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BOC C-DW Owner's Manual

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C-DW
C-DW
302, 452, and 652 Models
OM-223
166 538W
June 2000
Processes
Gas Metal Arc (MIG) Welding
Gas Metal Arc-Pulsed Welding
Flux Cored Arc Welding
Submerged Arc Welding
(452/652 Only)
Air Carbon Arc Cutting
and Gouging (452/652 Only)
Description
Arc Welding Power Source

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Summary of Contents for BOC C-DW

  • Page 1 June 2000 Processes Gas Metal Arc (MIG) Welding Gas Metal Arc-Pulsed Welding Flux Cored Arc Welding Submerged Arc Welding (452/652 Only) Air Carbon Arc Cutting and Gouging (452/652 Only) Description Arc Welding Power Source C-DW C-DW 302, 452, and 652 Models...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS ..........1-1.

  • Page 5: Section 1 - Safety Precautions

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message.
  • Page 6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense D Always ventilate confined spaces or use visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols for Installation, Operation, and Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 8: Emf Information

    1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields.

  • Page 9: Signification Des Symboles

    SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_Fre 4/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité...
  • Page 10 LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage D Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proxi- D Rester à l’écart des organes mobiles comme le mité...

  • Page 12: Principales Normes De Sécurité

    1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

  • Page 13: Section 2 - Definitions

    SECTION 2 – DEFINITIONS 2-1. General Precautionary Label 1/96 Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from welding electrode or wiring can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand.

  • Page 14: Input Connection Label

    2-2. Input Connection Label 1/96 Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from wiring can kill. Disconnect input plug or power before working on machine. Read the Owner’s Manual before working on this machine.
  • Page 15 2-5. Manufacturer’s Rating Labels For CE Products Match label to one on unit. See Section 3-4. OM-223 Page 11...
  • Page 16 2-6. Symbols And Definitions Note Some symbols are found only on CE products. Voltage Control/ Gas Metal Arc Amperes Temperature Panel Welding (GMAW) Output Circuit Breaker Remote Positive High Positive Low Negative Weld Inductance Weld Inductance Weld Input Output Terminal Output Terminal Output Terminal Protective Earth...

  • Page 17: Section 3 - Installation

    SECTION 3 – INSTALLATION 3-1. Specifications Amperes Input at Rated Load Output, 50 or 60 Hz, Rated Voltage Three-Phase Welding Range OCV DC Rating 200 V 230 V 380 V 400 V 440 V 460 V 575 V Output Model 300 A @ 32 (29) Volts 16.9...
  • Page 18 3-3. Volt-Ampere Curves Volt-ampere curves show mini- mum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall be- tween curves shown. A. 300 Amp Model B. 450 Amp Model C. 650 Amp Mod- va_curve1 – 4/95 – ST-171 224 / ST-171 225 / ST-171 226 OM-223 Page 14...

  • Page 19: Selecting A Location

    3-4. Selecting A Location Lifting Eye Lifting Forks Use lifting eye or lifting forks to move unit. Movement If using lifting forks, extend forks beyond opposite side of unit. Rating Label (Non CE Models Only) Use rating label to determine input power needs.

  • Page 20: Tipping

    3-6. Tipping Y Be careful when placing or moving unit over uneven surfaces. 3-7. 115 VAC Receptacle And Circuit Breakers Y Turn Off power before con- necting to receptacle. 115 V 15 A AC Receptacle Power is shared between RC9 and Remote 14 receptacle RC8 or terminal strip 1T (see Section 3-11).
  • Page 21 3-8. Weld Output Terminals And Selecting Cable Sizes Total Cable (Copper) Length In Weld Circuit Not Exceeding 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100 ft (30 m) Or Less (45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
  • Page 22 3-9. Electrical Service Guide 60 Hertz Models 300 Amp Model 450 Amp Model 650 Amp Model Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Rating In Amperes Time-Delay Normal Operating 3 Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) (34)

  • Page 23: 3-11.Remote 14 Receptacle Rc8 And Terminal Strip 1T Connections

    3-10. Remote 14 Receptacle RC8 And Terminal Strip 1T Information Socket Terminal Information 24 volts ac. Protected by circuit breaker CB2. 24 VOLTS AC Contact closure to A completes 24 volts ac contactor control circuit. Command reference; 0 to +10 volts dc. Remote control circuit common.

