ESAB ESABMig C420 User manual

Valid for serial no. 2370349 301 075 030919
ESABMig C420
Instruction manual Manuel d’instructions

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Rights reserved to alter specifications without notice.
Sous réserve de modifications sans avis préalable.
ENGLISH 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRANÇAIS 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGLISH
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TOCe
1 DIRECTIVE 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 SAFETY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 INTRODUCTION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Equipment 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 TECHNICAL DATA 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 INSTALLATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Placing 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Assembly of components 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Electrical installation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Mains power supply 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 OPERATION 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Connection and control devices 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Functions explanation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Recommended welding parameters 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 MAINTENANCE 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Inspection and cleaning 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 FAULT TRACING 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 ORDERING OF SPARE PARTS 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGRAM 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WEAR COMPONENTS 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1 DIRECTIVE
DECLARATION OF CONFORMITY
ESAB Welding Equipment AB, S–695 81 Laxå, Sweden, gives its unreserved guarantee that welding
power source ESABMig C420 from serial number 237 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 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 2003–03–10
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
The ESABMig C420 is step–controlled compact welding power unit incorporating wire feed
mechanism intended for MIG/MAG welding with solid wires of steel, stainless steel or aluminium, and
cored wires with or without shielding gas. The ESABMig C420 is not equipped with cooling system
and can operate only with appropriate gas cooled torches.
The ESABMig C420 is equipped with standard control unit (manual setting of all welding parameters)
and digital instrument (incorporating ”display–hold” function) for displaying of current and voltage.
Machines are fan–cooled and equipped with thermal overload protection.
ESAB’s accessories for the product can be found on page 38.
3.1 Equipment
The power source is supplied with:
SReturn cable 5m with return clamp
SShelf for gas cylinder
SInstruction manual
4 TECHNICAL DATA
ESABMig C420
Voltage 230/400–415/500V, 3~50Hz
230/440–460/575V, 3~60Hz
Permissible load
at100 % duty cycle 315 A/30V
at 60 % duty cycle 400 A/34V
at 50 % duty cycle 420 A/35V
Setting range (DC) 50A/16,5V–420A/35V
Open circuit voltage 16,6–46,5V
Open circuit power 520W
Efficiency at max current 77%
Power factor at max current 0,92
Control voltage 42V, 50/60Hz
Wire feed speed 75 – 1000inch/min (1,9 – 25,0m/min)
Burnback time 0 – 0,5s
Creep start OFF / ON
2/4 stroke 2 / 4
Welding gun connection EURO
Max diameter of wire bobbin 12inch (300mm)
Wire dimension range 0,023 – 1/16inch (0,6 – 1,6mm)
Dimensions lxwxh 36,8 x 25,2 x 31,5inch (935 x 640 x 800mm)
Weight 470lb (213kg)
Operating temperature +14 to 104oF (–10 to +40oC)
Enclosure class 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.
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
5.1 Placing
Position the welding power source so that its cooling air inlets and outlets are not
obstructed.
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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!
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 C420w 3∼ 50/60 Hz 3∼ 50 Hz 3∼ 50 Hz 3∼ 60 Hz 3∼ 60 Hz
Voltage V 230 400/415 500 440–460 575
Current A
at100% duty cycle 33 19 15 17 13
at 60% duty cycle 47 27 22 25 19
at 50% duty cycle 53 30 24 27 21
Cable area mm24 x 6AWG
Fuse, slow A 35 25 20 20 20
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6 OPERATION
General safety regulations for the handling of the equipment can be found on
page 4. 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 !
6.1 Connection and control devices
ESABMig C420
1Mains supply switch 10 Connection for return cable (–), medium in-
ductance
2Switch, coarse control 11 Connection for return cable (–), low induc-
tance
3Switch, precise control 12 Knob for wire speed setting
4Indicating lamp, power supply ON 13 Knob for selecting 2/4–stroke control mode
5Orange indicating lamp, overheating 14 Knob for selecting – creep start – ON/OFF
6EURO – connector (for welding gun) 15 Knob for burn–back time setting
9Connection for return cable (–), high induc-
tance 16 Digital instrument – V / A (standard)
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