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F-15-014-F

June, 2003

INSTRUCTION MANUAL

Digipulse 450i
Power Source

This manual provides installation and operation instructions for the following Digipulse 450i cutting package:

ESAB P/N 31120 - 208/230/460 V ac, 1 or 3 phase


ESAB P/N 31238 - 575 V ac, 3 phase, 60 Hz (refer to supplement F-15-015)
ESAB P/N 31690 - 220/380/415 V ac, 3 phase, 50 Hz (refer to supplement F-15-039)

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.
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 pro-
vided. 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 replace-
ment 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 TITLE PAGE


PARAGRAPH

SECTION 1 DESCRIPTION ................................................................................................. 5


1.1 Introduction ....................................................................................................... 5
1.2 Specifications .................................................................................................... 5

SECTION 2 INSTALLATION ................................................................................................ 6


2.1 General ............................................................................................................. 6
2.2 Unpacking and Placement ................................................................................ 6
2.3 Primary (Input) Connections.............................................................................. 6
2.4 Secondary (Output) Welding Connections ........................................................ 7
2.5 Control Interconnection ..................................................................................... 9
2.6 Optional Accessories ........................................................................................ 9

SECTION 3 OPERATION ..................................................................................................... 11


3.1 Introduction ....................................................................................................... 11
3.2 Duty Cycle......................................................................................................... 11
3.3 Power Source Welding Controls ....................................................................... 11
3.4 Sequence of Operation ..................................................................................... 12

SECTION 4 MAINTENANCE ............................................................................................... 13


4.1 General ............................................................................................................. 13
4.2 Cleaning ............................................................................................................ 13
4.3 Lubrication ........................................................................................................ 13

SECTION 5 TROUBLESHOOTING ..................................................................................... 14


5.1 Troubleshooting ................................................................................................ 14
5.2 Calibration Procedure ....................................................................................... 20

SECTION 6 REPLACEMENT PARTS ................................................................................. 25


6.1 General ............................................................................................................. 25
6.2 Ordering ............................................................................................................ 25

2
SAFETY PRECAUTIONS

WARNING: These Safety Precautions are for 5. Do not use equipment beyond its ratings. For example,
your protection. They summarize precautionary overloaded welding cable can overheat and create a fire
information from the references listed in Addi- hazard.
tional Safety Information section. Before per- 6. After completing operations, inspect the work area to make
forming any installation or operating procedures, be sure to certain there are no hot sparks or hot metal which could
read and follow the safety precautions listed below as well as cause a later fire. Use fire watchers when necessary.
all other manuals, material safety data sheets, labels, etc. 7. For additional information, refer to NFPA Standard 51B,
Failure to observe Safety Precautions can result in injury or "Fire Prevention in Use of Cutting and Welding Processes",
death. available from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
PROTECT YOURSELF AND OTHERS --
Some welding, cutting, and gouging pro- ELECTRICAL SHOCK -- Contact with live electrical parts
cesses are noisy and require ear pro- and ground can cause severe injury or death. DO NOT use
tection. The arc, like the sun, emits AC welding current in damp areas, if movement is con-
ultraviolet (UV) and other radiation and fined, or if there is danger of falling.
can injure skin and eyes. Hot metal can cause burns.
Training in the proper use of the processes and equip- 1. Be sure the power source frame
ment is essential to prevent accidents. Therefore: (chassis) is connected to the ground system
of the input power.
1. Always wear safety glasses with side shields in any work 2. Connect the workpiece to a good
area, even if welding helmets, face shields, and goggles electrical ground.
are also required. 3. Connect the work cable to the workpiece. A poor or
2. Use a face shield fitted with the correct filter and cover missing connection can expose you or others to a fatal
plates to protect your eyes, face, neck, and ears from shock.
sparks and rays of the arc when operating or observing
4. Use well-maintained equipment. Replace worn or dam-
operations. Warn bystanders not to watch the arc and not
to expose themselves to the rays of the electric-arc or hot aged cables.
metal. 5. Keep everything dry, including clothing, work area, cables,
3. Wear flameproof gauntlet type gloves, heavy long-sleeve torch/electrode holder, and power source.
shirt, cuffless trousers, high-topped shoes, and a welding 6. Make sure that all parts of your body are insulated from
helmet or cap for hair protection, to protect against arc rays work and from ground.
and hot sparks or hot metal. A flameproof apron may also 7. Do not stand directly on metal or the earth while working in
be desirable as protection against radiated heat and sparks. tight quarters or a damp area; stand on dry boards or an
4. Hot sparks or metal can lodge in rolled up sleeves, trouser insulating platform and wear rubber-soled shoes.
cuffs, or pockets. Sleeves and collars should be kept 8. Put on dry, hole-free gloves before turning on the power.
buttoned, and open pockets eliminated from the front of 9. Turn off the power before removing your gloves.
clothing 10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)
5. Protect other personnel from arc rays and hot sparks with for specific grounding recommendations. Do not mistake
a suitable non-flammable partition or curtains.
the work lead for a ground cable.
6. Use goggles over safety glasses when chipping slag or
grinding. Chipped slag may be hot and can fly far. Bystand-
ers should also wear goggles over safety glasses. ELECTRIC AND MAGNETIC FIELDS May be dangerous.
Electric current flowing through any conductor causes
FIRES AND EXPLOSIONS -- Heat from localized Electric and Magnetic Fields (EMF). Welding and
flames and arcs can start fires. Hot slag cutting current creates EMF around
or sparks can also cause fires and explo- welding cables and welding machines.
sions. Therefore: Therefore:

