0558004964 10/2005MultiPower 460 PulseDC Welding Power Source (Shipyard Model)INSTRUCTION MANUALESAB ITEM NO. 0558004922, MultiPower 460 Pulse - (2
10SECTION 1 SEGURIDAD 1. Asegúrese de que el chasis de la fuente de poder esté conectado a tierra através del sistema de electricidad prima
11SECTION 1 SEGURIDAD5. ADVERTENCIA-- Este producto cuando se uti-liza para soldaduras o cortes, produce humos o gases, los cuales contien
12SECTION 1 SEGURIDADSIGNIFICADO DE LOS SIMBOLOS -- Según usted avanza en la lectura de este folleto: Los Símbolos Sig-nifican ¡Atención! ¡Esté Alerta
13SECTION 1 SÉCURITÉ1.3 Safety - FrenchINCENDIES ET EXPLOSIONS -- La chaleur provenant des flammes ou de l'arc peut provoquer un incendie.
14SECTION 1 SÉCURITÉ3. Les soudeurs doivent suivre les procédures suivantes pour minimiser l'exposition aux champs électriques et magnétiques :
15SECTION 1 SÉCURITÉ1. Efforcez-vous de toujours confier les tâches d'installation, de dépannage et d'entretien à un personnel
16SECTION 1 SÉCURITÉSIGNIFICATION DES SYMBOLESCe symbole, utilisé partout dans ce manuel, signifie "Attention" ! Soyez vigilant ! Votre sécu
17SECTION 2 DESCRIPTION2.0. DescriptionThis manual has been prepared for use by an experienced operator. It provides information to familiarize t
18SECTION 2 DESCRIPTIONThe MultiPower 460 Pulse is a multi-process power source designed for Mig short circuiting, spray and pulse spray transfer (GM
19SECTION 2 DESCRIPTIONFigure 2-2. Control PanelC. Control Panel Description (Refer To Figures 2-2 & 2-3)1. Fault Lamp The RED fault light on th
This equipment will perform in conformity with the description thereof contained in this manual and accompa-nying labels and/or inserts when installed
20.045.040.0351/16.052WIRE TYPEWIRE DIAMETERPULSE SELECTIONEN-625 ERNiCrMo-3STAINLESSAL-4000AL-5000EN-60 ERNiCu-7METAL CORESTEELSTEELEN-67 ERCuNi05432
217. Preset ButtonPreset push button is used in conjunction with the VOLTAGE/CURRENT/TRIM knob to set the desired voltage / current. Pre-set switch is
22.045.040.0351/16.052WIRETYPEWIREDIAMETERPULSESELECTIONEN-625ERNiCrMo-3STAINLESSAL-4000AL-5000EN-60ERNiCu-7METALCORESTEELSTEELEN-67ERCuNi0549876Volta
23Figure 2-5. Remote Control PendantE. Optional Accessories1. Remote Control Pendant (P/N - 0558002871)This pendant (Figure 2-5) provides remote out
24SECTION 2 DESCRIPTION
25SECTION 3 INSTALLATION3.0. Installation A. LocationA proper installation site is necessary for the power source to provide dependable service.
