ESAB Origo M13y YardFeed 200 User manual

GB
Valid for serial no. 612-xxx-xxxx, 613-xxx-xxxx0459 937 101 GB 20120621
Origo™ M13y
YardFeed 200
Instruction manual

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TOCe
Rights reserved to alter specifications without notice.
1 SAFETY 4...........................................................
2 INTRODUCTION 6...................................................
2.1 Equipment 6................................................................
3 TECHNICAL DATA 7.................................................
4 INSTALLATION 8....................................................
4.1 Lifting instructions 8.........................................................
5 OPERATION 8.......................................................
5.1 Connections and control devices 9............................................
5.2 Function explanations 9......................................................
5.3 Wire feed pressure 11........................................................
5.4 Replacing and inserting wire 11................................................
5.5 Changing feed rollers 12......................................................
6 MAINTENANCE 12....................................................
6.1 Inspection and cleaning 12....................................................
7 ORDERING SPARE PARTS 13.........................................
DIAGRAM 14............................................................
ORDER NUMBER 16.....................................................
WEAR PARTS 18........................................................
ACCESSORIES 20.......................................................

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1 SAFETY
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 ob
served 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 equip
ment. Incorrect operation of the equipment may lead to hazardous situations which can result in in
jury to the operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with:
Sits operation
Slocation of emergency stops
Sits function
Srelevant safety precautions
Swelding and cutting
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 drafts
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 precautions when welding and
cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard
data.
ELECTRIC SHOCK - Can kill
SInstall and earth the 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!
CAUTION
Read and understand the instruction manual before
installing or operating.
CAUTION
This product is solely intended for arc welding.
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.
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Dispose of electronic equipment at the recycling facility!
In observance of European Directive 2002/96/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 can provide you with all necessary welding protection and accessories.
2 INTRODUCTION
The wire feed unit YardFeed 200 is intended for MIG/MAG welding together with
stepped and thyristor-controlled welding power sources.
It comes in different variants, see page 16.
The wire feed unit contains a four-wheel drive wire feed mechanism as well as
control electronics.
ESAB's accessories for the product can be found on page 20.
2.1 Equipment
The wire feed unit is supplied with:
SInstruction manual
SDecal with recommended wear parts
SGas flow meter
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3 TECHNICAL DATA
YardFeed 200
Mains voltage 42 V 50-60 Hz
Power requirement 150 VA
Motor current Imax 3.5 A
Settings data
Wire feed speed
Burnback time
2/4 stroke
Gas flushing
Wire inching
1.9 -25.0 m/min
0 -0.5 s
2 stroke or 4 stroke
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Gun connection EURO
Max. diameter wire bobbin 200 mm
Wire dimension
Fe
Ss
Al
Cored wire
0.6 - 1.2 mm
0.6 - 1.2 mm
1.0 - 1.2 mm
0.8 - 1.2 mm
Weight 11.3 kg
Dimensions (l x w x h) 593 x 210 x 302 mm
Operating temperature -10 to +40°C
Shielding gas
max pressure
All types intended for MIG/MAG welding
0.5 MPa ( 5 bar)
Type of cooling
max pressure
50% water / 50% monoetylenglycol
0.5 MPa ( 5 bar)
Maximum permissible load at
60% duty cycle 365 A
Enclosure class IP23
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or cut at
a certain load without overloading. The duty cycle is valid for 40°C.
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.
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4 INSTALLATION
The installation must be carried out by a professional.
WARNING
When welding in an environment with increased electrical danger, only power
sources intended for this environment may be used. These power sources are
marked with the symbol
4.1 Lifting instructions
5 OPERATION
General safety regulations for handling the equipment can be found on
page 4. Read through before you start using the equipment!
WARNING
Assure that the side panels are closed during operation.
WARNING
Rotating parts can cause injury, take great care.
WARNING
Risk of crushing when replacing the wire bobbin!
Do not use safety gloves when inserting the welding wire between the feed rollers.
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5.1 Connections and control devices
1Connection for welding current from power
source, (OKC)
8Safety contact switch
2Connection for shielding gas 9Connection for welding gun
3Connection for control cable from power
source
10 Toggle switch for gas flushing / wire
inching
4Connection RED, for coolant to power
source (cooling unit)
11 Toggle switch for 2 stroke/ 4 stroke
5Connection BLUE, for coolant from power
source (cooling unit)
12 Display
6Connection RED, for coolant from welding
gun
13 Knob for setting the voltage**
7Connection BLUE, with ELP* for coolant to
the welding gun
14 Knob for setting wire feed speed
