ESAB PSF 250 User manual

Instruction manual
0458 870 201 GB 20140514
PSF™250, 250C,305,315CLD
PSF™405,405RS3,405CRS3
PSF™410w,410wRS3,410Cw,
410CwRS3
PSF™505,510w,510wRS3

TABLE OF CONTENTS
0458 870 201 © ESAB AB 2014
1 SAFETY ................................................................................................................ 4
2 INTRODUCTION................................................................................................... 5
3 SHIPMENT AND PACKAGING ............................................................................ 6
4 TECHNICAL DATA ............................................................................................... 7
5 OPERATION ......................................................................................................... 9
5.1 Contact tip ............................................................................................................ 9
5.2 Wire liner............................................................................................................... 9
5.3 Replacing the wire liner.......................................................................................9
5.4 Gas nozzle .......................................................................................................... 10
5.5 Gas protection.................................................................................................... 10
5.6 Gas flow meter ................................................................................................... 10
5.7 Centrovac............................................................................................................ 10
6 MAINTENANCE.................................................................................................. 12
6.1 Daily or as necessary ........................................................................................12
6.2 Centrovac............................................................................................................ 12
7 FAULT-TRACING................................................................................................ 14
8 DISASSEMBLY AND DISPOSAL....................................................................... 15
9 ORDERING SPARE-PARTS............................................................................... 16
CUTTING LENGTH....................................................................................................17
ORDERING NUMBERS.............................................................................................18
WEAR PARTS............................................................................................................20
ACCESSORIES .........................................................................................................30
Rights reserved to alter specifications without notice.

1 SAFETY
0458 870 201 -4- © ESAB AB 2014
1 SAFETY
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting. Ask for your employer's safety practices which should
be based on manufacturers' hazard data.
ELECTRIC SHOCK - Can kill
• Install and earth the unit in accordance with applicable standards
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing
• Insulate yourself from earth and the workpiece
• 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 take fumes and gases away
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!
ESAB can provide you with all necessary welding protection and accessories.
CAUTION!
Read and understand the instruction manual before
installing or operating.

2 INTRODUCTION
0458 870 201 -5- © ESAB AB 2014
2 INTRODUCTION
PSF 250, 305, 405 and 505 form a series of self-cooling swan neck welding torches.
PSF wform a series of water-cooled swan neck welding torches.
PSF RS3 welding torches are equipped with program selectors for switching between preset
programs. Programs are preset at the welding power source.
PSF Cform a series of welding torches with smoke exhausters. The welding torches are
available with either self-cooling or water cooling systems and are of a swan-neck design.
PSF LD is a smaller welding torch. This welding torch is available in a variety of types; for
more information see the ordering number in the "Ordering numbers" chapter.
A range of accessories including welding tips, swan necks and contact tips are also
available.
Accessories for the product can be found in the "ACCESSORIES" chapter of this
manual.

3 SHIPMENT AND PACKAGING
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3 SHIPMENT AND PACKAGING
The components are carefully checked and packaged, however, damage may occur during
shipping.
Checking procedure on receipt of goods
Check that the shipment is correct by referring to the shipping note.
In case of damage
Check the package and components for damage (visual inspection).
In case of complaints
If the package and/or components have been damaged during shipment:
• Contact the last carrier immediately.
• Keep the packaging (for possible inspection by the carrier or supplier, or for returning the
goods).
Storage in an enclosed space
Ambient temperature for shipment and storage: -25°C to +55°C
Relative air humidity: up to 90% at a temperature of 20°C

