ESAB ESABMig 405 User manual
- Category
- Welding System
- Type
- User manual
This manual is also suitable for
0349 300 043 Valid for serial no. 246–xxx–xxxx 030409
ESABMig 405
ESABMig 505
Service manual
– 2 –TOCe
READ THIS FIRST 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component description 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ESABMig 405, 400–415V 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ESABMig 405, 230–500V 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ESABMig 505, 400–415V 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ESABMig 505, 230–500V 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION OF OPERATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1 Control board 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:1 Start 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:2 Overheating protection 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:3 Water connection 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:4 Water flow guard 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:5 Idle mode 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1 – Components position 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V7 Start booster – inductor short–circuiter 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V7:1 Principle of operation 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V7 – Components position 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP2 Digital instrument 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP2:1 Calibration and voltage correction 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP2:2 Connections to the digital instrument 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE INSTRUCTIONS 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What is ESD? 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTIONS 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Placing 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly of components 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly of stabilizer 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical installation 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mains power supply 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUNCTIONS EXPLANATION 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overheating protection 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water connection 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water flow guard 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idle mode 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inductance 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and cleaning 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Topping up the coolant 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDERING OF SPARE PARTS 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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 March 2003.
The ESABMig 405 and ESABMig 505 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 405 & ESABMig 505 are step switched power sources designed for
MIG/MAG–welding together with wire feed units ESABFeed 30 and the most of
ESAB wire feeders.
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
ESABMig 405
Voltage 400–415V, 3~50/60 Hz 230/400–415/500V 3~50 Hz
230/440–460 3~60Hz
Permissible load
at100 % duty cycle 280 A/28 V 280 A/28 V
at 60 % duty cycle 365 A/32 V 365 A/32 V
at 50 % duty cycle 400 A/34 V 400 A/34 V
Setting range (DC) 50A/16,5V–400A/34V 50A/16,5V–400A/34V
Open circuit voltage 17–45 V 17–45 V
Open circuit power 360 W 360 W
with cooling unit 600 W 600 W
Efficiency at max current 71% 71%
Power factor at max current 0,98 0,98
Control voltage 42 V, 50/60 Hz 42 V, 50/60 Hz
Dimensions lxwxh 812 x 552 x 925 812 x 552 x 925
Weight 144 kg 145 kg
with cooling unit 158 kg 158 kg
Operating temperature –10 to +40
o
C –10 to +40
o
C
Enclosure class IP 23 IP 23
Application classification
ESABMig 505
Voltage 400–415V, 3~50/60 Hz 230/400–415/500V 3~50 Hz
230/440–460 3~60Hz
Permissible load
at100 % duty cycle 390 A/33,5 V 390 A/33,5 V
at 60 % duty cycle 500 A/39 V 500 A/39 V
Setting range (DC) 50A/16,5V–500A/39V 50A/16,5V–500A/39V
Open circuit voltage 17–50 V 17–50 V
Open circuit power 440 W 440 W
with cooling unit 620 W 620 W
Efficiency at max current 82% 82%
Power factor at max current 0,92 0,92
Control voltage 42 V, 50/60 Hz 42 V, 50/60 Hz
Dimensions lxwxh 812 x 552 x 925 812 x 552 x 925
Weight 214 kg 215 kg
with cooling unit 228 kg 229 kg
Operating temperature –10 to +40
o
C –10 to +40
o
C
Enclosure class IP 23 IP 23
Application classification
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WIRING DIAGRAM
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 with control electronics.
C1–C3
Suppression capacitors 2uF 450V.
C4
Capacitor, 3uF 400V. Start and run capacitor for fan motor EV1.
C5
Capacitor, 6uF 400V. For speed reduction of the cooling fan.
C6, C7
Suppression capacitors 0.1uF 250V.
EV1
Fan
FU1
Circuit breaker, 10A. Protects the 42V supply to the wire feed unit.
H1
LED green. Lights when switch QF1 is in the ON position.
Blinks when is idle mode.
H2
LED yellow. Lights to indicate operation of the thermal cutouts.
Blinks to indicate loss of coolant when machine is equipped with flow
guard.
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 for ESABMig 405
5–step for ESABMig 505
QF3
Switch, for selecting welding voltage
10–step for ESABMig 405
8–step for ESABMig 505
R1
Resistor
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RS1
Shunt. Accessory.
60mV / 400A for ESABMig 405
60mV / 600A for ESABMig 505
SA1
Cooling water pump switch. Only on machines with water cooling.
SL1
Flow guard. Accessory.
ST1, ST2
Thermal switch. Protects the machine against excessive temperature.
ST3
Thermal switch. Controls the speed of fan motor EV1. The switch closes
when the temperature exceeds 80
o
C, energising relay on the PCB AP1.
TC1
Control transformer.
TC2
Transformer for CO2 heater. Accessory.