1.Remove all combustible materials well 1.Welders having pacemakers should con-
away from the work area or cover the materials with a sult their physician before welding. EMF
protective non-flammable covering. Combustible materi- may interfere with some pacemakers.
als include wood, cloth, sawdust, liquid and gas fuels, 2. Exposure to EMF may have other
solvents, paints and coatings, paper, etc. health effects which are unknown.
2. Hot sparks or hot metal can fall through cracks or crevices 3. Welders should use the following procedures to minimize
in floors or wall openings and cause a hidden smoldering exposure to EMF:
fire or fires on the floor below. Make certain that such A. Route the electrode and work cables together. Secure
openings are protected from hot sparks and metal. them with tape when possible.
3. Do not weld, cut or perform other hot work until the
B. Never coil the torch or work cable around your body.
workpiece has been completely cleaned so that there are
no substances on the workpiece which might produce C. Do not place your body between the torch and work
flammable or toxic vapors. Do not do hot work on closed cables. Route cables on the same side of your body.
containers. They may explode. D. Connect the work cable to the workpiece as close as
4. Have fire extinguishing equipment handy for instant use, possible to the area being welded.
such as a garden hose, water pail, sand bucket, or E. Keep welding power source and cables as far away from
portable fire extinguisher. Be sure you are trained in its your body as possible.
use.
3
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. Always have qualified personnel perform the installation,
Therefore: troubleshooting, and maintenance work. Do not perform
any electrical work unless you are qualified to perform
1. Always provide adequate ventilation in the work area by such work.
natural or mechanical means. Do not weld, cut, or gouge 2. Before performing any maintenance work inside a power
on materials such as galvanized steel, stainless steel, source, disconnect the power source from the incoming
copper, zinc, lead, beryllium, or cadmium unless positive electrical power.
mechanical ventilation is provided. Do not breathe fumes 3. Maintain cables, grounding wire, connections, power cord,
from these materials. and power supply in safe working order. Do not operate
2. Do not operate near degreasing and spraying operations. any equipment in faulty condition.
The heat or arc rays can react with chlorinated hydrocar- 4. Do not abuse any equipment or accessories. Keep
bon vapors to form phosgene, a highly toxic gas, and other equipment away from heat sources such as furnaces, wet
irritant gases. conditions such as water puddles, oil or grease, corrosive
3. If you develop momentary eye, nose, or throat irritation atmospheres and inclement weather.
while operating, this is an indication that ventilation is not 5. Keep all safety devices and cabinet covers in position and
adequate. Stop work and take necessary steps to improve in good repair.
ventilation in the work area. Do not continue to operate if 6. Use equipment only for its intended purpose. Do not
physical discomfort persists. modify it in any manner.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for
specific ventilation recommendations. ADDITIONAL SAFETY INFORMATION -- For
5. WARNING: This product, when used for welding or more information on safe practices for electric
cutting, produces fumes or gases which arc welding and cutting equipment, ask your
contain chemicals known to the State of supplier for a copy of "Precautions and Safe
California to cause birth defects and, in Practices for Arc Welding, Cutting and Goug-
some cases, cancer. (California Health & ing", Form 52-529.
Safety Code 25249.5 et seq.)
The following publications, which are available from the
American Welding Society, 550 N.W. LeJuene Road, Miami,
CYLINDER HANDLING -- Cylinders, if
FL 33126, are recommended to you:
mishandled, can rupture and violently
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
release gas. Sudden rupture of cylin-
2. AWS C5.1 - "Recommended Practices for Plasma Arc
der, valve, or relief device can injure or
Welding"
kill. Therefore:
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
1. Use the proper gas for the process and use the proper
4. AWS C5.3 - "Recommended Practices for Air Carbon Arc
pressure reducing regulator designed to operate from the
Gouging and Cutting"
compressed gas cylinder. Do not use adaptors. Maintain
5. AWS C5.5 - "Recommended Practices for Gas Tungsten
hoses and fittings in good condition. Follow manufacturer's
Arc Welding
operating instructions for mounting regulator to a com-
6. AWS C5.6 - "Recommended Practices for Gas Metal Arc
pressed gas cylinder.
Welding"
2. Always secure cylinders in an upright position by chain or
7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.
strap to suitable hand trucks, undercarriages, benches,
8. ANSI/AWS F4.1, "Recommended Safe Practices for Weld-
walls, post, or racks. Never secure cylinders to work
ing and Cutting of Containers That Have Held Hazardous
tables or fixtures where they may become part of an
Substances."
electrical circuit.
3. When not in use, keep cylinder valves closed. Have valve
MEANING OF SYMBOLS - As used through-
protection cap in place if regulator is not connected.
out this manual: Means Attention! Be Alert!
Secure and move cylinders by using suitable hand trucks.
Your safety is involved.
Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder. Means immediate hazards which, if not
5. For additional information, refer to CGA Standard P-1, avoided, will result in immediate, seri-
"Precautions for Safe Handling of Compressed Gases in ous personal injury or loss of life.
Cylinders", which is available from Compressed Gas
Association, 1235 Jefferson Davis Highway, Arlington, Means potential hazards which could
VA 22202. result in personal injury or loss of life.

Means hazards which could result in


minor personal injury.
4
PRCAUTIONS DE SCURIT
AVERTISSEMENT: Ces rgles de scurit ont pour objet du secteur o lon excute des soudures ou des coupes
d assurer votre protection. Veillez lire et observer les larc, moins de les recouvrir compltement dune
prcautions nonces ci-dessous avant de monter l bche non-inflammable. Ce type de matriaux comprend
quipement ou de commercer lutiliser. Tout dfaut notamment le bois, les vtements, la sciure, lessence,
dobservation de ces prcautions risque dentraner des le krosne, les peintures, les solvants, le gaz naturel,
blessures graves ou mortelles. lactylne, le propane et autres substances combus-
1. PROTECTION INDIVIDUELLE-- Les brlures de la peau tibles semblables.
et des yeux dues au rayonnement de larc lectrique ou b. Les tincelles ou les projections de mtal incandescent
du mtal incandescent, lors du soudage au plasma ou peuvent tomber dans des fissures du plancher ou dans
llectrode ou lors du gougeage larc, peuvent savrer des ouvertures des murs et y dclencher une ignition
plus graves que celles rsultant dune exposition lente cache. Veiller protger ces ouvertures des
prolonge au soleil. Aussi convient-il dobserver les tincelles et des projections de mtal.
prcautions suivantes: c. Nexcutez pas de soudures, de coupes, doprations
a. Portez un cran facial adquat muni des plaques de gougeage ou autres travaux chaud la surface de
protectrices et des verres filtrants appropris afin de barils, bidons, rservoirs ou autres contenants usags,
vous protger les yeux, le visage, le cou et les oreilles avant de les avoir nettoys de toute trace de substance
des tincelles et du rayonnement de larc lectrique susceptible de produire des vapeurs inflammables ou
lorsque vous effectuez des soudures ou des coupes ou toxiques.
lorsque vous en observez lexcution. d. En vue dassurer la prvention des incendies, il convient
AVERTISSEZ les personnes se trouvant proximit de de disposer dun matriel dextinction prt servir
faon ce quelles ne regardent pas larc et ce immdiatement, tel quun tuyau darrosage, un seau
quelles ne sexposent pas son rayonnement, ni eau, un seau de sable ou un extincteur portatif.
celui du mtal incandescent. e. Une fois le travail larc termin, inspectez le secteur de
b. Portez des gants ignifugs crispins, une tunique faon vous assurer quaucune tincelle ou projection
paisse manches longues, des pantalons sans rebord, de mtal incandescent ne risque de provoquer
des chaussures embout dacier et un casque de ultrieurement un feu.
soudage ou une calotte de protection, afin dviter 3. CHOC LECTRIQUE-- Le gougeage larc et larc au
dexposer la peau au rayonnement de larc lectrique plasma exige lemploi de tensions vide relativement
ou du mtal incandescent. ll est galement souhaitable importantes; or, celles-ci risquent de causer des
dutiliser un tablier ininflammable de faon se protger dommages corporels graves et mme mortels en cas
des tincelles et du rayonnement thermique. dutilisation inadquate. La gravit du choc lectrique
c. Les tincelles ou les projections de mtal incandescent reu dpend du chemin suivi par le courant travers le
risquent de se loger dans des manches retrousses, corps humain et de son intensit.
des bords relevs de pantalons ou dans des poches. a. Ne laissez jamais de surfaces mtalliques sous tension
Aussi convient-il de garder boutonns le col et les venir au contact direct de la peau ou de vtements
manches et de porter des vtements sans poches humides. Veillez porter des gants bien secs.
lavant. b. Si vous devez effectuer un travail sur une surface
d. Protgez des tincelles et du rayonnement de larc mtallique ou dans un secteur humide, veillez assu-rer
lectrique les autres personnes travaillant proximit votre isolation corporelle en portant des gants secs et
laide dun cran ininflammable adquat. des chaussures semelles de caoutchouc et en vous
e. Ne jamais omettre de porter des lunettes de scurit tenant sur une planche ou une plate-forme sche.
lorsque vous vous trouvez dans un secteur o lon c. Mettez toujours la terre le poste de soudage/coupage
effectue des oprations de soudage ou de coupage en le reliant par un cble une bonne prise de terre.
larc. Utilisez des lunettes de scurit crans ou d. Nutilisez jamais de cbles uss ou endommags. Ne
verres latraux pour piquer ou meler le laitier. Les surchargez jamais le cble. Utilisez toujours un
piquetures incandescentes de laitier peuvent tre quipement correctement entretenu.
projetes des distances considrables. Les personnes e. Mettez lquipement hors tension lorsquil nest pas en
se trouvant proximit doivent galement porter des service. une mise la masse accidentelle peut en effet
lunettes de protection. provoquer une surchauffe de lquipement et un danger
f. Le gougeage larc et le soudage larc au plasma dincendie. Ne pas enrouler ou passer le cble autour
produisent un niveau de bruit extrmement lev (de dune partie quelconque du corps.
100 114 dB) et exigent par consquent lemploi de f. Vrifiez si le cble de masse est bien reli la pice en
dispositifs appropris de protection auditive. un point aussi proche que possible de la zone de travail.
2. PRVENTION DES INCENDES-- Les projections de Le branchement des cbles de masse lossature du
laitier incandescent ou dtincelles peuvent provoquer btiment ou en un point loign de la zone de travail
de graves incendies au contact de matriaux combus- augmente en effet le risque de passage dun courant de
tibles solides, liquides ou gazeux. Aussi faut-il observer sortie par des chanes de
les prcautions suivantes:
a. loigner suffisamment tous les matriaux combustibles

