ESAB VI-450 Welding Power Source User manual

Brand: ESAB

Model: VI-450 Welding Power Source

Category: Welding System

Type: User manual

This manual is also suitable for

L-TEC VI-450 Welding Power Source

ESAB L-TEC VI-450 Welding Power Source is a versatile and powerful welding machine suitable for various welding applications. It can handle 230/460/575 V ac, 60 Hz or 220/380/415 V ac, 50 Hz power input, making it compatible with a wide range of power sources. This welding power source offers precise control over the welding process, enabling you to achieve high-quality welds. It features advanced technology that ensures stable arc performance, minimizing spatter and providing a smooth welding experience.

MAINTENANCE MANUAL

F-15-099

January, 1994

L-TEC VI-450

WELDING POWER SOURCE

230/460/575 V ac, 60 Hz...P/N 33322

220/380/415 V ac, 50 Hz...P/N 33323

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 (Section 1) 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 accom-

panying 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 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 manufac-

turer. 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.

READ AND UNDERSTAND THESE INSTRUCTIONS ALONG WITH

THE SAFETY SECTIONS CONTAINED IN THIS MANUAL.

Protect yourself and others. Be sure this information reaches all operators.

ELECTRIC SHOCK can kill.

Do not touch live electrical parts or electrodes with bare skin or wear wet gloves or

wet clothing.

FUMES AND GASES can be dangerous to your health.

Keep your head out of the fumes. Use enough ventilation, exhaust at the arc, or

both, to keep fumes and gases from your breathing zone and the general area.

Where this cannot be done, use an air-supplied respirator.

If welding causes dizziness, nausea or respiratory irritation, ventilation is inade-

quate. See your supervisor. See special precautions in references below when

welding on materials containing or coated with lead, mercury, zinc, beryllium, cad-

mium, chromium, nickel or other materials with toxic properties.

ARC RAYS can injure eyes and burn skin.

Protect your eyes and body with proper welding helmet, safety glasses, eye filter

lenses, and dark protective clothing.

NOISE can damage hearing.

Wear proper hearing protection.

Read and understand these instructions and your employer's safety guidelines.

See American National Standard Z49.1, "Safety in Welding and Cutting", published by

the American Welding Society, P.O. Box 351040, Miami, Florida 33153; O.S.H.A. Safety

and Health Standards, 29 CFR 1910, available from U.S. Government Printing Office,

Washington, D.C. 20402, and the safety section in this manual.

L-TEC VI-450 Power Source

SECTION 1

SAFETY

1-1

1.1 Introduction

These safety precautions are for your protection. They

summarize precautionary information contained in the

references section below and as noted herein. 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 precau-

tions can result in personal injury or death.

This symbol appearing throughout this

manual means “Attention! Be Alert! Your

safety is involved.”

The following definitions apply to WARNING and CAU-

TION symbols found throughout this manual:

USED TO CALL ATTENTION TO IMMEDIATE HAZ-

ARDS WHICH, IF NOT AVOIDED, WILL RESULT IN

IMMEDIATE, SERIOUS PERSONAL INJURY OR

LOSS OF LIFE.

USED TO CALL ATTENTION TO POTENTIAL HAZ-

ARDS WHICH COULD RESULT IN PERSONAL IN-

JURY OR LOSS OF LIFE.

USED TO CALL ATTENTION TO HAZARDS WHICH

COULD RESULT IN MINOR PERSONAL INJURY.

1.2 General

PROTECT YOURSELF AND OTHERS-Some weld-

ing, cutting, and gouging processes are noisy and

require ear protection. Skin and eye burns from arc

rays can be more severe than sunburn. Hot metal

can cause skin burns and heat rays may injure

eyes. Training in the proper use of the processes

and equipment is essential to prevent accidents.

• Always wear safety glasses with side shields in

any work area, even if a welding helmet, face

shield, or goggles are also required.

• 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 by-

standers not to watch the arc and not to expose

themselves to the rays of the electric-arc or hot

metal.

• 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.

• Hot sparks or metal can lodge in rolled up sleeves,

trouser cuffs, or pockets. Sleeves and collars

should be kept buttoned, and open pockets elimi-

nated from the front of clothing.

• Protect other personnel from arc rays and hot

sparks with a suitable non-flammable partition or

curtains.

• Use goggles over safety glasses while chipping

slag or grinding. Chipped slag may be hot and

can travel considerable distances. Bystanders

should also wear goggles over safety glasses.

1.3 Fire and Explosion

Heat from flames and arcs can act as ignition

sources. Hot slag or sparks can cause fire and

explosions.

