ESAB ESABMig C280 User manual

Brand: ESAB

Model: ESABMig C280

Category: Welding System

Type: User manual

This manual is also suitable for

ESABMig C340

ESAB ESABMig C280 is a step controlled switched power source designed for welding with solid steel, stainless steel or aluminum wire as well as tubular wire with or without shielding gas. It is equipped with spot welding function and integrated wire feed mechanism with feed rollers for solid wire, diameter 0.8, and 1.0 (4WD 1.0 and 1.2). It also features an instrument for display of current and voltage with hold function and calibration capability.

0349 300 036 Valid for serial no. 225–xxx–xxxx 030411

ESABMig C280

ESABMig C340

Service manual

– 2 –TOCe

READ THIS FIRST 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INTRODUCTION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TECHNICAL DATA 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SUPPRESSOR BOARD AP3 – ESABMig C280,

COMPONENT POSITIONS & SCHEMATIC DIAGRAM 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM, ESABMig C280 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Component description 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ESABMig C280, 400–415V 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ESABMig C280, 230–500V 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DESCRIPTION OF OPERATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1 Control board 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:1 Power supply 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:2 Start / Stop 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:3 Spot welding 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:4 Wire feed speed 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:5 Motor driving / braking 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:6 Burn–back, contactor, gas valve 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:7 Thermal overload cutout 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1 – ESABMig C280 component positions 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP2 Digital instrument ESABMig C280/C340 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP2:1 Calibration and voltage correction 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP2:2 Connections to the digital instrument 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM, ESABMig C340 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Component description 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ESABMig C340, 400–415V 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ESABMig C340, 230–500V 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DESCRIPTION OF OPERATION 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1 Control board 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:1 Power supply 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:2 2–stroke / 4–stroke 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:3 Start / Stop 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:4 Current relay, Creep start / Normal start 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:5 Motor driving / braking 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:6 Tachometer input 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:7 Burn–back time 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:8 Wire feed speed 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:9 Gas valve 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:10 Contactor 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1 – ESABMig C340 component positions 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE INSTRUCTIONS 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

What is ESD? 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTRUCTIONS 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Placing 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly of components 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical installation 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mains power supply 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connection and control devices 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting the wire feed pressure 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUNCTIONS EXPLANATION 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overheating protection 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inductance connection 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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MAINTENANCE 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection and cleaning 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ORDERING OF SPARE PARTS 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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.

This manual contains details of all design changes that have been made up to and

including August 2002.

The ESABMig C280 and ESABMig C340 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.

INTRODUCTION

The ESABMig C280 and ESABMig C340 are step controlled switched power sources in a

compact design, intended for welding with solid steel, stainless steel or aluminum wire as

well as tubular wire with or without shielding gas.

The possibility of welding with homogeneous wire/shielding gas and welding with gasless

tubular wire is obtained by switching the + and – connections on the switching terminal

above the wire feed unit.

The power units are fan–cooled and equipped with thermal overload protection.

The machines can be fitted with an instrument for display of current and voltage. It

incorporates a hold function and can be calibrated.

ESABMig C280 is equipped with spot welding function and integrated wire feed mechanism

with feed rollers for solid wire, diameter 0.8, and 1.0 (4WD 1.0 and 1.2).

ESABMig C340 is equipped with switch for 2/4 stroke trigger action with gas pre–flow and

gas post–flow in the 4 stroke mode, adjustable burnback time, creep start and integrated

wire feed mechanism with feed roller for solid wire, diameter 0.8, and 1.0

(4WD 1.0, and 1.2)