TM1
Main transformer.
V1–V6
Diode bridge
V7
Start booster.
XS1
Connector, 23–pole. For connection to/from the wire feed unit.
XS2–XS5
Main welding current contact, single–pole.
XT1
8–pole terminal block.
XT2
9–pole terminal block.
XT3
6–pole terminal block. Only for ESABMig 505 with 230–500V mains
connection.
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ESABMig 405, 400–415V
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ESABMig 405, 230–500V
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ESABMig 505, 400–415V
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ESABMig 505, 230–500V
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DESCRIPTION OF OPERATION
AP1 Control board
Control board AP1 switches fan, pump and wire feeder supply on and off.
Inputs – 60V dc, ouputs – relays 16A/250V + indicating LEDs.
AP1:1 Start
When switched on, indicators are checked 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. The fan and the coolant pump
are stopped.
The fan starts from the first start of welding. The coolant pump starts at the
same moment, if it is switched on by means of either the ELP switch on the
wire feeder, or the pump supply switch on the power source.
AP1:2 Overheating protection
The power source has 2–step control of fan speed and overheating protection.
If temperature crosses the threshold point, the fan starts to operate with
increased speed. If the internal temperature becomes too high, the supply of
the wire feeder is switched off. This state is indicated by permanent lighting of
the orange indicating lamp on the front of the unit. Wire feeder supply restores
automatically when the temperature falls down.
ESABMig 405
The thermal overload cutout ST1, is fitted in the L1 inductor winding. It opens
at temperature of 150
o
C, and closes at 120
o
C.
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ESABMig 505
Two, connected in series thermal overload cutouts are applied: ST1 is fitted in
the TM1 transformer winding; ST2 is fitted in the V1 diode bridge.
ST1, ST2 open at a temperature of 130
o
C, and close at 100
o
C.
AP1:3 Water connection
The ESABFeed 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 AP1. For the ESABFeeds the pump supply switch on the power source
should be left in position ”0/ELP”.
It is recommended to switch the power source off by means of the mains
switch ON/OFF for connecting the cooling water hoses to/from the ESABFeed
wire feed unit.
The pump supply switch must be in position ”I” exclusively for other types of
wire feeders, when a water cooled welding gun is used. When a self cooled
welding gun is used the pump switch must be in position ”ELP/0”.
Note. If a water cooled welding gun is used when the pump is inactive, the
welding gun might be damaged.
AP1:4 Water flow guard
The water flow guard interrupts and disables the welding in the event of loss of
coolant. This state is indicated by blinking of the orange indicating lamp on the
front of the power source.
If there is a lack a coolant flow, after 1 min the pump is switched off and
latched in that state. The pump restarts from that state along with start of
welding.
AP1:5 Idle mode
After long pause the control board switched the machine to the idle mode. The
fan is switched off 5 min after the last welding or after 5 min of work with
decreased speed without welding.
The pump is switched off 3 min after the last welding. When both fan and
pump are switched off the power supply lamp on the front panel is blinking.
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AP1 – Components position
V7 Start booster – inductor short–circuiter
V7:1 Principle of operation
The ESABMig 405 is supplied with an inductor short–circuiter that makes the welding starts
easier.
Terminal 1 is connected to inductor terminal XS3. When welding starts, IC1 is activated by
voltage drop across the inductor. Terminal 2 is connected to the positive terminal of the
welding current and provides a power supply for the circuit board. Thyristor TY1 on the
circuit board is triggered by IC1 and in turn triggers the short–circuiting thyristor, the gate of
which is connected to terminal 3. Terminal 4 is connected to the cathode of the
short–circuiting thyristor, that forms the neutral point of the circuit board.
A time delay, consisting of C6 and R5, causes IC1 to change state and interrupt the gate
current to thyristor TY1 after about 200 milliseconds. On conclusion of welding, C4
discharges through resistor R4. If a new weld start occurs before the voltage across C4 has
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fallen below the changeover voltage of IC1, the thyristor will not be turned on. This prevents
the thyristor from firing if the break in welding is less than about 0.5 seconds.
V7 – Components position
AP2 Digital instrument
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.
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.
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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.
AP2:2 Connections to the digital instrument
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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 Observe precautions for handling electrostatic
sensitive devices.
S Use proper static–proof bags and boxes.
ESD
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INSTRUCTIONS
This chapter is an extract from the instructions for ESABMig 405, ESABMig 505.
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.
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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 so that its cooling air inlets and outlets are not obstructed.
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!
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Assembly of stabilizer
Assemble the stabilizer if counter balance is to be installed on machine. The stabilizer
is an accessory.
Attention! Utilization of counter balance without stabilizer may cause the machine
tipping over.
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Electrical installation
ESABMig 405
ESABMig 505
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ESAB ESABMig 405 User manual
- Category
- Welding System
- Type
- User manual
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