15 572 H - 653cvcc

653 cvcc
DC Welding Power Source

Instruction Manual
F15-572-H 02/2006
This manual provides complete instructions for the following power sources starting with Serial No. M0RI603036, January 1996:

ESAB ITEM NO. 37830 - 653cvcc - 230/460/575 vac, 3 ph., 60 Hz
ESAB ITEM NO. 37831 - 653cvcc - 220/400 vac, 3 ph., 50 Hz CE
This equipment will perform in conformity with the description thereof contained in this manual and accompa-
nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-
tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment
should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme-
diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone
or written request for service advice be made to the Authorized Distributor from whom it was 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 ser-
vice facility designated by the manufacturer.
BE SuRE THIS INFORMATION REACHES THE OpERATOR.
YOu CAN gET ExTRA COpIES THROugH YOuR SupplIER.
These INSTRuCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding and cutting 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 be-
fore installing or operating this equipment.
CAuTION
uSER RESpONSIBIlITY
TABlE OF CONTENTS
1.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.1 Safety - English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1. Safety - Spanish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1. Safety - French . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
.0 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
. Receiving-Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
. Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
.4 Optional Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
.5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
.0 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
.1 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
. Receiving, Unpacking & Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
. Primary (input) Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.4 Output Welding Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
.5 Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.0 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4. Sequence of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
5.0 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6.0 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
6. Testing and Replacing Bridge Assembly Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
7.0 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7. Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Section / Title page
4
TABlE OF CONTENTS
5
SECTION 1 SAFETY pRECAuTIONS
1.0 Safety precautions
1.1 Safety - English
WARNINg: These Safety Precautions are
for your protection. They summarize pre-
cautionary information from the references
listed in Additional Safety Information sec-
tion. 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 Precautions can result in injury or death.
pROTECT YOuRSElF AND OTHERS --
Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (uV) and other radiation
and can injure skin and eyes. Hot metal can cause
burns. Training in the proper use of the processes
and equipment is essential to prevent accidents.
Therefore:
1. Always wear safety glasses with side shields in any
work area, even if welding helmets, face shields, and
goggles are also required.
. Use a face shield ftted with the correct flter and
cover plates to protect your eyes, face, neck, and
ears from sparks and rays of the arc when operat-
ing or observing operations. Warn bystanders not
to watch the arc and not to expose themselves to
the rays of the electric-arc or hot metal.
. Wear fameproof gauntlet type gloves, heavy long-
sleeve shirt, cufess 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 fameproof apron may also be desirable as protec-
tion against radiated heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cufs, or pockets. Sleeves and collars should
be kept buttoned, and open pockets eliminated from
the front of clothing.
5. Protect other personnel from arc rays and hot
sparks with a suitable non-fammable partition or
curtains.
6. Use goggles over safety glasses when chipping slag
or grinding. Chipped slag may be hot and can fy far.
Bystanders should also wear goggles over safety
glasses.
FIRES AND ExplOSIONS -- Heat from
fames and arcs can start fres. Hot
slag or sparks can also cause fres and
explosions. Therefore:
1. Remove all combustible materials well away from
the work area or cover the materials with a protec-
tive non-fammable covering. 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 foors or wall openings and cause a hid-
den smoldering fre or fres on the foor below. Make
certain that such openings are protected from hot
sparks and metal.
. 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 fammable or toxic vapors. Do not do hot
work on closed containers. They may explode.
4. Have fre extinguishing equipment handy for instant
use, such as a garden hose, water pail, sand bucket,
or portable fre extinguisher. Be sure you are trained
in its use.
5. Do not use equipment beyond its ratings. For ex-
ample, overloaded welding cable can overheat and
create a fre hazard.
6. After completing operations, inspect the work area
to make certain there are no hot sparks or hot metal
which could cause a later fre. Use fre watchers when
necessary.
7. For additional information, refer to NFPA Standard
51B, "Fire Prevention in Use of Cutting and Welding
Processes", available from the National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA
069.
ElECTRICAl SHOCK -- Contact with
live electrical parts and ground can
cause severe injury or death. DO NOT
use AC welding current in damp areas,
if movement is confned, or if there is
danger of falling.
6
1. Be sure the power source frame (chassis) is con-
nected to the ground system of the input power.
. Connect the workpiece to a good electrical
ground.
. Connect the work cable to the workpiece. A poor
or missing connection can expose you or others
to a fatal shock.
4. Use well-maintained equipment. Replace worn or
damaged cables.

5. Keep everything dry, including clothing, work
area, cables, torch/electrode holder, and power
source.
6. Make sure that all parts of your body are insulated
from work and from ground.
7. Do not stand directly on metal or the earth while
working in tight quarters or a damp area; stand
on dry boards or an insulating platform and wear
rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the
power.
9. Turn of the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on
next page) for specifc grounding recommenda-
tions. Do not mistake the work lead for a ground
cable.
ElECTRIC AND MAgNETIC FIElDS
May be dangerous. Electric cur-
rent fowing through any conduc-
tor causes localized Electric and
Magnetic Fields (EMF). Welding and
cutting current creates EMF around welding cables
and welding machines. Therefore:
1. Welders having pacemakers should consult their
physician before welding. EMF may interfere with
some pacemakers.
. Exposure to EMF may have other health efects which
are unknown.
. Welders should use the following procedures to
minimize exposure to EMF:
A. Route the electrode and work cables together.
Secure them with tape when possible.
B. Never coil the torch or work cable around your
body.
C. Do not place your body between the torch and
work cables. Route cables on the same side of
your body.
D. Connect the work cable to the workpiece as close
as possible to the area being welded.
E. Keep welding power source and cables as far
away from your body as possible.
FuMES AND gASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confned spaces. Do
not breathe fumes and gases. Shield-
ing gases can cause asphyxiation.
Therefore:
1. Always provide adequate ventilation in the work area
by natural or mechanical means. Do not weld, cut, or
gouge on materials such as galvanized steel, stain-
less steel, copper, zinc, lead, beryllium, or cadmium
unless positive mechanical ventilation is provided.
Do not breathe fumes from these materials.
. Do not operate near degreasing and spraying opera-
tions. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly
toxic gas, and other irritant gases.
. If you develop momentary eye, nose, or throat ir-
ritation while operating, this is an indication that
ventilation is not adequate. Stop work and take
necessary steps to improve ventilation in the work
area. Do not continue to operate if physical discom-
fort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specifc ventilation recommendations.
7
5. WARNINg: This product, when used for welding
or cutting, produces fumes or gases
which contain chemicals known to
the State of California to cause birth
defects and, in some cases, cancer.
(California Health & Safety Code
25249.5 et seq.)
CYlINDER HANDlINg -- Cylinders,
if mishandled, can rupture and vio-
lently release gas. Sudden rupture
of cylinder, valve, or relief device can
injure or kill. Therefore:
1. 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 adaptors. Maintain hoses and fttings in good
condition. Follow manufacturer's operating instruc-
tions for mounting regulator to a compressed gas
cylinder.
. Always secure cylinders in an upright position by
chain or strap to suitable hand trucks, undercar-
riages, benches, walls, post, or racks. Never secure
cylinders to work tables or fxtures where they may
become part of an electrical circuit.
. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not con-
nected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and fames.
Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases
in Cylinders", which is available from Compressed
Gas Association, 15 Jeferson Davis Highway,
Arlington, VA 0.
EQuIpMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
1. Always have qualifed personnel perform the instal-
lation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualifed to perform such work.
. Before performing any maintenance work inside a
power source, disconnect the power source from
the incoming electrical power.
. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do
not operate any equipment in faulty condition.
4. 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.
5. Keep all safety devices and cabinet covers in position
and in good repair.
6. Use equipment only for its intended purpose. Do
not modify it in any manner.
ADDITIONAl SAFETY INFORMATION -- For
more information on safe practices for
electric arc welding and cutting equip-
ment, ask your supplier for a copy of
"precautions and Safe practices for Arc
Welding, Cutting and gouging", Form
52-529.
The following publications, which are available from
the American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 16, are recommended to you:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
. AWS C5. - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5. - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
8
5. AWS C5.5 - "Recommended Practices for Gas Tung-
sten Arc Welding
6. AWS C5.6 - "Recommended Practices for Gas Metal
Arc Welding"
7. AWS SP - "Safe Practices" - Reprint, Welding Hand-
book.
8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."
MEANINg OF SYMBOlS - As used
throughout this manual: Means Atten-
tion! Be Alert! Your safety is involved.
Means immediate hazards which,
if not avoided, will result in im-
mediate, serious personal injury
or loss of life.
Means potential hazards which
could result in personal injury or
loss of life.
Means hazards which could result
in minor personal injury.
9
SECTION 1 SEguRIDAD
1.2 Safety - Spanish
ADVERTENCIA: Estas Precauciones de Se-
guridad son para su proteccin. Ellas hacen
resumen de informacin proveniente de las
referencias listadas en la seccin "Informacin Adi-
cional Sobre La Seguridad". Antes de hacer cualquier
instalacin o procedimiento de operacin , asegrese
de leer y seguir las precauciones de seguridad listadas
a continuacin as como tambin todo manual, hoja
de datos de seguridad del material, calcomanias, etc.
El no observar las Precauciones de Seguridad puede
resultar en dao a la persona o muerte.
pROTEJASE uSTED Y A lOS DEMAS--
Algunos procesos de soldadura, corte
y ranurado son ruidosos y requiren
proteccin para los odos. El arco,
como el sol , emite rayos ultravioleta
(uV) y otras radiaciones que pueden daar la piel
y los ojos. El metal caliente causa quemaduras. El
entrenamiento en el uso propio de los equipos y
sus procesos es esencial para prevenir accidentes.
por lo tanto:
1. Utilice gafas de seguridad con proteccin a los lados
siempre que est en el rea de trabajo, an cuando
est usando careta de soldar, protector para su cara
u otro tipo de proteccin.
. Use una careta que tenga el fltro correcto y lente
para proteger sus ojos, cara, cuello, y odos de las
chispas y rayos del arco cuando se est operando y
observando las operaciones. Alerte a todas las per-
sonas cercanas de no mirar el arco y no exponerse
a los rayos del arco elctrico o el metal fundido.
. Use guantes de cuero a prueba de fuego, camisa
pesada de mangas largas, pantaln de ruedo liso,
zapato alto al tobillo, y careta de soldar con capucha
para el pelo, para proteger el cuerpo de los rayos y
chispas calientes provenientes del metal fundido.
En ocaciones un delantal a prueba de fuego es
necesario para protegerse del calor radiado y las
chispas.
4. Chispas y partculas de metal caliente puede alojarse
en las mangas enrolladas de la camisa , el ruedo del
pantaln o los bolsillos. Mangas y cuellos debern
mantenerse abotonados, bolsillos al frente de la
camisa debern ser cerrados o eliminados.
5. Proteja a otras personas de los rayos del arco y chis-
pas calientes con una cortina adecuada no-famable
como divisin.
6. Use careta protectora adems de sus gafas de segu-
ridad cuando est removiendo escoria o puliendo.
La escoria puede estar caliente y desprenderse con
velocidad. Personas cercanas debern usar gafas
de seguridad y careta protectora.
FuEgO Y ExplOSIONES -- El calor de
las famas y el arco pueden ocacionar
fuegos. Escoria caliente y las chispas
pueden causar fuegos y explosiones.
por lo tanto:
1. Remueva todo material combustible lejos del rea
de trabajo o cubra los materiales con una cobija a
prueba de fuego. Materiales combustibles incluyen
madera, ropa, lquidos y gases famables, solventes,
pinturas, papel, etc.
. Chispas y partculas de metal pueden introducirse en
las grietas y agujeros de pisos y paredes causando
fuegos escondidos en otros niveles o espacios.
Asegrese de que toda grieta y agujero est cubierto
para proteger lugares adyacentes contra fuegos.
. No corte, suelde o haga cualquier otro trabajo
relacionado hasta que la pieza de trabajo est to-
talmente limpia y libre de substancias que puedan
producir gases infamables o vapores txicos. No
trabaje dentro o fuera de contenedores o tanques
cerrados. Estos pueden explotar si contienen vapores
infamables.
4. Tenga siempre a la mano equipo extintor de fuego
para uso instantneo, como por ejemplo una
manguera con agua, cubeta con agua, cubeta con
arena, o extintor porttil. Asegrese que usted esta
entrenado para su uso.
5. No use el equipo fuera de su rango de operacin. Por
ejemplo, el calor causado por cable sobrecarga en
los cables de soldar pueden ocasionar un fuego.
6. Despus de termirar la operacin del equipo, inspec-
cione el rea de trabajo para cerciorarse de que las
chispas o metal caliente ocasionen un fuego ms
tarde. Tenga personal asignado para vigilar si es
necesario.
7. Para informacin adicional , haga referencia a la
publicacin NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible
a travs de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 069.
CHOQuE ElECTRICO -- El contacto
con las partes elctricas energizadas
y tierra puede causar dao severo o
muerte. NO use soldadura de corri-
ente alterna (AC) en reas hmedas,
de movimiento confnado en lugares estrechos o
si hay posibilidad de caer al suelo.
10
SECTION 1 SEguRIDAD
1. Asegrese de que el chasis de la fuente de poder
est conectado a tierra atravs del sistema de
electricidad primario.
. Conecte la pieza de trabajo a un buen sistema de
tierra fsica.
. Conecte el cable de retorno a la pieza de trabajo.
Cables y conductores expuestos o con malas
conexiones pueden exponer al operador u otras
personas a un choque elctrico fatal.
4. Use el equipo solamente si est en buenas condi-
ciones. Reemplaze cables rotos, daados o con
conductores expuestos.
5. Mantenga todo seco, incluyendo su ropa, el rea de
trabajo, los cables, antorchas, pinza del electrodo,
y la fuente de poder.
6. Asegrese que todas las partes de su cuerpo estn
insuladas de ambos, la pieza de trabajo y tierra.
7. No se pare directamente sobre metal o tierra mien-
tras trabaja en lugares estrechos o reas hmedas;
trabaje sobre un pedazo de madera seco o una
plataforma insulada y use zapatos con suela de
goma.
8. Use guantes secos y sin agujeros antes de energizar
el equipo.
9. Apage el equipo antes de quitarse sus guantes.
10. Use como referencia la publicacin ANSI/ASC
Standard Z49.1 (listado en la prxima pgina) para
recomendaciones especfcas de como conectar el
equipo a tierra. No confunda el cable de soldar a
la pieza de trabajo con el cable a tierra.
CAMpOS ElECTRICOS Y MAgNETI-
COS - Son peligrosos. la corriente
elctrica fuye atravs de cualquier
conductor causando a nivel local
Campos Elctricos y Magnticos
(EMF). las corrientes en el rea de corte y soldadura,
crean EMF alrrededor de los cables de soldar y las
maquinas. por lo tanto:

