MultiPower 460 DC WELDING POWER SOURCE (Shipyard Model) INSTRUCTION MANUAL ESAB ITEM NO. 0558003401, MultiPower 460 - 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 SAFETY PRECAUTIONS 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. 5. Do not use equipment beyond its ratings.
SECTION 1 SAFETY PRECAUTIONS 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: EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death. 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 PRECAUCION DE SEGURIDAD 5. No use el equipo fuera de su rango de operación. Por ejemplo, el calor 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".
SECTION 1 1. 2. 3. 4. 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: Siempre provea ventilación adecuada en el área de trabajo por medio natural o mecánico. No solde, corte, o ranure materiales con hierro galvanizado, acero inoxidable, cobre, zinc, plomo, berílio, o cadmio a menos que provea ventilación mecánica positiva.
SECTION 1 PRÉCAUTIONS DE SÉCURITÉ 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. Les étincelles ou les projections de métal incandescent peuvent tomber dans des fissures du plancher ou dans des ouvertures des murs et y déclencher une ignition lente cachée.
SECTION 1 PRÉCAUTIONS DE SÉCURITÉ levage, des câbles de grue ou divers chemins électriques. 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. 4. VENTILATION-- La respiration prolongée des fumées résultant des opérations de soudage/coupage, à l’intérieur, d’un local clos, peut provoquer des malaises et des dommages corporels.
DESCRIPTION SECTION 2 2.0. GENERAL Before the MultiPower 460 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 460 is a multi-process power source designed for Mig short circuiting, spray transfer (GMAW), flux core (FCAW), Tig (GTAW), and stick (SMAW) welding and air carbon arc cutting/gouging (CAC-A) 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 Figures 2-3 and 2-4) 1. FAULT LAMP The RED fault light on the MultiPower 460 front panel indicates a problem with set-up parameters. 2. TEMPERATURE LAMP The TEMP lamp illuminates if an over temperature condition occurs within the MultiPower 460 power source. This condition may be caused by excessive duty cycle or over-current conditions.
SECTION 2 DESCRIPTION When using a DuraDrive 4-30 or DuraDrive 4-48 Wire Feeder, the wire feed speed is displayed in inches per minute (IPM) in the top display when the PRESET button is pressed and the wire speed adjustment knob on the wire feeder is rotated. The WFS LED beside the top display meter will light when the display is showing wire feed speed. 5. VOLTAGE / CURRENT / TRIM The arc voltage is controlled with this knob when the WELD PROCESS selector switch is in the MIG position.
SECTION 2 DESCRIPTION 7. INDUCTANCE TRIM This control is deactivated in the TIG and STICK modes. Inductance is used to optimize short circuiting arc performance by changing the current rise and fall time of each short circuit. This results in improved spatter control, weld bead wetting and arc stability.
SECTION 2 DESCRIPTION 4. CONTACTOR "ON/OFF" SWITCH This switch provides manual control of the welding contactor when the PROCESS switch on the control panel is in the MIG position (CV welding). An example of when to use this switch is when CV carbon arc gouging is needed or an "Off the Arc" wire feeder with secondary contactor is operated in the CV mode. 5.
SECTION 2 DESCRIPTION NOTE The FC-5B foot control or TC-2B hand control must be used with the MP-460 for remote current Tig current control. NOTE If a Foot Control or Remote Hand Control is used for continuous current control, place the PANEL/REMOTE switch in the PANEL POSITION and set the Panel Current knob to the maximum desired weld current. The remote device will then control the current between minimum and the maximum setting preset (proportional current control).
SECTION 2 DESCRIPTION 18
INSTALLATION SECTION 3 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.
INSTALLATION 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.
INSTALLATION 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.
INSTALLATION SECTION 3 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 3 INSTALLATION 24
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 460 power source can be used with several ESAB 42 volt wire feeders.
SECTION 4 OPERATION 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 460 is set for CV (constant voltage) welding. The power source will output open circuit voltage (OCV) when the Mig Gun trigger is depressed.
