MultiPower 460 Pulse DC WELDING POWER SOURCE (Shipyard Model) INSTRUCTION MANUAL ESAB ITEM NO. 0558003402, MultiPower 460 Pulse - 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 DESCRIPTION .................................................................................................................................... 11 SECTION 3 INSTALLATION ............................................................................................................................
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 qualité mais, chose plus grave encore, d’entraîner des dommages corporels graves, voire mortels en déclenchant des incendies ou des chocs électriques. Observez par conséquent les précautions suivantes: a. Efforcez-vous de toujours confier à un personnel qualifié 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. b.
DESCRIPTION SECTION 2 2.1. SAFETY Before the MultiPower 460 Pulse 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 are described at the end of the Safety Section in the front of this manual — read them and their specific text references carefully. 2.2.
SECTION 2 DESCRIPTION The MultiPower 460 Pulse 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 (CAC-A) applications. Table 1-1 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 Pulse 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 460 Pulse power source.
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 used only in the STANDARD mode and is deactivated in the TIG, STICK and PULSE 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 1. POWER ON/OFF SWITCH & LAMP The main power switch is located on the right front panel of the power source. This switch energizes the main transformer, control circuitry and illuminates the Power “ON” lamp. 2. WIRE FEEDER CONTROL RECEPTACLE (OPTIONAL) PN - 0558003003 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.
SECTION 2 NOTE When using the MP-460 Pulse, the STANDARD/PULSE switch must be in the STANDARD position for proportional current control using a TIG remote current device. DESCRIPTION E. OPTIONAL ACCESSORIES 1. REMOTE CONTROL PENDANT (PN - 0558002871) This pendant (Figure 2-6) provides remote output control and a contactor closure switch to close the contactor making the output terminals “hot”.
SECTION 2 DESCRIPTION 18
INSTALLATION SECTION 3 3.1. 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. Figure 3-3 illustrates 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) Before making any connections to the power source output terminals make sure that all primary input power to the machine is off. 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 4.1. 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. OPERATION A. WIRE FEEDER COMPATIBILITY The MultiPower 460 Pulse power source can be used with several types of wire feeders.
SECTION 4 OPERATION C. TIG WELDING NOTE When using the MP-460 Pulse, the STANDARD/PULSE switch must be in the STANDARD position for proportional current control using a TIG remote current device. When the PROCESS switch is placed in the TIG position, the MultiPower 460 Pulse is automatically set for CC (constant current) welding using the ESAB Touch TIG starting method. The voltage and current at the output terminals are maintained at low values until the electrode is shorted to the workpiece. Step 1.
OPERATION SECTION 4 D. STICK WELDING 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. When the PROCESS switch is placed in the STICK position, the MultiPower 460 Pulse establishes open circuit voltage (OCV) and output power is immediately available for welding.
SECTION 4 OPERATION E. AIR CARBON ARC GOUGING (CAC-A) 1. CONSTANT CURRENT Step 1. Place the Output PANEL/REMOTE switch into PANEL position if output current is regulated from the VOLTAGE/CURRENT knob on the power source front panel, or in REMOTE position if output current is regulated from the optional Hand Control. When the WELD PROCESS switch is moved to the TIG or STICK position, electrode becomes electrically “HOT”.
SECTION 4 OPERATION F. MIG & FLUX CORE WELDING PRESET PROCEDURE When the PROCESS switch is placed in the MIG position, the MultiPower 460 Pulse is set for CV (constant voltage) welding. The power source will output open circuit voltage (OCV) when the Mig Gun trigger is depressed. The following procedure assumes that the wire and gas have been installed. Step 1. Connect wire feeder to MultiPower 460 Pulse and set PANEL/REMOTE switch to REMOTE position. Step 2.
OPERATION SECTION 4 G. MIG PULSE WELDING The MultiPower 460 Pulse is designed to provide simple to use, high quality, preprogrammed synergic and non-synergic pulsed Mig welding. Synergic pulsed Mig welding means that pulse parameters (such as pulse height, pulse width, background current and pulse frequency) are automatically adjusted by the MultiPower 460 Pulse as the wire feed speed is changed by the operator.
OPERATION SECTION 4 The TRIM Knob on the front panel (Voltage knob) allows the operator to fine tune the pulse arc length and optimize the welding characteristics. When the PROCESS switch is placed in the MIG position and the STANDARD/PULSE switch is place in the PULSE position, the MultiPower 460 Pulse is set for pulse Mig welding. The MultiPower 460 Pulse provides an arc length TRIM adjustment from either the wire feeder or power source.
SECTION 4 OPERATION Step 6. Set the shielding gas flow rate to 35 cfh by activating the gas purge switch on the wire feeder or pulling the gun trigger and turning the adjustment knob on the Flowmeter Step 7 Set the voltage knob on the wire feeder to the "5" or center 12 o'clock position. Step 8. Connect the work cable to the workpiece and pull the gun trigger to start welding. Step 9 The voltage knob on the wire feeder becomes the ARC TRIM and is used to fine tune the arc length for best arc performance.
