick (SMAW) welding and air carbon arc cutting/gouging (CACA) applications. Table 2-1 outlines the electrical and physical specifications. A. POWER SOURCE The power source is a constant current (CC) and constant voltage (CV), three phase, secondary chopper dc design with solid state contactor and control circuitry.
SECTION 2 DESCRIPTION C. CONTROL PANEL DESCRIPTION (Refer to Figure 2-3 and 2-4) 1. FAULT LAMP The RED fault light on the Multipower 460PULSE front panel indicates a problem with set-up parameters. A "Steady" light "On" indicates there is no program for the material and wire diameter selected. A "Blinking" light indicates the wire feed speed is out of the recommended range. 2. TEMPERATURE LAMP The TEMP lamp illuminates if an over temperature condition occurs within the Multipower 460PULSE power source.
SECTION 2 DESCRIPTION 5. VOLTAGE/CURRENT TRIM The arc voltage is controlled with this knob when the WELD PROCESS selector switch is in the MIG position. The Mig arc voltage can be preset by pressing the PRESET button and reading the arc volts in the bottom digital display while rotating this knob. The arc current is controlled with this knob when the WELD PROCESS SWITCH is in the TIG or STICK position.
SECTION 2 DESCRIPTION short circuit frequency, fast reacting arc, to a lower short circuit frequency, soft and less spattering arc as the dial is turned clockwise. The optimized arc performance will vary depending on shielding gas, wire type and wire diameter. The operator can adjust this control to optimize welding characteristics. 8. MODE SWITCH This switch enables the Mig pulse or standard operation mode.
SECTION 2 DESCRIPTION 2. WIRE FEEDER CONTROL RECEPTACLE This 19-pin receptacle (J1) accepts the control cable from the wire feeder and handles all the control signals needed to operate a 42 Vac wire feeder. 3. REMOTE CONTROL RECEPTACLE This receptacle (J2) is provided for an optional 14-pin control cable from the optional remote pendant, Tig torch control or foot control . This receptacle is operative only if the PANEL/REMOTE switch on the power source front panel is in the REMOTE position. 4.
SECTION 3 INSTALLATION 3.0. INSTALLATION A. LOCATION A proper installation site is necessary for the power source to provide dependable service. A proper installation site permits freedom of air movement through the unit while minimizing exposure to dust, dirt, moisture, and corrosive vapors. A minimum of 18 inches (46 cm) is required between the side and rear panels of the power source and the nearest obstruction.
SECTION 3 ELECTRIC SHOCK CAN KILL! Before making electrical input connections to the power source, "Machinery Lockout Procedures" should be employed. If the connections are to be made from a line disconnect switch, place the switch in the off position and padlock it to prevent inadvertent tripping. If the connection is made from a fuse box, remove the corresponding fuses and padlock the box cover.
SECTION 3 INSTALLATION 5. Figures 3-3, 3-4 and 3-5 illustrate the input voltage terminal boards 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 (575VAC). If the power source is to be operated on another stated input voltage, the links must be reset for that particular input voltage.
SECTION 3 INSTALLATION D. OUTPUT WELDING CONNECTIONS (SECONDARY) Check the voltage links for proper voltage on the Input Terminal board before applying primary power. The output connections are located on the front panel (Figure 2-5). The positive connection is located at the bottom left corner and the negative connection is located at the bottom right corner. Table 3-2 provides the recommended secondary cable output sizes. 1.
SECTION 4 OPERATION 4.0. OPERATION Never operate the power source with the covers removed. In addition to the safety hazards, improper cooling may cause damage to the components. Keep side panels and top closed when unit is energized. Welding helmet, gloves, and other personal protection should always be worn when welding. A. WIRE FEEDER COMPATIBILITY The Multipower 460PULSE power source can be used with several ESAB 42 volt wire feeders.
SECTION 4 OPERATION the display will show average welding current and volts in the top and bottom display, respectively. After welding stops, the current display will again return to zero. There is no “HOLD” circuit for the display meters when using the TIG and STICK process modes. E. MIG WELDING PRESET PROCEDURE When the PROCESS switch is placed in the MIG position, the Multipower 460PULSE is set for CV (constant voltage) welding.
SECTION 4 OPERATION F. TIG WELDING When the PROCESS switch is placed in the TIG position, the Multipower 460PULSE is automatically set for CC (constant current) welding using the ESAB Touch TIG starting method. The voltage and current at the output lugs is maintained at low values until the tungsten electrode is shorted to the workpiece. Step 1. Be sure to set the polarity to DCEN (Electrode Negative) by connecting the Tig torch to the negative terminal lug on the front of the power source. Step 2.
SECTION 4 OPERATION Arc Force is automatically enabled when the WELD PROCESS switch is set to the STICK position. The level of Arc Force is automatically adjusted by the current preset being used. When the WELD PROCESS switch is moved to the TIG or STICK position, electrode becomes electrically “HOT”. Do not allow the electrode to contact ground potential until you are ready to make a weld. Step 1.