1. Soldadores u Operadores que use marca-pasos para
el corazn debern consultar a su mdico antes de
soldar. El Campo Electromagntico (EMF) puede
interferir con algunos marca-pasos.
. Exponerse a campos electromagnticos (EMF) puede
causar otros efectos de salud an desconocidos.
. Los soldadores debern usar los siguientes proced-
imientos para minimizar exponerse al EMF:
A. Mantenga el electrodo y el cable a la pieza de
trabajo juntos, hasta llegar a la pieza que usted
quiere soldar. Asegrelos uno junto al otro con
cinta adhesiva cuando sea posible.
B. Nunca envuelva los cables de soldar alrededor
de su cuerpo.
C. Nunca ubique su cuerpo entre la antorcha y el
cable, a la pieza de trabajo. Mantega los cables a
un slo lado de su cuerpo.
D. Conecte el cable de trabajo a la pieza de trabajo
lo ms cercano posible al rea de la soldadura.
E. Mantenga la fuente de poder y los cables de soldar
lo ms lejos posible de su cuerpo.
HuMO Y gASES -- El humo y los
gases, pueden causar malestar o
dao, particularmente en espacios
sin ventilacin. No inhale el humo
o gases. El gas de proteccin puede
causar falta de oxgeno.
por lo tanto:
1. Siempre provea ventilacin adecuada en el rea
de trabajo por medio natural o mecnico. No solde,
corte, o ranure materiales con hierro galvanizado,
acero inoxidable, cobre, zinc, plomo, berlio, o cad-
mio a menos que provea ventilacin mecnica
positiva . No respire los gases producidos por
estos materiales.
. No opere cerca de lugares donde se aplique sub-
stancias qumicas en aerosol. El calor de los rayos
del arco pueden reaccionar con los vapores de
hidrocarburo clorinado para formar un fosfgeno,
o gas txico, y otros irritant es.
. Si momentneamente desarrolla inrritacin de
ojos, nariz o garganta mientras est operando, es
indicacin de que la ventilacin no es apropiada.
Pare de trabajar y tome las medidas necesarias
para mejorar la ventilacin en el rea de trabajo.
No contine operando si el malestar fsico per-
siste.
4. Haga referencia a la publicacin ANSI/ASC Standard
Z49.1 (Vea la lista a continuacin) para recomen-
daciones especfcas en la ventilacin.
11
SECTION 1 SEguRIDAD
5. ADVERTENCIA-- Este producto cuando se uti-
liza para soldaduras o cortes,
produce humos o gases, los
cuales contienen qumicos
conocidos por el Estado de Cali-
fornia de causar defectos en el
nacimiento, o en algunos casos,
Cancer. (California Health &
Safety Code 25249.5 et seq.)
MANEJO DE CIlINDROS-- los
cilindros, si no son manejados
correctamente, pueden romp-
erse y liberar violentamente
gases. Rotura repentina del
cilindro, vlvula, o vlvula de
escape puede causar dao o
muerte. por lo tanto:
1. Utilize el gas apropiado para el proceso y utilize
un regulador diseado para operar y reducir la
presin del cilindro de gas . No utilice adapta-
dores. Mantenga las mangueras y las conexiones
en buenas condiciones. Observe las instrucciones
de operacin del manufacturero para montar el
regulador en el cilindro de gas comprimido.
. Asegure siempre los cilindros en posicin vertical
y amrrelos con una correa o cadena adecuada
para asegurar el cilindro al carro, transportes, tab-
lilleros, paredes, postes, o armazn. Nunca asegure
los cilindros a la mesa de trabajo o las piezas que
son parte del circuito de soldadura . Este puede ser
parte del circuito ellectrico.
. Cuando el cilindro no est en uso, mantenga la
vlvula del cilindro cerrada. Ponga el capote de
proteccin sobre la vlvula si el regulador no
est conectado. Asegure y mueva los cilindros
utilizando un carro o transporte adecuado. Evite
el manejo brusco de los
MANTENIMIENTO DEl EQuIpO -- Equipo
defectuoso o mal mantenido puede cau-
sar dao o muerte. por lo tanto:
1. Siempre tenga personal cualifcado para efec-
tuar l a instalacin, diagnstico, y mantenimiento
del equipo. No ejecute ningn trabajo elctrico a
menos que usted est cualifcado para hacer el
trabajo.
. Antes de dar mantenimiento en el interior de la
fuente de poder, desconecte la fuente de poder
del suministro de electricidad primaria.
. Mantenga los cables, cable a tierra, conexciones,
cable primario, y cualquier otra fuente de poder
en buen estado operacional. No opere ningn
equipo en malas condiciones.
4. No abuse del equipo y sus accesorios. Mantenga
el equipo lejos de cosas que generen calor como
hornos, tambin lugares hmedos como charcos
de agua , aceite o grasa, atmsferas corrosivas y
las inclemencias del tiempo.
5. Mantenga todos los artculos de seguridad y
coverturas del equipo en su posicin y en buenas
condiciones.
6. Use el equipo slo para el propsito que fue
diseado. No modifque el equipo en ninguna
manera.
INFORMACION ADICIONAl DE SEgu-
RIDAD -- para ms informacin sobre las
prcticas de seguridad de los equipos de
arco elctrico para soldar y cortar, pregunte
a su suplidor por una copia de "precautions
and Safe practices for Arc Welding, Cutting
and gouging-Form 52-529.
Las siguientes publicaciones, disponibles atravs de
la American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 16, son recomendadas para usted:
Welding"
Cutting"
1
SECTION 1 SEguRIDAD
SIgNIFICADO DE lOS SIMBOlOS
-- Segn usted avanza en la lectura
de este folleto: los Smbolos Sig-
nifcan Atencin! Est Alerta! Se
trata de su seguridad.
Signifca riesgo inmediato que,
de no ser evadido, puede resultar
inmediatamente en serio dao
personal o la muerte.
Signifca el riesgo de un peligro
potencial que puede resultar en
serio dao personal o la muerte.
Signifca el posible riesgo que
puede resultar en menores daos
a la persona.
1
SECTION 1 SCuRIT
1.3 Safety - French INCENDIES ET ExplOSIONS -- la
chaleur provenant des fammes ou de
l'arc peut provoquer un incendie. le
laitier incandescent ou les tincelles
peuvent galement provoquer un
incendie ou une explosion. par consquent :
1. loignez sufsamment tous les matriaux combus-
tibles de l'aire de travail et recouvrez les matriaux
avec un revtement protecteur ininfammable. Les
matriaux combustibles incluent le bois, les vte-
ments, la sciure, le gaz et les liquides combustibles,
les solvants, les peintures et les revtements, le
papier, etc.
. Les tincelles et les projections de mtal incan-
descent peuvent tomber dans les fssures dans
les planchers ou dans les ouvertures des murs et
dclencher un incendie couvant l'tage infrieur
Assurez-vous que ces ouvertures sont bien protges
des tincelles et du mtal incandescent.
. N'excutez pas de soudure, de coupe ou autre tra-
vail chaud avant d'avoir compltement nettoy la
surface de la pice traiter de faon ce qu'il n'ait
aucune substance prsente qui pourrait produire
des vapeurs infammables ou toxiques. N'excutez
pas de travail chaud sur des contenants ferms
car ces derniers pourraient exploser.
4. Assurez-vous qu'un quipement d'extinction
d'incendie est disponible et prt servir, tel qu'un
tuyau d'arrosage, un seau d'eau, un seau de sable
ou un extincteur portatif. Assurez-vous d'tre bien
instruit par rapport l'usage de cet quipement.
5. Assurez-vous de ne pas excder la capacit de
l'quipement. Par exemple, un cble de soudage
surcharg peut surchaufer et provoquer un in-
cendie.
6. Une fois les oprations termines, inspectez l'aire de
travail pour assurer qu'aucune tincelle ou projec-
tion de mtal incandescent ne risque de provoquer
un incendie ultrieurement. Employez des guetteurs
d'incendie au besoin.
7. Pour obtenir des informations supplmentaires,
consultez le NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible au
National Fire Protection Association, Batterymarch
Park, Quincy, MA 069.
CHOC lECTRIQuE -- le contact avec
des pices lectriques ou les pices
de mise la terre sous tension peut
causer des blessures graves ou mor-
telles. NE pAS utiliser un courant de
soudage c.a. dans un endroit humide, en espace
restreint ou si un danger de chute se pose.
AVERTISSEMENT : Ces rgles de scurit
ont pour but d'assurer votre protection. Ils
rcapitulent les informations de prcaution
provenant des rfrences dans la section
des Informations de scurit supplmentaires. Avant de
procder l'installation ou d'utiliser l'unit, assurez-vous
de lire et de suivre les prcautions de scurit ci-des-
sous, dans les manuels, les fches d'information sur la
scurit du matriel et sur les tiquettes, etc. Tout dfaut
d'observer ces prcautions de scurit peut entraner
des blessures graves ou mortelles.
pROTgEZ-VOuS -- les processus de
soudage, de coupage et de gougeage
produisent un niveau de bruit lev et
exige l'emploi d'une protection auditive. l'arc, tout
comme le soleil, met des rayons ultraviolets en plus
d'autre rayons qui peuvent causer des blessures la
peau et les yeux. le mtal incandescent peut causer
des brlures. une formation relie l'usage des
processus et de l'quipement est essentielle pour
prvenir les accidents. par consquent:

