ESABMig C420 ESABMig C420s - ESAB Welding & Cutting Products
Contents
1. AP 1 7 2 stroke motor test inching 4 stroke AP 1 8 AP2 1 Measuring and displaying of welding parameters AP1 9 Synergy control presets and indications APS3 CohtrobbOatd oe aa ADS SIS ruat itd ac tenes seda ata doe pud AP3 2 Overheating protection APS 3 Waler CONMCCION Ss dcn ot dac ah a ted dated das de cu doi ean AP3 4 Water flow guard ESABMig C420w optionally ARS y 92444161915 MEMOREM umu s poe PIC IC MS APS Component bOSIHOFS ft as Pedum Rut a Re RS bose Aout hes ear M i RR SERVICE INSTRUCTIONS 15 35 22 25 t Race IR IE N Whatis ESD Ser aac ga I e Eu Mp INSTHUCTIONS PR EU PIE SAU DE sa SAFETY a aries up acp hate INSTALLATION 4 etd aem rans Tao cub dut ocu cernit aL Denia ecd PACINO Assembly of components eod oo wem ie Dar A Electrical installation dans Salers Mairis DOWer ener eee un IE EE a Rea eee TOCe uu 22 22 32 OPERATION et ovate MC E odo tamed 36 CONNECTIONS AND CONTROL DEVICES2. Lies eT doce1 10 Edition 030410 ESABMig C420s C420sw TMi RES ABI 1 174 055 ars ar AN Ig ATP I RS 00 N d Edition 030410 doce1 DESCRIPTION OF OPERATION This description of operation describes the function of circuit boards and other components in the power unit It is divided into sections numbered to correspond to the circuit board numbers and divisions into function blocks AP1 Control board for C420w C420 Note AP1 0486 205 882 only for machines manufactured till May 2003 AP1 0486 205 886 only for machines manufactured after May 2003 AP1 1 Power supply E ci M 1 Power source 42V L el The wire feed unit receives 42 V from the control power supply transformer in the welding power unit via relay contact on AP3 42 V AC is supplied to the welding gun trigger switch the gas valve and the contactor DC power supplies Diodes D30 D33 rectify the 42 V supply to 60 V Capacitor C61 smooths the supply which is then used to power the wire feeder motor Transistor Q2 is a pre regulator that drops the voltage from 60 V to 20 V Q2 is current limited to about 200 mA VR1 and VR2 are voltage regulators producing 5 V and 15 V respectively The circuit board s microprocessor monitors the voltages If the 15 V supply falls below 13 V the wire feed unit is stopped
3. AP1 2 Activation contactor B 42VAC A 42VAC The start signal is connected to contactor KM1 docet 12 Edition 030410 AP1 3 Activation gas valve B 42VAC 50 solenoid _ valve The gas valve is connected to connectors F04 and FO5 AP1 4 2 stroke 4 stroke 4 stroke gt 2 stroke 2 stroke When switch SP2 is open 2 stroke control mode is selected This means that closing the welding gun trigger switch starts the wire feed motor opens the gas valve and closes the power unit contactor Releasing the switch stops the motor releases the contactor and closes the gas valve If burn back time is operative welding ceases after the burn back time has elapsed 4 stroke When switch SP21 is closed 4 stroke control mode is selected This means that first closure of the trigger switch operates the gas valve with the wire feed motor starting and the power unit contactor operating when the trigger switch Is released Closing the trigger switch for the second time stops the motor and de energises the contactor in the power unit Releasing the switch closes the gas valve If burn back time is operative welding ceases after the burn back time has elapsed docet 13 Edition 030410 AP1 5 Burn back time 134A 133A Kae 132A ibn burnback um The burn back time is the time from when motor braking starts until the machine contactor op
4. AP2 Digital instrument option for C420w C420 AP2 1 Calibration and voltage correction The meter has a possibility of the voltage and current calibration as well as a possibility of the current dependant voltage correction to show a voltage approximately equal to the actual arc voltage Since all meters are factory calibrated it is recommended to carry out a second calibration only if it s needed In most applications a zero voltage correction no correction is factory adjusted For the calibration an accurate reference meter and a resistance load are required The resistance load should force at least 100A current flow For calibration following actions should be done 1 Switch the machine on and load it The meter should indicate voltage and current presence 2 Press simultaneously both pushbuttons placed on the meter PC board In sequence symbols of the calibration modes appear U voltage calibration l current calibration dU voltage correction Release the buttons as the required mode appears 3 Adjust the voltage or the current value equal to the value shown the reference meter by means of the pushbuttons 51 2 Voltage calibration mode The reference meter should be connected to the same potentials as a calibrated meter Exclusively in this mode a voltage without correction is shown on display Voltage reduction mode The reference meter should be connected to the end of m
5. SWITZERLAND ESAB AG Dietikon Tel 41 1 741 25 25 Fax 41 1 740 30 55 North and South America ARGENTINA CONARCO Buenos Aires Tel 54 11 4 753 4039 Fax 54 11 4 753 6313 BRAZIL ESAB S A Contagem MG Tel 55 31 333 43 33 Fax 55 31 361 31 51 CANADA ESAB Group Canada Inc Missisauga Ontario Tel 1 905 670 02 20 Fax 1 905 670 48 79 MEXICO ESAB Mexico S A Monterrey Tel 52 8 350 5959 Fax 452 8 350 7554 USA ESAB Welding amp Cutting Products Florence SC Tel 1 843 669 44 11 Fax 1 843 664 44 58 ESAB AB SE 695 81 LAX SWEDEN Phone 46 584 81 000 Fax 46 584 123 08 www esab com Asia Pacific CHINA Shanghai ESAB A P Shanghai Tel 86 21 6539 7124 Fax 86 21 6543 6622 INDIA ESAB India Ltd Calcutta Tel 91 33 478 45 17 Fax 91 33 468 18 80 INDONESIA P T Esabindo Pratama Jakarta Tel 62 21 460 01 88 Fax 62 21 461 29 29 MALAYSIA ESAB Malaysia Snd Bhd Selangor Tel 60 3 703 36 15 Fax 60 3 703 35 52 SINGAPORE ESAB Singapore Pte Ltd Singapore Tel 65 861 43 22 Fax 65 861 31 95 ESAB Asia Pacific Pte Ltd Singapore Tel 65 861 74 42 Fax 65 863 08 39 SOUTH KOREA ESAB SeAH Corporation Kyung Nam Tel 82 551 289 81 11 Fax 82 551 289 88 63 UNITED ARAB EMIRATES ESAB Middle East Dubai Tel 971 4 338 88 29 Fax 971 4 338 87 29 Representative offices BULGARIA ESAB Representative Office Sofia Tel Fax 4359 2
