ESAB MultiPower 460 Pulse Instruction Manual Download Page 40 | Manualshive

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Wiring Diagram Section 1 - MultiPower 460 - 230/460/575V

0558003064-D

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Summary of Contents for MultiPower 460 Pulse

Page 1: ...007 MultiPower 460 Pulse DC WELDING POWER SOURCE INSTRUCTION MANUAL This manual provides complete instructions for the following power sources starting with Serial Number MxxJ211xxx March 2002 ESAB ITEM NO 0558002877 ...

Page 2: ...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 accor dancewiththeinstructionsprovided Thisequipmentmustbecheckedperiodically Malfunctioning orpoorlymaintainedequipmentshouldnotbeused Partsthatarebroken missing worn distorted or contaminated should be replaced immedi...

Page 3: ...3 TABLE OF CONTENTS SECTION TITLE PAGE SECTION 1 SAFETY 5 SECTION 2 DESCRIPTION 11 SECTION 3 INSTALLATION 19 SECTION 4 OPERATION 25 SECTION 5 MAINTENANCE 35 SECTION 6 REPLACEMENT PARTS 43 ...

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

Page 5: ...here are no substances on the workpiece which might pro duce flammable or toxic vapors Do not do hot work on closed containers They may explode 4 Have fire extinguishing equipment handy for instant use such as a garden hose water pail sand bucket or portable fire extinguisher Be sure you are trained in its use 5 Do not use equipment beyond its ratings For example overloaded welding cable can overh...

Page 6: ...r strike an arc on a cylinder 5 For additional information refer to CGA Standard P 1 Precautions for Safe Handling of Compressed Gases in Cylinders which is available from Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 EQUIPMENTMAINTENANCE Faultyorim properlymaintainedequipmentcancause injury or death Therefore 1 Always have qualified personnel perform the installa tion...

Page 7: ...or de fuego para uso instantáneo como por ejemplo una manguera con agua cubeta con agua cubeta con arena o extintor portátil Asegúrese que usted esta entrenado para su uso 5 No use el equipo fuera de su rango de operación Por ejemplo el calor causado por cable sobrecarga en los cables de soldar pueden ocasionar un fuego 6 Después de termirar la operación del equipo inspeccione el área de trabajo p...

Page 8: ...ilindros 4 Localize los cilindros lejos del calor chispas y flamas Nunca establezca un arco en el cilindro 5 Para información adicional haga referencia a la publicación CGA Standard P 1 Precautions for Safe Handling of Com pressed Gases in Cylinders disponible através del Com pressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 Las siguientes publicaciones disponibles através de...

Page 9: ...e AVERTISSEMENT Ces règles de sécurité ont pour objet d assurer votre protection Veillez à lire et à observer les précautions énoncées ci dessous avant de monter l équipement ou de commercer à l utiliser Tout défaut d observation de ces précautions risque d entraîner des blessures graves ou mortelles 1 PROTECTION INDIVIDUELLE Les brûlures de la peau et des yeux dues au rayonnement de l arc électri...

Page 10: ... matière de ventilation indiquées à l alinéa 6 de la norme Z49 1 de l AWS 5 ENTRETIEN DE L ÉQUIPEMENT Un équipement entretenu de façon défectueuse ou inadéquate risque non seulement de réaliser un travail de mauvaise 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 précauti...

Page 11: ...ionoftheMultiPower460Pulsepowersource DONOTattemptto installoroperatethisequipmentuntilyouhavereadandfullyunderstoodthese instructions The information presented here should be given careful consid eration to ensure proper installation and optimum weld performance of this equipment OPEN CIRCUIT VOLTAGE U2 80V DC Max RATED OUTPUT DUTY CYCLE 60 100 Current I2 500 A 450 A Voltage U2 40 V 38 V RATED IN...

Page 12: ...e fan will run when the power source is first powered up for approximately 30 seconds The fan will start again whenweldingbeginsandisatacurrentlevelabove50amps Thefanwill remain running for 6 minutes after welding stops and then shut down automatically Stainless steel frame for envirornmental durability Durable side and top panels will not corrode 100 duty cycle output at 460 amps Compatible with ...

Page 13: ...utputisturnedoffandtheunitmustbeallowed to cool The machine will automatically reset when the temperature falls to a safe level 3 PROCESS SELECTOR SWITCH Thethreepositionprocessselectorswitchislocatedintheupperright hand cornerofthecontrolpanel Theprocessselectorswitchpositionprovidesthe visualindicationofwhichweldprocess Mig Tigorstick hasbeenselected 4 DIGITAL DISPLAY METERS WFS AMPS VOLTS The d...