• Hydrogen explosions can occur when using water

tables.

• Remove all combustible materials well away

from the work area or completely cover the

materials with a protective non-flammable cover-

ing. Combustible materials include wood, cloth,

sawdust, liquid and gas fuels, solvents, paints

and coatings, paper, etc.

• 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.

L-TEC VI-450 Power Source

SECTION 1

SAFETY

1-2

connection could expose the operator or others

in the area to a fatal shock.

• Do not use worn or damaged cables. Do not

overload the cable. Use well maintained equip-

ment.

• When not operating, turn off the equipment.

Accidental overloading can cause overheating

and create a fire hazard. Do not coil or loop cable

over parts of the body.

• Be sure the proper size ground cable is con-

nected to the workpiece as close to the work area

as possible. Grounds connected to building

framework or other remote locations from the

work area increase the possibility of output cur-

rent passing through lifting chains, crane cables,

or various electrical parts.

• Keep clothing, controls, and power source dry.

Fix water leaks immediately (after shutting off

power).

• Refer to ANSI/ASC Standard Z49.1 (see listing

below) for specific grounding recommendations.

Do not mistake the work cable for a grounding

cable.

1.5 Fumes and Gases

Fumes and gases can cause discomfort and/or

harm, particularly in confined spaces. Do not

breathe fumes and gases. Shielding gases can

cause asphyxiation.

• Always provide adequate ventilation in the work

area by natural or mechanical ventilation means.

Do not weld, cut, or gouge on materials such as

galvanized steel, stainless steel, copper, zinc,

lead, beryllium, or cadmium unless positive me-

chanical ventilation is provided. Do not breathe

fumes and gases from these materials.

• Do not operate in locations close to chlorinated

hydrocarbon vapors coming from degreasing

and spraying operations. The heat or arc rays

can react with solvent vapors to form phosgene,

a highly toxic gas, and other irritant gases.

• If you develop momentary eye, nose, or throat

irritations while operating, this is an indication

that ventilation may not be adequate. Stop work

and take necessary steps to improve ventilation

• 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.

• 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.

• 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.

• For additional information refer to NFPA stan-

dard 51B, “Fire Prevention in Use of Cutting and

Welding Processes”, which is available from the

National Fire Protection Association,

Batterymarch Park, Quincy, MA 02269.

1.4 Electrical Shock

Contact with live electrical parts can cause severe

burns to the body or fatal shock. Severity of

electrical shock is determined by the path and

amount of current through the body. The higher

the voltage, the greater the hazard.

• Never allow live metal parts to touch bare skin or

any wet clothing. Be sure gloves are dry.

• When standing on metal or operating in a damp

area, make certain that you are well insulated.

Wear dry gloves and rubber-soled shoes and

stand on a dry board or platform.

• Do not stand on the plate or parts being cut during

the cutting process.

• Do not touch the plate or pick up cut parts while

cutting is in progress.

• Always ground the power source by connecting

a ground wire between the power source and the

ground system of the input power.

• Always make sure that the workpiece is con-

nected to a good earth ground.

• It is especially important with plasma cutting

equipment to be sure that the work cable is

connected to the workpiece. A poor or missing

L-TEC VI-450 Power Source

SECTION 1

SAFETY

1-3

in the work area. Do not continue to operate if

physical discomfort persists.

• Refer to ANSI/ASC Standard Z49.1 for specific

ventilation recommendations.

1.6 Equipment Maintenance

Faulty or improperly maintained equipment can

result in poor work, but more importantly, it can

cause physical injury or death through fires or

electrical shock.

• 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.

• Before performing any maintenance work inside

a power source, disconnect the power source

from the electrical power supply.

• Maintain cables, grounding wire, connections,

power cord, and power source in safe working

order. Do not operate any equipment in faulty

condition.

• 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.

• Keep all safety devices and cabinet covers in

position and in good repair.

• Use equipment for its intended purpose. Do not

modify it in any manner.

1.7 Cylinders

Cylinders, if mishandled, can rupture and violently

release gas. Sudden rupture of cylinder, cylinder

valve, or relief device can injure or kill.

• 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 adapters. Maintain hoses and fittings in

good condition. Follow manufacturer’s operating

instructions for mounting regulator to a com-

pressed gas cylinder.

• Always secure cylinders in an upright position by

chain or strap to suitable handtrucks, undercar-

riages, benches, walls, post, or racks. Never

secure cylinders to work tables or fixtures where

they may become part of an electrical circuit.

• When not in use, keep cylinder valves closed.

