F-15-098-A February, 1995 INSTRUCTION MANUAL VI 450 WELDING POWER SOURCE V A VO LT AG PR E ES ET VO LT AG 3 (CO NT CA TO L RO N) 4 5 E 6 2 LO AC MO TE VI- 450 INDU CT 7 1 3 RE 8 MIN 9 MAX 2 4 AN CE 5 6 7 1 MIN 8 9 MAX ON OF F SL OP E 300A MA X IND UC TA NC E This manual provides installation and operation instructions for the following VI 450 power sources: P/N 33322 - 230/460/575 V ac, 60 Hz P/N 33323 - 220/380/415 V ac, 50 Hz NOTE: This manual is also suitable for use with the L-TEC VI-450. It is also suitable for use with the ESAB Phase Arc II 450 made prior to April 1, 1995. These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for electric welding equipment, we urge you to read our booklet, "Precautions and Safe Practices for Arc Welding, Cutting, and Gouging," Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment. Be sure this information reaches the operator. You can get extra copies through your supplier. ESAB Welding & Cutting Products USER RESPONSIBILITY This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Defective equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom purchased. This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer. TABLE OF CONTENTS SECTION PARAGRAPH TITLE PAGE SECTION 1 1.1 1.2 1.3 1.3.1 1.3.2 1.3.3 1.4 1.4.1 1.4.2 1.5 DESCRIPTION ................................................................................................................................... General ............................................................................................................................................... Receiving-Handling ............................................................................................................................ Description ......................................................................................................................................... Available Models ................................................................................................................................ Power Source ..................................................................................................................................... Volt-Ampere Characteristics .............................................................................................................. Optional Accessories ......................................................................................................................... HC-3B Remote Voltage and Contactor Hand Pendant Control ........................................................ TR-22 Truck Kit .................................................................................................................................. Safety ................................................................................................................................................. 5 5 5 5 5 6 6 6 6 6 6 SECTION 2 2.1 2.2 2.3 2.4 2.5 2.5.1 2.5.2 2.5.3 INSTALLATION ................................................................................................................................. Location .............................................................................................................................................. Receiving, Unpacking and Placement ............................................................................................... Primary (Input) Electrical Connection ................................................................................................ Secondary (Output) Welding Connections ........................................................................................ Power Source/Wire Feeder/Control Interconnections ....................................................................... Wire Feeder Control ........................................................................................................................... Remote Voltage and Contactor Control ............................................................................................. Auxiliary 115 V ac Receptacle ........................................................................................................... 7 7 7 7 8 9 9 9 9 SECTION 3 3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.2 3.2.1 3.2.2 OPERATION ...................................................................................................................................... Controls .............................................................................................................................................. Power Switch (ON-OFF) .................................................................................................................... Voltage Preset/Contactor Control Switch .......................................................................................... Local/Remote Switch ......................................................................................................................... Voltage Control ................................................................................................................................... Inductance Control ............................................................................................................................. Over Temperature Indicator ............................................................................................................... Voltmeter and Ammeter ..................................................................................................................... Sequence of Operation ...................................................................................................................... General Procedures for Mig and Sub Arc .......................................................................................... Specific Procedures for Mig and Sub Arc .......................................................................................... 