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653 cvccDC Welding Power Source

Instrction Mana

F15572H 02/2006

This mana rovides comete instrctions or the oowin ower sorces startin with Seria No. M0RI603036, Janary 1996:

ESAB ITEM NO. 37830 653cvcc 230/460/575 vac, 3 h., 60 HzESAB ITEM NO. 37831 653cvcc 220/400 vac, 3 h., 50 Hz CE

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This equipment will perorm in conormity with the description thereo 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. Malunctioning or poorly maintained equipmentshould not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme-diately. Should such repair or replacement become necessary, the manuacturer recommends that a telephoneor written request or service advice be made to the Authorized Distributor rom whom it was purchased.

This equipment or any o its parts should not be altered without the prior written approval o the manuacturer.The user o this equipment shall have the sole responsibility or any malunction which results rom improperuse, aulty maintenance, damage, improper repair or alteration by anyone other than the manuacturer or a ser-vice acility designated by the manuacturer.

BE SuRE THIS INFORMATION REACHES THE OpERATOR.YOu CAN gET ExTRA COpIES THROugH YOuR SupplIER.

These INSTRuCTIONS are or eerienced oerators. I yo are not y amiiar with the

rincies o oeration and sae ractices or arc wedin and cttin eqiment, we reyo to read or booket, precations and Sae practices or Arc Wedin, Cttin, andgoin, Form 52529. Do NOT ermit ntrained ersons to insta, oerate, or maintainthis eqiment. Do NOT attemt to insta or oerate this eqiment nti yo have readand y nderstand these instrctions. I yo do not y nderstand these instrctions,contact yor sier or rther inormation. Be sre to read the Saety precations beore instain or oeratin this eqiment.

CAuTION

uSER RESpONSIBIlITY

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TABlE OF CONTENTS

1.0 Saety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51.1 Saety - English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51. Saety - Spanish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91. Saety - French . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

.0 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 . R e c e i v i n g - H a n d l i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8. Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18.4 Optional Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19.5 Saety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

.0 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. Receiving, Unpacking & Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. Primary (input) Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Output Welding Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4.0 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94.1 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94. Sequence o Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5 . 0 M a i n t e n a n c e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 . C l e a n i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6.0 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56. Testing and Replacing Bridge Assembly Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

7.0 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97. Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Section / Tite pae

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TABlE OF CONTENTS

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SECTION 1 SAFETY pRECAuTIONS

1.0 Saety precations 1.1 Saety Enish

WARNINg: These Saety Precautions areor your protection. They summarize pre-

cautionary inormation rom the reerenceslisted in Additional Saety Inormation sec-tion. Beore perorming any installation or operatingprocedures, be sure to read and ollow the saetyprecautions listed below as well as all other manuals,material saety data sheets, labels, etc. Failure to observeSaety Precautions can result in injury or death.

pROTECT YOuRSElF AND OTHERS Some wedin, cttin, and oinrocesses are noisy and reqire earrotection. The arc, ike the sn, emits

travioet uV and other radiationand can injre skin and eyes. Hot meta can casebrns. Trainin in the roer se o the rocessesand eqiment is essentia to revent accidents.Thereore:

1. Always wear saety glasses with side shields in anywork area, even i welding helmets, ace shields, andgoggles are also required.

. Use a ace shield tted with the correct lter andcover plates to protect your eyes, ace, neck, and

ears rom sparks and rays o the arc when operat-ing or observing operations. Warn bystanders notto watch the arc and not to expose themselves tothe rays o the electric-arc or hot metal.

. Wear ameproo gauntlet type gloves, heavy long-sleeve shirt, cuess trousers, high-topped shoes,and a welding helmet or cap or hair protection, toprotect against arc rays and hot sparks or hot metal.A ameproo apron may also be desirable as protec-tion against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,trouser cus, or pockets. Sleeves and collars should

be kept buttoned, and open pockets eliminated romthe ront o clothing.

5. Protect other personnel rom arc rays and hotsparks with a suitable non-ammable partition orcurtains.

6. Use goggles over saety glasses when chipping slagor grinding. Chipped slag may be hot and can y ar.Bystanders should also wear goggles over saetyglasses.

FIRES AND ExplOSIONS Heat romames and arcs can start fres. Hot

sa or sarks can aso case fres andeosions. Thereore:

1. Remove all combustible materials well away romthe work area or cover the materials with a protec-tive non-ammable covering. Combustible materialsinclude wood, cloth, sawdust, liquid and gas uels,solvents, paints and coatings, paper, etc.

. Hot sparks or hot metal can all through cracks orcrevices in oors or wall openings and cause a hid-den smoldering re or res on the oor below. Makecertain that such openings are protected rom hotsparks and metal.

. Do not weld, cut or perorm other hot work until theworkpiece has been completely cleaned so that thereare no substances on the workpiece which mightproduce ammable or toxic vapors. Do not do hotwork on closed containers. They may explode.

4. Have re extinguishing equipment handy or instantuse, such as a garden hose, water pail, sand bucket,or portable re extinguisher. Be sure you are trainedin its use.

5. Do not use equipment beyond its ratings. For ex-

ample, overloaded welding cable can overheat andcreate a re hazard.

6. Ater completing operations, inspect the work areato make certain there are no hot sparks or hot metalwhich could cause a later re. Use re watchers whennecessary.

7. For additional inormation, reer to NFPA Standard51B, "Fire Prevention in Use o Cutting and WeldingProcesses", available rom the National Fire Protec-tion Association, Batterymarch Park, Quincy, MA069.

ElECTRICAl SHOCK Contact withive eectrica arts and rond cancase severe injry or death. DO NOTse AC wedin crrent in dam areas,i movement is confned, or i there isdaner o ain.

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1. Be sure the power source rame (chassis) is con-nected to the ground system o the input power.

. Connect the workpiece to a good electricalground.

. Connect the work cable to the workpiece. A pooror missing connection can expose you or othersto a atal shock.

4. Use well-maintained equipment. Replace worn ordamaged cables.

5. Keep everything dry, including clothing, work

area, cables, torch/electrode holder, and powersource.

6. Make sure that all parts o your body are insulatedrom work and rom ground.

7. Do not stand directly on metal or the earth whileworking in tight quarters or a damp area; standon dry boards or an insulating platorm and wearrubber-soled shoes.

8. Put on dry, hole-ree gloves beore turning on thepower.

9. Turn o the power beore removing your gloves.

10. Reer to ANSI/ASC Standard Z49.1 (listed onnext page) or specic grounding recommenda-tions. Do not mistake the work lead or a groundcable.

ElECTRIC AND MAgNETIC FIElDS May be daneros. Eectric crrent owin throh any condctor cases ocaized Eectric and

Manetic Fieds EMF. Wedin andcttin crrent creates EMF arond wedin cabesand wedin machines. Thereore:

1. Welders having pacemakers should consult theirphysician beore welding. EMF may interere withsome pacemakers.

. Exposure to EMF may have other health eects whichare unknown.

. Welders should use the ollowing procedures tominimize exposure to EMF:

A. Route the electrode and work cables together.Secure them with tape when possible.

B. Never coil the torch or work cable around yourbody.

C. Do not place your body between the torch andwork cables. Route cables on the same side oyour body.

D. Connect the work cable to the workpiece as closeas possible to the area being welded.

E. Keep welding power source and cables as ar

away rom your body as possible.

FuMES AND gASES Fmes andases, can case discomort or harm,articary in confned saces. Donot breathe mes and ases. Shiedin ases can case ashyiation.

Thereore:

1. Always provide adequate ventilation in the work areaby natural or mechanical means. Do not weld, cut, orgouge on materials such as galvanized steel, stain-less steel, copper, zinc, lead, beryllium, or cadmiumunless positive mechanical ventilation is provided.Do not breathe umes rom these materials.

. Do not operate near degreasing and spraying opera-tions. The heat or arc rays can react with chlorinatedhydrocarbon vapors to orm phosgene, a highlytoxic gas, and other irritant gases.

. I you develop momentary eye, nose, or throat ir-ritation while operating, this is an indication thatventilation is not adequate. Stop work and takenecessary steps to improve ventilation in the workarea. Do not continue to operate i physical discom-ort persists.

4. Reer to ANSI/ASC Standard Z49.1 (see listing below)or specic ventilation recommendations.

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5. WARNINg: This rodct, when sed or wedinor cttin, rodces mes or aseswhich contain chemicas known tothe State o Caiornia to case birthdeects and, in some cases, cancer.

Caiornia Heath & Saety Code25249.5 et seq.

CYlINDER HANDlINg Cyinders,i mishanded, can rtre and vioenty reease as. Sdden rtreo cyinder, vave, or reie device caninjre or ki. Thereore:

1. Use the proper gas or the process and use theproper pressure reducing regulator designed tooperate rom the compressed gas cylinder. Do notuse adaptors. Maintain hoses and ttings in goodcondition. Follow manuacturer's operating instruc-tions or mounting regulator to a compressed gascylinder.

. Always secure cylinders in an upright position bychain or strap to suitable hand trucks, undercar-riages, benches, walls, post, or racks. Never securecylinders to work tables or xtures where they may

become part o an electrical circuit.

. When not in use, keep cylinder valves closed. Havevalve protection cap in place i regulator is not con-nected. Secure and move cylinders by using suitablehand trucks. Avoid rough handling o cylinders.

4. Locate cylinders away rom heat, sparks, and ames.Never strike an arc on a cylinder.

5. For additional inormation, reer to CGA Standard P-1,"Precautions or Sae Handling o Compressed Gasesin Cylinders", which is available rom CompressedGas Association, 15 Jeerson Davis Highway,Arlington, VA 0.

EQuIpMENT MAINTENANCE Faty orimroery maintained eqiment cancase injry or death. Thereore:

1. Always have qualied personnel perorm the instal-lation, troubleshooting, and maintenance work.Do not perorm any electrical work unless you arequalied to perorm such work.

. Beore perorming any maintenance work inside apower source, disconnect the power source romthe incoming electrical power.

