ESAB SVI 450i cvcc User manual

F15-071-D
December, 2003
INSTRUCTION MANUAL
SVI 450i cvcc
Power Source
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 forArc Welding,
Cutting, and Gouging," Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do
NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not
fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions
before installing or operating this equipment.
Be sure this information reaches the operator.
You can get extra copies through your supplier.
ESAB Welding &
Cutting Products
This manual provides installation and operation / maintenance and troubleshooting instructions for the following units:
ESAB P/N 31950 - 208/230/460 V ac, 1 or 3 Phase, 60 Hz
ESAB P/N 31955 - 575 V ac, 3 Phase, 60 Hz (Refer to Supplement F-15-072.)
ESAB P/N 31960 - 220/380/415 V ac, 3 Phase, 50 Hz (Refer to Supplement F-15-073.)
L-TEC P/N 35618 - 220/380/415 V ac, 3 Phase, 50 Hz (Refer to Supplement F-15-073.)

USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying
labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions 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 replacement be-
come necessary, the manufacturer recommends that a telephone or written request for service advice be made to the
Authorized Distributor from whom purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The
user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty
maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility
designated by the manufacturer.
TABLE OF CONTENTS
2
SECTION TITLE PAGE
PARAGRAPH
SECTION 1 DESCRIPTION ................................................................................................. 5
1.1 Introduction ....................................................................................................... 5
1.2 Optional Accessories ......................................................................................... 5
SECTION 2 INSTALLATION ................................................................................................ 6
2.1 General ............................................................................................................. 6
2.2 Unpacking and Placement ................................................................................ 6
2.3 Input Power Connections .................................................................................. 6
2.4 Output Welding Connections............................................................................. 8
2.5 MIG Control (J1) Interconnection ...................................................................... 9
2.6 Additional Remote Control (J2) Interconnection ................................................ 10
SECTION 3 OPERATION ..................................................................................................... 11
3.1 Introduction ....................................................................................................... 11
3.2 Duty Cycle ......................................................................................................... 11
3.3 Volt-Ampere (Slope) Characteristics ................................................................. 11
3.4 Power Source Welding Controls ....................................................................... 11
3.5 Sequence of Operation ..................................................................................... 12
SECTION 4 MAINTENANCE ................................................................................................ 15
4.1 General ............................................................................................................. 15
4.2 Cleaning ............................................................................................................ 15
4.3 Lubrication ........................................................................................................ 15
SECTION 5 TROUBLESHOOTING ..................................................................................... 16
5.1 Troubleshooting ................................................................................................ 16
SECTION 6 REPLACEMENT PARTS .................................................................................. 27
6.1 General ............................................................................................................. 27
6.2 Ordering ............................................................................................................ 27

3
WARNING: These Safety Precautions are for your
protection. They summarize precautionary infor-
mation from the references listed in Additional
Safety Information paragraph. Before performing any installa-
tion 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 pro-
cesses are noisy and require ear protec-
tion. The arc, like the sun, emits ultravio-
let (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.
2. 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 bystanders not to watch the arc and not
to expose themselves to the rays of the electric arc or hot
metal.
3. Wear flameproof gauntlet type gloves, heavy long-sleeved
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.
4. Hot sparks or metal can lodge in rolled up sleeves, trouser
cuffs, 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-flammable partition or curtains.
6. Use goggles over safety glasses when chipping slag or
grinding. Chipped slag may be hot and can fly far. Bystand-
ers should also wear goggles over safety glasses.
FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot slag
or sparks can also cause fires and explo-
sions. Therefore:
1. Remove all combustible materials well away from the work
area or cover the materials with a protective non-flammable
covering. Combustible materials include wood, cloth, saw-
dust, liquid and gas fuels, solvents, paints and coatings,
paper, etc.
2. 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.
3. Do not weld, cut or perform other hot work until the workpiece
has been completely cleaned so that there are no sub-
stances on the workpiece which might produce flammable
or toxic vapors. Do not do hot work on closed containers.
