ESAB ESABMig C420 User manual

Valid for serial no. 2370349 301 075 030919

ESABMig C420

Instruction manual Manuel d’instructions

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Rights reserved to alter specifications without notice.

Sous réserve de modifications sans avis préalable.

ENGLISH 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRANÇAIS 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGLISH

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TOCe

1 DIRECTIVE 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 SAFETY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 INTRODUCTION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 Equipment 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 TECHNICAL DATA 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 INSTALLATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Placing 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Assembly of components 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Electrical installation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 Mains power supply 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 OPERATION 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Connection and control devices 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Functions explanation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 Recommended welding parameters 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 MAINTENANCE 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 Inspection and cleaning 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 FAULT TRACING 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 ORDERING OF SPARE PARTS 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIAGRAM 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WEAR COMPONENTS 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACCESSORIES 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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C420e1

1 DIRECTIVE

DECLARATION OF CONFORMITY

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

power source ESABMig C420 from serial number 237 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 50199 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 2003–03–10

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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C420e1

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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C420e1

3 INTRODUCTION

The ESABMig C420 is step–controlled compact welding power unit incorporating wire feed

mechanism intended for MIG/MAG welding with solid wires of steel, stainless steel or aluminium, and

cored wires with or without shielding gas. The ESABMig C420 is not equipped with cooling system

and can operate only with appropriate gas cooled torches.

The ESABMig C420 is equipped with standard control unit (manual setting of all welding parameters)

and digital instrument (incorporating ”display–hold” function) for displaying of current and voltage.

Machines are fan–cooled and equipped with thermal overload protection.

ESAB’s accessories for the product can be found on page 38.

3.1 Equipment

The power source is supplied with:

SReturn cable 5m with return clamp

SShelf for gas cylinder

SInstruction manual

4 TECHNICAL DATA

ESABMig C420

Voltage 230/400–415/500V, 3~50Hz

230/440–460/575V, 3~60Hz

Permissible load

at100 % duty cycle 315 A/30V

at 60 % duty cycle 400 A/34V

at 50 % duty cycle 420 A/35V

Setting range (DC) 50A/16,5V–420A/35V

Open circuit voltage 16,6–46,5V

Open circuit power 520W

Efficiency at max current 77%

Power factor at max current 0,92

Control voltage 42V, 50/60Hz

Wire feed speed 75 – 1000inch/min (1,9 – 25,0m/min)

Burnback time 0 – 0,5s

Creep start OFF / ON

2/4 stroke 2 / 4

Welding gun connection EURO

Max diameter of wire bobbin 12inch (300mm)

Wire dimension range 0,023 – 1/16inch (0,6 – 1,6mm)

Dimensions lxwxh 36,8 x 25,2 x 31,5inch (935 x 640 x 800mm)

Weight 470lb (213kg)

Operating temperature +14 to 104oF (–10 to +40oC)

Enclosure class IP 23

Application classification

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C420e1

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.

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

5.1 Placing

Position the welding power source so that its cooling air inlets and outlets are not

obstructed.

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C420e1

5.2 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!

5.3 Electrical installation

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C420e1

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 C420w 3∼ 50/60 Hz 3∼ 50 Hz 3∼ 50 Hz 3∼ 60 Hz 3∼ 60 Hz

Voltage V 230 400/415 500 440–460 575

Current A

at100% duty cycle 33 19 15 17 13

at 60% duty cycle 47 27 22 25 19

at 50% duty cycle 53 30 24 27 21

Cable area mm24 x 6AWG

Fuse, slow A 35 25 20 20 20

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C420e1

6 OPERATION

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

page 4. 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 !

6.1 Connection and control devices

ESABMig C420

1Mains supply switch 10 Connection for return cable (–), medium in-

ductance

2Switch, coarse control 11 Connection for return cable (–), low induc-

tance

3Switch, precise control 12 Knob for wire speed setting

4Indicating lamp, power supply ON 13 Knob for selecting 2/4–stroke control mode

5Orange indicating lamp, overheating 14 Knob for selecting – creep start – ON/OFF

6EURO – connector (for welding gun) 15 Knob for burn–back time setting

9Connection for return cable (–), high induc-

tance 16 Digital instrument – V / A (standard)

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