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LG 453cc manual

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Table of contents for the manual

  • Page 1

    Be sure this information reaches the operator. You can get extra copies through your supplier. INSTRUCTION MANUAL F-15-591-A February, 2001 453cc & 553cc DC WELDING POWER SOURCES These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding equipment, we urge [...]

  • Page 2

    2 USER RESPONSIBILITY This equipment will perform in conformity with the description thereof 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. Malfunctioning or poorly maintained equipment sh[...]

  • Page 3

    3 T ABLE OF CONTENTS SECTION P ARAGRAPH TITLE P AGE SAFETY ENGLISH SAFETY PRECAUTIONS ..................................................................................................... ........... 4, 5 FRENCH SAFETY PRECAUTIONS ...................................................................................................... .......... 6, 7 [...]

  • Page 4

    4 WARNING: T hese Safety Precautions are for your protection. They summarize precaution- ary information from the references listed in Additional Safety Information section. Before performing any installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sh[...]

  • Page 5

    5 FUMES AND GASES -- Fumes and gases, can cause discomfort or harm, particularly in confined spaces. Do not breathe fumes and gases. Shield- ing gases can cause asphyxiation. Therefore: 1. Always provide adequate ventilation in the work area by natural or mechanical means. Do not weld, cut, or gouge on materials such as galvanized steel, stainless [...]

  • Page 6

    6 coupes à l’arc, à moins de les recouvrir complètement d’une bâche non-inflammable. Ce type de matériaux comprend notamment le bois, les vêtement s, la sciure, l’essence, le kérosène, les peintures, les solvants, le gaz naturel, l’acétylène, le propane et autres sub- stances combustibles semblables. b. Les étincelles ou les proj[...]

  • Page 7

    7 levage, des câbles de grue ou divers chemins électriques. g. Empêchez l’apparition de toute humidité, not amment sur vos vêtements, à la surface de l’emplacement de travail, des câbles, du porte-électrode et du poste de soudage/coupage. Rép arez immédiatement toute fuite d’eau. 4. VENTILA TION-- La respiration prolongée des fumé[...]

  • Page 8

    8 1.1 GENERAL This manual has been prepared for use by an experi- enced operator. It provides information to familiarize the operator with the design, installation and operation of the 482cc and 582cc model power sources. DO NOT attempt to install or operate this equipment until you have read and fully understood these instructions. The information[...]

  • Page 9

    9 1.3.2 Volt-Ampere Characteristics The curves shown in Figure 1-1 represent the volt- ampere static characteristics for the power source. These curves show the output voltage available at any given output current from the minimum to the maximum setting of the current control. Figure 1.1 Volt/Ampere Curves 1.4 OPTIONAL ACCESSORIES Stick Electrode H[...]

  • Page 10

    10 2.3 PRIMARY (INPUT) ELECTRICAL CONNEC- TION This power source is a three-phase unit and must be connected to a three-phase power supply. It is recom- mended that the unit be operated on a dedicated circuit to prevent impairment of performance due to an over- loaded circuit. ELECTRIC SHOCK CAN KILL! Before making elec- trical input connections to[...]

  • Page 11

    11 In p u t & GN D Fu s e Si z e Co nduct or* A m ps CU/ A W G 208 64 No. 6 90 220 61 No. 6 80 230 58 No. 6 80 482cc 400 33 No. 10 40 460 29 No . 10 40 575 23 No . 12 30 208 82 N o. 4 120 220 77 N o. 4 120 230 74 N o. 4 120 582cc 400 43 N o. 8 70 460 37 No. 8 60 575 30 No . 10 50 * S i zed per N ati onal C ode for 75 o C r ated c opper c onduc [...]

  • Page 12

    12 SECTION 2 INST ALLA TION D. Check all connections for proper tightness. En- sure all connections are correct and well insu- lated. E. Figure 2-2 illustrates the input voltage terminal board and the input voltage link connections. The particular voltages from which this power source may be operated are stated on the rating plate. The voltage link[...]

  • Page 13

    13 Figure 2.3 CONTROL CONNECTIONS OUTPUT RECEPTACLE 2.4 SW POWER SWITCH 63A 600V CKT. BREAKERS, 10A 32VDC, 250VAC SECTION 2 INST ALLA TION + -[...]

  • Page 14

    14 Never operate the power source with the cover re moved. In addition to the safety hazards, lmproper cooling may cause damage to the components. Keep side panels closed when unit is energized. Welding helmet, gloves, and other personal protec- tion should always be worn when welding. 3.1 CONTROLS (See Figure 3.1) 3.1.1 PowerSwitch(ON-OFF)/(I-O) T[...]

  • Page 15

    15 3.1.6 Over Temperature Indicator (Temp) This amber light will indicate when an internal overheat- ing condition has occurred and one of the thermal switches has opened. User control of the solid state contactor will be interrupted and power source output will shut down to protect critical components. Once cooled to a safe temperature, the therma[...]

  • Page 16

    16 4.1 GENERAL If this power source does not operate properly, stop work immediately and investigate the cause of the malfunction. Maintenance work must be per- formed by an experienced person, and electrical work by a trained electrician. Do not permit un- trained persons to inspect, clean, or repair this power source. Use only recommended replace[...]