  • Page 24: 3-12.Placing Jumper Links And Connecting Input Power

    3-12. Placing Jumper Links And Connecting Input Power 200 VOLTS 230 VOLTS 460 VOLTS Ref. S-174 976-A 230 VOLTS 460 VOLTS 575 VOLTS Ref. S-174 973-A 220 VOLTS 380 VOLTS 400 VOLTS 440 VOLTS (FACTORY OPTION) Ref. S-174 975-A Do not overtighten GND/PE jumper link nuts.

  • Page 25: Section 4 - Operation

    SECTION 4 – OPERATION 4-1. Controls (Non CE Models) Ref. ST-162 503-C Voltage Adjustment Control Power Switch With Indicator Light For front panel control of output, place switch in Panel position. For remote control of output, Turn control clockwise to increase voltage. High Temperature Shutdown Light place switch in Remote position, and connect Voltmeter value changes as control knob is...

  • Page 26: Section 5 - Maintenance & Troubleshooting

    SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Clean Repair or Replace tighten weld replace unreadable terminals. cracked labels. weld cable. 6 Months Blow out or vacuum inside. During heavy service, clean monthly 5-2.
  • Page 27 5-4. Troubleshooting Table Trouble Remedy No weld output; unit completely Place line disconnect switch in On position (see Section 3-12). inoperative. Check fuse F1, and replace if necessary (see Section 5-2). Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-12). Check for proper input power connections (see Section 3-12).
  • Page 28 Notes OM-223 Page 24...

  • Page 29: Section 6 - Electrical Diagram

    SECTION 6 – ELECTRICAL DIAGRAM For Primary Circuit Diagram Portion, refer to Circuit Diagram located inside wrapper of welding power source. SC-196 111-A Figure 6-1. Circuit Diagram OM-223 Page 25...

  • Page 30: Section 7 - Parts List

    SECTION 7 – PARTS LIST Hardware is common and not available unless listed. ST-800 992-F Figure 7-1 Main Assembly (452 Model Illustrated) OM-223 Page 26...
  • Page 31 Quantity Model Item Dia. Part Mkgs. Description 302 452 652 Figure 7-1 Main Assembly (452 Model Illustrated) ....+179 430 PANEL, side ......... . .
  • Page 32 Quantity Model Item Dia. Part Mkgs. Description 302 452 652 Figure 7-1 Main Assembly (452 Model Illustrated) (continued) ... . 189 839 TRANSFORMER, pwr main 230/460/575 (consisting of) ....
  • Page 33 Quantity Model Item Dia. Part Mkgs. Description 302 452 652 Figure 7-2 Panel, Front w/Components (Fig 7-1 Item 33) ....159 863 ELECTRONICS BOX ........
  • Page 34 Quantity Model Item Dia. Part Mkgs. Description 302 452 652 Figure 7-2 Panel, Front w/Components (Fig 7-1 Item 33) (continued) ..181 245 TERMINAL, pwr output red ......
  • Page 35 Item Dia. Part Mkgs. Description Quantity 175 070 Figure 7-3 Rectifier, Si Diode (302 Model) (Fig 7-1 Item 34) ..C7-12 ..048 420 CAPACITOR, cer disc .01uf 1000VDC ......
  • Page 36 Item Dia. Part Mkgs. Description Quantity Figure 7-5 Panel, Rear w/Components (Fig 7-1 Item 19) ....173 283 CHAMBER, plenum 14 in ........
  • Page 39 Warranty Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer) This limited warranty supersedes all previous manufacturers Limited Warranty shall not apply to: warranties and is exclusive with no other guarantees or warranties expressed or implied. Consumable components;...

  • Page 40: Options And Accessories

    Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Resources Available Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment...

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