1. Portez des lunettes protectrices munies d'crans la-
traux lorsque vous tes dans l'aire de travail, mme
si vous devez porter un casque de soudeur, un cran
facial ou des lunettes tanches.
. Portez un cran facial muni de verres fltrants et de
plaques protectrices appropries afn de protger
vos yeux, votre visage, votre cou et vos oreilles des
tincelles et des rayons de l'arc lors d'une opration
ou lorsque vous observez une opration. Avertissez
les personnes se trouvant proximit de ne pas re-
garder l'arc et de ne pas s'exposer aux rayons de l'arc
lectrique ou le mtal incandescent.
. Portez des gants ignifugis crispin, une chemise
paisse manches longues, des pantalons sans
rebord et des chaussures montantes afn de vous
protger des rayons de l'arc, des tincelles et du mtal
incandescent, en plus d'un casque de soudeur ou
casquette pour protger vos cheveux. Il est galement
recommand de porter un tablier ininfammable afn
de vous protger des tincelles et de la chaleur par
rayonnement.
4. Les tincelles et les projections de mtal incandescent
risquent de se loger dans les manches retrousses,
les rebords de pantalons ou les poches. Il est recom-
mand de garder boutonns le col et les manches et
de porter des vtements sans poches en avant.
5. Protgez toute personne se trouvant proximit des
tincelles et des rayons de l'arc l'aide d'un rideau ou
d'une cloison ininfammable.
6. Portez des lunettes tanches par dessus vos lunettes
de scurit lors des oprations d'caillage ou de
meulage du laitier. Les cailles de laitier incandescent
peuvent tre projetes des distances considrables.
Les personnes se trouvant proximit doivent gale-
ment porter des lunettes tanches par dessus leur
lunettes de scurit.
14
SECTION 1 SCuRIT
. Les soudeurs doivent suivre les procdures suivantes
pour minimiser l'exposition aux champs lectriques
et magntiques :
A. Acheminez l'lectrode et les cbles de masse
ensemble. Fixez-les l'aide d'une bande adhsive
lorsque possible.
B. Ne jamais enrouler la torche ou le cble de masse
autour de votre corps.
C. Ne jamais vous placer entre la torche et les cbles
de masse. Acheminez tous les cbles sur le mme
ct de votre corps.
D. Branchez le cble de masse la pice traiter le
plus prs possible de la section souder.
E. Veillez garder la source d'alimentation pour le
soudage et les cbles une distance approprie
de votre corps.
lES VApEuRS ET lES gAZ -- peuvent
causer un malaise ou des dommages
corporels, plus particulirement
dans les espaces restreints. Ne re-
spirez pas les vapeurs et les gaz. le
gaz de protection risque de causer
l'asphyxie. par consquent :
1. Assurez en permanence une ventilation adquate
dans l'aire de travail en maintenant une ventila-
tion naturelle ou l'aide de moyens mcanique.
N'efectuez jamais de travaux de soudage, de coup-
age ou de gougeage sur des matriaux tels que
l'acier galvanis, l'acier inoxydable, le cuivre, le zinc,
le plomb, le berylliym ou le cadmium en l'absence
de moyens mcaniques de ventilation efcaces. Ne
respirez pas les vapeurs de ces matriaux.
. N'efectuez jamais de travaux proximit d'une
opration de dgraissage ou de pulvrisation.
Lorsque la chaleur
ou le rayonnement de l'arc entre en contact avec les
vapeurs d'hydrocarbure chlor, ceci peut dclencher
la formation de phosgne ou d'autres gaz irritants,
tous extrmement toxiques.
. Une irritation momentane des yeux, du nez ou de la
gorge au cours d'une opration indique que la ven-
tilation n'est pas adquate. Cessez votre travail afn
de prendre les mesures ncessaires pour amliorer
la ventilation dans l'aire de travail. Ne poursuivez
pas l'opration si le malaise persiste.
4. Consultez ANSI/ASC Standard Z49.1 ( la page
suivante) pour des recommandations spcifques
concernant la ventilation.
1. Assurez-vous que le chssis de la source
d'alimentation est branch au systme de mise
la terre de l'alimentation d'entre.
. Branchez la pice traiter une bonne mise de
terre lectrique.
. Branchez le cble de masse la pice traiter et
assurez une bonne connexion afn d'viter le risque
de choc lectrique mortel.
4. Utilisez toujours un quipement correctement
entretenu. Remplacez les cbles uss ou endom-
mags.
5. Veillez garder votre environnement sec, incluant
les vtements, l'aire de travail, les cbles, le porte-
lectrode/torche et la source d'alimentation.
6. Assurez-vous que tout votre corps est bien isol
de la pice traiter et des pices de la mise la
terre.
7. Si vous devez efectuer votre travail dans un espace
restreint ou humide, ne tenez vous pas directe-
ment sur le mtal ou sur la terre; tenez-vous sur
des planches sches ou une plate-forme isole et
portez des chaussures semelles de caoutchouc.
8. Avant de mettre l'quipement sous tension, isolez
vos mains avec des gants secs et sans trous.
9. Mettez l'quipement hors tension avant d'enlever
vos gants.
10. Consultez ANSI/ASC Standard Z49.1 (list
la page suivante) pour des recommandations
spcifques concernant les procdures de mise
la terre. Ne pas confondre le cble de masse avec
le cble de mise la terre.
CHAMpS lECTRIQuES ET MAgN-
TIQuES comportent un risque
de danger. le courant lectrique
qui passe dans n'importe quel con-
ducteur produit des champs lec-
triques et magntiques localiss. le soudage et le
courant de coupage crent des champs lectriques
et magntiques autour des cbles de soudage et
l'quipement. par consquent :
1. Un soudeur ayant un stimulateur cardiaque doit
consulter son mdecin avant d'entreprendre une
opration de soudage. Les champs lectriques et
magntiques peuvent causer des ennuis pour cer-
tains stimulateurs cardiaques.
. L'exposition des champs lectriques et magn-
tiques peut avoir des efets nfastes inconnus pour
la sant.
15
SECTION 1 SCuRIT
1. Efforcez-vous de toujours confier les tches
d'installation, de dpannage et d'entretien un
personnel qualif. N'efectuez aucune rparation
lectrique moins d'tre qualif cet efet.
. Avant de procder une tche d'entretien
l'intrieur de la source d'alimentation, dbranchez
l'alimentation lectrique.
. Maintenez les cbles, les fls de mise la terre, les
branchements, le cordon d'alimentation et la source
d'alimentation en bon tat. N'utilisez jamais un
quipement s'il prsente une dfectuosit quel-
conque.
4. N'utilisez pas l'quipement de faon abusive. Gardez
l'quipement l'cart de toute source de chaleur,
notamment des fours, de l'humidit, des faques
d'eau, de l'huile ou de la graisse, des atmosphres
corrosives et des intempries.
5. Laissez en place tous les dispositifs de scurit et
tous les panneaux de la console et maintenez-les
en bon tat.
6. Utilisez l'quipement conformment son usage
prvu et n'efectuez aucune modifcation.
INFORMATIONS SupplMENTAIRES RElA-
TIVES lA SCuRIT -- pour obtenir de
l'information supplmentaire sur les rgles
de scurit observer pour l'quipement
de soudage l'arc lectrique et le coupage,
demandez un exemplaire du livret "precau-
tions and Safe practices for Arc Welding,
Cutting and gouging", Form 52-529.
Les publications suivantes sont galement recomman-
des et mises votre disposition par l'American Welding
Society, 550 N.W. LeJuene Road, Miami, FL 16 :
Welding"
Cutting"
5. AVERTISSEMENT : Ce produit, lorsqu'il est utilis
dans une opration de soudage ou de
coupage, dgage des vapeurs ou des
gaz contenant des chimiques consi-
dres par l'tat de la Californie comme
tant une cause des malformations
congnitales et dans certains cas, du
cancer. (California Health & Safety
Code 25249.5 et seq.)
MANIpulATION DES CYlINDRES --
la manipulation d'un cylindre, sans
observer les prcautions ncessaires,
peut produire des fissures et un
chappement dangereux des gaz.
une brisure soudaine du cylindre, de la soupape ou
du dispositif de surpression peut causer des bles-
sures graves ou mortelles. par consquent :
1. Utilisez toujours le gaz prvu pour une opration
et le dtendeur appropri conu pour utilisation
sur les cylindres de gaz comprim. N'utilisez jamais
d'adaptateur. Maintenez en bon tat les tuyaux et
les raccords. Observez les instructions d'opration
du fabricant pour assembler le dtendeur sur un
cylindre de gaz comprim.
. Fixez les cylindres dans une position verticale,
l'aide d'une chane ou une sangle, sur un chariot
manuel, un chssis de roulement, un banc, un mur,
une colonne ou un support convenable. Ne fxez
jamais un cylindre un poste de travail ou toute autre
dispositif faisant partie d'un circuit lectrique.
. Lorsque les cylindres ne servent pas, gardez les
soupapes fermes. Si le dtendeur n'est pas bran-
ch, assurez-vous que le bouchon de protection de
la soupape est bien en place. Fixez et dplacez les
cylindres l'aide d'un chariot manuel appropri.
Toujours manipuler les cylindres avec soin.
4. Placez les cylindres une distance approprie
de toute source de chaleur, des tincelles et des
fammes. Ne jamais amorcer l'arc sur un cylindre.
5. Pour de l'information supplmentaire, consultez
CGA Standard P-1, "Precautions for Safe Handling
of Compressed Gases in Cylinders", mis votre dis-
position par le Compressed Gas Association, 15
Jeferson Davis Highway, Arlington, VA 0.
ENTRETIEN DE l'QuIpEMENT -- un quipe-
ment entretenu de faon dfectueuse ou
inadquate peut causer des blessures
graves ou mortelles. par consquent :
16
SECTION 1 SCuRIT
SIgNIFICATION DES SYMBOlES
Ce symbole, utilis partout dans ce manuel,
signife "Attention" ! Soyez vigilant ! Votre
scurit est en jeu.
Signife un danger immdiat. la situation peut
entraner des blessures graves ou mortelles.
Signife un danger potentiel qui peut entraner des
blessures graves ou mortelles.
Signife un danger qui peut entraner des blessures
corporelles mineures.
DANgER
AVERTISSEMENT
ATTENTION
17
ESAB 653cvcc
Multi-process, three phase power sources de-
signed for heavy duty industrial DC welding ap-
plications
Use for Mig, fux cored wire, submerged arc and
stick electrode welding or air carbon arc gouging
Compatible with 42v wire feeders: MobileMaster IV,
2E, 4HD, 4HD Dual and with 115v wire feeders/
controls: Mig 35, Digimig, Digimig Dual, Digimatic
II, UEC-8, DuraDrive 4-30 and DuraDrive 4-48
115 vac outlet for water circulator or tools
Control electronics are protected from dirt and dust
in an easy-access compartment
Optional wire feed adaptor kits for Miller and Lin-
coln wire feeders
Ordering Information
ESAB Power Sources
653cvcc, 0/460/575 vac, ph, 60 Hz .................................................... 780
653cvcc, 0/400 (80-415) vac, ph, 50 Hz CE ................................... 78
ESAB 653cvcc Migmaster Packages
The following package includes an ESAB DC power source, wire
feeder, 8 ft. (.4m) control cable, 8 ft. (.4m) gas hose, .05/.045
in. (.9/1.mm) feed roll, - 15 ft. (4.5m) GunMaster gas-cooled gun,
15f t. work cable with clamp, 15 f t. wire feeder weld cable and
R--FM-580 regulator with adjustable fowmeter.
Migmaster 653cvcc, Mig 4HD, gM-400cc,
0/460/575 vac ......................................................................................... 64
Options & Accessories