4 TECHNICAL DATA
0458 870 201 -7- © ESAB AB 2014
4 TECHNICAL DATA
General torch data with reference to IEC/EN 60974-7
Type of voltage: DC voltage
Wire type: Standard round wire
Voltage measurement: Peak value of 113 V
Connection protection
Machine side (EN 60 529):
IP3X
Shielding gas: CO2or Ar/CO2
Enclosure class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration
by solid objects of 2.5 mm Ø and greater. Omitting second characteristic numeral.
Welding torch PSF 250 PSF 305 PSF 405
405 RS3
PSF 505 PSF 410w
410w RS3
PSF 510w
510w RS3
Permitted load at 60% duty cycle
Carbon dioxide CO2250 A 315 A 380 A 475 A - -
Mixed gas, Argon
(Al wire)
225 A 285 A 325 A 410 A - -
Permitted load at 100% duty cycle
Carbon dioxide CO2- - - - 400 A 500 A
Mixed gas, Argon
(Al wire)
- - - - 350 A 440 A
Recommended
gas flow
8-13
l/min
10-15
l/min
11-16
l/min
12-18
l/min
11-16
l/min
12-18
l/min
Wire diameter 0.6-1.0
mm
0.8-1.2
mm*
0.8-1.6
mm
1.0-2.4
mm
0.8-1.6
mm
1.0-2.4
mm
Weight 3.0 m hose
package
1.8 kg 2.5 kg 3.1 kg 3.9 kg 3.0 kg 3.3 kg
Weight 4.5 m hose
package
2.5 kg 3.3 kg 4.2 kg 5.3 kg 3.9 kg 4.0 kg
* Not recommended for 1.2 mm aluminium wire
Welding torch PSF 250 PSF 315C LD PSF 405C
PSF 405C RS3
PSF 410Cw
410Cw RS3
Permitted load at 60% duty cycle
Carbon dioxide CO2250 A 315 A 380 A -
Mixed gas, Argon
(Al wire)
225 A 285 A 325 A -
Permitted load at 100% duty cycle
Carbon dioxide CO2- - - 380 A
Mixed gas, Argon
(Al wire)
- - - 325 A
Recommended
gas flow
8-13 l/min 10-15 l/min 11-16 l/min 11-16 l/min

4 TECHNICAL DATA
0458 870 201 -8- © ESAB AB 2014
Welding torch PSF 250 PSF 315C LD PSF 405C
PSF 405C RS3
PSF 410Cw
410Cw RS3
Wire diameter 0.6-1.0 mm 0.8-1.2 mm* 1.0-1.6 mm 0.8-1.6 mm
Weight 3.0 m hose
package
3.5 kg 4.3 kg 4.6 kg 4.0 kg
Weight 4.5 m hose
package
5.0 kg 5.4 kg 6.8 kg 6.2 kg
* Not recommended for 1.2 mm aluminium wire
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or
cut at a certain load without overloading. The duty cycle is valid for 40°C/104°F.
Liquid cooled torches PSF 410w, PSF 410w RS3, PSF 510w, PSF 510w RS3,
PSF 410Cw, PSF 410Cw RS3
Type of cooling 50% water and 50% ethylglykol
Pressure max. 3.5 bar
Pressure min. 2.0 bar
Temperature max. 50°C
Flow 1.0 l/min

5 OPERATION
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5 OPERATION
General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it through before you start using the equipment!
5.1 Contact tip
The hole size of the contact tip is determined by the diameter of the wire, the type of inert
gas and the level of current used. See the "Wear parts" chapter.
5.2 Wire liner
The spiral steel wire liner that comes as standard with the welding torch can be used for all
types of wire of the intended size with exception of aluminium.
PTFE-wire liners are suitable for welding with all types of wires (Al, Ss, and Fe).
However, it is recommended that PTFE-wire liners are not used when welding using Fe and
CW wires that are thicker than 1.2 mm due to the increased instance of wear.
PTFE-wire liners have a considerably shorter life than the standard steel spiral.
In order to ensure that you enjoy a satisfactory level of wire feed, select a wire liner in the
table in the "Wear parts" chapter.
5.3 Replacing the wire liner
1. Fit the correct nipple.
NOTE!
Each wire guide is supplied with 2 nipples, 1 for ESAB connection and 1 for
EURO connection.
a) ESAB connection
b) EURO connection
2. Remove the gas nozzle and the tip adaptor.
3. Fit the wire liner in the hose package.
4. Cut the wire guide to the correct length using a projectile "X" as shown in the figure
below.
While cutting, the welding torch must be extended with the wire guide fully inserted into
the rear connector.
5. Remove sharp edges inside the liner after cutting.