SECTION 4 OPERATION Step 5. CV-Carbon Arc Gouging Only - Place the Process Switch in the MIG position and the Contactor Toggle switch to the "ON" position. See Figures 4-4 and 4-5. When the WELD PROCESS switch is moved to the TIG or STICK position, electrode becomes electrically “HOT”. Do not allow the electrode to contact ground potential until you are ready to make a weld. Step 6. Turn the air on the gouging electrode holder "ON and start gouging by touching or scratch starting the electrode.
SECTION 4 OPERATION The preprogrammed wire types, wire diameters and shielding gases are listed in Table 4-2. The TRIM allows the operator to fine tune the pulse arc length and optimize the welding. When the PROCESS switch is placed in the MIG position and the MIG MODE switch is placed in the PULSE position, the Multipower 460PULSE is set for CC over CC (constant current) pulse welding. The power source will output open circuit voltage (OCV) when the Mig Gun trigger is depressed.
SECTION 4 OPERATION The following procedure assumes the wire feed and voltage adjustments will be made from the wire feeder front panel and wire and gas have been installed. See Table 4-2 for the recommended shielding gases for each wire alloy type. Set the flowrate at 30 to 40 cfh for argon mixtures. A. PULSE MIG SETUP Step 1. Place the WELD PROCESS switch in the MIG (center) position Step 2. Set the MIG MODE switch to the PULSE position. Step 3. Set the PANEL/REMOTE switch to the REMOTE position.
SECTION 4 OPERATION B. PULSE PROCESS CONTROL 1. Use a tip-to-work distance (TTW) of 3/8" to 5/8". This refers to the distance between the end of the Mig gun contact tip and the workpiece or weld puddle. The tip-to-work distance can also be used to adjust the stability of the arc. Changes in distance will cause the arc to shorten or lengthen as desired for best results. Excessive tip to work movement can cause arc instability. Maintaining a constant TTW will insure the best arc stability and consistency. 2.
SECTION 4 OPERATION The selectable pulse parameters are any combination of WIRE TYPE or WIRE DIAMETER selected using the PULSE SELECTION switches. Not all combinations will produce acceptable pulse characteristics but by using the pulse tables provided in this manual, reasonable pulse combinations can be selected for trial. This will take some trial and error but the added flexibility and expanded pulse range of the non-synergic mode can be beneficial for many welding applications.
SECTION 4 OPERATION F. PULSE PARAMETERS Tables 4-3 through 4-8 list the approximate pulse weld parameters for each material and diameter available. These are provided for general reference only. Actual pulse parameters can vary with the equipment set-up, welding application and shielding gases being used. The wire feed speed ranges shown in the tables are the same as programmed into the Multipower 460 Micro.
SECTION 4 OPERATION Table 4-3 Multipower 460PULSE Carbon Steel Data Table .035 Steel WFS Range (IPM) Pulse Peak (Amps) 75 125 175 225 275 325 375 425 475 525 575 625 675 725 312 318 325 331 337 343 350 356 362 368 375 381 387 394 .040 Steel Pulse Pulse Pulse Background Frequency Width (Amps) (Hz) (ms) 1.70 1.70 1.70 1.70 1.70 1.70 1.70 1.70 1.70 1.70 1.70 1.70 1.70 1.
SECTION 4 OPERATION Table 4-4 Multipower 460PULSE Stainless Steel Data Table .035 Stainless WFS Range (IPM) Pulse Peak (Amps) 100 150 200 250 300 350 400 450 500 550 600 650 700 300 300 300 300 300 300 300 300 300 300 300 300 300 .040 Stainless Pulse Pulse Pulse Background Frequency Width (Amps) (Hz) (ms) 1.64 1.71 1.78 1.86 1.93 2.00 2.07 2.14 2.21 2.28 2.35 2.42 2.
SECTION 4 OPERATION Table 4-5 Multipower 460PULSE 4000 Aluminum .035 4043 AIuminum WFS Range (IPM) Pulse Peak (Amps) 200 250 300 350 400 450 500 550 600 650 239 246 253 260 266 273 280 287 294 301 .040 4043 Aluminum Pulse Pulse BackPulse Width ground Frequency (ms) (Amps) (Hz) 1.80 1.80 1.80 1.80 1.80 1.80 1.80 1.80 1.80 1.
SECTION 4 OPERATION Table 4-6 Multipower 460PULSE 5000 Aluminuml Data Table .035 5356 Aluminum WFS Range (IPM) Pulse Peak (Amps) 200 250 300 350 400 450 500 550 600 650 260 264 268 272 276 280 284 288 292 296 .040 5356 Aluminum Pulse Pulse BackPulse Width ground Frequency (ms) (Amps) (Hz) 1.70 1.70 1.70 1.70 1.70 1.70 1.70 1.70 1.70 1.
SECTION 4 OPERATION Table 4-7 Multipower 460PULSE Metal Core Carbon Steel Data Table .035 Metal Core CS WFS Range (IPM) Pulse Peak (Amps) Pulse Width (ms) 300 350 400 450 500 550 600 300 306 313 320 326 333 340 2.50 2.50 2.50 2.50 2.50 2.50 2.50 Pulse Background (Amps) 39 49 58 68 77 86 96 .
