F-15-591-A February, 2001 INSTRUCTION MANUAL 453cc & 553cc DC WELDING POWER SOURCES This manual provides complete instructions for the following power sources: ESAB 230/460 vac, 3 ph., 60 Hz ESAB 230/460/575 vac, 3ph., 60 Hz ESAB 220/400 vac, 3 ph., 50 Hz ESAB 220/400 vac, 3 ph., 50 Hz, CE 453cc Item No. 453cc - 0558001274 453cc - 0558001275 453cc - 0558001276 453cc - 0558001277 553cc Item No.
USER RESPONSIBILITY This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately.
TABLE OF CONTENTS SECTION PARAGRAPH TITLE SAFETY ENGLISH FRENCH SAFETY PRECAUTIONS ................................................................................................................ 4, 5 SAFETY PRECAUTIONS ................................................................................................................ 6, 7 SECTION 1 1.1 1.2 1.3 1.3.1 1.3.2 1.4 1.5 DESCRIPTION ...................................................................................................................
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.
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.
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.
PRÉCAUTIONS DE SÉCURITÉ g. 4. a. b. c. d. e. f. 5. 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.
SECTION 1 DESCRIPTION 1.1 GENERAL When requesting information concerning this equipment, it is essential that Item number, Serial number and Model number of the equipment be supplied. This manual has been prepared for use by an experienced operator. It provides information to familiarize the operator with the design, installation and operation of the 482cc and 582cc model power sources. DO NOT attempt to install or operate this equipment until you have read and fully understood these instructions.
SECTION 1 DESCRIPTION These controls provide remote output current control and contactor operation. Each control is equipped with 30 ft. (9.1 m) cable/plug assembly that mates with the optional Remote Control Kit described above. The current adjustment is limited to the range as set by the current control on the power source. The contactor and current panel/remote switches on the power source must be in remote position when operating with any of the remote controls. 1.3.
SECTION 2 INSTALLATION 2.1 LOCATION 2.3 PRIMARY (INPUT) ELECTRICAL CONNECTION 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 2 INSTALLATION Recommended Cable Strip Lengths Rear Panel (Inside View) Strain Relief 5" Ground Fault Switch* 10" TB3 Located on Fan Bracket SWITCH GROUND LUG NUT HORSESHOE Figure 2.1 Connecting Primary Power Leads Table 2.1 Recommended Input Conductor Size and Line Fuses Rated Input 100% Duty Cycle Rating 482cc 453CC 553CC 582cc Volts Am ps 208 220 230 400 460 575 208 220 230 400 460 575 64 61 58 33 29 23 82 77 74 43 37 30 o Input & GND Fus e Size Conductor* Am ps CU/AWG No.
SECTION 2 INSTALLATION D. Check all connections for proper tightness. Ensure all connections are correct and well insulated. 2.5 CONTROL CONNECTIONS E. Figure 2-2 illustrates the input voltage terminal board 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.
SECTION 2 INSTALLATION Figure 2.3 CONTROL CONNECTIONS SW POWER SWITCH 63A 600V CKT. BREAKERS, 10A 32VDC, 250VAC - + OUTPUT RECEPTACLE 2.
SECTION 3 OPERATION 3.1.2 Arc Force Control. This control is used for stick welding only.The lower settings provide less short circuit current and a softer, more stable arc. The higher settings provide more short circuit current and a forceful, more penetrating arc. For most Stick welding, set the knob at 3 or 4 and readjust up (forceful) or down (softer) as desired. Never operate the power source with the cover re moved.
SECTION 3 OPERATION 3.1.6 Over Temperature Indicator (Temp) B. Place the Power ON-OFF switch to the ON position or close the main(wall) disconnect switch. This amber light will indicate when an internal overheating condition has occurred and one of the thermal switches has opened. User control of the solid state contactor will be interrupted and power source output will shut down to protect critical components.