They may explode.
4. 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.
5. Do not use equipment beyond its ratings. For example,
overloaded welding cable can overheat and create a fire
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 fire. Use fire 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 Protection Association,
Batterymarch Park, Quincy, MA 02269.
ELECTRICAL SHOCK — Contact can
cause severe injury or death. Do NOT use
AC output in damp areas, if movement is
confined, or if danger of falling exists. Put
on dry, hole-free gloves before turning on
the power. Also:
1. Be sure the power source frame (chassis) is connected to
the ground system of the input power.
2. Connect the workpiece to a good electrical ground.
3. Connect the work cable to the workpiece. A poor or missing
connection can expose the operator 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. Fix water leaks
immediately.
6. Make sure that you are well insulated, especially when
standing on metal or working in tight quarters or in a damp
area. Wear rubber-soled shoes and stand on a dry board or
insulating platform.
7. Turn off the power before removing your gloves.
8. Refer to ANSI/ASC Standard Z49.1 (see listing below) for
specific grounding recommendations. Do not mistake the
work lead for a ground cable.
ELECTRIC AND MAGNETIC FIELDS —
May be dangerous. Electric current flow-
ing through any conductor causes local-
ized Electric and Magnetic Fields (EMF).
Welding and cutting current creates EMF
around welding cables and welding ma-
chines. Therefore:
1. Welders having pacemakers should consult their physician
before welding. EMF may interfere with some pacemakers.
2. Exposure to EMF may have other health effects which are
unknown.
3. 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.

4
2. Before performing any maintenance work inside a power
source, disconnect the power source from the incoming
electrical power.
3. 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 elec-
tric arc welding and cutting equipment, 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 33126, are recommended to you:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon Arc
Gouging and Cutting"
5. AWS C5.5 - "Recommended Practices for Gas Tungsten
Arc Welding"
6. AWS C5.6 - "Recommended Practices for Gas Metal Arc
Welding"
7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held Haz-
ardous Substances."
This symbol appearing throughout this manual
means Attention! Be Alert! Your safety is
involved.
The following definitions apply to DANGER, WARNING,
CAUTION found throughout this manual:
Used to call attention to immediate hazards
which, if not avoided, will result in immedi-
ate, serious personal injury or loss of life.
Used to call attention to potential hazards
which could result in personal injury or loss
of life.
Used to call attention to hazards which
could result in minor personal injury.
FUMES AND GASES -- Fumes and gases,
can cause discomfort or harm, particu-
larly in confined spaces. Do not breathe
fumes and gases. Shielding 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, stainless steel, copper,
zinc, lead, beryllium, or cadmium unless positive mechani-
cal ventilation is provided. Do not breathe fumes from these
materials.
2. Do not operate near degreasing and spraying operations.
The heat or arc rays can react with chlorinated hydrocarbon
vapors to form phosgene, a highly toxic gas, and other
irritant gases.
3. If you develop momentary eye, nose, or throat irritation
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 discomfort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for
specific ventilation recommendations.
CYLINDER HANDLING -- Cylinders, if mis-
handled, can rupture and violently re-
lease 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 fittings in good condition. Follow manufacturer's
operating instructions for mounting regulator to a com-
pressed gas cylinder.
2. Always secure cylinders in an upright position by chain or
strap to suitable hand trucks, undercarriages, benches,
walls, post, or racks. Never secure cylinders to work tables
or fixtures where they may become part of an electrical
circuit.
3. When not in use, keep cylinder valves closed. Have valve
protection cap in place if regulator is not connected. Secure
and move cylinders by using suitable hand trucks. Avoid
rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames. 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 Asso-
ciation, 1235 Jefferson Davis Highway, Arlington, VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or im-
properly maintained equipment can cause
injury or death. Therefore:
1. 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.