5 OPERATION
0458 870 201 - 10 - © ESAB AB 2014
6. Fit the tip adaptor and the gas nozzle.
7. Fit the welding torch on the power source.
a) Turn the connecting section counterclockwise until it resistance is met.
b) The wire guide should go in.
5.4 Gas nozzle
There is a spatter protector fitted inside the gas nozzle. This must be in position during
welding in order to prevent the welding spatter jamming and thereby causing a short circuit in
the swan neck.
Gas nozzles with larger and smaller openings are available as accessories for each type of
welding torch. See the "Wear parts" chapter.
5.5 Gas protection
Several factors are important for good gas protection. The most important are:
1. Selection of shielding gas. Mixed gas and Argon require a greater flow
than carbon dioxide.
2. Set flow quantity. See Technical data (to be measured at the
gas nozzle.)
3. Set welding current. High welding currents requires greater gas
flow.
4. Position of welding joint. A vertical position requires greater gas flow.
5. Type of welding joint. External corner joints require a greater gas
flow than butt joints. Conversely, fillet joints
require a lower gas flow.
6. Smoke evacuation on the welding torch. Using smoke evacuation increases the need
for inert gas by 10-12%.
7. Angle of welding torch to the job. Anling the welding torch at less than 45° may
result in poor gas protection.
5.6 Gas flow meter
A gas flow meter to measure gas flow through the welding torch is available as an accessory
see the "Accessories" chapter .
5.7 Centrovac
Integrated smoke evacuation
You can tailor the level of suction by opening the damper on the topside of the handle.
PSF 250C/PSF 315C LD
When welding in narrow positions it may be necessary to reduce the suction. This can be
achieved by opening the slots as shown below.

5 OPERATION
0458 870 201 - 11 - © ESAB AB 2014
Suction source for welding torches with integrated smoke evacuation
In order to achieve full suction power, the smoke evacuation welding torch must be
connected to a suction source where pressure does not fall below 15 KPa.

6 MAINTENANCE
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6 MAINTENANCE
NOTE!
Regular maintenance is important for safe, reliable operation.
CAUTION!
All warranty undertakings from the supplier cease to apply if the customer
attempts any work to rectify any faults in the product during the warranty period.
6.1 Daily or as necessary
A regular programme of care and maintenance reduces unnecessary and expensive
downtime.
• Each time a wire bobbin is changed, the welding hose should be removed from the
supply unit and cleaned with compressed air.
• The wire end must not have sharp edges when inserted into the wire liner. This is
especially important when using PTFE wire liners.
Tips and nozzles
• Remove the gas nozzle, spatter protector, tip adapter and contact tip.
• Clean any spatter from the gas nozzle, tip adaptor and contact tip so that the shielding
gas can flow freely, thus eliminating the risk of a short circuit.
• Check that the gas nozzle is free from defects. Damaged or worn tips/nozzles should be
replaced with a new one.
• The spatter protector in the gas nozzle must be replaced once its front end wears thin.
• Select contact tip to suit wire dimension.
• Mount the fittings.
• Welding spray in the gas nozzle diminishes gas protection and increases the danger of
spark-over. Clean the equipment on a regular basis and use sparing amounts of welding
paste or welding spray.
• The gas nozzle and the front parts of the welding torch must be kept free of weld spatter.
Spray anti-spatter agent at an angle into the gas nozzle from two directions. Use ESAB
anti-spatter agent to prevent spatter sticking.
NOTE!
Never spray directly into the nozzle. Too much spray can attract dirt.
• The contact tip should be replaced when the hole opening is worn to more than double
the wire diameter. Make sure that the new tip is screwed into the base.
6.2 Centrovac
Cleaning welding torches with integrated smoke evacuation

6 MAINTENANCE
0458 870 201 - 13 - © ESAB AB 2014
In order to maintain a constant level of suction, the inside of the welding torch handle should
be cleaned on a regular basis. The appropriate length of time between cleans is dependant
on how often the equipment is used and the amount of dust and oil contained in the welding
smoke.