. Maintain cables, grounding wire, connections, powercord, and power supply in sae working order. Donot operate any equipment in aulty condition.

4. Do not abuse any equipment or accessories. Keepequipment away rom heat sources such as urnaces,wet conditions such as water puddles, oil or grease,

corrosive atmospheres and inclement weather.

5. Keep all saety devices and cabinet covers in positionand in good repair.

6. Use equipment only or its intended purpose. Donot modiy it in any manner.

ADDITIONAl SAFETY INFORMATION Formore inormation on sae ractices or

eectric arc wedin and cttin eqiment, ask yor sier or a coy o"precations and Sae practices or ArcWedin, Cttin and goin", Form52529.

The ollowing publications, which are available romthe American Welding Society, 550 N.W. LeJuene Road,Miami, FL 16, are recommended to you:

1. ANSI/ASC Z49.1 - "Saety in Welding and Cutting"

. AWS C5.1 - "Recommended Practices or Plasma ArcWelding"

. AWS C5. - "Recommended Practices or Plasma ArcCutting"

4. AWS C5. - "Recommended Practices or Air CarbonArc Gouging and Cutting"

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5. AWS C5.5 - "Recommended Practices or Gas Tung-sten Arc Welding

6. AWS C5.6 - "Recommended Practices or Gas MetalArc Welding"

7. AWS SP - "Sae Practices" - Reprint, Welding Hand-book.

8. ANSI/AWS F4.1, "Recommended Sae Practices orWelding and Cutting o Containers That Have HeldHazardous Substances."

MEANINg OF SYMBOlS As sed

throhot this mana: Means Attention! Be Aert! Yor saety is invoved.

Means immediate hazards which,i not avoided, wi rest in immediate, serios ersona injryor oss o ie.

Means otentia hazards whichcod rest in ersona injry oross o ie.

Means hazards which cod restin minor ersona injry.

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SECTION 1 SEguRIDAD1.2 Saety Sanish

ADVERTENCIA: Estas Precauciones de Se-guridad son para su proteccin. Ellas hacenresumen de inormacin proveniente de las

reerencias listadas en la seccin "Inormacin Adi-cional Sobre La Seguridad". Antes de hacer cualquierinstalacin o procedimiento de operacin , asegresede leer y seguir las precauciones de seguridad listadasa continuacin as como tambin todo manual, hojade datos de seguridad del material, calcomanias, etc.El no observar las Precauciones de Seguridad puederesultar en dao a la persona o muerte.

pROTEJASE uSTED Y A lOS DEMASAnos rocesos de sodadra, cortey ranrado son ridosos y reqirenroteccin ara os odos. E arco,como e so , emite rayos travioeta

uV y otras radiaciones qe eden daar a iey os ojos. E meta caiente casa qemadras. Elentrenamiento en e so roio de os eqios yss rocesos es esencia ara revenir accidentes.por o tanto:

1. Utilice gaas de seguridad con proteccin a los ladossiempre que est en el rea de trabajo, an cuandoest usando careta de soldar, protector para su carau otro tipo de proteccin.

. Use una careta que tenga el ltro correcto y lentepara proteger sus ojos, cara, cuello, y odos de laschispas y rayos del arco cuando se est operando yobservando las operaciones. Alerte a todas las per-sonas cercanas de no mirar el arco y no exponersea los rayos del arco elctrico o el metal undido.

. Use guantes de cuero a prueba de uego, camisapesada de mangas largas, pantaln de ruedo liso,zapato alto al tobillo, y careta de soldar con capuchapara el pelo, para proteger el cuerpo de los rayos ychispas calientes provenientes del metal undido.En ocaciones un delantal a prueba de uego esnecesario para protegerse del calor radiado y laschispas.

4. Chispas y partculas de metal caliente puede alojarseen las mangas enrolladas de la camisa , el ruedo delpantaln o los bolsillos. Mangas y cuellos debernmantenerse abotonados, bolsillos al rente de lacamisa debern ser cerrados o eliminados.

5. Proteja a otras personas de los rayos del arco y chis-pas calientes con una cortina adecuada no-amablecomo divisin.

6. Use careta protectora adems de sus gaas de segu-ridad cuando est removiendo escoria o puliendo.

La escoria puede estar caliente y desprenderse convelocidad. Personas cercanas debern usar gaasde seguridad y careta protectora.

FuEgO Y ExplOSIONES E caor deas amas y e arco eden ocacionar

eos. Escoria caiente y as chisaseden casar eos y eosiones.por o tanto:

1. Remueva todo material combustible lejos del reade trabajo o cubra los materiales con una cobija aprueba de uego. Materiales combustibles incluyenmadera, ropa, lquidos y gases amables, solventes,pinturas, papel, etc.

. Chispas y partculas de metal pueden introducirse enlas grietas y agujeros de pisos y paredes causandouegos escondidos en otros niveles o espacios.

Asegrese de que toda grieta y agujero est cubiertopara proteger lugares adyacentes contra uegos.. No corte, suelde o haga cualquier otro trabajo

relacionado hasta que la pieza de trabajo est to-talmente limpia y libre de substancias que puedanproducir gases inamables o vapores txicos. Notrabaje dentro o uera de contenedores o tanquescerrados. Estos pueden explotar si contienen vaporesinamables.

4. Tenga siempre a la mano equipo extintor de uegopara uso instantneo, como por ejemplo unamanguera con agua, cubeta con agua, cubeta con

arena, o extintor porttil. Asegrese que usted estaentrenado para su uso.5. No use el equipo uera de su rango de operacin. Por

ejemplo, el calor causado por cable sobrecarga enlos cables de soldar pueden ocasionar un uego.

6. Despus de termirar la operacin del equipo, inspec-cione el rea de trabajo para cerciorarse de que laschispas o metal caliente ocasionen un uego mstarde. Tenga personal asignado para vigilar si esnecesario.

7. Para inormacin adicional , haga reerencia a lapublicacin NFPA Standard 51B, "Fire Prevention in

Use o Cutting and Welding Processes", disponiblea travs de la National Fire Protection Association,Batterymarch Park, Quincy, MA 069.

CHOQuE ElECTRICO E contactocon as artes ectricas enerizadasy tierra ede casar dao severo omerte. NO se sodadra de corriente aterna AC en reas hmedas,

de movimiento confnado en ares estrechos osi hay osibiidad de caer a seo.

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SECTION 1 SEguRIDAD

1. Asegrese de que el chasis de la uente de poderest conectado a tierra atravs del sistema deelectricidad primario.

. Conecte la pieza de trabajo a un buen sistema detierra sica.

. Conecte el cable de retorno a la pieza de trabajo.Cables y conductores expuestos o con malasconexiones pueden exponer al operador u otraspersonas a un choque elctrico atal.

4. Use el equipo solamente si est en buenas condi-ciones. Reemplaze cables rotos, daados o conconductores expuestos.

5. Mantenga todo seco, incluyendo su ropa, el rea detrabajo, los cables, antorchas, pinza del electrodo,y la uente de poder.

6. Asegrese que todas las partes de su cuerpo estn

insuladas de ambos, la pieza de trabajo y tierra.7. No se pare directamente sobre metal o tierra mien-tras trabaja en lugares estrechos o reas hmedas;trabaje sobre un pedazo de madera seco o unaplataorma insulada y use zapatos con suela degoma.

8. Use guantes secos y sin agujeros antes de energizarel equipo.

9. Apage el equipo antes de quitarse sus guantes.10. Use como reerencia la publicacin ANSI/ASC

Standard Z49.1 (listado en la prxima pgina) pararecomendaciones especcas de como conectar el

equipo a tierra. No conunda el cable de soldar ala pieza de trabajo con el cable a tierra.

CAMpOS ElECTRICOS Y MAgNETICOS Son eirosos. la corrienteectrica ye atravs de caqiercondctor casando a nive ocaCamos Ectricos y Manticos

EMF. las corrientes en e rea de corte y sodadra,crean EMF arrededor de os cabes de sodar y asmaqinas. por o tanto:

1. Soldadores u Operadores que use marca-pasos parael corazn debern consultar a su mdico antes desoldar. El Campo Electromagntico (EMF) puedeintererir con algunos marca-pasos.

. Exponerse a campos electromagnticos (EMF) puedecausar otros eectos de salud an desconocidos.

. Los soldadores debern usar los siguientes proced-imientos para minimizar exponerse al EMF:

A. Mantenga el electrodo y el cable a la pieza detrabajo juntos, hasta llegar a la pieza que ustedquiere soldar. Asegrelos uno junto al otro concinta adhesiva cuando sea posible.

B. Nunca envuelva los cables de soldar alrededorde su cuerpo.

C. Nunca ubique su cuerpo entre la antorcha y elcable, a la pieza de trabajo. Mantega los cables aun slo lado de su cuerpo.

D. Conecte el cable de trabajo a la pieza de trabajolo ms cercano posible al rea de la soldadura.

E. Mantenga la uente de poder y los cables de soldarlo ms lejos posible de su cuerpo.

HuMO Y gASES E hmo y osases, eden casar maestar odao, articarmente en esaciossin ventiacin. No inhae e hmoo ases. E as de roteccin ede

casar ata de oeno.por o tanto:

1. Siempre provea ventilacin adecuada en el reade trabajo por medio natural o mecnico. No solde,

corte, o ranure materiales con hierro galvanizado,acero inoxidable, cobre, zinc, plomo, berlio, o cad-mio a menos que provea ventilacin mecnicapositiva . No respire los gases producidos porestos materiales.

. No opere cerca de lugares donde se aplique sub-stancias qumicas en aerosol. El calor de los rayosdel arco pueden reaccionar con los vapores dehidrocarburo clorinado para ormar un osgeno,o gas txico, y otros irritant es.

. Si momentneamente desarrolla inrritacin de

ojos, nariz o garganta mientras est operando, esindicacin de que la ventilacin no es apropiada.Pare de trabajar y tome las medidas necesariaspara mejorar la ventilacin en el rea de trabajo.No contine operando si el malestar sico per-siste.