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TECHNICAL DATA

Voltage 400–415 V, 3∼ 50/60 Hz 230/400–415/500V3∼50Hz

230/440–460V, 3∼60Hz

Permissible load at

100% duty cycle 150 A/22 V 150 A/22 V

60 % duty cycle 190 A/24 V 190 A/24 V

30 % duty cycle 280 A/28 V 280 A/28 V

Setting range (DC) 30A/15V–280A/28V 30A/15V–280A/28V

Open circuit voltage 15–38 V 15–38 V

Open circuit power 190 W 190 W

Efficiency 69% 69%

Power factor 0.97 0.97

Control voltage 42 V, 50/60 Hz 42 V, 50/60 Hz

Wire feed speed 1,9 – 19m/min 1,9 – 19m/min

Burnback time 0 – 0,25s 0 – 0,25s

Spot welding 0,2 – 2,5s 0,2 – 2,5s

Welding gun connection EURO EURO

Dimensions lxwxh 840x425x830 840x425x830

Weight 91 kg 91 kg

Operating temperature –10 to +40

C –10 to +40

Enclosure class IP 23 IP 23

Application classification

Voltage 400–415 V, 3∼ 50/60 Hz 230/400–415/500V3∼50Hz

230/440–460V, 3∼60Hz

Permissible load at

100% duty cycle 195 A/24 V 195 A/24 V

60 % duty cycle 250 A/27 V 250 A/27 V

30 % duty cycle 340 A/31 V 340 A/31 V

Setting range (DC) 40A/16V–340A/31V 40A/16V–340A/31V

Open circuit voltage 16–40 V 16–40 V

Open circuit power 240 W 240 W

Efficiency 77% 77%

Power factor 0.95 0.95

Control voltage 42 V, 50/60 Hz 42 V, 50/60 Hz

Wire feed speed 1,9 – 20m/min 1,9 – 20m/min

Burnback time 0 – 0,5s 0 – 0,5s

Creep start OFF / ON OFF / ON

2/4 stroke 2 / 4 2 / 4

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Welding gun connection EURO EURO

Dimensions lxwxh 840x425x830 840x425x830

Weight 114 kg 114 kg

Operating temperature –10 to +40

C –10 to +40

Enclosure class IP 23 IP 23

Application classification

SUPPRESSOR BOARD AP3 – ESABMig C280,

COMPONENT POSITIONS & SCHEMATIC DIAGRAM

Components positions

Schematic diagram

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WIRING DIAGRAM, ESABMig C280

Component description

WARNING !

STATIC ELECTRICITY can damage circuit

boards and electronic components.

S Observe precautions for handling electrostatic

sensitive devices.

S Use proper static–proof bags and boxes.

ESD

AP1 Circuit board

AP2 Digital instrument, accessory

AP3 Suppressor board, see circuit diagram below

C1, C2, C3, CES Capacitor 0,1uF/250V

EV1 Fan

FU1 – FU5 Fuse

HL1 Lamp, white, On/Off

KM1 Contactor 42V, 50–60Hz

L1 Inductor

M1 Feed unit motor rated voltage 24V

QF1 Switch, ON/OFF

R1 Resistor

R2 Varistor

RES Resistor

RP1 Potentiometer, wire feed speed

RP2 Potentiometer with switch, spot welding

RS1 Shunt, accessory

SA1 10–step switch, for selecting welding voltage

ST1 Thermal oveload cutout, opens at 110

C. The cutout is mounted at the

cooling fins of the diode bridge.

ST2 Thermal overload cutout, opens at 110

C. The cutout is mounted at 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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V7 Led yellow indication, thermal overload

XS1, XS2 Main welding current contact, single – pole

XT2 9 – pole terminal block

YV1 Gas valve

Edition 030411

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ESABMig C280, 400–415V

Edition 030411

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ESABMig C280, 230–500V

Edition 030411

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DESCRIPTION OF OPERATION

AP1 Control board

AP1:1 Power supply

The circuit board uses two different supply voltages: 16 V for the electronics

and

42 V for power supply to the motor, contactor and gas valve.

Power supply to the electronic circuitry

The 16 V power supply from transformer TC1 is rectified by diodes D3–D6 and

regulated to 15V by voltage regulator VR1.

42 V power supply

A_42VAC and B_42VAC are used as control power supplies for the contactor

and gas valve. Indicating lamp HL1 is mounted on the front of the machine and

shows that the power is turned on. The supply is rectified by diode bridge BR1.

The output voltage (60 V) supplies the wire feed unit motor.

AP1:2 Start / Stop

Closing contact SB1 on the welding torch starts the welding process.

The ESABMig C280 provides only two–stroke control mode.

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AP1:3 Spot welding

The ESABMig C280 has a spot welding capability. The function is active when

the switch in potentiometer RP2 is closed.

Spot welding time is adjustable between 0.2 and 2.5s.

If the welding torch trigger switch is released during a spot welding, the

welding sequence will be interrupted. If the switch is held closed for longer

than the spot welding time, welding stops when the spot weld time is up. To

restart, the switch must be released and then operated again.

AP1:4 Wire feed speed

The wire feed speed adjustment range is 1.9 to 19m/min.

The +5.1V reference voltage (+/–1%) is derived from the PWM circuit, which

generates gate pulses for the motor drive transistor.

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AP1:5 Motor driving / braking

Driving

The motor is powered by the smoothed +60V supply. Pulse width modulation

of transistor Q5 controls the motor voltage. The pulse frequency is about 9kHz,

and maximum conduction time of the pulses is about 98% of the pulse cycle.