Page 14: ...during welding For MIG PULSE welding the arc length arc voltage is controlled with this knob The WELD PROCESS switch is placed in the MIG position and the mode switch is placed in the PULSE position The knob should be place at the 12 o clock position as the synergic preset for the wire feed speed WIRE TYPE and WIRE DIAMETER choosen by the operator using the PULSE SELECTION switches The arc length ...

Page 15: ...tch enables the Mig pulse operation mode When this switch is in the MIG PULSE position the pulse parameters are determined by the WIRE TYPE and WIRE DIAMETER position on the PULSE SELECTION switches 9 PULSE SELECTION SWITCHES WIRE TYPE Use this switch to select the WIRE TYPE installed on the wire feeder The position of this switch and the WIRE DIAMETER switch selects the pulse parameters to be use...

Page 16: ...cooler heated CO2 regulator or small hand tools The receptacle is rated 115 Vac 10 amps with a floating neutral 6 42VAC AND 115 VAC CIRCUIT BREAKER CB1 CB2 These resetable 10 amp circuit breakers CB1 CB2 protect the 42 volt wire feeder control and 115 volt auxiliary receptacle circuitry against over current Table 7 1 provides troubleshooting information E OPTIONAL ACCESSORIES 1 REMOTEHANDCONTROL P...

Page 17: ...weld current on the MP 460 front panel is defeated NOTE When using a DuraDrive wire feeder or any wire feeder with Remote Voltage control from the feeder front panel connected simultaneously with a remote current control Tig device FC 5B or TC 2B proportional control of the TIG remote current will be controlled by the position of the feeder voltage control knob when the PANEL REMOTE switch is in t...

Page 18: ...18 DESCRIPTION SECTION 2 ...

Page 19: ...move the power source from the container Remove all packing materials Check the container for any loose parts c Check air passages at front and rear of cabinet making sure that packing material has not obstructed air flow through the power source d Installtheliftingboltfurnishedwiththepowersourcesintothetopofthe unit e After selecting an installation site place the power source in the desired loca...

Page 20: ...e from a line disconnect switch place the switch in the off position and padlock it to prevent inadvert ent tripping If the connection is made from a fuse box remove the corresponding fuses and padlock the box cover If it is not possible to use padlocks attach a red tag to the line disconnect switch or fuse box warning others that the circuit is being worked on The chassis must be connected to an ...

Page 21: ... the strain relief on the input cable 4 Checkallconnectionsforpropertightness Ensureallconnectionsare correctandwell insulated INSTALLATION SECTION 3 ELECTRIC SHOCK CAN KILL Before making electrical input connections to the power source Machinery Lock out 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 i...

Page 22: ...ce is to be operated on another stated input voltage the links must be reset for that particularinputvoltage Alwaysverifytheinputvoltageandcheckthelinkarrangementregardlessof factory setting The voltage links are set up by reconfiguring the copper link bars to the silk screened voltagedesignationsforthedesiredvoltage Figure 3 3 Input Terminal Board Configuration for 230 460 575 Model factory suppl...

Page 23: ...ated at the bottom right corner Table 3 2 provides the recommended secondary cable output sizes 1 CONNECTIONSFROMTHEWIREFEEDER The wire feeder control cable connects to the 19 pin J1 receptacle on thelowerfrontleftoftheMultiPower460Pulse Thesecondaryoutput cable connects in most cases between the positive output lug of the MultiPower 460 Pulse and the power connection block of the wire feeder See ...

Page 24: ...24 INSTALLATION SECTION 3 ...

Page 25: ...display respectively The displays have a HOLD circuitthatretainstheweldingconditions Afterweldingstops thedisplaywill continuetoshowthelastaverageweldingcurrentandvoltagesampled for10 seconds then returns to 0 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 ener...

Page 26: ...he following procedure assumes the wire feed and voltage adjustments will be made from the wire feeder front panel and wire and gas have been installed Step 1 Connect wire feeder to MultiPower 460 Pulse and set PANEL RE MOTE switch to REMOTE position Step 2 Set the STANDARD PULSE switch to the STANDARD position Step 3 Place the WELD PROCESS switch in the MIG center position Step 4 Press and releas...

Page 27: ...ing preset proportional current control Maximum Tig weld cur rent is 525 amps G STICK WELDING When the PROCESS switch is placed in the STICK position the MultiPower 460 Pulse establishes open circuit voltage OCV and output power is immediatelyavailableforwelding ThismeansthattheSTICKelectrodeholder is HOT and an arc will strike when the electrode comes in contact with the workpiece or any other ob...