11 11 11 11 11 11 12 12 12 12 12 12 SECTION 4 4.1 4.2 4.3 4.3.1 4.3.2 4.3.3 4.3.4 MAINTENANCE ................................................................................................................................. General ............................................................................................................................................... Cleaning ............................................................................................................................................. Inspection and Service ....................................................................................................................... Fan Motor ........................................................................................................................................... Transformer ........................................................................................................................................ Wire Feeder and Control Circuits ...................................................................................................... Over Temperature Protection ............................................................................................................ 13 13 13 13 13 13 13 13 SECTION 5 5.1 5.2 TROUBLESHOOTING ....................................................................................................................... General ............................................................................................................................................... Testing and Replacing Bridge Assembly Components ..................................................................... 14 14 14 SECTION 6 6.1 6.2 PARTS ................................................................................................................................................ General ............................................................................................................................................... Ordering .............................................................................................................................................. 29 29 29 SAFETY PRECAUTIONS WARNING: These Safety Precautions are for your protection. They summarize precautionary 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 sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death. 5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and create a fire hazard. 6. After completing operations, inspect the work area to make certain there are no hot sparks or hot metal which could cause a later fire. Use fire watchers when necessary. 7. For additional information, refer to NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. PROTECT YOURSELF AND OTHERS -Some welding, cutting, and gouging processes are noisy and require ear protection. The arc, like the sun, emits ultraviolet (UV) and other radiation and can injure skin and eyes. Hot metal can cause burns. Training in the proper use of the processes and equipment is essential to prevent accidents. Therefore: ELECTRICAL SHOCK -- Contact with live electrical parts and ground can cause severe injury or death. DO NOT use AC welding current in damp areas, if movement is confined, or if there is danger of falling. 1. Always wear safety glasses with side shields in any work area, even if welding helmets, face shields, and goggles are also required. 2. Use a face shield fitted with the correct filter and cover plates to protect your eyes, face, neck, and ears from sparks and rays of the arc when operating or observing operations. Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric-arc or hot metal. 3. Wear flameproof gauntlet type gloves, heavy long-sleeve shirt, cuffless trousers, high-topped shoes, and a welding helmet or cap for hair protection, to protect against arc rays and hot sparks or hot metal. A flameproof apron may also be desirable as protection against radiated heat and sparks. 4. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and collars should be kept buttoned, and open pockets eliminated from the front of clothing 5. Protect other personnel from arc rays and hot sparks with a suitable non-flammable partition or curtains. 6. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be hot and can fly far. Bystanders should also wear goggles over safety glasses. 1. Be sure the power source frame (chassis) is connected to the ground system of the input power. 2. Connect the workpiece to a good electrical ground. 3. Connect the work cable to the workpiece. A poor or missing connection can expose you or others to a fatal shock. 4. Use well-maintained equipment. Replace worn or damaged cables. 5. Keep everything dry, including clothing, work area, cables, torch/electrode holder, and power source. 6. Make sure that all parts of your body are insulated from work and from ground. 7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand on dry boards or an insulating platform and wear rubber-soled shoes. 8. Put on dry, hole-free gloves before turning on the power. 9. Turn off the power before removing your gloves. 10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specific grounding recommendations. Do not mistake the work lead for a ground cable. ELECTRIC AND MAGNETIC FIELDS — May be dangerous. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding and cutting current creates EMF around welding cables and welding machines. Therefore: FIRES AND EXPLOSIONS -- Heat from flames and arcs can start fires. Hot slag or sparks can also cause fires and explosions. Therefore: 1. Remove all combustible materials well away from the work area or cover the materials with a protective nonflammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc. 2. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hidden smoldering fire or fires on the floor below. Make certain that such openings are protected from hot sparks and metal.“ 3. Do not weld, cut or perform other hot work until the workpiece has been completely cleaned so that there are no substances on the workpiece which might produce flammable or toxic vapors. Do not do hot work on closed containers. They may explode. 