4. Haga reerencia a la publicacin ANSI/ASC StandardZ49.1 (Vea la lista a continuacin) para recomen-daciones especcas en la ventilacin.

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SECTION 1 SEguRIDAD

5. ADVERTENCIA Este rodcto cando se tiiza ara sodadras o cortes,rodce hmos o ases, oscaes contienen qmicosconocidos or e Estado de Cai

ornia de casar deectos en enacimiento, o en anos casos,Cancer. Caiornia Heath &Saety Code 25249.5 et seq.

MANEJO DE CIlINDROS losciindros, si no son manejadoscorrectamente, eden romerse y iberar vioentamenteases. Rotra reentina deciindro, vva, o vva de

escae ede casar dao omerte. por o tanto:

1. Utilize el gas apropiado para el proceso y utilizeun regulador diseado para operar y reducir lapresin del cilindro de gas . No utilice adapta-dores. Mantenga las mangueras y las conexionesen buenas condiciones. Observe las instruccionesde operacin del manuacturero para montar elregulador en el cilindro de gas comprimido.

. Asegure siempre los cilindros en posicin vertical

y amrrelos con una correa o cadena adecuadapara asegurar el cilindro al carro, transportes, tab-lilleros, paredes, postes, o armazn. Nunca asegurelos cilindros a la mesa de trabajo o las piezas queson parte del circuito de soldadura . Este puede serparte del circuito ellectrico.

. Cuando el cilindro no est en uso, mantenga lavlvula del cilindro cerrada. Ponga el capote deproteccin sobre la vlvula si el regulador noest conectado. Asegure y mueva los cilindrosutilizando un carro o transporte adecuado. Eviteel manejo brusco de los

MANTENIMIENTO DEl EQuIpO Eqiodeectoso o ma mantenido ede casar dao o merte. por o tanto:

1. Siempre tenga personal cualicado para eec-tuar l a instalacin, diagnstico, y mantenimientodel equipo. No ejecute ningn trabajo elctrico amenos que usted est cualicado para hacer eltrabajo.

. Antes de dar mantenimiento en el interior de lauente de poder, desconecte la uente de poderdel suministro de electricidad primaria.

. Mantenga los cables, cable a tierra, conexciones,cable primario, y cualquier otra uente de poderen buen estado operacional. No opere ningnequipo en malas condiciones.

4. No abuse del equipo y sus accesorios. Mantengael equipo lejos de cosas que generen calor comohornos, tambin lugares hmedos como charcosde agua , aceite o grasa, atmseras corrosivas y

las inclemencias del tiempo.5. Mantenga todos los artculos de seguridad ycoverturas del equipo en su posicin y en buenascondiciones.

6. Use el equipo slo para el propsito que uediseado. No modique el equipo en ningunamanera.

INFORMACION ADICIONAl DE SEguRIDAD para ms inormacin sobre asrcticas de seridad de os eqios de

arco ectrico ara sodar y cortar, rentea s sidor or na coia de "precationsand Sae practices or Arc Wedin, Cttinand goinForm 52529.

Las siguientes publicaciones, disponibles atravs dela American Welding Society, 550 N.W. LeJuene Road,Miami, FL 16, son recomendadas para usted:

1. ANSI/ASC Z49.1 - "Saety in Welding and Cutting"

. AWS C5.1 - "Recommended Practices or Plasma ArcWelding"

. AWS C5. - "Recommended Practices or Plasma ArcCutting"

4. AWS C5. - "Recommended Practices or Air CarbonArc Gouging and Cutting"

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SECTION 1 SEguRIDAD

SIgNIFICADO DE lOS SIMBOlOS Sen sted avanza en a ectrade este oeto: los Smboos Sinifcan Atencin! Est Aerta! Setrata de s seridad.

Sinifca rieso inmediato qe,de no ser evadido, ede restarinmediatamente en serio daoersona o a merte.

Sinifca e rieso de n eirootencia qe ede restar enserio dao ersona o a merte.

Sinifca e osibe rieso qeede restar en menores daosa a ersona.

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SECTION 1 SCuRIT1.3 Saety French INCENDIES ET ExplOSIONS la

chaer rovenant des ammes o de'arc et rovoqer n incendie. leaitier incandescent o es tinceesevent aement rovoqer n

incendie o ne eosion. par consqent :

1. loignez sufsamment tous les matriaux combus-tibles de l'aire de travail et recouvrez les matriauxavec un revtement protecteur ininammable. Lesmatriaux combustibles incluent le bois, les vte-ments, la sciure, le gaz et les liquides combustibles,les solvants, les peintures et les revtements, lepapier, etc.

. Les tincelles et les projections de mtal incan-descent peuvent tomber dans les ssures dansles planchers ou dans les ouvertures des murs etdclencher un incendie couvant l'tage inrieurAssurez-vous que ces ouvertures sont bien protges

des tincelles et du mtal incandescent.. N'excutez pas de soudure, de coupe ou autre tra-

vail chaud avant d'avoir compltement nettoy lasurace de la pice traiter de aon ce qu'il n'aitaucune substance prsente qui pourrait produiredes vapeurs inammables ou toxiques. N'excutezpas de travail chaud sur des contenants ermscar ces derniers pourraient exploser.

4. Assurez-vous qu'un quipement d'extinctiond'incendie est disponible et prt servir, tel qu'untuyau d'arrosage, un seau d'eau, un seau de sableou un extincteur portati. Assurez-vous d'tre bien

instruit par rapport l'usage de cet quipement.5. Assurez-vous de ne pas excder la capacit del'quipement. Par exemple, un cble de soudagesurcharg peut surchauer et provoquer un in-cendie.

6. Une ois les oprations termines, inspectez l'aire detravail pour assurer qu'aucune tincelle ou projec-tion de mtal incandescent ne risque de provoquerun incendie ultrieurement. Employez des guetteursd'incendie au besoin.

7. Pour obtenir des inormations supplmentaires,consultez le NFPA Standard 51B, "Fire Prevention in

Use o Cutting and Welding Processes", disponible auNational Fire Protection Association, BatterymarchPark, Quincy, MA 069.

CHOC lECTRIQuE le contact avecdes ices ectriqes o es icesde mise a terre sos tension etcaser des bessres raves o mortees. NE pAS tiiser n corant de

sodae c.a. dans n endroit hmide, en esacerestreint o si n daner de chte se ose.

AVERTISSEMENT : Ces rgles de scuritont pour but d'assurer votre protection. Ilsrcapitulent les inormations de prcautionprovenant des rrences dans la section

des Inormations de scurit supplmentaires. Avant deprocder l'installation ou d'utiliser l'unit, assurez-vous

de lire et de suivre les prcautions de scurit ci-des-sous, dans les manuels, les ches d'inormation sur lascurit du matriel et sur les tiquettes, etc. Tout dautd'observer ces prcautions de scurit peut entranerdes blessures graves ou mortelles.

pROTgEZVOuS les rocesss desodae, de coae et de oeaerodisent n nivea de brit ev et

eie 'emoi d'ne rotection aditive. l'arc, totcomme e soei, met des rayons travioets en sd'atre rayons qi event caser des bessres aea et es ye. le mta incandescent et caser

des brres. une ormation reie 'sae desrocesss et de 'qiement est essentiee orrvenir es accidents. par consqent:

1. Portez des lunettes protectrices munies d'crans la-traux lorsque vous tes dans l'aire de travail, mmesi vous devez porter un casque de soudeur, un cranacial ou des lunettes tanches.

. Portez un cran acial muni de verres ltrants et deplaques protectrices appropries an de protgervos yeux, votre visage, votre cou et vos oreilles destincelles et des rayons de l'arc lors d'une oprationou lorsque vous observez une opration. Avertissezles personnes se trouvant proximit de ne pas re-

garder l'arc et de ne pas s'exposer aux rayons de l'arclectrique ou le mtal incandescent.. Portez des gants igniugis crispin, une chemise

paisse manches longues, des pantalons sansrebord et des chaussures montantes an de vousprotger des rayons de l'arc, des tincelles et du mtalincandescent, en plus d'un casque de soudeur oucasquette pour protger vos cheveux. Il est galementrecommand de porter un tablier ininammable ande vous protger des tincelles et de la chaleur parrayonnement.

4. Les tincelles et les projections de mtal incandescentrisquent de se loger dans les manches retrousses,les rebords de pantalons ou les poches. Il est recom-

mand de garder boutonns le col et les manches etde porter des vtements sans poches en avant.

5. Protgez toute personne se trouvant proximit destincelles et des rayons de l'arc l'aide d'un rideau oud'une cloison ininammable.

6. Portez des lunettes tanches par dessus vos lunettesde scurit lors des oprations d'caillage ou demeulage du laitier. Les cailles de laitier incandescentpeuvent tre projetes des distances considrables.Les personnes se trouvant proximit doivent gale-ment porter des lunettes tanches par dessus leurlunettes de scurit.

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SECTION 1 SCuRIT

. Les soudeurs doivent suivre les procdures suivantespour minimiser l'exposition aux champs lectriqueset magntiques :A. Acheminez l'lectrode et les cbles de masse

ensemble. Fixez-les l'aide d'une bande adhsive

lorsque possible.B. Ne jamais enrouler la torche ou le cble de masse

autour de votre corps.C. Ne jamais vous placer entre la torche et les cbles

de masse. Acheminez tous les cbles sur le mmect de votre corps.

D. Branchez le cble de masse la pice traiter leplus prs possible de la section souder.

E. Veillez garder la source d'alimentation pour lesoudage et les cbles une distance appropriede votre corps.

lES VApEuRS ET lES gAZ eventcaser n maaise o des dommaescorores, s articirementdans es esaces restreints. Ne resirez as es vaers et es az. leaz de rotection risqe de caser'ashyie. par consqent :

1. Assurez en permanence une ventilation adquatedans l'aire de travail en maintenant une ventila-tion naturelle ou l'aide de moyens mcanique.

