PSF 260C,
PSF 415C, PSF 415C RS3,
PSF 420Cw, PSF 420Cw RS3
GB Instruction manual
DOKP4M4070
TABLE OF CONTENTS
DOKP4M4070
© ESAB AB 2020
Inhalt
1 SAFETY ............................................................................................................................ 4
1.1 Meaning of symbols ................................................................................................... 4
2 INTRODUCTION ............................................................................................................... 7
3 SHIPMENT AND PACKAGING ......................................................................................... 7
4 TECHNICAL DATA ............................................................................................................ 8
5 OPERATION .................................................................................................................... 10
5.2 Equipping the torch .................................................................................................. 10
5.3 Fitting the central adaptor to the equipment ............................................................. 10
5.4 Connecting the cooling circuit .................................................................................. 10
5.5 Setting the level of shielding gas .............................................................................. 11
5.6 Checklist .................................................................................................................. 11
5.7 Changing wire .......................................................................................................... 11
5.8 Starting and stopping the welding process .............................................................. 11
6 MAINTENANCE .............................................................................................................. 12
6.1 Overview .................................................................................................................. 12
6.2 Cable assembly ....................................................................................................... 12
6.3 Cleaning the wire feed ............................................................................................. 12
6.4 Steel liner / Plastic liner ............................................................................................ 12
6.5 Cleaning the swan neck ........................................................................................... 14
6.6 Checking the cooling system ................................................................................... 14
7 TROUBLESHOOTING .................................................................................................... 15
8 ORDERING SPARE PARTS ............................................................................................ 16
ORDERING NUMBERS ......................................................................................................... 17
Torch neck PSF 260C ........................................................................................................ 18
Torch neck PSF 415C ........................................................................................................ 19
Torch neck PSF 420Cw ...................................................................................................... 20
WEAR PARTS .................................................................................................................... 21
PSF 260C ........................................................................................................................ 21
PSF 415C ........................................................................................................................ 22
PSF 420Cw ..................................................................................................................... 23
Contact tips PSF 260C, PSF 415C, PSF 420Cw ............................................................... 24
Steel liner ............................................................................................................................ 25
PTFE liner ........................................................................................................................... 26
PA Liner with bronze front end ........................................................................................... 26
Rights reserved to alter specifications without notice.
1 SAFETY
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© 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 unauthorized 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
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© 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
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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.
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© ESAB AB 2020
2 INTRODUCTION
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.
The ESAB PSF Centrovac MIG / MAG welding torches combine the advantages of the
PSF Standard Series with the ability off extraction fume in one process.
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
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PSF 415C RS3
PSF 420Cw RS3
Type of cooling
Air
Air
Water
Permitted load at:
60% duty cycle*
100% duty cycle
flow
temperature**
4 TECHNICAL DATA
Welding torch PSF 260C
Carbon dioxide CO
2
Mixed gas, Ar/CO2 M21
Recommended gas
Extraction volume:
Differential pressure
250 A 380 A 430 A
225 A 325 A 430 A
8-12 l/min 10-18 l/min 10-20 l/min
40 m³/h 60 m³/h 53 m³/h
1,4 Pa 4,0 Pa 2,9 Pa
PSF 415C,
Wire diameter 0.6-1.0 mm 0.8-1.6 mm 1.0-1.6 mm
Operating
-10 °C to 40 °C -10 °C to 40 °C -10 °C to 40 °C
PSF 420Cw,
* The capacity may be reduced up to 30% when pulse welding.
** When using liquid cooled torches in freezing conditions, use an adequate cooling liquid.
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General torch data with reference to IEC/EN 60 974−7
4 TECHNICAL DATA
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.
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
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 must 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.
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