During the Off parts of the pulse cycle, the motor current freewheels through

diode D35.

At 24V motor supply voltage, the wire feed roller speed is 160r/min +/–5%.

At a roller speed of 200r/min, the wire feed speed is 19m/min +/–5%.

Speed control

The gate pulses to transistor Q5 are generated by a PWM circuit. Resistors

R84 and R85 form a potential divider that provides voltage signal that is

proportional to the wire speed. The PWM circuit compares the set speed with

the actual speed.

Current limit

The current limit is set at 5,5A. The motor current is measured by resistor R68,

which produces a voltage drop proportional to the current (1A = 100mV). The

current limit restricts the conduction time of the gate pulses to transistor Q5.

Braking

When the motor starts, capacitor C22 gets charged via diode D18. The voltage

is limited to 15V by zener diode D13. The LED in optocoupler IC4 is activated

when braking is required, connecting C22 (15V) to the gate of transistor Q3.

The transistor conducts and short–circuits the motor voltage via resistors R69

and R70, that limit the braking current to about 20A.

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AP1:6 Burn–back, contactor, gas valve

Burn–back time

The burn–back time is the time from when motor braking starts until the main

contactor opens. When welding stops, capacitor C38 is discharged through

potentiometer R21. The time can be adjusted from 0 to 0.25 seconds.

Energising the contactor

The contactor is controlled by triac TC2.

Gas valve

The gas valve is connected to board contacts A5 and A6.

ESABMig C280

The valve receives its power supply from triac TC2 via resistor R20 (0?).

ESABMig C340

The valve receives its power supply from triac TC1.

AP1:7 Thermal overload cutout

The thermal overload cutout ST1 is mounted on the cooling fins of the diode

bridge, and operates at a temperature of 110

C in both machines. The thermal

overload cutout ST2 is mounted in the winding of transformer TM1, and

operates at a temperature of 110

C in ESABMig C280.

A current normally flows through the cutouts from the +20V supply via R2 and

D2, and from the +15V supply via R8. The voltage at contact C1 is kept low by

the switch. If a cutout operates, C1 goes high and the output signals from the

board are disabled.

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Operation of the cutout causes a current to flow from +20V to 0V via R2, D1

and LED V7, which indicates operation of the cutout.

AP1 – ESABMig C280 component positions

AP2 Digital instrument ESABMig C280/C340

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.

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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.

Edition 030411

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AP2:2 Connections to the digital instrument

Edition 030411

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WIRING DIAGRAM, ESABMig C340

Component description

WARNING !

STATIC ELECTRICITY can damage circuit

boards and electronic components.

S Observe precautions for handling electrostatic

sensitive devices.

S Use proper static–proof bags and boxes.

ESD

AP1 Circuit board

AP2 Digital instrument, accessory

C1, C2, C3, CES Capacitor 0,1uF/250V

EV1 Fan

FU1 – FU5 Fuse

G1 Tachogenerator, incorporated in motor M01

HL1 Lamp, white, On/Off

KM1 Contactor 42V, 50–60Hz

L1 Inductor

M1 Feed unit motor rated voltage 24V

QF1 Switch, ON/OFF

R1 Resistor

R2 Varistor

RES Resistor

RP1 Potentiometer, wire feed speed

RP2 Potentiometer, burn–back time

RS1 Shunt, accessory

SA1 4–step switch, coarse selection of welding voltage

SA2 10–step switch, fine selection of welding voltage

S1 Switch, creep start ON/OFF

S2 Switch, 2/4–stroke

ST1 Thermal overload cutout, opens at 120

C. Mounted at the cooling fins

of the diode bridge.

ST2 Thermal overload cutout, opens at 130

C. Mounted at the winding of

transformer TM1.

TC1 Control transformer

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TC2 Transformer for CO2 heater, accessory

TC3 Transformer for digital instrument, accessory

TM1 Main transformer

V1–V6 Diode bridge

V7 Led yellow indication, thermal overload

XP Connector

XS1, XS2 Main welding current contact, single – pole

XT2 9 – pole terminal block

YV1 Gas valve

Edition 030411

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ESABMig C340, 400–415V

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ESAB ESABMig C280 User manual

Brand: ESAB

Model: ESABMig C280

Category: Welding System

Type: User manual

This manual is also suitable for

ESABMig C340

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ESAB ESABMig C280 User manual

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ESAB ESABMig C280 User manual

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