4. Have fire extinguishing equipment handy for instant use, such as a garden hose, water pail, sand bucket, or portable fire extinguisher. Be sure you are trained in its use. 1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers. 2. Exposure to EMF may have other health effects which are unknown. 3. Welders should use the following procedures to minimize 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 your body. C. Do not place your body between the torch and work cables. Route cables on the same side of your body. D. Connect the work cable to the workpiece as close as possible to the area being welded. E. Keep welding power source and cables as far away from your body as possible. 3 10/98 EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death. Therefore: FUMES AND GASES -- Fumes and gases, can cause discomfort or harm, particularly in confined spaces. Do not breathe fumes and gases. Shielding gases can cause asphyxiation. Therefore: 1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do not perform any electrical work unless you are qualified to perform such work. 2. Before performing any maintenance work inside a power source, disconnect the power source from the incoming electrical power. 3. Maintain cables, grounding wire, connections, power cord, and power supply in safe working order. Do not operate any equipment in faulty condition. 4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such as furnaces, wet conditions such as water puddles, oil or grease, corrosive atmospheres and inclement weather. 5. Keep all safety devices and cabinet covers in position and in good repair. 6. Use equipment only for its intended purpose. Do not modify it in any manner. 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 steel, copper, zinc, lead, beryllium, or cadmium unless positive mechanical ventilation is provided. Do not breathe fumes from these materials. 2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and other irritant gases. 3. If you develop momentary eye, nose, or throat irritation while operating, this is an indication that ventilation is not adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not continue to operate if physical discomfort persists. 4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specific ventilation recommendations. 5. WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code §25249.5 et seq.) ADDITIONAL SAFETY INFORMATION -- For more information on safe practices for electric arc welding and cutting equipment, ask your supplier for a copy of "Precautions and Safe Practices for Arc Welding, Cutting and Gouging", Form 52-529. The following publications, which are available from the American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are recommended to you: 1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting" 2. AWS C5.1 - "Recommended Practices for Plasma Arc Welding" 3. AWS C5.2 - "Recommended Practices for Plasma Arc Cutting" 4. AWS C5.3 - "Recommended Practices for Air Carbon Arc Gouging and Cutting" 5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding“ 6. AWS C5.6 - "Recommended Practices for Gas Metal Arc Welding"“ 7. AWS SP - "Safe Practices" - Reprint, Welding Handbook. 8. ANSI/AWS F4.1, "Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances." CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release gas. Sudden rupture of cylinder, valve, or relief device can injure or kill. Therefore: 1. Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder. Do not use adaptors. Maintain hoses and fittings in good condition. Follow manufacturer's operating instructions for mounting regulator to a compressed gas cylinder. 2. Always secure cylinders in an upright position by chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure cylinders to work tables or fixtures where they may become part of an electrical circuit. 3. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable hand trucks. Avoid rough handling of cylinders. 4. Locate cylinders away from heat, sparks, and flames. Never strike an arc on a cylinder. 5. For additional information, refer to CGA Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", which is available from Compressed Gas Association, 1235 Jefferson Davis Highway, Arlington, VA 22202. MEANING OF SYMBOLS - As used throughout this manual: Means Attention! Be Alert! Your safety is involved. Means immediate hazards which, if not avoided, will result in immediate, serious personal injury or loss of life. Means potential hazards which could result in personal injury or loss of life. Means hazards which could result in minor personal injury. 4 SP98-10 SECTION 1 DESCRIPTION 1.1 GENERAL When requesting information concerning this equipment, it is essential that Stock, Serial and Model numbers of the equipment be supplied. This manual has been prepared for use by an experienced operator. It provides information to familiarize the operator with the design, installation and operation of this equipment. 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 optimum performance of this equipment. 1.3 DESCRIPTION The VI 450 is designed for Mig short arc, spray arc and flux core welding, as well as submerged arc applications. 