N'eectuez jamais de travaux de soudage, de coup-age ou de gougeage sur des matriaux tels quel'acier galvanis, l'acier inoxydable, le cuivre, le zinc,le plomb, le berylliym ou le cadmium en l'absencede moyens mcaniques de ventilation efcaces. Nerespirez pas les vapeurs de ces matriaux.

. N'eectuez jamais de travaux proximit d'uneopration de dgraissage ou de pulvrisation.Lorsque la chaleurou le rayonnement de l'arc entre en contact avec lesvapeurs d'hydrocarbure chlor, ceci peut dclencherla ormation de phosgne ou d'autres gaz irritants,

tous extrmement toxiques.. Une irritation momentane des yeux, du nez ou de la

gorge au cours d'une opration indique que la ven-tilation n'est pas adquate. Cessez votre travail ande prendre les mesures ncessaires pour amliorerla ventilation dans l'aire de travail. Ne poursuivezpas l'opration si le malaise persiste.

4. Consultez ANSI/ASC Standard Z49.1 ( la pagesuivante) pour des recommandations spciquesconcernant la ventilation.

1. Assurez-vous que le chssis de la sourced'alimentation est branch au systme de mise la terre de l'alimentation d'entre.

. Branchez la pice traiter une bonne mise deterre lectrique.

. Branchez le cble de masse la pice traiter etassurez une bonne connexion an d'viter le risquede choc lectrique mortel.

4. Utilisez toujours un quipement correctemententretenu. Remplacez les cbles uss ou endom-mags.

5. Veillez garder votre environnement sec, incluantles vtements, l'aire de travail, les cbles, le porte-lectrode/torche et la source d'alimentation.

6. Assurez-vous que tout votre corps est bien isolde la pice traiter et des pices de la mise laterre.

7. Si vous devez eectuer votre travail dans un espacerestreint ou humide, ne tenez vous pas directe-ment sur le mtal ou sur la terre; tenez-vous surdes planches sches ou une plate-orme isole etportez des chaussures semelles de caoutchouc.

8. Avant de mettre l'quipement sous tension, isolezvos mains avec des gants secs et sans trous.

9. Mettez l'quipement hors tension avant d'enlevervos gants.

10. Consultez ANSI/ASC Standard Z49.1 (list la page suivante) pour des recommandations

spciques concernant les procdures de mise la terre. Ne pas conondre le cble de masse avecle cble de mise la terre.

CHAMpS lECTRIQuES ET MAgNTIQuES comortent n risqede daner. le corant ectriqeqi asse dans n'imorte qe condcter rodit des chams ec

triqes et mantiqes ocaiss. le sodae et ecorant de coae crent des chams ectriqeset mantiqes ator des cbes de sodae et

'qiement. par consqent :

1. Un soudeur ayant un stimulateur cardiaque doitconsulter son mdecin avant d'entreprendre uneopration de soudage. Les champs lectriques etmagntiques peuvent causer des ennuis pour cer-tains stimulateurs cardiaques.

. L'exposition des champs lectriques et magn-tiques peut avoir des eets nastes inconnus pourla sant.

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SECTION 1 SCuRIT

1. Eorcez-vous de toujours conier les tchesd'installation, de dpannage et d'entretien unpersonnel quali. N'eectuez aucune rparationlectrique moins d'tre quali cet eet.

. Avant de procder une tche d'entretien l'intrieur de la source d'alimentation, dbranchezl'alimentation lectrique.

. Maintenez les cbles, les ls de mise la terre, lesbranchements, le cordon d'alimentation et la sourced'alimentation en bon tat. N'utilisez jamais unquipement s'il prsente une dectuosit quel-conque.

4. N'utilisez pas l'quipement de aon abusive. Gardezl'quipement l'cart de toute source de chaleur,notamment des ours, de l'humidit, des aquesd'eau, de l'huile ou de la graisse, des atmosphrescorrosives et des intempries.

5. Laissez en place tous les dispositis de scurit ettous les panneaux de la console et maintenez-lesen bon tat.

6. Utilisez l'quipement conormment son usageprvu et n'eectuez aucune modication.

INFORMATIONS SupplMENTAIRES RElATIVES lA SCuRIT por obtenir de'inormation smentaire sr es resde scrit observer or 'qiementde sodae 'arc ectriqe et e coae,demandez n eemaire d ivret "precations and Sae practices or Arc Wedin,Cttin and goin", Form 52529.

Les publications suivantes sont galement recomman-

des et mises votre disposition par l'American WeldingSociety, 550 N.W. LeJuene Road, Miami, FL 16 :1. ANSI/ASC Z49.1 - "Saety in Welding and Cutting". AWS C5.1 - "Recommended Practices or Plasma Arc

Welding". AWS C5. - "Recommended Practices or Plasma Arc

Cutting"4. AWS C5. - "Recommended Practices or Air Carbon

Arc Gouging and Cutting"

5. AVERTISSEMENT : Ce rodit, orsq'i est tiisdans ne oration de sodae o decoae, dae des vaers o desaz contenant des chimiqes considres ar 'tat de a Caiornie comme

tant ne case des maormationsconnitaes et dans certains cas, dcancer. Caiornia Heath & SaetyCode 25249.5 et seq.

MANIpulATION DES CYlINDRES la maniation d'n cyindre, sansobserver es rcations ncessaires,et rodire des issres et nchaement danere des az.

une brisre sodaine d cyindre, de a soae o

d disositi de srression et caser des bessres raves o mortees. par consqent :

1. Utilisez toujours le gaz prvu pour une oprationet le dtendeur appropri conu pour utilisationsur les cylindres de gaz comprim. N'utilisez jamaisd'adaptateur. Maintenez en bon tat les tuyaux etles raccords. Observez les instructions d'oprationdu abricant pour assembler le dtendeur sur uncylindre de gaz comprim.

. Fixez les cylindres dans une position verticale, l'aide d'une chane ou une sangle, sur un chariot

manuel, un chssis de roulement, un banc, un mur,une colonne ou un support convenable. Ne xezjamais un cylindre un poste de travail ou toute autredispositi aisant partie d'un circuit lectrique.

. Lorsque les cylindres ne servent pas, gardez lessoupapes ermes. Si le dtendeur n'est pas bran-ch, assurez-vous que le bouchon de protection dela soupape est bien en place. Fixez et dplacez lescylindres l'aide d'un chariot manuel appropri.Toujours manipuler les cylindres avec soin.

4. Placez les cylindres une distance appropriede toute source de chaleur, des tincelles et desammes. Ne jamais amorcer l'arc sur un cylindre.

5. Pour de l'inormation supplmentaire, consultezCGA Standard P-1, "Precautions or Sae Handlingo Compressed Gases in Cylinders", mis votre dis-position par le Compressed Gas Association, 15Jeerson Davis Highway, Arlington, VA 0.

ENTRETIEN DE l'QuIpEMENT un qiement entreten de aon dectese oinadqate et caser des bessresraves o mortees. par consqent :

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SECTION 1 SCuRIT

SIgNIFICATION DES SYMBOlESCe symboe, tiis artot dans ce mane,sinife "Attention" ! Soyez viiant ! Votrescrit est en je.

Sinife n daner immdiat. la sitation etentraner des bessres raves o mortees.

Sinife n daner otentie qi et entraner desbessres raves o mortees.

Sinife n daner qi et entraner des bessrescororees mineres.

DANgER

AVERTISSEMENT

ATTENTION

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ESAB 653cvccMulti-process, three phase power sources de-signed or heavy duty industrial DC welding ap-

plicationsUse or Mig, fux cored wire, submerged arc and

stick electrode welding or air carbon arc gougingCompatible with 42v wire eeders: MobileMaster IV,

2E, 4HD, 4HD Dual and with 115v wire eeders/controls: Mig 35, Digimig, Digimig Dual, Digimatic

II, UEC-8, DuraDrive 4-30 and DuraDrive 4-48

115 vac outlet or water circulator or toolsControl electronics are protected rom dirt and dust

in an easy-access compartmentOptional wire eed adaptor kits or Miller and Lin-

coln wire eeders

Ordering Inormation

ESAB Power Sources653cvcc, 0/460/575 vac, ph, 60 Hz .................................................... 780653cvcc, 0/400 (80-415) vac, ph, 50 Hz CE ...................................78

ESAB 653cvcc Migmaster PackagesThe ollowing package includes an ESAB DC power source, wireeeder, 8 t. (.4m) control cable, 8 t. (.4m) gas hose, .05/.045in. (.9/1.mm) eed roll, - 15 t. (4.5m) GunMaster gas-cooled gun,15t. work cable with clamp, 15 t. wire eeder weld cable andR--FM-580 regulator with adjustable owmeter.Mimaster 653cvcc, Mi 4HD, gM-400cc,

0/460/575 v ac .........................................................................................64

Options & AccessoriesHC3B Hand Contro, 0 t. (9.1m) cable

(requires 055800146) ..........................................................................88Mini Boom or Mi 4HD (requires Swivel Post) ..................................4Swive post, use with Mig 4HD or Mig E wire eeders ..................... 617Ato Fan Kit ....................................................................................................6707TR29 Trck Kit..................................................................................................794Remote Contro Kit ............................................................................055800146Mier Wire Feeder Adator Kit (4 vac only) .........................0558001415lincon Wire Feeder Adator Kit ................................................0558001416Work Cabe with Cam (15 t.) ............................ ......................... 0558001440Feeder Cabe with l (15 t.) ........................................................0558001441

SpecifcationsRated DC Output* @ 100% duty cycle,

50/60 Hz, cv or cc 65cvcc .........................................650 amps @ 44 vdcRated DC Output* @ 60% duty cycle,

50/60 Hz, cv or cc 65cvcc .........................................750 amps @ 44 vdcOpen Circuit Voltage, 50/60 Hz 65cvcc ...................54 vdc (cv)/59 vdc (cc)Primary Input Voltage & Current @ rated 100% duty cycle load

65cvcc, 0/460 vac, 60 Hz, ph ......................................108/54 amps65cvcc, 0/460/575 vac, 60 Hz, ph .......................108/54/4 amps65cvcc, 0/400 (80-415) vac, 50 Hz, ph ......................................................................................................................................10/56 (59-54) amps

Power Factor @ rated load .................................................................................8%Auxiliary Output Power (receptacle) ....................115 vac, 50/60 Hz, 10 amps

W x L x H ..........................18.75 in. (46 cm) x .5 in. (8 cm) x 5 in. (64 cm)Net Weight,** 60 Hz 65cvcc .......................... ............................ 49 lb. (4 kg)Shipping Weight** (approximate), 60 Hz 65cvcc .................50 lb. (9 kg)

* For 208 vac, 60 Hz and 380 vac, 50 Hz service, derate output currentrating 10%.

