ESAB ESABArc 300 User manual
- Category
- Welding System
- Type
- User manual
This manual is also suitable for
0700 160 034 Valid for serial no. 316--xxx--xxxx030815
ESABArc 250
ESABArc 300
ESABArc 400
Service manual
2
READ THIS FIRST
................................................................................
3
SAFETY
.................................................................................................
3
INTRODUCTION
..................................................................................
4
TECHNICAL DATA
...............................................................................
4
LOAD CHARACTERISTICS
................................................................
5
WIRING DIAGRAM
...............................................................................
6
MAINS POWER SUPPLY
....................................................................
8
OPERATION
.........................................................................................
8
MAINTENANCE
...................................................................................
9
FAULT TRACING
.................................................................................
9
ORDERING OF SPARE PARTS
........................................................
15
SPARE PARTS LIST
...........................................................................
17
3
1 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 connection diagram as a form of index for the description of operation. All
component names in the connection diagram are listed in the component description.
Welding power source ESABArc250/300/400 from serial number 316 000 0001
onwards, conforms to standard EN 60974-1 and with standard 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 standards.
2SAFETY
WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE
PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH
SHOULD BE BASED ON MANUFACTURER’S HAZARD DATA.
ELECTRICAL SHOCK - Can kill
•
Install and earth the welding unit in accordance with applicable standards.
•
Do not touch live electrical parts or electrode with bare skin, wet gloves or wet clothing.
•
Insulate yourself from earth and the workpice.
•
Ensure your working stance is safe.
FUMES AND GASES – Can be dangerous to health
•
Keep your head out of the fumes.
•
Use ventilation, extraction at the arc, or both, to keep fumes and gases from your breathing zone and
the general area.
ARC RAYS – Can injure
eyes and burn skin.
•
Protect your eyes and body. Use the correct welding screen and filter lens and wear protective clothing.
•
Protect bystanders with suitable screens or curtains.
FIRE HAZARD
•
Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE – Excessive noise can damage hearing
•
Protect your ears. Use earmuffs or other hearing protection.
•
Warn bystanders of the risk
MALFUNCTION – Call for expert assistance in the event of malfunction,
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
4
3 INTRODUCTION
ESABArc 250, ESABArc 300 and ESABArc 400 are moving core power sources
intended for welding with coated electrodes (MMA welding).
The welding power source supply direct current, which allows you to weld most alloyed
and non-alloyed steels, stainless steel and cast iron.
ESABArc 250 and ESABArc 300 are suitable for welding with coated electrodes from
∅
1,6 to
∅
5 mm and ESABArc 400 accepting up to
∅
6 mm.
4 TECHNICAL DATA
ESABArc250 ESABArc 300 ESABArc 400
Permitted load at:
40% duty cycle
100% duty cycle
Setting range
Open circuit voltage
Open circuit power
Power factor cos
ϕ
(at max. current)
Enclosure class
Application class
Weight
250A/30V
140A/25,6V
50A/22V-250A/30V
65-75V
490W
0,52
IP23
S
98kg
285A/31,4V
150A/26V
55A/22,2V-300A/32V
65-75 V
590W
0,54
IP23
S
105 kg
400A/36V
230A/29,2V
65A/22,6V-400A/36V
70-80V
750W
0,58
IP23
S
158kg
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can
weld at a certain load without overloading.
Enclosure class
The IP code indicates enclosure class, i.e. the degree of protection against penetration
by solid objects and 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.
S
5
5 LOAD CHARACTERISTICS
(
ESABArc250 ESABArc300
(
6
6 WIRING DIAGRAM
6.1 Diagram ESABArc 250/300
Component description
EV1
Cooling fan
HL1
Indicating lamp, 230V, white. Indicates mains switch on.
QF1
Mains switch. Power is supplied to the main transformer when the mains switch
is set to position I, the fan starts and indicator lamp HL1 is lit.
R1
Resistor, 18k
W
11W
RV1
Varistor
ST1
Thermostat mounted on the transformer primary coil. The thermostat prevents
overheating and operates at a temperature of 105
0
C. Resetting takes place
automatically as soon as the power source has cooled down.