HC-3B Hand Control, 0 ft. (9.1m) cable
(requires 055800146) .......................................................................... 88
Mini Boom for Mig 4HD (requires Swivel Post) .................................. 4
Swivel post, use with Mig 4HD or Mig E wire feeders ..................... 617
Auto Fan Kit .................................................................................................... 6707
TR-29 Truck Kit .................................................................................................. 794
Remote Control Kit ............................................................................055800146
Miller Wire Feeder Adaptor Kit (4 vac only) ......................... 0558001415
lincoln Wire Feeder Adaptor Kit ................................................ 0558001416
Work Cable with Clamp (15 ft.) ..................................................... 0558001440
Feeder Cable with lug (15 ft.) ........................................................0558001441
Specifcations
Rated DC Output* @ 100% duty cycle,
50/60 Hz, cv or cc 65cvcc .........................................650 amps @ 44 vdc
Rated DC Output* @ 60% duty cycle,
50/60 Hz, cv or cc 65cvcc .........................................750 amps @ 44 vdc
Open Circuit Voltage, 50/60 Hz 65cvcc ................... 54 vdc (cv)/59 vdc (cc)
Primary Input Voltage & Current @ rated 100% duty cycle load
65cvcc, 0/460 vac, 60 Hz, ph ...................................... 108/54 amps
65cvcc, 0/460/575 vac, 60 Hz, ph .......................108/54/4 amps
65cvcc, 0/400 (80-415) vac, 50 Hz, ph ...........................................
........................................................................................... 10/56 (59-54) amps
Power Factor @ rated load .................................................................................8%
Auxiliary Output Power (receptacle) ....................115 vac, 50/60 Hz, 10 amps
W x L x H .......................... 18.75 in. (46 cm) x .5 in. (8 cm) x 5 in. (64 cm)
Net Weight,** 60 Hz 65cvcc ...................................................... 49 lb. (4 kg)
Shipping Weight** (approximate), 60 Hz 65cvcc .................50 lb. (9 kg)
* For 208 vac, 60 Hz and 380 vac, 50 Hz service, derate output current
rating 10%.
** For 50 Hz models, add 40 lb. (18kg)
Shown with optional DuraDrive 4
-48 wire feeder,

GM-400 Mig welding torch, TR-29 Truck kit,
15 ft. work cable and welding wire
SECTION 2 DESCRIpTION
18
Table 2-1. Specifcations for 653cvcc
NOTE: The 653cvcc may also operate from a 200 (208)-volt a.c. primary input using the 230-volt changeover connections. However, when connected to
this source (200-volt), the output voltage is derated 10%.
2.1 gENERAl
This manual provides information to familiarize the operator with the design, installation and operation of the 65cvcc
model power source. DO NOT attempt to install or operate this equipment until you have read and fully understand
these instructions. The information presented here should be given careful consideration to ensure optimum perfor-
mance of this equipment.
2.2 RECEIVINg-HANDlINg
Upon receipt, remove all packing material and carefully inspect for any damage that may have occurred during shipment.
Any claims for loss or damage that may have occurred in transit must be fled by the purchaser with the carrier. A copy of
the bill of lading and freight bill will be furnished by the carrier on request.
When requesting information concerning this equipment, it is essential that the Item number, Serial number and Model
number of the equipment be supplied.
2.3 DESCRIpTION
The 65cvcc is a multi-process power sources designed for Mig and spray transfer (GMAW), fux core (FCAW), and stick
(SMAW) welding as well as submerged arc welding (SAW) and air carbon arc cutting/gouging (CAC-A) applications. Table
-1 outlines the electrical and physical specifcations of the available models.
OPEN CIRCUIT VOLTAGE (U
0
) 54 vdc (cv)/59 vdc (cc)
RATED DUTY CYCLE 60% 100%
OUTPUT Current (I
) 750 A 650 A (60Hz)/600 A (50Hz)