OPERATION SECTION 4 NOTE The FC-5B foot control or TC-2B hand control must be used with the MP-460 for remote current Tig current control. F. TIG WELDING When the PROCESS switch is placed in the TIG position, the MultiPower 460 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.
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 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. OPERATION Step 4. 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. Step 5. Turn the air on the gouging electrode holder "ON and start gouging by touching or scratch starting the electrode.
SECTION 4 OPERATION 30
SECTION 5 MAINTENANCE 5.0 MAINTENANCE AND TROUBLESHOOTING A. CLEANING Periodically, remove the cover from the power source and blow accumulated dust and dirt from the air passages and interior components by using clean low pressure air. The frequency of cleaning required depends upon the environment in which the power source is used. It is imperative that all air passages be kept as clean as possible in order to allow adequate air flow to provide proper cooling.
SECTION 5 MAINTENANCE Table 5-1 TroubleshootinggGuide CONDITION Unit Inoperative ACTION A. B. C. D. E. No Output -- Fan Running A. B. C. D. Limited Output or Low Open-Circuit Voltage A. No input power. Check main line (user's) switch fuses -- replace if needed. Poor or improper input (terminal board) connections. Defective on/off switch -- replace. Thermal light on. Main transformer overheating. Also check for proper cooling, proper primary hookup, or shorted turn on secondary.
0558003034-B Schematic Diagram - MultiPower 460 - 230/460/575V 33
0558003034-B Schematic Diagram (Continued) - MultiPower 460 - 230/460/575V 34
0558003064-D Wiring Diagram Section 1 - MultiPower 460 - 230/460/575V 35
0558003064-D Wiring Diagram Section 2 - MultiPower 460 - 230/460/575V 36
0558003064-D Wiring Diagram Section 3 - MultiPower 460 - 230/460/575V 37
SECTION 5 MAINTENANCE 38
SECTION 6 A. REPLACEMENT PARTS 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 6 REPLACEMENT PARTS 16 14 17 15 12, 13 10 11 18 8,9 19 7 20, 21 4, 5 3 2 1 NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 QTY. REQ. ITEM NO. 2 1 1 2 3 678025 952219 951916 634515 951474 2 2 2 1 1 2 3 1 1 1 3 1 1 1 1 1 950122 0558001019 13730632 952895 38196 634515 951474 2091514 954008 636702 951474 9512240 0558002969 950945 952209 0558003003 DESCRIPTION Terminal Assembly Outlet 110V (Square) Connection Box Rcpt.
SECTION 6 REPLACEMENT PARTS 3 2 5 1 6 4 7 NO. QTY. REQ. ITEM NO.
SECTION 6 REPLACEMENT PARTS 6 2 1 4 42
SECTION 6 REPLACEMENT PARTS 2 1 3 4 NO. QTY. REQ. ITEM NO. 1 2 3 4 2 1 12 1 17280110 0558002712 672065 36110 DESCRIPTION Res WW Fix'd ST 100W 5% 100.
SECTION 6 REPLACEMENT PARTS 3 2 4 1 5 NO. QTY. REQ. ITEM NO.
SECTION 6 REPLACEMENT PARTS 3 4 2 5 1 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 6 DESCRIPTION SCR 480V 18A Panel MNT Transducer Current SW THML D/T 176 15A 120V Q/D IGBT 600V/300A Capacitor 1.
SECTION 6 REPLACEMENT PARTS 2 1 7 3 4 5 6 46
REVISION HISTORY Original release of this manual - 05/2003. Revision A (05SEP03) - Added 19-pin receptacle to illustrations on cover and Pages 15, 29 and 40. Also added Items 20 and 21 to illustration and replacements parts table per Mike Palumbo red-lines. Also updated schematics on Pages 34 thru 37. 10 / 2004 revision - Updated wiring diagram (0558003064) per CN# 043141.
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