ESAB SVI 450i cvcc, Instruction Manual

Page 1: ... 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 This manual provides installation and operation maintenance and troubleshoot...

Page 2: ...is 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 2 SECTION TITLE PAGE PARAGRAPH SECTION 1 DESCRIPTION 5 1 1 Introduction 5 1 2 Optional Accessories 5 SECTION 2 INSTALLATION 6 2 1 Gener...

Page 3: ... completely cleaned so that there are no sub stances 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 5 Do not use equipment beyond its ratings For example overl...

Page 4: ... 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 steel copper zinc lead beryllium or cadmium unless positive mechani cal ventilation is provided Do not breathe fumes from these materials 2 Do not operate near degreasing and spraying operations The heat or arc rays c...

Page 5: ...ws the operator to select the opti mum cv slope curve characteristic and or inductance conditionrequiredforyourMIGweldingapplication Refer to table 1 1 for specifications 1 2 OPTIONAL ACCESSORIES A To avoid duplication of MIG accessories which may or may not be required for the various MIG systems pleaserefertotheindividualwirefeeder or control instruction booklets provided for your system B For a...

Page 6: ...e chance of nuisance fault tripping or damage due to transients caused by other equipment loads such as resistance welders punch presses large electric motors etc If nuisance tripping caused by transients becomes a problem ESABhasa primarylineconditioner P N 15983 which may be added to filter out transient voltages Contactyourdistributorfordetails Pleasenote that the conditioner will not correct f...

Page 7: ...using 208 or 230 volt input two links on the input terminal board located insidethepowersource mustberepositionedas marked on the plate see Figure 2 2 The input terminal board connections will be visible after removing the top cover C The factory supplied input power cable is con nected to the power source ON OFF switch However if customers wish to connect their own input power leads proceed as fo...

Page 8: ...al deterioration and increased resistance due to corrosion This leads to poor performance as described above To ensure good torch performance periodically replace the water cooled power cable The welding output receptacles are located on the front panel one negative and one positive receptacle Two male plug connectors P N 950693 are supplied with the power source for attachment to customer supplie...

Page 9: ...Cable size is based on direct current insulated copper conductors 100 duty cycle and a voltage drop of 4 or less volts The welding cable insulation must have a voltage rating that is high enough to withstand the open circuit voltage of the machine Cam Lock jack plug connectors will not accept smaller than No 2 gauge cable Also remember that for MIG Pulse conditions we recommend only 4 0 cable be u...

Page 10: ...thatthepowersource sPanel Remote switch must be set to REMOTE to provide cur rent regulation and or contactor control at the welding location When the FC 5B foot or TC 2B torch accessory is connected full range current regulation and contactor control are available from the remote accessory When the HC 3B hand control is connected the processswitchmustplacedintheCC TIG STICK position to set up the...

Page 11: ...resume weld ing Iftrippingcontinues stopandrefertosection 5 3 1 INTRODUCTION This section is intended to familiarize personnel with the operational procedures applicable to the SVI 450i cvcc powersource Informationcontainedinthissectionshould be read carefully before operation of the power source Never under any circumstances operate the power source with the cover or side panels removed In additi...

Page 12: ...le control allows the operator to fine tune the induc tanceneededtomaketheweldpuddlemorefluid and minimize the weld spatter produced during MIG short arc applications When short arc welding stainless steel high values of induc tance should be used with A1025 helium rich shielding gas This potentiometer should be set to minimum for all pulse and standard spray arc welding applications H Digital MIG...

Page 13: ...y abort if the torch switch is energized for 2 seconds without striking a welding arc This will most likely occur if you use the torch switch to thread new wire inthetorchlinerorforwireinchingoperations Itwill not occur if you use the recommended cold wire inching controls provided on the feeder for these functions If an abort does occur simply reset the control as described in the appropriate wir...