5
levage, des cbles de grue ou divers chemins dommages corporels graves, voire mortels en
lectriques. dclenchant des incendies ou des chocs lectriques.
g. Empchez lapparition de toute humidit, notamment Observez par consquent les prcautions suivantes:
sur vos vtements, la surface de lemplacement de a. Efforcez-vous de toujours confier un personnel qua-lifi
travail, des cbles, du porte-lectrode et du poste de linstallation, le dpannage et lentretien du poste de
soudage/coupage. Rparez immdiatement toute fuite soudage et de coupage. Neffectuez aucune rparation
deau. lectrique sur lquipement moins dtre qua-lifi cet
4. VENTILATION-- La respiration prolonge des fumes effet.
rsultant des oprations de soudage/coupage, b. Ne procdez jamais une tche dentretien quelconque
lintrieur, dun local clos, peut provoquer des malaises lintrieur du poste de soudage/coupage, avant davoir
et des dommages corporels. Aussi convient-il dbranch lalimentation lectrique.
dobserver les prcautions suivantes: c. Maintenez en bon tat de fonctionnement les cbles, le
a. Assurez en permanence une aration adquate de cble de masse, les branchements, le cordon
lemplacement de travail en maintenant une ventilation dalimentation et le poste de soudage/coupage. Nutilisez
naturelle ou laide de moyens mcaniques. Neffectuez jamais le poste ou lquipement sil prsente une
jamais de travaux de soudage ou de coupage sur des dfectuosit quelconque.
matriaux de zinc, de plomb, de beryllium ou de cad- d. Prenez soin du poste de soudage et de coupage et des
mium en labsence de moyens mcaniques de ventila- quipements accessoires. Gardez-les lcart des
tion capables dempcher linhalation des fumes sources de charleur, notamment des fours, de lhumidit,
dgages par ces matriaux. des flaques deau maintenez-les labri des traces
b. Neffectuez jamais de travaux de soudage ou de dhuile ou de graisse, des atmosphres corrosives et
coupage proximit de vapeurs dhydrocarbure chlor des intempries.
rsultant doprations voisines de dgraissage ou de e. Laissez en place tous les dispositifs de scurit et tous
pulvrisation. La chaleur dgage ou le rayonnement les panneaux de larmoire de commande en veillant
de larc peut dclencher la formation de phosgne -- les garder en bon tat.
gaz particulirement toxique -- et dautres gaz irritants, f. Utilisez le poste de soudage/coupage conformment
partir des vapeurs de solvant. son usage prvu et neffectuez aucune modification.
c. Une irritation momentane des yeux, du nez ou de la 6. INFORMATIONS COMPLMENTAIRES RELATIVES
gorge constate au cours de lutilisation de lquipement LA SCURIT--
dnote un dfaut de ventilation. Arrtez-vous de travailler Pour obtenir des informations complmentaires sur les
afin de prendre les mesures nces- saires rgles de scurit observer pour le montage et
lamlioration de la ventilation. Ne poursuivez pas lutilisation dquipements de soudage et de coupage
lopration entreprise si le malaise persiste. lectriques et sur les mthodes de travail
d. Certaines commandes comportent des canalisations recommandes, demandez un exemplaire du livret N
o circule de lhydrogne. Larmoire de commande est 52529 Precautions and Safe Practices for Arc Weld-
munie dun ventilateur destin empcher la formation ing, Cutting and Gouging publi par ESAB. Nous
de poches dhydrogne, lesquelles prsentent un dan- conseillons galement de consulter les publications sui-
ger dexplosion; ce ventilateur ne fonctionne que si vantes, tenues votre disposition par lAmerican Weld-
linterrupteur correspondant du panneau avant se trouve ing Society, 550 N.W. LeJuene Road, Miami, FL 32126:
plac en position ON (Marche). Veillez manuvrer a. Safety in Welding and Cutting AWS Z49.1
cette commande en vrifiant si le couvercle est bien en b. Recommended Safe Practices for Gas-Shielded Arc
place, de faon assurer lefficacit de la ventilation Welding AWS A6. 1.
ainsi ralise. Ne jamais dbrancher le ventilateur. c. Safe Practices for Welding and Cutting Containers That
e. Les fumes produites par lopration de soudage ou de Have Held Combustibles AWS-A6.0.
coupage peuvent savrer toxiques. Aussi est-il d. Recommended Safe Practices for Plasma Arc Cutting
ncessaire de disposer en permanence dun dispositif AWS-A6. 3.
adquat de ventilation de type aspirant, afin dlimi-ner e. Recommended Safe Practices for Plasma Arc Weld-
du voisinage de loprateur tout dgagement de fume ing AWS-C5. 1.
visible. f. Recommended Safe Practices for Air Carbon Arc
f. Consultez les recommandations particulires en matire Gouging and Cutting AWS-C5. 3.
de ventilation indiques lalina 6 de la norme Z49.1 g. Code For Safety in Welding and Cutting CSA-Standard
de lAWS. W117. 2.
5. ENTRETIEN DE LQUIPEMENT-- Un quipement
entretenu de faon dfectueuse ou inadquate risque
non seulement de raliser un travail de mauvaise
qualit mais, chose plus grave encore, dentraner des

6
SECTION 1 DESCRIPTION

1.1 INTRODUCTION 1.2 SPECIFICATIONS

The Digpulse 450i is a CV/CC inverter-type power Rated Output @:


source specifically designed and dedicated for use with ....60% Duty .......................... 450 amps @ 38 V dc
a Digipulse wire feeder or Digipulse mechanized/robotic ....100% Duty ......................... 350 amps @ 34 V dc
control. When combined, these components work to- Open Circuit Voltage (Max.) ......................... 72 V dc
gether to provide a pulsed MIG system that self-adjusts Input Voltage ................... 230/460 V ac, 3 ph. 60 Hz
while welding to give optimum arc performance. The Input Current @ Rated Load ... 80 amps @ 230 V ac
Digipulse system is also designed to provide non-pulsed ................................................................................
digital logic needed for convenient MIG short and spray ............................................... 40 amps @ 460 V ac
arc welding applications. Dimensions
................. 15.25" (387 mm) w x 23.0" (584 mm) d x
When operated in its Constant Current (CC) setting, the ...................................................... 15.5" (394 mm)h
Power Source can be used for a wide range of dc Stick, Weight .............................................. 166 lbs (70 kg)
scratch-start TIG, and air-carbon arc gouging applica-
tions.

Figure 1-1. MIG Mode - VA Curves

Figure 1-2. Duty Cycle Rating Chart

7
SECTION 2 INSTALLATION

2.1 GENERAL chance of nuisance (fault) tripping or damage due to


transients caused by other equipment loads such as
Proper installation will contribute to safe, satisfac- resistance welders, punch presses, large electric
tory, and trouble-free operation of the welding setup. motors, etc.
It is suggested that each step in this section be
studied carefully and followed as closely as pos- If nuisance tripping caused by transients becomes a
sible. problem, ESAB has a "primary line conditioner" (P/
N 31102) which may be added to filter out transient
2.2 UNPACKING AND PLACEMENT voltages . Contact your distributor for details.
Please note that the conditioner will not correct for
A. Immediately upon receipt of the equipment, sustained line voltages which exceed the limits of
inspect for damage which may have occurred its rated voltage inputs.
in transit. Notify the carrier of any defects or
damage at once. The Power Source is designed to provide line
voltage compensation within 10 percent of the rated
B. After removing the components from the ship- 230/460 volt input to maintain its rated output and
ping container(s), check the containers for any protect its power electronics. If these limits are
loose parts. Remove all packing materials. exceeded, serious damage to the unit could occur.
Therefore, prior to installation, it is suggested that
C. Check air passages of Power Source for any the proposed line circuit be checked (with a meter)
packing materials that may obstruct air flow at two or three different time periods of the day to
through the Power Source. make sure the power load does not exceed the
Power Source's input limits. If input power cannot
D. If the equipment is not to be installed immedi- be maintained within the 10 percent limits, consult
ately, store it in a clean, dry, well-ventilated your local power company or call ESAB for pos-
area. sible solutions.