6. This manual contains details of all design changes that have been made up to and including March 2003 The ESABMig C420w C420 and ESABMig C420sw C420s are designed and tested in accordance with international and European standard IEC EN 60974 1 and EN 50199 On completion of service or repair work it is the responsibility of the person s etc performing the work to ensure that the product does not depart from the requirements of the above standard WARNING Many parts of the power unit are at mains voltage INTRODUCTION The ESABMig C420w C420sw are step controlled compact welding power units incorporating wire feed mechanism intended for MIG MAG welding with solid wires of steel stainless steel or aluminium and cored wires with or without shielding gas The ESABMig C420w 420sw are equipped with cooling liquid system for welding torch The ESABMig C420 420s are not equipped with cooling system and can operate only with appropriate gas cooled torches The ESABMig C420w 420 is equipped with standard control unit manual setting of all welding parameters and ESABMig C420sw 420s contains additional synergy control facility preprogrammed welding parameters The power units are fan cooled and equipped with thermal overload protection The machines can be fitted with a flow guard C420sw C420w TECHNICAL DATA 20 20 C4205 64208w Voltage 400 415V 3 50 60Hz 400 415V 3 50 60Hz Perm
7. 14 shows wire speed reference selector 16 shall be in position m min Operator selects the required voltage 2 3 and he may set wire speed wthin full range 1 6 25m min with knob 12 During welding process the upper row of display shows actual welding voltage or current depending on selection with switch 15 When welding process is stopped displayed values are frozen dimmed display Synergy control mode In synergy control mode the operator first has to preselect material gas 19 and wire diameter 20 While changing the voltage with the voltage selectors 2 3 digital instrument 14 and lamps 17 18 on the front panel show welding parameters synergy status lamp 17 is green only in synergy mode when correct welding parameters are set or red when incorrect or not allowed welding parameters are set then machine operation is disabled Note Lamp is also red in all control modes e if during welding gun trigger pressed any voltage selector 2 3 is operated then the operation of the machine is disabled immediately until the trigger is released e when the gun trigger is pressed while turning on the machine with switch 1 One of the lamps 18 points at recommended current outlet with appropriate inductance 9 10 11 Digital display 14 shows values depending on display selectors 15 16 and machine status Before welding start the upper display shows expected values of w
8. 2 C3 x eg 3x2uF 5 400 415 161 FU2 ua 1X 3 15AT 42V 400 415 440 460 080 X L OPIIONAL CO HEAIER M1 X 51a XT 1 au BR OWN BLACK Z 53 m e X BuF C4 902 PE E z 52 B 5 E gt E KM1 SL1 OPTION 1 5 N S2 KMT ST3 STT INDUCTOR uw INDUCTOR ST2 BRIDGE x 9 5 E ONLY INSTALLED INESABMig C420w E TO BE CONNECTED TO XT 1 8 EN SL1 NOT INSTALLED 1 for E SAB Mig C420 E e 8 e Edition 030410 doce1 ESABMig C420 C420w OFS TM1 jc 2 4 Ul 5 ie B 5 2 ast Bj U3 ld L 14 7 173 18 21 22 8j 16 25 1 28 10 U7 126 LIB 28 UB UID T 1185 00 60mV i gt 3 4 12 V Us BR ANS Z A 23 2 24 V8 7 Ais 18 33 VB A A dH 99 VU 3B v 11 21 i i JH VAB HLA 38 Ag pu 1332 aU M2 WT Pes i 4990 WI csf I b 1313 24 STROKE 20 Mes re ui J for AP 1 0486 205 886 for AP 1 0486 205 882 e Dc Oo m START 1 RES
9. 36 ESABMig 420 420 36 ESABMIG C4208W C4208 22 lupa eda huq vos MUS de goat 37 Setting the wire feed pressure 39 FUNCTIONS EXPLANATION 39 ESABMISG C420W C 420 iio u dein hyip ch are ee BS dei eder en Aas mcd Date ave toa 40 ESABMig 42065 4206 40 MAINTENANGE usa 42 Inspeclion and iier ul D eee 42 Topping up ING COOLGDE 43 ORDERING OF SPARE PARTS 43 NOTES asa thay sasa CN DLE bee ened cL teas 44 TOCe d READ THIS FIRST Maintenance and repair work should be performed by an experienced person and electrical work only by a trained electrician Use only recommended replacement parts This service manual is intended for use by technicians with electrical electronic training for help in connection with fault tracing and repair Use the wiring diagram as a form of index for the description of operation The circuit board is divided into numbered blocks which are described individually in more detail in the description of operation All component names in the wiring diagram are listed in the component description
10. ESAB Logic Pump doce2 37 Edition 030410 14 15 16 17 5 4 E K lt OIRE 224 ay 12 m 13 3 2 1 N o d E we E a i i B i i BI M M 1 raw 49 doce2 38 Edition 030410 Setting the wire feed pressure Start by making sure that the wire moves smoothly through the wire guide Then set the pressure of the wire feeder s pressure rollers It is important that the pressure is not too great I gt lt 5mm cmek0p10 Fig 1 Fig 2 To check that the feed pressure is set correctly you can feed out the wire against an insulated object e g a piece of wood When you hold the welding gun approx 5 mm from the piece of wood fig 1 the feed rollers should slip If you hold the welding gun approx 50 mm from the piece of wood the wire should be fed out and bend fig 2 FUNCTIONS EXPLANATION Start When switched on indicating lamps 4 5 are on for 2 seconds Normally if the machine is not overheated it should start to work in idle mode which is indicated by blinking of the supply ON lamp The fan and the coolant pump are stopped The fan starts at the first start of welding The coolant pump starts at the same moment if it is switched on with ELP switch on the water outlet 7 Overheating protection The power source has 2 step contro
11. _ 417 Edition 030410 AP1 Component positions 0486 205 886 5 3 P R85 Ler j Lot O S el sce int 92 i Eee se Sel oh oe ane BC JEN 5 5 gg a iai eon S PP O 6 Gndl Gnd3 Gnd2 er al _ L la H gt e ee Tw un a aE es Eur 8 CRI ICI CIO ICS ICIO p26 82 054 aa aE Ka A ys sm ee cae C32 C40 RIS CI Edition 030410 18 doce AP1 Component positions 0486 205 882 014 02 got ETa EE Q QR EFE 486 205 51 e 9 l Trl n3 n5 gt ro C Q gt To C20 2 C25 C 7 gt 255 um E del 36 5 ARGS RAH c67 E per 15 65 59 905 99906 BL mc ica Loo 54 9 2 XE tE mm um T 554 n3 e o kolo t ka ux co lt gt o eo 2 C35 3 E E 2 BH _ O e co pom C CA d 98H 264 G84 docet 19 Edition 030410