Have valve protection cap in place if not con-

nected for use. Secure and move cylinders by

using suitable hand trucks. Avoid rough handling

of cylinders.

• Locate cylinders away from heat, sparks, or

flame of a welding, cutting, or gouging operation.

Never strike an arc on a cylinder.

• For additional information, refer to CGA Stan-

dard P-1, “Precautions for Safe Handling of

Compressed Gases in Cylinders”, which is avail-

able from Compressed Gas Association, 1235

Jefferson Davis Highway, Arlington, VA 22202.

1.8 References

For more information on safe practices for setting up

and operating electric welding and cutting equipment

and on good working habits, ask your ESAB supplier for

a copy of “Precautions and Safe Practices for Electric

Welding and Cutting”, Form 52-529.

The following publications, which are available from the

American Welding Society, 550 LeJuene Road, Miami,

FL 33126, are recommended to you:

• ANSI/ASC Z49.1 - “Safety in Welding and Cut-

ting”

• AWS C5.1 - “Recommended Practices for

Plasma Arc Welding”

• AWS C5.2 - “Recommended Practices for

Plasma Arc Cutting”

• AWS C5.3 - “Recommended Practices for Air

Carbon Arc Gouging and Cutting”

• AWS C5.5 - “Recommended Practices for Gas

Tungsten Arc Welding”

• AWS C5.6 - “Recommended Practices for Gas

Metal Arc Welding”

• AWS SP - “Safe Practices” - Reprint, Welding

Handbook.

L-TEC VI-450 Power Source

SECTION 2

MAINTENANCE

2-1

2.1 General

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 recom-

mended replacement parts.

BE SURE THAT THE BRANCH CIRCUIT OR MAIN

DISCONNECT SWITCH IS OFF, OR ELECTRICAL

INPUT FUSES ARE REMOVED, BEFORE ATTEMPT-

ING 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.

2.2 Cleaning

Periodically, remove the cover from the Power Source

and blow accumulated dust and dirt from the air pas-

sages and interior components by using clean low

pressure air. The frequency of cleaning required de-

pends 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 insula-

tion on all power cables and replace if necessary.

FAILURE TO REPLACE WORN OR DAMAGED

CABLES MAY RESULT IN A BARE CABLE TOUCH-

ING A GROUND SURFACE. THE RESULTING ELEC-

TRICAL ARC MAY DAMAGE UNPROTECTED EYES

AND WILL PRESENT A SERIOUS FIRE HAZARD.

BODY CONTACT WITH A BARE CABLE, CONNEC-

TOR, OR CONDUCTOR MAY RESULT IN SEVERE

ELECTRICAL SHOCK, CAUSING SERIOUS BURNS

OR DEATH.

2.3 Inspection and Service

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.

2.3.1 Fan Motor

Keep the fan motor free of accumulated dust and lint by

using low pressure air. Lubricate the motor every three

months with a few drops of SAE-20 non-detergent oil.

2.3.2 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.

2.3.4 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.

2.3.5 Over-Temperature Protection

If the Power Source reaches an abnormally high inter-

nal temperature, the thermal protection relay will

deenergize, shutting down the Power Source but leav-

ing 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.

L-TEC VI-450 Power Source

SECTION 3

TROUBLESHOOTING

3-1

3.1 General

DISCONNECT PRIMARY POWER AT WALL

SWITCH, OR CIRCUIT BREAKER, BEFORE AT-

TEMPTING INSPECTION OR WORK INSIDE THE

POWER SOURCE.

If the Power Source is operating improperly, the follow-

ing troubleshooting information may be used to locate

the source of the trouble.

Check the problem against the symptoms in the follow-

ing troubleshooting guide. 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 capaci-

tors, or any other sign of damage or discoloration.

3.2 Testing and Replacing Bridge Assem-

bly 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).

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 mount-

ing 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.

L-TEC VI-450 Power Source

SECTION 3

TROUBLESHOOTING

3-2

Table 3-1. 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 READING

P1-8 P1-9 115 V ac

P2-8 (SCR1)

P2-7 (SCR2)

P2-3 (SCR3)

P2-6 (SCR4)

P2-1 (SCR5)

P2-4 (SCR6)

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**

P2-5 (SCR1)

P2-2 (SCR2)

P2-12 (SCR3)

P2-9 (SCR4)

P2-10 (SCR5)

P2-11 (SCR6)

OTB+ (Flat) .3 V dc with

contactor on

*Refer to Schematic Diagram

**Varies with VCP (R1)

L-TEC VI-450 Power Source

SECTION 3

TROUBLESHOOTING

3-3

Table 3-2. Troubleshooting Guide

CONDITION ACTION

Unit inoperative A.