1.3.1 AVAILABLE MODELS 1.2 RECEIVING-HANDLING VI 450 230/460/575, 60 Hz, 3 phase, P/N 33322 VI 450 220/380/415, 50 Hz, 3 phase, P/N 33323 Upon receipt, remove all packing material and carefully inspect for any damage that may have occurred during shipment. Any claims for loss or damage that may have occurred in transit must be filed by the purchaser with the carrier. A copy of the bill of lading and freight bill will be furnished by the carrier on request. Table 2-1. Specifications OPEN CIRCUIT VOLTAGE (Uo) 13-52 V DUTY CYCLE OUTPUT Flat Steep 65% 100% Current (I2) 500 A 450 A Voltage (U2) 40 V 38 V Current (I2) 350 A 300 A Voltage (U2) 34 V 32 V Volts (U1) Current (I1) Flat Current (I1) Flat 230 V 73 A 66 A 460 V 36 A 33 A 575 V 29 A 26 A 220 V 77 A 69 A 380 V 44 A 40 A 415 V 41 A 37 A 60 Hz INPUT 3 Phase 50 Hz Power Factor at Rated Output 83% Maximum Welding Range 500 A/40 V - 50 A/14 V Maximum Auxiliary Power 115 V ac @ 10 A, 60 Hz PHYSICAL SPECIFICATIONS VI 450 Power Source Height 31.0" (79.0 cm) Width 21.6" (55.0 cm) Depth 33.0" (83.9 cm) Net Weight 465 lbs (211 kg) Shipping Weight 487 lbs (221 kg) 5 DESCRIPTION SECTION 1 1.3.2 POWER SOURCE The power source is a constant potential, Silicon Controlled Rectifier (SCR), three phase, star-connected transformer/rectifier type dc unit with solid state contactor and control circuitry. It provides the volt-ampere curve characteristics desired for Mig and submerged arc welding. The power source is equipped with a thermally controlled fan. It helps to minimize the amount of dirt, spatter and dust deposited in the power source as a result of a continuously running cooling fan. It consists of two relays and a thermal switch which allow the fan to run only when welding and when necessary to provide cooling to the internal magnetics and components. range remote output control and provides a contactor closure switch to close the contactor making the output terminal "hot" at all times for arc gouging. The local/ remote switch on the front panel must be placed in the remote position when using this accessory. 60 50 40 30 STEEP FLAT 20 NOTE: As shipped, this feature is disabled. To activate the thermal fan control circuit, remove the left side panel. Locate relay K4 on the rear left transformer mounting support. Move the white wire from terminal 1 to terminal 5. When activated, it is normal for the cabinet sheet metal to be hot to the touch when in the idle mode (fan not running). When required, the fan will automatically energize and cool the internal components as well as the cabinet sheet metal. 10 0 100 200 300 400 500 Figure 1-1. Volt-Ampere Curves 1.3.3 VOLT-AMPERE CHARACTERISTICS 1.4.2 TR-22 TRUCK KIT, P/N 33650 The curves shown in Figure 1-1 represent the voltampere static characteristics for the power source. The slant of these curves is referred to as the 'slope' and is generally defined as the 'voltage drop per 100 amperes of current use.' These curves show the output voltage available at any given output current for the minimum and maximum settings of the voltage control. Values for other settings will fall between the minimum and maximum curves. Because the volt-ampere slope is fixed, it is possible to select welding conditions by estimating the open-circuit voltage required for the load current. The static voltage-ampere slope is not affected by the inductor rheostat setting. This accessory provides for complete mobility of the power source. The kit consists of front castors, rear two cylinder rack and wheels, gas cylinder bracket, and handle. 1.4 OPTIONAL ACCESSORIES 1.4.1 HC-3B REMOTE VOLTAGE AND CONTACTOR HAND PENDANT CONTROL (P/N 33838) This accessory operates in parallel with the power source's voltage control potentiometer to provide full VI 450 Power Source 6 1.5 SAFETY Before the equipment is put into operation, the safety section at the front of this manual should be read completely. This will help avoid possible injury due to misuse or improper welding applications. The definitions relating to the DANGER, WARNING, and CAUTION safety notations are described at the end of the Safety Section in the front of this manual — read them and their specific text references carefully. SECTION 2 INSTALLATION 2.1 LOCATION A proper installation site is necessary for the unit to provide dependable service. This means the power source should be placed in a way that provides freedom of air movement through the unit while minimizing exposure to dust, dirt, moisture, and corrosive vapors. A minimum of 18 inches (46 cm) is required between the side and rear panels of the power source and the nearest obstruction. C. Check air passages at front and rear of cabinet, making sure that no packing materials that may obstruct air flow through the power source. D. After selecting an installation site (see paragraph 2.1), place the power source in the desired location. The unit may be lifted either by using the lifting ring or by forklift truck. If a forklift is used for lifting the unit, be sure that the lift forks are long enough to extend completely under the base. The selected site should also allow easy removal of the power source outer enclosure for maintenance. See Figure 2-1 for overall dimensions of the unit. LIFT EYE Do not use filters on this unit as they would restrict the volume of intake air. Output ratings on this unit are based on an unobstructed supply of cooling air drawn over its internal components. Warranty is void if any type of filtering device is used. 2.88" V A 33.82" VO LT AG PR E ES ET VO LT AG 3 (CON TA OR CA L ON ) 4 5 E 6 2 LO CT MO TE CT 3 8 MIN 9 MA 450 INDU 7 1 RE VI- 2 4 AN CE 5 6 7 1 X MIN 8 9 MA This power source is a three-phase unit and must be connected to a three-phase power supply. It is recommended that the unit be operated on a dedicated circuit to prevent impairment of performance due to an overloaded circuit. X ON OFF SLO PE 300A 2.3 PRIMARY (INPUT) ELECTRICAL CONNECTION MAX IND UC TA NC E 33.0" 21.63" Figure 2-1. Dimensions 2.2 RECEIVING, UNPACKING AND PLACEMENT A. Immediately upon receipt of the power source, inspect for damage which may have occurred in transit. Notify the carrier of any defects or damage. B. Remove the power source from the container. Remove all packing materials. Check the container for any loose parts. ELECTRIC SHOCK CAN KILL! Before making electrical input connections to the power source, "Machinery Lockout Procedures" should be employed. If the connections are to be made from a line disconnect switch, place the switch in the off position and padlock it to prevent inadvertent tripping . If the connection is made from a fusebox, remove the corresponding fuses and padlock the box cover. 