ESAB MultiPower 460 Pulse User manual

F-15-721-A 05/2003
Multipower 460PULSE
DC WELDING POWER SOURCES
INSTRUCTION MANUAL
ESAB ITEM NO. 0558002877, Multipower 460PULSE - 230/460/575 vac, 3 ph., 60 Hz

2
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles
ofoperationandsafepracticesforarcweldingandcuttingequipment,weurgeyoutoreadourbooklet,
"PrecautionsandSafePracticesforArcWelding,Cutting,andGouging,"Form52-529. DoNOTpermit
untrainedpersonstoinstall,operate,ormaintain thisequipment. DoNOTattempttoinstalloroperate
this equipment until you have read and fully understand these instructions. If you do not fully
understandtheseinstructions,contactyoursupplierforfurtherinformation. BesuretoreadtheSafety
Precautions before installing or operating this equipment.
BESURE THIS INFORMATION REACHESTHE OPERATOR.
YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.
USER RESPONSIBILITY
Thisequipmentwillperforminconformitywiththedescriptionthereofcontainedinthismanualand
accompanyinglabelsand/orinsertswheninstalled,operated,maintainedandrepairedinaccor-
dancewiththeinstructionsprovided. Thisequipmentmustbecheckedperiodically. Malfunction-
ingorpoorlymaintainedequipmentshouldnotbeused. Partsthatarebroken,missing,worn,
distortedorcontaminatedshouldbereplacedimmediately. Shouldsuchrepairorreplacement
becomenecessary,themanufacturerrecommendsthatatelephoneorwrittenrequestforservice
advicebemadetothe AuthorizedDistributorfromwhom itwaspurchased.
Thisequipmentoranyofitspartsshouldnotbealteredwithoutthepriorwrittenapprovalofthe
manufacturer. Theuserofthisequipmentshallhavethesoleresponsibilityforanymalfunction
whichresultsfromimproperuse,faultymaintenance,damage,improperrepairoralterationby
anyoneotherthanthemanufactureroraservicefacilitydesignatedbythemanufacturer.

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TABLE OF CONTENTS
SECTION TITLE PAGE
SECTION 1 SAFETY .............................................................................................................................................. 5
SECTION 2 DESCRIPTION ....................................................................................................................................11
2.0 General ...............................................................................................................................................13
2.1 Description .........................................................................................................................................13
SECTION 3 INSTALLATION .................................................................................................................................19
SECTION 4 OPERATION .......................................................................................................................................23
SECTION 5 MAINTENANCE.................................................................................................................................. 39
5.0 Cleaning .............................................................................................................................................. 39
SECTION6 TROUBLESHOOTING ........................................................................................................................ 41
6.0 Troubleshooting.................................................................................................................................. 41
Schematic Diagrams ..........................................................................................................................42
SECTION 7 REPLACEMENTPARTS.................................................................................................................... 47

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TABLE OF CONTENTS

5
WARNING: These Safety Precautions are for
your protection. They summarize precaution-
ary information from the references listed in
Additional Safety Information section. 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.FailuretoobserveSafetyPrecautionscanresult
in injury or death.
PROTECT YOURSELF AND OTHERS--
Somewelding,cutting,andgougingpro-
cesses are noisy and require ear pro-
tection. The arc, like the sun, emits ul-
traviolet (UV) and other radiation and
can injure skin and eyes. Hot metal can cause burns.
Training in the proper use of the processes and equip-
ment is essential to prevent accidents. Therefore:
1. Alwayswearsafetyglasses withsideshieldsinanywork
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. Wearflameproofgauntlettypegloves,heavylong-sleeve
shirt, cuffless trousers, high-topped shoes, and a weld-
ing helmet or cap for hair protection, to protect against
arcrays and hot sparks or hotmetal.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 nonflammable partition or curtains.
6. Use goggles over safety glasses when chipping slag or
grinding. Chipped slag may be hot and can fly far.
Bystandersshouldalsoweargogglesoversafetyglasses.
FIRES AND EXPLOSIONS -- Heat from
flamesandarcs canstartfires.Hotslag
or sparks can also cause fires and ex-
plosions.Therefore:
1. Remove all combustible materials well away from the
work area or cover the materials with a protective non-
flammablecovering.Combustiblematerialsincludewood,
cloth,sawdust, liquid and gas fuels, solvents,paintsand
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 substances on the workpiece which might pro-
duce flammable or toxic vapors. Do not do hot work on
closed containers. They may explode.
4. Havefire extinguishingequipmenthandyfor instantuse,
such as a garden hose, water pail, sand bucket, or
portable fire extinguisher. Be sure you are trained in its
use. 10/98
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 neces-
sary.
7. For additional information, refer to NFPA Standard 51B,
"Fire Prevention in Use of Cutting and Welding Pro-
cesses",availablefromtheNationalFireProtectionAsso-
ciation, Batterymarch Park, Quincy, MA 02269.
ELECTRICALSHOCK--Contactwithlive
electrical parts and ground can cause
severe injury or death. DO NOT use AC
welding current in damp areas, if move-
ment is confined, or if there is danger of
falling.
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 you or others to a fatal
shock.
4. Use well-maintained equipment. Replace worn or dam-
aged cables.
5. Keepeverythingdry,includingclothing,workarea,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. Putondry,hole-free gloves before turningonthepower.
9. Turn off the power before removing your gloves.
10. Referto ANSI/ASCStandardZ49.1(listedonnextpage)
forspecificgroundingrecommendations.Donotmistake
the work lead for a ground cable.
ELECTRIC AND MAGNETIC FIELDS —
Maybedangerous.Electriccurrentflow-
ing through any conductor causes lo-
calized Electric and Magnetic Fields
(EMF). Welding and cutting current cre-
ates EMF around welding cables and
welding machines. Therefore:
1. Welders having pacemakers should consult their physi-
cian before welding. EMF may interfere with some pace-
makers.
2. ExposuretoEMFmayhaveother 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.
SECTION 1 SAFETY PRECAUTIONS