Voltage (U
) 44 V 44 V

RATED Phase 60 Hz Volts (U
1
) Current (I
1
) Flat Current (I
1
) Flat
INPUT 0 V 14 A 108 A
460 V 6 A 54 A
575 V 50 A 4 A
50 Hz 0 V 17 A 10 A
400 V 70 A 56 A
Power Factor at Rated Output 8%
Welding Range 750 A/44 V - 50 A/14 V
Auxiliary Power 115 V ac @ 10 A, 60 Hz
PHYSICAL SPECIFICATIONS 60 Hz. 50 Hz.
Height (without lift eye) 5.0 (6. cm)
Width 18.8 (48. cm)
Depth .5 (81.9 cm)
Net Weight 49 lbs (4 kg) 58 lbs (40 kg)
Shipping Weight 50 lbs (8 kg) 58 lbs (44 kg)
19
2.4 OpTIONAl ACCESSORIES
2.4.1 TR-29 Truck Kit (Item No. 37924)
This truck kit provides complete mobility of the power source. The kit consists of castors, rear cylinder rack and wheels,
gas cylinder bracket, cylinder chain, and pull handle.
2.4.2 Swivel Mount Kit (Item No. 36172)
This kit allows ESAB wire feeders with swivel base mounts to be mounted to the top of the power source on an insulated
swivel mount. This allows the feeder to freely rotate, relieving potential wire feed problems while increasing the working
area of the torch.
2.5 SAFETY
Before the equipment is put into operation, the safety section at the front of this manual should be read completely. This
will help avoid possible injury due to misuse or improper installation.
The defnitions relating to the:

safety notations are described at the end of the Safety Section in the front of this manual read them and their spe-
cifc text references carefully.
60
0
50
40
0
0
10
0 100 00 00 400 600 700 800 500 900
D.C. OuTpuT CuRRENT (AMpS)
CV MODE FOR MIg/SuB ARC
AMpS
V
o
l
t
s
MAx.
MIN.
60
0
50
40
0
0
10
0 100 00 00 400 600 700 800 1000 500 900
AMpS
MIN. MAx.
V
o
l
t
s
D.C. OuTpuT CuRRENT (AMpS)
CC MODE FOR STICK/ARC gOugINg/SuB ARC
Figure 2-1. Volt-Ampere Curves
2.3.1 power Source
The power source is a constant current/constant potential, Silicon Controlled Rectifer (SCR), three-phase, star-connected
transformer/rectifer type dc unit with solid state contactor and control circuitry. It provides the volt-ampere characteris-
tics desired for conventional MIG, fux core and submerged arc welding in the CV mode or stick welding and arc gouging
in the CC mode.
2.3.2 Volt-Ampere Characteristics
The curves shown in Figure -1 represent the volt-ampere static characteristics for the power source. The slant of these
curves is referred to as the "slope" and is generally defned as the "voltage drop per 100 amperes of current use". These
curves show the output voltage available at any given output current from the minimum to the maximum setting of the
voltage control. Because the volt-ampere slope is fxed, it is possible to select welding conditions by estimating the open-
circuit voltage required for the load current when operating in the CV mode.
0
1
SECTION 3 INSTAllATION
3.1 lOCATION
A proper installation site is necessary for the power source to provide dependable service. A proper installation site permits
freedom of air movement through the unit while minimizing exposure to dust, dirt, moisture, and corrosive vapors. A mini-
mum of 18 inches (46 cm) is required between the side and rear panels of the power source and the nearest obstruction.
The selected site should also allow easy removal of the power source outer enclosure for maintenance. See Table -1 for
overall dimensions of the unit.
3.2 RECEIVINg, uNpACKINg AND plACEMENT
A. Immediately upon receipt of the power source, inspect for damage which may have occurred in transit. Notify the
carrier of any defects or damage.
B. Remove the power source from the container. Remove all packing materials. Check the container for any loose
parts.
C. Check air passages at front and rear of cabinet, making sure that no packing materials that may obstruct air fow
through the power source.
D. Install the lifting ring furnished with the power sources into the top of the unit.

E. After selecting an installation site, place the power source in the desired location. The unit may be lifted either
by using the lifting ring or by forklift truck. If a forklift is used for lifting the unit, be sure that the lift forks are long
enough to extend completely under the base.
Do not use flters on this unit as they would restrict the volume of
intake air required for proper cooling. Output ratings on this unit are
based on an unobstructed supply of cooling air drawn over its internal
components. Warranty is void if any type of fltering device is used.
CAuTION
CAuTION
For lifting purposes and for keeping dust, moisture, and other for-
eign material from entering the power source, the lifting eyebolt
must be fully tightened with a tool.
3.3 pRIMARY (INpuT) ElECTRICAl CONNECTION

This power source is a three-phase unit and must be connected to a three-phase power supply. It is recommended that the
unit be operated on a dedicated circuit to prevent impairment of performance due to an overloaded circuit.
Table 3-1. Recommended Sizes for Input
Conductors and line Fuses
* Sized per National Code for 80 C rated copper conductors @ 0 C ambient. Not more than three conductors in raceway or cable. Local
codes should be followed if they specify sizes other than those listed
A. The primary power leads must be insulated copper conductors. Three power leads and one ground wire are required.
Either rubber covered cable or conduit (fexible or solid) may be used. Table -1 provides recommended input conduc-
tors and line fuse sizes.
B. Remove the top cover. Identify primary power connections, TB, and the ground lug located on the A-Frame bracket.
Refer to fgure .1.
ElECTRIC SHOCK CAN KIll! BEFORE MAKINg ElECTRICAl INpuT
CONNECTIONS TO THE pOWER SOuRCE, "MACHINERY lOCKOuT
pROCEDuRES" SHOulD BE EMplOYED. IF THE CONNECTIONS ARE
TO BE MADE FROM A lINE DISCONNECT SWITCH, plACE THE SWITCH
IN THE OFF pOSITION AND pADlOCK IT TO pREVENT INADVERTENT
TRIppINg . IF THE CONNECTION IS MADE FROM A FuSEBOx, REMOVE
THE CORRESpONDINg FuSES AND pADlOCK THE BOx COVER. IF IT IS
NOT pOSSIBlE TO uSE pADlOCKS, ATTACH A RED TAg TO THE lINE
DISCONNECT SWITCH (OR FuSE BOx) WARNINg OTHERS THAT THE
CIRCuIT IS BEINg WORKED ON.
WARNINg
Rated Input
@ 100% Duty Cycle
Input & GND
Conductor *
CU / AWG
Fuse
Size
Amps
Volts Amps
0
0
400
460
575
68
66
7
6
No. 6
No. 6
No. 8
No. 8
No. 10
100
100
60
60
50
C. Thread the properly stripped input and ground conduc-

tors through the large strain relief in the rear panel of the
power source. Connect the three input conductors to the
three input terminals on TB (see fgure -1). To connect
the ground conductor, thread the ground wire through the
ground fault switch bracket and connect to the ground lug
provided on the A-Frame.
D. Check all connections for proper tightness. Ensure all con-
nections are correct and well-insulated.
Recommended Cable Strip lengths
Primary Cable
(Supplied by
Customer)
Ground Fault
Switch & Bracket
TB-
L1, L, L
Connection
Ground
Connection
THE CHASSIS MuST BE CONNECTED TO AN AppROVED ElECTRICAl
gROuND. FAIluRE TO DO SO MAY RESulT IN ElECTRICAl SHOCK,
SEVERE BuRNS OR DEATH.
WARNINg
Figure 3-1. Connecting primary power leads
4
Figure 3-2. Input Terminal Board Confguration for 230/460/575 Model
(factory supplied in the 575 confguration)
230 Vac Input 460 Vac Input 575 Vac Input
Figure 3-3. Input Terminal Board Confgura-
tion 230/460 Model (factory supplied in the
460 confguration)
460 Vac Input
230 Vac Input
Figure 3-4. Input Terminal Board Confgura-
tion 220/400 Model (factory supplied in the
400 confguration)
220 Vac Input 400 Vac Input
*
*
*
E. Figures -, - & -4 illustrate the input voltage terminal board and the input voltage link connections. The particular
voltages from which this power source may be operated are stated on the rating plate. The voltage links were factory
set for highest voltage stated on the rating plate. If the power source is to be operated on another stated input voltage,
the links must be reset for that particular input voltage. Always verify the input voltage and check the link arrangement
regardless of factory setting. The voltage links are set up by reconfguring the copper link bars to the voltage designa-
tions for the desired voltage.
5
The output connections are located on the front panel (Figure -5). The negative connection is located at the bottom right
corner and the positive (high inductance and low inductance) connections are located at the bottom left corner. Table -
provides the recommended cable output sizes.
3.5 CONTROl CONNECTIONS
The wire feeder receptacle and 115 VAC Auxiliary control are mounted on a removable plate. This plate may be exchanged
for diferent applications.
Optional Available Plates:
Blank (P/N 790M)
Terminal Block for Lincoln - 4vac & 115vac feeders - (P/N 0558001416)
Miller 14 pin Receptacle for 4vac feeders only - (P/N 0558001415)
Refer to Figure -5.
Table 3-2. Output Cable Sizes (Secondary)
* Total cable length includes work and electrode cables. Cable size is based on direct current, insulated copper conductors, 100-percent duty cycle
and a voltage drop of 4 or less volts. The welding cable insulator must have a voltage rating that is high enough to withstand the open circuit volt-
age of the power source.
BEFORE MAKINg ANY CONNECTIONS TO THE pOWER SOuRCE OuT-
puT TERMINAlS, MAKE SuRE THAT All pRIMARY INpuT pOWER TO
THE MACHINE IS OFF.
3.4 OuTpuT WElDINg CONNECTIONS (SECONDARY)
WARNINg
Welding
Current
Total Length (Feet) of Cable in Weld Circuit*
50 100 150 0 50
100 6 4 1/0
150 4 1 1/0 /0
00 1 1/0 /0 /0
50 1/0 /0 /0 4/0
00 1 /0 /0 4/0 4/0
400 /0 /0 4/0 4/0 -/0
500 /0 /0 4/0 -/0 -/0
6
3.5.1 Wire Feeder Control
The Wire feeder control cable connection is provided by a 19-pin receptacle (J1) located on the left-hand side of the power
source front panel. This receptacle will operate all ESAB wire feeders with 19 pin control cables including the Mig E, Mig
4HD, Mig 4HD Dual, Mig 5XL, Mig 8A, Mig 5, Digimig, Digimig Dual as well as the UEC-8, Digimatic II and Analog Interface
mechanized controls.
3.5.2 Remote Control (Optional)
This function is provided by an optional 14-pin receptacle (J) located on the front panel directly below connector J1. It
receives a mating plug from a Hand Control Assembly (optional). This receptacle is operative only if the panel remote switch
on the power source front panel is in the "Remote" position.
3.5.3 Auxiliary 115 V AC Receptacle
A 115 Vac receptacle is provided to supply power to accessories such as a water cooler, heated CO
regulator, or small hand