  • Page 17

    17 5.1 GENERAL DISCONNECT primary power at wall switch, or circuit breaker, before attempting inspection or work inside the power source. If the power source is operating improperly, the follow- ing troubleshooting information may be used to locate the source of the trouble. Check the problem against the symptoms in the follow- ing troubleshooting [...]

  • Page 18

    18 CO NDI T I O N A CT I O N Unit I noperat iv e A . No input power . Check main line (us er' s ) s wit ch f us es -- r eplace if needed. B. Poor or im proper input (t erm inal board) connec tions . C. Def ect iv e on / of f s wit ch on f r ont pane l - - replac e. D. M ain t r ans f or m er ov er heat ing. A ls o c hec k f or pr oper cooling,[...]

  • Page 19

    19 6.1 GENERAL Always provide the series or serial number of the unit on which the parts will be used. The serial number is stamped on the unit nameplate. 6.2 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 par[...]

  • Page 20

    20 SECTION 6 REPLACEMENT P ARTS 453cc-553cc View 1 - Front[...]

  • Page 21

    21 SECTION 6 REPLACEMENT P ARTS 453cc-553cc View 2 - Top Panel[...]

  • Page 22

    22 SECTION 6 REPLACEMENT P A RTS 453cc-553cc View 3 - Angled Front[...]

  • Page 23

    23 SECTION 6 REPLACEMENT P ARTS 453cc-553cc View 4 - Rear[...]

  • Page 24

    24 SECTION 6 REPLACEMENT P A RTS 453cc-553cc View 5 - Internal Rear View[...]

  • Page 25

    25 SECTION 6 REPLACEMENT P ARTS 453cc-553cc View 6 - Internal Front View[...]

  • Page 26

    26 SECTION 6 REPLACEMENT P ARTS D-0558001568-A 453cc-553cc Schematic Diagram- 50/60 HZ NOTES: 1. REFER TO WIRING DIAGRAMS FOR ALL CONNECTION POINTS. 2. USE TYWRAPS 631507 (ITEM 41), 99511578 (ITEM 130), 180W66 (ITEM 145), 180W68 (ITEM 146). TO CONFINE LOOSE WIRE AS REQUIRED. USE 71200732 (ITEM 123) TO SECURE FILTER CAPACITORS. USE HEAT SHRINK 90863[...]

  • Page 27

    27 SECTION 6 REPLACEMENT P ARTS 453cc-553cc Wiring Diagram- Primary 3 PH D-0558001569[...]

  • Page 28

    28 SECTION 6 REPLACEMENT P ARTS 453cc-553cc Wiring Diagram Secondary - 50/60 HZ D-0558001570-A[...]

  • Page 29

    29 1 954838 1 LABEL SUBARC STICK 2 954839 1 LABEL MIG 3 836121 1 PCB DIGITAL METER PCB2 4 836173 1 BLADE FAN 14" 5 838127 1 PCB CONTROL PCB1 838128 1 CONTROL PCB 6 8634515 2 SW TGGL SPDT 2 POS 15A 125V S2,3 7 8672065 6 STRAP TERMINAL 8 8678025 2 TERM AY 9 8950122 2 CKT BREAKER 10A 32VDC 250VAC CB1,2 10 8950219 1 RELIEF STRAIN 2.00 11 8950711 2[...]

  • Page 30

    30 41 631507 AR TYWRAP MEDIUM 42 634220 2 TAB 43 647361 1 GND1 LUG TERMINAL 2-8 WIRE 1/4 STUD 44 672786 1 BOLT EYE .75-10 X 2.00 45 950167 1 GROMMET RUB 1.12 ID X 1.50 GD X .06 W 46 950905 1 TERM IL/M .250 TS X 14-16 AWG 47 951504 1 J5 PLUG HOUSING 15 POS 49 952067 1 CONNECTOR 20 AWG 3 PIN P1 50 952068 1 MTA-156 COVER 3 PIN 51 952070 1 CONNECTOR 20[...]

  • Page 31

    31 SECTION 6 REPLACEMENT P ARTS Bill of Materials 453cc/553cc DC Welding Power Source ITEM PART OR NO. CODE NO. QTY. DESCRIPTION SYMBOL 133 99512240 1 LABEL CAUTION LIFT EYE 134 99512558 2 BRACKET RESISTOR #18 135 0558001010 1 TERMINAL BLOCK 3 POS TB3 136 0558001011 1 BOX PCB GRAY 137 0558001012 3 PLUG HOUSING 2 POS 138 0558001014 3 SEAL WIRE 2 POS[...]

  • Page 32

    F-15-591-A 2/2001 Printed in U.S.A. IF YOU DO NOT KNOW WHOM TO CALL Telephone: (800) ESAB-123/ Fax: (843) 664-4452/ Web:http://www.esab.com Hours: 7:30 AM to 5:00 PM EST A. CUSTOMER SERVICE QUESTIONS: Order Entry Product Availability Pricing Delivery Order Changes Saleable Goods Returns Shipping Information Eastern Distribution Center Telephone: (8[...]