ESAB Mig L305 is a step-switched power source designed for MIG/MAG welding. It features 10 welding voltage settings and a 25 - 300A current range, making it suitable for a variety of welding applications. The built-in fan cooling and thermal overload protection ensure reliable operation even under heavy use. The compact design and low weight make it easy to move and store, while the IP23 enclosure class allows for indoor and outdoor use.
ESAB Mig L305 is a step-switched power source designed for MIG/MAG welding. It features 10 welding voltage settings and a 25 - 300A current range, making it suitable for a variety of welding applications. The built-in fan cooling and thermal overload protection ensure reliable operation even under heavy use. The compact design and low weight make it easy to move and store, while the IP23 enclosure class allows for indoor and outdoor use.
0349 300 067 Valid for serial no. 647, 628--xxx--xxxx071022
Mig L305
Mig L405
Origo
S
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READ THIS FIRS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component description 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OrigoTM Mig L305 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OrigoTM Mig L405 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION OF OPERATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P1 Digital instrument 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P1:1 Calibration and voltage correction 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P1:2 Connections to the digital instrument 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE INSTRUCTIONS 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What is ESD? 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermal switch (thermostat) replacement procedure 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTIONS 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Placing 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly of counter balance 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly of components 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical installation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mains power supply 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection and control devices 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overheating protection 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inductance connection 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and cleaning 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Topping up the coolant 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULT TRACING 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDERING OF SPARE PARTS 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTES 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Edition 071022
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READ THIS FIRS
The 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.
This manual contains details of all design changes that have been made up to and
including October 2007.
The Origo
TM
Mig L305, Mig L405 are designed and tested in accordance with interna-
tional and European standard IEC/EN 60974--1 and EN 60974--10.
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.
INTRODUCTION
The Origo
TM
Mig L305, Mig L405 are step switched power sources designed for
MIG/MAG--welding together with wire feed units OrigoFeed.
The power units are fan--cooled and equipped with thermal overload protection.
The machines can be fitted with an instrument that displays current and voltage.
It incorporates a hold function and can be calibrated.
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TECHNICAL DATA
Origo
TM
Mig L305 Origo
TM
Mig L405 Origo
TM
Mig L405
Voltage 400--415V, 3∼
∼∼
∼50/60 Hz 400--415V, 3∼
∼∼
∼50/60 Hz 230/400--415/500V
3∼
∼∼
∼50 Hz 230/440--460
3∼
∼∼
∼60Hz
Permissible load
at100 % duty cycle 150A 280 A/28 V 280 A/28 V
at 60 % duty cycle 190A 365 A/32 V 365 A/32 V
at 50 % duty cycle -- 400 A/34 V 400 A/34 V
at 25 % duty cycle 300A -- --
Setting range (DC) 30A/15V--300A/29V 50A/16,5V--400A/34V 50A/16,5V--400A/34V
Open circuit voltage 17--40V 17--45 V 17--45 V
Open circuit power 190 W 360 W 360 W
with cooling unit -- 600 W 600 W
Efficiency at max cur-
rent
69% 71% 71%
Power factor at max
current
0,97 0,98 0,98
Control voltage 42 V, 50/60 Hz 42 V, 50/60 Hz 42 V, 50/60 Hz
Dimensions lxwxh 782 x 425 x 830 812 x 552 x 925 812 x 552 x 925
Weight 89 kg 142 kg 143 kg
with cooling unit -- 156 kg 156 kg
Operating temperatu-
re
--10 to +40
o
C --10 to +40
o
C --10 to +40
o
C
Enclosure class IP 23 IP 23 IP 23
Application classifi-
cation
Duty cycle
The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer-
tain load without overloading.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Equipment marked IP23 is designed for indoor and outdoor use.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
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WIRING DIAGRAM
Component description
WARNING !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
S
SS
S Observe precautions for handling electrostatic
sensitive devices.