tools. The receptacle is rated 115 Vac / 10 amps.
3.5.4 42V Circuit Breaker (CB1)
The 4V resettable circuit breaker (CB1) protects the 4 volt wire feeder/control circuitry against over current. (Table 6-
provides troubleshooting information).
3.5.5 115V Circuit Breaker (CB2)
The 115V resettable circuit breaker (CB) protects the 115 volt auxiliary receptacle and wire feeder/control circuitry against
over current. (Table 6- provides troubleshooting information).
3.5.6 External grounding Conductor protection
This feature will de-energize the power source output if current fow is detected in the external ground conductor. When this
happens, the Fault light on the front control panel will illuminate. It will remain lit until the fault is corrected or the power
source power switch (S1) is turned of.
7
Figure 3-5. Connection Diagram
653cvcc
.4
Negative
Output
Receptacle
.4, 4.1.7
High Inductance for
STICK WElDINg (SMAW)
SuBMERgED ARC WElDINg (SAW)
ARC CuTTINg/gOugINg (CAC-A)
MIg WElDINg (gMAW) optional
Positive Output
Receptacle
.4, 4.1.7
Low Inductance for
MIg WElDINg (gMAW)
Flux CORED WElDINg (FCAW)
ARC gOugINg (CAC-A) optional
PosItive Output
Receptacle
.5.5
CB
.5.4
CB1
4.1.1
POWER "ON-OFF"
SWITCH
.5.1
WIRE FEEDER
CONTROL
RECEPTACLE
REMOVABLE
PANEL
.5.
115V ac
AUXILIARY
RECEPTACLE
8
9
SECTION 4 OpERATION
4.1 CONTROlS (See Figure 4-1)
4.1.1 power Switch (ON-OFF)/(I-O)
The power switch is located on the front panel of the power source. In the "of" ("O") position, the unit is shut down; however,
power is still present in the unit. To fully shut down the power source, power must be disconnected at the line disconnect
switch or the fuse box.
With the switch in the "on" ("I") position, power is provided to the main transformer and the low voltage control circuitry.
4.1.1.1 power Indicator
This white light will indicate that the power switch is in the on position and power has been applied to the main transformer
and low voltage circuitry.
4.1.1.2 Fault Indicator
This red light will indicate that current was fowing through the external ground conductor. It will also illuminate if a short
occurs (momentary or permanent) between the +1 volt J1-E; the +10 volt (J-E) and either the chassis ground or the nega-
tive terminal of the power source. The power source output terminals are de-energized and the fault must be corrected
before resuming operation.
4.1.2 Output panel/Remote Switch
With this switch in the Panel position, output voltage is controlled by adjusting the voltage potentiometer on the front
panel to the desired output. In the Remote position, output is controlled using an optional remote voltage control via
receptacle J.
Never operate the power source with the cover removed. In addition
to the safety hazards, improper cooling may cause damage to the
components. Keep side panels closed when unit is energized. Weld-
ing helmet, gloves, and other personal protection should always be
worn when welding.
Figure 4-1. Control locations
4.1.4
4.1.5
4.1.
4.1.
4.1.8
4.1.9
4.1.1.1
4.1.1.
CAuTION
0
4.1.3 Output Voltage/Current Control
This control allows the operator to adjust the output voltage in the CV mode and output current in the CC mode. Placing
the Panel/Remote switch in the Remote position disables the output control on the front panel. Calibration marks are to
provide a rough guide in setting voltage and current.
4.1.4 Over Temperature Indicator (Temp.)
This amber light will indicate when an internal overheating condition has occurred and one of the thermal switches has
opened. User control of the solid state contactor will be interrupted and power source output will shut down to protect
critical components. Once cooled to a safe temperature, the thermal switch will automatically reset and output control will
be restored.
4.1.5 Voltmeter and Ammeter
A digital voltmeter and ammeter provides an accurate indication of dc output voltage and current.
4.1.6 Over Current protection
The 65cvcc incorporates automatic over current protection. If an over current condition occurs, the automatic circuitry will
fold back the output current to a level that will prevent damage to the power source. The power source will remain in this
low current fold back mode until the arc is broken, the torch trigger is released or the contactor switch is reset.
4.1.7 High & low Inductance Receptacles
The 65cvcc provides high and low inductance output connections (see fgure -5). Both are positive output terminals. The
high inductance terminal slows the power source dynamic response. This means the output current will build at a slower
rate compared to the low inductance terminals. The welding process and application will determine which terminal should
be used. The chart below provides suggested terminal connections.
4.1.8 Contactor, On/Remote Switch
The Contactor Control switch is located on the front panel of the power source. In the on position, the solid state contactor
is energized and output power is available at the output terminals. The "Remote" position allows the solid state contactor
to be controlled from a remote Mig wire feeder or mechanized sub arc control.
4.1.9 process Switch (CC-CV)
The process switch allows for selection of the output characteristics of the power source depending on the welding process
being used. The CV position produces a Flat volt-amp characteristic and is mostly used for the Mig (GMAW) and Submerged
Arc (SAW) welding processes and occasionally with Air Carbon Arc Cutting (CAC-A). The CC position produces a Drooping
characteristic most popular for Stick (SMAW), CAC-A and sometimes SAW.
SECTION 4 OpERATION
Process Switch CC CV
Inductance High Low High Low
Mig Solid Wire (GMAW) X X
1
X
Flux Cored (FCAW) X X
Sub Arc (SAW) X X
X
Arc Gouging (CAC-A) X X
X
1. Small diameter wires (<1/16-inch) with argon mixtures.
. </-inch diameter wires.
. Fast dynamic response (optional setting only).
1
SECTION 4 OpERATION
ElECTRIC SHOCK CAN KIll! "MACHINERY lOCKOuT pROCEDuRES"
SHOulD BE EMplOYED. IF IT IS NOT pOSSIBlE TO uSE pADlOCKS,
ATTACH A RED TAg TO THE lINE DISCONNECT SWITCH (OR FuSE BOx)
WARNINg OTHERS THAT THE CIRCuIT IS BEINg WORKED ON.
4.2 SEQuENCE OF OpERATION
Prior to performing the steps below, open the wall disconnect switch or remove the fuse from the fuse box to electrically
isolate the power source.
ElECTRIC SHOCK CAN KIll! WHEN THE CONTACTOR SWITCH IS IN
THE "ON" pOSITION, OuTpuT pOWER WIll BE pRESENT THROugH-
OuT THE WElDINg CIRCuIT; ie. CABlES, WIRE FEEDER, WIRE SpOOl,
DRIVE STAND, guN, AND ElECTRODE. BE SuRE All ARE ClEAR OF
THE WORKpIECE OR ARCINg WIll RESulT.
4.2.1 general procedures for the CV-MIg (gMAW), SuB ARC (SAW) and CC-STICK (SMAW), SuB
ARC (SAW) processes
A. Make the secondary output connections to the positive and negative output receptacles. See paragraph .4 and
fgure -5.
B. Make the control connections. Refer to the appropriate wire feeder, mechanized control, and/or torch instruction
booklets for additional process requirements or control connections.
C. If primary input connections have been made to the power switch, and on the input terminal board to match the
incoming voltage, close the main wall disconnect switch or reinstall fuses in the fuse box.
4.2.2 Specifc procedures for the CV-MIg (gMAW) and SuB ARC (SAW) processes
A. Set the Output Panel/Remote switch to the desired setting.
B. Set the Process switch to the CV position.
C. Set the contactor switch to "Remote".
D. Set the power switch on the rear panel to the "on" ("I") position. The fan will run for 0 seconds and stop automati-
cally if welding current does not exceed 100 amps. The fan will automatically turn of after 6 minutes when the
contactor is "of" and the welding current is below 100 amps.
E. To preset the approximate welding voltage, place the Contactor switch to the "on" position. This will energize the
power source output, allowing the voltage to be preset using the Output Voltage/Current Control dial and observ-
ing the voltmeter.
WARNINg
WARNINg
SECTION 4 OpERATION
F. After setting the desired voltage condition, turn the contactor switch back to the remote position. This position
requires a remote start control in order to start the welding sequence.
NOTE:
A PCB and resistor pack discharges capacitor voltage to eliminate the electrode "sparking" or "arcing"
potential.

