ESAB ESABMig C340 User manual

ESABMig C340
ESAB
Brand
ESAB
Model
ESABMig C340
Category
Welding System
Type
User manual

This manual is also suitable for

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Edition 030411
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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)
Edition 030411
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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
o
C –10 to +40
o
C
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
Edition 030411
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Welding gun connection EURO EURO
Dimensions lxwxh 840x425x830 840x425x830
Weight 114 kg 114 kg
Operating temperature –10 to +40
o
C –10 to +40
o
C
Enclosure class IP 23 IP 23
Application classification
SUPPRESSOR BOARD AP3 – ESABMig C280,
COMPONENT POSITIONS & SCHEMATIC DIAGRAM
Components positions
Schematic diagram
Edition 030411
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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
o
C. The cutout is mounted at the
cooling fins of the diode bridge.
ST2 Thermal overload cutout, opens at 110
o
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
Edition 030411
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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
– 9 –d1sc2834
ESABMig C280, 400–415V
Edition 030411
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d1sc2834
ESABMig C280, 230–500V
Edition 030411
– 11 –d1sc2834
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.
Edition 030411
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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.
Edition 030411
– 13 –d1sc2834
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.
Edition 030411
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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
o
C in both machines. The thermal
overload cutout ST2 is mounted in the winding of transformer TM1, and
operates at a temperature of 110
o
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.
Edition 030411
– 15 –d1sc2834
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.
Edition 030411
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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
– 17 –d1sc2834
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
o
C. Mounted at the cooling fins
of the diode bridge.
ST2 Thermal overload cutout, opens at 130
o
C. Mounted at the winding of
transformer TM1.
TC1 Control transformer
Edition 030411
– 19 –d1sc2834
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 C340 User manual

ESABMig C340
ESAB
Brand
ESAB
Model
ESABMig C340
Category
Welding System
Type
User manual
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