6
FUMES AND GASES -- Fumes and
gases,cancausediscomfortorharm,
particularly in confined spaces. Do
notbreathefumesandgases.Shield-
ing gases can cause asphyxiation.
Therefore:
1. Always provide adequate ventilation in the work area by
naturalormechanical means.Donotweld, cut,orgouge
on materials such as galvanized steel, stainless steel,
copper,zinc,lead,beryllium,orcadmiumunlesspositive
mechanicalventilationisprovided.Donotbreathefumes
from these materials.
2. 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.
3. If you develop momentary eye, nose, or throat irritation
whileoperating,thisisanindicationthatventilationisnot
adequate. Stop work and take necessary steps to im-
prove 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.
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.)
CYLINDERHANDLING--Cylinders,ifmis-
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'soperatinginstructionsformountingregu-
lator to a compressed gas cylinder.
2. Always secure cylinders in an upright position by chain
orstraptosuitablehandtrucks,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 con-
nected. 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,
"Precautionsfor SafeHandlingof CompressedGasesin
Cylinders", which is available from Compressed Gas
Association, 1235 Jefferson Davis Highway, Arlington,
VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
1. Always have qualified personnel perform the installa-
tion, troubleshooting, and maintenance work. Do not
perform any electrical work unless you are qualified to
perform such work.
2. Beforeperforminganymaintenanceworkinsideapower
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, Mi-
ami, 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. AWSC5.5-"RecommendedPracticesforGasTungsten
Arc Welding“
6. AWSC5.6-"RecommendedPracticesforGasMetalArc
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 through-
out this manual: Means Attention! Be Alert!
Your safety is involved.
Means immediate hazards which, if
not avoided, will result in immediate,
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.
SP98-10
SECTION 1 SAFETY PRECAUTIONS

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ADVERTENCIA: Estas Precauciones de
Seguridad son para su protección. Ellas hacen
resumen de información proveniente de las
referencias listadas en la sección "Información
Adicional Sobre La Seguridad". Antes de hacer
cualquier instalación o procedimiento de operación , asegúrese
de leer y seguir las precauciones de seguridad listadas a
continuación así como también todo manual, hoja de datos de
seguridad del material, calcomanias, etc. El no observar las
Precauciones de Seguridad puede resultar en daño a la persona
o muerte.
PROTEJASE USTED Y A LOS DEMAS--
Algunos procesos de soldadura, corte y
ranuradoson ruidososyrequirenprotección
para los oídos. El arco, como el sol , emite
rayos ultravioleta (UV) y otras radiaciones
quepueden dañarlapiely losojos. 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 protección a los lados siempre
queestéenel áreadetrabajo,aúncuandoestéusandocareta
de soldar, protector para su cara u otro tipo de protección.
2. Use una careta que tenga el filtro correcto y lente para
proteger sus ojos, cara, cuello, y oídos de las chispas y rayos
del arco cuando se esté operando y observando las
operaciones.Alerteatodaslaspersonascercanasdenomirar
elarcoyno exponersealos rayosdelarcoeléctricooel metal
fundido.
3. Use guantes de cuero a prueba de fuego, camisa pesada de
mangas largas, pantalón 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
metalfundido.Enocacionesundelantal apruebadefuego es
necesario para protegerse del calor radiado y las chispas.
4. Chispas y partículas de metal caliente puede alojarse en las
mangas enrolladas de la camisa , el ruedo del pantalón o los
bolsillos. Mangas y cuellos deberán mantenerse abotonados,
bolsillos al frente de la camisa deberán ser cerrados o
eliminados.
5. Proteja a otras personas de los rayos del arco y chispas
calientesconunacortina adecuadano-flamablecomodivisión.
6. Use careta protectora además de sus gafas de seguridad
cuandoestéremoviendoescoriaopuliendo.Laescoriapuede
estar caliente y desprenderse con velocidad. Personas
cercanas deberánusargafasdeseguridadycaretaprotectora.
FUEGO Y EXPLOSIONES -- El calor de las
flamas 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 área de trabajo
o cubra los materiales con una cobija a prueba de fuego.
Materiales combustibles incluyen madera, ropa, líquidos y
gases flamables, solventes, pinturas, papel, etc.
2. Chispas y partículas de metal pueden introducirse en las
grietas y agujeros de pisos y paredes causando fuegos
escondidos en otros niveles o espacios. Asegúrese de que
toda grieta y agujero esté cubierto para proteger lugares
adyacentes contra fuegos.
3. No corte, suelde o haga cualquier otro trabajo relacionado
hasta que la pieza de trabajo esté totalmente limpia y libre de
substanciasquepuedanproducirgasesinflamablesovapores
tóxicos. No trabaje dentro o fuera de contenedores o tanques
cerrados. Estos pueden explotar si contienen vapores
inflamables.
4. Tenga siempre a la mano equipo extintor de fuego para uso
instantáneo, como por ejemplo una manguera con agua, cubeta con
agua,cubetaconarena,oextintorportátil.Asegúrese queusted esta
entrenado para su uso.
5. Nouseelequipofueradesurangodeoperación.Porejemplo,elcalor
causado por cable sobrecarga en los cables de soldar pueden
ocasionar un fuego.
6. Después de termirar la operación del equipo, inspeccione el área de
trabajoparacerciorarsedequelaschispaso metalcalienteocasionen
un fuego más tarde. Tenga personal asignado para vigilar si es
necesario.
7. Para información adicional , haga referencia a la publicación NFPA
Standard 51B, "Fire Prevention in Use of Cutting and Welding
Processes", disponible a través de la National Fire Protection Asso-
ciation, Batterymarch Park, Quincy, MA 02269.
CHOQUE ELECTRICO -- El contacto con las
partes eléctricas energizadas y tierra puede
causar daño severo o muerte. NO use soldadura
de corriente alterna (AC) en áreas húmedas, de
movimiento confinado en lugares estrechos o si
hay posibilidad de caer al suelo.
1. Asegúrese de que el chasis de la fuente de poder esté conectado
a tierra através del sistema de electricidad primario.
2. Conecte la pieza de trabajo a un buen sistema de tierra física.
3. Conecte el cable de retorno a la pieza de trabajo. Cables y
conductoresexpuestosoconmalas conexiones puedenexponeral
operador u otras personas a un choque eléctrico fatal.
4. Useelequiposolamentesiestáenbuenascondiciones.Reemplaze
cables rotos, dañados o con conductores expuestos.
5. Mantenga todo seco, incluyendo su ropa, el área de trabajo, los
cables, antorchas, pinza del electrodo, y la fuente de poder.
6. Asegúrese que todas las partes de su cuerpo están insuladas de
ambos, la pieza de trabajo y tierra.
7. No se pare directamente sobre metal o tierra mientras trabaja en
lugares estrechos o áreas húmedas; trabaje sobre un pedazo de
maderasecoouna plataformainsuladayusezapatosconsuelade
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 publicación ANSI/ASC Standard Z49.1
(listado en la próxima página) para recomendaciones específicas
decomo conectarel equipoa tierra. Noconfunda elcable desoldar
a la pieza de trabajo con el cable a tierra.
CAMPOS ELECTRICOS Y MAGNETICOS -Son
peligrosos. La corriente eléctrica fluye através
de cualquier conductor causando a nivel local
Campos Eléctricos y Magnéticos (EMF). Las
corrienteseneláreadecorteysoldadura, crean
EMF alrrededor de los cables de soldar y las
maquinas. Por lo tanto:
1. Soldadores u Operadores que use marca-pasos para el corazón
deberán consultar a su médico antes de soldar. El Campo
Electromagnético (EMF) puede interferir con algunos marca-pasos.
2. Exponerse a campos electromagnéticos (EMF) puede causar otros
efectos de salud aún desconocidos.
3. Los soldadores deberán usar los siguientes procedimientos para
minimizar exponerse al EMF:
A. Mantengaelelectrodoyelcablealapiezadetrabajojuntos,hasta
llegar a la pieza que usted quiere soldar. Asegúrelos 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 entrela antorchay elcable, ala piezade
trabajo. Mantega los cables a un sólo lado de su cuerpo.
D. Conecte el cable de trabajo a la pieza de trabajo lo más cercano
posible al área de la soldadura.
E. Mantenga la fuente de poder y los cables de soldar lo más lejos
posible de su cuerpo.
SECTION 1 PRECAUCION DE SEGURIDAD