Page 14: ...TTING CURRENT SETTING A MEDIUM ARC FORCE RANGE MAX AF MAXIMUM CURRENT MIN AF MINIMUM CURRENT AMPERES DC VOLTS DC 700 600 500 400 300 200 100 0 80 70 60 50 40 30 20 10 0 DUTY CYCLE 1ø DUTY CYCLE 3ø 120 110 OUTPUT CURRENT MAX SHORT CIRCUIT MAX AMBIENT OF 40 O C DUTY CYCLE BASED ON 10 MINUTE PERIOD AND DUTY CYCLE 100 90 70 80 60 50 40 30 20 10 0 600 500 400 300 200 100 0 Figure 3 2 Duty Cycle Rating ...

Page 15: ... the unit and the amount of dust in the atmosphere 4 3 LUBRICATION Fan motors with oil tubes located on the side of the motor require lubrication after 1 year of service Motors without oiltubesarepermanentlylubricatedforlifeandshouldnot require any attention 4 1 GENERAL If the power source does not operate properly stop work immediatelyandinvestigatethecauseofthemalfunction Maintenanceworkmustbepe...

Page 16: ...pair shop 5 1 TROUBLESHOOTING Electric shock can kill Ensure all primary power to the power source has been externally disconnected Open wall disconnect switch or circuit breaker be fore attempting inspection of work inside of the power source Capacitors can explode causing personal injury To avoid injury carefully read and do the following The subject warning concerns the four power filter ing ca...

Page 17: ...endant control Check circuit breaker and reset if tripped Check J2 and disconnect pendant foot control Check MIG contactor signal see ICB troubleshooting Check STICK contactor signal see ICB troubleshooting No open circuit voltage Defective SCR1 R1 Missing bias voltage to Inverter Control Board ICB False thermal indication to ICB Defective ICB See SCR1 troubleshooting See ICB troubleshooting See I...

Page 18: ...ration Incorrect slope setting for application Excessive welding cable length Welding cable size too small High resistance torch power cable Inverter Control Board ICB calibration Defective ICB Check incoming power to unit all three phases Reference VA curves and change slope according to required output volts and amps Recommend max cable length work and torch of 100 ft Recommend 4 0 cable for MIG...

Page 19: ...P1 2 12 V ac P1 2 P1 3 12 V ac P1 8 P1 10 24 V ac P1 8 P1 9 12 V ac P1 9 P1 10 12 V ac D Input Bridge IBR Troubleshooting See Figure 5 1 Resistance Checks Probe Probe Measurement IBR 1 2 3 IBR diode forward drop IBR IBR 1 2 3 open IBR IBR 1 2 3 diode forward drop IBR 1 2 3 IBR open Voltage Checks Using meter high impedance diode scale Using meter low impedance diode scale TB 1 375 290 V dc 230 V a...

Page 20: ...f reads open then replace R1 SCR1 G SCR1 K diode forward drop low impedance using diode scale Gate Lead from Inverter Control should be disconnected If reads short then replace SCR 1 Voltage Checks SCR1 G SCR1 K 0 V dc Torch switch deenergized 0 6 V dc Torch switch energized if missing check Inverter Control ...

Page 21: ... T1 T2 POWER CABLE CONNECTIONS CAPACITOR MOUNTING BRACKETS BEHIND BOARD P1 CONTROL PLUS TYP TRANSISTOR MOUNTING SCREW TOTAL 16 ISOBAR TYPICAL EACH SIDE P C BOARD MOUNTING SCREW TYPICAL EACH SIDE T3 T4 POWER CABLE CONNECTIONS Torque Specifications IBR Case to Heatsink 40 lb in Terminals 25 lb in SCR1 Case to Heatsink 25 lb in Terminals 25 lb in PA1 Transistors Case to Isobar 10 lb in When replacing...

