ESAB ESABMig C240s User manual

Brand: ESAB

Model: ESABMig C240s

Category: Welding System

Type: User manual

This manual is also suitable for

ESABMig C240

ESAB ESABMig C240s is a compact, step-controlled switched power source for welding with solid steel, stainless steel, or aluminum wire, as well as tubular wire with or without shielding gas. Its fan-cooled and thermally protected design ensures reliable operation even under demanding conditions. The ESABMig C240s offers precise welding control with a setting range of 20A/15V to 240A/23V, making it suitable for a variety of welding applications.

0349 300 046 Valid for serial no. 310−xxx−xxxx 040721

ESABMig C240

ESABMig C240s

Service manual

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

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

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

WIRING DIAGRAM, ESABMig C240 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Component description 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ESABMig C240, 230/400−415V 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DESCRIPTION OF OPERATION, ESABMig C240 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1 Control board 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:1 Power supply 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:2 Start / Stop 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:3 Spot welding 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:4 Wire feed speed 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:5 Motor driving / braking 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:6 Burn−back time, contactor, gas valve 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:7 Thermal overload protection 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1 − ESABMig C240 component positions 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP2 Digital instrument ESABMig C240 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP2:1 Calibration and voltage correction 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP2:2 Connections to the digital instrument 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM, ESABMig C240s 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Component description 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ESABMig C240s, 400−415V 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ESABMig C240s, 230V 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DESCRIPTION OF OPERATION, ESABMig C240s 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

AP1:2 Start / Stop 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:3 Spot welding 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:4 Wire feed speed / Creep start 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:5 Motor control 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:6 Burn−back, contactor, gas valve 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:7 Thermal overload cutout 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:8 2−stroke / inching / 4−stroke 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1+AP2:1 Measurement and display of welding parameters 28. . . . . . . . . . . . . . . . . . . . . . . . . .

AP1+AP2:2 Synergy control presets and indications 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1 − ESABMig C240s component positions 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP2 − ESABMig C240s component positions 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE INSTRUCTIONS 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

What is ESD? 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTRUCTIONS 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Placing 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly of components 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical installation 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mains power supply 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connection and control devices 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting the wire feed pressure 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUNCTIONS EXPLANATION 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ESABMig C240 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ESABMig C240s 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection and cleaning 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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ORDERING OF SPARE PARTS 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NOTES 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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 January 2004.

The ESABMig C240s and ESABMig C240 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 C240s and ESABMig C240 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 ESABMig C240 can be fitted with an instrument for display of current and voltage. It

incorporates a hold function and can be calibrated.

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TECHNICAL DATA

ESABMig C240 ESABMig C240s

Voltage 230/400−415V, 3∼ 50/60Hz 230/400−415V, 3∼ 50/60Hz

Permissible load at

100% duty cycle 130A 130A

60 % duty cycle 170A 170A

30 % duty cycle 240A 240A

Setting range (DC) 20A /15V−240A / 23,0V 20A /15V−240A / 23,0V

Open circuit voltage 14 − 32V 14 − 32V

Open circuit power 190W 190W

Efficiency 76% 76%

Power factor 0.95 0.95

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

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

Creep start − + (auto)

2/4 stroke & motor inching − +

Welding gun connection EURO EURO

Wire dimension range 0,6 − 1,0mm 0,6 − 1,0mm

Max diameter of wire bobin 300mm 300mm

Dimensions lxwxh 840x425x830 840x425x830

Weight 94 kg 97 kg

Operating temperature −10 ÷ +40

C −10 ÷ +40

Enclosure class IP 23 IP 23

Application classification

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, ESABMig C240

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

CES, RES ESD suppression elements

CVS, RVS ESD suppression elements (optional for digital instrument)

EV1 Fan

FU1 − FU5 Fuse

HL1 LED green, On/Off

KM1 Contactor 42V, 50−60Hz

L1 Inductor

M1 Feed unit motor rated voltage 24V

QF1 Switch, ON/OFF

QF2 Switch, welding voltage selector − coarse setting

QF3 Switch, welding voltage selector − fine setting

R1 Resistor

RP1 Potentiometer, wire feed speed

RP2 Potentiometer with switch, spot welding

RS1 Shunt (accessory)