E. The location of the welding equipment should be


carefully selected to ensure satisfactory and
dependable service. Choose a location rela-
ELECTRIC SHOCK CAN KILL! PRECAUTION-
tively close to a properly fused supply of elec-
ARY MEASURES SHOULD BE TAKEN TO PRO-
trical power.
VIDE MAXIMUM PROTECTION AGAINST ELEC-
TRICAL SHOCK. BE SURE THAT ALL POWER IS
F. The Power Source components are maintained
OFF BY OPENING THE LINE (WALL) DISCON-
at proper operating temperatures by forced air
NECT SWITCH WHEN PRIMARY ELECTRICAL
drawn through the cabinet by the fan unit on the
CONNECTIONS ARE MADE TO THE POWER
rear panel. For this reason, it is important the
SOURCE. TO BE DOUBLY SAFE, CHECK YOUR
machine be located in an open area where air
INPUT LEADS WITH A VOLTMETER TO MAKE
can circulate freely at the front and rear open-
SURE THAT ALL POWER IS OFF.
ings. If space is at a premium, leave at least 1
foot of clearance between the rear of the Power
A. A line (wall) disconnect switch, with fuses or
Source and wall or other obstruction. The area
circuit breakers, should be provided at the main
around the unit should be relatively free of dust,
power panel (see Figure 2-2). The customer
fumes, and excessive heat. It is also desirable
can either use the factory-supplied input power
to locate the unit so the cover can be removed
cable (No. 6 AWG, 4/c, type SO (90 C), 12-ft
easily for cleaning and maintenance.
lg) or provide his own input power leads. The
primary power leads should be insulated copper
2.3 PRIMARY (INPUT) CONNECTIONS conductors and include a 3-phase power lead
with one ground wire. The wires may be heavy
The Digipulse 450i Power Source is a 3-phase unit rubber covered cable or run in a solid or flexible
and must be connected to a "clean-unloaded" 3- conduit. Refer to Table 2-1 for recommended
phase supply power line. An unloaded line is input conductors and line fuse sizes.
essential for good performance and lessens the
8
SECTION 2 INSTALLATION

Table 2-1. Recommended Sizes for


Input Conductors and Line Fuses
Rated Load Input & Time-Delay
Gnd. Fuse Size
Conductor* Amps
Volts Amps CU/AWG
230 80 6 100 Figure 2-1. Input Voltage Terminal Board
460 40 8 50 (TB) Connections

D. Recheck all connections to make sure they are


*Sizes per National Electric Code for 90C rated copper conductors
@ 30 C ambient. Not more than three conductors in raceway or
tight, well insulated, and properly connected.
cable. Local codes should be followed if they specify sizes other
than those listed above. 2.4 SECONDARY (OUTPUT) WELDING
CONNECTIONS
B. As shipped, the Power Source is set up for 460
volt input power. If using a 230 volt input, two
links on the input terminal board (located inside
the unit) must be repositioned as marked on the
plate (see Figure 2-1). The input terminal board
BEFORE MAKING ANY CONNECTIONS TO THE
connections will be visible after removing the top
POWER SOURCE OUTPUT TERMINALS, MAKE
cover.
SURE THAT ALL PRIMARY INPUT POWER TO
THE UNIT IS DEENERGIZED (OFF) AT THE
C. The factory-supplied input power cable is con-
CUSTOMER'S DISCONNECT SWITCH.
nected to the Power Source ON-OFF switch.
However, if the customer wishes to connect his
A. Digipulse MIG Setup (see Figure 2-2). This
own input power leads, proceed as follows:
Power Source is designed to provide MIG
With the top cover and left side panel removed,
welding operating characteristics only when the
thread the input conductor cable from the wall
J2 control receptacle is "vacant" (meaning no
disconnect switch through the strain relief hole
accessories are plugged in) or, if the remote
in the rear panel. Connect the primary leads to
HC-3B Hand Control (P/N 30783) is plugged in.
the Line Switch (LS) for either single- or 3-
The Process Switch must be set in the Digital-
phase input and the ground lead (green) to the
MIG (center) position for Digipulse controls.
stud on the base of the unit as shown in Figure
Additionally, proper operation of the Power
2-2. After making sure the connections are
Source depends on the use of copper output
secured, tighten the strain relief coupling to
cables that are insulated, of adequate size, in
secure the input cable.
good condition, and properly connected to the
machine using the jack plug connectors pro-
vided with the Power Source. It is recom-
mended only 4/0 welding output cable be used
regardless of length and current to be used, and
IT IS OF THE UTMOST IMPORTANCE THAT that these cables be kept as short as possible
THE CHASSIS BE CONNECTED TO AN AP- (Total length including work and electrode leads
PROVED ELECTRICAL GROUND TO PREVENT should not exceed 100 feet. Beyond this dis-
ACCIDENTAL SHOCK. TAKE CARE NOT TO tance, there will be performance deterioration.
CONNECT THE GROUND WIRE TO ANY OF Consult with the factory if you have an applica-
THE PRIMARY LEADS. tion of this nature.)

Particular attention should be paid to high


resistance in the welding circuit; specifically,
the work cable/circuit and water-cooled torch
cable. It is recommended that the Power
9
SECTION 2 INSTALLATION
Source/Wire Feeder and workpiece be placed The welding output receptacles are located on
as close together as possible to limit resistance the front panel; one negative (-) and one positive
in the welding circuit. High resistance in the (+) receptacle. Two male plug connectors (P/
welding circuit can cause performance deterio- N 950693) are supplied with the Power Source
ration (loss of "heat" input, popping of weld for attachment to customer supplied 4/0 welding
puddle, bushy arcs, etc.). Ensure the work cables (see Figure 2-2). This Power Source is
cable is large enough (refer to Table 2-2), kept designed for conventional and pulsed MIG
as short as possible, properly insulated, se- spray arc applications using Direct Current
curely connected to the workpiece, and that all Reverse Polarity (DCRP) setup. In a DCRP
connections are clean and tightly secured. If a setup, the torch or electrode is positive (+), and
separate work circuit is used (such as in the workpiece is negative (-).
mechanical fixturing, shipbuilding, robot
fixturing, etc.), make sure the work circuit is B. Stick/Scratch-Start TIG/ Arc Gouging Setup
secure and presents a low resistance path to the (see Figure 2-3). These processes require
flow of welding current. Also, the power cable
on a water-cooled torch is normally subject to
gradual deterioration and increased resistance
due to corrosion. This leads to poor perfor-
mance as described above. To assure good
torch performance, the water-cooled power
cable should be replaced periodically.

Figure 2-2. MIG Interconnection Diagram

10
SECTION 2 INSTALLATION

constant current (CC) type curve characteris-


tics for proper operation. These characteristics
Table 2-2. Recommended Welding Cable Sizes
are only provided when one of the remote
accessories (FC-5, TC-2) is plugged into the J2
receptacle or when the remote HC-3 Hand Welding Total Length (Feet) of Cable in Weld Circuit*
Control is connected to J2 and its Process
Switch is set in the CC-TIG/Stick position. Current 50 100 150 200 250
Select the desired welding mode, accessories, 100 6** 4** 3** 2 1
and polarity as shown in figure 2-3. The output 150 4** 3** 1 1/0 2/0
cables can be connected for DCRP or DCSP : 200 3** 1 1/0 2/0 3/0
250 2 1/0 2/0 3/0 4/0
meaning that for a DCRP setup, the electrode
300 1 2/0 3/0 4/0 4/0
holder/torch is POS (+) and the work is NEG (- 400 2/0 3/0 4/0 4/0 --
); whereas for a DCSP setup, the electrode 500 3/0 3/0 4/0 -- --
holder/torch is NEG (-) and the work is POS (+).

