ESAB MultiPower 460 Instruction Manual
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ESAB MultiPower 460 Instruction Manual

Dc welding power source
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MultiPower 460
DC Welding Power Source
This manual provides complete instructions for the following power sources starting with Serial Number MORJ143001,
October 2001:
ESAB ITEM NO. 0558002669, MultiPower 460cvcc - 230/460/575 vac, 3 ph., 60 Hz
Instruction Manual
F15-666-A
07 / 2003

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Summary of Contents for ESAB MultiPower 460

  • Page 1 DC Welding Power Source This manual provides complete instructions for the following power sources starting with Serial Number MORJ143001, October 2001: ESAB ITEM NO. 0558002669, MultiPower 460cvcc - 230/460/575 vac, 3 ph., 60 Hz Instruction Manual F15-666-A 07 / 2003...

  • Page 2: User Responsibility

    Copies of this manual can be obtained by any of the following; Contacting your local ESAB supplier. Downloading a copy from the ESAB web site at www.esabna.com Sending a written request to ESAB WELDING &...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION TITLE PAGE SECTION 1 SAFETY .............................. 10 SECTION 2 DESCRIPTION ............................ 10 SECTION 3 OPTIONAL EQUIPMENT & ACCESSORIES ..................15 SECTION 4 INSTALLATION ..........................16 SECTION 5 OPERATION ............................19 SECTION 6 MAINTENANCE ..........................24 SECTION 7 TROUBLESHOOTING ........................
  • Page 4 SAFETY PRECAUTIONS WARNING: hese Safety Precautions are for 5. Do not use equipment beyond its ratings. For example, your protection. They summarize precaution- overloaded welding cable can overheat and create a fire ary information from the references listed in hazard. Additional Safety Information section.
  • Page 5 SAFETY PRECAUTIONS FUMES AND GASES -- Fumes and EQUIPMENT MAINTENANCE -- Faulty or gases, can cause discomfort or harm, improperly maintained equipment can particularly in confined spaces. Do cause injury or death. Therefore: not breathe fumes and gases. Shield- ing gases can cause asphyxiation. 1.
  • Page 6 PRECAUCION DE SEGURIDAD No use el equipo fuera de su rango de operación. Por ejemplo, el calor ADVERTENCIA: Estas Precauciones de causado por cable sobrecarga en los cables de soldar pueden Seguridad son para su protección. Ellas hacen ocasionar un fuego. resumen de información proveniente de las 6.
  • Page 7 MANTENIMIENTO DEL EQUIPO -- Equipo HUMO Y GASES -- El humo y los gases, pueden causar malestar o daño, defectuoso o mal mantenido puede causar particularmente espacios daño o muerte. Por lo tanto: ventilación. No inhale el humo o gases. El gas de protección puede causar falta de 1.
  • Page 8 PRÉCAUTIONS DE SÉCURITÉ coupes à l’arc, à moins de les recouvrir complètement AVERTISSEMENT: Ces règles de sécurité ont pour objet d’une bâche non-inflammable. Ce type de matériaux d’ assurer votre protection. Veillez à lire et à observer les comprend notamment le bois, les vêtements, la sciure, précautions énoncées ci-dessous avant de monter l’...
  • Page 9 L’armoire de commande est 52529 “Precautions and Safe Practices for Arc Weld- munie d’un ventilateur destiné à empêcher la forma- ing, Cutting and Gouging” publié par ESAB. Nous tion de poches d’hydrogène, lesquelles présentent un conseillons également de consulter les publications sui-vantes, tenues à...