Note! Display (digital instrument) and coolant connections only available on certain models.
* ELP = ESAB Logic Pump, see point 5.2.
** Voltage regulation from the wire feed unit does not function with step regulated power sources.
5.2 Function explanations
Water connection
The wire feed unit with water connection is equipped with a detection system ELP
(ESAB Logic Pump) which checks that the water hoses are connected. When
connecting a water-cooled welding gun, the water pump starts.
Detection only works with power sources that are equipped with ELP.
Strain relief
Hook the strain relief onto the hook on the rear side of the feeder unit and the
connection cable.
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Safety contact switch
0Welding OFF
1Welding ON
Heat ON (accessory) and welding OFF
The bobbin area is heated so that the welding
wire is not damp when welding .
Gasflow control and burnback time
A= Controlling gas flow.
B= Gas flow meter
C= Setting burnback time.
Burnback time is a delay between the time
when the wire starts to brake until the time
when the power source switches off the
welding voltage. Too short burnback time
results in a long wire stickout after completion
of welding, with a risk of the wire being caught
in the solidifying weld pool. Too long burnback
time results in a shorter stickout, with
increased risk of the arc striking back to the contact tip.
Gas flushing
Gas flushing is used when measuring the gas flow or to flush any air or moisture
from the gas hoses before welding starts. Gas flushing occurs for as long as the
toggle switch is held depressed and occurs without voltage or wire feed starting.
Wire inching
Wire inching is used when one needs to feed wire without welding voltage being
applied. The wire is fed as long as the toggle switch is depressed.
2 stroke
With 2-stroke gasflow starts when the welding gun trigger switch is pressed. The
welding process then starts. Releasing the trigger switch stops welding entirely and
starts burn back time (if selected).
4 stroke
With 4 stroke, the gas flow starts when the welding gun trigger switch is pressed in
and the wire feed starts when it is released. The welding process continues until the
switch is pressed in again, the wire feed and burn back time (if selected) stops when
the switch is released.
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Voltage
Higher voltage increases the arc length and produces a hotter, wider arc.
NOTE! Voltage regulation from the wire feed unit does not function with step
regulated power sources.
Wire feed speed
This sets the required feed speed of the filler wire in m/minute.
5.3 Wire feed pressure
Start by 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 insulated object, 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 be
fed out and bend (fig. 2).
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5.4 Replacing and inserting wire
SOpen the side panel.
SDisconnect the pressure sensor by folding it backwards, the pressure rollers
slide up.
SStraighten out the new wire 10-20 cm. File away burrs and sharp edges from the
end of the wire before inserting it into the wire feed unit.
SMake sure that the wire goes properly into the feed roller's track and into the
outflow nozzle or wire guide.
SSecure the pressure sensor.
SClose the side panel.
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5.5 Changing feed rollers
SOpen the side panel.
SDisconnect the pressure sensor (1) by folding it
backwards, the pressure rollers slide up.
SDisconnect the pressure rollers (2) by turning the
axle (3) 1/4 turn clockwise and pulling out the axle.
The pressure rollers disconnect.
SDisconnect the feed rollers (4) by unscrewing the
nuts (5) and pulling out the rollers.
During installation, repeat the above in reverse order.
Choice of track in the feed rollers
Turn the feed roller with the dimensioning mark for the required
track towards you.
6 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
CAUTION
All guarantee undertakings from the supplier cease to apply if the customer attempts any
work to rectify any faults in the product during the guarantee period.
6.1 Inspection and cleaning
Wire feed unit
Check regularly that the wire feed unit is not clogged with dirt.
SCleaning and replacement of the wire feed unit mechanism's worn parts should
take place at regular intervals in order to achieve trouble-free wire feed. Note
that if pre-tensioning is set too hard, this can result in abnormal wear on the
pressure roller, feed roller and wire guide.
The brake hub
The hub is adjusted when delivered.
SAdjust the brake hub so that wire is slightly slack when wire
feed stops.
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Welding gun
SThe welding gun's wear parts should be cleaned and replaced at regular
intervals in order to achieve trouble-free wire feed. Blow the wire guide clean
regularly and clean the contact tip.
7 ORDERING SPARE PARTS
YardFeed 200 is designed and tested in accordance with the international and Europe
an standards EN 60974-5 and EN 60974-10. It is the obligation of the service unit
which has carried out the service or repair work to make sure that the product still
conforms to the said standard.
Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication.
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© ESAB AB 2005
Diagram
G
12
1317
1316
13G1
13XS6
F04F03
E01
E02
1313
1312
13XS5
CURRENT RELAY
13XS9
F01
F02
1309
1310
13XS6
WELDING GUN
42VAC
F
A
B
13RP2
3
2
1VOLTAGE
1367
1368
1369
1335
1333
1334
POWER SOURCE
+15VB
REF
0VB
13C4
J
L
K
13XP1
R
S
1320
1321
13XP2
H
1366
1366
U
D
E
V
T
U
D
E
V
T
1361
1362
1363
1364
1365
H
J
F
A
B
K
L
X
Y
Arc Voltage
12V Display
0V
Load Display
Clock Display
Data Display
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YardFeed 200