G. Begin welding. Observe the voltmeter, ammeter, and the weld. Readjust the voltage and wire feed speed settings
as necessary to obtain a satisfactory weld.
H. When welding is completed, release torch switch. (This action will de-energize the power source solid state contactor
and remove dc power from the output terminals.)
4.2.3 Specifc procedures for the CC-Stick Welding (SMAW) and Arc gouging (CAC-A) processes
A. Place the Output Panel/Remote switch into PANEL position if output current is regulated from the Output Voltage/
Current dial on the panel, or in REMOTE position if output current is regulated from the optional Hand Control.
B. Set the Output Voltage/Current Control to provide the approximate desired welding current using the control knob
as the reference. Example - set knob to 5 for approximately 450 amps output.
C. Set the Contactor switch to the ON position -- this will energize the solid-state contactor and all associated circuitry
up to the output terminals.
D. Place the Process Control switch in the CC position.
E. Commence welding by touch or scratch starting the electrode.
SECTION 5 MAINTENANCE
5.1 general
5.2 Cleaning
Periodically, remove the cover from the power source and blow accumulated dust and dirt from the air passages and inte-
rior components by using clean, dry low pressure air. The frequency of cleaning required depends 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 fow to provide proper cool-
ing.
After cleaning with low pressure air, check for and tighten any loose hardware, including all electrical connections. Check
for frayed and/or cracked insulation on all power cables and replace if necessary.
CAuTION
WARNINg
If this power source does not operate properly, stop work immedi-
ately 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 recommended
replacement parts.
WARNINg
BE SuRE THAT THE BRANCH CIRCuIT OR MAIN DISCONNECT SWITCH
IS OFF, OR ElECTRICAl INpuT FuSES ARE REMOVED, BEFORE AT-
TEMpTINg ANY INSpECTION OR WORK INSIDE THE pOWER SOuRCE.
plACINg THE pOWER SWITCH IN THE OFF pOSITION DOES NOT RE-
MOVE All pOWER FROM INSIDE THE pOWER SOuRCE.
FAIluRE TO REplACE WORN OR DAMAgED CABlES MAY RESulT IN
A BARE CABlE TOuCHINg A gROuNDED OBJECT. THE RESulTINg
ElECTRICAl ARC MAY INJuRE uNpROTECTED EYES AND WIll pRES-
ENT A SERIOuS FIRE HAZARD. BODY CONTACT WITH A BARE CABlE,
CONNECTOR, OR CONDuCTOR MAY RESulT IN SEVERE ElECTRICAl
SHOCK, CAuSINg SERIOuS BuRNS OR DEATH.
4
5.3 Inspection and Service
Keep the power source dry, free of oil and grease, and protected at all times from damage by hot metal and sparks.
5.3.1 Fan Motor
Keep the fan motor free of accumulated dust and lint.
5.3.2 Transformer
Other than periodically cleaning the dust and dirt from the transformer, no maintenance is required. Ensure that only clean,
dry, low pressure air is used.
5.3.3 Wire Feeder and Control Circuits
These circuits are protected by two 10 amp circuit breakers mounted in the front panel. If these open, the contactor and
wire feeder will not operate.
5.3.4 Over Temperature protection
If the power source reaches an abnormally high internal temperature, the thermal protection will deenergize the contactor
circuit, shutting down the power source but leaving the cooling fan on. After the power source has cooled to a safe level,
the thermal protection will automatically reset. While de-energized, the contactor and wire feeder cannot be operated.
5.3.5 Digital Voltmeter/Ammeter Calibration
To verify the accuracy of the digital volt/ammeter combination, the following calibration procedure can be performed
periodically:
1. Place the Panel/Remote switch in Panel position.
. Disconnect cables from the output terminals and then connect an accurate DC voltmeter to the output terminals.
. Place the Contactor switch in the On position.
4. With the primary input power on, turn the Voltage control knob until you get 5V on the DC voltmeter. Compare the
reading with the reading on the digital voltmeter on the front panel.
5. If there is a diference in the voltage readings, open front control panel by removing the two mounting screws from
the upper corners, remove meter board from its four mounting posts, and adjust the trimpot (R1) on the meter board
with a small screwdriver until the digital meter reading matches the DC voltmeter reading. When satisfed, reassemble
meter board and front control panel.
SECTION 5 MAINTENANCE
5
SECTION 6 TROuBlESHOOTINg
6.1 general
If the power source is operating improperly, the following troubleshooting information may be used to locate the source
of the trouble.
Check the problem against the symptoms in the following troubleshooting guide (Table 6-.) The remedy for the prob-
lem 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 capacitors, or any other sign of damage or discoloration.
6.2 Testing and Replacing Bridge Assembly Components
The SCRs used in the power source are devices which allow current to fow in only one direction. The SCRs are designed
to provide long trouble-free operation; however, should a failure occur, they may require replacement.
A. Testing SCRs.
1. Remove top and right side panel from the power source.
. Locate the main rectifer assembly containing the SCRs.
. Electrically isolate main bridge assembly by disconnecting 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 minimum of 0
meg ohms.
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 installing a jumper from 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 (0-50 ohms).
IMPORTANT
When replacing SCRs, make sure mounting surfaces are clean. Using Alcoa No. 2 EJC Electrical Joint Compound or an equivalent,
apply a thin coat to the SCR mounting surface and positively locate in place on the heatsinks. Place the clamp in position with the
bolts through the holes in the heatsinks and proceed as follows:
WARNINg
DISCONNECT pRIMARY pOWER AT WAll SWITCH, OR CIRCuIT
BREAKER, BEFORE ATTEMpTINg INSpECTION OR WORK INSIDE THE
pOWER SOuRCE.
6
1. Tighten the bolts evenly until fnger tight noting that the nuts are not rotating.
. Tighten the bolts /4 turn plus an 1/8 turn using a socket wrench on the bolt heads and rotating only in 1/4 turn incre-
ments plus 1/8 turn alternating between the bolts noting that the nuts are not rotating.
Table 6-1. pCB Voltage Tests*
NOTE:
All voltage readings are taken with the front access panel open and the power switch "ON".
* Refer to Schematic Diagram
** Varies with VCP (R1)
WARNINg
ElECTRICAl SERVICE AND REpAIR SHOulD BE ATTEMpTED ONlY BY
A TRAINED ElECTRICIAN.
FROM TO READING
P8-5 OTB+ +10 V dc
P8-7 OTB+ 0-10 V dc**
P6-6 (SCR1)
P6-5 (SCR)
P6-4 (SCR)
P6- (SCR4)
P6- (SCR5)
P6-1 (SCR6)
OTB+ . V dc with
contactor on
7
Table 6-2. Troubleshooting guide
CONDITION ACTION
Unit Inoperative A. No input power. Check main line (users) switch fuses replace if needed.
B. Poor or improper input (terminal board) connections.
C. Defective on/of switch replace.
D. Thermal light on. Main transformer overheating. Also check for proper cooling,
proper primary hookup, or shorted turn on secondary.
E. Thermal light on. Fan motor not operating check motor and leads.
F. External Ground Conductor fault indicator ON. - Check for cause and correct.
Turn power switch OFF then ON to reset.
G. Loss of primary phase. Check that LED on control PCB is not lit. If lit, fnd & replace
defective fuse.

No Output Fan Running A. Poor or improper electrical input check input connections on TB.
B. Poor connections at output terminals/work station check, tighten or replace.
C. Main transformer overheating thermal switches tripped due to restricted cool-
ing air. Temperature light on front panel will be lit. Let unit cool down.
D. PC board defective or loose PC board connector(s) if loose, reinsert; if defective,
replace.
Limited Output or
Low Open-Circuit Voltage A. Input voltage jumper links on terminal board improperly set check for proper
voltage.
B. Poor output connections. Take apart, clean, and tighten securely.
C. Panel-Remote switch in Remote position and remote voltage pot disabled.
D. Over current condition had occurred. Unit is in fold back mode. See Section
4.1.6.
Erratic Weld Current A. Welding cable size too small use correct cables.
B. Loose welding cable connection (will usually get hot) tighten connections.
C. Improper wire feeder setup.
D. Defective SCR in bridge rectifer.
E. PC board defective replace.
High Output, No Voltage Control A. PC board defective or loose reset and/or replace board.
No 115 Volt ac Output A. Circuit breaker tripped. Check 115V CB Reset.
Line Fuse Blows When Power
Source is First Turned On A. Shorted SCR in Main Bridge replace.
B. Shorted capacitor in Capacitor Bank.
Wire Feeder is Inoperative A. Loose feeder control cable Check and tighten all connections.
B. A Circuit Breaker tripped Check 4V CB1 and 115V CB Reset.
8
NOTL:
Schematlcs and wlrlng Dlagrams on ll x l7
paper are lncluded
lnslde the back cover of thls manual.
9
SECTION 7 REplACEMENT pARTS
7.1 general
Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on
the unit nameplate.
To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this
equipment. The use of non-ESAB parts may void your warranty.
Replacement parts may be ordered from your ESAB Distributor.
Be sure to indicate any special shipping instructions when ordering replacement parts.
Refer to the Communications Guide located on the back page of this manual for a list of customer service phone
numbers.
7.2 Ordering
Bill of material items that have blank part numbers are provided for customer information only.
Hardware items should be available through local sources.
Note
7.0 Replacement parts
40
653cvcc Front panel View
195
41
653cvcc Front Isometric View
4
653cvcc Internal View
4
653cvcc Rear Isometric View
44
653cvcc Internal View
45
653cvcc Top Internal View
46
Bill of Materials
653cvcc DC Welding power Source
ITEM pART OR
NO. CODE NO. QTY. DESCRIpTION SYMBOl

