ESABMig 405-505.pdf

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ESABMig 405
ESABMig 505
Service manual
0349 300 043
030409
Valid for serial no. 246−xxx−xxxx
READ THIS FIRST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ESABMig 405, 400−415V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ESABMig 405, 230−500V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ESABMig 505, 400−415V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ESABMig 505, 230−500V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1 Control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:1 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:2 Overheating protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:3 Water connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:4 Water flow guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:5 Idle mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1
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Components position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V7 Start booster
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inductor short−circuiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V7:1 Principle of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V7
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Components position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP2 Digital instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP2:1 Calibration and voltage correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP2:2 Connections to the digital instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What is ESD? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Placing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly of stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mains power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUNCTIONS EXPLANATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overheating protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water flow guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idle mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inductance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Topping up the coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDERING OF SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TOCe
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READ THIS FIRST
Maintenance and repair work should be performed by an experienced person, and
electrical work only by a trained electrician. Use only recommended replacement parts.
This service manual is intended for use by technicians with electrical/electronic training for
help in connection with fault−tracing and repair.
Use the wiring diagram as a form of index for the description of operation. The circuit
board is divided into numbered blocks, which are described individually in more detail in
the description of operation. All component names in the wiring diagram are listed in the
component description.
This manual contains details of all design changes that have been made up to and
including March 2003.
The ESABMig 405 and ESABMig 505 are designed and tested in accordance with
international and European standard IEC/EN 60974−1 and EN 50199.
On completion of service or repair work, it is the responsibility of the person(s) etc.
performing the work to ensure that the product does not depart from the requirements
of the above standard.
INTRODUCTION
The ESABMig 405 & ESABMig 505 are step switched power sources designed for
MIG/MAG−welding together with wire feed units ESABFeed 30 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 that displays current and voltage.
It incorporates a hold function and can be calibrated.
1s405505
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3
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Edition 030409
TECHNICAL DATA
Voltage
Permissible load
at100 % duty cycle
at 60 % duty cycle
at 50 % duty cycle
Setting range (DC)
Open circuit voltage
Open circuit power
with cooling unit
Efficiency
at max current
Power factor
at max current
Control voltage
Dimensions lxwxh
Weight
with cooling unit
Operating temperature
Enclosure class
Application classification
ESABMig 505
400−415V, 3~50/60 Hz
390 A/33,5 V
500 A/39 V
50A/16,5V−500A/39V
17−50 V
440 W
620 W
82%
0,92
42 V, 50/60 Hz
812 x 552 x 925
214 kg
228 kg
−10
to +40
o
C
IP 23
ESABMig 405
400−415V, 3~50/60 Hz
280 A/28 V
365 A/32 V
400 A/34 V
50A/16,5V−400A/34V
17−45 V
360 W
600 W
71%
0,98
42 V, 50/60 Hz
812 x 552 x 925
144 kg
158 kg
−10
to +40
o
C
IP 23
230/400−415/500V 3~50 Hz
230/440−460 3~60Hz
280 A/28 V
365 A/32 V
400 A/34 V
50A/16,5V−400A/34V
17−45 V
360 W
600 W
71%
0,98
42 V, 50/60 Hz
812 x 552 x 925
145 kg
158 kg
−10
to +40
o
C
IP 23
Voltage
Permissible load
at100 % duty cycle
at 60 % duty cycle
Setting range (DC)
Open circuit voltage
Open circuit power
with cooling unit
Efficiency
at max current
Power factor
at max current
Control voltage
Dimensions lxwxh
Weight
with cooling unit
Operating temperature
Enclosure class
Application classification
230/400−415/500V 3~50 Hz
230/440−460 3~60Hz
390 A/33,5 V
500 A/39 V
50A/16,5V−500A/39V
17−50 V
440 W
620 W
82%
0,92
42 V, 50/60 Hz
812 x 552 x 925
215 kg
229 kg
−10
to +40
o
C
IP 23
1s405505
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Edition 030409
WIRING DIAGRAM
Component description
WARNING !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
ESD
S
S
Observe precautions for handling electrostatic
sensitive devices.
Use proper static−proof bags and boxes.
AP1
C1−C3
C4
C5
C6, C7
EV1
FU1
H1
H2
Circuit board with control electronics.
Suppression capacitors 2uF 450V.
Capacitor, 3uF 400V. Start and run capacitor for fan motor EV1.
Capacitor, 6uF 400V. For speed reduction of the cooling fan.
Suppression capacitors 0.1uF 250V.
Fan
Circuit breaker, 10A. Protects the 42V supply to the wire feed unit.
LED green. Lights when switch QF1 is in the ON position.
Blinks when is idle mode.
LED yellow. Lights to indicate operation of the thermal cutouts.
Blinks to indicate loss of coolant when machine is equipped with flow
guard.
Contactor 42V 50Hz. Main contactor.
Inductor.
Pump, 230V 50Hz 0.2kW. Only machines with water cooling.
Digital instrument.
Main ON/OFF switch.
Switch, for selecting welding voltage
4−step for ESABMig 405
5−step for ESABMig 505
Switch, for selecting welding voltage
10−step for ESABMig 405
8−step for ESABMig 505
Resistor
KM1
L1
M1
P1
QF1
QF2
QF3
R1
1s405505
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Edition 030409

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