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F-15-591-A
February, 2001
INSTRUCTION MANUAL
453cc & 553cc
DC WELDING POWER SOURCES
This manual provides complete instructions for the following power sources:
453cc 553cc
Item No. Item No.
ESAB 230/460 vac, 3 ph., 60 Hz 453cc - 0558001274 553cc - 0558001278
ESAB 230/460/575 vac, 3ph., 60 Hz 453cc - 0558001275 553cc - 0558001279
ESAB 220/400 vac, 3 ph., 50 Hz 453cc - 0558001276 553cc - 0558001280
ESAB 220/400 vac, 3 ph., 50 Hz,
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USER RESPONSIBILITY This equipment will perform in conformity with the description thereof contained in this manual and accompa- nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc- tions 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. Should such repair or replacement
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TABLE OF CONTENTS SECTION PARAGRAPH TITLE PAGE SAFETY ENGLISH SAFETY PRECAUTIONS ................................................................................................................ 4, 5 FRENCH SAFETY PRECAUTIONS ................................................................................................................ 6, 7 SECTION 1 DESCRIPTION..................................................................................................................................
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SAFETY PRECAUTIONS WARNING: These Safety Precautions are for 5. Do not use equipment beyond its ratings. For example, your protection. They summarize precaution- overloaded welding cable can overheat and create a fire ary information from the references listed in hazard. Additional Safety Information section. Before 6. After completing operations, inspect the work area to performing any installation or operating procedures, be make certain there are no hot sparks or hot metal which sure to read
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SAFETY PRECAUTIONS EQUIPMENT MAINTENANCE -- Faulty or FUMES AND GASES -- Fumes and improperly maintained equipment can gases, can cause discomfort or harm, cause injury or death. Therefore: particularly in confined spaces. Do not breathe fumes and gases. Shield- 1. Always have qualified personnel perform the installa- ing gases can cause asphyxiation. tion, troubleshooting, and maintenance work. Do not Therefore: perform any electrical work unless you are qualified to perform such work. 1. Alway
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PRÉCAUTIONS DE SÉCURITÉ coupes à l’arc, à moins de les recouvrir complètement AVERTISSEMENT: Ces règles de sécurité ont pour objet d’une bâche non-inflammable. Ce type de matériaux d’ assurer votre protection. Veillez à lire et à observer les comprend notamment le bois, les vêtements, la sciure, précautions énoncées ci-dessous avant de monter l’ l’essence, le kérosène, les peintures, les solvants, le équipement ou de commercer à l’utiliser. Tout défaut gaz naturel, l’acétylène, le propane et aut
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PRÉCAUTIONS DE SÉCURITÉ déclenchant des incendies ou des chocs électriques. levage, des câbles de grue ou divers chemins électriques. Observez par conséquent les précautions suivantes: g. Empêchez l’apparition de toute humidité, notamment a. Efforcez-vous de toujours confier à un personnel qua- lifié l’installation, le dépannage et l’entretien du poste sur vos vêtements, à la surface de l’emplacement de travail, des câbles, du porte-électrode et du poste de de soudage et de coupage. N’effectuez
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SECTION 1 DESCRIPTION 1.1 GENERAL When requesting information concerning this equip- This manual has been prepared for use by an experi- ment, it is essential that Item number, Serial number enced operator. It provides information to familiarize and Model number of the equipment be supplied. the operator with the design, installation and operation of the 482cc and 582cc model power sources. DO NOT 1.3 DESCRIPTION attempt to install or operate this equipment until you have read and fully understo
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SECTION 1 DESCRIPTION These controls provide remote output current control 1.3.2 Volt-Ampere Characteristics and contactor operation. Each control is equipped with The curves shown in Figure 1-1 represent the volt- 30 ft. (9.1 m) cable/plug assembly that mates with the ampere static characteristics for the power source. optional Remote Control Kit described above. The These curves show the output voltage available at any current adjustment is limited to the range as set by the given output curre