** For 50 Hz models, add 40 lb. (18kg)

Shown with optional DuraDrive 4 -48 wire eeder,

GM-400 Mig welding torch, TR-29 Truck kit,

15 t. work cable and welding wire

SECTION 2 DESCRIpTION

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Tabe 21. Secifcations or 653cvcc

NOTE: The 653cvcc may also operate from a 200 (208)-volt a.c. primary input using the 230-volt changeover connections. However, when connected to

this source (200-volt), the output voltage is derated 10%.

2.1 gENERAl

This manual provides inormation to amiliarize the operator with the design, installation and operation o the 65cvccmodel power source. DO NOT attempt to install or operate this equipment until you have read and ully understandthese instructions. The inormation presented here should be given careul consideration to ensure optimum peror-

mance o this equipment.

2.2 RECEIVINgHANDlINg

Upon receipt, remove all packing material and careully inspect or any damage that may have occurred during shipment.Any claims or loss or damage that may have occurred in transit must be led by the purchaser with the carrier. A copy othe bill o lading and reight bill will be urnished by the carrier on request.

When requesting inormation concerning this equipment, it is essential that the Item number, Serial number and Modelnumber o the equipment be supplied.

2.3 DESCRIpTION

The 65cvcc is a multi-process power sources designed or Mig and spray transer (GMAW), ux core (FCAW), and stick(SMAW) welding as well as submerged arc welding (SAW) and air carbon arc cutting/gouging (CAC-A) applications. Table-1 outlines the electrical and physical specications o the available models.

OPEN CIRCUIT VOLTAGE (U0) 54 vdc (cv)/59 vdc (cc)

RATED DUTY CYCLE 60% 100%

OUTPUT Current (I) 750 A 650 A (60Hz)/600 A (50Hz)

Voltage (U) 44 V 44 V

RATED Phase 60 Hz Volts (U1) Current (I1) Flat Current (I1) FlatINPUT 0 V 14 A 108 A

460 V 6 A 54 A

575 V 50 A 4 A

50 Hz 0 V 17 A 10 A

400 V 70 A 56 A

Power Factor at Rated Output 8%

Welding Range 750 A/44 V - 50 A/14 V

Auxiliary Power 115 V ac @ 10 A, 60 Hz

PHYSICAL SPECIFICATIONS 60 Hz. 50 Hz.

Height (without lit eye) 5.0 (6. cm)

Width 18.8 (48. cm)

Depth .5 (81.9 cm)

Net Weight 49 lbs (4 kg) 58 lbs (40 kg)

Shipping Weight 50 lbs (8 kg) 58 lbs (44 kg)

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2.4 OpTIONAl ACCESSORIES

2.4.1 TR29 Trck Kit Item No. 37924This truck kit provides complete mobility o the power source. The kit consists o castors, rear cylinder rack and wheels,gas cylinder bracket, cylinder chain, and pull handle.

2.4.2 Swive Mont Kit Item No. 36172This kit allows ESAB wire eeders with swivel base mounts to be mounted to the top o the power source on an insulatedswivel mount. This allows the eeder to reely rotate, relieving potential wire eed problems while increasing the workingarea o the torch.

2.5 SAFETY

Beore the equipment is put into operation, the saety section at the ront o this manual should be read completely. Thiswill help avoid possible injury due to misuse or improper installation.

The denitions relating to the:

saety notations are described at the end o the Saety Section in the ront o this manual read them and their secifc tet reerences carey.

60

0

50

40

0

0

10

0 100 00 00 400 600 700 800500 900

D.C. OuTpuT CuRRENT AMpSCV MODE FOR MIg/SuB ARC

AMpS

Volts

MAx.

MIN.

60

0

50

40

0

0

10

0 100 00 00 400 600 700 800 1000500 900AMpS

MIN. MAx.Volts

D.C. OuTpuT CuRRENT AMpSCC MODE FOR STICK/ARC gOugINg/SuB ARC

Fire 21. VotAmere Crves

2.3.1 power SorceThe power source is a constant current/constant potential, Silicon Controlled Rectier (SCR), three-phase, star-connectedtransormer/rectier type dc unit with solid state contactor and control circuitry. It provides the volt-ampere characteris-tics desired or conventional MIG, ux core and submerged arc welding in the CV mode or stick welding and arc gougingin the CC mode.

2.3.2 VotAmere CharacteristicsThe curves shown in Figure -1 represent the volt-ampere static characteristics or the power source. The slant o thesecurves is reerred to as the "slope" and is generally dened as the "voltage drop per 100 amperes o current use". Thesecurves show the output voltage available at any given output current rom the minimum to the maximum setting o thevoltage control. Because the volt-ampere slope is xed, it is possible to select welding conditions by estimating the open-circuit voltage required or the load current when operating in the CV mode.


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1

SECTION 3 INSTAllATION

3.1 lOCATION

A proper installation site is necessary or the power source to provide dependable service. A proper installation site permitsreedom o air movement through the unit while minimizing exposure to dust, dirt, moisture, and corrosive vapors. A mini-mum o 18 inches (46 cm) is required between the side and rear panels o the power source and the nearest obstruction.

The selected site should also allow easy removal o the power source outer enclosure or maintenance. See Table -1 oroverall dimensions o the unit.

3.2 RECEIVINg, uNpACKINg AND plACEMENT

A. Immediately upon receipt o the power source, inspect or damage which may have occurred in transit. Notiy thecarrier o any deects or damage.

B. Remove the power source rom the container. Remove all packing materials. Check the container or any looseparts.

C. Check air passages at ront and rear o cabinet, making sure that no packing materials that may obstruct air owthrough the power source.

D. Install the liting ring urnished with the power sources into the top o the unit.

E. Ater selecting an installation site, place the power source in the desired location. The unit may be lited eitherby using the liting ring or by orklit truck. I a orklit is used or liting the unit, be sure that the lit orks are longenough to extend completely under the base.

Do not se fters on this nit as they wod restrict the vome ointake air reqired or roer cooin. Ott ratins on this nit arebased on an nobstrcted sy o cooin air drawn over its internacomonents. Warranty is void i any tye o fterin device is sed.

CAuTION

CAuTIONFor itin roses and or keein dst, moistre, and other orein materia rom enterin the ower sorce, the itin eyebotmst be y tihtened with a too.

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3.3 pRIMARY INpuT ElECTRICAl CONNECTION

This power source is a three-phase unit and must be connected to a three-phase power supply. It is recommended that theunit be operated on a dedicated circuit to prevent impairment o perormance due to an overloaded circuit.

Tabe 31. Recommended Sizes or IntCondctors and line Fses

* Sized per National Code or 80 C rated copper conductors @ 0 C ambient. Not more than three conductors in raceway or cable. Localcodes should be ollowed i they speciy sizes other than those listed

A. The primary power leads must be insulated copper conductors. Three power leads and one ground wire are required.Either rubber covered cable or conduit (exible or solid) may be used. Table -1 provides recommended input conduc-tors and line use sizes.

B. Remove the top cover. Identiy primary power connections, TB, and the ground lug located on the A-Frame bracket.Reer to gure .1.

ElECTRIC SHOCK CAN KIll! BEFORE MAKINg ElECTRICAl INpuTCONNECTIONS TO THE pOWER SOuRCE, "MACHINERY lOCKOuTpROCEDuRES" SHOulD BE EMplOYED. IF THE CONNECTIONS ARETO BE MADE FROM A lINE DISCONNECT SWITCH, plACE THE SWITCHIN THE OFF pOSITION AND pADlOCK IT TO pREVENT INADVERTENTTRIppINg . IF THE CONNECTION IS MADE FROM A FuSEBOx, REMOVETHE CORRESpONDINg FuSES AND pADlOCK THE BOx COVER. IF IT ISNOT pOSSIBlE TO uSE pADlOCKS, ATTACH A RED TAg TO THE lINEDISCONNECT SWITCH (OR FuSE BOx) WARNINg OTHERS THAT THECIRCuIT IS BEINg WORKED ON.


WARNINg

Rated Input@ 100% Duty Cycle

Input & GNDConductor *

CU / AWG

FuseSize

AmpsVolts Amps

00400460575

686676

No. 6No. 6No. 8No. 8

No. 10

100100606050

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C. Thread the properly stripped input and ground conduc-tors through the large strain relie in the rear panel o thepower source. Connect the three input conductors to thethree input terminals on TB (see gure -1). To connectthe ground conductor, thread the ground wire through theground ault switch bracket and connect to the ground lugprovided on the A-Frame.

D. Check all connections or proper tightness. Ensure all con-nections are correct and well-insulated.

Recommended Cabe Stri lenths

Primary Cable(Supplied by

Customer)

Ground FaultSwitch & Bracket

TB-L1, L, LConnection

GroundConnection

THE CHASSIS MuST BE CONNECTED TO AN AppROVED ElECTRICAlgROuND. FAIluRE TO DO SO MAY RESulT IN ElECTRICAl SHOCK,SEVERE BuRNS OR DEATH.


