ESAB PSF 260 User manual

Instruction manual 0GGCAGH*ccgjdb+
0463 645 001 GB 20201104
PSF260, PSF315, PSF315RS3,
PSF415, PSF415RS3,
PSF420w, PSW420wRS3,
PSF430w, PSF430wRS3,
PSF515, PSF520w,
PSF520wRS3

TABLE OF CONTENTS
0463 645 001 © ESAB AB 2020
1SAFETY ....................................................................................................... 5
1.1 Meaning of symbols............................................................................... 5
1.2 Safety precautions ................................................................................. 5
2INTRODUCTION.......................................................................................... 8
3SHIPMENT AND PACKAGING ................................................................... 9
4TECHNICAL DATA ...................................................................................... 10
5OPERATION ................................................................................................ 12
5.1 Fitting the liner........................................................................................ 12
5.2 Equipping the torch................................................................................ 12
5.3 Fitting the central adaptor to the equipment ....................................... 12
5.4 Connecting the cooling circuit.............................................................. 12
5.5 Setting the level of shielding gas.......................................................... 13
5.6 Checklist ................................................................................................. 13
5.7 Changing wire......................................................................................... 13
5.8 Starting and stopping the welding process......................................... 13
6MAINTENANCE........................................................................................... 14
6.1 Overview ................................................................................................. 14
6.2 Cable assembly ...................................................................................... 14
6.3 Cleaning the wire feed ........................................................................... 14
6.4 Steel liner / Plastic liner ......................................................................... 14
6.5 Cleaning the swan neck......................................................................... 17
6.6 Checking the cooling system................................................................ 17
7TROUBLESHOOTING................................................................................. 18
8ORDERING SPARE PARTS ........................................................................ 19
ORDERING NUMBERS....................................................................................... 20
SPARE PARTS LIST............................................................................................ 22
Torch neck PSF 260................................................................................................... 22
Torch neck PSF315, PSF415, PSF415straight, PSF515 .................................... 23
Torch neck PSF420w, 420wstraight, PSF430w, PSF520w ................................. 25
WEAR PARTS...................................................................................................... 27
PSF 260 ...................................................................................................................... 27
PSF 315 ................................................................................................................... 28
PSF 415 ................................................................................................................... 29
PSF 515 ................................................................................................................... 30
PSF 420w................................................................................................................. 31
PSF 430w................................................................................................................. 32
PSF 520w................................................................................................................. 33
Contact tips PSF 260, PSF 315, PSF 415, PSF 515, PSF 420w, PSF430w, PSF
520w............................................................................................................................
34
Contact tips M6.......................................................................................................... 35

TABLE OF CONTENTS
0463 645 001 © ESAB AB 2020
Steel liner ................................................................................................................... 35
PTFE liner................................................................................................................... 37
PA Liner with bronze front end ................................................................................ 37
Rights reserved to alter specifications without notice.

1 SAFETY
0463 645 001 -5- © ESAB AB 2020
1 SAFETY
1.1 Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual
and follow all labels, employer´s safety practices and
Safety Data Sheets (SDSs).
1.2 Safety precautions
Users of ESAB 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 equipment. The following
recommendations 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
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 equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
○ no unauthorised person is stationed within the working area of the equipment
when it is started up
○ no-one is unprotected when the arc is struck or work is started with the
equipment
3. The workplace must:
○ be suitable for the purpose
○ be free from drafts

1 SAFETY
0463 645 001 -6- © ESAB AB 2020
4. Personal safety equipment:
○ Always wear recommended personal safety equipment, such as safety glasses,
flame-proof clothing, safety gloves
○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which
could become trapped or cause burns
5. General precautions:
○ Make sure the return cable is connected securely
○ Work on high voltage equipment may only be carried out by a qualified
electrician
○ Appropriate fire extinguishing equipment must be clearly marked and close at
hand
○ Lubrication and maintenance must not be carried out on the equipment during
operation
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting.
ELECTRIC SHOCK - Can kill
• Install and ground the unit in accordance with instruction manual.
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.
• Insulate yourself from work and ground.
• Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
• Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.
• Exposure to EMF may have other health effects which are unknown.
• Welders should use the following procedures to minimize exposure to
EMF:
○ Route the electrode and work cables together on the same side of
your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or work
cable around your body. Keep welding power source and cables as
far away from your body as possible.
○ Connect the work cable to the workpiece as close as possible to the
area being welded.
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.
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.