© ESAB AB 2005
13AP01 Control board
M
+-
Red Black
13M1
13XS8
J01 J02 B06 B07
2
1
1326
1325
13XS11
2 / 4 STROKE
13S3
1354
1355
1357
1356
K01
K02
K04
K03
GAS PURGE
INCHING
13XS2
13S4
BURNBACKTIME
G04 G05
1315
1314
13XS7
13YV1
1383 1382
G02G01
G03
1373 1372
HEATINGKIT
13R1
13XS4
13S2
3
A1
1327 1328
C
2
9
7
8
13S1
WATER CONNECTION
MONITORING
2
2
1
1
3
2
1
A02
A01
A03
13RP1
WIRE FEED
13XS1
1
2
31353
1352
1351
1
2
3
B04
B03
B05
13RP3
13XS11
3
4
51350
1349
1348
1
2
3
13AP02
Digital instrument
01
02
03
04
05
13XS12
13C5
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YardFeed 200
© ESAB AB 2005
Order number
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Ordering no. Denomination Type
0459 906 881 Wire feed unit OrigotYardFeed 200 with control panel M13Y
0459 906 882 Wire feed unit OrigotYardFeed 200 with digital instrument and control
panel M13Y
0459 906 891 Wire feed unit OrigotYardFeed 200 with water cooling and control panel
M13Y
0459 906 892 Wire feed unit OrigotYardFeed 200 with water cooling, digital instrument
and control panel M13Y
0459 839 005 Spare parts list OrigotYardFeed 200
Instruction manuals and the spare parts list are available on the Internet at www.esab.com

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YardFeed 200
© ESAB AB 2005
Wear parts
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Item Ordering no. Denomination Wire type Wire dimensions
HI 1 0455 072 002
0456 615 001
Intermediate nozzle
Intermediate nozzle
Fe, Ss & cored
Al
HI 2 0469 837 880
0469 837 881
Outlet nozzle
Outlet nozzle
Fe, Ss & cored
Al
Ø 2.0 mm steel for 0.6-1.2 mm
Ø 2.0 mm plastic for 0.8-1.2 mm
HI 3 0191 496 114 Key
HI 4 0215 701 007 Locking washer
HI 5a 0459 440 001 Motor gear euro
Item Ordering no. Denomination Wire type Wire dimensions Groove
typ
Roller
markings
HI 5b 0459 052 001 Feed/pressure rollers Fe, Ss & cored Ø 0.6 & 0.8 mm V0.6 S2 & 0.8 S2
0459 052 002 Feed/pressure rollers Fe, Ss & cored Ø 0.8 & 0.9/1.0 mm V0.8 S2 & 0.9/1.0 S2
0459 052 003 Feed/pressure rollers Fe, Ss & cored Ø 0.9/1.0 & 1.2 mm V0.9/1.0 S2 & 1.2 S2
0458 825 001 Feed/pressure rollers Cored Ø 0.9/1.0 & 1.2 mm V-Knurled 1.0 R2 & 1.2 R2
0458 824 001 Feed/pressure rollers Al Ø 0.8 & 0.9/1.0 mm U0.8 A2 & 1.0 A2
0458 824 002 Feed/pressure rollers Al Ø 1.0 & 1.2 mm U1.0 A2 & 1.2 A2
0458 824 003 Feed/pressure rollers Al Ø 1.2 mm U1.2 A2
Use only pressure and feed rollers marked A2, R2 or S2.
The rollers are marked with wire dimension in mm, some are also marked with inch.
Item Ordering no. Denomination Notes
HI 6 Washer Ø 16/5x1
HI 7 Screw M4x12
HI 8 Screw M6x12
HI 9 Washer Ø 16/8.4x1.5
HI 10 0469 838 001 Cover
HI 11 0458 722 880 Axle and Nut
HI 12 0459 441 880 Gear adapter
HI 13 0455 049 001 Inlet nozzle For Fe, Ss, Al and cored wire
0460 007 001 Inlet nozzle Long-life for Fe, Ss, Al and cored wire
HI 14 0458 999 001 Shaft
Welding with aluminium wire
In order to weld with aluminium wire, proper rollers, nozzles and liners for aluminium wire MUST be
used, It is recommended to use 3 m long welding gun for aluminium wire, equipped with appropriate
wear parts.

YardFeed 200
© ESAB AB 2005
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YardFeed 200
© ESAB AB 2005
Accessories
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Digital Volt / Ampere meter .............. 0455 173 882
Gas flow meter ......................... 0460 005 880
Heating kit ............................. 0459 941 880
Control panel protection ................. 0459 961 880
Strain relief for welding gun ............. 0457 341 881
Water kit ................................ 0460 006 880