* Total cable length includes work and electrode cables. 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.
regardless of your secondary welding cable setup ** Cam-Lock jack plug connectors will not accept smaller than #2
(dcrp or dcsp), in order to prevent electrical shock, gauge cable. Also, remember that for MIG-Pulse conditions we
it is necessary that you connect the workpiece to an recommend only 4/0 cable be used due to pulse-peak currents.
approved electrical (earth) ground. The work cable
lead is not a ground lead. it is used to complete the 2.5 CONTROL INTERCONNECTION
welding circuit between the Power Source and the
workpiece. this connection (at the workpiece) must
be made to a clean, exposed metal surface that is
free of paint, rust, mill scale, etc. a separate
connection is required to ground the workpiece to
an approved earth ground. the work cable should Ensure all TIG/Stick remote control accessories are
be the same rating as the torch/electrode cable physically disconnected from receptacle J2 when
lead. making a Digipulse setup.

Proper operation of the Power Source depends to a Because the Digipulse 450i is only dedicated for
great extent on the use of copper output cables that use with Digipulse type Wire Feeders and mecha-
are insulated, adequately sized, in good condition nized/Robotic Controls, the specific hookup and
and properly connected to the machine using the interconnecting control cable(s) part numbers will
jack plug connectors provided. It is recommended only be covered in the instructional booklets for
that the output cables be kept as short as possible, those Controls/Wire Feeders as follows:
placed close together, and be of adequate current
carrying capacity. The resistance of the output F-15-012 Digipulse Wire Feeder
cables and connections cause a voltage drop which F-15-013 Teach Mode Operating Instructions
is added to the voltage of the arc. Excessive cable for Teach Option
resistance can reduce the maximum current output
of the Power Source. Refer to table 2-2 to select 2.6 OPTIONAL ACCESSORIES
the recommended output cable size.
To avoid duplication of MIG accessories which may
or may not be required for the various Digipulse
systems, please refer to the individual Digipulse
Wire Feeder/Control instruction booklets provided
for your system. For applicable Stick/TIG accesso-
ries, refer to figure 2-3.

11
SECTION 2 INSTALLATION

Figure 2-3. Stick/Scratch-Start TIG/Arc Gouging Interconnection Diagram

12
SECTION 3 OPERATION

3.1 INTRODUCTION C. Troubleshooting Lights.

This section is intended to familiarize personnel 1. Temperature (PL2). This will light if
with the operational procedures applicable to the components in the Power Source
Digipulse 450i Power Source. Information contained overheat. The contactor will then
in this section should be read carefully before deenergize. Allow the Power Source to
operation of the Power Source. cool with the line switch in the "ON"
position (the fan will help cool the
Power Source) before continuing
welding operations when light goes off.
NEVER, UNDER ANY CIRCUMSTANCES, OPER-
2. Fault (PL3). This light functions as a
ATE THE POWER SOURCE WITH THE COVER
visual detector for two specific fault
OR SIDE PANELS REMOVED. IN ADDITION TO
conditions: overcurrent or over/
THE SAFETY HAZARD, IMPROPER COOLING
undervoltage indication. In either case,
MAY CAUSE DAMAGE TO INTERNAL COMPO-
if a fault is detected in the inverter
NENTS. ALSO MAKE SURE YOU ARE AD-
bridge, the contactor will deenergize
EQUATELY PROTECTED BEFORE WELDING.
and the Power Source will stop welding.
WELDING HELMET, GLOVES, SAFETY GLASSES,
If an overcurrent condition caused the
AND EAR PROTECTION SHOULD ALWAYS BE
problem, the fault light will energize and
WORN.
remain "steady-on." Do not attempt to
restart welding (refer to section 5). If
3.2 DUTY CYCLE an over or undervoltage condition
occurs, the fault light will flash. Since
Duty cycle is defined as the ratio of load time to
this can often be caused by a transient,
total time. Standard current ratings are based on a
retry the torch switch to resume weld-
10-minute cycle. The Digipulse 450i Power Source
ing. If tripping continues, stop and refer
has two duty cycles; a 60% duty cycle rating which
to section 5.
allows 450i amperes @ 38 V dc, and a 100% duty
cycle rating which allows 350 amperes @ 34 V dc D. Inductance Control Potentiometer (ICP).
(see Figure 2-2). The 100% duty cycle means that a This control allows the operator to set and
350 ampere rated load can be applied continuously regulate the desired amount of inductance
with no adverse effect on the Power Source. The required for standard MIG short arc welding
60% duty cycle rating means that the 450i ampere operations. Variable control allows the operator
rated load can be applied for a total of 6 minutes to fine tune the inductance needed to make the
and shut off for a total 4 minutes in a 10-minute weld puddle more fluid and minimize the weld
period. If the welding current is decreased, the duty spatter produced during MIG short arc applica-
cycle can be increased. Conversely, if the welding tions. When short arc welding stainless steel,
current is increased, the duty cycle must be de- high values of inductance should be used with
creased. A1025 helium rich shielding gas. This potenti-
ometer should be set to minimum for all pulse
3.3 POWER SOURCE WELDING and standard spray arc welding applications.
CONTROLS
E. Digital MIG Control Receptacle (J1). This 19-
A. On-Off Line Switch (LS). Placed in the "on" pin remote control receptacle receives a mating
position, this switch (located on the rear panel) connector from the Digipulse Wire Feeder or
provides primary input power to start the cooling other Digipulse Controls (see Figure 2-2).
fan motor and energize the secondary control
circuitry. Power light (PL1) on the front panel F. TIG/Stick Control Receptacle (J2). This 8-pin
should illuminate. remote control receptacle, located on the rear
panel, receives a mating connector from the
B. Digital Ammeter. This instrument provides TIG/Stick accessories (see Figure 2-3).
direct reading of the average welding current.

13
SECTION 3 OPERATION
G. Reset Circuit Breaker (CB). A 10 ampere 5. Set the variable inductance control (on the front
circuit breaker (on the rear panel) provides panel) to provide the amount of inductance
protection to the 115 volt control circuit. If an desired for MIG short arc welding. For MIG
overload occurs, the breaker will trip and sus- spray arc and pulsed MIG welding, this
pend all operation. To restore service, depress control should be set at MINIMUM.
the breaker button to reset the circuit.
6. For remaining Digipulse Wire Feeder or
H. Auxiliary 115 Volt Receptacle (J3). This re- Digipulse Control operations, refer to the appro-
ceptacle supplies 5 amperes of 115 V/5 A power priate instruction booklet supplied for your
for auxiliary equipment. particular system.
I. Welding Output Receptacles. Two output B. Stick/Scratch-Start TIG Welding
receptacles are located on the front panel - one
negative (-) and one positive (+) (see Figure 2- 1. Depending on the process being used, make all
2 and 2-3). secondary output connections to the Power
Source output receptacles (refer to Figure 2-
3.4 SEQUENCE OF OPERATION 3).

2. Connect appropriate control accessories to


receptacle J2 (refer to Figure 2-3).
never, under any circumstances, operate the Power
Source without cover or panels in place. in addition 3. After the primary input connections have been
to the safety hazard, improper cooling may cause made, close the main wall disconnect switch
overheating which will damage the internal compo- or circuit breaker.
nents. also, make sure you are adequately pro-
tected before welding. welding helmet, gloves, 4. Place the Power Source ON-OFF line switch
safety glasses, and ear protection should always be (on the rear panel) to the ON position. This will
worn. start the cooling fan and apply power to the
control circuitry as indicated by the illuminated
A. Digipulse MIG Welding POWER pilot light on the front panel.