SECTION 1 DESCRIPTION
5
1.1 INTRODUCTION
The SVI 450i cvcc is a high performance constant voltage
(cv)/constant current (cc) 450-ampere industrial inverter
power source that is designed with adjustable output
(voltage or current), slope, and inductance. Exclusive
power MOSFET inverter technology combined with solid
state electronics provides state-of-the-art, multi-process
welding performance including MIG (short arc, spray arc,
cored wire), Stick, TIG, and air carbon arc gouging. The
SVI 450i cvcc offers all this versatility and performance in
one compact power source.
The power source is designed to operate in the cv mode
for outstanding MIG short arc performance as well as MIG
spray-arc and cored wire welding. It is compatible with
ESAB's full line of digital and conventional wire feeders for
unmatched accuracy and performance.
The constant current mode for Stick, TIG (scratch-start),
and air carbon arc gouging applications is provided by
connecting one of the remote control devices and select-
ing the cc process mode.
The power source's electronic output (voltage or current)
adjustment provides full-range regulation either locally
from the front panel or from a remote control. A conve-
nient panel-mounted digital meter provides selectable
output voltage or current readings for welding accuracy.
The panel-mounted 3-step slope selector and variable
inductance control allows the operator to select the opti-
mum cv slope/curve characteristic and/or inductance
condition required for your MIG welding application. Refer
to table 1-1 for specifications.
1.2 OPTIONAL ACCESSORIES
A. To avoid duplication of MIG accessories which
may or may not be required for the various MIG
systems, please refer to the individual wire feeder
or control instruction booklets provided for your
system.
B. For applicable Stick/TIG accessories, refer to
figure 2-3 and/or the following:
1. TC-2B Torch Controls (30 ft lg), P/N 33839
2. FC-5B Foot Control (30 ft lg), P/N 33646
3. FC-5B EHD (Extra Heavy Duty) Foot Control
(30 ft lg), P/N 33841
4. HC-3B Hand Control (30 ft lg), P/N 33838
5. HC-4B Hand Control w/Arc Force (30 ft lg),
P/N 33840
6. Ultra-Pulse 450i Mig Pulse Pendant Control,
P/N 34946. Easy to use synergic pulse control
automatically provides precise parameters
for pulsed MIG welding. Must be used with
Mig 4HD wire feeder. (Control cable (8 ft
lg) included.)
7. Cart, P/N 31700. Provides complete mobility
for power source, wire feeder, gas cylinder(s)/
water cooler (vertical).
Table 1-1. SVI 450i cvcc Specifications
Input Voltage 208 V ac, 1 or 3 phase, 60 Hz 230 V ac, 1 or 3 phase, 60 Hz 460 V ac, 3 phase, 60 Hz
Input Current @ Rated Load 80 A 65 A 40 A
Open Circuit Voltage 72 V dc
Rated Output @ 60% Duty Cycle 450 A @ 38 V dc, 3 phase
275 A @ 31 V dc, 1 phase
450 A @ 38 V dc, 3 phase
275 A @ 31 V dc, 1 phase
450 A @ 38 V dc, 3 phase
275 A @ 31 V dc, 1 phase
Dimensions
width
length
height
15.25" (385 mm)
24.25" (616 mm)
15.75" (400 mm) + 2" (51 mm) for handle
Shipping Weight
Net Weight
172 lbs (78 kg)
161 lbs (74 kg)

6
SECTION 2 INSTALLATION
2.1 GENERAL
Proper installation will contribute to safe, satisfactory, and
trouble-free operation of the welding setup. It is sug-
gested that each step in this section be studied carefully
and followed as closely as possible.
2.2 UNPACKING AND PLACEMENT
A. Immediately upon receipt of the equipment, in-
spect for damage which may have occurred in
transit. Notify the carrier of any defects or dam-
age at once.
B. After removing the components from the ship-
ping container(s), check the container(s) for any
loose parts. Remove all packing materials.
C. Check air passages of power source for any
packing materials that may obstruct air flow
through the power source.
