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653 cvcc

DC Welding Power Source

Instruction Manual

F15-572-H

02/2006

This manual provides complete instructions for the following power sources starting with Serial No. M0RI603036, January 1996:

ESAB ITEM NO. 37830 - 653cvcc - 230/460/575 vac, 3 ph., 60 Hz
ESAB ITEM NO. 3783

- 653cvcc - 220/400 vac, 3 ph., 50 Hz CE

Summary of Contents for 653 cvcc

Page 1: ...l F15 572 H 02 2006 This manual provides complete instructions for the following power sources starting with Serial No M0RI603036 January 1996 ESAB ITEM NO 37830 653cvcc 230 460 575 vac 3 ph 60 Hz ESA...

Page 2: ...e responsibility for any malfunction which results from improper use faulty maintenance damage improper repair or alteration by anyone other than the manufacturer or a ser vice facility designated by...

Page 3: ...ion 21 3 2 Receiving Unpacking Placement 21 3 3 Primary input Electrical Connection 22 3 4 Output Welding Connections 25 3 5 Control Connections 25 4 0 Operation 29 4 1 Controls 29 4 2 Sequence of Ope...

Page 4: ...4 TABLE OF CONTENTS...

Page 5: ...clothing 5 Protect other personnel from arc rays and hot sparks with a suitable non flammable partition or curtains 6 Usegogglesoversafetyglasseswhenchippingslag orgrinding Chippedslagmaybehotandcanfl...

Page 6: ...ExposuretoEMFmayhaveotherhealtheffectswhich are unknown 3 Welders should use the following procedures to minimize exposure to EMF A Route the electrode and work cables together Secure them with tape...

Page 7: ...available from Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 EQUIPMENT MAINTENANCE Faulty or improperly maintained equipment can cause injury or death Therefore 1 Alwaysh...

Page 8: ...Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances MEANING OF SYMBOLS As used throughout this manual Means Atten tion Be Alert Your safety is involved Meansimmed...

Page 9: ...s del arco y chis pascalientesconunacortina adecuadano flamable como divisi n 6 Usecaretaprotectoraadem sdesusgafasdesegu ridad cuando est removiendo escoria o puliendo La escoria puede estar caliente...

Page 10: ...2 Exponerseacamposelectromagn ticos EMF puede causar otros efectos de salud a n desconocidos 3 Los soldadores deber n usar los siguientes proced imientos para minimizar exponerse al EMF A Mantenga el...

Page 11: ...IMIENTO DEL EQUIPO Equipo defectuoso o mal mantenido puede cau sar da o o muerte Por lo tanto 1 Siempre tenga personal cualificado para efec tuar l a instalaci n diagn stico y mantenimiento del equipo...

Page 12: ...n Est Alerta Se trata de su seguridad Significa riesgo inmediato que de no ser evadido puede resultar inmediatamente en serio da o personal o la muerte Significa el riesgo de un peligro potencial que...

Page 13: ...on Ils r capitulent les informations de pr caution provenant des r f rences dans la section desInformationsdes curit suppl mentaires Avantde proc der l installationoud utiliserl unit assurez vous de l...

Page 14: ...ise persiste 4 Consultez ANSI ASC Standard Z49 1 la page suivante pour des recommandations sp cifiques concernant la ventilation 1 Assurez vous que le ch ssis de la source d alimentation est branch au...

Page 15: ...z contenant des chimiques consi d resparl tatdelaCaliforniecomme tant une cause des malformations cong nitales et dans certains cas du cancer California Health Safety Code 25249 5 et seq MANIPULATION...

Page 16: ...Soyez vigilant Votre s curit est en jeu Signifie un danger imm diat La situation peut entra ner des blessures graves ou mortelles Signifieundangerpotentielquipeutentra nerdes blessures graves ou mort...

Page 17: ...and Control 30 ft 9 1m cable requires 0558001436 33838 Mini Boom for Mig 4HD requires Swivel Post 34322 Swivel Post use with Mig 4HD or Mig 2E wire feeders 36172 Auto Fan Kit 36707 TR 29 Truck Kit 379...

Page 18: ...d freight bill will be furnished by the carrier on request When requesting information concerning this equipment it is essential that the Item number Serial number and Model number of the equipment be...

Page 19: ...MIG SUB ARC AMPS Volts MAX MIN 60 0 50 40 30 20 10 0 100 200 300 400 600 700 800 1000 500 900 AMPS MIN MAX Volts D C OUTPUT CURRENT AMPS CC MODE FOR STICK ARC GOUGING SUB ARC Figure 2 1 Volt Ampere C...

Page 20: ...20 SECTION 2 DESCRIPTION...

Page 21: ...s Check the container for any loose parts C Check air passages at front and rear of cabinet making sure that no packing materials that may obstruct air flow through the power source D Install the lift...

Page 22: ...le 3 1 provides recommended input conduc tors and line fuse sizes B Remove the top cover Identify primary power connections TB3 and the ground lug located on the A Frame bracket Refer to figure 3 1 EL...

Page 23: ...bracket and connect to the ground lug provided on the A Frame D Check all connections for proper tightness Ensure all con nections are correct and well insulated Recommended Cable Strip Lengths Primar...