TM1
Main transformer, three-phase with movable core.
V1
Three-phase rectifier bridge.
V2
Yellow LED lights up in case of overheating.
XS1
Welding terminal (+)
XS2
Welding terminal (-)
XT1
Terminal block. The mains cable is connected to the terminal block XT1 (using
terminals L1, L2 and L3) and PE-terminal.
XT2
Terminal block
Z1
EMC filter mounted on the diode bridge V1 (in according to EN 50199)
7
6.2 Diagram ESABArc 400
Component description
EV1
Cooling fan
HL1
Indicating lamp, 230V, white. Indicates mains switch on.
KM1
Contactor 230V, 50-60Hz
QF1
Mains switch On/Off. When the switch is set to position I, power is supplied to the
control transformer TC1, contactor coil KM1 and main transformer TM1, the fan
starts and indicator lamp HL1 is lit.
R1
Resistor, 12k
W
4W
RV1
Varistor
ST1
Thermostat mounted on the cooling fins of the diode bridge V1 and operates at a
temperature of 100
0
C. Resetting takes place automatically as soon as the power
source has cooled down.
ST2
Thermostat mounted in the transformer primary coil and operates at a
temperature of 135
0
C. Resetting takes place automatically as soon as the power
source has cooled down.
TC1
Control power supply transformer (230-400-450-500V/230V)
TM1
Main transformer, three-phase with movable core.
V1
Three-phase rectifier bridge.
V2
Yellow LED lights up in case of overheating.
XS1
Welding terminal (+)
XS2
Welding terminal (-)
XT1
Terminal block. The mains cable is connected to the terminal block XT1 (using
terminals L1, L2 and L3) and PE-terminal.
XT2
Terminal block
Z1
EMC filter mounted on the diode bridge V1 (in according to EN 50199)
8
7 MAINS POWER SUPPLY
• Check that the welding power source is configured for the available mains supply
before connecting it to the mains.
• The mains cable is connected to the connection plinth XT1 (using terminals L1,
L2 and L3) and PE-terminal.
• Make sure that the connection plinth XT1 and XT2 are wired for the correct
mains power supply. (When delivered rectifiers are wired for the mains voltage
3x400-415V, 50Hz).
• Connect the mains cable to an earthed mains terminal according to the relevant
regulations and install a properly fuses in the main fuse box.
ESABArc250
Mains voltage (V) 230 400-415
440-460
500
Frequency (Hz) 50/60 50 60 50
Max. eff. supply current (A) 34 19,5 17 15
Fuse slow (A)
35 20 20 16
Mains cable area (mm
2
)
4x6 4x4
4x4 4x2,5
ESABArc 300
Mains voltage (V) 230 400-415
440-460
500
Frequency (Hz) 50/60 50 60 50
Max. eff. supply current (A) 36 21 18 16
Fuse slow (A)
35 25 20 16
Mains cable area (mm
2
)
4x6 4x4
4x4 4x2,5
ESABArc 400
Mains voltage (V) 230 400-415
440-460
500
Frequency (Hz) 50/60 50 60 50
Max. eff. supply current (A) 56 32 28 25
Fuse slow (A)
63 35 35 25
Mains cable area (mm
2
)
4x10 4x6
4x6 4x4
8 OPERATION
Start-up
• Start the welding power source by setting the mains switch to position “I”. The
white lamp will light up and the fan will start.
• Set the welding current, using the crank on the front. The selected welding
current is shown by the dial. Follow the instructions on the electrode package for
the recommended welding current.
• Connect welding and return cables to the terminals marked + and - on the front
of the power source. Polarity reversal is carried out by changing over the welding
and return cable connections. Connect return cable to the work piece.
• The power source is now ready for welding.
9
9 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
Inspection and cleaning
Normally it is sufficient to blow the welding power source clean regularly using dry
compressed air (reduced pressure), and to clean the filter in the front regularly.