8
HUMO Y GASES -- El humo y los gases,
pueden causar malestar o daño,
particularmente en espacios sin ventilación.
Noinhaleelhumo ogases.Elgasdeprotección
puede causar falta de oxígeno. Por lo tanto:
1. Siempre provea ventilaciónadecuada
en el área de trabajo por medio natural o mecánico. No solde,
corte, o ranure materiales con hierro galvanizado, acero
inoxidable, cobre, zinc, plomo, berílio, o cadmio a menos que
provea ventilación mecánica positiva . No respire los gases
producidos por estos materiales.
2. No operecercadelugaresdondeseapliquesubstanciasquímicas
en aerosol. El calor de los rayos del arco pueden reaccionar con
losvapores dehidrocarburo clorinado paraformarun fosfógeno,
o gas tóxico, y otros irritant es.
3. Si momentáneamente desarrolla inrritación de ojos, nariz o
garganta mientras est á operando, es indicación de que la
ventilación no es apropiada. Pare de trabajar y tome las
medidas necesarias para mejorar la ventilación en el área de
trabajo. No continúe operando si el malestar físico persiste.
4. Hagareferenciaalapublicación ANSI/ASC Standard Z49.1 (Vea
la lista a continuación) para recomendaciones específicas en la
ventilación.
5. ADVERTENCIA-- Este producto cuando se utiliza para
soldaduras o cortes, produce humos o
gases, los cuales contienen químicos
conocidosporel EstadodeCalifornia de
causar defectos en el nacimiento, o en
algunos casos,Cancer.(CaliforniaHealth
& Safety Code §25249.5 et seq.)
MANEJO DE CILINDROS-- Los
cilindros, si no son manejados
correctamente, pueden romperse y
liberar violentamente gases. Rotura
repentina del cilindro, válvula, o válvula
de escape puede causar daño o muerte.
Por lo tanto:
1. Utilize el gas apropiado para el proceso y utilize un regulador
diseñado para operar y reducir la presión del cilindro de gas
. No utilice adaptadores. Mantenga las mangueras y las
conexiones en buenas condiciones. Observe las instrucciones
de operación del manufacturero para montar el regulador en el
cilindro de gas comprimido.
2. Asegure siempre los cilindros en posición vertical y amárrelos
con una correa o cadena adecuada para asegurar el cilindro al
carro, transportes,tablilleros,paredes,postes, o armazón.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
elélectrico.
3. Cuandoelcilindronoestáenuso,mantenga la válvuladelcilindro
cerrada. Ponga el capote de protección sobre la válvula si el
regulador no está conectado. Asegure y mueva los cilindros
utilizando uncarro o transporteadecuado. Evite elmanejo brusco
de los cilindros.
4. Localize los cilindros lejos del calor, chispas, y flamas. Nunca
establezca un arco en el cilindro.
5. Para información adicional, haga referencia a la publicación CGA
Standard P-1, "Precautions for Safe Handling of Compressed
Gases in Cylinders", disponible através del Compressed Gas
Association, 1235 Jefferson Davis Highway, Arlington, VA 22202.
Significa riesgo inmediato que, de no ser
evadido, puede resultar inmediatamente en
serio daño personal o la muerte.
Significa el riesgo de un peligro potencial
quepuederesultarenseriodañopersonal o
la muerte.
Significaelposibleriesgo quepuederesultar
en menores daños a la persona.
MANTENIMIENTO DEL EQUIPO -- Equipo
defectuoso o mal mantenido puede causar
daño o muerte. Por lo tanto:
1. Siempre tenga personal cualificado para efectuar l a
instalación, diagnóstico, y mantenimiento del equipo. No
ejecute ningún trabajo eléctrico a menos que usted esté
cualificado para hacer el trabajo.
2. Antes de dar mantenimiento en el interior de la fuente de
poder, desconecte la fuente de poder del suministro de
electricidad primaria.
3. Mantenga los cables, cable a tierra, conexciones, cable
primario, y cualquier otra fuente de poder en buen estado
operacional. No opere ningún equipo en malas condiciones.
4. No abuse del equipo y sus accesorios. Mantenga el equipo
lejos de cosas que generen calor como hornos, también
lugares húmedos como charcos de agua , aceite o grasa,
atmósferas corrosivas y las inclemencias del tiempo.
5. Mantenga todos los artículos de seguridad y coverturas del
equipo en su posición y en buenas condiciones.
6. Use el equipo sólo para el propósito que fue diseñado. No
modifique el equipo en ninguna manera.
INFORMACION ADICIONAL DE SEGURIDAD --
Para más información sobre las prácticas de
seguridad de los equipos de arco eléctrico 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 atravésde la American
Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, son
recomendadas para usted:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWSC5.1 - "RecommendedPracticesforPlasma 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 Hazardous Sub-
stances."
SIGNIFICADO DE LOS SIMBOLOS -- Según usted
avanza en la lectura de este folleto: Los Símbolos
Significan ¡Atención! ¡Esté Alerta! Se trata de su
seguridad.
SECTION 1 PRECAUCION DE SEGURIDAD

