ESAB Origo Mig C420 PRO Bedienungsanleitung

Valid for serial no. 6270349 301 112 070104

Mig C420 PRO

Mig C420w PRO

Origo

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Instruction manual

ENGLISH

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TOCe

1 DIRECTIVE 3........................................................

2 AFETY 3...........................................................

3 INTRODUCTION 5...................................................

3.1 Equipment 5................................................................

4 TECHNICALDATA 5.................................................

5 IN TALLATION 6....................................................

5.1 Placing 6...................................................................

5.2 Assem lyofcomponents 7...................................................

5.3 Electricalinstallation 7.......................................................

5.4 Mainspowersupply 8........................................................

6 OPERATION 8.......................................................

6.1 Connectionandcontroldevices 9.............................................

6.2 Weldingwithoutgas 10.......................................................

6.3 Wirefeedpressure 10........................................................

6.4 Replacingandinsertingwire 10................................................

6.5 Start 11.....................................................................

6.6 Overheatingprotection 11.....................................................

6.7 Waterconnection 11..........................................................

6.8 Waterflowguard 11..........................................................

6.9 Idlemode 11................................................................

6.10 OrigoTM Mig C420w PRO / OrigoTM Mig C420 PRO 11. . . . . . . . . . . . . . . . . . . . . . . . . . .

7 MAINTENANCE 12....................................................

7.1 Inspectionandcleaning 12....................................................

7.2 Toppingupthecoolant 13.....................................................

8 FAULTTRACING 13...................................................

9 ORDERINGOF PAREPART 13......................................

DIAGRAM 14............................................................

ACCE ORIE 20.......................................................

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1 DIRECTIVE

DECLARATION OF CONFORMITY

ESAB AB, Welding Equipment, SE--695 81 Laxå, Sweden, gives its unreserved guarantee that weld-

ing power source OrigoTM Mig C420 PRO, OrigoTM Mig C420w PRO from serial num er 627 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 IEC/EN 60974--10 in accordance with the requirements of

directive (89/336/EEC) and addendum (93/68/EEC).

--------------------------------------------------------------------------------------------------------------------------------------

Kent Eim rodt

Glo al Director Equipment and Automation

ESAB AB

695 81 LAXÅ

SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924

Laxå 2006--09--05

2 AFETY

Users of ESAB welding equipment have the ultimate responsi ility for ensuring that anyone who

works on or near the equipment o serves all the relevant safety precautions. Safety precautions

must meet the requirements that apply to this type of welding equipment. The following recommen-

dations should e o served in addition to the standard regulations that apply to the workplace.

All work must e carried out y 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 e 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:

Se suita le for the purpose

Se 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, racelets, rings, etc., which could ecome

trapped or cause urns.

5. General precautions

SMake sure the return ca le is connected securely.

SWork on high voltage equipment may only be carried out by a qualified electrician.

SAppropriate fire extinquishing equipment must e clearly marked and close at hand.

SLu rication and maintenance must not e carried out on the equipment during operation.

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WARNING!

Read and understand the instruction manual

efore installing or operating.

WARNING

READ AND UNDER TAND THE IN TRUCTION MANUAL BEFORE IN TALLING OR OPERATING.

ARC WELDING AND CUTTING CAN BE INJURIOU TO YOUR ELF AND OTHER . TAKE PRECAU-

TION WHEN WELDING. A K FOR YOUR EMPLOYER’ AFETY PRACTICE WHICH HOULD BE

BA ED ON MANUFACTURER ’ HAZARD DATA.

ELECTRIC HOCK -- Can kill

SInstall and earth the welding unit in accordance with applica le standards.

SDo not touch live electrical parts or electrodes with are skin, wet gloves or wet clothing.

SInsulate yourself from earth and the workpiece.

SEnsure your working stance is safe.

FUME AND GA E -- Can be dangerous to health

SKeep your head out of the fumes.

SUse ventilation, extraction at the arc, or oth, to take fumes and gases away from your reathing zone

and the general area.

ARC RAY -- Can injure eyes and burn skin.

SProtect your eyes and ody. Use the correct welding screen and filter lens and wear protective

clothing.

SProtect ystanders with suita le screens or curtains.

FIRE HAZARD

SSparks (spatter) can cause fire. Make sure therefore that there are no inflamma le materials near y.

NOI E -- Excessive noise can damage hearing

SProtect your ears. Use earmuffs or other hearing protection.

SWarn ystanders of the risk.

MALFUNCTION -- Call for expert assistance in the event of malfunction.

PROTECT YOUR ELF AND OTHER !

Do not use the power source for thawing frozen pipes.

WARNING!

This product is solely intended for arc welding.

Do not dispose of electrical equipment together with normal waste!

In o servance of European Directive 2002/96/EC on Waste Electrical and Electronic

Equipment and its implementation in accordance with national law, electrical equipment

that has reached the end of its life must e collected separately and returned to an

environmentally compati le recycling facility. As the owner of the equipment, you should

get information on approved collection systems from our local representative.