S
SS
S Use proper static--proof bags and boxes.
ESD
Origo
TM
Mig L305
C1, C2, CES
Capacitor, 0,1 uF 250V
EV1
Fan
HL1
Lamp, green, On/Off
HL2
Lamp, yellow. Thermal overload cutout
KM1
Main contactor 42V, 50--60Hz
L1
Inductor
AP2
Digital instrument, accessory
QF1
Switch, ON/OFF
R1
Resistor
R2
Varistor
RS1
Shunt, accessory
SA1
10--step switch, selection of welding voltage
ST1
Thermal overload cutout, opens at 120
o
C. Mounted at the cooling fins of
the diode bridge.
ST2
Thermal overload cutout, opens at 160
o
C. Mounted in the winding of
transformer TM1.
TC1
Control transformer.
TC2
Transformer for CO2 heater, accessory.
TC3
Transformer for digital instrument, accessory
TM1
Main transformer.
V1--V6
Diode bridge
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XS1
Connector, 15--pole. For connection to/from the wire feed unit.
XT1
3--pole terminal block.
XT2, XT3
connector, flat pin.
Edition 071022
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Origo
TM
Mig L305, 400--415V
Edition 071022
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1sO3545
Origo
TM
Mig L405
C1--C3
Suppression capacitors 2uF 450V.
C4
Capacitor, 3uF 400V. Start and run capacitor for fan motor EV1.
C6, C7
Suppression capacitors 0.1uF 250V.
EV1
Fan
HL1
Indicating lamp 42V, white. Lights when switch QF1 is in the ON position.
HL2
Indicating lamp 42V, yellow. Lights to indicate operation of the thermal
cutouts.
KM1
Contactor 42V 50Hz. Main contactor.
L1
Inductor.
M1
Pump, 230V 50Hz 0.2kW. Only machines with water cooling.
P1
Digital instrument.
QF1
Main ON/OFF switch.
QF2
Switch, for selecting welding voltage, 4--step.
QF3
Switch, for selecting welding voltage, 10--step.
R1
Resistor
RS1
Shunt 60mV / 400A, accessory.
SA1
Cooling water pump switch. Only on machines with water cooling.
ST1
Thermal switch. 150_C Protects the machine against excessive
temperature. Mounted on inductor.
TC1
Control transformer.
TC2
Transformer for CO2 heater, accessory.
TM
1
Main transformer.
V1--V6
Diode bridge
XS1
Connector, 15--pole. For connection to/from the wire feed unit.
XS2--XS5
Main welding current contact, single--pole.
XT1
3--pole terminal block.
XT2
9--pole terminal block.
Edition 071022
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Origo
TM
Mig L405, 400--415V
Edition 071022
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1sO3545
Origo
TM
Mig L405, 230--500V
Edition 071022
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DESCRIPTION OF OPERATION
P1 Digital instrument
P1:1 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, ”I” -- 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 by the reference meter
by means of the pushbuttons: S1 -- ”+”, S2 -- ”--”.
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 correction mode
The reference meter should be connected to the end of mass 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.
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P1:2 Connections to the digital instrument
SERVICE INSTRUCTIONS
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 component 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.
WARNING !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
S
SS
S Observe precautions for handling electrostatic
sensitive devices.
S
SS
S Use proper static--proof bags and boxes.
ESD
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Thermal switch (thermostat) replacement procedure
1. Spare thermostat must be the same type as replaced one.
2. Spare thermostat should be mounted within radius of 10mm or less from broken
thermostat. If it’s possible and safe for transformer winding, broken thermostat may be
removed. Then the spare thermostat is to be mounted right in place of broken one.
3. Spare thermostat should adjoin protected winding as tight as possible.
4. Spare thermostat must be secured with silicone glue of working temperature of 200
o
C
or higher.
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2sO3545
INSTRUCTIONS
This chapter is an extract from the instructions for Origo
TM
Mig L305, Mig L405.
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.