9
a. Éloigner suffisamment tous les matériaux combus-
tibles du secteur où l’on exécute des soudures ou des
coupes à l’arc, à moins de les recouvrir complètement
d’une bâche non-inflammable. Ce type de matériaux
comprend notamment le bois, les vêtements, la sciure,
l’essence, le kérosène, les peintures, les solvants, le
gaz naturel, l’acétylène, le propane et autres sub-
stances combustibles semblables.
b. Les étincelles ou les projections de métal incandes-
cent peuvent tomber dans des fissures du plancher ou
dans des ouvertures des murs et y déclencher une
ignition lente cachée. Veiller à protéger ces ouvertures
des étincelles et des projections de métal.
c. N’exécutez pas de soudures, de coupes, d’opérations
de gougeage ou autres travaux à chaud à la surface
de barils, bidons, réservoirs ou autres contenants
usagés, avant de les avoir nettoyés de toute trace de
substance susceptible de produire des vapeurs
inflammables ou toxiques.
d. En vue d’assurer la prévention des incendies, il
convient de disposer d’un matériel d’extinction prêt à
servir immédiatement, tel qu’un tuyau d’arrosage, un
seau à eau, un seau de sable ou un extincteur portatif.
e. Une fois le travail à l’arc terminé, inspectez le secteur
de façon à vous assurer qu’aucune étincelle ou projec-
tion de métal incandescent ne risque de provoquer
ultérieurement un feu.
3. CHOC ÉLECTRIQUE-- Le gougeage à l’arc et à l’arc
au plasma exige l’emploi de tensions à vide
relativement importantes; or, celles-ci risquent de
causer des dommages corporels graves et même
mortels en cas d’utilisation inadéquate. La gravité du
choc électrique reçu dépend du chemin suivi par le
courant à travers le corps humain et de son intensité.
a. Ne laissez jamais de surfaces métalliques sous ten-
sion venir au contact direct de la peau ou de
vêtements humides. Veillez à porter des gants bien
secs.
b. Si vous devez effectuer un travail sur une surface
métallique ou dans un secteur humide, veillez à assu-
rer votre isolation corporelle en portant des gants secs
et des chaussures à semelles de caoutchouc et en
vous tenant sur une planche ou une plate-forme
sèche.
c. Mettez toujours à la terre le poste de soudage/coupage
en le reliant par un câble à une bonne prise de terre.
d. N’utilisez jamais de câbles usés ou endommagés. Ne
surchargez jamais le câble. Utilisez toujours un
équipement correctement entretenu.
e. Mettez l’équipement hors tension lorsqu’il n’est pas en
service. une mise à la masse accidentelle peut en
effet provoquer une surchauffe de l’équipement et un
danger d’incendie. Ne pas enrouler ou passer le câble
autour d’une partie quelconque du corps.
f. Vérifiez si le câble de masse est bien relié à la pièce en
un point aussi proche que possible de la zone de
travail. Le branchement des câbles de masse à
l’ossature du bâtiment ou en un point éloigné de la
zone de travail augmente en effet le risque de pas-
sage d’un courant de sortie par des chaînes de
AVERTISSEMENT: Ces règles de sécurité ont pour objet d’
assurer votre protection. Veillez à lire et à observer les
précautions énoncées ci-dessous avant de monter l’
équipement ou de commercer à l’utiliser. Tout défaut
d’observation de ces précautions risque d’entraîner des
blessures graves ou mortelles.
1. PROTECTION INDIVIDUELLE-- Les brûlures de la
peau et des yeux dues au rayonnement de l’arc
électrique ou du métal incandescent, lors du soudage
au plasma ou à l’électrode ou lors du gougeage à l’arc,
peuvent s’avérer plus graves que celles résultant d’une
exposition prolongée au soleil. Aussi convient-il
d’observer les précautions suivantes:
a. Portez un écran facial adéquat muni des plaques
protectrices et des verres filtrants appropriés afin de
vous protéger les yeux, le visage, le cou et les oreilles
des étincelles et du rayonnement de l’arc électrique
lorsque vous effectuez des soudures ou des coupes ou
lorsque vous en observez l’exécution.
AVERTISSEZ les personnes se trouvant à proximité de
façon à ce qu’elles ne regardent pas l’arc et à ce
qu’elles ne s’exposent pas à son rayonnement, ni à
celui du métal incandescent.
b. Portez des gants ignifugés à crispins, une tunique
épaisse à manches longues, des pantalons sans
rebord, des chaussures à embout d’acier et un casque
de soudage ou une calotte de protection, afin d’éviter
d’exposer la peau au rayonnement de l’arc électrique
ou du métal incandescent. ll est également souhaitable
d’utiliser un tablier ininflammable de façon à se
protéger des étincelles et du rayonnement thermique.
c. Les étincelles ou les projections de métal incandescent
risquent de se loger dans des manches retroussées,
des bords relevés de pantalons ou dans des poches.
Aussi convient-il de garder boutonnés le col et les
manches et de porter des vêtements sans poches à
l’avant.
d. Protégez des étincelles et du rayonnement de l’arc
électrique les autres personnes travaillant à proximité à
l’aide d’un écran ininflammable adéquat.
e. Ne jamais omettre de porter des lunettes de sécurité
lorsque vous vous trouvez dans un secteur où l’on
effectue des opérations de soudage ou de coupage à
l’arc. Utilisez des lunettes de sécurité à écrans ou
verres latéraux pour piquer ou meûler le laitier. Les
piquetures incandescentes de laitier peuvent être
projetées à des distances considérables. Les
personnes se trouvant à proximité doivent également
porter des lunettes de protection.
f. Le gougeage à l’arc et le soudage à l’arc au plasma
produisent un niveau de bruit extrêmement élevé (de
100 à 114 dB) et exigent par conséquent l’emploi de
dispositifs appropriés de protection auditive.
2. PRÉVENTION DES INCENDES-- Les projections de
laitier incandescent ou d’étincelles peuvent provoquer
de graves incendies au contact de matériaux combus-
tibles solides, liquides ou gazeux.Aussi faut-il observer
les précautions suivantes:
9/97
SECTION 1 PRÉCAUTIONS DE SÉCURITÉ