1 SAFETY
0463 645 001 -7- © ESAB AB 2020
MOVING PARTS - Can cause injuries
• Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.
• Stop engine before installing or connecting unit.
• Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure that there are no inflammable
materials nearby.
• Do not use on closed containers.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
Class A equipment is not intended for use in residential
locations where the electrical power is provided by the
public low-voltage supply system. There may be
potential difficulties in ensuring electromagnetic
compatibility of class A equipment in those locations,
due to conducted as well as radiated disturbances.
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.
ESAB has an assortment of welding accessories and personal protection equipment
for purchase. For ordering information contact your local ESAB dealer or visit us on
our website.

2 INTRODUCTION
0463 645 001 -8- © ESAB AB 2020
2 INTRODUCTION
The MIG / MAG welding torches of this series are exclusively intended for shielded- arc
welding using inert gas (MIG) or active gas (MAG) for industrial and commercial use by
suitably trained employees. The torches are only available in manual versions.

3 SHIPMENT AND PACKAGING
0463 645 001 -9- © ESAB AB 2020
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 with 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: -20°C to +55°C
Relative air humidity: up to 90% at a temperature of 20°C

4 TECHNICAL DATA
0463 645 001 - 10 - © ESAB AB 2020
4 TECHNICAL DATA
Welding torch PSF 260 PSF315,
PSF315RS3
PSF415,
PSF415RS3
PSF 515
Type of cooling Air Air Air Air
Permitted load at 60% duty cycle*
Carbon dioxide CO2250 A 315 A 380 A 450 A
Mixed gas, Ar/CO2M21 225 A 285 A 325 A 400 A
Recommended gas
flow
8-12 l/min 8-15 l/min 10-18 l/min 10-20 l/min
Wire diameter 0.6-1.0 mm 0.8-1.2 mm 0.8-1.6 mm 1.0-1.6 mm
Operating
temperature**
-10 °C to 40 °C -10 °C to 40 °C -10 °C to 40 °C -10 °C to 40 °C
* The capacity may be reduced up to 30% when pulse welding.
Welding torch PSF 420w,PSF420wRS3,
PSF430w, PSF430wRS3
PSF 520w,PSF520wRS3
Type of cooling Water Water
Permitted load at 100% duty cycle*
Carbon dioxide CO2450 A 500 A
Mixed gas, Ar/CO2M21 450 A 500 A
Recommended gas
flow
10-20 l/min 10-20 l/min
Wire diameter 0.8-1.6 mm 1.0-1.6 mm
Operating
temperature**
-10 °C to 40 °C -10 °C to 40 °C
* The capacity may be reduced up to 30% when pulse welding.
** When using liquid cooled torches in freezing conditions, use an adequate cooling liquid.
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld at
a certain load without overloading. The duty cycle is valid for 40 °C / 104 °F, or below.
General torch data with reference to IEC/EN 60 974−7
Type of guidance: Manual
Wire type: Standard round wire
Voltage rating: The control circuit and trigger switch are
rated for a voltage of 42 V, max. 1 A
Specifications of the torch cooling circuit (for
liquid cooled torches only):
• minimum flow 1.2 l/min
• min. water pressure: 2.5 bar
• max. water pressure: 3.5 bar
• input temperature: max. 40 °C
• return temperature: max. 60 °C
• cooling capacity: min. 1000 W, up to
2000 W depending on the application

4 TECHNICAL DATA
0463 645 001 - 11 - © ESAB AB 2020
Liquid cooled torches
Return temperatures of more than 60 °C can shorten the lifetime of the torch or cause
damage or destruction of the torch. The cooler must always be filled with sufficient cooling
liquid, refer to the instruction manual for the cooling unit. In case of a high thermal load on
the torch, use a cooler with sufficient capacity. Use only special cooling fluid containing
corrosion inhibitors for welding torches. For suitable products, contact your nearest ESAB
dealer.
The ratings are valid for cable lengths from 3.0 to 5.0 m.
The rated loads refer to a standardized case of use. Under special conditions, e.g. in case of
high heat reflection on the torch, the torch could overheat even when operated below the
rated load. In this case choose a more powerful model or lower the duty cycle.
Conditions of intended use
1. The welding torch should only be used within the above mentioned technical
specifications and for its intended purpose.
2. The type of torch has to be chosen according to the welding application. The required
duty-cycle and load, the type of cooling, guiding method and the wire diameter have to
be considered. If increased requirements exist, for example caused by pre-heated
work pieces, high heat reflection in corners, etc. these must be taken into account by
choosing a welding torch with adequate reserve in rated load.
3. The product must be protected from humidity and moisture during transport, storage
and operation.