  • Page 10: Safety

    This manual has been prepared for use by an experienced operator. It provides information to familiarize the operator with the design, installation and opera- tion of the MultiPower 460 power source. DO NOT attempt to install or operate this equipment until you have read and fully understood these instructions. The information presented here should be given careful consideration to ensure proper installation and optimum weld performance of this equipment.
  • Page 11 Tig (GTAW) and arc gouging in the CC (constant current) mode. Features • Auto Fan - The MultiPower 460 fan will run when the power source is first powered up and will raining running for 6 minutes then shut don. The fan will start again when welding begins and is at a current level above 50 amps.
  • Page 12 2. TEMPERATURE LAMP The TEMP lamp illuminates if an over temperature condition occurs within the MultiPower 460 power source. This condition may be caused by excessive duty cycle or over-current conditions. When an over temperature condition occurs, the welding output is turned off and the unit must be allowed to cool.
  • Page 13 SECTION 2 DESCRIPTION When using a DuraDrive 4-30 or DuraDrive 4-48 Wire Feeder, the wire feed speed is displayed in inches per minute (IPM) in the top display when the PRESET button is pressed and the wire speed adjustment knob on the wire feeder is rotated.
  • Page 14 115 volt auxiliary receptacle circuitry against over current. (Table 7-1 provides troubleshooting information). Main Power On/Off Switch Control Panel Circuit Breakers CB1 & 2 Wire Feeder Connector Contactor On/Off Switch Remote Pendant Connection 115 Vac 10 Amps Receptacle Output Connections Figure 2-5. MultiPower 460...

  • Page 15: Optional Equipment & Accessories

    D. PULSE MIG UPGRADE KIT (PN - 0558002671) maximum current of the remote device This kit adds pulse gas metal arc welding to the MultiPower 460 and includes is controlled by the MP-460 front panel and new control front panel.

  • Page 16: Installation

    INSTALLATION SECTION 4 IV. INSTALLATION A. LOCATION A proper installation site is necessary for the power source to provide dependable service. A proper installation site permits freedom of air movement through the unit while minimizing exposure to dust, dirt, moisture, and corrosive vapors.
  • Page 17 INSTALLATION SECTION 4 1. The primary power leads must be insulated copper conductors. Three power leads and one ground wire are required. Either rubber covered cable or conduit (flexible or solid) may be used. Table 4-1 provides recommended input conductors and line fuse sizes. 2.
  • Page 18 SECTION 4 INSTALLATION 230 Vac Input 460 Vac Input 575 Vac Input Input Terminal Board Configuration for 230/460/575 Model 460 Vac Input 230 Vac Input 220 Vac Input 400 Vac Input Input Terminal Board Configuration 220/400 Model Input Terminal Board Configuration 230/460 Model Figure 4-3 Input Terminal Board Unit is factory shipped in the 575 Vac configuration...
  • Page 19 2. CONNECTIONS FOR STICK AND TIG WELDING The Tig torch and stick electrode holder connect directly to the appropriate MultiPower 460 output lugs on the lower front panel. The choice of the Positive or Negative terminal depends on the welding process and electrode type being used.
  • Page 20 SECTION 4 INSTALLATION...

  • Page 21: Operation

    OPERATION V. OPERATION A. WIRE FEEDER COMPATIBILITY The MultiPower 460 Pulse power source can be used with several ESAB 42 Never operate the power source volt wire feeders. The model wire feeder being used will determine the setup with the covers removed. In addi- method and operator interface.
  • Page 22 PRESET PROCEDURE E. MIG WELDING When the PROCESS switch is placed in the MIG position, the MultiPower 460 is set for CV (constant voltage) welding. The power source will output open circuit voltage (OCV) when the Mig Gun trigger is depressed. The following procedure assumes the wire feed and voltage adjustments will be made from the wire feeder front panel and wire and gas have been installed.
  • Page 23 OPERATION F. TIG WELDING When the PROCESS switch is placed in the TIG position, the MultiPower 460 is automatically set for CC (constant current) welding using the ESAB Touch TIG starting method. The voltage and current at the output lugs is maintained at low values until the electrode is shorted to the workpiece.
  • Page 24 SECTION 5 OPERATION G. STICK WELDING When the PROCESS switch is placed in the STICK position, the MultiPower When the WELD PROCESS switch is 460 establishes open circuit voltage (OCV) and output power is immediately moved to the TIG or STICK posi- available for welding.
  • Page 25 SECTION 5 OPERATION H. AIR CARBON ARC GOUGING (CAC-A) 1. CONSTANT CURRENT and CONSTANT VOLTAGE GOUGING When the WELD PROCESS switch is Step 1. Place the Output PANEL/REMOTE switch into PANEL position if moved to the TIG or STICK position, output current is regulated from the VOLTAGE/CURRENT knob on the electrode becomes electrically power source front panel, or in REMOTE position if output current is...