12. acrea Gan e er ce edt ela Vae o os AP TO Tachomieter een Ur sce a en Pet alae dette a nes AP1 9 Creep start Current relay PUP AO San etur bbw bead utei wins AT a doce d Ste Pac d re e da adeb A patei AP1 Component positions 0486 205 886 AP1 Component positions 0486 205 882 AP2 Digital instrument option for 420 420 AP2 1 Calibration and voltage correction AP2 2 Connections to the digital instrument AP1 0349 303 176 AP2 0349 303 193 control boards C420s C420SW A SUI et era 4 AP 1 3 Welding current detection AP1 4 Welding parameter setting APTS Motor driving 7 Draking Rey Dt acsee en e te dui ar V eee ee AP1 6 Burnback time contactor gas
13. by the programm stored in the microprocessor synergy control mode The upper limit of the speed reference signal may be adjusted by trim pot R51A 4 9V at TP5 refered to TP1 when RP4 max in standard mode corresponds to 25m min Additional speed reference adjustment is performed by the trim potentiometer R53 it allows to shift upwards the whole speed range within O 0 5m min so as to correct especially the minimum speed of wire Note this correction is not shown on speed reference display 14 Calibration of the actual motor speed i e matching the speed reference signal is carried out by the trim potentiometer R7 on the pcb it may be necessary only when wire feed motor is changed A P1 V REF max 4 9V 5VC RS1A Wire feed 5 7 X6 RP4 X6 GNDCA GNDCA doce1 23 Edition 030410 There is built in creep speed function in the program ca 60 of work speed but not less than 1 2m min i e welding starts with reduced wire speed and when welding current relay picks up see sec 3 the speed rise up to the value pre set with RP4 Independently of the current relay after ca 0 77 sec the speed increases automatically to the work speed V REF voltage is the analog reference signal for motor speed control circuit the digital reference speed is displayed on the front control panel display 14 lower row with selected m min In standard control mode Synergy OFF with switch 21 in wire
14. off 3 min after the last welding When both fan and pump are switched off the power supply lamp 4 on the front panel is blinking ESABMig C420w C420 The ESABMig C420w 420 is equipped with standard control unit Welder can manually select and adjust all welding parameters Wire speed 1 9 25m min is set with knob 12 The stroke control 2 4 stroke is selected with switch 13 Creep start i e start with 50 wire speed is toggled ON OFF with switch 14 Burn back time is set with knob 15 The machines C420w C400 can be fitted with a digital instrument that displays current and voltage It incorporates a hold function ESABMig C420sw C420s ESABMig C420sw 420s control unit enables two ways of welding control e the standard control welder can manually select and adjust all welding parameters switch SYNERGY 19 set to OFF e the synergy control partly preprogrammed welding parameters switch SYNERGY 19 set to any material gas group The stroke control 2 4 stroke or motor inching only wire feed motor is activated is selected with switch 22 Burn back time is adjusted with knob 21 Spot welding turning on and time setting 0 5 4s is activated with knob 13 For machines C420sw C420s digital instrument is included as standard doce2 40 Edition 030410 Standard control mode When standard control mode is selected lamps 17 18 are off and only a lower row of digital display
15. power supply 60V is used for motor control 60VS is used for energizing of some input control circuits see next sections These voltages may vary with load mains voltage deviation from 15 to 10 26V intermediate voltage for A2 also supplies the relays K1 and K2 on the pcb AP1 2 Start stop doce1 AP1 T gun 650 5 o Closing contact on the welding torch starts the welding process or only motor M2 motor test inching depending on control mode selection see section 7 NOTE When the machine is turned on while the torch trigger is depressed operation of the machine is disabled LED 17 on the front control panel emits red light 22 Edition 030410 AP1 3 Welding current detection Current relay Signal from current relay is used for detection of welding current presence after closing of the torch trigger AP1 4 Welding parameter setting NOTE 1 In the AP1 diagrams in the next sections there are shown electronic reference potentials GNDCA and GND not marked they are both galvanically connected and accessible at test point TP1 NOTE Device numbers refer to the chapter OPERATION Connections and control devices A Wire feed speed creep start The wire speed setting range is 1 6 to 25 meter minute Speed value is set by the potentiometer 4 12 in the front control panel standard control mode see sec 9A or
16. selected for displaying open contact corresponds to m min Display 14 on AP2 operates in 3 modes e Before start of welding bright indicators expected values of V or A only in synergy mode and recommended material thickness or wire speed reference are displayed e During welding bright indicators actual values of V or A are displayed e After stop of welding dimmed indicators memorised values of V and A are displayed HOLD function docet 27 Edition 030410 AP1 9 Synergy control presets and indications doce1 Synergy ON OFF and material gas selection 10 position selector S2 on AP1 item 21 in wire feeder compartment serves for selection of control mode 1st position STANDARD control mode i e SYNERGY is OFF remaining positions correspond to SYNERGY control mode for presetting of different sets of electrode material and shield gases NOTE S2 output is BCD coded Synergy control OFF ON and material gas selection S2 Wire diameter presetting R61 GNDCA GNDCA Presetting of wire electrode diameter is performed with the potentiometer R61 on AP1 item 22 in feeder compartment Welding voltage selection Welder may select required value of welding voltage with switch QF2 coarse setting and QF3 fine setting Each position of the voltage selectors is identified by microprocessor so as to determine optimum welding parameter In standard control mode there a