By applying this European Directive you will improve the environment and human health!

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3 INTRODUCTION

The OrigoTM Mig C420 PRO, OrigoTM Mig C420w PRO are step--controlled compact welding power

units 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 OrigoTM Mig C420w PRO are equipped with cooling liquid system for welding torch. The OrigoTM

Mig C420 PRO are not equipped with cooling system and can operate only with appropriate gas

cooled torches.

The power units are fan--cooled and equipped with thermal overload protection.

The machines can e fit with a flow guard (OrigoTM Mig C420w PRO).

E AB’s accessories for the product can be found on page 20.

3.1 Equipment

The power source is supplied with:

SWelding gun PSF 410W -- 4,5m

SReturn ca le 5m with return clamp

SShelf for gas cylinder

SInstruction manual

4 TECHNICAL DATA

OrigoTM Mig C420 PRO / OrigoTM Mig C420w PRO

Voltage 400--415V, 3∼

∼∼

∼50Hz

Permissible load

at100 % duty cycle 315 A/30V

at 60 % duty cycle 400 A/34V

at 50 % duty cycle 420 A/35V

etting range (DC) 50A/16,5V--420A/35V

Open circuit voltage 14--47V

Open circuit power 520W

with cooling unit 730W

Efficiency at max current 77%

Power factor at max current 0,92

Control voltage 42V, 50/60Hz

Wire feed speed 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 bob-

bin 300mm

Wire dimension range 0,6 -- 1,6mm

Dimensions lxwxh 935 x 640 x 800mm

Weight 215kg

with cooling unit 230kg

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Operating temperature --10 to +40oC

Enclosure class IP 23

Application classification

Cooling unit

(100 % duty cycle)

P1l/min 1200 W @ 25˚C

pmax 3,5 ar

Coolant 50 % water / 50% glycol

Coolant quantity 5,5 l

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 y solid

o jects or water. Equipment marked IP23 is designed for indoor and outdoor use.

Application class

The sym ol indicates that the power source is designed for use in areas with increased

electrical hazard.

5 IN TALLATION

The installation must be executed by a professional.

ote!

Connect the power source to the electricity mains with a network impedance of 0.268

Ω

or lower. If the

network impedance is higher, there is a risk of flicker in the illuminators.

WARNING!

This product is intended for industrial use. In a domestic environment this product may cause radio

interference. It is the user’s responsi ility to take adequate precautions.

5.1 Placing

Position the welding power source such way that its cooling air inlets and outlets are

not o structed.

The power supply should e lifted y means of its lifting

eye. The handle is only intended for pulling it along the

ground.

Lifting instructions

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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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C420Pe

5.4 Mains power supply

Check that the unit is connected to the correct mains power supply voltage, and that

it is protected y the correct fuse size. A protective earth connection must e made,

in accordance with regulations.

Rating plate with supply connection data

3∼50 Hz

Voltage V 400/415

Current A

at100% duty cycle 19

at 60% duty cycle 27

at 50% duty cycle 30

Cable area mm2

24 x 4

Fuse, slow A 25

B: The mains cable areas and fuse si es 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

si es 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.

To prevent the reel sliding off the hu : Lock the reel in place y turning

the red kno as shown on the warning la el attached next to the hu .

WARNING!

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WARNING -- TIPPING RI K!

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 e provided !

6.1 Connection and control devices

1Mains supply switch 10 Connection for return ca le (--), medium in-

ductance

2Switch, coarse control 11 Connection for return ca le (--), low induc-

tance

3Switch, precise control 12 Kno for wire speed setting

4Indicating lamp, power supply ON 13 Kno for selecting 2/4--stroke control mode

5Orange indicating lamp, overheating and

loss of coolant* 14 Kno for selecting -- creep start -- ON/OFF

6EURO -- connector (for welding gun) 15 Kno for urn-- ack time setting

7Connection for cooling water to the welding

gun (Blue -- with ELP** switch) 16 Digital instrument -- V / A

(option,see page 20)

8Connection for cooling water from the weld-

ing gun (Red) 17 Water flow guard (option,see page 20)

9Connection for return ca le (--), high induc-

tance

* Indicating loss of coolant, only when water flow guard is used, see point 6.8

** ELP = ESAB Logic Pump, see point 6.7.

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6.2 Welding without gas

6.3 Wire feed pressure

Start y making sure that the wire moves smoothly through the wire guide. Then

set the pressure of the wire feeder’s pressure rollers. It is important that the

pressure is not too great.

Fig 1 Fig 2

To check that the feed pressure is set correctly, you can feed out the wire against

an insolated o ject, e.g. a piece of wood.

When you hold the gun approx. 5 mm from the piece of wood (fig. 1) the feed

rollers should slip.

If you hold the gun approx. 50 mm from the piece of wood, the wire should e

fed out and end (fig. 2).

6.4 Replacing and inserting wire

SOpen the side panel.

SDisconnect the pressure sensor y folding it ackwards, the pressure rollers

slide up.

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