WARNINg

Fire 31. Connectin primary power leads

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Fire 32. Int Termina Board Confration or 230/460/575 Mode

actory sied in the 575 confration

230 Vac Int 460 Vac Int 575 Vac Int

Fire 33. Int Termina Board Confration 230/460 Mode actory sied in the

460 confration

460 Vac Int230 Vac Int

Fire 34. Int Termina Board Confration 220/400 Mode actory sied in the

400 confration

220 Vac Int 400 Vac Int

*

*

*

SECTION 3 INSTAllATIONE. Figures -, - & -4 illustrate the input voltage terminal board and the input voltage link connections. The particular

voltages rom which this power source may be operated are stated on the rating plate. The voltage links were actoryset or highest voltage stated on the rating plate. I the power source is to be operated on another stated input voltage,the links must be reset or that particular input voltage. Always veriy the input voltage and check the link arrangementregardless o actory setting. The voltage links are set up by reconguring the copper link bars to the voltage designa-tions or the desired voltage.

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5


The output connections are located on the ront panel (Figure -5). The negative connection is located at the bottom rightcorner and the positive (high inductance and low inductance) connections are located at the bottom let corner. Table -provides the recommended cable output sizes.

3.5 CONTROl CONNECTIONS

The wire eeder receptacle and 115 VAC Auxiliary control are mounted on a removable plate. This plate may be exchangedor dierent applications.

Optional Available Plates: Blank (P/N 790M) Terminal Block or Lincoln - 4vac & 115vac eeders - (P/N 0558001416) Miller 14 pin Receptacle or 4vac eeders only - (P/N 0558001415)

Reer to Figure -5.

Tabe 32. Ott Cabe Sizes Secondary

* Total cable length includes work and electrode cables. Cable size is based on direct current, insulated copper conductors, 100-percent duty cycleand a voltage drop o 4 or less volts. The welding cable insulator must have a voltage rating that is high enough to withstand the open circuit volt-age o the power source.

BEFORE MAKINg ANY CONNECTIONS TO THE pOWER SOuRCE OuT-puT TERMINAlS, MAKE SuRE THAT All pRIMARY INpuT pOWER TOTHE MACHINE IS OFF.

3.4 OuTpuT WElDINg CONNECTIONS SECONDARY

WARNINg

WeldingCurrent

Total Length (Feet) o Cable in Weld Circuit*

50 100 150 0 50

100 6 4 1/0

150 4 1 1/0 /000 1 1/0 /0 /0

50 1/0 /0 /0 4/0

00 1 /0 /0 4/0 4/0

400 /0 /0 4/0 4/0 -/0

500 /0 /0 4/0 -/0 -/0

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3.5.1 Wire Feeder ControThe Wire eeder control cable connection is provided by a 19-pin receptacle (J1) located on the let-hand side o the powersource ront panel. This receptacle will operate all ESAB wire eeders with 19 pin control cables including the Mig E, Mig4HD, Mig 4HD Dual, Mig 5XL, Mig 8A, Mig 5, Digimig, Digimig Dual as well as the UEC-8, Digimatic II and Analog Interacemechanized controls.

3.5.2 Remote Contro OtionaThis unction is provided by an optional 14-pin receptacle (J) located on the ront panel directly below connector J1. Itreceives a mating plug rom a Hand Control Assembly (optional). This receptacle is operative only i the panel remote switchon the power source ront panel is in the "Remote" position.

3.5.3 Aiiary 115 V AC RecetaceA 115 Vac receptacle is provided to supply power to accessories such as a water cooler, heated CO

regulator, or small hand

tools. The receptacle is rated 115 Vac / 10 amps.

3.5.4 42V Circit Breaker CB1The 4V resettable circuit breaker (CB1) protects the 4 volt wire eeder/control circuitry against over current. (Table 6-

provides troubleshooting inormation).

3.5.5 115V Circit Breaker CB2The 115V resettable circuit breaker (CB) protects the 115 volt auxiliary receptacle and wire eeder/control circuitry againstover current. (Table 6- provides troubleshooting inormation).

3.5.6 Eterna grondin Condctor protectionThis eature will de-energize the power source output i current ow is detected in the external ground conductor. When thishappens, the Fault light on the ront control panel will illuminate. It will remain lit until the ault is corrected or the powersource power switch (S1) is turned o.


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7

Fire 35. Connection Diaram

653cvcc

.4NegativeOutput

Receptacle

.4, 4.1.7High Inductance or

STICK WElDINg SMAWSuBMERgED ARC WElDINg SAWARC CuTTINg/gOugINg CACAMIg WElDINg gMAW otiona

Positive Output

Receptacle

.4, 4.1.7Low Inductance or

MIg WElDINg gMAW

Flux CORED WElDINg FCAWARC gOugINg CACA otionaPosItive Output

Receptacle

.5.5CB

.5.4CB1

4.1.1POWER "ON-OFF"

SWITCH

.5.1WIRE FEEDER

CONTROLRECEPTACLE

REMOVABLEPANEL

.5.115V ac

AUXILIARYRECEPTACLE


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SECTION 4 OpERATION

4.1 CONTROlS See Fire 41

4.1.1 power Switch ONOFF/IOThe power switch is located on the ront panel o the power source. In the "o" ("O") position, the unit is shut down; however,power is still present in the unit. To ully shut down the power source, power must be disconnected at the line disconnectswitch or the use box.

With the switch in the "on" ("I") position, power is provided to the main transormer and the low voltage control circuitry.

4.1.1.1 power IndicatorThis white light will indicate that the power switch is in the on position and power has been applied to the main transormerand low voltage circuitry.

4.1.1.2 Fat IndicatorThis red light will indicate that current was owing through the external ground conductor. It will also illuminate i a shortoccurs (momentary or permanent) between the +1 volt J1-E; the +10 volt (J-E) and either the chassis ground or the nega-tive terminal o the power source. The power source output terminals are de-energized and the ault must be correctedbeore resuming operation.

4.1.2 Ott pane/Remote SwitchWith this switch in the Panel position, output voltage is controlled by adjusting the voltage potentiometer on the rontpanel to the desired output. In the Remote position, output is controlled using an optional remote voltage control via

receptacle J.

Never oerate the ower sorce with the cover removed. In additionto the saety hazards, imroer cooin may case damae to thecomonents. Kee side anes cosed when nit is enerized. Wedin hemet, oves, and other ersona rotection shod aways be

worn when wedin.

Fire 41. Contro locations

4.1.4

4.1.5

4.1.

4.1.

4.1.8

4.1.9

4.1.1.1

4.1.1.

CAuTION

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4.1.3 Ott Votae/Crrent ControThis control allows the operator to adjust the output voltage in the CV mode and output current in the CC mode. Placingthe Panel/Remote switch in the Remote position disables the output control on the ront panel. Calibration marks are toprovide a rough guide in setting voltage and current.

4.1.4 Over Temeratre Indicator Tem.This amber light will indicate when an internal overheating condition has occurred and one o the thermal switches hasopened. User control o the solid state contactor will be interrupted and power source output will shut down to protectcritical components. Once cooled to a sae temperature, the thermal switch will automatically reset and output control willbe restored.

4.1.5 Votmeter and AmmeterA digital voltmeter and ammeter provides an accurate indication o dc output voltage and current.

4.1.6 Over Crrent protectionThe 65cvcc incorporates automatic over current protection. I an over current condition occurs, the automatic circuitry will

old back the output current to a level that will prevent damage to the power source. The power source will remain in thislow current old back mode until the arc is broken, the torch trigger is released or the contactor switch is reset.

4.1.7 Hih & low Indctance RecetacesThe 65cvcc provides high and low inductance output connections (see gure -5). Both are positive output terminals. Thehigh inductance terminal slows the power source dynamic response. This means the output current will build at a slowerrate compared to the low inductance terminals. The welding process and application will determine which terminal shouldbe used. The chart below provides suggested terminal connections.

4.1.8 Contactor, On/Remote SwitchThe Contactor Control switch is located on the ront panel o the power source. In the on position, the solid state contactoris energized and output power is available at the output terminals. The "Remote" position allows the solid state contactor

to be controlled rom a remote Mig wire eeder or mechanized sub arc control.

4.1.9 process Switch CCCVThe process switch allows or selection o the output characteristics o the power source depending on the welding processbeing used. The CV position produces a Flat volt-amp characteristic and is mostly used or the Mig (GMAW) and SubmergedArc (SAW) welding processes and occasionally with Air Carbon Arc Cutting (CAC-A). The CC position produces a Droopingcharacteristic most popular or Stick (SMAW), CAC-A and sometimes SAW.

SECTION 4 OpERATION

Process Switch CC CV

Inductance High Low High Low

Mig Solid Wire (GMAW) X X 1 XFlux Cored (FCAW) X XSub Arc (SAW) X X XArc Gouging (CAC-A) X X X

1. Small diameter wires (

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SECTION 4 OpERATION

ElECTRIC SHOCK CAN KIll! "MACHINERY lOCKOuT pROCEDuRES"SHOulD BE EMplOYED. 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.

4.2 SEQuENCE OF OpERATION

Prior to perorming the steps below, open the wall disconnect switch or remove the use rom the use box to electricallyisolate the power source.

ElECTRIC SHOCK CAN KIll! WHEN THE CONTACTOR SWITCH IS INTHE "ON" pOSITION, OuTpuT pOWER WIll BE pRESENT THROugH-OuT THE WElDINg CIRCuIT; ie. CABlES, WIRE FEEDER, WIRE SpOOl,DRIVE STAND, guN, AND ElECTRODE. BE SuRE All ARE ClEAR OFTHE WORKpIECE OR ARCINg WIll RESulT.

4.2.1 genera procedres or the CVMIg gMAW, SuB ARC SAW and CCSTICK SMAW, SuBARC SAW processes

A. Make the secondary output connections to the positive and negative output receptacles. See paragraph .4 andgure -5.

B. Make the control connections. Reer to the appropriate wire eeder, mechanized control, and/or torch instructionbooklets or additional process requirements or control connections.

C. I primary input connections have been made to the power switch, and on the input terminal board to match theincoming voltage, close the main wall disconnect switch or reinstall uses in the use box.

4.2.2 Secifc procedres or the CVMIg gMAW and SuB ARC SAW processes

A. Set the Output Panel/Remote switch to the desired setting.

B. Set the Process switch to the CV position.

C. Set the contactor switch to "Remote".

D. Set the power switch on the rear panel to the "on" ("I") position. The an will run or 0 seconds and stop automati-cally i welding current does not exceed 100 amps. The an will automatically turn o ater 6 minutes when thecontactor is "o" and the welding current is below 100 amps.