SECTION 4 OPERATION Table 4-8 Multipower 460PULSE Metal Core Stainless Steel Data Table .035 Metal Core SS WFS Range (IPM) Pulse Peak (Amps) Pulse Width (ms) Pulse Background (Amps) .040 Metal Core SS WFS Pulse Peak Range (Amps) (IPM) Pulse Frequency (Hz) NO PROGRAM Pulse Peak (Amps) Pulse Width (ms) 125 200 275 350 425 500 575 650 725 343 357 370 384 397 411 425 438 452 1.90 1.90 1.90 1.90 1.90 1.90 1.90 1.90 1.
SECTION 5 MAINTENANCE 5.0. CLEANING If this power source does not operate properly, stop work immediately and investigate the cause of the malfunction. Maintenance work must be performed by an experienced person, and electrical work by a trained electrician. Do not permit untrained persons to inspect, clean, or repair this power source. Use only recommended replacement parts.
SECTION 5 MAINTENANCE 40
TROUBLESHOOTING SECTION 6 6.0. TROUBLESHOOTING If the power source is operating improperly, the following troubleshooting information may be used to locate the source of the trouble. DISCONNECT primary power at wall switch, or circuit breaker, before attempting inspection or work inside the power source. Check the problem against the symptoms in the following troubleshooting guide (Table 6-1.) The remedy for the problem may be quite simple.
0558003034-B Multipower 460PULSE Wiring Diagram SECTION 6 TROUBLESHOOTING 42
0558003064-A Multipower 460PULSE Schematic Diagram (Sheet 1 of 3) SECTION 6 TROUBLESHOOTING 43
0558003064-A Multipower 460PULSE Schematic Diagram (Sheet 2 of 3) SECTION 6 TROUBLESHOOTING 44
0558003064-A Multipower 460PULSE Schematic Diagram (Sheet 3 of 3) SECTION 6 TROUBLESHOOTING 45
SECTION 6 TROUBLESHOOTING 46
SECTION 7 REPLACEMENT PARTS A. REPLACEMENT PARTS Replacement Parts are illustrated on the following figures. When ordering replacement parts, order by part number and part name, as illustrated on the figure. 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. B. ORDERING To assure proper operation, it is recommended that only genuine ESAB parts and products be used with this equipment.
SECTION 7 REPLACEMENT PARTS 16 14 15 12, 13 17 10 11 18 19 8, 9 7 6 4, 5 3 2 1 Figure 7-1 - Front View, Multipower 460PULSE 48
SECTION 7 REPLACEMENT PARTS Figure 7-1 - Front View, Multipower 460PULSE NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 QTY. REQ. ITEM NO. 2 1 1 2 3 1 2 2 2 1 1 2 3 1 1 1 3 1 1 1 678025 952219 952937 634515 951474 952209 950122 0558001818 13730632 952895 38196 634515 951474 91514 954008 636702 951474 9512240 0558002969 950945 CIRCUIT SYMBOL DESCRIPTION Terminal Assembly Outlet 110V (Square) Connection Box Rcpt.
SECTION 7 REPLACEMENT PARTS 3 2 5 1 6 4 7 Figure 7-2 - Inside Front View, Multipower 460PULSE NO. QTY. REQ. 1 2 3 4 5 6 7 3 3 1 1 1 1 1 ITEM NO.
SECTION 7 REPLACEMENT PARTS 6 2 1 4 51
SECTION 7 REPLACEMENT PARTS 2 1 3 4 Figure 7-3 - Inside Rear View, Multipower 460PULSE NO. QTY. REQ. ITEM NO. 1 2 3 4 2 1 12 20 17280110 0558002712 672065 36110 DESCRIPTION Res WW Fix'd ST 100W 5% 100.
SECTION 7 REPLACEMENT PARTS 3 4 2 5 1 Figure 7-4 External Rear View, Multipower 460PULSE NO. QTY. REQ. ITEM NO.
SECTION 7 REPLACEMENT PARTS 3 7 4 2 5 1 6 Figure 7-5 External Top View, Multipower 460 NO. QTY. REQ. ITEM NO. 1 2 3 4 5 6 7 1 1 1 3 1 3 1 952938 951997 951085 0558002557 951940 0558002844 38186 DESCRIPTION SCR 480V 18A Panel MNT Transducer Current SW THML D/T 176 15A 120V Q/D IGBT 600V/300A Capacitor 1.0uf 600VDC 10% Capacitor, 35000UF 100VDC PCB Driver Assy.
SECTION 7 REPLACEMENT PARTS 2 1 7 3 4 5 6 55
NOTES 56
NOTES 57
NOTES 58
REVISION HISTORY 1. 05/2003 - General editorial changes.
ESAB Welding & Cutting Products, Florence, SC Welding Equipment COMMUNICATION GUIDE - CUSTOMER SERVICES A. CUSTOMER SERVICE QUESTIONS: Telephone: (800)362-7080 / Fax: (800) 634-7548 Order Entry Product Availability Pricing Delivery Order Changes Saleable Goods Returns Shipping Information Hours: 8:00 AM to 7:00 PM EST 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.