17. 420w optionally The water flow guard interrupts and disables the welding in the event of loss of coolant This state is indicated by blinking of the orange indicating lamp on the front of the power source If there is a lack a coolant flow after 1 min the pump is switched off and latched in this state The pump restarts from this state along with starting of welding AP3 5 Idle mode When long inactivity of the machine the control board AP3 turns the machine to the idle mode The fun is switched off 5 min after the last welding or after 5 min of work with decreased speed without welding The pump is switched off 3 min after the last welding When both fan and pump are switched off the power supply lamp on the front panel is blinking AP3 Component positions a i ike TT B 300067 4 doce1 31 Edition 030410 SERVICE INSTRUCTIONS WARNING STATIC ELECTRICITY can damage circuit boards and electronic components e Observe precautions for handling electrostatic sensitive devices e Use proper static proof bags and boxes What is ESD A sudden transfer or discharge of static electricity from one object to another ESD stands for Electrostatic Discharge How does ESD damage occur ESD can cause damage to sensitive electrical components but is not dangerous to people ESD damage occurs when an ungrounded person or object with a static charge comes into contact with a co
18. 974 42 88 EGYPT ESAB Egypt Dokki Cairo Tel 20 2 390 96 69 Fax 20 2 393 32 13 ROMANIA ESAB Representative Office Bucharest Tel Fax 40 1 322 36 74 RUSSIA CIS ESAB Representative Office Moscow Tel 7 095 937 98 20 Fax 7 095 937 95 80 ESAB Representative Office St Petersburg Tel 7 812 325 43 62 Fax 7 812 325 66 85 Distributors For addresses and phone numbers to our distributors in other countries please visit our home page www esab com 030210
19. EE ESAB ESABMig C420 ESABMig C420s Service manual 030410 0349 300 041 READ THIS FIRS INTRODUCTION dep ed iun ien Qo eee ean TECHNICAL DATA DOR E od B tira e Dro Sn WIRING DIAGRAM rerien ac riter eo pc ES e RESI obit Rae Facit dace fob e Fia Component 25 a RR EE REDIMERE DEA ESABMig C420 C420W ERE enc ec a dee Ee Ree t ESABMIQ C420 C420W eh ded eee ieee ee ene t dde ESABMIG 206 4206 eran t uc iocus te aes ESABMig C4208S C420SW ici Edere ERE REI are a ee RR d nee ee DESCRIPTION OF OPERATION i453 5 59 iex a AP1 Control board for 420 420 API scent au bertus eae Ce eae i EE 2 Activation CONTACION bern orden BR Re et od Do ee gt doe latte tetro bo o e direc APT 3 ACUVALION Gas Value is u Shu wee Pudet a Sues xen a S RE Reed Dues uices 5 7 4 SUOKO ix annis eI EO Bek Re a Qe Rhe Beh a nea AE T OSBUITISDSCK dO pate Grades Poe br et d deer A AFP 1 6 Wire feed speed Motor drvilig 7 Drakifig Rae Det
20. GND GNDCA test point TP1 MUST be kept separated measurement inputs 1 2 x3 TUER i mee ATTENTION While testing keep always GND and GNDB isolated doce1 26 Edition 030410 Negative voltage maximum 60V and positive 60mV shunt signal are applied to the AP1 Those signals are converted into pulse frequency signals FU and FI respectively that are processed in microprocessor e FU frequency is 6 4 kHz for 40V input adj by R97 e Fl frequency is 6 4 kHz for 60mV 400A input adj by R88 NOTE signals on TP7 and TP8 are referred to TP6 Parameters displaying and display mode selection AP2 XL 281880 E s e 3 E m i lt lt e req mm EI J R45 4 2 Sv1 VI r 7 4D Display mode selection R45 5 2 x4 2 Sv2 mm 2 m min as mm r min 2 ESABMig C420s C420sw is equipped with 2 row display located on AP2 which includes 2 selectors for choosing of displayed parameters items 1 4 7 5 1 6 With SV1 switch 15 V or A display is selected open contact correspondents to With SV2 switch 16 recommended thickness of welded material mm or reference wire speed m min is
21. NIU ss 3 WIRE RP SPEED 3 CN 69 4 58 1 OFF ofA 11 A 4 CREEP 59 BART 9 Edition 030410 ESABMig C420s C420sw OF 3 TM1 1 7452 4 Ul 5 U2 B 1 3 13 x 14 7 17 1 8 U5 22 qui un TTT 25 s Ur 1 QF2 3 2 25 1 26 28 UB 094 ll Ut a lll Gu un 12 sg U2j c2 i ie 7 11 y 12 14 V3 dx UR II 15 gt 1A 15 V4 D B 3a 3 20 16 V5 23 L 24 1 VB 2 d 27 54 2 18 V7 a Los MET 21 i 28 33 vg 25 95 15 w 18 ea vus Mos 12 I 59 3 4 5 400 415 161 FU2 25 800mAT 2 E FUG 4 p SAT 12 49 HI 29 v 30 38 WB M1 54 21 22 39 X 7 51a SE EN 17 V 18 au WID 2 41 Wit 5 fi 42 14412 SHOWN F m RF xd XXX 5 3 2n C4 90 56 taal 9130 A X 3 3i X HN py 572 SL1 OPTION 62 KM1 ST3 ST 1 INDUCTOR O gt INDUCTOR ST2 BRIDGE ES xm X ONLY INSTALLED INESABMig C420sw 5 D r 9 91 XA TO BE CONNECTED XTt 8 a WHEN SL1 NOT INSTALLED E XXX 3polfor ESA BMig C420s TC2 1 12 400 4195 440 460 ag CCP yep 0009
22. ZECH REPUBLIC ESAB VAMBERK s r o Prague Tel 420 2 819 40 885 Fax 420 2 819 40 120 DENMARK Aktieselskabet ESAB Copenhagen Valby Tel 45 36 30 01 11 Fax 45 36 30 40 03 FINLAND ESAB Oy Helsinki Tel 358 9 547 761 Fax 358 9 547 77 71 FRANCE ESAB France S A Cergy Pontoise Tel 33 1 30 75 55 00 Fax 33 1 30 75 55 24 GERMANY ESAB GmbH Solingen Tel 49 212 298 0 Fax 49 212 298 204 GREAT BRITAIN ESAB Group UK Ltd Waltham Cross Tel 44 1992 76 85 15 Fax 44 1992 71 58 03 ESAB Automation Ltd Andover Tel 44 1264 33 22 33 Fax 44 1264 33 20 74 HUNGARY ESAB Kft Budapest Tel 436 1 20 44 182 Fax 436 1 20 44 186 ITALY ESAB Saldatura S p A Mesero Mi Tel 39 02 97 96 81 Fax 39 02 97 28 91 81 THE NETHERLANDS ESAB Nederland B V Utrecht Tel 31 30 248 59 22 Fax 431 30 248 52 60 ESAB NORWAY AS ESAB Larvik Tel 47 33 12 10 00 Fax 47 33 11 52 03 POLAND ESAB 5 2 Warszaw Tel 48 22 813 99 63 Fax 48 22 813 98 81 PORTUGAL ESAB Lda Lisbon Tel 4351 1 837 1527 Fax 351 1 859 1277 SLOVAKIA ESAB Slovakia s r o Bratislava Tel 421 7 44 88 24 26 Fax 421 7 44 88 87 41 SPAIN ESAB Ib rica S A Alcobendas Madrid Tel 34 91 623 11 00 Fax 34 91 661 51 83 SWEDEN ESAB Sverige AB Gothenburg Tel 46 31 50 95 00 Fax 46 31 50 92 22 ESAB International AB Gothenburg Tel 46 31 50 90 00 Fax 46 31 50 93 60
23. ass cable and to the torch current tip which are connected to the external load In this mode as well as during the regular work the meter shows a voltage taking in account voltage drops on cables and welding torch An adjustment of the voltage correction should be carried out only in assumption of the proper voltage calibration and in the presence of load current above 100A 5S C36 OO I Weed Co MP T 51 BE EER 02 1 Duc NER yor dps Rege 0122455789 125456789 1011 12 _ 20 Edition 030410 doce1 AP2 2 Connections to the digital instrument CURRENT SENSING Ss TRICK POLARITY CURRENT SENSING doce1 21 Edition 030410 AP1 0349 303 176 AP2 0349 303 193 control boards for C420s C420sw AP1 1 Power suply The circuit board uses one supply voltage 42VAC rectified by the bridge V2 for power supply to the motor and control circuitry 60V 60VS 26V I N Q Q R3 R4 EN gt TU A2 2 7805 R29 TP4 VY ler c2 LP ug p m ES an N C9 X11 C4 5 V2 C 30V TP1 GND GND 60VS power supply from diode V1 through R1A R1 is regulated to 15V by voltage regulator A1 60VS from V1 through R3 V3A R4 is regulated to 5V by voltage regulator A2 15V is used for supplying of the motor control electronic 5V supplies microprocessor control circuits 60V 60VS