D. If the equipment is not to be installed immedi-
ately, store it in a clean, dry, well-ventilated area.
E. The location of the power source should be
carefully selected to ensure satisfactory and de-
pendable service. Choose a location relatively
close to a properly fused supply of electrical
power.
F. The power source components are maintained
at proper operating temperatures by forced air
drawn through the cabinet by the fan unit on the
rear panel. For this reason, it is important to
locate the power source in an open area where
air can circulate freely at the front and rear
openings. If space is at a premium, leave at least
1 foot of clearance between the rear of the power
source and wall or other obstruction. The area
around the power source should be relatively
free of dust, fumes, and excessive heat. It is also
desirable to locate the power source so the cover
can be removed easily for cleaning and mainte-
nance.
2.3 INPUT POWER CONNECTIONS
The SVI 450i power source must be connected to a
"clean-unloaded" supply power line. An unloaded line is
essential for good performance and lessens the chance
of nuisance (fault) tripping or damage due to transients
caused by other equipment loads such as resistance
welders, punch presses, large electric motors, etc.
If nuisance tripping caused by transients becomes a
problem, ESAB has a "primary line conditioner" (P/
N 15983) which may be added to filter out transient
voltages . Contact your distributor for details. Please note
that the conditioner will not correct for sustained line
voltages which exceed the limits of its rated voltage
inputs.
The power source is designed to provide line voltage
compensation within 10 percent of the rated 208/230/
460-volt input to maintain its rated output and protect its
power electronics. If these limits are exceeded, serious
damage to the power source could occur. Therefore,
prior to installation, it is suggested that the proposed line
circuit be checked with a meter at two or three different
time periods of the day to make sure the power load does
not exceed the power source's input limits. If input power
cannot be maintained within the 10 percent limits, consult
your local power company or call ESAB for possible
solutions.
Electric shock can kill! Precautionary measures
should be taken to provide maximum protection
against electrical shock. Be sure that all power is off
by opening the line (wall) disconnect switch when
primary electrical connections are made to the power
source. To be doubly safe, check your input leads
with a voltmeter to make sure all power is off.
A. A line (wall) disconnect switch, with fuses or
circuit breakers, should be provided at the main
power panel (see Figure 2-1). The customer may
either use the factory-supplied input power cable
(No. 6 AWG, 4/c, type SO (90 °C), 12-ft lg) or
provide his own input power leads. The primary
power leads should be insulated copper conduc-
tors and include two (1 phase) or three (3 phase)
power leads and one ground wire. The wires may
be heavy rubber-covered cable or run in a solid or
flexible conduit. Refer to table 2-1 for recom-
mended input conductors and line fuse sizes.

SECTION 2 INSTALLATION
7
Table 2-1. Recommended Sizes for Input
Conductors and Line Fuses
switch through the strain relief hole in the rear
panel. Connect the primary leads to the Line
Switch (LS) for either single- or 3-phase input
and the ground lead (green) to the stud on the
base of the unit as shown in figure 2-1. After
making sure the connections are secured, tighten
the strain relief coupling to secure the input
cable.
It is of the utmost importance that the chassis be
connected to an approved electrical ground to pre-
vent accidental shock. Take care not to connect the
ground wire to any of the primary leads.
D. Recheck all connections to make sure they are
tight, well insulated, and properly connected.
208
208
208208
DOUBLE LINKS
230460230
230460230
Figure 2-2. Input Voltage Terminal Board
(TB) Connections
Rated Load
Volts Amps
Input &
Gnd.
Conductor*
CU/AWG
Time-Delay
Fuse Size
Amps
208
230
460
80
65
40
6
6
8
90
80
60
* Sizes per National Electric Code for 90 °C rated copper conductors
@ 30 °C ambient. Not more than three conductors in raceway or
cable. Local codes should be followed if they specify sizes other
than those listed above.
B. As shipped, the power source is set up for 460-
volt input power. If using 208- or 230-volt input,
two links on the input terminal board (located
inside the power source) must be repositioned as
marked on the plate (see Figure 2-2). The input
terminal board connections will be visible after
removing the top cover.