10
levage, des câbles de grue ou divers chemins
électriques.
g. Empêchez l’apparition de toute humidité, notamment
sur vos vêtements, à la surface de l’emplacement de
travail, des câbles, du porte-électrode et du poste de
soudage/coupage. Réparez immédiatement toute
fuite d’eau.
4. VENTILATION-- La respiration prolongée des fumées
résultant des opérations de soudage/coupage, à
l’intérieur, d’un local clos, peut provoquer des mal-
aises et des dommages corporels. Aussi convient-il
d’observer les précautions suivantes:
a. Assurez en permanence une aération adéquate de
l’emplacement de travail en maintenant une ventila-
tion naturelle ou à l’aide de moyens mécaniques.
N’effectuez jamais de travaux de soudage ou de
coupage sur des matériaux de zinc, de plomb, de
beryllium ou de cadmium en l’absence de moyens
mécaniques de ventilation capables d’empêcher
l’inhalation des fumées dégagées par ces matériaux.
b. N’effectuez jamais de travaux de soudage ou de
coupage à proximité de vapeurs d’hydrocarbure
chloré résultant d’opérations voisines de dégraissage
ou de pulvérisation. La chaleur dégagée ou le
rayonnement de l’arc peut déclencher la formation de
phosgène -- gaz particulièrement toxique -- et d’autres
gaz irritants, à partir des vapeurs de solvant.
c. Une irritation momentanée des yeux, du nez ou de la
gorge constatée au cours de l’utilisation de
l’équipement dénote un défaut de ventilation. Arrêtez-
vous de travailler afin de prendre les mesures néces-
saires à l’amélioration de la ventilation. Ne poursuivez
pas l’opération entreprise si le malaise persiste.
d. Certaines commandes comportent des canalisations
où circule de l’hydrogène. L’armoire de commande est
munie d’un ventilateur destiné à empêcher la forma-
tion de poches d’hydrogène, lesquelles présentent un
danger d’explosion; ce ventilateur ne fonctionne que
si l’interrupteur correspondant du panneau avant se
trouve placé en position ON (Marche). Veillez à
manœuvrer cette commande en vérifiant si le
couvercle est bien en place, de façon à assurer
l’efficacité de la ventilation ainsi réalisée. Ne jamais
débrancher le ventilateur.
e. Les fumées produites par l’opération de soudage ou
de coupage peuvent s’avérer toxiques. Aussi est-il
nécessaire de disposer en permanence d’un dispositif
adéquat de ventilation de type aspirant, afin d’élimi-
ner du voisinage de l’opérateur tout dégagement de
fumée visible.
f. Consultez les recommandations particulières en
matière de ventilation indiquées à l’alinéa 6 de la
norme Z49.1 de l’AWS.
5. ENTRETIEN DE L’ÉQUIPEMENT-- Un équipement
entretenu de façon défectueuse ou inadéquate risque
non seulement de réaliser un travail de mauvaise
qualité mais, chose plus grave encore, d’entraîner des
dommages corporels graves, voire mortels en
déclenchant des incendies ou des chocs électriques.
Observez par conséquent les précautions suivantes:
a. Efforcez-vous de toujours confier à un personnel qua-
lifié l’installation, le dépannage et l’entretien du poste
de soudage et de coupage. N’effectuez aucune
réparation électrique sur l’équipement à moins d’être
qua-lifié à cet effet.
b. Ne procédez jamais à une tâche d’entretien
quelconque à l’intérieur du poste de soudage/
coupage, avant d’avoir débranché l’alimentation
électrique.
c. Maintenez en bon état de fonctionnement les câbles,
le câble de masse, les branchements, le cordon
d’alimentation et le poste de soudage/coupage.
N’utilisez jamais le poste ou l’équipement s’il présente
une défectuosité quelconque.
d. Prenez soin du poste de soudage et de coupage et
des équipements accessoires. Gardez-les à l’écart
des sources de charleur, notamment des fours, de
l’humidité, des flaques d’eau maintenez-les à l’abri des
traces d’huile ou de graisse, des atmosphères corro-
sives et des intempéries.
e. Laissez en place tous les dispositifs de sécurité et tous
les panneaux de l’armoire de commande en veillant à
les garder en bon état.
f. Utilisez le poste de soudage/coupage conformément à
son usage prévu et n’effectuez aucune modification.
6. INFORMATIONS COMPLÉMENTAIRES RELATIVES
À LA SÉCURITÉ--
Pour obtenir des informations complémentaires sur les
règles de sécurité à observer pour le montage et
l’utilisation d’équipements de soudage et de coupage
électriques et sur les méthodes de travail
recommandées, demandez un exemplaire du livret N°
52529 “Precautions and Safe Practices for Arc Weld-
ing, Cutting and Gouging” publié par ESAB. Nous
conseillons également de consulter les publications
sui-vantes, tenues à votre disposition par l’American
Welding Society, 550 N.W. LeJuene Road, Miami, FL
32126:
a. “Safety in Welding and Cutting” AWS Z49.1
b. “Recommended Safe Practices for Gas-Shielded Arc
Welding “AWS A6. 1.
c. “Safe Practices for Welding and Cutting Containers
That Have Held Combustibles” AWS-A6.0.
d. “Recommended Safe Practices for Plasma Arc Cut-
ting” AWS-A6. 3.
e. “Recommended Safe Practices for Plasma Arc Weld-
ing” AWS-C5. 1.
f. “Recommended Safe Practices for Air Carbon Arc
Gouging and Cutting” AWS-C5. 3.
g. “Code For Safety in Welding and Cutting”
CSA-Standard W117. 2.
9/97
SECTION 1 PRÉCAUTIONS DE SÉCURITÉ