  • Page 26: Maintenance

    SECTION 6 MAINTENANCE VI. CLEANING Periodically, remove the cover from the power source and blow accumulated If this power source does not operate dust and dirt from the air passages and interior components by using clean low properly, stop work immediately and pressure air.

  • Page 27: Troubleshooting

    SECTION 7 TROUBLESHOOTING VII. TROUBLESHOOTING If the power source is operating improperly, the following troubleshooting information may be used to locate the source of the trouble. DISCONNECT primary power at wall Check the problem against the symptoms in the following troubleshooting switch, or circuit breaker, before at- tempting inspection or work inside guide (Table 7-1.) The remedy for the problem may be quite simple.

  • Page 28: Replacement Parts

    SECTION 8 REPLACEMENT PARTS...
  • Page 29 B. ORDERING To assure proper operation, it is recommended that only genuine ESAB parts and products be used with this equipment. The use of non-ESAB parts may void your warranty. Replacement parts may be ordered from your ESAB distributor or from: ESAB Welding &...
  • Page 30 SECTION 8 REPLACEMENT PARTS 12, 13 9, 10 4, 5 Figure 8-1 - Front View, MultliPower 460...
  • Page 31 SECTION 8 REPLACEMENT PARTS Figure 8-1 - Front View, MultliPower 460 QTY. ITEM CIRCUIT REQ. DESCRIPTION SYMBOL 678025 Terminal Assembly 952219 Outlet 110V (Square) 952937 Connection Box Rcpt. 14FS X-ROT 634515 SW TGGL SPDT 2 Pos 14A 125V Q/D S3, 5 951474 Switch Seal Black 952209...
  • Page 32 SECTION 8 REPLACEMENT PARTS Figure 8-2 - Inside Front View, MultliPower 460 QTY. ITEM REQ. DESCRIPTION SYMBOL 9951191 Diode Fwd 200V 250A 9951191 Diode Rev 200V 250A 954864 Label 3 Phase 2062334 Fan Motor 1/3 HP 1625 RPM 954699 Label Warning Fan Hazard 36173 Blade Fan 14"...
  • Page 33 SECTION 8 REPLACEMENT PARTS...
  • Page 34 SECTION 8 REPLACEMENT PARTS Figure 8-3 - Inside Rear View, MultliPower 460 QTY. ITEM REQ. DESCRIPTION SYMBOL 17280110 Res WW Fix'd ST 100W 5% 100.00 R3, R4 0558002712 Transformer 230/460/575V 672065 Strap Terminal 36110 Board Input Terminal 230/460/575V...
  • Page 35 SECTION 8 REPLACEMENT PARTS Figure 8-4 External Rear View, MultliPower 460 QTY. ITEM CIRCUIT REQ. DESCRIPTION SYMBOL 1312733 Label for Install Use COP Wire 950219 Relief Strain 2" (Non-enclosed) 672786 Bolt Eye 0558001371 Panel Top Kydex Env 0558001370 Panel Left Side Kydex...
  • Page 36 SECTION 8 REPLACEMENT Figure 8-4 External Top View, MultliPower 460 QTY. ITEM REQ. DESCRIPTION SYMBOL 952938 SCR 480V 18A Panel MNT 951997 Transducer Current 951085 SW THML D/T 176 15A 120V Q/D 0558003077 Matched Triple IGBT Kit - 600V/300A Q1, 2, 3 951940 Capacitor 1.0uf 600VDC 10% 0558002844...
  • Page 37 SECTION 8 REPLACEMENT PARTS...
  • Page 38 SECTION 8 REPLACEMENT PARTS...

  • Page 39: Revision History

    Revision History Revision A: Updated primary power leads illustration and added input terminal board configurations. Changed IGBT item number from 0558002557 to 0558003077 which is the matched triple IGBT kit. Revision dated 07 / 2003: Five notes were added to Page 15 that provide information on the foot and / or the hand control pendants.
  • Page 40 ESAB Welding & Cutting Products, Florence, SC Welding Equipment COMMUNICATION GUIDE - CUSTOMER SERVICES A. CUSTOMER SERVICE QUESTIONS: Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST Order Entry Product Availability Pricing Order Information Returns B. ENGINEERING SERVICE:...

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