SECTION 4 MAINTENANCE 4.1 GENERAL 4.3.1 Fan Motor Keep the fan motor free of accumulated dust and dirt. 4.3.2 Transformer 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 TROUBLESHOOTING 5.1 GENERAL Remove the jumper from the gate. The meter reading should increase (3050 ohms). B. Replacing the SCRs. DISCONNECT primary power at wall switch, or circuit breaker, before attempting inspection or work inside the power source. IMPORTANT 1. When replacing SCR’s, make sure mounting surfaces are clean. Using Alcoa No. 2 EJC Electrical Joint Compound or an equivalent, apply a thin coat to the SCR mounting surface and positively locate in place on the heatsinks.
SECTION 5 CONDITION Unit Inoperative TROUBLESHOOTING B. C. A. B. C. D. E. A. ACTION No input power. Check main line (user's) switch fuses -- replace if needed. Poor or improper input (terminal board) connections. Defective on/off switch on front panel -- replace. Main transformer overheating. Also check for proper cooling, proper primary hookup, or shorted turn on secondary. Fan motor not operating -- check motor and leads. Gound fault indicator "ON". - Check for cause and correct.
SECTION 6 REPLACEMENT PARTS 6.1 GENERAL 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. Replacement parts may be ordered from your ESAB distributor. For a list of Authorized Distributors in your area, contact ESAB at 1-800-ESAB-123. 6.2 ORDERING For your convenience an ESAB Communication Guide listing important contact phone numbers has been printed on the rear cover of this book.
SECTION 6 REPLACEMENT PARTS 453cc-553cc View 1 - Front 20
SECTION 6 REPLACEMENT PARTS 453cc-553cc View 2 - Top Panel 21
SECTION 6 REPLACEMENT PARTS 453cc-553cc View 3 - Angled Front 22
SECTION 6 REPLACEMENT PARTS 453cc-553cc View 4 - Rear 23
SECTION 6 REPLACEMENT PARTS 453cc-553cc View 5 - Internal Rear View 24
SECTION 6 REPLACEMENT PARTS 453cc-553cc View 6 - Internal Front View 25
D-0558001568-A 453cc-553cc Schematic Diagram- 50/60 HZ NOTES: 1. REFER TO WIRING DIAGRAMS FOR ALL CONNECTION POINTS. 2. USE TYWRAPS 631507 (ITEM 41), 99511578 (ITEM 130), 180W66 (ITEM 145), 180W68 (ITEM 146). TO CONFINE LOOSE WIRE AS REQUIRED. USE 71200732 (ITEM 123) TO SECURE FILTER CAPACITORS. USE HEAT SHRINK 90863007 (ITEM 126), 90863202 (127) AND 90863203 (ITEM 128) TO INSULATE BARRELS OF TERMINALS. 3.
D-0558001569 453cc-553cc Wiring Diagram- Primary 3 PH SECTION 6 REPLACEMENT PARTS 27
D-0558001570-A 453cc-553cc Wiring Diagram Secondary - 50/60 HZ SECTION 6 REPLACEMENT PARTS 28
SECTION 6 REPLACEMENT PARTS Bill of Materials 453cc/553cc DC Welding Power Source ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 PART OR CODE NO.
SECTION 6 REPLACEMENT PARTS Bill of Materials 453cc/553 DC Welding Power Source ITEM NO. 41 42 43 44 45 46 47 49 50 51 52 53 54 55 56 59 60 62 63 64 65 66 67 69 70 71 72 73 74 75 76 77 78 79 80 122 123 124 125 126 127 128 129 130 PART OR CODE NO.
SECTION 6 REPLACEMENT PARTS Bill of Materials 453cc/553cc DC Welding Power Source ITEM NO. 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 159 160 161 162 166 167 PART OR CODE NO.
ESAB Welding & Cutting Products, Florence, SC Welding Equipment COMMUNICATION GUIDE - CUSTOMER SERVICES A. CUSTOMER SERVICE QUESTIONS: Order Entry Product Availability Order Changes Saleable Goods Returns Pricing Delivery Shipping Information Eastern Distribution Center Telephone: (800)362-7080 / Fax: (800) 634-7548 Central Distribution Center Telephone: (800)783-5360 / Fax: (800) 783-5362 Western Distribution Center Telephone: (800) 235-4012/ Fax: (888) 586-4670 B.