11
■ Multi-process, three phase power source de-
signed for heavy duty Industrial DC welding
applications.
■ Use for High Performance Mig, Pulse Mig, Flux
Coredwire,Stickelectrode welding, Tig and Air
CarbonArc Gouging
■ SuperSwitchTechnologydesign, providessuperior
inverterlikeperformance in the weldingarc while
providing SCR like reliability.
■ Variable inductance for fine tuning of the arc
characteristics in short arc welding.
■ Built-in arc force control for superior stick electrode
performance.
■ Digitalpresetofvoltage/amperage on all process at
the front panel.
■ Sheetmetalpartsand hardware made of stainless
steel. Top and side panel made of Kydex polymer
forsuperiordurability in harsh environments.
■ Auto Fan feature standard in the unit for energy
savings. Automatically turns the fan motor on and
offwhen needed.
■ Energy and power efficient, the best in its class
witha92%efficiency figure. Saves energy and
reduces power costs. Uses up to 50% less
current than conventional SCR machines. See
chart, next page.
■ Convenient 115Vac auxiliary power receptacle.
■ Synergic / Non-Synergic Mig Pulse welding
capability with the intelligence built into the power
source (Standard on pulse unit, optional in the
standard unit) Allows you to do Pulse Mig with
almost any wire feeder.
■ 100% Solid State, no mechanical contactor
■ Compatible with DuraDrive 4-30 and DuraDrive 4-
48 wire feeders.
Specifications:
Rated DC Output @ 100% Duty Cycle
50/60Hz, cv or cc .............................. .450 amps 38 vdc
Rated DC Output @ 60% Duty Cycle
50/60Hz, cv or cc ............................... 500 amps 39 vdc
Welding Range ..................................10A/12V to 500A/40V
Open Circuit Voltage Max. .......................................... 80vdc
Primary Input Voltage and Current @ 100% Duty Cycle
230/460/575Vac, 60Hz 3ph ...................66/33/26 amps
Power Factor at Rated Output ...................................... 89%
Efficiency at Rated Output ............................................ 92%
Auxiliary Output Power .............. 115Vac 50/60Hz, 10 amps
SECTION 2 DESCRIPTION
Physical Dimensions:
WxLxH ........... 18.8”(483mm), 32.5” (819mm), 25”(622mm)
Net Weight ................................................. 322 lbs.(146 Kg)
Shipping Weight......................................... 375 lbs. (170Kg)
How to Order:
Multipower 460PULSE 230/460/575Vac
50/60 Hz 3ph .........................................0558002877

12
Options & Accessories:
Remote Hand Control...........................0558002871
Thispendantprovidesremoteoutputcontrolandacontactor
closure switch to close the contactor making the output
terminals “hot”. The PANEL/REMOTE switch on the Multip-
ower 460PULSE control panel must be placed in the RE-
MOTEpositionwhenusingthisaccessory. Thependanthas
the capability to change weld processes and is designed to
work with wire feeders without remote voltage control.
TR-29 Truck....................................................37924
Thistruckkitprovidescompletemobilityofthepowersource.
The kit consists of front casters, rear cylinder rack for two
cylinders, gas cylinder bracket and chain, and pull handle.
Wire Feeder Swivel Mount Kit......................36172
This kit allows the wire feeder to be placed on an insulated
swivelpostontopofthepower source.Thefeedercanfreely
rotate, relieving potential wire feed problems.
Remote Hand Control
Multipower 460 Better than the Competition
1/16" Cored Wire Comparison
welding @ 300a 28v - 40% duty cycle
0
5
10
15
20
25
30
35
40
45
ESAB350 Mpi
SVI-450i
ESAB353cv
ESAB 453cv
ESAB 452cvcc ESAB 653cvcc
MultiPower 460 Pulse
Miller Dimension 452
Lincoln DC400
Primary Line Current Draw (amps)
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
Power Factor
Primary Line Current Draw Power Factor
SECTION 2 DESCRIPTION
TR-29 Truck Kit

13
Table 2-1. Specifications for Multipower 460PULSE
2.0. GENERAL
Before the Multipower 460PULSE power source is put into operation, the
safetysectionatthefrontofthismanualshouldbereadcompletely. Thiswill
helpavoid possible injurydue to misuseor improper installation.
Thedefinitions relatingtothesafetynotationsbelow:
are described at the end of the Safety Section in the front of this manual —
read them and their specific text references carefully.
2.1. DESCRIPTION
Thismanualhasbeenpreparedforusebyanexperiencedoperator. Itprovides
information to familiarize the operator with the design, installation and
operation of the Multipower 460PULSE power source. DO NOT attempt to
installoroperatethisequipmentuntilyouhavereadandfullyunderstoodthese
instructions. Theinformationpresentedhereshouldbegivencarefulconsid-
eration to ensure proper installation and optimum weld performance of this
equipment.
OPEN CIRCUIT VOLTAGE (U2) 80V DC Max.
RATED
OUTPUT
DUTYCYCLE 60% 100%
Current (I2)500A450A
Voltage (U2) 40 V 38 V
RATED
INPUT 3 Phase
60 Hz
Volts (U1) Current (I1) Flat Current (I1) Flat
208/230 V 76 A 66 A
460 V 38 A 33 A
575 V 31 A 26 A
50 Hz 220 V 79 A 68 A
400 V 43 A 37 A
Power Factor at Rated Output 89%
Welding Range 10 A/12 V - 500 A/40 V
Auxiliary Power 115 V ac @ 10 A, 60 Hz
PHYSICAL SPECIFICATIONS
Height (without lift eye) 25.0" (62.2 cm)
Width 18.8" (48.3 cm)
Depth 32.5" (81.9 cm)
Net Weight 322lbs (146 kg)
Shipping Weight 375lbs (170 kg)
SECTION 2 DESCRIPTION

14
TheMultipower460PULSE isamulti-process powersourcedesignedforMig
shortcircuiting,sprayandpulsespraytransfer(GMAW),fluxcore(FCAW),Tig
(GTAW),andstick(SMAW)weldingandaircarbonarccutting/gouging(CAC-
A) applications. Table 2-1 outlines the electrical and physical specifications.
A. POWER SOURCE
Thepowersource is a constantcurrent(CC) and constant voltage(CV),three
phase, secondary chopper dc design with solid state contactor and control
circuitry. It provides the volt-ampere characteristics desired for conventional
MIG and flux core arc welding in the CV (constant voltage) mode or stick
welding, Tig (GTAW) and arc gouging in the CC (constant current) mode.
Features
• AutoFan-TheMultipower460PULSEfanwillrunwhenthepowersource
isfirstpoweredupandwillcontinuerunningfor6minutesthenshutdown.
Thefanwillstartagainwhenweldingbeginsandatcurrentlevelsabove50
amps. Thefanwillremainrunningfor6minutesafterweldingstopsandthen
shutdown automatically.
• Stainless steel frame for environmental durability.
• Durable composite side and top panels will not corrode.
• 100% duty cycle output at 450 amps.
• Compatible with all ESAB 42 vac wire feeders.
B. VOLT - AMPERE CHARACTERISTICS
ThecurvesshowninFigure2-1representthestaticvolt-amperecharacteristics
forthepowersource. Theslantofthesecurvesisreferredtoasthe"slope"and
isgenerallydefinedasthevoltagedropper100amperesofcurrentuse.These
curves show the output voltage available at any given output current from the
minimumtothe maximum setting of the voltage/current control.
Figure 2-1 - Multipower 460 Volt-Ampere Curves
SECTION 2 DESCRIPTION