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. A. The primary power leads should be insulated copper conductors. Three power leads and one ground wire are required. Either rubber covered cable or conduit (flexible or solid) may VI 450 Power Source 7 INSTALLATION SECTION 2 be used. Table 2-1 provides recommended input conductors and line fuse sizes. B. Open the access door on the right side of the machine. Identify primary power input connections on the input terminal board, customer ground connection to chassis ground lug, and primary voltage-changeover terminal board. Refer to Figures 2-2 and 2-3. Table 2-1. Recommended Sizes for Input Conductors and Line Fuses 230 460 575 66 33 26 No. 4 No. 8 No. 10 100 50 50 Before making any connections to the power source output terminals, make sure that all primary input power to the machine is off. *Sized per National Code for 80 °C rated copper conductors @ 30 °C ambient. Not more than three conductors in raceway or cable. Local codes should be followed if they specify sizes other than those listed above. 23 0 230 57 5 230 5 57 60 4 575 460 575 460 230 0 46 30 2 230 57 5 L1 575 460 230 0 46 30 2 L2 L3 0 46 30 2 C. Thread the input and ground cable(s) through the large strain-relief hole in the rear panel of the power source. Connect the primary power leads to terminals L1, L2, and L3 on the input terminal board. Secure the strain relief on the input cable. Connect the ground wire to the terminal lug, which is located directly below the input terminal board on the chassis base inside the cabinet. 230 460 230 575 Amps Input & Fuse Size GND Amps Conductor CU/AWG 5 Volts 2.4 SECONDARY (OUTPUT) WELDING CONNECTIONS 57 Rated Input nal board (Figure 2-2) illustrates the primary voltage link connections. The voltage links on this board are factory set for highest voltage operation and must be reset for the required service voltage. Figure 2-2 shows the required connections to reestablish the desired service voltage. The voltage links are set up by reconfiguring the copper link bars to the silkscreened voltage designations for the desired voltage. 230 Figure 2-2. Voltage Changeover Input Terminal Board (230/460/575 V illustrated) The chassis must be connected to an approved electrical ground. Failure to do so may result in severe electrical shock, causing severe burns or death. D. Recheck all connections for proper tightness. Ensure all connections are correct and wellinsulated. E. The primary voltage-changeover input termiVI 450 Power Source 8 The output terminals are located on the front panel (Figure 2-3). Four output terminals are provided. The two NEGATIVE (-) (high inductance and low inductance) terminals are located at the bottom right-hand corner and the two POSITIVE (+) (steep slope and flat slope) terminals are located at the bottom left corner. The output cable connections will depend on the materials to be welded and on the welding process desired. Table 2-2 provides the recommended cable output sizes. 2.5 POWER SOURCE/WIRE FEEDER/ SECTION 2 INSTALLATION CONTROL INTERCONNECTIONS Refer to Figure 2-3. Ten amperes of 115 V ac power can be supplied to external accessories by connecting them to receptacle J3 on the rear panel directly above the fuses. 2.5.1 WIRE FEEDER CONTROL Wire feeder control connections are provided by a 19pin amphenol connector (J1) located on the rear panel of the power source in the upper right-hand corner. 2.5.2 REMOTE VOLTAGE AND CONTACTOR CONTROL This function is provided by a 14-pin amphenol connector (J2) located on the rear panel directly below connector J1. It receives a mating plug from a Hand Control Assembly (optional). This receptacle is operative only if the Local/Remote switch on the power source front panel is in the "Remote" position. 2.5.3 AUXILIARY 115 V AC RECEPTACLE Table 2-2. Secondary Cable Sizes Weldin Current Total Length (Feet) of Cable in Weld Circuit* 50 100 150 200 250 100 6 4 3 2 1/0 150 4 3 1 1/0 2/0 200 3 1 1/0 2/0 3/0 250 2 1/0 2/0 3/0 4/0 300 1 2/0 3/0 4/0 4/0 400 2/0 3/0 4/0 4/0 2-2/0 500 3/0 3/0 4/0 2-2/0 2-3/0 *Total cable length includes work and electrode cables. Cable size is based on direct current, insulated copper conductors, 100percent duty cycle and a voltage drop of 4 or less volts. The welding cable insulator must have a voltage rating that is high enough to withstand the open circuit voltage of the machine. VI 450 Power Source 9 INSTALLATION SECTION 2 Figure 2-3. Interconnection Diagram VI 450 Power Source 10 SECTION 3 OPERATION 3.1.2 VOLTAGE PRESET/CONTACTOR CONTROL SWITCH 3.1 CONTROLS (See Figure 3-1) The Voltage Preset switch is located on the front panel of the power source. In the Preset (on) position, the solid state contactor is energized from the power source. In the Remote (maintained) position, the solid state contactor is energized from a remote location, such as a wire feeder. The "on" position thus allows presetting an approximate welding condition without actually striking an arc. The "maintained" position allows the solid state contactor and the constant voltage output to be controlled from a remote Mig wire feeder or mechanized sub arc control. 3.1.1 POWER SWITCH (ON-OFF) 3.1.3 LOCAL/REMOTE SWITCH The power switch is located on the front panel of the power source. In the "off" position, the unit is essentially shut down. With the switch in the "off" position, power is still present at the main contactor and at the switch itself. To fully shut down the power source, power must be disconnected at the line disconnect switch or the fuse box, depending upon the installation. With this switch in the Local position, output is controlled by setting the voltage potentiometer on the front panel to the output desired. In the Remote position, output is controlled using the optional Remote Voltage Control Assembly via connector J2. With the switch in the "on" position, 115 V ac power is provided to energize the main contactor coil, closing the main contactor which provides input power to the main transformer and the low voltage control circuitry. This control allows the operator to regulate the required amount of welding voltage. Placing the Local/Remote switch in the Remote position disables the voltage control. Never, under any circumstances, operate the power source with the cover removed. In addition to the safety hazards, which are considerable, improper cooling may cause damage to the components. Keep side panels closed when unit is energized. Welding helmet, gloves, and other personal protection should always be worn when welding. 