24. elding current A or voltage V both only in SYNERGY mode the lower display shows wire speed reference m min or recommended maximum thickness mm of workpiece During welding upper display shows actual welding voltage or current the lower display as above After welding stop the upper display shows last memorised HOLD values of voltage or current dimmed display Wire speed is set by program stored in the microprocessor and the knob 12 shall be set to middle position O If necessary the operator may correct the preset speed reference with that knob within 20 of the set value doce2 41 Edition 030410 MAINTENANCE Regular maintenance is important for safe reliable operation Maintenance must be executed by a professional Only those persons who have appropriate electrical knowledge authorised personnel may remove the safety plates Note All guarantee undertakings from the supplier cease to apply if the customer himself attempts any work in the product during the guarantee period in order to rectify any faults Inspection and cleaning Check regularly that the power source is free from dirt The power source should be regularly blown clean using dry compressed air at reduced pressure More frequently in dirty environments Otherwise the air inlet outlet may become blocked and cause overheating To avoid this you can use an airfilter The brake hub The hub is adjusted when delivered if
25. ens It can be adjusted by potentiometer RP2 between O and 0 5 seconds AP1 6 Wire feed speed 134 R78 wire feed Potentiometer RP1 controls the wire feed speed over a range from 1 9 to 25 metres minute 14 Edition 030410 AP1 7 Motor driving braking 015 1330 M2 25 1332 E03 Driving The motor is powered by the smoothed 60 V supply Pulse width modulation controlled by transistor Q3 is used to vary the motor voltage The pulse frequency is 12 kHz and the maximum conducting time of the pulses is 97 of the pulse cycle time Freewheeling diode D11 maintains motor current during the pulse breaks At a drive roller speed of 266 r min the wire feed speed is 25 m min The voltage drop across resistor R92 provides a signal that is proportional to the motor current When the current exceeds 15 4 A IC6 2 turns off the gate pulse to Q3 When the current drops Q3 conducts again at the next gate pulse Braking When the motor starts capacitor C60 charges up to 15 V with zener diode D20 limiting the voltage across it Braking is activated by the optocoupler When the transistor in is turned on by the LED 15 V from capacitor C60 is connected to the gate of transistor Q4 Transistor Q4 turns on and short circuits the motor through the resistors R85 R87 AP1 0486 205 886 resistors limit the braking current to about 20 A NB On AP1 0486 205 882 on
26. feeder compartment welder may set the wire speed in full range with the potentiometer RP4 When synergy control mode is active switch 21 in any position but OFF signal from RP4 serves only as correcting value within 20 of preset in microprocessor program speed value Note That correction is counted from the middle point of RP4 B Spot welding setting AP1 28 Mees 5VC Spot welding 5 GNDCA 2 RP3 6 R48B R56 C50 C47 GNDCA GNDCA i X6 C51 R55 Turning right the potentiometer with switch in the front panel 13 welder may select the function spot welding i e time controled welding process HP3 allows to adjust the process duration within 0 5 4 5 sec Normal welding is selected when RP3 is set in the utmost left position AP1 5 Motor driving braking doce 60V ra Motor voltage feedback R24 Matar x R Driving The motor is powered by the smoothed 60 V supply Pulse width modulation on transistor V8 controls the motor voltage The pulse frequency is about 16 kHz and maximum conduction time of the pulses is about 95 of the pulse cycle time During the off parts of the pulse cycle the motor current freewheels through diode V10 24 Edition 030410 At 42V motor supply voltage the wire feed roller speed is 258 r min 5 At a roller soeed of 265r min the wire feed speed is 25 m min Speed control The gate pul
27. icates loss of coolant Contactor 42 V 50 Hz For energising of the welding circuit Pump motor 230 V 50 Hz 0 2 kW Only machines with water cooler Motor rated voltage 42 V DC wire feed unit Main ON OFF switch Welding voltage selector coarse setting Welding voltage selector fine setting Shunt 60 mV 400 A optional accessory _6 Edition 030410 S2 SL1 ST1 ST2 ST3 TC1 TC2 TM1 V1 V2 XB1 XB2 XB4 doce1 ELP switch on the cooling water outlet activates pump M1 Only in machines with water cooler Flow guard optional accessory only in machines with water cooler Thermal switch overheating protection in the inductor L1 NC 120 C Thermal switch overheating protection on the bridge V1 NC 120 C Thermal switch change over the speed of the fan motor EV1 NO 80 C The switch opens when the machine temperature falls to 60 C Control power supply transformer Transformer for CO2 heater optional accessory Main transformer Diode bridge 3ph Diode bridge 1ph ESABMig C420sw C420s only EURO Connector for welding gun connection Welding current socket single pole return current wire 9 pole 3 pole terminal block machine with without water cooler respectively Auxilary 1 pole connector 2 pole terminal block optional accessory Terminal block for polarity reversing Edition 030410 ESABMig C420 C420w 2 2414 C1