15
Figure 2-3. Pulse Control Panel
C. CONTROLPANELDESCRIPTION
(Refer to Figure 2-3 and 2-4)
1. FAULT LAMP
The RED fault light on the Multipower 460PULSE front panel indicates a
problemwithset-up parameters. A "Steady" light "On"indicates there is no
program for the material and wire diameter selected. A "Blinking" light
indicatesthe wire feedspeed is outof the recommendedrange.
2. TEMPERATURELAMP
TheTEMPlampilluminatesifanovertemperatureconditionoccurswithinthe
Multipower 460PULSE power source. This condition may be caused by
excessivedutycycleorover-current conditions.Whenanovertemperature
conditionoccurs,theweldingoutputisturnedoffandtheunitmustbeallowed
tocool.Themachinewillautomaticallyresetwhenthetemperaturefallstoa
safelevel.
3. PROCESS SELECTOR SWITCH
Thethreepositionprocessselectorswitchislocatedintheupperright-hand
cornerofthecontrolpanel. Theprocessselectorswitchpositionprovidesthe
visualindicationofwhichweldprocess(Mig,Tigorstick)hasbeenselected.
4. DIGITAL DISPLAY/METERS (WFS, AMPS & VOLTS)
The digital displays located on the left side of the control panel are
multifunctional depending on the welding process being used. The top
displayreadswirefeedspeedininchesperminuteintheMIGPRESETmode
and welding current (amps) in the TIG and STICK PRESET mode. During
weldingbothdisplaysindicateaverageweldingcurrentandaveragewelding
voltage.
Whenusinga DuraDrive4-30or DuraDrive4-48Wire Feeder,thewire feed
speed is displayed in inches per minute (IPM) in the top display when the
PRESETbutton ispressed andthewirespeedadjustmentknobonthewire
feederisrotated. TheWFS LEDbesidethetopdisplaymeterwilllightwhen
the display is showing wire feed speed.
Fault
Lamp
WFS-IPM
Lamp Amps
Lamp
Digital Meter
Amps/WFS
Power “ON”
Lamp
Temperature
Lamp
Digital Meter
Volts
SECTION 2 DESCRIPTION

16
5. VOLTAGE/CURRENTTRIM
The arc voltage is controlled with this knob when the WELD PROCESS
selectorswitchisintheMIGposition. TheMigarcvoltagecanbepresetby
pressingthe PRESET buttonand readingthearc voltsin the bottomdigital
display while rotating this knob.
The arc current is controlled with this knob when the WELD PROCESS
SWITCHisintheTIGorSTICKposition. Theweldingcurrentcanbepreset
inamperesbypressingthePRESETbuttonandreadingthecurrent(amps)
inthe top digitaldisplaywhile rotatingthisknob. The average weldcurrent
will be displayed during welding.
For MIG PULSE welding, the arc length (arc voltage) is controlled with this
knob. The WELD PROCESS switch is placed in the MIG position and the
MIGMODE switchisplacedinthePULSEposition. TheTRIMPRESETknob
shouldbeplaceatthe12o'clockpositionasthesynergicpresetforthewire
feedspeed,WIRETYPEandWIREDIAMETERchosenbytheoperatorusing
thePULSESELECTIONswitches. Thearclengthcanthenbeadjustedby
turningtheknobclockwisetoincreasethearclengthorcounterclockwiseto
decreasethe arc.
6. PANEL/REMOTE SWITCH
Withthis switchinthe PANEL position,output voltageinthe CVmode and
theoutputcurrentintheCCmodearecontrolledbyadjustingtheVOLTAGE/
CURRENT/TRIM knob on the power source control panel to the desired
output. IntheREMOTEposition,outputiscontrolledusingaremotecontrol
device such as a wire feeder, hand control or foot control.
7. INDUCTANCE TRIM
Thiscontrolis usedonlyin theMIGprocess modeandis deactivatedinthe
TIG,STICK and MIG PULSEmodes. Inductance is used tooptimizeshort
circuitingarcperformancebychangingthecurrentriseandfalltimeofeach
shortcircuit. Thisresultsinimprovedspattercontrol,weldbeadwettingand
arcstability. TheshortcircuitingMigarcperformancewillchangefromahigh
NOTE:
A DuraDrive Wire Feeder is required to
preset wire feed speed.
Figure 2-4. Pulse Control Panel
Preset
Button
Mig Mode
Switch Panel/
Remote
Current
Voltage Material Selection
(Pulse)
Wire Diameter
Selector (Pulse)
Weld Process
Switch
Inductance
SECTION 2 DESCRIPTION

17
Figure 2-5. Multipower 460
Main Power
On/Off Switch
Output
Connections
Wire Feeder
Connector
Remote Pendant
Connection
Contactor On/Off
Switch
Circuit Breakers
CB1 & 2
Control Panel
115 Vac
10 Amps
Receptacle
short circuit frequency, fast reacting arc, to a lower short circuit frequency,
softandlessspatteringarcasthedialisturnedclockwise. Theoptimizedarc
performancewillvarydependingonshieldinggas,wiretypeandwirediameter.
The operator can adjust this control to optimize welding characteristics.
8. MODESWITCH
This switch enables the Mig pulse or standard operation mode. When this
switchisinthePULSE position,thepulseparametersaredeterminedbythe
WIRE TYPE and WIRE DIAMETER position on the PULSE SELECTION
switches.UsetheSTANDARDpositionforCVMIG,TIGandSTICKwelding.
TheMultipower460willdefaulttominimumvoltageiftryingtoTIGorSTICKweld
in the PULSE position.
9. PULSE SELECTION SWITCHES
WIRETYPE
Use this switch to select the WIRE TYPE installed on the wire feeder. The
position of this switch and the WIRE DIAMETER switch selects the pulse
parameters to be used during welding in the Mig pulse mode.
WIREDIAMETER
Use this switch to select the WIRE DIAMETER installed on the wire feeder.
The position of this switch and the WIRE TYPE switch selects the pulse
parameters to be used during welding in the Mig pulse mode.
D. POWER SOURCE FRONT PANEL DESCRIPTION
(Refer to Figure 2-5)
1. POWER ON/OFF SWITCH & LAMP
Themainpowerswitchislocatedontherightfrontpanelofthepowersource.
Thisswitchenergizes the main transformer, controlcircuitry and illuminates
thePower“ON”lamp.(RefertoFigure2-1)
SECTION 2 DESCRIPTION

