ESAB ESABMig 405 User manual

Valid for serial no. 2460349 301 042 030429
ESABMig 405
ESABMig 505
Bruksanvisning
Brugsanvisning
Bruksanvisning
Käyttöohjeet
Instruction manual
Betriebsanweisung
Manuel d’instructions
Gebruiksaanwijzing
Instrucciones de uso
Istruzioni per l’uso
Manual de instruções
 
 
  
 

– 2 –
Rätt till ändring av specifikationer utan avisering förbehålles.
Ret til ændring af specifikationer uden varsel forbeholdes.
Rett til å endre spesifikasjoner uten varsel forbeholdes.
Oikeudet muutoksiin pidätetään.
Rights reserved to alter specifications without notice.
Änderungen vorbehalten.
Sous réserve de modifications sans avis préalable.
Recht op wijzigingen zonder voorafgaande mededeling voorbehouden.
Reservado el derecho de cambiar las especificaciones sin previo aviso.
Ci riserviamo il diritto di variare le specifiche senza preavviso.
Reservamo–nos o direito de alterar as especificações sem aviso prévio.
      
     
         
      
SVENSKA 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DANSK 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NORSK 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUOMI 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGLISH 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DEUTSCH 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRANÇAIS 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NEDERLANDS 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ESPAÑOL 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ITALIANO 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PORTUGUÊS 133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 !                                            
!"#$% &'(                                                
)*#$+ &,-                                                
./0+/1 &2'                                               

ENGLISH
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TOCe
1 DIRECTIVE 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 SAFETY 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 INTRODUCTION 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Equipment 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 TECHNICAL DATA 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 INSTALLATION 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Placing 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Assembly of components 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Assembly of stabilizer 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Electrical installation 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 Mains power supply 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 OPERATION 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Connection and control devices 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Function explanations 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 MAINTENANCE 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Inspection and cleaning 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Topping up the coolant 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 FAULT TRACING 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 ORDERING OF SPARE PARTS 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGRAM 198. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES 203. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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405,505e
1 DIRECTIVE
DECLARATION OF CONFORMITY
ESAB Welding Equipment AB, S–695 81 Laxå, Sweden, gives its unreserved guarantee that welding
power source ESABMig 405 & ESABMig 505 from serial number 246 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 add-
endum (93/68/EEC).
–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Henry Selenius
Vice President
ESAB AB Arc Equipment
Box 8004
402 77 GÖTEBORG
SWEDEN Tel: + 46 31 509000 Fax: + 46 31 509261
Laxå 24.02.2003
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.
GB

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405,505e
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.
GB

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405,505e
3 INTRODUCTION
The ESABMig 405 and ESABMig 505 are step switched power sources designed for
MIG/MAG–welding together with wire feed units ESABFeed 30, ESABFeed 48
and the most of ESAB wire feeders.
The power units are fan–cooled and equipped with thermal overload protection.
The machines can be fitted with an instrument for display of current and voltage. It
incorporates a hold function and can be calibrated.
The machines can be fitted with a flow guard.
ESAB’s accessories for the product can be found on page 203.
3.1 Equipment
The power source is supplied with:
SReturn cable 5m with return clamp
SShelf for gas cylinder
SGuide pin for wire feed unit
SInstruction manual
4 TECHNICAL DATA
ESABMig 405
Voltage 400–415V, 3~50/60 Hz 230/400–415/500V 3~50 Hz
230/440–460 3~60Hz
Permissible load
at100 % duty cycle 280 A/28 V 280 A/28 V
at 60 % duty cycle 365 A/32 V 365 A/32 V
at 50 % duty cycle 400 A/34 V 400 A/34 V
Setting range (DC) 50A/16,5V–400A/34V 50A/16,5V–400A/34V
Open circuit voltage 17–45 V 17–45 V
Open circuit power 360 W 360 W
with cooling unit 600 W 600 W
Efficiency at max current 71% 71%
Power factor at max current 0,98 0,98
Control voltage 42 V, 50/60 Hz 42 V, 50/60 Hz
Dimensions lxwxh 812 x 552 x 925 812 x 552 x 925
Weight 144 kg 145 kg
with cooling unit 158 kg 158 kg
Operating temperature –10 to +40oC–10 to +40oC
Enclosure class IP 23 IP 23
Application classification
GB

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405,505e
ESABMig 505
Voltage 400–415V, 3~50/60 Hz 230/400–415/500V 3~50 Hz
230/440–460 3~60Hz
Permissible load
at100 % duty cycle 390 A/33,5 V 390 A/33,5 V
at 60 % duty cycle 500 A/39 V 500 A/39 V
Setting range (DC) 50A/16,5V–500A/39V 50A/16,5V–500A/39V
Open circuit voltage 17–50 V 17–50 V
Open circuit power 440 W 440 W
with cooling unit 620 W 620 W
Efficiency at max current 82% 82%
Power factor at max current 0,92 0,92
Control voltage 42 V, 50/60 Hz 42 V, 50/60 Hz
Dimensions lxwxh 812 x 552 x 925 812 x 552 x 925
Weight 214 kg 215 kg
with cooling unit 228 kg 229 kg
Operating temperature –10 to +40oC–10 to +40oC
Enclosure class IP 23 IP 23
Application classification
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
GB

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405,505e
5.1 Placing
Position the welding power source such that its cooling air inlets and outlets are not
obstructed.
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!
GB

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405,505e
5.3 Assembly of stabilizer
Assemble the stabilizer if counter balance is to be installed on machine. The stabilizer
is an accessory. Ordering number you can find on page 204.
Attention! Utilization of counter balance without stabilizer may cause the machine
tipping over.
5.4 Electrical installation
ESABMig 405
GB

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405,505e
ESABMig 505
GB