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:
S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding
2. The operator must ensure that:
S no unauthorised person is stationed within the working area of the equipment when it is
started up.
S no--one is unprotected when the arc is struck
3. The workplace must:
S be suitable for the purpose
S be free from draughts
4. Personal safety equipment
S Always wear recommended personal safety equipment, such as safety glasses, flame--proof
clothing, safety gloves.
S Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions
S Make sure the return cable is connected securely.
S Work on high voltage equipment may only be carried out by a qualified electrician.
S Appropriate fire extinquishing equipment must be clearly marked and close at hand.
S Lubrication and maintenance must not be carried out on the equipment during operation.
INSTALLATION
The installation must be executed by a professional.
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.
Edition 071022
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The power supply should be lifted by means of its lifting
eye. The handle is only intended for pulling it along the
ground.
Lifting instructions
Placing
Position the welding power source such way that its cooling air inlets and outlets are
not obstructed.
Assembly of counter balance
Assemble the stabilizer + CB KIT if the counter balance is to be installed on machine.
The stabilizer + CB KIT is an accessory. Ordering number you can find in user manual.
Attention! Utilization of counter balance without stabilizer may cause the machine
tipping over.
Edition 071022
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2sO3545
Assembly of components
During transport, the rear wheels of the power source are in their forward position.
Before use, place the wheels in their rear position.
WARNING!
Edition 071022
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Electrical installation
L405
Edition 071022
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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
L305 3∼ 50/60 Hz
Voltage V 400/415
Current A
at100% duty cycle 7
at 60% duty cycle 10
at 25% duty cycle 18
Cable area mm
2
22
2
4 x 2,5
Fuse, slow A 16
L405 3∼ 50 Hz 3∼ 50/60 Hz 3∼ 50 Hz 3∼ 60 Hz 3∼ 60 Hz
Voltage V 230 400/415 500 230 440/460
Current A
at100% duty cycle 28 16 13 28 14
at 60% duty cycle 42 24 19 41 21
at 50% duty cycle 45 28 20 45 22
Cable area mm
2
22
2
4 x 6 4 x 2,5 4 x 2,5 4 x 6 4 x 2,5
Fuse, slow A 25 20 20 25 20
NB: The mains cable areas and fuse sizes as shown 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.
OPERATION
General safety regulations for the handling of the equipment appear from page
14. Read through before you start using the equipment!
WARNING -- TIPPING RISK!
There is a risk of tipping while transportation and operation, if the welding machine leans
more than 10
o
. In that case appropriate securing has to be provided !
Edition 071022
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Connection and control devices
1 Mains supply switch 8 Connection for return cable (--), high induc-
tance
2 Main supply switch for cooling unit 9 Connection for return cable (--), low induc-
tance
3 Switch, precise control 10 Connection for welding current cable (+)
4 Switch, coarse control 11 Connection for control cable for wire feeder
5 Indicating lamp, power supply ON 12 Connection RED for cooling water from the
wire feed unit
6 Orange indicating lamp, overheating 13 Connection BLUE for cooling water to the
wire feed unit
7 Space for digital meter (optional),
see user manual
Overheating protection
A thermal overload cutout protects against overheating. The cutout resets automatically
when the unit has cooled.
Inductance connection
Higher inductance produces a more flowing weld and fewer spatters. Lower inductance
produces a harsher sound and a stable, concentrated arc.
Edition 071022
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MAINTENANCE
Regular maintenance is important for safe, reliable operation.
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.
Topping up the coolant
We recommend a 50/50 % mixture of water and ethylene glycol.
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ESAB Mig L305 is a step-switched power source designed for MIG/MAG welding. It features 10 welding voltage settings and a 25 - 300A current range, making it suitable for a variety of welding applications. The built-in fan cooling and thermal overload protection ensure reliable operation even under heavy use. The compact design and low weight make it easy to move and store, while the IP23 enclosure class allows for indoor and outdoor use.
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