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.

Fan motor not operating -- check motor and leads. Remember, this is normal when

the thermal fan control circuit is activated.

Main contactor defective -- check for proper operation.

No Output -- Fan

Running

Poor or improper electrical input -- check input connections on TB.

Poor connections at output terminals/work station -- check, tighten or replace.

Main transformer overheating -- thermal switches tripped due to restricted cooling

air. Let unit cool down.

Solid-state breaker tripped due to current overload.

PC board defective or loose PC board connector(s) -- if loose, reinsert; if defective,

replace.

Limited Output or Low

Open-Circuit Voltage

Input voltage jumper links on terminal board improperly set -- check for proper

voltage.

Poor output connections. Take apart, clean, and reassemble.

Unit may be single-phasing -- check incoming power for three phases.

Panel-Remote switch in Remote position and remote voltage pot disabled.

Erratic Weld Current A.

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.

High Output, No

Voltage Control

PC board defective or loose -- reset and/or replace board.

No 115 Volt ac Output A.

Check secondary of control transformer (T2) for 115 V ac.

Circuit breaker tripped -- reset.

Line Fuse Blows When

Power Source is First

Turned On

Shorted SCR in Main Bridge -- replace.

Shorted capacitor in Capacitor Bank.

Wire Sparks and

Sticks to Workpiece at

End of Weld

Allow 2 to 4 seconds for capacitor banks to discharge after completing the weld and

before touching wire to workpiece.

If doubling the discharge rate is desired (twice as fast) and the thermal fan circuit is

not activated (generate excessive heat), change R5 (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 R5.

L-TEC VI-450 Power Source

SECTION 3

TROUBLESHOOTING

3-4

Figure 3-1. L-TEC VI-450 Power Source Schematic Diagram - 60 Hz (Sheet 1 of 2)

NOTE: Recent modifications to the power source may not be reflected in this

schematic. For up-to-date information on your model, refer to the schematic

on the inside cover of the power source or contact the factory.

L-TEC VI-450 Power Source

SECTION 3

TROUBLESHOOTING

3-5

Figure 3-1. L-TEC VI-450 Power Source Schematic Diagram - 60 Hz (Sheet 2 of 2)

L-TEC VI-450 Power Source

SECTION 3

TROUBLESHOOTING

3-6

Figure 3-2. L-TEC VI-450 Power Source Wiring Diagram - 60 Hz (Sheet 1 of 4)

L-TEC VI-450 Power Source

SECTION 3

TROUBLESHOOTING

3-7

Figure 3-2. L-TEC VI-450 Power Source Wiring Diagram - 60 Hz (Sheet 2 of 4)

L-TEC VI-450 Power Source

SECTION 3

TROUBLESHOOTING

3-8

Figure 3-2. L-TEC VI-450 Power Source Wiring Diagram - 60 Hz (Sheet 3 of 4)

L-TEC VI-450 Power Source

SECTION 3

TROUBLESHOOTING

3-9

Figure 3-2. L-TEC VI-450 Power Source Wiring Diagram - 60 Hz (Sheet 4 of 4)

L-TEC VI-450 Power Source

SECTION 3

TROUBLESHOOTING

3-10

Figure 3-3. L-TEC VI-450 Power Source Schematic Diagram - 50 Hz (Sheet 1 of 2)

NOTE: Recent modifications to the power source may not be reflected in this

schematic. For up-to-date information on your model, refer to the schematic

on the inside cover of the power source or contact the factory.

L-TEC VI-450 Power Source

SECTION 3

TROUBLESHOOTING

3-11

Figure 3-3. L-TEC VI-450 Power Source Schematic Diagram - 50 Hz (Sheet 2 of 2)

L-TEC VI-450 Power Source

SECTION 3

TROUBLESHOOTING

3-12

Figure 3-4. L-TEC VI-450 Power Source Wiring Diagram - 50 Hz (Sheet 1 of 4)

L-TEC VI-450 Power Source

SECTION 3

TROUBLESHOOTING

3-13

Figure 3-4. L-TEC VI-450 Power Source Wiring Diagram - 50 Hz (Sheet 2 of 4)

L-TEC VI-450 Power Source

SECTION 3

TROUBLESHOOTING

3-14

Figure 3-4. L-TEC VI-450 Power Source Wiring Diagram - 50 Hz (Sheet 3 of 4)

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ESAB VI-450 Welding Power Source User manual

Brand: ESAB

Model: VI-450 Welding Power Source

Category: Welding System

Type: User manual

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L-TEC VI-450 Welding Power Source

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