26 ELECTRIC SHOCK CAN KILL! BEFORE MAKING ELECTRICAL INPUT CONNECTIONS TO THE POWER SOURCE, "MACHINERY LOCKOUT PROCEDU
27SECTION 3 INSTALLATIONThe primary power leads must be insulated copper conductors. Three power leads and one ground wire are re-quired. Either rub
28SECTION 3 INSTALLATIONELECTRIC SHOCK CAN KILL! BEFORE MAKING ELECTRICAL INPUT CONNECTIONS TO THE POWER SOURCE, "MACHINERY LOCKOUT
29SECTION 3 INSTALLATIONCHECK THE VOLTAGE LINKS FOR PROPER VOLTAGE ON THE INPUT TERMINAL BOARD BEFORE APPLYING PRIMARY POWER.Figure 3-4. In
TABLE OF CONTENTS1.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30SECTION 3 INSTALLATIONBEFORE MAKING ANY CONNECTIONS TO THE POWER SOURCE OUTPUT TERMINALS MAKE SURE THAT ALL PRIMARY INPUT POWER TO THE MACHINE IS
31SECTION 4 OPERATIONNever operate the power source with the covers removed. In addition to the safety hazards, improper cooling may cause da
32C. Tig Welding (Lift Start Tig)When the PROCESS switch is placed in the LIFT START TIG position, the MultiPower 460 Pulse is automatically set for
33Figure 4-2 Standard Stick Setup ProcedureBe sure to set the polarity to DCEP (Electrode Positive) by placing the Electrode Holder cable in the Posi
34SECTION 4 OPERATIONNOTEDue to the "Built-In" Arc Force in the stick mode, the actual current may be greater than the preset value. See R
35SECTION 4 OPERATIONFigure 4-5 Standard Mig Setup Procedure1324.045.040.0351/16.052WIRE TYPEWIRE DIAMETERPULSE SELECTIONEN-625 ERNiCrMo-3STAINLESSA
36.045.040.0351/16.052WIRE TYPEWIRE DIAMETERPULSE SELECTIONEN-625 ERNiCrMo-3STAINLESSAL-4000AL-5000EN-60 ERNiCu-7METAL CORESTEELSTEELEN-67 ERCuNi05432
37SECTION 4 OPERATIONTable 4-1. Wire Types, Diameter and Shield Gases for Pulse MigMaterial Type DiametersShielding Gas (AWS D
38SECTION 4 OPERATION1. Pulse Mig Arc StabilityMany variables can affect the arc stability of pulse MIG welding. Some examples are:Differences in shi
39SECTION 5 MAINTENANCEF. Over Temperature ProtectionIf the power source reaches an abnormally high internal temperature, the thermal protection will
4TABLE OF CONTENTS
40SECTION 5 MAINTENANCEWhat is ESD?A sudden transfer or discharge of static electricity from one object to another. ESD stands for Electrostatic Dis
41SECTION 5 MAINTENANCESince IGBT gates are insulated from any other conducting region, care should be taken to prevent static build up, which could
42SECTION 5 MAINTENANCEC2 E1E2C1G2E2Set the VOM to ohms then check for continuity between all the legs of the IGBT. No continuity should be measured
43SECTION 5 MAINTENANCEOnce the IGBT is turned on, remove the power source and the unit should stay on.C2 E1E2C1G2E2Short the gate leads (you can use
44SECTION 5 MAINTENANCEI. TroubleshootingIf the power source is operating improperly, the following troubleshooting information may be used to locate
45SECTION 5 MAINTENANCETable 5-1. Troubleshooting GuideCONDITION ACTIONUnit Inoperative No input power. Check main line (user’s) sw
46SECTION 5 MAINTENANCEFigure 5-2. READY/ON Light OFF Figure 5-3. Fan Does Not Run NOTE:Schematics and Wiring Diagrams on 11" x 17" paper a