3.1.4 VOLTAGE CONTROL 3.1.5 3.1.4 3.1.7 V A VO LT AG PR E ES ET VO LT AG 3 (CO NT CA TO L RO N) 4 5 E 6 2 LO AC MO TE VI- 450 INDU CT 7 1 3 RE 8 MIN 9 MAX 2 4 AN CE 5 6 7 1 MIN 8 9 MAX ON 3.1.2 OFF 3.1.6 3.1.3 SL OP E 300A MA X IND UC TA NC E 3.1.1 Figure 3-1. Control Locations VI 450 Power Source 11 SECTION 3 3.1.5 INDUCTANCE CONTROL This control allows the desired amount of inductance to be set and regulated during short arc welding operations. Variable control allows the operator to fine tune the inductance needed to make the weld puddle more fluid and to minimize weld spatter. 3.1.6 OVER TEMPERATURE INDICATOR This indicator will light when an internal overheating condition has occurred and one of the thermal switches has opened, causing the power source to shut down to protect critical components. 3.1.7 VOLTMETER AND AMMETER A voltmeter (0-60V) and ammeter (0-800A) provide an accurate indication of dc open circuit and welding voltage, and welding current. 3.2 SEQUENCE OF OPERATION Prior to performing the steps below, open the wall disconnect switch or remove fuse from fuse box to electrically isolate the power source. 3.2.1 GENERAL PROCEDURES FOR MIG AND SUB ARC A. Make the secondary output connections to the positive and negative output terminals. B. Make the control connections. Refer to the appropriate wire feeder, mechanized control, and/or torch instruction booklets for additional process requirements or control connections. C. If primary power connections have been made to the main contactor, and the voltage changeover terminal board and control transformer jumpers properly match the incoming voltage, close the main wall disconnect switch or reinstall fuses in the fuse box. VI 450 Power Source 12 OPERATION 3.2.2 SPECIFIC PROCEDURES FOR MIG AND SUB ARC A. Set the local/remote switch to the desired setting. B. Set the on-off switch to the "on" position. C. To preset the approximate welding voltage, place the contactor switch to the "closed" (on) position. This action will energize the power source on output terminals, allowing the desired voltage condition to be preset using the Voltage Control potentiometer and observing the voltmeter. D. After setting the desired voltage condition, release the Voltage Preset switch. This mode requires a remote start control activation in order to start the welding sequence. E. Set the variable inductance control to the desired amount of inductance. Lower inductance settings may be required in order to obtain better arc starts. The established arc and puddle characteristics can then be fine tuned under load. F. Commence welding. Observe the voltmeter, ammeter, and the weld. Readjust the voltage, inductance, and wire feed speed settings as necessary to obtain a satisfactory weld. G. When welding is completed, release torch switch at the remote location. (This action will deenergize the power source solid state contactor and remove dc power from the output terminals.) If the welding operation terminates prematurely, check the front panel overheat light. If the light is on, internal overtemperature conditions have caused the thermal switches to open, deenergizing the solid state contactor. When the unit has sufficiently cooled, these switches will reset, the overheat light will go out, and welding may resume. SECTION 4 MAINTENANCE 4.1 GENERAL 4.3 INSPECTION AND SERVICE If this Power Source does not operate properly, stop work immediately and investigate the cause of the malfunction. Maintenance work must be performed by an experienced person, and electrical work by a trained electrician. Do not permit untrained persons to inspect, clean, or repair this Power Source. Use only recommended replacement parts. Regularly, check cylinder valves, regulators, hoses, and gas connections for leaks using a soap solution or a leak test solution. Keep the Power Source dry, free of oil and grease, and protected at all times from damage by hot metal and sparks. 4.3.1 FAN MOTOR BE SURE THAT THE BRANCH CIRCUIT OR MAIN DISCONNECT SWITCH IS OFF, OR ELECTRICAL INPUT FUSES ARE REMOVED, BEFORE ATTEMPTING ANY INSPECTION OR WORK INSIDE THE POWER SOURCE. PLACING THE POWER SWITCH IN THE OFF POSITION DOES NOT REMOVE ALL POWER FROM INSIDE THE POWER SOURCE. 4.2 CLEANING Periodically, remove the cover from the Power Source and blow accumulated dust and dirt from the air passages and interior components by using clean low pressure air. The frequency of cleaning required depends upon the environment in 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 flow to provide proper cooling. After cleaning with low pressure air, check for and tighten any loose hardware, including all electrical connections. Check for frayed and/or cracked insulation on all power cables and replace if necessary. Keep the fan motor free of accumulated dust and lint by using low pressure air. Lubricate the motor every 3 months with a few drops of SAE-20 non-detergent oil. 4.3.2 TRANSFORMER Other than periodically cleaning the dust and dirt from the transformer as described above, no maintenance is required. Ensure that only clean, dry, low pressure air is used. 4.3.3 WIRE FEEDER AND CONTROL CIRCUITS These circuits are protected by two 10 amp fuses mounted in the rear panel fuse holder (CB1, 2). If these fuses fail, the contactor, shielding gas, and wire feeder will not operate. When replacing a fuse in the welding Power Source, ensure that the proper size fuse is used as a replacement. 