5 OPERATION
0463 645 001 - 12 - © ESAB AB 2020
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!
CAUTION!
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.
DANGER!
In the event of an emergency, the power supply must be switched off immediately.
For further action in such circumstances, refer to the instruction manual for the
power source for more information.
The welding torch can be used in any welding position.
Contact with hot items might cause damage to the torch and the cable assembly.
Do not drag the power source using the torch.
Do not pull the cable assembly over sharp edges. Do not bend the cable assembly sharply.
5.1 Fitting the liner
Fit the correct wire guide liner for the application, as needed to suit the wire type and
diameter. See chapter "MAINTENANCE" section "Steel liner / Plastic liner".
NOTE!
For information on how to install new liners and about correct assembly
procedure, see the chapter entitled “Maintenance”
Steel liner = for steel wires
Plastic liner = for aluminium, copper, nickel and stainless steel wires
5.2 Equipping the torch
The torch must be equipped according to the wire diameter and wire material. Choose the
right liner, contact tip, tip adaptor, gas nozzle and gas diffuser (as applicable). A detailed
overview of the suitable parts is found in the spare parts list for the torch.
Tighten the tip adaptor and the contact tip with an adequate tool.
Make sure that all required parts shown in the spare parts list, e.g. insulators, are installed.
Welding without these items might cause immediate destruction of the torch.
5.3 Fitting the central adaptor to the equipment
1. Check that the wire guide liner is fitted correctly.
2. Insert the central plug into the socket on the wire feed unit and secure it by tightening
the adaptor nut firmly by hand.
5.4 Connecting the cooling circuit
Connect the water hoses to the cooling unit: blue for water flow forward from the cooler to the
torch; red for heated water flow backwards from the torch to the cooler. Before using a water

5 OPERATION
0463 645 001 - 13 - © ESAB AB 2020
cooled torch, the air has to be removed from the cooling circulation by running the cooler for
a few minutes.
CAUTION!
Wrongly connected water hoses can cause overheating and damage of the torch neck
and water-power cable. Regularly check the coolant level and throughput on the
cooling unit. Insufficient cooling might cause overheating and damage of the torch
neck and water-power cable.
NOTE!
To achieve an optimal gas- and water flow, place the cable assemblies and the gas
and water hoses as straight as possible. Kinked hoses will cause overheating and can
damage the torch. Protect cables and supply hoses from damage.
5.5 Setting the level of shielding gas
Set the quantity of gas required on the gas regulator. The type and quantity of gas to be used
depend on the welding task to be performed.
5.6 Checklist
Check the cable assembly before connecting it to the wire feed unit to confirm the wire liner
is suitable for the wire diameter and type.
Check the front end consumable parts on the swan neck, whether the correct contact tip etc.
is being used for the wire diameter and type.
5.7 Changing wire
When changing the wire, ensure that the end of the wire is deburred.
Insert the wire into the wire feeding unit in accordance with the operating instructions.
When inserting the wire, press the wire jog button on the wire feed unit.
5.8 Starting and stopping the welding process
The wire feeder and the welding process will be started by pulling the torch trigger.
Depending on the configuration of the welding machine, the welding process will be stopped
by either letting go of the trigger or by pulling the trigger a second time. Refer to the
instruction manual for the power source for more information.
DANGER!
The torch head might reach very high temperatures during operation, there is a risk of
severe burns. Let it cool down under observation, there is risk of fire. Do not place the
hot torch on or near heat-sensitive objects. For water cooled torches, the cooling
system should remain switched on for some minutes after the welding process has
been stopped.
When leaving the workplace the system must be secured against unintended
operation, preferably by switching off the power source.

