ESAB ESABMig C240 User manual

Valid for serial no. 3100349 301 064 060324
ESABMig C240
ESABMig C240s
Instruction manual

ENGLISH
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TOCe
1 DIRECTIVE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 SAFETY 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 INTRODUCTION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Equipment 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 TECHNICAL DATA 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 INSTALLATION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Placing 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Assembly of components 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Electrical installation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Mains power supply 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 OPERATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Connection and control devices 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Functions explanation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 ESABMig C240 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 ESABMig C240s 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 MAINTENANCE 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Inspection and cleaning 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 FAULT TRACING 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 ORDERING OF SPARE PARTS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGRAM 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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C240e
1 DIRECTIVE
DECLARATION OF CONFORMITY
ESAB Welding Equipment AB, S−695 81 Laxå, Sweden, gives its unreserved guarantee that welding
power source ESABMig C240 / ESABMig C240s from serial number 310 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 60974−10 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 03.12.2003
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.
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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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3 INTRODUCTION
ESABMig C240 & ESABMig C240s are step controlled power sources in a compact design, intended
for welding with solid steel, stainless steel or aluminium wire as well as tubular wire with or without
shielding gas.
The possibility of welding with homogeneous wire/shielding gas and welding with gasless tubular wire
is obtained by switching the + and −connections on the switching terminal above the wire feed unit.
ESAB’s accessories for the product can be found on page 19.
3.1 Equipment
The power source is supplied with:
SWelding gun PSF 250 −3m
SReturn cable 3,5m with return clamp
SShelf for gas cylinder
SInstruction manual
4 TECHNICAL DATA
ESABMig C240 ESABMig C240s
Voltage 230/400−415V, 3∼50/60Hz 230/400−415V, 3∼50/60Hz
Permissible load at
100% duty cycle 130A 130A
60 % duty cycle 170A 170A
30 % duty cycle 240A 240A
Setting range (DC) 20A /15V−240A / 23,0V 20A /15V−240A / 23,0V
Open circuit voltage 14 −32V 14 −32V
Open circuit power 190W 190W
Efficiency 76% 76%
Power factor 0.95 0.95
Control voltage 42 V, 50/60Hz 42 V, 50/60Hz
Wire feed speed 1,9 −19m/min 1,9 −19m/min
Burnback time 0 −0,25s 0 −0,25s
Spot welding 0,2 −2,5s 0,2 −2,5s
Creep start −+ (auto)
2/4 stroke & motor inching −+
Welding gun connection EURO EURO
Wire dimension range 0,6 −1,0mm 0,6 −1,0mm
Max diameter of wire bobin 300mm 300mm
Dimensions lxwxh 840x425x830 840x425x830
Weight 94 kg 97 kg
Operating temperature −10 ÷+40oC−10 ÷+40oC
Enclosure class IP 23 IP 23
Application classification
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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.
5.1 Placing
Position the welding power source such way that its cooling air inlets and outlets are
not obstructed.
5.2 Assembly of components
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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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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 C240/C240s 3∼ 50/60 Hz 3∼ 50/60 Hz
Voltage V 230 400/415
Current A
at 100% duty cycle 8.6 5.3
at 60% duty cycle 12.4 7.6
at 30% duty cycle 21 12
Cable area mm24 x 2.5 4 x 1.5
Fuse slow A 20 16
NB: The mains cable areas and fuse sizes as shown above are in accordance with Swedish
regulations. They may not be applicable in other countries: make sure that the cable area and fuse
sizes comply with the relevant national regulations.
6 OPERATION
General safety regulations for the handling of the equipment can be found on
page 3. 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 !
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6.1 Connection and control devices
ESABMig C240
1Mains supply switch 7Connection for return cable (−), high induc-
tance
2Switch, coarse control 8Connection for return cable (−), low induc-
tance
3Switch, precise control 9Knob for wire speed setting
4Indicating lamp, power supply ON 10 Knob for spot welding −ON/OFF and time
setting
5Orange indicating lamp, overheating 11 Digital instrument −V / A
(option,see page 19)
6EURO −connector (for welding gun) 12 Knob for burn−back time setting
ESABMig C240s
1Mains supply switch 11 Digital display for welding parameters
2Switch, coarse control 12 Switch for display selection −Volt. or Amp
3Switch, precise control 13 Switch for display selection −m/min or mm
4Indicating lamp, power supply ON 14 Lamp indicating status of synergy control
5Orange indicating lamp, overheating 15 Lamps indicating recommended (−) current
output −max/min inductance
6EURO −connector (for welding gun) 16 Switch for ”Synergy”−ON/OFF and ma-
terial/gas selection
7Connection for return cable (−), high induc-
tance 17 Knob for selection of the wire diameter
8Connection for return cable (−), low induc-
tance 18 Knob for burn−back time setting
9Knob for wire speed setting / correction 19 Mode selector 2−stroke / / 4−stroke
10 Knob for spot welding −ON/OFF and time
setting
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6.2 Functions explanation
6.2.1 Overheating protection
When the machine is switched on with the mains switch [1], indicating lamp [4] is on and
lamp [5] off −the machine is ready to operate. If the internal temperature becomes too
high, the welding is interrupted and disabled. This state is indicated by lighting of the
orange indicating lamp [5] on the front of the machine. It resets automatically when the
temperature has fallen.
6.2.2 Inductance connection
Higher inductance produces a more flowing weld and fewer spatters. Lower inductance
produces a harsher sound and a stable, concentrated arc.
6.3 ESABMig C240
The ESABMig C240 is equipped with standard control unit. Welder can manually
select and adjust all welding parameters.
SWire speed (1,9 −19m/min).
SSpot−welding time.
SBurn back time.
The machine C240 can be fitted with a digital instrument that displays current and
voltage. It incorporates a hold function (see page 19).
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