4.3.4 OVER TEMPERATURE PROTECTION FAILURE TO REPLACE WORN OR DAMAGED CABLES MAY RESULT IN A BARE CABLE TOUCHING A GROUND SURFACE. THE RESULTING ELECTRICAL ARC MAY DAMAGE UNPROTECTED EYES AND WILL PRESENT A SERIOUS FIRE HAZARD. BODY CONTACT WITH A BARE CABLE, CONNECTOR, OR CONDUCTOR MAY RESULT IN SEVERE ELECTRICAL SHOCK, CAUSING SERIOUS BURNS OR DEATH. If the Power Source reaches an abnormally high internal temperature, the Thermal Fan Kit relay will deenergize, shutting down the Power Source but leaving the cooling fan on. After the Power Source has cooled to a safe level, this relay will be energized and normal operation will be restored. While deenerigized, the contactor, shielding gas, and wire feeder cannot be operated. VI 450 Power Source 13 SECTION 5 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 following troubleshooting information may be used to locate the source of the trouble. Check the problem against the symptoms in the following troubleshooting guide (Table 5-2.) The remedy for the problem may be quite simple. If the cause cannot be quickly located, open up the unit and perform a simple visual inspection of all the components and wiring. Check for proper terminal connections, loose or burned wiring or components, blown fuses, bulged or leaking capacitors, or any other sign of damage or discoloration. 5.2 TESTING AND REPLACING BRIDGE ASSEMBLY COMPONENTS The silicon diodes and SCRs used in the Power Source are devices which allow current to flow in only one direction. The diodes and SCRs are designed to provide long trouble-free operation; however, should a failure occur, they may require replacement. A. Testing SCRs. 1. Locate the main rectifier assembly containing the silicon diodes and SCRs. 2. Remove top and right side panel from the Power Source. 3. Electrically isolate main bridge assembly by disconnecting the capacitor bank and resistor R5. 4. With the ohmmeter on RX1 scale, place the positive lead on the anode (end of SCR with screw threads) and the negative lead on the cathode (positive output terminal on the front panel). The meter should read 30-50 ohms (high resistance). VI 450 Power Source 14 TROUBLESHOOTING 5. Reverse leads and check each SCR. All readings should again show high resistance. The SCRs are bad if they show low resistance in either direction. 6. Check the gate circuit on the SCRs by jumpering the gate lead to the anode of the SCR. The meter should read less than 5 ohms. Remove the jumper from the gate. The meter reading should increase (30-50 ohms). When replacing diodes on SCRs, make sure mounting surfaces are clean. Coat mounting surfaces with Alcoa No. 2 EJC Electrical Joint Compound. Use a torque wrench to tighten diodes and SCRs. Recommended torques are 20-30 in-lbs for diodes; 125-150 in-lbs for SCRs. SECTION 5 TROUBLESHOOTING Table 5-1. PCB Voltage Tests* NOTE All voltage readings are taken with the front access panel open. ELECTRICAL SERVICE AND REPAIR SHOULD BE ATTEMPTED ONLY BY A TRAINED ELECTRICIAN. SCR VOLTAGES (INPUT) FROM TO P1-8 P2-8 (SCR1) P2-7 (SCR2) P2-3 (SCR3) P2-6 (SCR4) P2-1 (SCR5) P2-4 (SCR6) READING P1-9 115 V ac OTB+ (Flat) 14 V ac SCR VOLTAGES (OUTPUT) FROM TO READING P1-11 OTB+ (Flat) +10 V dc P1-4 OTB+ (Flat) 0-10 V dc** OTB+ (Flat) .3 V dc with contactor on P2-5 (SCR1) P2-2 (SCR2) P2-12 (SCR3) P2-9 (SCR4) P2-10 (SCR5) P2-11 (SCR6) *Refer to Schematic Diagram **Varies with VCP (R1) VI 450 Power Source 15 TROUBLESHOOTING SECTION 5 Table 5-2. Troubleshooting Guide CONDITION ACTION Unit inoperative A. B. C. D. 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 transformer overheating -- thermal switches tripped due to restricted cooling air. Let unit cool down. D. Solid-state breaker tripped due to current overload. E. PC board defective or loose PC board connector(s) -- if loose, reinsert; if defective, replace. Limited Output or Low Open-Circuit Voltage A. Input voltage jumper links on terminal board improperly set -- check for proper voltage. B. Poor output connections. Take apart, clean, and reassemble. C. Unit may be single-phasing -- check incoming power for three phases. D. Panel-Remote switch in Remote position and remote voltage pot disabled. Erratic Weld Current A. B. C. D. E. F. High Output, No Voltage Control No 115 Volt ac Output No input power. Check main line (user's) switch fuses -- replace if needed. Poor or improper input (terminal board) connections. Defective ROS switch on front panel -- replace. Main transformer overheating. Also check for proper cooling, proper primary hookup, or shorted turn on secondary. E. Fan motor not operating -- check motor and leads. Remember, this is normal when Thermal Fan Kit is used. F. Main contactor defective -- check for proper operation. Welding cable size too small -- use correct cables. Loose welding cable connection (will usually get hot) -- tighten all connections. Improper wire feeder setup. Defective SCR in bridge rectifier. PC board defective -- replace. Unit may be single phasing -- check the incoming power for three phases. PC board defective or loose -- reset and/or replace board. A. Check secondary of control winding on main transformer for 115 V ac. B. Circuit breaker tripped -- reset. Line Fuse Blows When A. Shorted SCR in Main Bridge -- replace. Power Source is First B. Shorted capacitor in Capacitor Bank. Turned On Wire Sparks and Sticks to Workpiece at End of Weld VI 450 Power Source 16 A. Allow 2 to 4 seconds for capacitor banks to discharge after completing the weld and before touching wire to workpiece. B. If doubling the discharge rate is desired (twice as fast) and you are not using the Thermal Fan Kit (generate excessive heat), change R1 (16 ohm, 300 watt) resistor to 8 ohm, 300 watt resistor (P/N 17300008). To quadruple the discharge rate (four times as fast), two 8 ohm resistors may be connected in parallel in place of R1. SECTION 5 TROUBLESHOOTING Figure 5-1. VI 450 Power Source Schematic Diagram - 60 Hz (Sheet 1 of 2) VI 450 Power Source 17 TROUBLESHOOTING SECTION 5 Figure 5-1. VI 450 Power Source Schematic Diagram - 60 Hz (Sheet 2 of 2) VI 450 Power Source 18 SECTION 5 TROUBLESHOOTING Figure 5-2. VI 450 Power Source Wiring Diagram - 60 Hz (Sheet 1 of 4) VI 450 Power Source 19 TROUBLESHOOTING SECTION 5 Figure 5-2. VI 450 Power Source