Page 28: ...lace STANDARD PULSE switch in the STANDARD position Step 5 While holding the PRESET button turn the VOLTAGE CURRENT knob to the desired weld current in the top digital display window Step 6 Strike the electrode on the workpiece and start welding Trim the welding current as needed for the desired weld pool control H AIRCARBONARCGOUGING CAC A 1 CONSTANTCURRENTandCONSTANTVOLTAGEGOUGING Step 1 Place t...

Page 29: ...l current may be greater than the preset value Step 5 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 6 Turn the air on the gouging electrode holder ON and start gouging by touching or scratch starting the electrode For CV Carbon Arc Gouging and Off the Arc wire feeders ONLY Figure 4 5 Contactor...

Page 30: ...rogrammed synergic pulse data The preprogammed WIRE TYPES WIRE DIAMETERS and shielding gases are listed in Table 4 2 Table 4 2 Wire Types Diameter and Shield Gases SECTION 4 OPERATION Material Type Diameters Shielding Gas AWS Designation Carbon Steel 035 040 045 052 062 Ar 5 CO2 SG AC 5 Ar 8 CO2 SG AC 8 Ar 10 CO2 SG AC 10 Ar 2 O2 SG AO 2 Ar 8 CO2 2 O2 SG ACO 8 2 StainlessSteel 035 040 045 062 Ar 2...

Page 31: ...ion ThisisalsotrueiftheTRIMisbeingsetfromthewirefeeder REMOTEposition The operator can change to STANDARD MIG CV by simply moving the STANDARD PULSE switch to the STANDARD position and resetting the arc length using the voltage control on the wire feeder Thefollowingprocedureassumesthewirefeedandvoltageadjustmentswillbe madefromthewirefeederfrontpanelandwireandgashavebeeninstalled See Table4 1fort...

Page 32: ...nt can cause arc instability Maintaining a constant TTW will insure the best arc stability and consistency 2 For the best arc stability keep the arc on the front edge of the molten puddle and use a 5 to 10 degree gun angle from the vertical 3 If the arc is crackling or if spatter is excessive lengthen the arc by adjusting the TRIM knob If the arc is fluttering or difficult to control then shorten ...

Page 33: ...feeder without tachometer feedback is used b An Off the Arc wire feeder is used c TheMigwiretypeordiameterinstalledonthewirefeederdoesnothave a pulse synergic line available d Pulsearccharacteristicsotherthanthosepreprogrammedaredesired Byusingacombinationofadjustingthewirefeedspeedonthewirefeederand TRIM setting on the MultiPower 460 Pulse the pulse Mig welding arc can be tune in and stabilized T...

Page 34: ...ne the pulse parameters requied to make the weld Figure 4 6 Jumper Plug Installed Factory Shipped Jumper Plug Removed and Harness connected Non SynergicMode Thepulseparametersaredeterminedbythepositionof the pulse selection switches the MultiPower 460 Pulse TRIM knob and Wire Feed Speed preset Figure 4 7 Jumper Plug Removed and Harness Connected ...

Page 35: ...re air is used E WIREFEEDERCONTROLCIRCUITS Thesecircuitsareprotectedbyone10ampcircuitbreakermountedinthefront panel If these open the contactor and wire feeder will not operate F OVERTEMPERATUREPROTECTION If the power source reaches an abnormally high internal temperature the thermalprotectionwilldeenergizethecontactorcircuit shuttingdownthepower source but leaving the cooling fan on After the pow...

Page 36: ...utput or Low Open Circuit Voltage A B C Input voltage jumper links on terminal board improperly set check for proper voltage Poor output connections Take apart clean and reassemble Panel Remote switch in Remote position and remote voltage pot disabled Erratic Weld Current A B C D Welding cable size too small use correct cables Loose welding cable connection will usually get hot t ighten all connec...

Page 37: ...37 Schematic Diagram Section 1 MultiPower 460 230 460 575V 0558003034 C ...

Page 38: ...38 Schematic Diagram Section 2 MultiPower 460 230 460 575V 0558003034 C ...

Page 39: ...39 Schematic Diagram Section 3 MultiPower 460 230 460 575V 0558003034 C ...

Page 40: ...40 Wiring Diagram Section 1 MultiPower 460 230 460 575V 0558003064 D ...

Page 41: ...41 Wiring Diagram Section 2 MultiPower 460 230 460 575V 0558003064 D ...

Page 42: ...42 Wiring Diagram Section 3 MultiPower 460 230 460 575V 0558003064 D ...