1 95488 1 LABEL SUBARC STICK
95489 1 LABEL MIG
611 1 PCB DIGITAL METER PCB
4 617 1 BLADE FAN 14"
5 810 1 PCB CONTROL PCB1
6 64515 SW TGGL SPDT POS 15A 15V S,,4
7 67065 6 STRAP TERMINAL, VOLTAGE CHANGELINE
8 67805 TERM AY OUTPUT
9 9501 CKT BREAKER 10A VDC 50VAC CB1,
10 95019 1 RELIEF STRAIN .00
11 950711 SW THERMAL 194FT S,,4
1 950768 DIODE FWD 00V 00A D1,
1 950945 1 SW PWR DISC 100A 600V S1
14 951474 SW SEAL BLACK
15 954008 1 LABEL DANGER HIGH VOLTAGE
16 064 1 MOTOR FAN 1/ HP 165RPM M1
17 055800104 SCR ASSY
18 4149 1 CLIP ANNEALED
0 6110 1 BOARD INPUT TERMINAL 0/460V/575
1 609 1 CABLE DIGITAL METER PCB P10
7861M 1 BASE
4 786M 1 PANEL FRONT BOTTOM
5 055800169 1 PANEL RIGHT SIDE ENV
6 055800170 1 PANEL LEFT SIDE ENV
7 055800178 1 CONTROL PANEL BLACK
8 7867M 1 PANEL REAR
0 7869 1 HIGH TAP INDUCTOR BUSBAR
1 7870 1 LOW TAP INDUCTOR BUSBAR
7871 1 SHUNT
787 INSULATOR KYDEX
4 7890 1 XFMR MAIN 0/460/575V T1
5 788 1 INDUCTOR L1
6 7907 1 SCHEMATIC DIAG 65 CVCC
7 7908 1 WIRING DIAG SEC 65 CVCC
8 0558001044 1 WIRING DIAG PRI PH AFRAME
4 64761 1 TERMINAL LUG
44 67786 1 BOLT EYE .75-10 X .00
45 950167 1 GROMMET RUB 1.1 ID X 1.50 GD X .06 W
46 950905 1 TERM IL/M .50 TS X 14-16 AWG
47 951504 1 PLUG HOUSING 15 POS J5
48 055800101 1 CAP HOUSING POSITION
49 95067 1 CONNECTOR 0 AWG PIN P1
50 95068 1 MTA-156 COVER PIN
51 95070 1 CONNECTOR 0 AWG 7 PIN P5
5 95071 1 MTA-156 COVER 7 PIN
5 9507 CONNECTOR 0 AWG 1 PIN P,4,7
54 9507 1 TERM BLOCK 1 POS
57 9509 1 PANEL RECEPTACLE 19 PIN F J1
47
ITEM pART OR
Bill of Materials
653cvcc DC Welding power Source (Cont'd)
58 9519 1 OUTLET 110V SQUARE J
61 95445 1 LABEL LR-0071 CSA NRTL/C
6 954506 1 LABEL ISO 900
6 954868 1 OVERLAY 65 CVCC BLK
64 954846 1 LABEL RATING 65 CVCC 0/460/575
65 95480 1 LABEL SCHEMATIC 65
66 091514 1 LABEL WARNING WELD AND CUT
67 091558 1 LABEL GND BILK .50 X 1.8
69 1706 1 POT LIN 10K W .88L
71 171781 1 MTA-156 COVER 10 PIN
7 1741 MTA-156 COVER 1 PIN
7 177 1 LABEL FOR INSTALL USSE COP WIRE
74 174588 1 LOGO ESAB CLEAR
75 17511 1 CONNECTOR 0 AWG 6 PIN P6
76 1751 1 MTA-156 COVER 6 PIN
77 175508 1 SHROUD FAN
78 1700016 1 RES RW FIXD ST 00W 10% 16.00
79 99477 1 RUBBER .188 X .500
1 995140 1 LABEL CAUTION LIFT EYE
14 9951558 1 BRACKET RESISTOR #18
15 0558001010 1 TERMINAL BLOCK POS TB
16 05580010 1 BOX PCB BLACK
17 055800101 PLUG HOUSING POS
18 0558001014 SEAL WIRE POS
19 0558001015 SEAL INTER
140 0558001016 1 CAP 9 POS J6
141 0558001018 1 INSULATOR STAND OFF
14 0558001019 1 KNOB 1.57 DIA
14 05580010M 1 PANEL FRONT TOP
147 604GY 1 BRACKET FAN
148 6048M 4 LEG AFRAME
149 6049M 1 BAIL LIFTING
15 790M 1 BLANKING PLATE
15 7901M 1 19 AND 110V PANEL
154 055800171 1 PANEL TOP ENV
155 7899 1 LOWER BAFFLE
156 179157 LAMP WHITE 48V PL1
157 951754 1 LAMP LED YEL 1V PL
158 95610 1 LAMP LED RED 1V PL
161 8100 1 CE FILTER ASSY FN1
16 954565 1 LABEL CE
16 95 STAND OFF 1/4-0 X .75
164 05580017 HINGE ACCESS
166 954864 1 LABEL THREE PHASE
171 0558001407 SEAL WIRE 15 POS
17 0558001408 1 SEAL INTER 15 POS
17 0558001406 1 SEAL WIRE 9 POS
181 9598 1 RELAY SOLID STATE 660V 10
48
ITEM pART OR
Bill of Materials
653cvcc DC Welding power Source (Cont'd)
18 055800579 1 BRACKET MOUNTING
185 950466 1 CAP HOUSING 15 POS
186 0648 1 PLUG HOUSING 9 POS
187 0558001409 1 CONNECTION INTERFACE SEAL 9
188 95015 1 CONTACT PIN
189 95609 1 CONN RECEPT 16 PIN TAFA P10
19 055800417 1 BRACKET - GROUND FAULT
194 170 BUSHING - GROUND FAULT
195 0558005656 1 CAP METAL PROTECTION
49
50
NOTES
51
REVISION HISTORY
The "A" edition of this booklet includes a rewrite of the primary electrical connection.
The "B" edition of this booklet includes:
Schematic and Wiring Diagrams
Additional replacement parts
The "C" edition updated part numbers, edited graphics on pages 10 and 1 and removed references to 5cvcc Parts.
The "D" edition updated complete parts list.
The "E" edition covers the reinstallation of a Ground Fault Switch and Bracket and Ground Connection.
The "F" edition of this manual provides modifcations requiring an updated display PCB, timer module, an additional PCB,
mounting brackets, resistor pack and associated wiring mounted to the "A" frame support near the output rectifer bridge.
These modifcations are for a "fan on demand" feature. These modifcations will afect serial no.'s M0RI6006 and above.
Replacement Parts listings have also been updated.See dneco# 079 & service bulletin 0_01_001.
The "G" edition of this manual updated Section , Front Panel showing control locations. Section .1 has been reconfgured
to resemble the 5 & 45 manuals. Minor editorial changes have also been made. Front cover picture also updated.
The H revision updates the format and front cover picture (no records of the G revision being released, E revision was
currently on the web & G was in the folder but apparently never released). Added p/n 0558005656, item 195, metal cap
protection and illustration to replacement parts.
The H revision of 0/006 made editorial change to reference Lincoln & Miller feeders in section .5.
F15-572-H 02/2006
A. CUSTOMER SERVICE QUESTIONS:
Telephone: (800)6-7080 / Fax: (800) 64-7548 Hours: 8:00 AM to 7:00 PM EST
Order Entry Product Availability Pricing Order Information Returns
B. ENGINEERING SERVICE:
Telephone: (84) 664-4416 / Fax : (800) 446-569 Hours: 7:0 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting
C. TECHNICAL SERVICE:
Telephone: (800) ESAB-1/ Fax: (84) 664-445 Hours: 8:00 AM to 5:00 PM EST
Part Numbers Technical Applications Specifcations Equipment Recommendations
D. LITERATURE REQUESTS:
Telephone: (84) 664-556 / Fax: (84) 664-5548 Hours: 7:0 AM to 4:00 PM EST
E. WELDING EQUIPMENT REPAIRS:
Telephone: (84) 664-4487 / Fax: (84) 664-5557 Hours: 7:0 AM to :0 PM EST
Repair Estimates Repair Status
F. WELDING EQUIPMENT TRAINING
Telephone: (84)664-448 / Fax: (84) 679-5864 Hours: 7:0 AM to 4:00 PM EST
Training School Information and Registrations
G. WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-1 Hours: 7:0 AM to 4:00 PM EST
H. TECHNICAL ASST. CONSUMABLES:
Telephone : (800) 9-7070 Hours: 7:0 AM to 5:00 PM EST
IF YOu DO NOT KNOW WHOM TO CAll
Telephone: (800) ESAB-1
Fax: (84) 664-446
Hours: 7:0 AM to 5:00 PM EST
or
visit us on the web at http://www.esabna.com
The ESAB web site ofers
Comprehensive Product Information
Material Safety Data Sheets
Warranty Registration
Instruction Literature Download Library
Distributor Locator
Global Company Information
Press Releases
Customer Feedback & Support
ESAB Welding & Cutting products, Florence, SC Welding Equipment
COMMuNICATION guIDE - CuSTOMER SERVICES

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DC Welding Power Source

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-48 wire feeder,

) 750 A 650 A (60Hz)/600 A (50Hz)

3.3 pRIMARY (INpuT) ElECTRICAl CONNECTION

C. Thread the properly stripped input and ground conduc-

regulator, or small hand

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