7 FAULT-TRACING
0458 870 201 - 14 - © ESAB AB 2014
7 FAULT-TRACING
Please also read the operating instructions for the welding components, e.g. power source
and wire feed unit.
If the measures described below are not successful, consult your dealer or the manufacturer.
Problem Cause Solution
Welding torch becomes too
hot
• Contact tip is not tight
enough.
• Electrical connections to
the welding torch and to
the workpiece.
• Check and tighten.
• Check and tighten.
No trigger function • Control cable
interrupted/faulty.
• Check/repair.
Wire burnt back on the
contact tip at stop
• Wrong burn back time
set.
• Worn contact tip.
• Decrease the burn back
time.
• Replace.
Irregular wire feed • Liner blocked.
• Contact tip and wire
diameter do not match.
• Wrong tension set on the
wire feed unit.
• Blow through in both
directions.
• Replace contact tip.
• Correct according to
manufacturer's
instructions.
Short arc between the gas
nozzle and workpiece.
• Spatter bridge between
the contact tip and gas
nozzle.
• Clean and spray the
inside of the gas nozzle.
Variable arc • Contact tip is worn or
does not match the wire
diameter.
• Incorrect welding
parameters set.
• Liner worn.
• Check/replace the
contact tip.
• Correct the welding
parameters.
• Replace the wire liner.
Porous welds • Large amount of spatter
in the gas nozzle.
• Insufficient or total lack of
shielding gas.
• Draught is disturbing the
shielding gas.
• Clean the gas nozzle.
• Check contents of the
gas bottle/hoses and the
pressure setting.
• Shield welding area with
protective screens.

8 DISASSEMBLY AND DISPOSAL
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8 DISASSEMBLY AND DISPOSAL
NOTE!
Dispose of electronic equipment at the recycling
facility!
In observance of European Directive 2012/19/EC on
Waste Electrical and Electronic Equipment and its
implementation in accordance with national law, electrical
and/or electronic equipment that has reached the end of
its life must be disposed of at a recycling facility.
As the person responsible for the equipment, it is your
responsibility to obtain information on approved collection
stations.
For further information contact the nearest ESAB dealer.
The welding torch system is mainly made from steel, plastics and non-ferrous metal and
must be disposed of in compliance with local environmental regulations. The dsiposal of
coolant is also subject to local requirements.

9 ORDERING SPARE-PARTS
0458 870 201 - 16 - © ESAB AB 2014
9 ORDERING SPARE-PARTS
PSF 250/305/405/505/405 RS3, PSF 410w/510w/410w RS3/510w RS3, PSF 250C/315C
LD/405C/405C RS3/410Cw, 410Cw RS3 is designed and tested in accordance with the
international and European standards EN 60974-7 and IEC/EN 60974-7 . 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 back cover of this
document. 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.

CUTTING LENGTH
0458 870 201 - 17 - © ESAB AB 2014
CUTTING LENGTH
Welding torch Length Adapter Size X Helix Size X
PSF™ 250 3.0 m 0366 314 001 21 mm
PSF™ 250 4.5 m 0366 314 001 25 mm
PSF™ 305 3.0 m 0366 394 001 24 mm 0368 311 001 20 mm
PSF™ 305 4.5 m 0366 394 001 27 mm 0368 311 001 23 mm
PSF™ 405/405 RS3 3.0 m 0460 819 001 17 mm 0368 311 001 20 mm
PSF™ 405/405 RS3 4.5 m 0460 819 001 20 mm 0368 311 001 23 mm
PSF™ 505 3.0 m 0366 395 001 21 mm
PSF™ 505 4.5 m 0366 395 001 24 mm
PSF™ 410w/410w RS3 3.0 m 0460 819 001 23 mm 0368 311 001 26 mm
PSF™ 410w/410w RS3 4.5 m 0460 819 001 32 mm 0368 311 001 35 mm
PSF™ 510w/510w RS3 3.0 m 0460 819 001 23 mm 0368 311 001 26 mm
PSF™ 510w/510w RS3 4.5 m 0460 819 001 32 mm 0368 311 001 35 mm
PSF™ 250C 3.0 m 0366 314 001 21 mm
PSF™ 250C 4.5 m 0366 314 001 25 mm
PSF™ 315C LD 3.0 m 0366 394 001 24 mm 0366 311 001 20 mm
PSF™ 315C LD 4.5 m 0366 394 001 27 mm 0366 311 001 23 mm
PSF™ 405C 3.0 m 0460 819 001 17 mm 0368 311 001 20 mm
PSF™ 405C 4.5 m 0460 819 001 20 mm 0368 311 001 23 mm
PSF™ 410Cw/410Cw RS3 3.0 m 0460 819 001 23 mm 0366 311 001 26 mm
PSF™ 410Cw/410Cw RS3 4.5 m 0460 819 001 32 mm 0366 311 001 35 mm