28. in advance to the contactor gas preflow time 0 27sec and closes with delay gas postflow time 0 4sec 25 Edition 030410 AP1 7 2 stroke motor test inching 4 stroke 5VC Control mode selector 2 Stroke Motor test 4 Stroke AP 1 1 With switch 51 AP1 in the motor compartment item 24 welder may select the following control modes 2 stroke When the switch on welding gun is pressed welding process starts wire feed motor gas valve and power unit contactor are active When switch on welding is released welding process stops motor is immediately inactive contactor is inactive when burnback time is elapsed and gas valve is inactive with delay of the postflow time Motor test inching When the switch on welding gun is pressed only wire feed motor starts gas valve and contactor remain inactive 4 stroke When the switch on welding gun is pressed 1st time only gas valve is turned on after releasing the switch welding process starts motor and contactor are active Pressing the switch again stops the motor and deactivates the contactor after burnback time opening the switch cuts off the gas flow AP1 8 AP2 1 Measuring and displaying of welding parameters NOTE All circuits of the U I measurment part of the AP1 are galvanically isolated from other circuits on AP1 hence the reference potentials GNDB test point TP7 connected with welding power circuit and
29. inking of the supply ON lamp The fan and the coolant pump are stopped The fan starts from the first start of welding The coolant pump starts at the same moment if it is switched on by means of the ELP switch located on the water outlet to the welding gun AP3 2 Overheating protection The power source includes 2 step control of the fan speed and overheating protection If temperature crosses the threshold point the fan starts to operate with increased speed If the internal temperature becomes too high the supply of the PCB is cut off disabling operation of the machine This state is indicated by permanent lighting of the orange indicating lamp on the front of the unit AP1 supply restores automatically when the temperature falls down The thermal overload cutout ST1 is fitted in the inductor winding L1 it opens at temperature of 120 9C ST2 is located on the heatsink of the V1 rectifier and opens at 120 C NC contacts of the ST1 and ST2 are connected in series activating thermal overload alarm Thermal switch ST3 is also located in the L1 winding its NO contact at 80 C turns over the fan speed docet 30 Edition 030410 AP3 3 Water connection The ESABMig C420w has a sensor ELP ESAB Logic Pump which senses whether the water hoses of the welding gun are connected When a water cooled welding gun is connected the water pump is activated by means of control board AP3 4 Water flow guard ESABMig C
30. issible load at100 duty cycle 315 A 30V 315 A 30V at 60 duty cycle 400 A 34V 400 A 34V at 50 duty cycle 420 A 35V 420 A 35V Setting range DC 50A 16 5V 420A 35V 50A 16 5V 420A 35V Open circuit voltage 14 47 14 47 4 Edition 030410 doce1 Open circuit power with cooling unit Efficiency at max current Power factor at max current Control voltage Wire feed speed Burnback time Creep start 2 4 stroke Welding gun connection Max diameter of wire bobbin Wire dimension range Dimensions Weight with cooling unit Operating temperature Enclosure class Application classification 520W 730W 77 0 92 42V 50 60Hz 1 9 25 0m min 0 0 55 2 4 EURO 300mm 0 6 1 6mm 935 x 640 x 800mm 209kg 217kg 10 to 40 C IP 23 5 520W 730W 77 0 92 42V 50 60Hz 1 6 25 0m min 0 0 35s ON 2 4 EURO 300mm 0 6 1 6mm 935 x 640 x 800mm 209kg 217kg 10 to 40 C IP 23 5 ESABMig C420 C420w 230 400 415 500V 3 50Hz 230 440 460 3 60Hz Voltage Permissible load at100 96 duty cycle at 60 96 duty cycle at 50 duty cycle Setting range DC Open circuit voltage Open circuit power with cooling unit Efficiency at max current Power factor at max current Control voltage Wire feed speed Burnback time Creep start 2 4 stroke Welding gun connection Max diameter of wire bobbin Wire dimension range Dime
31. l of fan speed and overheating protection If temperature crosses the threshold point the fan starts to run with increased speed If the internal temperature becomes too high the welding is interrupted and disabled This state is indicated by permanent lighting of the orange indicating lamp on the front of the unit It resets automatically when the temperature falls down Water connection The ESABMig C420w C420sw have a sensor ELP ESAB Logic Pump which senses whether the water hoses of the welding gun are connected When a water cooled welding gun is connected the water pump is active It is recommended to switch the power source off by means of the mains switch ON OFF 1 for connecting the cooling water hoses to from the ESABMig C420sw C420w doce2 39 Edition 030410 Water flow guard The machines with cooling unit C420w C420sw can be fitted with a water flow guard option see page NO TAG The water flow guard interrupts and disables the welding in event of loss of coolant This state is indicated by blinking of the orange indicating lamp on the front of the power source If there is a lack a coolant flow after 1 min the pump is switched off and latched in this state The pump restarts from that state along with start of welding Idle mode The machine has an idle mode The fan is switched off 5 min after the end of the last welding or after 5 min of work with decreased speed without welding The pump is switched
32. ly R86 amp R86 are installed docet 15 Edition 030410 AP1 8 Tachometer input The tachometer G1 is fitted inside the motor casing Comparator IC5 2 converts the sine wave signal from the tachogenerator to a square wave at the same frequency AP1 9 Creep start Current relay CREEP START SP1 Creep start The creep start function is activated when switch SP1 is open AP1 0486 205 886 e closed AP1 0486 205 882 Creep start means that the motor runs at a speed of 1 9 m minute until the current relay is activated When the relay operates the speed increases to the set speed If the current relay has not operated within one second after starting the motor increases to the set speed Current relay The current relay operates if the welding current exceeds 20 A doce1 16 Edition 030410 AP1 10 Start Stop Welding un g ba 1310 L The trigger switch in the welding gun is supplied at 42 V AC Closing the switch energises optocoupler IC10 pulling down the voltage across C46 A2VAC OV OV AP1 11 Processor doce1 The processor stores the machine program It monitors the power supply voltages if the voltages drop to too low a level wire feed is stopped as described in section AP1 1 above The processor also monitors speed If the wire speed deviates from the set value by more than 1 5 m min for more than five seconds wire feed will be stopped