C. The factory-supplied input power cable is con-
nected to the power source ON-OFF switch.
However, if customers wish to connect their own
input power leads, proceed as follows: With the
top cover and left side panel removed, thread the
input conductor cable from the wall disconnect
26
4
-
+
1ø Hookup
3ø Hookup
For interconnecting control cable(s) part number(s) and
hookup,refertoappropriatesysteminstructionbookletsand
paragraph2.5.
Customer'sFusedLineDisconnectSwitch
Makesureallinputpowerisdisconnected
beforeperforminganyoperationinsidethepowersource.
No. 6 AWG, 4/c, type SO, 12-ft lg
i
nputpowercablefactoryinstalledto
l
ine switch (LS) or customer may
i
nstallown4-conductor(3phase)or
3-conductor (1 phase) cable and
g
round(seeparagraph2.3)andcon-
n
ect to Line Switch as shown.
19-pinMIG
ReceptacleJ1
Ground
Stud
Line Switch (LS) Rear View
Approved
EarthGround To Wire Feeder/
PlumbingBox/Torch.
See appropriate in-
structionbooklet.
MALECONNECTOR
(suppliedw/powersource)
WELDING CABLES (customer
supplied, see Table 2-1) are set
up for DCRP (negative to work)
operation.Seeparagraph2.4.
To Work
NEGATIVE (-)
OUTPUT
POSITIVE (+)
OUTPUT
Figure 2-1. Input Power and MIG Interconnection Diagram

8
SECTION 2 INSTALLATION
2.4 OUTPUT WELDING CONNECTIONS
Before making any connections to the power source
output terminals, make sure that all primary input
power to the power source is deenergized (off) at the
customer's disconnect switch.
A. MIG Setup (see Figure 2-1). This power source
is designed to provide MIG welding operating
characteristics only when the J2 control recep-
tacle is "vacant" (meaning no accessories are
plugged in) or, if the remote HC-3B or HC-4B
hand control is plugged in. The process switch
must be set in the CV-MIG position for conven-
tional wire feeders or in the DIGITAL-MIG (cen-
ter) position for Digimig/Digimatic controls. Ad-
ditionally, proper operation of the power source
depends on the use of copper output cables that
are insulated, of adequate size, in good condi-
tion, and properly connected to the machine
using the jack plug connectors provided with the
power source. It is recommended that only 4/0
welding output cable be used, regardless of
length and current, and that these cables be kept
as short as possible. (Total length including work
and electrode leads should not exceed 100 feet.
Beyond this distance, there will be performance
deterioration. Consult with the factory if you have
an application of this nature.)
Pay particular attention to high resistance in the
welding circuit; specifically, the work cable/circuit
and water-cooled torch cable. It is recommended
that the power source/wire feeder and workpiece
be placed as close together as possible to limit
resistance in the welding circuit. High resistance
in the welding circuit can cause performance
deterioration (loss of "heat" input, popping of
weld puddle, bushy arcs, etc.). Ensure the work
cable is large enough, kept as short as possible,
properly insulated, securely connected to the
workpiece, and that all connections are clean
and tightly secured. If a separate work circuit is
used (such as in mechanical fixturing, shipbuild-
ing, robot fixturing, etc.), make sure the work
circuit is secure and presents a low resistance
path to the flow of welding current. Also, the
power cable on a water-cooled torch is normally
subject to gradual deterioration and increased
resistance due to corrosion. This leads to poor
performance as described above.
To ensure good torch performance, periodically
replace the water-cooled power cable.
The welding output receptacles are located on
the front panel; one negative (-) and one positive
(+) receptacle. Two male plug connectors (P/N
950693) are supplied with the power source for
attachment to customer supplied 4/0 welding
cables (see Table 2-1 and Figure 2-1). This
power source is designed for conventional and
digital MIG applications using Direct Current
Reverse Polarity (DCRP) setup. In a DCRP
setup, the torch or electrode is positive (+), and
the workpiece is negative (-).