Wiring Diagram - 60 Hz (Sheet 2 of 4) VI 450 Power Source 20 SECTION 5 TROUBLESHOOTING Figure 5-2. VI 450 Power Source Wiring Diagram - 60 Hz (Sheet 3 of 4) VI 450 Power Source 21 TROUBLESHOOTING SECTION 5 Figure 5-2. VI 450 Power Source Wiring Diagram - 60 Hz (Sheet 4 of 4) VI 450 Power Source 22 SECTION 5 TROUBLESHOOTING Figure 5-3. VI 450 Power Source Schematic Diagram - 50 Hz (Sheet 1 of 2) VI 450 Power Source 23 TROUBLESHOOTING SECTION 5 Figure 5-3. VI 450 Power Source Schematic Diagram - 50 Hz (Sheet 2 of 2) VI 450 Power Source 24 SECTION 5 TROUBLESHOOTING Figure 5-4. VI 450 Power Source Wiring Diagram - 50 Hz (Sheet 1 of 4) VI 450 Power Source 25 TROUBLESHOOTING SECTION 5 Figure 5-4. VI 450 Power Source Wiring Diagram - 50 Hz (Sheet 2 of 4) VI 450 Power Source 26 SECTION 5 TROUBLESHOOTING Figure 5-4. VI 450 Power Source Wiring Diagram - 50 Hz (Sheet 3 of 4) VI 450 Power Source 27 TROUBLESHOOTING SECTION 5 Figure 5-4. VI 450 Power Source Wiring Diagram - 50 Hz (Sheet 4 of 4) VI 450 Power Source 28 SECTION 6 6.1 GENERAL Replacement Parts are illustrated on the following figures. When ordering replacement parts, order by part number and part name, as illustrated on the figure. DO NOT ORDER BY PART NUMBER ALONE. 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 PARTS Replacement parts may be ordered from your ESAB distributor or from: ESAB Welding & Cutting Products Attn: Customer Service Dept. PO Box 100545, Ebenezer Road Florence, SC, 29501-0545 Be sure to indicate any special shipping instructions when ordering replacement parts. To order parts by phone, contact ESAB at 1-803-6645540 or 4460. Orders may also be faxed to 1-800-6347548. Be sure to indicate any special shipping instructions when ordering replacement parts. Refer to the Communication Guide located on the last page of this manual for a list of customer service phone numbers. VI 450 Power Source 29 SECTION 6 REPLACEMENT PARTS 9,13 8,12 7 1 6 V A VO LT A PR GE ES ET 5 VO LT 3 (CO NTA CA L RO N) RE MO TE VI- 4 E IND UC TA 7 1 3 8 MIN 9 MA 2 4 5 NC E 6 7 1 X 450 4 AG 5 6 2 LO CTO MIN 8 9 MA X ON OF F 3 SL OP E 300 AM AX 2 IND UC TA NC E 10,11 Figure 6-1. VI 450 (Front View) ITEM NO. QTY REQ. PART NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 1 1 1 1 1 1 1 1 1 4 2 1 1 13735182 672508 634515 2134926 634516 951278 951280 639541 672507 13733935 13792513 2062201 2062171 VI 450 Power Source 30 DESCRIPTION LIGHT, INDICATOR SWITCH, 3-POS. SWITCH, TOGGLE, SPDT LIGHT, INDICATOR SWITCH, TOGGLE, SPDT VOLTMETER, DC, 60 V AMMETER, DC, 600 A POTENTIOMETER, 15 K RHEOSTAT, 300 W, 12 OHM RECEPTACLE, CABLE CONNECTOR, QUICK (SUPPLIED) KNOB KNOB CIRCUIT DESIG. PL1 S1 S3 PL2 S2 VM AM R1 R2 SECTION 6 REPLACEMENT PARTS 1 2 4 3 Figure 6-2. VI 450 Control Access Panel (Open) ITEM NO. QTY REQ. PART NO. 1 2 3 4 1 1 1 1 13735102 635686 675312 950417 DESCRIPTION RELAY, 3PDT, 42 V BLOCK, TERMINAL, 8-POINT PC BOARD ASSY RELAY, DPDT, 24 V CIRCUIT DESIG. K2 TB5 PCB1 K3* * K3 relay was added starting with Ser. No. D94E48975 (5/94) for improved main transformer protection. VI 450 Power Source 31 SECTION 6 REPLACEMENT PARTS 1,2 11 10 3 9 8 7 6 5 4 Figure 6-3. VI 450 (Left Side View) ITEM NO. QTY REQ. PART NO. 1 1 2 3 4 5 6 1 1 1 1 1 7 8 9 10 11 1 1 1 1 2 33332 33217 673502 33769 33216 635686 33486 33141 33162 672330 673676 2062334 13735308 VI 450 Power Source 32 DESCRIPTION TRANSFORMER, CONTROL (60 HZ) TRANSFORMER, CONTROL (50 HZ) CONTACTOR, 75 A SHUNT INDUCTOR ASSY BLOCK, TERMINAL, 8-POINT TRANSFORMER ASSY, MAIN (60 HZ) TRANSFORMER ASSY, MAIN (50 HZ) RESISTOR ASSY, SLOPE SPIDER, FAN BLADE, FAN MOTOR, FAN RELAY, DPDT, 120 V AC CIRCUIT DESIG. T2 K1 SH L1 TB4 T1 R4 M1 K4,5 SECTION 6 REPLACEMENT PARTS BRIDGE ASSY (REFER TO FIGURE 6-6) 1 5 2 6 4 3 Figure 6-4. VI 450 (Right Side View) ITEM NO. QTY REQ. PART NO. 1 2 1 1 3 4 5 6 1 1 1 3 951541 33328 33171 951201 17300016 673459 672348 DESCRIPTION BLOCK, TERMINAL, 20-POINT BOARD, TERMINAL (60 HZ) BOARD, TERMINAL (50 HZ) FUSE, 10 A, 600 V RESISTOR, 16 OHM, 300 W CAPACITOR, 9800 uF, 50 V DC CAPACITOR, .01 uF, 1.0 KV CIRCUIT DESIG. TB2 TB1 F1,2 R5 C13-22 C10-12 VI 450 Power Source 33 SECTION 6 REPLACEMENT PARTS 1 5 2 4 3 Figure 6-5. VI 450 (Rear View) ITEM NO. QTY REQ. PART NO. 1 2 3 4 5 1 1 1 1 1 951539 951540 951540 647298 950122 VI 450 Power Source 34 DESCRIPTION RECEPTACLE, 19-PIN RECEPTACLE, 14-PIN PANEL, REAR, SILKSCREENED RECEPTACLE, 115 V, DUPLEX CIRCUIT BREAKER, 10 AMP CIRCUIT DESIG. J1 J2 J3 CB1,2 SECTION 6 REPLACEMENT PARTS 1 2 3 4 Figure 6-6. Bridge Assembly ITEM NO. QTY REQ. PART NO. 1 2 3 4 6 6 6 3 672348 13735018 950841 950711 DESCRIPTION CAPACITOR, .01 uF, 1.0 KV CORE, TOROID THYRISTOR, SCR SWITCH, THERMAL CIRCUIT DESIG. C1-6 L2-7 SCR1-6 TS1-3 VI 450 Power Source 35 COMMUNICATIONS GUIDE A. CUSTOMER SERVICE QUESTIONS: Telephone: (803) 664-5540 / FAX: (800) 634-7548 Order Entry Product Availability Pricing Order Changes Hours: 8:30 AM to 5:00 PM EST B. ENGINEERING SERVICE: Telephone: (803) 664-4416 or -5550 / FAX: (800) 446-5693 Welding Equipment Troubleshooting Warranty Returns Hours: 7:30 AM to 5:00 PM EST C. TECHNICAL SERVICE: Telephone: (803) 664-5547 / FAX: (803) 664-5575 Part Numbers Technical Applications Performance Features Technical Specifications Hours: 7:30 AM to 5:00 PM EST D. LITERATURE REQUESTS: Telephone: (803) 664-5501 / FAX: (803) 664-5575 Hours: 7:30 AM to 4:00 PM EST E. WELDING EQUIPMENT REPAIRS: Telephone: (803) 664-4487 / FAX: (803) 664-5557 Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST F. WELDING EQUIPMENT TRAINING: Telephone: (803) 664-5524 / FAX: (803) 664-5575 Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST G. WELDING PROCESS ASSISTANCE: Telephone: (803) 664-4248 / FAX: (803) 664-4454 Hours: 7:30 AM to 4:00 PM EST H. TECHNICAL ASST. CONSUMABLES: Telephone: (800) 934-9353 Hours: 7:30 AM to 5:00 PM EST IF YOU DO NOT KNOW WHOM TO CALL Telephone: (803) 664-5540 and (803) 664-4460 Hours: 7:30 AM to 5:00 PM EST ESAB Welding & Cutting Products F-15-098-A 2/95 1.5M Printed in U.S.A. PO Box 100545 Florence SC 295010545