ESAB Smart Fan Timer Kit Installation guide

Brand: ESAB

Model: Smart Fan Timer Kit

Type: Installation guide

Required tools:

No. 2 Phillips screwdriver Thin blade 1/8” standard screwdriver

Diagonal cutting pliers Electrician knife

7/16” combination wrench Crimp Tool for Wire Joint

Electrical Shock Hazard

Disconnect welding machine from A.C. power source before installing kit.

Installation should be done only by qualified individuals.

1. Remove 8 screws holding handles to the top of machine. Remove both handles and top cover.

2. Viewing machine from the rear, remove the right side panel. Note that the bottom three side panel

holes are slotted. Complete removal of these three screws is not necessary.

3. Remove the #8-32 screw indicated in Figure 1 and discard. Orient the timer module so that mod-

ule terminals 4 and 5 are located on the left side of the module. Mount the timer module to the

welder as shown in Figure 1 using the screw, lock washer, plain washer and spacer provided in the

kit.

4. Locate the large input voltage selector terminal board TB on top of the welder. Carefully fold back

the ‘fish paper’ insulation and remove the 4 screws holding the terminal board to the welder. Lift

the terminal board high enough to gain access to its bottom side.

5. Locate the terminal marked ‘8’. There should be a black wire and a brown wire on the terminal.

Using the 7/16” wrench, remove the nut, lock washer and plain washer from the terminal. Remove

the black wire.

6. Cut the terminal from the black wire. Cut wire as close to terminal as possible. Strip approximately

3/8” insulation from the wire.

7. Route the timer module black wires into the compartment beneath TB. Connect the black timer

module wire without a terminal to the wire stripped in step 6 above. Twist wires together and install

wire nut provided in the kit. Securely tighten wire nut.

8. Connect black timer module wire with ring terminal to TB terminal 8. Brown wire should remain on

TB terminal 8. Replace terminal washer, lock washer and nut and tighten securely.

9. Use two wire ties to dress wires to existing bundle of wires exiting through notch in top of welder

chassis. Reposition TB terminal board taking care not to pinch any wires between terminal board

and welder chassis. Secure with 4 screws removed previously.

10. Locate the large Inverter Control Board printed circuit board (ICB) on top of the welder and then

locate the connector on the PCB labeled P3. This connector will be on the side of the ICB nearest

the rear of the welder. The location of connector P3 position 1 is printed on the ICB. Determine

the location of positions 4 and 5. Route the two violet wires from the timer module to P3 and install

one wire in P3 position 4 and the other wire in P3 position 5. There should be no other wires in

these two terminals. Use the small straight blade screwdriver to securely tighten the terminal

F-15-609

March, 2000

Instructions for

INSTALLATION

SMART FAN TIMER KIT

P/N—0558001742

For ESAB 450i CC/CV Welding Power Supply

screws. Do not over tighten.

11. Locate the P5 connector on the PCB. This connector is located just above the timer module. The

location of connector P5 position 1 is printed on the ICB. Determine the location of positions 8 and

10. Route the two red wires from the timer module to P5 and install one red wire in P5 position 8

along side the orange wire already there. Install the other red wire in P5 position 10 along side the

blue wire already there. Make sure all wire strands of both wires are inside the terminal before

tightening the terminal screw.

12. Dress the violet and red timer module wires using the remaining wire ties. Gently bend all of the

wires exiting the timer module connectors so they will not interfere with the welder side panel when

it is reinstalled.

13. Reinstall the welder side panel, top cover and handles previously removed.

14. Test the installation by setting up the welder and initiating an arc. The cooling fan should come on

the instant an arc is struck and remain on for approximately 4 minutes after the last arc is struck.

Note that it is normal for the fan to occasionally come on when A.C. power is first applied to the

welder. If no arc is struck, the fan will shut off in 4 minutes.

Timer Module

Figure 1

F-15-609 3/2000 Printed in U.S.A.

ESAB Smart Fan Timer Kit Installation guide

ESAB Smart Fan Timer Kit Installation guide

ESAB Smart Fan Timer Kit Installation guide

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