B.Stick/Scratch-Start TIG/ Arc Gouging Setup
(see Figure 2-3). These processes require
constant current (cc) type curve characteristics
for proper operation. These characteristics are
only provided when one of the remote accesso-
ries (FC-5B, TC-2B) is plugged into the J2 recep-
tacle or when the remote HC-3B or HC-4B hand
control is connected to J2 and its process switch
is set in the CC-TIG/Stick position. Select the
desired welding mode, accessories, and polarity
as shown in figure 2-3. The output cables may be
connected for DCRP or DCSP; meaning that for
a DCRP setup, the electrode holder/torch is POS
(+) and the work is NEG (-); whereas for a
DCSP setup, the electrode holder/torch is NEG (-
) and the work is POS (+).
Regardless of your secondary welding cable setup
(DCRP or DCSP), in order to prevent electrical shock,
it is necessary that you connect the workpiece to an
approved electrical (earth) ground. The work cable
lead is not a ground lead. It is used to complete the
welding circuit between the power source and the
workpiece. This connection (at the workpiece) must
be made to a clean, exposed metal surface that is free
of paint, rust, mill scale, etc. A separate connection
is required to ground the workpiece to an approved
earth ground. The work cable should be the same
rating as the torch/electrode cable lead.
Proper operation of the power source depends to a great
extent on the use of copper output cables that are
insulated, adequately sized, in good condition and prop-
erly connected to the machine using the jack plug connec-
tors provided. It is recommended that the output cables
be kept as short as possible, placed close together, and
be of adequate current carrying capacity. The resistance

SECTION 2 INSTALLATION
9
+
-
J2
J1
NOTE:Forccoperation,eitheroftheseremoteacces-
sories(FC-5BorTC-2B)mustbepluggedin.However,
for MIG operations, these particular controls must be
unpluggedinordertoprovideconstantvoltage.
FC-5BFootControl
TC-2BTorchControl
HC-3B or HC-4B Hand Control
TIGTorch Adaptor (Insulatefrom ground bytaping.)
GasSupply/Hose
TIG Torch w/Gas Valve
STICK
WORK DCSP (+)
WORK DCRP (-)
STICK
(2)MaleConnectorfor#2thru#40AWG
(suppliedw/powersource).
POWERCABLE/CONNECTION
NOTE: To provide cc operation with the HC-3B or HC-4B plugged in,
simplyplaceitsprocessswitchintheCC-TIG/STICKposition.Constant
voltageisprovidedintheCV-MIGpositionfor"non-digital"conventional
MIG operations and in the DIGITAL-MIG (center position) for "digital-
microprocessor"MIGoperations.
Connect Work to Approved Earth Ground
of the output cables and connections cause a voltage
drop which is added to the voltage of the arc. Excessive
cable resistance can reduce the maximum current output
of the power source. Refer to table 2-2 to select the
recommended output cable size.
Welding Total Length (Feet) of Cable in Weld Circuit*
Current 50 100 150 200 250
100
150
200
250
300
400
500
6**
4**
3**
2
1
2/0
3/0
4**
3**
1
1/0
2/0
3/0
3/0
3**
1
1/0
2/0
3/0
4/0
4/0
2
1/0
2/0
3/0
4/0
4/0
--
1
2/0
3/0
4/0
4/0
--
--
* Total cable length includes work and electrode cables. Cable size
is based on direct current, insulated copper conductors, 100% duty
cycle, and a voltage drop of 4 or less volts. The welding cable
insulation must have a voltage rating that is high enough to
withstand the open circuit voltage of the machine.
** Cam-Lock jack plug connectors will not accept smaller than No. 2
gauge cable. Also, remember that for MIG-Pulse conditions we
recommend only 4/0 cable be used due to pulse-peak currents.