1. Make all secondary output connections to the


Power Source output receptacles as described
in section 2 (see Figure 2-2) and as shown in Ensure the contactor control switch on the TC-2B torch
control or the Stick control pendant is in its OFF
the appropriate Wire Feeder and/or Control
position (until you're ready to weld); otherwise, the
instruction booklets. electrode will be energized and may cause a short or
electrical shock.
2. Make the necessary control connections to
receptacle J1 as described in section 2 (see 5. The variable inductance control need not be set
Figure 2-2) and J2, if necessary. Make sure that for these processes because it is isolated from
FC-5B or TC-2B is unplugged from J2, or if HC- this circuit.
3B is plugged in, the Process Switch is in the
Digital-MIG (center) position. 6. Full range current control is provided and regu-
lated by the potentiometer on the selected
3. After the primary input connections have been remote controls.
made in accordance with section 2, close the
main wall disconnect switch or circuit breaker. 7. To establish the welding arc, position the torch/
electrode near the workpiece. Close the remote
4. Place the Power Source ON-OFF line switch torch/foot control or turn ON the pendant. This
(on rear panel) to the ON position. This will start will energize the solid-state contactor and pro-
the cooling fan and apply power to the control
circuitry as indicated by the illuminated POWER
pilot light on the front panel.

14
SECTION 4 MAINTENANCE

4.1 GENERAL 4.2 CLEANING

If the Power Source does not operate properly, stop Since there are no moving parts (other than the fan)
work immediately and investigate the cause of the in the Power Source, maintenance consists mainly
malfunction. Maintenance work must be performed of keeping the interior of the cabinet clean. Peri-
by an experienced person, and electrical work by a odically, remove the cover from the cabinet and,
trained electrician. Do not permit untrained persons wearing proper eye protection, blow accumulated
to inspect, clean, or repair this equipment. Use dust and dirt from the air passages and the interior
only recommended replacement parts. components using clean low pressure air. It is
imperative that the air passages to the interior of
the unit be kept free of dirt accumulation to ensure
adequate circulation of cooling air; especially, over
the rectifier bridge plates. The length of time
between cleaning will depend on the location of the
ENSURE THE WALL DISCONNECT SWITCH OR
unit and the amount of dust in the atmosphere.
CIRCUIT BREAKER IS OPEN BEFORE AT-
TEMPTING ANY INSPECTION OR WORK ON THE
INSIDE OF THE POWER SOURCE. ALWAYS 4.3 LUBRICATION
WEAR SAFETY GOGGLES WITH SIDE SHIELDS
WHEN BLOWING OUT THE POWER SOURCE Fan motors with oil tubes located on the side of the
WITH THE LOW PRESSURE AIR. motor require lubrication after 1 year of service.
Motors without oil tubes are permanently lubricated
for life and should not require any attention.

15
SECTION 5 TROUBLESHOOTING
5.1 Troubleshooting 5. Apply input power to the Power Source, and perform
the low voltage checks described in the following
tables.

6. After the low voltage checks are completed, discon-


nect input power to Power Source and reconnect IBR
(+) and (-) leads to module, and reinstall the unit's side
panels.
ENSURE ALL PRIMARY POWER TO THE POWER
SOURCE HAS BEEN EXTERNALLY DISCON- 7. With the side panels in place, reapply input power to
the Power Source and perform high voltage checks
NECTED. OPEN WALL DISCONNECT SWITCH
(designated by H.V. )listed in the following tables.
OR CIRCUIT BREAKER BEFORE ATTEMPTING
INSPECTION OF WORK INSIDE OF THE POWER
SOURCE. A. Digipulse Wire Feeder or Control

If it is determined that the Wire Feeder is operating


improperly, refer to the troubleshooting information
located in booklet F-15-012.
CAPACITORS CAN EXPLODE CAUSING PER-
SONAL INJURY. TO AVOID INJURY, CAREFULLY B. Digipulse Power Source
READ AND DO THE FOLLOWING:
If the Power Source is operating improperly, the
THE SUBJECT WARNING CONCERNS THE FOUR following troubleshooting information may be used
POWER FILTERING CAPACITORS MOUNTED to locate the source of the problem.
BEHIND POWER BOARD #1 AND #2 (FOR LOCA-
TION, SEE FIGURE 6-3). Check the problem using the following troubleshoot-
ing guide. The potential problems are listed in
This potential hazard exists when the side panels are removed
"most probable" order, and the remedy may be quite
and power is ON. This should only occur when troubleshoot-
ing the Power Source. simple. If the cause cannot be located quickly,
open up the unit and perform a simple visual
Safe troubleshooting practice requires a systematic procedure inspection of all components and wiring. Check for
as follows:
secure terminal and plug connections, loose or
1. Disconnect primary input power to Power Source. burned wiring or components, bulged or leaking
capacitors, or any other sign of damage or discol-
2. Remove panels and perform visual inspection for oration. Always follow this general rule -- Do not
obvious problems; loose wiring and plug connections,
replace a printed circuit (PC) board until you have
damaged or discolored components, etc.
made all of the checks listed in the following guide.
3. Perform resistance checks described in the following Always put the power switch in its OFF position
tables. before removing or installing a PC board. Take
great care not to grasp or pull on components when
4. With input power deenergized and side panels re-
moved, locate the Input Bridge Module (IBR) (see removing a PC board and always place a removed
Figures 5-1 and 6-5). Using the existing wiring dia- board on a static-free surface. If a PC board is
gram (Figure 5-4), disconnect and tape the large gray determined to be the problem, check with your
leads attached to terminals IBR (+) and IBR (-). This
ESAB supplier for a replacement. Provide the
will prevent high voltage input to power boards #1 and
#2, eliminating the potential hazard while performing distributor with the part number of the board, as well
the low voltage checks in step 5. as the serial number of the Power Source. Do not
attempt to repair the board yourself. Warranty
NOTE
on a PC board will be null and void if repaired by
High voltage checks, listed in the following tables, must be
performed with the side panels installed and IBR leads
connected. To distinguish the high voltage checks (from low
voltage) we have indicated these readings with the following
symbol H.V.

16
SECTION 5 TROUBLESHOOTING
TROUBLESHOOTING GUIDE

PROBLEM POSSIBLE CAUSE CIRCUIT CHECKS


Unit inoperative - fan Single-phase operation Check incoming power to unit - all three
does not run phases

Incorrect linkages on voltage changeover Check links on voltage changeover


board terminal board

Defective Line Switch (LS) Perform continuity check on Line Switch

Blows input line fuses Defective Input Bridge (IBR) See IBR Troubleshooting

Incorrect linkages on voltage changeover Check links on voltage changeover


board terminal board

Defective PB1/PB2 See PB1/PB2 Troubleshooting


No open circuit 115 V ac circuit breaker tripped Check circuit breaker and reset if tripped
voltage
MIG mode operation
1. Stick pendant/control plugged into Check J2 and disconnect pendant/foot
J2 control

Check MIG contactor signal - see


2. No contactor signal from wire Inverter Control Board troubleshooting
feeder/control

STICK mode operation Check STICK contactor signal - see


1. No contactor signal from inverter control troubleshooting
pendant/control
No open circuit Defective SCR1/R1 See SCR1 troubleshooting
voltage
Missing bias voltage to Inverter Control See ICB troubleshooting
Board (ICB)

False thermal indication to ICB See ICB troubleshooting

Defective ICB Replace ICB


Excessive open circuit Defective resistor/capacitor across Output Check components R4, C7, R5, C8
voltage Bridge (OBR)

Thermal overload Exceeding duty cycle rating See duty cycle rating chart

Exceeding max rated ambient 40 C (104 F)


temperature

17
SECTION 5 TROUBLESHOOTING

TROUBLESHOOTING GUIDE - Continued

PROBLEM POSSIBLE CAUSE CIRCUIT CHECKS


Flashing fault indicator Input voltage not within +15% and -10% of Check incoming voltage to unit - all three
rated requirements phases

Excessive line impedance Check voltage TB-1 (+) to TB-4(-). See


IBR troubleshooting

Defective Inverter Control Board (ICB) Replace ICB


Continuous fault Defective PB1/PB2 See PB1/PB2 troubleshooting
indicator
Defective Output Bridge Module (OBR1-4) See OBR troubleshooting

CT1/CT2 lead open Disconnect P4 connector to inverter


control and make continuity check P4-1
to P4-2/P4-4 to P4-5

Missing shunt signal to Inverter Control See ICB troubleshooting


Board (ICB)

Defective ICB Replace ICB


Low welding output Single-phase operation Check incoming power to unit - all three
phases

Excessive welding cable length Recommend max cable length (work and
torch) of 100 ft.