6 MAINTENANCE
0463 645 001 - 14 - © ESAB AB 2020
6 MAINTENANCE
6.1 Overview
NOTE!
Regular maintenance is important for safe and reliable operation.
Cleaning and replacement of the welding torch’s wear parts should take place at regular
intervals in order to achieve trouble−free wire feed. Blow the wire guide clean regularly and
clean the contact tip.
WARNING!
Before carrying out cleaning, servicing and repair work, the following shutdown
procedure must be followed.
1. Switch off the power supply.
2. Close off the gas supply.
Make sure that the power supply and gas remain turned off all the time while
servicing the equipment.
6.2 Cable assembly
Check the torch and cable assembly for damages prior to use. Damages must be repaired by
qualified personnel before further use of the product.
6.3 Cleaning the wire feed
Disconnect the torch cable assembly from the equipment and lay it out straight.
Unscrew the nut and pull out the wire guide liner. Remove other parts from the swan neck.
Blow compressed air through the wire conduit from both ends in order to remove wire
shavings.
Insert the liner into the wire conduit and screw the nut back on.
NOTE!
New liners must be cut to the correct length.
6.4 Steel liner / Plastic liner
If a wire feeding problem cannot be solved by exchanging the contact tip and cleaning the
wire guide channel, the liner should be replaced.
Liner and welding wire should be inserted while the cable assembly is laid out straight.

6 MAINTENANCE
0463 645 001 - 15 - © ESAB AB 2020
Installing a steel liner
1. Remove the sleeve nut from the
central connector, remove the gas
nozzle, contact tip and tip holder
from the torch.
2. Insert the liner through the central
connector and lock it with the sleeve
nut.
3. Gently push back the front part of
the liner into the torch as far as it will
go, do not apply force. Mark the end
of the torch neck on the liner.
4. Cut the liner to the correct length
using a projectile "X" measured from
the marking as shown in the figure.
Remove the liner from the torch and carefully
smoothen its front end. If needed, grind down
burred edges. Make sure the inner hole is
completely open.
For insulated liners, remove the insulation at
the front end so that the remaining insulation
ends approximately at the front end of the
torch handle.
Reinstall the liner and lock it with the sleeve
nut. Install all equipment parts on the torch
neck.
Cutting length
Welding torch Projectile "X"
PSF 260 16mm
PSF 315,PSF 315 RS3 16mm
PSF 415, PSF 415 RS3 12mm
PSF 515 17mm
PSF 420w, PSF 420w RS3, PSF430w,
PSF430wRS3
12mm
PSF 520w, PSF 520w RS3 12mm

6 MAINTENANCE
0463 645 001 - 16 - © ESAB AB 2020
Installing a plastic liner
1. Remove the sleeve nut from the
central connector, remove the gas
nozzle, contact tip and tip holder
from the torch.
2. Insert the liner through the central
connector and lock it with the sleeve
nut.
3. Gently push back the front part of
the liner into the torch as far as it will
go, do not apply force. Mark the end
of the torch neck on the liner.
4. Cut the liner to the correct length
using a projectile "X" measured from
the marking as shown in the figure.
Slightly chamfer the liner front end
after the liner has been cut to the
correct length.
NOTE!
If the liner has a bronze front end, first cut the plastic liner to a suitable length and
let the bronze liner stick out approximately 40-50 mm from the torch neck. Attach
the bronze liner to the front of the plastic liner and only then cut this liner
assembly to the precise length.
If it is difficult to insert the liner into the torch,
make a clean cut at the front end of the liner
and chamfer the edges (e.g. with a pencil
sharpener).
Install all equipment parts on the torch neck.
Cutting length
Welding torch Projectile "X"
PSF 260 13mm
PSF 315, PSF 315 RS3 13mm
PSF 415, PSF 415 RS3 9mm
PSF 515 14mm
PSF 420w, PSF 420w RS3, PSF430w,
PSF430wRS3
9mm
PSF 520w, PSF 520w RS3 9mm

6 MAINTENANCE
0463 645 001 - 17 - © ESAB AB 2020
6.5 Cleaning the swan neck
• Clean the inside of the gas nozzle regularly to remove welding spatter and spray with
ESAB® anti-spatter agent.
• Check the consumables for visible damage and replace if necessary.
6.6 Checking the cooling system
Make sure that the cooling liquid is clean, change it if required. Impurities in the cooling liquid
can obstruct the torch water channels. Always use suitable cooling fluid for torches with
corrosion inhibitors.