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SECTION 2 INSTALLATION 2.1 LOCATION 2.3 PRIMARY (INPUT) ELECTRICAL CONNEC- TION A proper installation site is necessary for the power source to provide dependable service. A proper instal- This power source is a three-phase unit and must be lation site permits freedom of air movement through the connected to a three-phase power supply. It is recom- unit while minimizing exposure to dust, dirt, moisture, mended that the unit be operated on a dedicated circuit and corrosive vapors. A minimum of 18
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SECTION 2 INSTALLATION Recommended Cable Strip Lengths Rear Panel (Inside View) Strain Relief Ground Fault 5" Switch* 10" TB3 Located on SWITCH Fan Bracket GROUND LUG NUT HORSESHOE Figure 2.1 Connecting Primary Power Leads Table 2.1 Recommended Input Conductor Size and Line Fuses Rated Input Input & 100% Duty Cycle Rating GND Fuse Size Conductor* Amps Volts Am ps CU/AWG 208 64 No. 6 90 220 61 No. 6 80 230 58 No. 6 80 453CC 482cc 400 33 No. 10 40 460 29 No. 10 40 575 23 No. 12 30 208 82 No. 4 120
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SECTION 2 INSTALLATION 2.5 CONTROL CONNECTIONS D. Check all connections for proper tightness. En- sure all connections are correct and well insu- Refer to Figure 2-3. lated. 2.5.1 Remote Control (Optional) E. Figure 2-2 illustrates the input voltage terminal board and the input voltage link connections. This function is provided by an optional 14-pin recep- The particular voltages from which this power tacle (J2) located on the front panel directly below source may be operated are stated on the
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SECTION 2 INSTALLATION Figure 2.3 CONTROL CONNECTIONS SW POWER CKT. BREAKERS, SWITCH 10A 32VDC, 250VAC 63A 600V - + OUTPUT RECEPTACLE 2.4 13
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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, Never operate the power source with the cover re more stable arc. The higher settings provide more short moved. In addition to the safety hazards, lmproper circuit current and a forceful, more penetrating arc. For cooling may cause damage to the components. most Stick welding, set the knob at 3 or 4 and readjust Keep side panels closed when
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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 This amber light will indicate when an internal overheat- switch. ing condition has occurred and one of the thermal switches has opened. User control of the solid state C. Adjust the current control on the power source contactor will be interrupted and power source output to the approximate desired welding current. will shut down to protect critical c
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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, Other than periodically cleaning the dust and dirt from stop work immediately and investigate the cause of the transformer, no maintenance is required. Ensure the malfunction. Maintenance work must be per- that only clean, dry, low pressure air is used. formed by an experienced person, and electrical work by a trained electricia
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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 IMPORTANT circuit breaker, before attempting inspection or 1. When replacing SCR’s, make sure mounting work inside the power source. surfaces are clean. Using Alcoa No. 2 EJC Electrical Joint Compound or an equivalent, If the power source is operating improperly, the follow- apply a thin coat to the SCR mounting s
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SECTION 5 TROUBLESHOOTING CONDITION ACTION Unit Inoperative A. No input power. Check main line (user's) switch fuses -- replace if needed. B. Poor or improper input (terminal board) connections. C. Defective on/off switch on front panel -- replace. D. Main transformer overheating. Also check for proper cooling, proper primary hookup, or shorted turn on secondary. E. Fan motor not operating -- check motor and leads. F. Gound fault indicator "ON". - Check for cause and correct. Turn power switch "
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SECTION 6 REPLACEMENT PARTS 6.1 GENERAL Replacement parts may be ordered from your ESAB Always provide the series or serial number of the unit distributor. For a list of Authorized Distributors in your on which the parts will be used. The serial number is area, contact ESAB at 1-800-ESAB-123. stamped on the unit nameplate. For your convenience an ESAB Communication Guide 6.2 ORDERING listing important contact phone numbers has been printed on the rear cover of this book. To assure proper operati
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