In dusty and dirty environment the welding power source should be cleaned at shorter
intervals.
Where necessary, lubricate the chain and sprocket using heat-resistant grease. When
required, the gliding surfaces of the leakage cores can also be smeared with a thin
coating of this grease.
10 FAULT TRACING
The following measurements have been made with a main supply voltage of
about 390 V AC. According to this voltage it is possible to get different results
which must be in the range of ±10% from the values stated here below .
10.1 Main supply voltage measurement
Test the following AC voltage between the three main phases L1-L2, L1-L3 and L2-L3
obtaining the same result.
Switch on the welding power source by setting the mains switch to position “I”.
The same voltage between the main phases L1-L2 must be measured also at the
primary of control transformer TC1 (only for ESABArc400).
10
10.2 Primary circuit voltages measurement
Measure the voltage between the centre and each phase (L1, L2 and L3).
The same voltage must be measured also at the terminals of the fan EV1 and signal
lamp HL1 (ESABArc 250/300)
The same voltage must be measured also at the terminals of the fan EV1, signal lamp
HL1, secondary of control transformer TC1 and contactor coil KM1 (ESABArc400).
10.3 Primary circuit fault tracing
Type of fault Possible cause
The power source does not switch on or
does not remain switched on.
•
Off/On switch open or defective.
•
Blown mains supply fuses.
•
One or more phases missing.
•
Thermic protection open (ESABArc400)
•
Damaged or not feeded contactor coil
(ESABArc400).
11
10.4 Secondary circuit voltage measurement
Measurement should be done between the three AC inlets of the rectifiers bridge. The
secondary of the transformer is connected to the three AC inlets of the bridge by a delta
connection.
ESABArc 250/300 - voltage at a minimum adjustment
ESABArc 250/300 - voltage at a maximum adjustment
12
ESABArc 400 - voltage at a minimum adjustment
ESABArc 400 - voltage at a maximum adjustment
10.5 Secondary circuit fault tracing
Type of fault Possible cause
Missing one phase
•
Defective transformer.
•
The connection from the transformer to
the rectifier are disconnected or short-
circuited.
•
Rectifier bridge is short-circuited.
13
10.6 Welding circuit voltage measurement
Measurement should be done between the welding terminals (+) and (-).
ESABArc 250/300 - voltage at a minimum adjustment
ESABArc 250/300 - voltage at a maximum adjustment
ESABArc 250/300 –voltage in case the thermostat is open
14
ESABArc 400 - voltage at a minimum adjustment
ESABArc 400 - voltage at a maximum adjustment
10.7 Welding circuit fault tracing
Type of fault Possible cause
Open circuit voltage is too low or absent
•
Defective rectifier bridge.
•
The connection from the rectifier to the
welding terminals are disconnected or
short-circuited.
•
Rectifier bridge is short-circuited.
•
Thermostat is open
15
11 ORDERING OF SPARE PARTS
ESABArc250/300/400 is designed and tested in accordance with the international
and European standards IEC/EN 60 974-1 and EN 60 974-1.
It is the obligation of the service unit which has carried out the service or repair
work to make sure that the product still conforms to the said standard.
Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication. When ordering, please state product type, serial number, designation
and spare part number in accordance with the spare parts list.
This facilitates dispatch and ensures correct delivery.
16
17
Spare parts list
C
= component designation in the circuit diagram
Quantity
Item
no.
ESAB
Arc 250
ESAB
Arc 300
ESAB
Arc 400
Ordering
no.
Denomination
C
1 2 2 2 0160 362 881 Welding terminal, OKC XS1, XS2
2 1 1 0317 636 011 Crank
2 1 0700 160 005 Crank
3 1 1 0700 160 001 Switch QF1
3 1 0700 160 002 Switch QF1
4 1 1 1 0317 636 081 LE diode, yellow V2
5 1 1 1 0466 130 001 Signal lamp, white HL1
6 1 1 0700 160 003 Dial, complete with spring and
cariers
6 1 0700 160 004 Dial, complete with spring and
cariers
7 1 0700 160 032 Aux. transformer TC1
8 1 0700 160 031 Contactor KM1
9 2 2 0317 636 016 Wheel
9 2 0700 160 006 Wheel
1
2
3
4
5 6
7
8
9
18
C
= component designation in the circuit diagram
Quantity
Item
no.