Page 22: ...5 V dc Digital Meter Bias P5 1 P2 9 10 V dc DC Bias P4 7 P4 8 115 V ac MIG Contactor Signal P4 9 P4 10 24 V ac Stick Contactor Signal P2 10 P3 1 72 V dc Arc Voltage open circuit P1 1 P1 2 10 0 3 mV Shunt Signal 100 amps P1 4 P1 5 10 0 3 mV Meter Signal 100 amps P3 3 P2 2 12 V dc MIG Mode Select 0 V dc Stick Mode Select P3 9 P3 10 0 V dc Thermal Normal 12 V dc Thermal Overload P2 5 P2 2 0 V dc Stee...

Page 23: ...SECTION 5 TROUBLESHOOTING 23 Figure 5 3 Inverter Control Board ICB Top View Layout TP1 TP2 ...

Page 24: ...POWER BOARD 2 1 T2 4 5 P3 2 3 P6 1 5 25W CTR1 2 PB1 POWER BOARD 1 1 2W IND P6 9 4 X3 R5 P1 10 U 100 3 T2 3 X19 POS R9 H2 05UF P6 10 K2 2 3 B OBR4 X2 14 PB1 P1 5 C8 X2 P6 8 A T IBR INPUT BRIDGE MODULE 3 P2 9 2 P6 7 B 10A OBR3 P6 3 X1 D PL2 LS LINE SWITCH CB1 X1 2 P5 5 1 2 3 PB1 P1 4 H1 13 CT2 OBR2 1 05UF 1 P5 6 05UF P1 6 SAFETY GROUND X2 T4 X18 C7 C CONTACTOR 100W C6 P6 4 OBR1 10 1 2W WELD 5 25W D ...

Page 25: ...X6 ORN B X9 WHT BLK L1 X4 A H1 X8 WHT L1 X2 BLK 1 GRN X7 BLK 2 TB 6 X6 X1 IBR 2 5 TB 8 TS2 3 YEL BRN BRN 1 BLK BLU RED IBR 1 POS OUTPUT BLK IBR 3 MTR X2 TB 9 ORN PB1 GRY PB1 PB1 X1 B COIL PB1 6 PB1 GRY 4 GRY 2 TB 5 PB1 P1 9 GRY P1 10 X2 P1 8 BRN TB 7 P1 3 P1 2 GRY P1 1 TB 8 A COIL X2 OBR BUS 1 X3 GRY OBR BUS 2 GRY IND BX1 J2 K GRY X2 X1 IND AX1 B IND AX2 BX2 GRY WHT H1 H2 GRY R3 1 A WHT H1 4 H2 3 ...

Page 26: ...IO BLU K2 MTR X1 BLK CTR2 H2 3 WHT PB2 WHT WHT J3 1 WHT BLK 2 K2 9 OBR1 BUS1 BLK CTR2 H1 P3 P4 L1 X3 1 VIO P2 BLK L1 X1 RED CLR CB2 2 VIEW C SH T2 K2 6 P1 1 J1 N ICB P5 NEG OUTPUT BLK T1 BLK 9 BLK T1 3 VIEW C ICB BLK P1 6 BLU T1 1 GRY VIO SHLD TP B P1 P1 2 WHT J1 U BLK GRY SP A BLU P6 CB1 2 TB 4 CTR1 X17 BRN J1 P ICB P1 3 BLK TP 10 MTR AH2 CTR1 X16 TB 2 GRY 9 RED TP MTR AH1 P6 10 CTR1 X15 K 2 ICB ...

Page 27: ...s 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 Cutting Products Attn Customer Service Dept PO Box 100545 Ebenezer Road Florence SC 29501 0545 Besuretoindicateanyspecialshippinginstructionswhen ordering replacement parts To order parts by phone contact ESAB at 1 803 664 5540...