E. To preset the approximate welding voltage, place the Contactor switch to the "on" position. This will energize thepower source output, allowing the voltage to be preset using the Output Voltage/Current Control dial and observ-ing the voltmeter.

WARNINg

WARNINg

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SECTION 4 OpERATION

F. Ater setting the desired voltage condition, turn the contactor switch back to the remote position. This positionrequires a remote start control in order to start the welding sequence.

NOTE:A PCB and resistor pack discharges capacitor voltage to eliminate the electrode "sparking" or "arcing"

potential.

G. Begin welding. Observe the voltmeter, ammeter, and the weld. Readjust the voltage and wire eed speed settings

as necessary to obtain a satisactory weld.

H. When welding is completed, release torch switch. (This action will de-energize the power source solid state contactorand remove dc power rom the output terminals.)

4.2.3 Secifc procedres or the CCStick Wedin SMAW and Arc goin CACA processes

A. Place the Output Panel/Remote switch into PANEL position i output current is regulated rom the Output Voltage/Current dial on the panel, or in REMOTE position i output current is regulated rom the optional Hand Control.

B. Set the Output Voltage/Current Control to provide the approximate desired welding current using the control knobas the reerence. Example - set knob to 5 or approximately 450 amps output.

C. Set the Contactor switch to the ON position -- this will energize the solid-state contactor and all associated circuitryup to the output terminals.

D. Place the Process Control switch in the CC position.

E. Commence welding by touch or scratch starting the electrode.

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SECTION 5 MAINTENANCE

5.1 genera

5.2 Ceanin

Periodically, remove the cover rom the power source and blow accumulated dust and dirt rom the air passages and inte-rior components by using clean, dry low pressure air. The requency o cleaning required depends upon the environmentin 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 ow to provide proper cool-ing.

Ater cleaning with low pressure air, check or and tighten any loose hardware, including all electrical connections. Checkor rayed and/or cracked insulation on all power cables and replace i necessary.

CAuTION

WARNINg

I this ower sorce does not oerate roery, sto work immediatey and investiate the case o the manction. Maintenancework mst be erormed by an eerienced erson, and eectricawork by a trained eectrician. Do not ermit ntrained ersons toinsect, cean, or reair this ower sorce. use ony recommendedreacement arts.

WARNINg

BE SuRE THAT THE BRANCH CIRCuIT OR MAIN DISCONNECT SWITCHIS OFF, OR ElECTRICAl INpuT FuSES ARE REMOVED, BEFORE AT-TEMpTINg ANY INSpECTION OR WORK INSIDE THE pOWER SOuRCE.plACINg THE pOWER SWITCH IN THE OFF pOSITION DOES NOT RE-MOVE All pOWER FROM INSIDE THE pOWER SOuRCE.

FAIluRE TO REplACE WORN OR DAMAgED CABlES MAY RESulT INA BARE CABlE TOuCHINg A gROuNDED OBJECT. THE RESulTINgElECTRICAl ARC MAY INJuRE uNpROTECTED EYES AND WIll pRES-ENT A SERIOuS FIRE HAZARD. BODY CONTACT WITH A BARE CABlE,CONNECTOR, OR CONDuCTOR MAY RESulT IN SEVERE ElECTRICAlSHOCK, CAuSINg SERIOuS BuRNS OR DEATH.

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4

5.3 Insection and ServiceKeep the power source dry, ree o oil and grease, and protected at all times rom damage by hot metal and sparks.

5.3.1 Fan MotorKeep the an motor ree o accumulated dust and lint.

5.3.2 TransormerOther than periodically cleaning the dust and dirt rom the transormer, no maintenance is required. Ensure that only clean,dry, low pressure air is used.

5.3.3 Wire Feeder and Contro CircitsThese circuits are protected by two 10 amp circuit breakers mounted in the ront panel. I these open, the contactor andwire eeder will not operate.

5.3.4 Over Temeratre protectionI the power source reaches an abnormally high internal temperature, the thermal protection will deenergize the contactor

circuit, shutting down the power source but leaving the cooling an on. Ater the power source has cooled to a sae level,the thermal protection will automatically reset. While de-energized, the contactor and wire eeder cannot be operated.

5.3.5 Diita Votmeter/Ammeter CaibrationTo veriy the accuracy o the digital volt/ammeter combination, the ollowing calibration procedure can be perormedperiodically:

1. Place the Panel/Remote switch in Panel position.. Disconnect cables rom the output terminals and then connect an accurate DC voltmeter to the output terminals.. Place the Contactor switch in the On position.4. With the primary input power on, turn the Voltage control knob until you get 5V on the DC voltmeter. Compare the

reading with the reading on the digital voltmeter on the ront panel.

5. I there is a dierence in the voltage readings, open ront control panel by removing the two mounting screws romthe upper corners, remove meter board rom its our mounting posts, and adjust the trimpot (R1) on the meter boardwith a small screwdriver until the digital meter reading matches the DC voltmeter reading. When satised, reassemblemeter board and ront control panel.

SECTION 5 MAINTENANCE

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5

SECTION 6 TROuBlESHOOTINg

6.1 genera

I the power source is operating improperly, the ollowing troubleshooting inormation may be used to locate the sourceo the trouble.

Check the problem against the symptoms in the ollowing troubleshooting guide (Table 6-.) The remedy or the prob-lem may be quite simple. I the cause cannot be quickly located, open up the unit and perorm a simple visual inspectiono all the components and wiring. Check or proper terminal connections, loose or burned wiring or components, blownuses, bulged or leaking capacitors, or any other sign o damage or discoloration.

6.2 Testin and Reacin Bride Assemby Comonents

The SCRs used in the power source are devices which allow current to ow in only one direction. The SCRs are designedto provide long trouble-ree operation; however, should a ailure occur, they may require replacement.

A. Testing SCRs.

1. Remove top and right side panel rom the power source.. Locate the main rectier assembly containing the SCRs.. Electrically isolate main bridge assembly by disconnecting resistor R5.4. With the ohmmeter on RX1 scale, place the positive lead on the anode (end o SCR with screw threads) and the

negative lead on the cathode (positive output terminal on the ront panel). The meter should read minimum o 0meg ohms.

5. Reverse leads and check each SCR. All readings should again show high resistance. The SCRs are bad i they showlow resistance in either direction.

6. Check the gate circuit on the SCRs by installing a jumper rom the gate lead to the anode o the SCR. The meter shouldread less than 5 ohms. Remove the jumper rom the gate. The meter reading should increase (0-50 ohms).

IMPORTANT

When replacing SCRs, 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. Place the clamp in position with the

bolts through the holes in the heatsinks and proceed as follows:

WARNINgDISCONNECT pRIMARY pOWER AT WAll SWITCH, OR CIRCuITBREAKER, BEFORE ATTEMpTINg INSpECTION OR WORK INSIDE THE

pOWER SOuRCE.

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6

1. Tighten the bolts evenly until nger tight noting that the nuts are not rotating.. Tighten the bolts /4 turn plus an 1/8 turn using a socket wrench on the bolt heads and rotating only in 1/4 turn incre-

ments plus 1/8 turn alternating between the bolts noting that the nuts are not rotating.

Tabe 61. pCB Votae Tests*

NOTE:

All voltage readings are taken with the ront access panel open and the power switch "ON".

* Reer to Schematic Diagram** Varies with VCP (R1)


WARNINg ElECTRICAl SERVICE AND REpAIR SHOulD BE ATTEMpTED ONlY BYA TRAINED ElECTRICIAN.

FROM TO READING

P8-5 OTB+ +10 V dc

P8-7 OTB+ 0-10 V dc**

P6-6 (SCR1)

P6-5 (SCR)P6-4 (SCR)P6- (SCR4)P6- (SCR5)P6-1 (SCR6)

OTB+ . V dc with

contactor on

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7

Tabe 62. Trobeshootin gide

CONDITION ACTION

Unit Inoperative A. No input power. Check main line (users) switch uses replace i needed.B. Poor or improper input (terminal board) connections.C. Deective on/o switch replace.D. Thermal light on. Main transormer overheating. Also check or proper cooling,

proper primary hookup, or shorted turn on secondary.E. Thermal light on. Fan motor not operating check motor and leads.F. External Ground Conductor ault indicator ON. - Check or cause and correct.

Turn power switch OFF then ON to reset.G. Loss o primary phase. Check that LED on control PCB is not lit. I lit, nd & replace

deective use.

No Output Fan Running A. Poor or improper electrical input check input connections on TB.B. Poor connections at output terminals/work station check, tighten or replace.

C. Main transormer overheating thermal switches tripped due to restricted cool-ing air. Temperature light on ront panel will be lit. Let unit cool down.D. PC board deective or loose PC board connector(s) i loose, reinsert; i deective,

replace.

Limited Output orLow Open-Circuit Voltage A. Input voltage jumper links on terminal board improperly set check or proper

voltage.B. Poor output connections. Take apart, clean, and tighten securely.C. Panel-Remote switch in Remote position and remote voltage pot disabled.D. Over current condition had occurred. Unit is in old back mode. See Section

4.1.6.

Erratic Weld Current A. Welding cable size too small use correct cables.B. Loose welding cable connection (will usually get hot) tighten connections.C. Improper wire eeder setup.D. Deective SCR in bridge rectier.E. PC board deective replace.

High Output, No Voltage Control A. PC board deective or loose reset and/or replace board.

No 115 Volt ac Output A. Circuit breaker tripped. Check 115V CB Reset.

Line Fuse Blows When PowerSource is First Turned On A. Shorted SCR in Main Bridge replace.

B. Shorted capacitor in Capacitor Bank.

Wire Feeder is Inoperative A. Loose eeder control cable Check and tighten all connections.B. A Circuit Breaker tripped Check 4V CB1 and 115V CB Reset.


