Related Manuals for ESAB ESABMig C420
Summary of Contents for ESAB ESABMig C420
- Page 1 ESABMig C420 ESABMig C420s Service manual 0349 300 041 030410 Valid for serial no. 237–xxx–xxxx...
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Page 2: Table Of Contents
............ESABMig C420/C420w . - Page 3 OPERATION ............... CONNECTIONS AND CONTROL DEVICES .
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Page 4: Read This First
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. - Page 5 217kg Operating temperature –10 to +40 –10 to +40 Enclosure class IP 23 IP 23 Application classification ESABMig C420/C420w Voltage 230/400–415/500V 3~50Hz 230/440–460 3~60Hz Permissible load at100 % duty cycle 315 A/30V at 60 % duty cycle 400 A/34V at 50 % duty cycle...
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Page 6: Wiring Diagram
WIRING DIAGRAM Component description WARNING ! STATIC ELECTRICITY can damage circuit boards and electronic components. Observe precautions for handling electrostatic sensitive devices. 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 ). - Page 7 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 Thermal switch – overheating protection, on the bridge V1 ( NC, 120 Thermal switch –...
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Page 8: Esabmig C420/C420W
ESABMig C420/C420w Edition 030410 – 8 – doce1... -
Page 9: Esabmig C420/C420W
ESABMig C420/C420w Edition 030410 – 9 – doce1... -
Page 10: Esabmig C420S/C420Sw
ESABMig C420s/C420sw Edition 030410 – 10 – doce1... -
Page 11: Esabmig C420S/C420Sw
ESABMig C420s/C420sw Edition 030410 – 11 – doce1... -
Page 12: Description Of Operation
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 –... -
Page 13: Ap1:3 Activation, Gas Valve
AP1:3 Activation, gas valve The gas valve is connected to connectors F04 and F05. AP1:4 2–stroke / 4–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. -
Page 14: Ap1:5 Burn-Back Time
AP1:5 Burn–back time The burn–back time is the time from when motor braking starts until the machine contactor opens. It can be adjusted by potentiometer RP2 between 0 and 0.5 seconds. AP1:6 Wire feed speed Potentiometer RP1 controls the wire feed speed over a range from 1.9 to 25 metres/minute. -
Page 15: Ap1:7 Motor Driving / Braking
AP1:7 Motor driving / braking 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. -
Page 16: Ap1:8 Tachometer Input
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 The creep start function is activated when switch SP1 is: open (AP1 –... -
Page 17: Ap1:10 Start / Stop
AP1:10 Start / Stop 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. AP1:11 Processor 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. -
Page 18: Ap1 Component Positions (0486 205 886)
AP1 Component positions (0486 205 886) Edition 030410 – 18 – doce1... -
Page 19: Ap1 Component Positions (0486 205 882)
AP1 Component positions (0486 205 882) Edition 030410 – 19 – doce1... -
Page 20: Ap2 Digital Instrument (Option For C420W/C420)
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. -
Page 21: Ap2:2 Connections To The Digital Instrument
AP2:2 Connections to the digital instrument Edition 030410 – 21 – doce1... -
Page 22: Ap1 (0349 303 176), Ap2 (0349 303 193) Control Boards
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. +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 +15V is used for supplying of the motor control electronic... -
Page 23: Ap1:3 Welding Current Detection
AP1:3 Welding current detection 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);... -
Page 24: Ap1:5 Motor Driving / Braking
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. -
Page 25: Ap1:6 Burnback Time, Contactor, Gas Valve
At 42V motor supply voltage, the wire feed roller speed is 258 r/min +/–5%. At a roller speed of 265r/min, the wire feed speed is 25 m/min. Speed control The gate pulses 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). -
Page 26: Ap1:7 2-Stroke / Motor Test (Inching) / 4-Stroke
AP1:7 2–stroke / motor test (inching) / 4–stroke With switch S1 on 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). - Page 27 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. FU* – frequency is 6,4 kHz for – 40V input (adj. by R97) FI* –...
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Page 28: Ap1:9 Synergy Control Presets And Indications
AP1:9 Synergy control presets and indications 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 Wire diameter presetting... - Page 29 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 status Depending on parameter presets made by welder (voltage, material/gas, wire diameter), microprocessor determines and displays necessary data and signals.
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Page 30: Ap3 Control Board
AP3 Control board Control board AP3 switches on and off. the fan, pump and supply voltage for AP1. Signal levels: inputs: 60V dc ouputs: relays 16A/250V + indicating LED diodes. 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 blinking of the supply–ON lamp. -
Page 31: Ap3:3 Water Connection
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. -
Page 32: Service Instructions
SERVICE INSTRUCTIONS WARNING ! STATIC ELECTRICITY can damage circuit boards and electronic components. Observe precautions for handling electrostatic sensitive devices. 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. -
Page 33: Instructions
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 of welding equipment. The following recommen- dations should be observed in addition to the standard regulations that apply to the workplace. -
Page 34: Installation
INSTALLATION 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. -
Page 35: Electrical Installation
Electrical installation 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 ESABMig C420w/C420sw 3∼... -
Page 36: Operation
Connection for cooling water from the weld- Water flow guard ing gun (Red) Connection for return cable (–), high induc- tance * Indicating loss of coolant, only when water flow guard is used ** ELP = ESAB Logic Pump Edition 030410 – 36 – doce2... -
Page 37: Esabmig C420Sw/C420S
Connection for return cable (–), low induc- Water flow guard tance Knob for wire speed setting / correction * Indicating loss of coolant, only when water flow guard is used ** ELP = ESAB Logic Pump Edition 030410 – 37 – doce2... - Page 38 Edition 030410 – 38 – doce2...
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Page 39: Setting The Wire Feed Pressure
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. -
Page 40: Esabmig C420W/C420
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. - Page 41 Standard control mode When standard control mode is selected lamps [17, 18] are off and only a lower row of digital display [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 –...
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Page 42: Maintenance
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. -
Page 43: Topping Up The Coolant
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. Edition 030410 – 43 –... -
Page 44: Notes
NOTES – 44 – notes... - Page 45 – 45 – notes...
- Page 46 ESAB subsidiaries and representative offices Europe NORWAY Asia/Pacific Representative offices AS ESAB AUSTRIA BULGARIA CHINA Larvik ESAB Ges.m.b.H ESAB Representative Office Shanghai ESAB A/P Tel: +47 33 12 10 00 Vienna–Liesing Sofia Shanghai Fax: +47 33 11 52 03 Tel: +43 1 888 25 11...
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