Page 28: ...3733935 32059GY 31128YL 672831 32057GY 31130YL LAMP WHITE LAMP RED SWITCH TOGGLE SPDT METER DIGITAL POTENTIOMETER TRIM KNOB P O ITEM NO 5 PANEL RIGHT SIDE CONNECTOR FEMALE PANEL FRONT SILKSCREENED PANEL LEFT SIDE SWITCH TOGGLE SPDT PANEL CONTROL SILKSCREENED PANEL TOP PL1 PL2 PL3 SW1 SW2 DPM ICP VCP SW3 SVI 450i cvcc Figure 6 1 SVI 450i cvcc Front View 1 2 4 5 3 SW1 6 7 8 9 10 12 11 3 SW2 ...

Page 29: ... ITEM NO QTY REQ PART NO DESCRIPTION CIRCUIT SYMBOL 1 2 3 1 1 1 31135 31133 31134 INDUCTOR MOUNTED ON FRONT PART OF CHASSIS BASE TRANSFORMER MAIN MOUNTED ON TOP OF INDUCTOR TRANSFORMER CONTROL MOUNTED ON CHASSIS BASE UNDER FAN MOTOR IND MTR CTR1 Figure 6 2 SVI 450i cvcc Top View 1 3 2 ...

Page 30: ...SECTION 6 REPLACEMENT PARTS 30 Figure 6 3 SVI 450i cvcc Top View 1 2 ITEM NO QTY REQ PART NO DESCRIPTION CIRCUIT SYMBOL 1 2 1 1 31143 38082 TERMINAL BOARD SCREEN PRINTED PC BOARD ASSY CONTROL TB ICB ...

Page 31: ...NO QTY REQ PART NO DESCRIPTION CIRCUIT SYMBOL 1 2 3 4 5 6 7 1 1 1 1 1 1 1 674991 17282010 950516 950702 951023 17250005 951022 PC BOARD ASSY POWER RESISTOR 10 OHM 100 W CAPACITOR 0 05 µF 600 V CAPACITOR 0 01 µF 125 V MODULE SCR RESISTOR 5 OHM 50 W INPUT BRIDGE MODULE PB1 R2 C5 C9 SCR1 R1 IBR ...

Page 32: ...1 12 1 2 3 1 1 1 1 4 1 1 1 1 674991 17725005 950516 13735102 33938 993717 635686 951184 951085 950702 17282010 31132 PC BOARD ASSY POWER RESISTOR 5 OHM 25 W CAPACITOR 0 05 µF 600 V RELAY 42 V 3 POLE CHOKE COMMON MODE TRANSFORMER TERMINAL STRIP 8 POSITION DIODE OUTPUT SWITCH THERMAL 80 C CAPACITOR 0 01 µF 100 W RESISTOR 10 OHM 100 W SHUNT PB2 R4 5 C8 K2 L1 CTR2 T1 OBR1 4 TS1 C10 R3 SH ...

Page 33: ... ITEM NO QTY REQ PART NO DESCRIPTION CIRCUIT SYMBOL 1 2 3 4 5 6 7 8 9 10 1 1 1 1 1 1 2 1 1 1 950822 680970 679384GY 950592 97W63 952219 950122 31126GY 951476 951475 SWITCH ROTOR 3PST MOTOR FAN SHROUD FAN BLADE FAN CONNECTOR CABLE GRIP RECEPTACLE 125 V 15 A CIRCUIT BREAKER 10 A REAR PANEL RECEPTACLE 14 PIN RECEPTACLE 19 PIN LS FM J3 CB1 2 J2 J1 ...

Page 34: ...SECTION 6 REPLACEMENT PARTS 34 ...

Page 35: ...SECTION 6 REPLACEMENT PARTS 35 ...

Page 36: ...M EST Warranty Returns Authorized Repair Stations C TECHNICAL SERVICE Telephone 800 ESAB 123 Fax 843 664 4452 Part Numbers Technical Applications Hours 8 00 AM to 5 00 PM EST Performance Features Technical Specifications Equipment Recommendations D LITERATURE REQUESTS Telephone 843 664 5562 Fax 843 664 5548 Hours 7 30 AM to 4 00 PM EST E WELDING EQUIPMENT REPAIRS Telephone 843 664 4487 Fax 843 664...