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8


/05&

4DIFNBUJDTBOE8JSJOH%JBHSBNTPOwYw

QBQFSBSFJODMVEFE

JOTJEFUIFCBDLDPWFSPGUIJTNBOVBM

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9

SECTION 7 REplACEMENT pARTS

7.1 genera

Always provide the serial number o the unit on which the parts will be used. The serial number is stamped onthe unit nameplate.

To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with thisequipment. The use o non-ESAB parts may void your warranty.

Replacement parts may be ordered rom your ESAB Distributor.

Be sure to indicate any special shipping instructions when ordering replacement parts.

Reer to the Communications Guide located on the back page o this manual or a list o customer service phonenumbers.

7.2 Orderin

Bill o material items that have blank part numbers are provided or customer inormation only.Hardware items should be available through local sources.

Note

7.0 Reacement parts

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40


653cvcc Front pane View

195

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653cvcc Front Isometric View

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4


653cvcc Interna View

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653cvcc Rear Isometric View

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653cvcc Interna View

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653cvcc To Interna View

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Bi o Materias653cvcc DC Wedin power Sorce

ITEM pART ORNO. CODE NO. QTY. DESCRIpTION SYMBOl

1 95488 1 LABEL SUBARC STICK

95489 1 LABEL MIG 611 1 PCB DIGITAL METER PCB4 617 1 BLADE FAN 14"5 810 1 PCB CONTROL PCB16 64515 SW TGGL SPDT POS 15A 15V S,,47 67065 6 STRAP TERMINAL, VOLTAGE CHANGELINE8 67805 TERM AY OUTPUT9 9501 CKT BREAKER 10A VDC 50VAC CB1,

10 95019 1 RELIEF STRAIN .0011 950711 SW THERMAL 194FT S,,41 950768 DIODE FWD 00V 00A D1,1 950945 1 SW PWR DISC 100A 600V S114 951474 SW SEAL BLACK15 954008 1 LABEL DANGER HIGH VOLTAGE16 064 1 MOTOR FAN 1/ HP 165RPM M117 055800104 SCR ASSY18 4149 1 CLIP ANNEALED0 6110 1 BOARD INPUT TERMINAL 0/460V/5751 609 1 CABLE DIGITAL METER PCB P10 7861M 1 BASE4 786M 1 PANEL FRONT BOTTOM5 055800169 1 PANEL RIGHT SIDE ENV6 055800170 1 PANEL LEFT SIDE ENV7 055800178 1 CONTROL PANEL BLACK8 7867M 1 PANEL REAR

0 7869 1 HIGH TAP INDUCTOR BUSBAR1 7870 1 LOW TAP INDUCTOR BUSBAR 7871 1 SHUNT 787 INSULATOR KYDEX4 7890 1 XFMR MAIN 0/460/575V T15 788 1 INDUCTOR L16 7907 1 SCHEMATIC DIAG 65 CVCC7 7908 1 WIRING DIAG SEC 65 CVCC8 0558001044 1 WIRING DIAG PRI PH AFRAME4 64761 1 TERMINAL LUG44 67786 1 BOLT EYE .75-10 X .0045 950167 1 GROMMET RUB 1.1 ID X 1.50 GD X .06 W46 950905 1 TERM IL/M .50 TS X 14-16 AWG

47 951504 1 PLUG HOUSING 15 POS J548 055800101 1 CAP HOUSING POSITION49 95067 1 CONNECTOR 0 AWG PIN P150 95068 1 MTA-156 COVER PIN51 95070 1 CONNECTOR 0 AWG 7 PIN P55 95071 1 MTA-156 COVER 7 PIN5 9507 CONNECTOR 0 AWG 1 PIN P,4,754 9507 1 TERM BLOCK 1 POS57 9509 1 PANEL RECEPTACLE 19 PIN F J1

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Bi o Materias653cvcc DC Wedin power Sorce Cont'd

58 9519 1 OUTLET 110V SQUARE J

61 95445 1 LABEL LR-0071 CSA NRTL/C6 954506 1 LABEL ISO 9006 954868 1 OVERLAY 65 CVCC BLK64 954846 1 LABEL RATING 65 CVCC 0/460/57565 95480 1 LABEL SCHEMATIC 6566 091514 1 LABEL WARNING WELD AND CUT67 091558 1 LABEL GND BILK .50 X 1.869 1706 1 POT LIN 10K W .88L71 171781 1 MTA-156 COVER 10 PIN7 1741 MTA-156 COVER 1 PIN7 177 1 LABEL FOR INSTALL USSE COP WIRE74 174588 1 LOGO ESAB CLEAR75 17511 1 CONNECTOR 0 AWG 6 PIN P676 1751 1 MTA-156 COVER 6 PIN77 175508 1 SHROUD FAN78 1700016 1 RES RW FIXD ST 00W 10% 16.0079 99477 1 RUBBER .188 X .500

1 995140 1 LABEL CAUTION LIFT EYE14 9951558 1 BRACKET RESISTOR #1815 0558001010 1 TERMINAL BLOCK POS TB16 05580010 1 BOX PCB BLACK17 055800101 PLUG HOUSING POS18 0558001014 SEAL WIRE POS19 0558001015 SEAL INTER140 0558001016 1 CAP 9 POS J6

141 0558001018 1 INSULATOR STAND OFF14 0558001019 1 KNOB 1.57 DIA14 05580010M 1 PANEL FRONT TOP147 604GY 1 BRACKET FAN148 6048M 4 LEG AFRAME149 6049M 1 BAIL LIFTING15 790M 1 BLANKING PLATE15 7901M 1 19 AND 110V PANEL154 055800171 1 PANEL TOP ENV155 7899 1 LOWER BAFFLE156 179157 LAMP WHITE 48V PL1157 951754 1 LAMP LED YEL 1V PL158 95610 1 LAMP LED RED 1V PL

161 8100 1 CE FILTER ASSY FN116 954565 1 LABEL CE16 95 STAND OFF 1/4-0 X .75164 05580017 HINGE ACCESS166 954864 1 LABEL THREE PHASE171 0558001407 SEAL WIRE 15 POS17 0558001408 1 SEAL INTER 15 POS17 0558001406 1 SEAL WIRE 9 POS181 9598 1 RELAY SOLID STATE 660V 10

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Bi o Materias653cvcc DC Wedin power Sorce Cont'd

18 055800579 1 BRACKET MOUNTING

185 950466 1 CAP HOUSING 15 POS186 0648 1 PLUG HOUSING 9 POS187 0558001409 1 CONNECTION INTERFACE SEAL 9188 95015 1 CONTACT PIN189 95609 1 CONN RECEPT 16 PIN TAFA P1019 055800417 1 BRACKET - GROUND FAULT194 170 BUSHING - GROUND FAULT195 0558005656 1 CAP METAL PROTECTION

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NOTES

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REVISION HISTORY

The "A" edition o this booklet includes a rewrite o the primary electrical connection.

The "B" edition o this booklet includes:

Schematic and Wiring Diagrams Additional replacement parts

The "C" edition updated part numbers, edited graphics on pages 10 and 1 and removed reerences to 5cvcc Parts.

The "D" edition updated complete parts list.

The "E" edition covers the reinstallation o a Ground Fault Switch and Bracket and Ground Connection.

The "F" edition o this manual provides modications requiring an updated display PCB, timer module, an additional PCB,mounting brackets, resistor pack and associated wiring mounted to the "A" rame support near the output rectier bridge.These modications are or a "an on demand" eature. These modications will aect serial no.'s M0RI6006 and above.Replacement Parts listings have also been updated.See dneco# 079 & service bulletin 0_01_001.

The "G" edition o this manual updated Section , Front Panel showing control locations. Section .1 has been reconguredto resemble the 5 & 45 manuals. Minor editorial changes have also been made. Front cover picture also updated.

The H revision updates the ormat and ront cover picture (no records o the G revision being released, E revision wascurrently on the web & G was in the older but apparently never released). Added p/n 0558005656, item 195, metal capprotection and illustration to replacement parts.

The H revision o 0/006 made editorial change to reerence Lincoln & Miller eeders in section .5.

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F15572H 02/2006

A. CUSTOMER SERVICE QUESTIONS:Telephone: (800)6-7080 / Fax: (800) 64-7548 Hours: 8:00 AM to 7:00 PM ESTOrder Entry Product Availability Pricing Order Inormation Returns

B. ENGINEERING SERVICE:Telephone: (84) 664-4416 / Fax : (800) 446-569 Hours: 7:0 AM to 5:00 PM ESTWarranty Returns Authorized Repair Stations Welding Equipment Troubleshooting

C. TECHNICAL SERVICE:Telephone: (800) ESAB-1/ Fax: (84) 664- 445 Hours: 8:00 AM to 5:00 PM ESTPart Numbers Technical Applications Specications Equipment Recommendations

D. LITERATURE REQUESTS:Telephone: (84) 664-556 / Fax: (84) 664-5548 Hours: 7:0 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS:Telephone: (84) 664- 4487 / Fax: (84) 664-5557 Hours: 7:0 AM to :0 PM ESTRepair Estimates Repair Status

F. WELDING EQUIPMENT TRAININGTelephone: (84)664-448 / Fax: (84) 679-5864 Hours: 7:0 AM to 4:00 PM ESTTraining School Inormation and Registrations

G. WELDING PROCESS ASSISTANCE:Telephone: (800) ESAB-1 Hours: 7:0 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES:

Telephone : (800) 9-7070 Hours: 7:0 AM to 5:00 PM EST

IF YOu DO NOT KNOW WHOM TO CAll

Telephone: (800) ESAB-1Fax: (84) 664-446

Hours: 7:0 AM to 5:00 PM ESTor

visit us on the web at http://www.esabna.comThe ESAB web site oers

Comprehensive Product InormationMaterial Saety Data Sheets

Warranty RegistrationInstruction Literature Download Library

Distributor LocatorGlobal Company Inormation

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ESAB Wedin & Cttin prodcts, Forence, SC Wedin EqimentCOMMuNICATION guIDE CuSTOMER SERVICES

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