33. mponent or assembly that is grounded A rapid discharge can occur causing damage This damage can take the form of immediate failure but it is more likely that system performance will be affected and the component will fail prematurely How do we prevent ESD damage ESD damage can be prevented by awareness If static electricity is prevented from building up on you or on anything at your work station then there cannot be any static discharges Nonconductive materials e g fabrics or insulators e g plastics generate and hold static charge so you should not bring unnecessary nonconductive items into the work area It is obviously difficult to avoid all such items so various means are used to drain off any static discharge from persons to prevent the risk of ESD damage This is done by simple devices wrist straps connected to ground and conductive shoes Work surfaces carts and containers must be conductive and grounded use only antistatic packaging materials Overall handling of ESD sensitive devices should be minimized to prevent damage 32 Edition 030410 doce INSTRUCTIONS This chapter is an extract from the instructions for ESABMig C420w C420 and ESABMig C420sw C420s SAFETY Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions Safety precautions must meet the requirements that apply to this type
34. nsions Ixwxh Weight with cooling unit Operating temperature Enclosure class Application classification doce 315 A 30V 400 A 34V 420 A 35V 50A 16 5V 420A 35V 14 47V 520W 730W 77 0 92 42V 50 60Hz 1 9 25 0m min 0 0 55 2 4 EURO 300mm 0 6 1 6mm 935 x 640 x 800mm 209kg 217kg 10 to 40 C IP 23 Edition 030410 WIRING DIAGRAM Component description WARNING STATIC ELECTRICITY can damage circuit boards and electronic components AP1 AP2 AP3 1 C4 C5 C6 C8 CES EV1 G1 H1 H2 KM1 M1 M2 QF1 QF2 QF3 RS doce e Observe precautions for handling electrostatic sensitive devices e Use proper static proof bags and boxes Control circuit board with control electronics see page XX and YY Digital instrument see page XX and YY Control circuit board see page XX EMC capacitors 2 uF 450 V Capacitor 3 uF 400 V Start and run capacitor for fan motor EV1 Capacitor 6 uF 400 V For speed reduction of the cooling fan Suppression capacitors 0 1 uF 250 V Fan Tachogenerator 660 Hz output at a wire speed of 25m min The tachogenerator is incorporated in motor M2 ESABMig C420w C420 only Indicating lamp green Lights when switch QF1 is in the ON position Indicating lamp yellow Lights when thermal overload thermal cut out active If the machine is equipped with flow guard the lamp also ind
35. nstruction manual before installing or operating doce2 33 Edition 030410 INSTALLATION A WARNING This product is intended for industrial use In a domestic environment this product may cause radio interference It is the user s responsibility to take adequate precautions Lifting instructions The power supply should be lifted by means of its lifting eye The handle is only intended for pulling it along the ground Placing Position the welding power source so that its cooling air inlets and outlets are not obstructed Assembly of components A WARNING During transport the rear wheels of the power source are in their forward position Before use place the wheels in their rear position doce2 34 Edition 030410 Electrical installation 400 415V 3 50Hz Mains power supply Check that the unit is connected to the correct mains power supply voltage and that it is protected by the correct fuse size A protective earth connection must be made in accordance with regulations Rating plate with supply connection data gf ss gt d b mi PC lt lt 3 NY AMI LS LM ESABMig C420w C420sw 3 50 60 Hz Voltage V 400 415 Current A at100 duty cycle 19 at 60 duty cycle 27 at 5096 duty cycle 30 Cable area mm Fuse slow A 25 NB The mains cable areas and fuse sizes as sh
36. of welding equipment The following recommen dations should be observed in addition to the standard regulations that apply to the workplace All work must be carried out by trained personnel well acquainted with the operation of the welding equipment Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the operator and damage to the equipment 1 Anyone who uses the welding equipment must be familiar with e its operation location of emergency stops its function relevant safety precautions welding 2 The operator must ensure that e no unauthorised person is stationed within the working area of the equipment when it is started up no one is unprotected when the arc is struck 3 The workplace must be suitable for the purpose be free from draughts 4 Personal safety equipment e Always wear recommended personal safety equipment such as safety glasses flame proof clothing safety gloves Do not wear loose fitting items such as scarves bracelets rings etc which could become trapped or cause burns 5 General precautions e Make sure the return cable is connected securely e Work on high voltage equipment may only be carried out by a qualified electrician e Appropriate fire extinquishing equipment must be clearly marked and close at hand e Lubrication and maintenance must not be carried out on the equipment during operation WARNING Read and understand the i
37. only when water flow guard is used ELP ESAB Logic Pump doce2 36 Edition 030410 SIN 00 Z E om AN 6 __ eee 6 L es ri ESABMig C420sw C420s 1 Mains supply switch 13 Knob for spot welding ON OFF and time setting 2 Switch coarse control 14 Digital display for welding parameters 3 Switch precise control 15 Switch for display selection Volt or Amp 4 Indicating lamp power supply ON 16 Switch for display selection m min or mm 5 Orange indicating lamp overheating and 17 Lamp indicating status of synergy control loss of coolant 6 EURO connector for welding gun 18 Lamps indicating recommended current output max med min inductance 7 Connection for cooling water to the welding 19 Switch for Synergy ON OFF and ma gun Blue with ELP switch terial gas selection 8 Connection for cooling water from the weld 20 Knob for selection of the wire diameter ing gun Red 9 Connection for return cable high induc 21 Knob for burn back time setting tance 10 Connection for return cable medium in 22 Mode selector 2 stroke motor test ductance 4 stroke 11 Connection for return cable low induc 123 Water flow guard tance 12 Knob for wire speed setting correction Indicating loss of coolant only when water flow guard is used ELP