47SECTION 5 MAINTENANCEFigure 5-4. No Weld Power (STICK Position)Figure 5-5. Meter Display is BlankNo weld power(Stick position)Power Light is OnVeri
48SECTION 5 MAINTENANCEFigure 5-7. Ammeter Displays 760AFigure 5-6. PRESET Does Not FunctionPreset does not function(unit welds)Does preset work when
49SECTION 5 MAINTENANCEFigure 5-8. Over Temperature Light is ONOver Templight is on Was the Duty Cycle exceeded?Allow time for machineto coolReplace
5SECTION 1 SAFETY PRECAUTIONS1.0 Safety Precautions1.1 Safety - EnglishWARNING: These Safety Precautions are for your protection. They summariz
50SECTION 5 MAINTENANCE
51SECTION 6 REPLACEMENT PARTS6.1 GeneralAlways provide the serial number of the unit on which the parts will be used. The serial number is stamped o
52SECTION 6 REPLACEMENT PARTS123,4568(behind control panel)7 QTY. ITEM CIRCUIT NO. REQ. NO. DESCRIPTION SYMBOL 1 1 952219 Outle
53 SECTION 6 REPLACEMENT PARTS QTY. ITEM CIRCUIT NO. REQ. NO. DESCRIPTION SYMBOL 1 1 2091514 Label Warning Arc Welding & Cu
54SECTION 6 REPLACEMENT PARTS62 1,5 QTY. ITEM CIRCUIT NO. REQ. NO. DESCRIPTION SYMBOL 1 1 634519 Switch Toggle 4PDT S6 2 1 055
55SECTION 6 REPLACEMENT PARTS12345 QTY. ITEM CIRCUIT NO. REQ. NO. DESCRIPTION SYMBOL 1 1 13732733 Label for Install Use COP Wir
56SECTION 6 REPLACEMENT PARTS QTY. ITEM NO. REQ. NO. DESCRIPTION SYMBOL 1 3 99511916 Diode Fwd 200V 250A D1, D3, D5
57SECTION 6 REPLACEMENT PARTS12543 QTY. ITEM NO. REQ. NO. DESCRIPTION SYMBOL 1 1 952938 SCR 480V 18A Panel MNT SSR1 2 1 951997
58SECTION 6 REPLACEMENT PARTS123, 4 QTY. ITEM NO. REQ. NO. DESCRIPTION SYMBOL 1 2 17280110 Res WW Fix'd ST 100W 5% 100.00 R
59REVISION HISTORYPreliminary release - 08/2004Released - 09/2004Added IGBT and diode test data in Section 5 and updated schematic package - 12 / 2004
6SECTION 1 SAFETY PRECAUTIONS 1. Be sure the power source frame (chassis) is con-nected to the ground system of the input power. 2. Connect the
0558004964 10/2005A. CUSTOMER SERVICE QUESTIONS: Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST Order Entry P
M2M3ESAB ASY 38211REV.12345612345678910123412345671357911131516141210864219168++++++++++14796328+++15V-15VCOMMON(+)VREF.(+)Earc/10WIRE SPEED REF.VOLTS
12645+DSGDGS.1.01H11AA1H11AA1100uf1K1KCT5RT6INV15REF14NIV16COMP3INV2NIV1DT4O.C.13C113C18E18E19GNDVcc712+1uf+1uf68.1K68.1K174K174K1.3K1.3K10K10K1uf+1K.
4.99KR164DO NOT LOAD : R164R164DO NOT LOAD : R164(-)E arc(-)E arc(+)E arc(+)E arcMAX.INDUCTANCEPRE-SETCURRENT SENSORCURRENT SENSORTO FAN RELAYTO FAN R
RA2RA2RA3RA3RA4RA4MCLRMCLRVSSVSSRBORBORB1RB1RB2RB2RB3RB3RA1RA1RA0RA0OSC1OSC1OSC2OSC2VDDVDDRB7RB7RB6RB6RB5RB5RB4RB4U1U1PIC16C711PIC16C711(99513603)(995
C11000uF+U3HPCL-22318VCCOUT7GND5+IN1-IN3C2220uF+R8R24.02KD11N4007J1-1D218VJ1-2D318VJ1-3D418VJ1-4D518VJ1-5J1-6U1MC7815CTIN1OUT3GND2R55.0D81N4148D91N414
7SECTION 1 SAFETY PRECAUTIONS5. WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known t
8SECTION 1 SAFETY PRECAUTIONS5. AWS C5.5 - "Recommended Practices for Gas Tung-sten Arc Welding“6. AWS C5.6 - "Recommended Practices for
9SECTION 1 SEGURIDAD1.2 Safety - SpanishADVERTENCIA: Estas Precauciones de Se-guridad son para su protección. Ellas hacen resumen de información pro
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