18
2. WIRE FEEDER CONTROL RECEPTACLE
This 19-pin receptacle (J1) accepts the control cable from the wire feeder
andhandlesall the control signals neededtooperate a 42 Vac wirefeeder.
3. REMOTE CONTROL RECEPTACLE
Thisreceptacle(J2)isprovidedforanoptional14-pincontrolcablefromthe
optional remote pendant, Tig torch control or foot control . This receptacle
is operative only if the PANEL/REMOTE switch on the power source front
panel is in the REMOTE position.
4. CONTACTOR "ON/OFF" SWITCH
This switch provides manual control of the welding contactor when the
PROCESS switch on the control panel is in the MIG position (CV welding).
An example of when to use this switch is when CV carbon arc gouging is
neededoran"OfftheArc"wirefeederwithsecondarycontactorisoperated
in the CV mode.
5. AUXILIARY 115 VAC RECEPTACLE
A 115 Vac receptacle is provided to supply power to accessories such as a
water cooler, heated CO2regulator, or small hand tools. The receptacle is
rated 115 Vac / 10 amps with a floating neutral.
6. 42VAC AND 115 VAC CIRCUIT BREAKER (CB1 & CB2)
Theseresetable10ampcircuitbreakers(CB1&CB2)protectthe42voltwire
feeder/controland115voltauxiliaryreceptaclecircuitryagainstovercurrent.
(Table6-1providestroubleshootinginformation).
SECTION 2 DESCRIPTION

19
Table 3-1. Recommended Sizes for Input
ConductorsandLineFuses
*Sized per National Code for 80 °C rated copper conductors @ 30 °C ambient. Not
morethanthreeconductorsinracewayorcable. Localcodesshouldbefollowedifthey
specify sizes other than those listed above.
3.0. INSTALLATION
A. LOCATION
Aproperinstallation site is necessaryforthe power source to providedepend-
ableservice.Aproperinstallationsitepermitsfreedomofairmovementthrough
theunitwhileminimizingexposuretodust,dirt,moisture,andcorrosivevapors.
A minimum 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 2-1 for overall dimensions of the unit.
B. RECEIVING, UNPACKING AND PLACEMENT
When requesting information concerning this equipment, it is essential that
Itemnumber,SerialnumberandModelnumberoftheequipmentbesupplied.
1. Uponreceipt,removeallpackingmaterialandcarefullyinspectforany
damagethat mayhaveoccurred duringshipment. Anyclaims forloss
or damage that may have occurred in transit must be filed by the
purchaserwiththecarrier. Acopyofthebillofladingandfreightbillwill
be furnished by the carrier on request.
2. Remove the power source from the container. Remove all packing
materials. Check the container for any loose parts.
3. Check air passages at front and rear of cabinet, making sure that
packingmaterialhasnot obstructedairflowthroughthepowersource.
4. Installtheliftingboltfurnishedwiththepowersourcesintothetopofthe
unit.
5. Afterselectinganinstallationsite,placethepowersourceinthedesired
location. Theunitmaybeliftedeitherbyusingtheliftingboltorbyforklift
truck. Ifa forkliftis used forlifting theunit, be surethat thelift forksare
long enough to extend completely under the base.
C. PRIMARY (INPUT) ELECTRICAL CONNECTION
This power source is a three-phase unit and must be connected to a three-
phasepowersupply.Itisrecommendedthattheunitbeoperatedonadedicated
circuit to prevent impairment of performance due to an overloaded circuit.
For lifting purposes and for keeping
dust, moisture, and other foreign ma-
terial from entering the power source,
the lifting eyebolt must be fully tight-
ened with a tool.
Do not use filters 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 filtering
device is used.
Rated Input
@ 100% Duty Cycle Input &
GND
Conductor*
CU/AWG
Fuse
Size
Amps
Volts Amps
220
230
400
460
575
68
66
37
33
26
No. 6
No. 6
No. 8
No. 8
No. 10
100
100
60
60
50
SECTION 3 INSTALLATION

20
1. The primary power leads must be insulated copper conductors. Three
power leads and one ground wire are required. Either rubber covered
cable or conduit (flexible or solid) may be used. Table 3-1 provides
recommended input conductors and line fuse sizes.
2. Remove the top cover. Identify primary power input connection block,
chassisgroundlugontheframe,andprimaryinputterminalboard. Refer
toFigures3-1through3-6.
3. Whenusingtheprovidedstrainrelief,refertoFigure3-2forpropercable
striplengths. Itisimportanttofollowthecablestripguidetoensurethat
if the primary input cable is ever pulled from the strain relief, the input
conductorswillbepulledfromtheTerminalBlock beforethegroundlead
ispulledfromthegroundlug.Oncestripped,threadtheinputandground
conductorsthroughthe largestrain-relief in therearpanel ofthe power
source. Connect the ground wire to the terminal lug located on the "A"
framesupport.ConnecttheprimarypowerleadstoterminalsL1,L2,and
L3 on the input power block. Secure the strain relief on the input cable.
4. Check all connectionsfor proper tightness. Ensure all connectionsare
correct and well-insulated.
ELECTRIC SHOCK CAN KILL! Before
makingelectricalinput connections to
the power source, "Machinery Lock-
out 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 fuse box,
remove the corresponding fuses and
padlock the box cover. If it is not pos-
sible to use padlocks, attach a red tag
to the line disconnect switch (or fuse
box) warning others that the circuit is
being worked on.
Figure 3-1 Primary Power Leads
L1, L2, L3 & Ground
(3)PRIMARY
INPUT
CONDUCTORS
24"
Green
The chassis must be connected to an
approved electrical ground. Failure to
do so may result in electrical shock,
severe burns or death.
SECTION 3 INSTALLATION
Figure 3-2 Recommended Cable Strip Lengths