38. own above are in accordance with Swedish regulations They may not be applicable in other countries make sure that the cable area and fuse sizes comply with the relevant national regulations doce2 35 Edition 030410 OPERATION General safety regulations for the handling of the equipment can be found on page 33 Read through before you start using the equipment WARNING gt a Rotating parts can cause injury take great care A WARNING TIPPING RISK There is a risk of tipping while transportation and operation if the welding machine leans more than 10 In that case appropriate securing has to be provided CONNECTIONS AND CONTROL DEVICES ESABMig C420w C420 1 Mains supply switch 10 Connection for return cable medium in ductance 2 Switch coarse control 11 Connection for return cable low induc tance 3 Switch precise control 12 Knob for wire speed setting 4 Indicating lamp power supply 13 Knob for selecting 2 4 stroke control mode 5 Orange indicating lamp overheating and 14 Knob for selecting creep start ON OFF loss of coolant 6 EURO connector for welding gun 15 Knob for burn back time setting 7 Connection for cooling water to the welding 16 Digital instrument V A gun Blue with ELP switch 8 Connection for cooling water from the weld 17 Water flow guard ing gun Red 9 Connection for return cable high induc tance Indicating loss of coolant
39. re no restrictions for voltage selection i e it is possible to weld with any selected parameters see NOTE1 below In synergy control mode depending on the preset wire diameter and material gas operation is enabled only for optimum values of voltage LED 17 in the front panel lights green and all indications are active otherwise 17 is red other indications are inactive and operation is disabled NOTE1 Independently on the selected control mode operation of the machine is disabled LED 17 in red in following cases any of the selectors QF2 QF3 is operated during welding process mains voltage deviation from 400V is more then 15 28 Edition 030410 R75A ms 1 o 60VS t x Of or Sl x E m n m e oo 4 c nc x X8 E ost es E cal ed 8 End s x8 d C55 amp ls 5 X8 4 8 Voltage selector coarse 3 RBBA p 4 C56 RB6B RB6C a 132 34 XB R86D hh ess Mee 29 31 a Voltage selector fing Ji 1 1 NOTE2 In above diagram are shown contacts of the selectors QF2 and QF3 for 400V machine version for another machine versions contact designation may differ from those above refer to the relevant wiring diagrams in order to identify actual connection Indication of synergy control stat
40. readjustment is required follow the instructions below Adjust the brake hub so that wire is slightly slack when wire feed stops Welding gun e Cleaning and replacement of the welding gun s wear parts should take place at regular intervals in order to achieve trouble free wire feed Blow the wire guide clean regularly and clean the contact tip Wire feed unit Check regularly that the wire feed unit is not clogged with dirt e Cleaning and replacement of the wire feed unit mechanism s worn parts should take place at regular intervals in order to achieve trouble free wire feed Note that if pre tensioning is set too hard this can result in abnormal wear on the pressure roller feed roller and wire guide doce2 42 Edition 030410 Topping up the coolant We recommend a 50 50 mixture of water and ethylene glycol ORDERING OF SPARE PARTS Spare parts may be ordered through your nearest ESAB dealer see the last page of this publication doce2 43 Edition 030410 NOTES notes 44 notes 45 ESAB subsidiaries and representative offices Europe AUSTRIA ESAB Ges m b H Vienna Liesing Tel 43 1 888 25 11 Fax 43 1 888 25 11 85 BELGIUM S A ESAB N V Brussels Tel 32 2 745 11 00 Fax 32 2 726 80 05 THE C
41. ses for transistor V8 are generated by a PWM circuit which compares speed reference from microprocessor electronic with signal proportional to the motor voltage R10 R24 Current limit The current limit is set at 13 A The motor current is measured by resistor R32 which produces a voltage drop proportional to the current 1A 33mV The current limit restricts the conduction time of the gate pulses to transistor V8 Compensation of motor x R voltage Current signal allows to compensate voltage drop on motor armature resistance so as to improve wire transportation at low speed settings Compensation is adjusted via trim potentiometer R9B recommended setting is 60 80 of the pot range Braking Motor braking is activated by the turning on the V9 transistor braking curent flows thru R29A R29B R30 and its maximum value is limited to ca 18A AP1 6 Burnback time contactor gas valve doce1 BURNBACK Time setting GNDCA Burnback time The burnback time is the time from when motor braking starts until the main contactor opens The burnback time can be adjusted from 0 to 0 35 seconds with potentiometer R470n the pcb signal to the microprocessor R47 is located in the auxilary control panel inside wire feed compartment pos 23 Activation contactor and gas valve Contactor KM1 is switched on by the relay K1 which is controlled by transistor V14 Gas valve YV1 is controlled by V12 and K2 Valve YV1 opens
42. us LED red Operation disabled H4 GNDB 7 Depending on parameter presets made by welder voltage material gas wire diameter microprocessor determines and displays necessary data and signals When the combination of the presets is incorrect or prohibited red LED H4 17 warns the operator and all control function are disabled See also NOTE in section 2 NOTE1 in section 9C When all presets are optimal correct green LED H4 7177 informs that welding is enabled When welding functions are enabled there are displayed expected welding parameters see section 8B and also relevant green LED H5 H6 or 18 indicates recommended inductance output for the return cable Lmin Lmed L max docet 29 Edition 030410 AP3 Control board Control board switches on and off the fan pump and supply voltage for AP1 Signal levels e inputs 60V dc e ouputs relays 16A 250V indicating LED diodes R31 Lr R30 c19 v14 V19 5 On 4 I 4 NM ON OFF X3 5 FLOW GUARD OPTION THERMAL SWITCH m OVERHEATING ST3 THERMAL SWITCH 2 6 CONTROL THE SPEED OF FAN KM1 2 4 CONTACTOR X2 3 S2 x2 2 PUMP SWITCH X2 1 AP3 1 Start When switched on indicating lamps are tested for 2 seconds Normally if the machine is not overheated it should start to work in idle mode which is indicated by bl
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