ESAB ESABMig C240 User manual

Valid for serial no. 3100349 301 064 060324

ESABMig C240

ESABMig C240s

Instruction manual

ENGLISH

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TOCe

1 DIRECTIVE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 SAFETY 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 INTRODUCTION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 Equipment 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

5 INSTALLATION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Placing 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Assembly of components 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Electrical installation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 Mains power supply 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 OPERATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Connection and control devices 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Functions explanation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 ESABMig C240 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 ESABMig C240s 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 MAINTENANCE 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 Inspection and cleaning 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 FAULT TRACING 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 ORDERING OF SPARE PARTS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIAGRAM 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACCESSORIES 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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C240e

1 DIRECTIVE

DECLARATION OF CONFORMITY

ESAB Welding Equipment AB, S−695 81 Laxå, Sweden, gives its unreserved guarantee that welding

power source ESABMig C240 / ESABMig C240s from serial number 310 complies with standard IEC/

EN 60974−1, in accordance with the requirements of directive (73/23/EEC) and addendum

(93/68/EEC) and with standard EN 60974−10 in accordance with the requirements of directive

(89/336/EEC) and addendum (93/68/EEC).

−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−

Henry Selenius

Vice President

ESAB Welding Equipment AB

695 81 LAXÅ

SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924

Laxå 03.12.2003

2 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:

Sits operation

Slocation of emergency stops

Sits function

Srelevant safety precautions

Swelding

2. The operator must ensure that:

Sno unauthorised person is stationed within the working area of the equipment when it is

started up.

Sno−one is unprotected when the arc is struck

3. The workplace must:

Sbe suitable for the purpose

Sbe free from draughts

4. Personal safety equipment

SAlways wear recommended personal safety equipment, such as safety glasses, flame−proof

clothing, safety gloves.

SDo not wear loose−fitting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautions

SMake sure the return cable is connected securely.

SWork on high voltage equipment may only be carried out by a qualified electrician.

SAppropriate fire extinquishing equipment must be clearly marked and close at hand.

SLubrication and maintenance must not be carried out on the equipment during operation.

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C240e

WARNING

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-

TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE

BASED ON MANUFACTURERS’ HAZARD DATA.

ELECTRIC SHOCK −Can kill

SInstall and earth the welding unit in accordance with applicable standards.

SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

SInsulate yourself from earth and the workpiece.

SEnsure your working stance is safe.

FUMES AND GASES −Can be dangerous to health

SKeep your head out of the fumes.

SUse ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone

and the general area.

ARC RAYS −Can injure eyes and burn skin.

SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.

SProtect bystanders with suitable screens or curtains.

FIRE HAZARD

SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE −Excessive noise can damage hearing

SProtect your ears. Use earmuffs or other hearing protection.

SWarn bystanders of the risk.

MALFUNCTION −Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

WARNING!

Read and understand the instruction manual

before installing or operating.

Do not use the power source for thawing frozen pipes.

WARNING!

This product is solely intended for arc welding.

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C240e

3 INTRODUCTION

ESABMig C240 & ESABMig C240s are step controlled power sources in a compact design, intended

for welding with solid steel, stainless steel or aluminium 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.

ESAB’s accessories for the product can be found on page 19.

3.1 Equipment

The power source is supplied with:

SWelding gun PSF 250 −3m

SReturn cable 3,5m with return clamp

SShelf for gas cylinder

SInstruction manual

4 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 ÷+40oC−10 ÷+40oC

Enclosure class IP 23 IP 23

Application classification

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C240e

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.

5 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.

5.1 Placing

Position the welding power source such way that its cooling air inlets and outlets are

not obstructed.

5.2 Assembly of components

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C240e

During transport, the rear wheels of the power source are in their forward position.

Before use, place the wheels in their rear position.

WARNING!

5.3 Electrical installation

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C240e

5.4 Mains power supply

Check that the unit is connected to the correct mains power supply voltage, and that

it is protected by the correct fuse size. A protective earth connection must be made,

in accordance with regulations.

Rating plate with supply connection data

ESABMig C240/C240s 3∼ 50/60 Hz 3∼ 50/60 Hz

Voltage V 230 400/415

Current A

at 100% duty cycle 8.6 5.3

at 60% duty cycle 12.4 7.6

at 30% duty cycle 21 12

Cable area mm24 x 2.5 4 x 1.5

Fuse slow A 20 16

NB: The mains cable areas and fuse sizes as shown above are in accordance with Swedish

regulations. They may not be applicable in other countries: make sure that the cable area and fuse

sizes comply with the relevant national regulations.

6 OPERATION

General safety regulations for the handling of the equipment can be found on

page 3. Read through before you start using the equipment!

WARNING!

Rotating parts can cause injury, take great care.

WARNING −TIPPING RISK!

There is a risk of tipping while transportation and operation, if the welding machine leans

more than 10o. In that case appropriate securing has to be provided !

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C240e

6.1 Connection and control devices

ESABMig C240

1Mains supply switch 7Connection for return cable (−), high induc-

tance

2Switch, coarse control 8Connection for return cable (−), low induc-

tance

3Switch, precise control 9Knob for wire speed setting

4Indicating lamp, power supply ON 10 Knob for spot welding −ON/OFF and time

setting

5Orange indicating lamp, overheating 11 Digital instrument −V / A

(option,see page 19)

6EURO −connector (for welding gun) 12 Knob for burn−back time setting

ESABMig C240s

1Mains supply switch 11 Digital display for welding parameters

2Switch, coarse control 12 Switch for display selection −Volt. or Amp

3Switch, precise control 13 Switch for display selection −m/min or mm

4Indicating lamp, power supply ON 14 Lamp indicating status of synergy control

5Orange indicating lamp, overheating 15 Lamps indicating recommended (−) current

output −max/min inductance

6EURO −connector (for welding gun) 16 Switch for ”Synergy”−ON/OFF and ma-

terial/gas selection

7Connection for return cable (−), high induc-

tance 17 Knob for selection of the wire diameter

8Connection for return cable (−), low induc-

tance 18 Knob for burn−back time setting

9Knob for wire speed setting / correction 19 Mode selector 2−stroke / / 4−stroke

10 Knob for spot welding −ON/OFF and time

setting

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C240e

6.2 Functions explanation

6.2.1 Overheating protection

When the machine is switched on with the mains switch [1], indicating lamp [4] is on and

lamp [5] off −the machine is ready to operate. If the internal temperature becomes too

high, the welding is interrupted and disabled. This state is indicated by lighting of the

orange indicating lamp [5] on the front of the machine. It resets automatically when the

temperature has fallen.

6.2.2 Inductance connection

Higher inductance produces a more flowing weld and fewer spatters. Lower inductance

produces a harsher sound and a stable, concentrated arc.

6.3 ESABMig C240

The ESABMig C240 is equipped with standard control unit. Welder can manually

select and adjust all welding parameters.

SWire speed (1,9 −19m/min).

SSpot−welding time.

SBurn back time.

The machine C240 can be fitted with a digital instrument that displays current and

voltage. It incorporates a hold function (see page 19).

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