Too small a size welding cable being Recommend 4/0 cable for Mig
used applications

Replace torch if defective/use torch with


High resistance torch power cable voltage pickup lead

See ICB troubleshooting


Inverter Control Board (ICB) calibration
Replace ICB
Defective ICB
Excessive welding Missing arc voltage feedback to Inverter See ICB troubleshooting
output Control Board (ICB)

ICB calibration See ICB troubleshooting

Defective ICB See ICB troubleshooting

18
SECTION 5 TROUBLESHOOTING

TROUBLESHOOTING GUIDE - Continued

PROBLEM POSSIBLE CAUSE CIRCUIT CHECKS


Amp Meter blank or Missing +5 V at Inverter Control Board See ICB troubleshooting
reads incorrect (ICB)

Shunt calibration Check millivolt drop across shunt -


should read 100.3 mV per 100 amps
output
Defective ICB
Replace ICB
Defective meter
Replace meter

C. Power Boards, PB1/PB2, Troubleshooting (See Voltage Checks (T.S. deenergized)


Figures 5-1 and 5-2)
(+) Probe (-) Probe Measurement

TB-1(+) TB-3(-) 324 V dc H.V.


TB-2(+) TB-4(-) 325 V dc H.V.

Make sure input power is disconnected (OFF) Gate-1 Source-1 -12 V dc


and voltage between T1 and T2 is zero.
Gate-2 Source-2 -12 V dc
Resistance Checks
P1-1 P1-3 24 V ac
(+)Probe (-)Probe Measurement P1-1 P1-2 12 V ac
P1-2 P1-3 12 V ac
Drain-1 Source-1 5k ohms nominal*
Source-1 Drain-1 diode forward drop** P1-8 P1-10 24 V ac
Gate-1 Source-1 1k ohms nominal* P1-8 P1-9 12 V ac
P1-9 P1-10 12 V ac

Drain-2 Source-2 5k ohms nominal*


Source-2 Drain-2 diode forward drop**
Gate-2 Source-2 1k ohms nominal*

* Using meter high impedance diode scale.


**Using meter low impedance diode scale.

19
SECTION 5 TROUBLESHOOTING

D. Input Bridge, IBR, Troubleshooting (See Figure E. Output Bridge, OBR, Troubleshooting (See
5-1) Figure 5-2)

Resistance Checks Resistance Checks

(+) Probe (-) Probe Measurement Anode-1 Cathode diode forward


drop**
IBR-1,2,3 IBR (+) diode forward Anode-2 Cathode diode forward
drop** drop**
IBR (+) IBR-1,2,3 open*
Cathode Anode-1 open*
IBR (-) IBR-1,2,3 diode forward Cathode Anode-2 open*
drop**
IBR-1,2,3 IBR (-) open * *Using meter high impedance diode scale.
**Using meter low impedance diode scale.
*Using meter high impedance diode scale.
**Using meter low impedance diode scale. NOTE
H.V.
TB-1(+) 375-290 V dc @ 230 V ac If any of the above readings are incorrect, remove
(+15%/-10%) H.V. the bus bars and check modules OBR1-4 individu-
TB-4(-) 750-580 V dc @ 460 V ac ally. Replace modules which are defective.
(+15%/-10%)

F. SCR1 Troubleshooting (See Figure 5-1)

Resistance Checks

SCR1-A SCR1-K 5 ohms If reads open, then replace R1

If reads short, then replace SCR-1

SCR1-G SCR1-K diode forward drop (low impedance using diode scale)

Voltage Checks

SCR1-G SCR1-K 0 V dc Torch switch deenergized

0.6 V dc Torch switch energized - if missing, check Inverter


Control

20
SECTION 5 TROUBLESHOOTING
CAPACITOR MOUNTING BRACKETS
(BEHIND BOARD) *
P1, CONTROL PLUG *

*To replace Power Boards (PB-1 & PB-2), Disconnect cables from T1-T4, Disconnect
control plug P1, loosen capacitor mounting brackets behind board, remove and retain
transistor mounting screws and two mounting screws at bottom of board. NEVER,
UNDER ANY CIRCUMSTANCES, REMOVE OR LOOSEN ISOBARS ATTACHED TO HEAT
SINK!
T1, T2, POWER CABLE CONNECTIONS *
(TYP.) TRANSISTOR MOUNTING * Torque Specifications
SCREW (TOTAL-16)
IBR
Case to Heatsink - 40 lb in.
Terminals - 25 lb. in.

PA2 - Transistors

Case to Isobar - 10 lb.in.

When replacing the


components, make
sure mounting
surfaces are clean.
Coat surfaces with
Dow-Corning #340
silicon heat sink
compound or
equivalent. All
hardware must be
torqued to above
specifications.
ISOBAR, TYPICAL EACH SIDE *
P.C. BOARD MOUNTING SCREW, TYPICAL EACH SIDE *

T3, T4, POWER CABLE CONNECTIONS *

Figure 5-2. Right Side Power/Control Components (PB-2, OBR-1,2,3,4)


CAPACITOR MOUNTING BRACKETS
P1, CONTROL PLUG * (BEHIND BOARD) *

*To replace Power Boards (PB-1 & PB-2), Disconnect cables from T1-T4, Disconnect
control plug P1, loosen capacitor mounting brackets behind board, remove and retain
transistor mounting screws and two mounting screws at bottom of board. NEVER,
UNDER ANY CIRCUMSTANCES, REMOVE OR LOOSEN ISOBARS ATTACHED TO HEAT
SINK!
Torque Specifications T1, T2, POWER CABLE CONNECTIONS *

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.


(TYP.) TRANSISTOR MOUNTING *
When replacing the SCREW (TOTAL-16)
components, make
sure mounting
surfaces are clean.
Coat surfaces with
Dow-Corning #340
silicon heat sink
compound or
equivalent. All
hardware must be
torqued to above
specifications. ISOBAR, TYPICAL EACH SIDE *
P.C. BOARD MOUNTING
SCREW, TYPICAL EACH SIDE *

T3, T4, POWER CABLE CONNECTIONS *

Figure 5-1. Left Side Power/Control Components (PB-1, SCR1, IBR, R1)
21
SECTION 5 TROUBLESHOOTING

G. Inverter Control Board, ICB, Troubleshooting (See Figure 5-3)

Voltage Checks

(+) Probe (-) Probe Measurements

P5-8 P5-9 18 V ac AC Bias


P5-8 P5-10 36 V ac AC Bias

P5-6 P2-9 12 V dc DC Bias


P5-5 P2-9 -12 V dc DC Bias
P5-3 P1-6 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 H.V.

P1-1 P1-2 10 0.3 mV Shunt Signal/100 amps


P1-4 P1-5 10 0.3 mV Meter Signal/100 amps

P2-4 P2-3 1.3 to 0 V dc Inductance Control (Min to Max)

P3-3 P2-2 12 V dc MIG Mode Select


0 V dc Stick Mode Select

P3-2 P2-9 12 V dc Pulsed MIG Select


0 V dc STD MIG Select

P3-9 P3-10 0 V dc Thermal-Normal


12 V dc Thermal-Overload

5.2 CALIBRATION PROCEDURE

The following calibration should be performed after confirming the above voltage checks. Use a calibrated
external means of measuring output voltage and current.

The Wire Feeder should be set to schedule zero and in the Synergic/Spray Arc mode (Digipulse 450i Wire
Feeder control always operates in the Synergic mode.)

To set the Wire Feeder control to schedule zero, depress the WIRE DIA./MATL. key and simultaneously hold
down the IPM DEC key position for 2.5 seconds until a zero appears in the IPM window. Release both switch
keys and set the following data in the IPM and VOLTS window as described below.