Page 43: ... used with this equip ment The use of non ESAB parts may void your warranty Replacement parts may be ordered from your ESAB distributor or from ESAB Welding Cutting Products Attn Customer Service Dept P O Box 100545 411 S Ebenezer Road Florence SC 29501 0545 Be sure to indicate any special shipping instructions when ordering replacement parts To order parts by phone contact ESAB at 1 843 664 5540 ...

Page 44: ...se 1 2 678025 Terminal Assembly 2 1 952219 Outlet 110V Square 3 1 952937 Connection Box Rcpt 14FS X ROT 4 2 634515 SW TGGL SPDT 2 Pos 14A 125V Q D S3 5 5 3 951474 Switch Seal Black 6 1 952209 Recpt Panel 19 Pin 7 2 950122 Ckt Breaker 10A 32VDC 250VAC CB1 2 8 1 672786 Bolt Eye 75 10 X 2 00SL STL GR 9 1 38211 Control PCB PCB1 ...

Page 45: ...Normally Open S4 5 1 38196 PCB Display Assembly PCB2 6 2 634515 SW TGGL SPDT 2 POS 14A 125V Q D S3 5 7 3 951474 Switch Seal Black 8 1 91514 Label Warning Arc Welding Cutting 9 1 672786 Bolt Eye 10 1 954008 Danger High Voltage 11 1 636702 SW TGGL SPDT 3 POS 10A 250V SCR S2 12 1 9512240 Label Caution Lifting Eye 13 1 0558002969 Panel Right Side 14 1 36107 SW Pwr Disc S1 15 2 950167 Rubber Gromet 16 ...

Page 46: ... DESCRIPTION SYMBOL 0558002877 MultiPower 460 Pulse 1 1 0558002892 Switch Toggle 4PDT 2 2 0558001818 Knob Ribbed 3 1 954945 Overlay Multipower 460 Pulse 4 1 634515 Switch TGGL SPDT 2 POS 14A 124V Q D 5 1 951474 Switch Seal Black 6 1 0558002667 Panel Control Pulse 4 5 ...

Page 47: ...S QTY ITEM CIRCUIT NO REQ NO DESCRIPTION SYMBOL 0558002877 MultiPower 460 Pulse 1 1 13732733 Label for Install Use COP Wire 2 1 950219 Relief Strain 2 Non enclosed 3 1 0558001371 Panel Top Kydex Env 4 1 0558001370 Panel Left Side Kydex Env ...

Page 48: ...0558002877 MultiPower 460 Pulse 1 3 99511916 Diode Fwd 200V 250A 2 3 99511915 Diode Rev 200V 250A 3 1 954864 Label 3 Phase 4 1 2062334 Fan Motor 1 3 HP 1625 RPM 5 1 954699 Label Warning Fan Hazard 6 1 36173 Blade Fan 14 5 or 6 Fin 7 1 33939 Inductor 7 Turn 1 2 5 6 7 4 3 ...

Page 49: ...RTS QTY ITEM NO REQ NO DESCRIPTION SYMBOL 0558002877 MultiPower 460 Pulse 1 2 17280110 Res WW Fix d ST 100W 5 100 00 R3 R4 2 1 0558002712 Transformer 230 460 575V T1 3 12 672065 Strap Terminal 4 1 36110 Board Input Terminal 230 460 575V ...

Page 50: ... NO REQ NO DESCRIPTION SYMBOL 0558002877 MultiPower 460 Pulse 1 1 952938 SCR 480V 18A Panel MNT 2 1 951997 Transducer Current SH1 3 1 951085 SW THML D T 176 15A 120V Q D TS6 4 3 0558003077 IGBT 600V 300A Q1 2 3 5 1 951940 Capacitor 1 0uf 600VDC 10 C4 ...

Page 51: ... 12 2003 02 2004 revision Added note on Page 33 concerning Non Synergic pulse operation 10 2004 revision Updated wiring diagram 0558003064 per CN 043141 02 2007 revision Updated 0558003034 Schematic from Rev B to Rev C per Dave Perkins 23FEB07 e mail ...

Page 52: ...thorized Repair Stations WeldingEquipmentTroubleshooting C TECHNICAL SERVICE Telephone 800 ESAB 123 Fax 843 664 4452 Hours 8 00 AM to 5 00 PM EST Part Numbers Technical Applications Specifications Equipment Recommendations D LITERATUREREQUESTS Telephone 843 664 5562 Fax 843 664 5548 Hours 7 30 AM to 4 00 PM EST E WELDING EQUIPMENT REPAIRS Telephone 843 664 4487 Fax 843 664 5557 Hours 7 30 AM to 3 ...

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