SB1 Welding gun switch

ST1, ST2 Thermal oveload cutout, protection against excessive temperature

TC1 Control transformer

TC2 Transformer for CO2 heater, accessory

TC3 Transformer for digital instrument accessory (accessory)

TM1 Main transformer

V1 Main diode bridge

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V2 Control voltage diode bridge

V7 LED yellow indicator, thermal overload

XT1,XT4 Terminal block

XT3 Terminals for output polarity reversing

XT5 Connector

YV1 Gas valve

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ESABMig C240, 230/400−415V

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DESCRIPTION OF OPERATION, ESABMig C240

AP1 Control board

AP1:1 Power supply

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

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

16V supply

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

regulated to 15V by voltage regulator VR1.

42V 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 (60V) supplies the

wire feed unit motor.

AP1:2 Start / Stop

Closing of the contact SB1 in the welding torch starts the welding process.

The ESABMig C240 provides only two−stroke control mode.

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AP1:3 Spot welding

The ESABMig C240 has a spot welding feature. It is active when the switch in

potentiometer RP2 is closed. Spot welding time is adjustable between 0.2 and 2.5

seconds.

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

will be interrupted. If the switch is held closed for longer than the spot weld time,

welding stops when the spot weld time is up.

To restart, the trigger must be released and then pressed again.

AP1:4 Wire feed speed

The +5.1 V reference voltage (±1 %) is derived from the PWM circuit, that

generates gate pulses for the motor drive transistor.

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

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AP1:5 Motor driving / braking

Driving

The motor is powered with the smoothed +60 V 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 time.

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 160 r/min ±5%. At a roller

speed of 200 r/min, the wire feed speed is 19 m/min ±5 %.

Speed control

The gate pulses to transistor Q5 are generated by a PWM circuit. Resistors R84

and R85 form a voltage 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 5.5 A. The motor current is measured with resistor R68,

that 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 charges via diode D18. The voltage is limited

to 15V with 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 shorts the motor voltage via resistors R69 and R70, hat

limit the braking current to about 20 A.

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AP1:6 Burn−back time, 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.

Contactor

The contactor is controlled by triac TC2.

Gas valve

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

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

AP1:7 Thermal overload protection

The thermal overload cutout ST2 is mounted on the cooling fins of the diode

bridge, and operates at a temperature of 130_C.

The thermal overload cutout ST1 is mounted in the winding of transformer TM1 and

operates at a temperature of 130_C.

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.

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

V7 that indicates operation of the cutout.

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AP1 − ESABMig C240 component positions

AP2 Digital instrument ESABMig C240

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.

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3 Adjust the voltage or the current value equal to the value displayed on 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.

AP2:2 Connections to the digital instrument

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WIRING DIAGRAM, ESABMig C240s

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 Display

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

CES, RES ESD suppression elements

EV1 Fan

FU1 − FU5 Fuse

HL1 LED green, On/Off

KM1 Contactor 42V, 50−60Hz

L1 Inductor

M1 Feed unit motor rated voltage 24V

QF1 Switch, ON/OFF

QF2 Switch, welding voltage selector − coarse setting

QF3 Switch, welding voltage selector − fine setting

R1 Resistor

R2 Resistor

RP3 Potentiometer, wire feed speed

RP4 Potentiometer with switch, spot welding

RS1 Shunt

SB1 Welding gun switch (trigger)

ST1, ST2 Thermal oveload cutout, protection against excessive temperature

TC1 Control transformer

TC2 Transformer for CO2 heater, accessory

TM1 Main transformer

V1 Main diode bridge

V2 Control voltage diode bridge

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V3 − V6 LED indicators for synergy control mode

V7 LED yellow indicator, thermal overload

XT1,XT4 Terminal block

XT3 Terminals for output polarity reversing

XT5 Connector

XS1 Intermediate connector

YV1 Gas valve

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ESABMig C240s, 400−415V

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ESABMig C240s, 230V

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ESAB ESABMig C240s User manual

Brand: ESAB

Model: ESABMig C240s

Category: Welding System

Type: User manual

This manual is also suitable for

ESABMig C240

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ESAB ESABMig C240s User manual

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ESAB ESABMig C240s User manual

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