Connect voltmeter between TP1 and P2-9. With torch deenergized, adjust the
offset voltage to read 010 mV by
means of R44.

22
SECTION 5 TROUBLESHOOTING
Set 0.1 in the VOLTS window and 40 in the IPM window. Short circuit the contact tip to the work piece and
energize the torch switch.

P2-8 P2-9 0 V dc If these voltages are unavailable, refer to the Wire


P1-10 P2-9 2 V dc Feeder booklet for troubleshooting procedures.
Output Current 455 amps Current can be trimmed by means of R38.

Set 3.0 in the VOLTS window and 0 in the IPM window. Short circuit the contact tip to the work piece and
energize the torch switch.

P2-8 P2-9 3 V dc If these voltages are unavailable, refer to the Wire


P1-10 P2-9 0 V dc Feeder booklet for troubleshooting procedures.
Output Current 4005 amps Current can be trimmed by means of R3.

TP1

TP2

Figure 5-3. Inverter Control Board (ICB) (Top View Layout)


23
D-31121-J

24
Figure 5-4. Digipulse 450i Schematic Diagram - 208/230/460 V, 3 Phase, 60 Hz
D-31122-K

25
Figure 5-5. Digipulse 450i Wiring Diagram - 230/460 V, 3 Phase, 60 Hz (Sheet 1 of 2)
D-31122-K

26
Figure 5-5. Digipulse 450i Wiring Diagram - 230/460 V, 3 Phase, 60 Hz (Sheet 2 of 2)
SECTION 6 REPLACEMENT PARTS

6.1 GENERAL Replacement parts may be ordered from your ESAB


distributor or from:
Replacement Parts are illustrated on the following
figures. When ordering replacement parts, order by ESAB Welding & Cutting Products
Attn: Customer Service Dept.
part number and part name, as illustrated on the
PO Box 100545, Ebenezer Road
figure. DO NOT ORDER BY PART NUMBER Florence, SC, 29501-0545
ALONE.
Be sure to indicate any special shipping instructions
Always provide the series or serial number of the when ordering replacement parts.
unit on which the parts will be used. The serial
number is stamped on the unit nameplate. To order parts by phone, contact ESAB at 1-803-
664-5540 or 4460. Orders may also be faxed to 1-
6.2 ORDERING 800-634-7548. Be sure to indicate any special
shipping instructions when ordering replacement
To assure proper operation, it is recommended that parts.
only genuine ESAB parts and products be used with
this equipment. The use of non-ESAB parts may Refer to the Communication Guide located on the
void your warranty. last page of this manual for a list of customer
service phone numbers.

27
1
2
10

i
450
L SE
IPU
DIG
5
-G
NE

9 +
PO
S 6

8 7

Figure 6-1. Digipulse 450i Power Source (Front View)

ITEM QTY PART CIRCUIT


NO. REQ. NO. DESCRIPTION SYMBOL

1 1 951031
951526 LAMP, POWER, GREEN PL1
2 2 951032 LAMP, RED PL2, PL3
3 1 951795
951042 METER, DIGITAL DPM
4 1 2062018 INDUCTOR CONTROL POT. ICP
1 950814
13730611 KNOB (P/O ITEM NO. 4)
5 1 31129 RIGHT SIDE PANEL
6 2 950694
13733935 FEMALE WELD CONNECTOR
7 1 31124
32059 FRONT PANEL, SILKSCREENED
8 1 31128 LEFT SIDE PANEL
9 1 32056
31136 CONTROL PANEL, SILKSCREENED
10 1 31130 TOP PANEL

28
REF: MATCHED
SET CAPACITORS
ARE PART OF PB1
AND PB2.

1
2,3

Figure 6-2. Digipulse 450i Power Source (Top View)

ITEM QTY PART CIRCUIT


NO. REQ. NO. DESCRIPTION SYMBOL

1 1 31134 CONTROL TRANSFORMER (MOUNTED ON CTR1


CHASSIS BASE UNDER FAN MOTOR)

2 1 31135 INDUCTOR ASSY (MOUNTED ON FRONT PART OF IND


CHASSIS BASE)

1 2062211 THERMAL SWITCH (180C) (P/O ITEM NO. 2) TS2

31133 MAIN TRANSFORMER (MOUNTED ON TOP OF MTR


3 1 INDUCTOR ASSY)
T2
1 951041 TERMINAL BLOCK, 4-POS. (P/O ITEM NO. 3)

29
1

Figure 6-3. Digipulse 450i Power Source (Top View)

ITEM QTY PART CIRCUIT


NO. REQ. NO. DESCRIPTION SYMBOL

1 1 31143 TERMINAL BOARD, SCREEN PRINTED TB

2 1 31400 PC BOARD ASSY, INVERTER CONTROL ICB

30
1

7,8 2

3
4

Figure 6-4. Digipulse 450i Power Source (Left Side View)

ITEM QTY PART CIRCUIT


NO. REQ. NO. DESCRIPTION SYMBOL

11 1 674991 PC BOARD ASSY, POWER PB1


24 1 950702 CAPACITOR C9
35 1 951023 SCR MODULE SCR1
46 1 17250005 RESISTOR R1
57 1 951022 INPUT BRIDGE MODULE IBR
6 1 951313 CAPACITOR
7 1 951056 INSULATOR, ISOBAR
8 1 31154 ISOBAR, ALUMINUM

31
3
1
10

11
8 7
3,9 2

Figure 6-5. Digipulse 450i Power Source (Right Side View)

ITEM QTY PART CIRCUIT


NO. REQ. NO. DESCRIPTION SYMBOL

1 1 674991 PC BOARD ASSY, POWER PB2


2 2 17725005 RESISTOR R4,R5
3 3 950516 CAPACITOR C7,C8
4 1 33938 CHOKE COMMON MODE L1
5 1 993717 TRANSFORMER CTR2
6 1 635686 TERMINAL STRIP, 8-POS T1
7 1 951085 THERMAL SWITCH (80C) TS1
8 1 950702 CAPACITOR, .01uF, 125V C10
9 1 17282010 RESISTOR, 10 OHM 100W NON-IND. R2&R3
10 1 31132 SHUNT SH
11 4 951184 OUTPUT DIODE OBR1-4

32
10
1

9 2,3

4
7

6 5

Figure 6-6. Digipulse 450i Power Source (Rear


View)

ITEM QTY PART CIRCUIT


NO. REQ. NO. DESCRIPTION SYMBOL

1 1 950822 SWITCH, POWER LINE LS


2 1 680970 MOTOR, FAN FM
3 1 679384 SHROUD, FAN
4 1 950592 BLADE, FAN
5 1 97W63 CONNECTOR, CABLE GRIP
6 1 951033
952219 AUX. RECEPTACLE, 115 V, 10 A J3
7 2 950122 CIRCUIT BREAKER, 10 A CB1,2
8 1 31126 REAR PANEL
9 1 951476 RECEPTACLE, 14-PIN, STICK/TIG J2
10 1 951475 RECEPTACLE, 19-PIN, DIGITAL J1

33
NOTES

34
REVISIONS

1. Revisions of June 2003 include changes to part numbers in the REPLACEMENT PARTS SECTION on pages
28 - 33. Part numbers updated per 8/21/02 mark-up.
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS:


Order Entry Product Availability Pricing Delivery
Order Changes Saleable Goods Returns Shipping Information

Eastern Distribution Center


Telephone: (800)362-7080 / Fax: (800) 634-7548

Central Distribution Center


Telephone: (800)783-5360 / Fax: (800) 783-5362

Western Distribution Center


Telephone: (800) 235-4012/ Fax: (888) 586-4670

B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693


Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM 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) 664-5557


Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST

F. WELDING EQUIPMENT TRAINING:


Telephone: (843)664-4428 / Fax: (843) 679-5864
Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST

G. WELDING PROCESS ASSISTANCE:


Telephone: (800) ESAB-123 / Fax: (843) 664-4454 Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES:


Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST

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

F-15-014-F 06/2003 Printed in U.S.A.