7 TROUBLESHOOTING
0463 645 001 - 18 - © ESAB AB 2020
7 TROUBLESHOOTING
If the measures described below are not successful, consult your dealer or the manufacturer.
Read the operating instructions for the welding components, e.g. power source and wire feed
unit.
Problem Possible cause Action
Torch becomes too hot • Contact tip / tip holder
not tight enough
• Cooling system is not
working well
• Torch overstrained
• Cable assembly
defective
• Check and tighten
hand-tight
• Check water flow, filling
level and cleanliness
• Observe technical data,
if needed, choose a
different type
• Check cables, tubes
and connections
Wire feeding problems • Contact tip is worn
• Liner is worn / dirty
• Consumables used are
not suitable for the wire
diameter or material
• Wire feeder not set-up
properly
• Cable assembly is bent
or laid out in small radii
• Wire is contaminated
• Exchange contact tip
• Check the liner, blow
through in both
directions. Exchange if
needed.
• Check with spare part
list
• Check the wire feeding
rolls, the contact
pressure and the spool
brake
• Check the cable
assembly and lay it out
straight
• Use a cleaning felt
Porous welds • Gas swirl caused by
spatter adherence
• Too small or extremely
high gas flow in the
torch
• Gas supply defective
• Air draft at the work
place
• Moisture or
contamination on the
wire or on the work
piece
• Clean the torch head,
use gas diffuser /
spatter protection
• Check flow rate with
measurement tool
• Check flow rate and
possible leakage
• Install shielding
• Check the wire and the
work piece, use less or
different anti-spatter
liquid
Variable arc • Contact tip is worn
• Wrong welding
parameters
• Exchange contact tip
• Correct the welding
parameters
Welding process does not
start
• Control cable is broken
or the trigger is
defective
• Check and repair the
trigger connections,
clean the trigger switch
or exchange it

8 ORDERING SPARE PARTS
0463 645 001 - 19 - © ESAB AB 2020
8 ORDERING SPARE PARTS
CAUTION!
Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.
The PSF260, PSF315, PSF415, PSF515, PSF420w, PSF430w and PSF520w are
designed and tested in accordance with international and European standards IEC/EN
60974-7. On completion of service or repair work, it is the responsibility of the person(s)
performing the work to ensure that the product still complies with the requirements of the
above standard.
Spare parts and wear parts can be ordered through your nearest ESAB dealer, see
esab.com. 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.

ORDERING NUMBERS
0463 645 001 - 20 - © ESAB AB 2020
ORDERING NUMBERS
Ordering number Denomination Type Notes
Gas cooled torches
0700 025 020 PSF260 Welding torch 3m Euro-Central connector
0700 025 021 PSF260 Welding torch 4m Euro-Central connector
0700 025 022 PSF260 Welding torch 5m Euro-Central connector
0700 025 030 PSF315 Welding torch 3m Euro-Central connector
0700 025 031 PSF315 Welding torch 4m Euro-Central connector
0700 025 032 PSF315 Welding torch 5m Euro-Central connector
0700 025 033 PSF315 RS3 Welding torch 4m Euro-Central connector
0700 025 037 PSF 315 RS3 Welding torch 5 m Euro-Central connector
0700 025 040 PSF415 Welding torch 3m Euro-Central connector
0700 025 041 PSF415 Welding torch 4m Euro-Central connector
0700 025 042 PSF415 Welding torch 5m Euro-Central connector
0700 025 043 PSF415 RS3 Welding torch 4m Euro-Central connector
0700 025 050 PSF515 Welding torch 3m Euro-Central connector
0700 025 051 PSF515 Welding torch 4m Euro-Central connector
0700 025 052 PSF515 Welding torch 5m Euro-Central connector
Water cooled torches
0700 025 060 PSF420w Welding torch 3m Euro-Central connector
0700 025 061 PSF420w Welding torch 4m Euro-Central connector
0700 025 062 PSF420w Welding torch 5 m Euro-Central connector
0700 025 063 PSF420w RS3 Welding torch 3 m Euro-Central connector
0700 025 064 PSF 420wRS3 Welding torch 4 m Euro-Central connector
0700 025 065 PSF 420w RS3 Welding torch 5 m Euro-Central connector
0700 025 076 PSF 430w Welding torch 3 m Euro-Central connector
0700 025 077 PSF 430w Welding torch 4 m Euro-Central connector