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ESAB 453cc User Manual

ESAB 453cc
32 pages
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INSTRUCTION MANUAL
F-15-591-A
February, 2001
453cc & 553cc
DC WELDING POWER SOURCES
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding equipment, we urge 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.
This manual provides complete instructions for the following power sources:
453cc 553cc
Item No. Item No.
ESAB 230/460 vac, 3 ph., 60 Hz 453cc - 0558001274 553cc - 0558001278
ESAB 230/460/575 vac, 3ph., 60 Hz 453cc - 0558001275 553cc - 0558001279
ESAB 220/400 vac, 3 ph., 50 Hz 453cc - 0558001276 553cc - 0558001280
ESAB 220/400 vac, 3 ph., 50 Hz, CE 453cc - 0558001277 553cc - 0558001281

Questions and Answers:

ESAB 453cc Specifications

General IconGeneral
BrandESAB
Model453cc
CategoryWelding System
LanguageEnglish

Summary

USER RESPONSIBILITY

PREFACE

Provides an overview of the manual's purpose and intended audience.

SECTION 1 DESCRIPTION

GENERAL

Provides an overview of the manual's purpose and intended audience.

RECEIVING-HANDLING

Details procedures for inspecting and handling the equipment upon receipt.

DESCRIPTION

Outlines the general features and design of the power sources.

POWER SOURCE

Describes the technical specifications and construction of the power source unit.

OPTIONAL ACCESSORIES

Lists and briefly describes available accessories for the power source.

SAFETY

Directs users to read all safety precautions before operating the equipment.

SAFETY PRECAUTIONS

PROTECT YOURSELF AND OTHERS

Emphasizes personal protection from arc radiation, noise, and hot metal.

FIRES AND EXPLOSIONS

Details precautions to prevent fires and explosions caused by welding operations.

ELECTRICAL SHOCK

Outlines essential safety measures to prevent electric shock hazards.

ELECTRIC AND MAGNETIC FIELDS

Discusses potential EMF exposure and methods to minimize it.

FUMES AND GASES

Addresses hazards from welding fumes and gases and necessary ventilation.

CYLINDER HANDLING

Provides guidelines for the safe handling and storage of gas cylinders.

EQUIPMENT MAINTENANCE

Stresses the importance of proper maintenance to prevent injury or death.

ADDITIONAL SAFETY INFORMATION

Directs users to further resources for safe welding practices.

SECTION 2 INSTALLATION

LOCATION

Specifies requirements for a suitable installation site to ensure proper operation.

RECEIVING, UNPACKING AND PLACEMENT

Guides the user through the process of unpacking and positioning the unit.

PRIMARY (INPUT) ELECTRICAL CONNECTION

Explains how to safely connect the power source to the electrical supply.

OUTPUT WELDING CONNECTIONS (SECONDARY)

Details how to connect welding cables to the output terminals.

CONTROL CONNECTIONS

Describes connections for remote controls and auxiliary power.

SECTION 3 OPERATION

Power Switch (ON-OFF)

Explains the function and operation of the main power switch.

Arc Force Control

Describes the purpose and adjustment of the arc force control for stick welding.

Contactor, On/Remote Switch

Details the function of the contactor switch and remote operation.

Current Panel/Remote Switch

Explains how to select between panel and remote current control.

Current Control

Describes the function of the main current adjustment knob.

Over Temperature Indicator (Temp)

Explains the function of the amber light indicating overheating.

Voltmeter and Ammeter

Details the digital display for output voltage and current.

Fault Indicator

Explains the function of the red light indicating an external ground fault.

OPERATION SET-UP

Guides the user through preparing the machine for welding.

Stick Welding (SMAW) Air Carbon Arc Gouging (ACAG) and Scratch Start Tig Welding (GTAW)

Provides setup instructions for specific welding processes.

Mig Spray Arc (GMAW) and Flux Cored (FCAW) Welding with "Off the Arc" Wire Feeder

Refers to the wire feeder manual for setup instructions.

SECTION 4 MAINTENANCE

GENERAL

Provides general guidelines and cautions for maintenance tasks.

CLEANING

Details procedures for cleaning the power source to ensure proper cooling.

INSPECTION AND SERVICE

Outlines general inspection and service recommendations.

Fan Motor

Advises on keeping the fan motor free of dust and dirt.

Transformer

Mentions periodic cleaning of the transformer.

Control Circuits

Refers to circuit breakers protecting control circuits.

Over Temperature Protection

Explains how the thermal protection system operates.

Digital Voltmeter/Ammeter Calibration

Provides a procedure for verifying the accuracy of the digital meters.

SECTION 5 TROUBLESHOOTING

GENERAL

Provides general warnings and advice for troubleshooting.

TESTING AND REPLACING BRIDGE ASSEMBLY COMPONENTS

Details procedures for testing and replacing SCRs.

PCB VOLTAGE TESTS

Outlines voltage tests for Printed Circuit Boards.

Unit Inoperative

Describes troubleshooting steps for a unit that will not operate.

No Output - Fan Running

Provides troubleshooting steps when there is no output but the fan runs.

Limited Output or Low Open-Circuit Voltage

Offers solutions for reduced output or low open-circuit voltage.

Erratic Weld Current

Suggests causes and fixes for inconsistent weld current.

High Output, No Voltage Control

Addresses issues with high output but lack of voltage control.

No 115 Volt ac Output

Troubleshoots the absence of 115V AC output.

Line Fuse Blows When Power Source is First Turned On

Guides troubleshooting when the line fuse blows upon startup.

SECTION 6 REPLACEMENT PARTS

GENERAL

Provides general guidance for ordering replacement parts.

ORDERING

Explains how to order genuine ESAB parts and products.

Bill of Materials

Lists part numbers, descriptions, and quantities for the power source.

Bill of Materials

Continues the list of replacement parts with part numbers and descriptions.

Bill of Materials

Concludes the listing of replacement parts and their details.

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