Page 24: ...ATION E Figures 3 2 3 3 3 4 illustrate 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 ra...

Page 25: ...4vac feeders only P N 0558001415 Refer to Figure 3 5 Table 3 2 Output Cable Sizes Secondary Total cable length includes work and electrode cables Cable size is based on direct current insulated copper...

Page 26: ...Auxiliary 115 V AC Receptacle A 115 Vac receptacle is provided to supply power to accessories such as a water cooler heated CO2 regulator or small hand tools The receptacle is rated 115 Vac 10 amps 3...

Page 27: ...TTING GOUGING CAC A MIG WELDING GMAW optional Positive Output Receptacle 3 4 4 1 7 Low Inductance for MIG WELDING GMAW FLUX CORED WELDING FCAW ARC GOUGING CAC A optional PosItive Output Receptacle 3 5...

Page 28: ...28 SECTION 3 INSTALLATION...

Page 29: ...will also illuminate if a short occurs momentary or permanent between the 12 volt J1 E the 10 volt J2 E and either the chassis ground or the nega tive terminal of the power source The power source out...

Page 30: ...he 653cvcc provides high and low inductance output connections see figure 3 5 Both are positive output terminals The high inductance terminal slows the power source dynamic response This means the out...

Page 31: ...nections Refer to the appropriate wire feeder mechanized control and or torch instruction booklets for additional process requirements or control connections C If primary input connections have been m...

Page 32: ...ower from the output terminals 4 2 3 Specific Procedures for the CC Stick Welding SMAW and Arc Gouging CAC A Processes A Place the Output Panel Remote switch into PANEL position if output current is r...

Page 33: ...not operate properly stop work immedi ately 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...

Page 34: ...n will automatically reset While de energized the contactor and wire feeder cannot be operated 5 3 5 Digital Voltmeter Ammeter Calibration To verify the accuracy of the digital volt ammeter combinatio...

Page 35: ...e the main rectifier assembly containing the SCRs 3 Electrically isolate main bridge assembly by disconnecting resistor R5 4 With the ohmmeter on RX1 scale place the positive lead on the anode end of...

Page 36: ...noting that the nuts are not rotating Table 6 1 PCB Voltage Tests NOTE All voltage readings are taken with the front access panel open and the power switch ON Refer to Schematic Diagram Varies with VC...

Page 37: ...down D PCboarddefectiveorloosePCboardconnector s ifloose reinsert ifdefective replace Limited Output or Low Open Circuit Voltage A Input voltage jumper links on terminal board improperly set check fo...

Page 38: ...38 SECTION 6 TROUBLESHOOTING 05 4DIFNBUJDT BOE 8JSJOH JBHSBNT PO w Y w QBQFS BSF JODMVEFE JOTJEF UIF CBDL DPWFS PG UIJT NBOVBM...

Page 39: ...non ESAB parts may void your warranty Replacement parts may be ordered from your ESAB Distributor Be sure to indicate any special shipping instructions when ordering replacement parts Refer to the Co...

Page 40: ...40 SECTION 7 REPLACEMENT PARTS 653cvcc Front Panel View 195...

Page 41: ...41 SECTION 7 REPLACEMENT PARTS 653cvcc Front Isometric View...

Page 42: ...42 SECTION 7 REPLACEMENT PARTS 653cvcc Internal View...

Page 43: ...43 SECTION 7 REPLACEMENT PARTS 653cvcc Rear Isometric View...

Page 44: ...44 SECTION 7 REPLACEMENT PARTS 653cvcc Internal View...

Page 45: ...45 SECTION 7 REPLACEMENT PARTS 653cvcc Top Internal View...

Page 46: ...CABLE DIGITAL METER PCB P10 23 37861M 1 BASE 24 37862M 1 PANEL FRONT BOTTOM 25 0558001369 1 PANEL RIGHT SIDE ENV 26 0558001370 1 PANEL LEFT SIDE ENV 27 0558001378 1 CONTROL PANEL BLACK 28 37867M 1 PA...

Page 47: ...188 X 500 133 99512240 1 LABEL CAUTION LIFT EYE 134 99512558 1 BRACKET RESISTOR 18 135 0558001010 1 TERMINAL BLOCK 3 POS TB3 136 0558001033 1 BOX PCB BLACK 137 0558001012 3 PLUG HOUSING 2 POS 138 055...

Page 48: ...Cont d 182 0558003579 1 BRACKET MOUNTING 185 950466 1 CAP HOUSING 15 POS 186 2062348 1 PLUG HOUSING 9 POS 187 0558001409 1 CONNECTION INTERFACE SEAL 9 188 950125 1 CONTACT PIN 189 952609 1 CONN RECEPT...

Page 49: ...49 SECTION 7 REPLACEMENT PARTS...

Page 50: ...50 NOTES...

Page 51: ...ort near the output rectifier bridge These modifications are for a fan on demand feature These modifications will affect serial no s M0RI603036 and above Replacement Parts listings have also been upda...

Page 52: ...x 843 664 5557 Hours 7 30 AM to 3 30 PM EST Repair Estimates Repair Status F WELDING EQUIPMENT TRAINING Telephone 843 664 4428 Fax 843 679 5864 Hours 7 30 AM to 4 00 PM EST Training School Information...

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