ESAB
Arc 250
ESAB
Arc 300
ESAB
Arc 400
Ordering
no.
Denomination
C
1 1 1 1 Cable inlet
F
29
2 1 1 0317 636 039 Fan EV1
2 1 0700 160 007 Fan EV1
3 1 1 0317 636 038 Fan protection
4 1 0700 160 008 Diode bridge V1
4 1 0700 160 009 Diode bridge V1
4 1 0700 160 010 Diode bridge V1
5 1 0700 160 011 Transformer
230/400V
TM1
5 1 0700 160 012 Transformer
230/400V
TM1
5 1 0700 160 013 Transformer
230/400V
TM1
5 1 0700 160 014 Transformer
230/400/500V
TM1
5 1 0700 160 015 Transformer
230/400/500V
TM1
5 1 0700 160 016 Transformer
230/400/500V
TM1
6 3 Secondary coil
6 3 Secondary coil
6 3 Secondary coil
7 3 Primary coil
230/400V
7 3 Primary coil
230/400V
7 3
Primary coil
230/400V
7 3
Primary coil
230/400/500V
7 3 Primary coil
230/400/500V
7 3 Primary coil
230/400/500V
8 1 1 0700 160 035 Movable core, complete
17-18
12
14 15
4
2-3
1
5
67
1319
8
11
10
16
9
19
8 1 0700 160 036 Movable core, complete
9 1 1 Core tensioner and springs
9 1 Core tensioner and springs
10 1 1 1 Core worm (upper)
11 1 1 1 Core worm (lower)
12 1 1 Leakage core (lower)
12 1 Leakage core (lower)
13 1 1 Leakage core (upper)
13 1 Leakage core (upper)
14 2 2 Core guide rod
14 2 Core guide rod
15 2 2 Core guide with leaf springs
15 2 Core guide with leaf springs
16 1 1 0700 160 027 Transmission chain
16 1 0700 160 028 Transmission chain
17 2 2 2 0700 160 029 Chain bridge
18 2 2 2 0317 636 080 Axial ball bearing
19 2 2 Terminal block XT1, XT2
19 2 Terminal block XT1, XT2
ESAB AB
SE--695 81 LAXÅ
SWEDEN
Phone +46 584 81 000
Fax +46 584 123 08
www.esab.co m
030210
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 CZECH REPUBLIC
ESAB V AMBERK s.r.o.
Prague
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Copenhagen--Valby
Tel:+4536300111
Fax:+4536304003
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel:+33130755500
Fax:+33130755524
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:+3612044182
Fax:+3612044186
ITALY
ESAB Saldatura S.p.A.
Mesero (Mi)
Tel:+3902979681
Fax:+390297289181
THE NETHERLANDS
ESAB Nederland B.V.
Utrecht
Tel: +31 30 248 59 22
Fax: +31 30 248 52 60
NORWAY
AS ESAB
Larvik
Tel:+4733121000
Fax:+4733115203
POLAND
ESAB Sp.z.o.o
Warszaw
Tel: +48 22 813 99 63
Fax: +48 22 813 98 81
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 1 837 1527
Fax: +351 1 859 1277
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel:+421744882426
Fax:+421744888741
SPAIN
ESAB Ibérica S.A.
Alcobendas (Madrid)
Tel: +34 91 623 11 00
Fax: +34 91 661 51 83
SWEDEN
ESAB Sverige AB
Gothenburg
Tel:+4631509500
Fax:+4631509222
ESAB International AB
Gothenburg
Tel:+4631509000
Fax:+4631509360
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: +52 8 350 7554
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 44 58
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: +359 2 974 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.co m
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ESAB ESABArc 300 User manual
- Category
- Welding System
- Type
- User manual
- This manual is also suitable for
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