ORDERING NUMBERS
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ORDERING NUMBERS
Ordering number Type Description
0368 100 882 PSF™ 250 Welding torch 3.0 m
0368 100 883 PSF™ 250 Welding torch 4.5 m
0458 401 880 PSF™ 305 Welding torch 3.0 m
0458 401 881 PSF™ 305 Welding torch 4.5 m
0458 401 882 PSF™ 405 Welding torch 3.0 m
0458 401 883 PSF™ 405 Welding torch 4.5 m
0458 401 884 PSF™ 505 Welding torch 3.0 m
0458 401 885 PSF™ 505 Welding torch 4.5 m
0458 401 893 PSF™ 405 RS3 Welding torch 4.5 m
0458 400 882 PSF™ 410w Welding torch 3.0 m
0458 400 883 PSF™ 410w Welding torch 4.5 m
0458 400 886 PSF™ 410w Welding torch 5.0 m
0458 400 884 PSF™ 510w Welding torch 3.0 m
0458 400 885 PSF™ 510w Welding torch 4.5 m
0458 400 887 PSF™ 510w Welding torch 5.0 m
0458 400 898 PSF™ 410w RS3 Welding torch 3.0 m
0458 400 899 PSF™ 410w RS3 Welding torch 4.5 m
0458 400 900 PSF™ 510w RS3 Welding torch 3.0 m
0458 400 901 PSF™ 510w RS3 Welding torch 4.5 m
0459 694 990 Spare Parts Catalogue
Technical documentation is available on the Internet at: www.esab.com

ORDERING NUMBERS
0458 870 201 - 19 - © ESAB AB 2014
Ordering number Type Description
0468 410 882 PSF™ 250C Welding torch 3.0 m
0468 410 883 PSF™ 250C Welding torch 4.5 m
0468 410 885 PSF™ 315C LD Welding torch 3.0 m
0468 410 886 PSF™ 315C LD Welding torch 4.5 m
0458 499 882 PSF™ 405C Welding torch 3.0 m
0458 499 883 PSF™ 405C Welding torch 4.5 m
0458 450 880 PSF™ 410Cw Welding torch 3.0 m
0458 450 881 PSF™ 410Cw Welding torch 4.5 m
0458 450 884 PSF™ 410Cw RS3 Welding torch 3.0 m
0458 450 885 PSF™ 410Cw RS3 Welding torch 4.5 m
0459 694 990 Spare Parts Catalogue
Technical documentation is available on the Internet at: www.esab.com

WEAR PARTS
0458 870 201 - 20 - © ESAB AB 2014
WEAR PARTS
Wear parts PSF™ 250
Item Denomination Ordering number Notes
101 Gas Nozzle "slip-on" 0469 752 880
102 Spatter protection "slip-on" 0469 538 001
103 Cooling sleeve 0469 756 880
104 Gas nozzle 0458 464 881 Standard
105 Gas nozzle 0458 470 881 Straight
106 Gas nozzle 0458 465 881 Conical
107 Spatter protection 0458 471 002
108 Contact tip See the "Contact tips" table
109 Tip adaptor M6 0366 314 001 Standard
110 Swan neck complete 0366 315 880 Standard
111 Swan neck complete 0467 985 880 60°
112 Swan neck complete 0366 329 880 Straight