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
0458 870 201 -6- © ESAB AB 2014
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
0458 870 201 -9- © ESAB AB 2014
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.