SECTION 4 OPERATION 3. SHIELDING GASES Table 4-2 lists the types of shielding gas mixtures that can be used with the MultiPower 460 Pulse. The wire burn-off rate and synergic operation can vary with changes in shielding gas. The TRIM knob is used to compensate for small changes in shield gas composition. 4. SYNERGIC PULSE OPERATION The MultiPower 460 Pulse can be converted to Pulse Mig synergic operation by adding optional components.
SECTION 4 OPERATION Jumper Plug Removed and Harness connected (as factory shipped) Non-Synergic Mode - The pulse parameters are determined by the position of the pulse selection switches, the MultiPower 460 Pulse TRIM knob and Wire Feed Speed preset. Figure 4-7 Jumper Plug Removed and Harness Connected Jumper Plug Installed Synergic Mode - Pulse circuitry is looking for a 1 volt per 100 inches per minute signal to determine the pulse parameters requied to make the weld.
SECTION 5 MAINTENANCE 5.1. 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. 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. Loss of primary phase. Find & replace defective fuse.
0558003034-C Schematic Diagram Section 1 - MultiPower 460 - 230/460/575V 37
0558003034-C Schematic Diagram Section 2 - MultiPower 460 - 230/460/575V 38
0558003034-C Schematic Diagram Section 3 - MultiPower 460 - 230/460/575V 39
0558003064-D Wiring Diagram Section 1 - MultiPower 460 - 230/460/575V 40
0558003064-D Wiring Diagram Section 2 - MultiPower 460 - 230/460/575V 41
0558003064-D Wiring Diagram Section 3 - MultiPower 460 - 230/460/575V 42
SECTION 6 REPLACEMENT PARTS 6.1. 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. 6.2. ORDERING To assure proper operation, it is recommended that only genuine ESAB parts and products be used with this equipment.
SECTION 6 REPLACEMENT PARTS 8 9 7 6 10 4, 5 3 2 1 NO. QTY. REQ. ITEM NO. 1 2 3 4 5 6 7 8 9 10 2 1 1 2 3 1 2 1 1 1 0558003402 678025 952219 952937 634515 951474 32385 950122 672786 38211 951835 DESCRIPTION MultiPower 460 Pulse (Shipyard Model) Terminal Assembly Outlet 110V (Square) Connection Box Rcpt. 14FS X-ROT SW TGGL SPDT 2 Pos 14A 125V Q/D Switch Seal Black Contactor Plate (ShipYard Model) Ckt Breaker 10A 32VDC/250VAC Bolt Eye .75—10 X 2.
SECTION 6 REPLACEMENT PARTS 3, 4 9 6, 7 8 11 5 10 2 12 13 14 1 NO. QTY. REQ. ITEM NO. 1 2 0558003402 678025 MultiPower 460 Pulse (Shipyard Model) Terminal Assembly 2 3 4 5 6 7 8 9 10 2 2 1 1 2 3 1 1 1 3 1 1 1 2 0558001818 13730632 952895 38196 634515 951474 91514 954008 636702 951474 9512240 0558002969 950945 38246 Knob 1.31 Dia. (B) Pot Lin *10.0K 2.00W 0.
SECTION 6 REPLACEMENT PARTS 1 4,5 9, 10 2 7, 10 8, 10 7, 10 6 12 11 QTY. REQ. ITEM NO.
SECTION 6 REPLACEMENT PARTS 2 3 4 1 5 NO. QTY. REQ. ITEM NO.
SECTION 6 REPLACEMENT PARTS 3 2 8 4 5 1 6 7 NO. QTY. REQ. ITEM NO.
SECTION 6 REPLACEMENT PARTS 2 3 4 1 NO. QTY. REQ. ITEM NO. 1 2 3 4 2 1 12 1 0558003402 17280110 0558002712 672065 36110 DESCRIPTION SYMBOL MultiPower 460 Pulse (Shipyard Model) Res WW Fix'd ST 100W 5% 100.
SECTION 6 REPLACEMENT PARTS 3 4 2 5 1 NO. QTY. REQ. ITEM NO. 1 2 3 4 5 1 1 1 3 1 0558003402 952938 951997 951085 0558003077 951940 DESCRIPTION SYMBOL MultiPower 460 Pulse (Shipyard Model) SCR 480V 18A Panel MNT Transducer Current SW THML D/T 176 15A 120V Q/D IGBT 600V/300A Capacitor 1.
REVISION HISTORY 1. 07 / 2003 - "A" REVISION - Updated all front panel diagrams to show new layout, also updated front panel diagram in replacement parts section to show new & additional parts. Replaced overlay, p/n 955277 and panel, control pulse, p/n 0558002667 with silkscreened panel, p/n 0558004308. See C/N #033182. 2. 04 / 2004 - "B" REVISION - Made various changes to the Description and Operation sections to update incorrect information.
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