2.5 MIG CONTROL (J1)
INTERCONNECTION
IMPORTANT
In order to provide MIG welding (cv) operating char-
acteristics, make sure that the J2 Remote Control
receptacle is either "vacant" (meaning no remote
accessories are plugged-in) or, if the HC-3B or HC-
4B hand control is plugged in, its process switch
must be set in the CV-MIG position for conventional
non-digital wire feeders or in the DIGITAL-MIG (cen-
ter) position for digital-microprocessor type feeder/
controls.
Please note that all control cable functions for MIG
operations must be connected through control receptacle
J1 (19-pin amphenol) on the rear panel (see Figure 2-1).
Additionally, if remote voltage control for "non-digital"
conventional feeder/controls (only) is desired, you can
also plug in the HC-3B or HC-4B hand control accessory
to Remote Control receptacle J2 to provide this function
(see paragraph 2.6).
To make the control interconnections for various MIG
equipment controls, select from the appropriate cable
assemblies listed on table 2-3.
Figure 2-3. Stick/Scratch-Start TIG/Carbon Arc Gouging Interconnection Diagram
Table 2-2. Recommended Welding Cable Sizes

10
SECTION 2 INSTALLATION
Table 2-3. Control Interconnection Cables
Cable Lengths
Wire Feeders
Mig 35 Mig 2E and Mig 4HD
Digimig, Digimig Dual,
and Digimatic II
6-ft (1.8 m) P/N 31829 -- P/N 30686
30-ft (9.1 m) P/N 31830 P/N 34378 P/N 30780
60-ft (18.3 m) P/N 31831 P/N 34377 P/N 30781
2.6 ADDITIONAL REMOTE CONTROL (J2)
INTERCONNECTION
A. For non-digital conventional MIG operations. This
8-pin remote control receptacle (J2) can be used
to provide full-range remote voltage regulation
from the HC-3B or HC-4B hand control. Note that
the power source’s Panel/Remote switch must
be set to REMOTE to provide this feature. When
connected, the HC-3B's or HC-4B’s process
switch must be set to its CV-MIG position to
provide constant voltage (cv) operation and volt-
age regulation from its potentiometer. Also re-
member that the contactor switch is nonfunc-
tional for this process — contactor control is
provided by the torch switch through receptacle
J1.
B. For Stick, TIG, or Arc Gouging operations (see
Figure 2-3). These processes require constant
current (cc) characteristics for proper operation,
and this is only provided when one of the remote
control accessories (FC-5B or TC-2B) is con-
nected to receptacle J2, or when the HC-3B or
HC-4B hand control is connected to J2 and its
process switch is set in the CC-TIG/STICK posi-
tion. Note that the power source’s Panel/Remote
switch must be set to REMOTE to provide cur-
rent regulation and/or contactor control at the
welding location. When the FC-5B foot or TC-2B
torch accessory is connected, full-range current
regulation and contactor control are available
from the remote accessory.
When the HC-3B hand control is connected, the
process switch must placed in the CC-TIG/STICK
position to set up the power source for constant
current operation. Remote current regulation is
provided from the CURRENT potentiometer. The
CONTACTOR control switch must be placed in
the ON position to provide welding power to the
torch/electrode.
If the HC-4B hand control is connected, you must
place its Process switch in the CC position to set
up the power source for constant current opera-
tion. Remote current regulation (up to full range)
is provided from the CURRENT control potenti-
ometer. The CONTACTOR control switch must
be placed in the ON position to provide welding
output current to the torch/electrode. The HC-4B
also incorporates two additional control features;
a TIG/Stick selector and an Arc Force potentiom-
eter that functionally operates in the STICK mode.
The TIG and Stick modes provide the same cc
type volt-ampere curve characteristic; however,
the slope of the STICK curves can be further
adjusted by regulating the Arc Force control pot.
The lower Arc Force settings provide less short
circuit current and a softer, more stable arc;
whereas the high settings provide more short
circuit current and a forceful, more penetrating
arc.