ESAB Origo Mag C140 User manual

Valid for serial no. 6260349 301 114 071119
Mag C140/C150
Mag C170/C200/C250
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 7....................................................
5.1 Placing 7...................................................................
5.2 Assem lyofcomponents 7...................................................
5.3 Electricalinstallation 9.......................................................
5.4 Mainspowersupply 10........................................................
6 OPERATION 10.......................................................
6.1 Connectionandcontroldevices 11.............................................
6.2 Weldingwithoutgas 12.......................................................
6.3 Wirefeedpressure 12........................................................
6.4 Replacingandinsertingwire 12................................................
6.5 Overheatingprotection 13.....................................................
7 MAINTENANCE 13....................................................
7.1 Inspectionandcleaning 13....................................................
8 FAULTTRACING 14...................................................
9 ORDERINGOF PAREPART 14......................................
DIAGRAM 15............................................................
WEARCOMPONENT 21.................................................
WEARCOMPONENT 22.................................................
ACCE ORIE 23.......................................................

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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 Mag C140/C150/C170/C200/C250 from serial num er 626 are constructed
and tested in compliance with the standard EN 60974--1 and EN 60974--10 in accordance with the
requirements of directive (2006/95/EC) and (2004/108/EEC).
------------------------------------------------------------------------------------------------------------------------------------
Kent Eim rodt
Glo al Director
Equipment and Automation
Laxå 2007--01--17
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
OrigoTM Mag C140/C150/C170/C200/C250 are step controlled power sources in a compact design,
intended for welding with solid steel, stainless steel or aluminium wire as well as tu ular wire with or
without shielding gas.The possi ility of welding with homogeneous wire/shielding gas and welding with
gasless tu ular wire is o tained y switching the + and -- connections on the switching terminal y the
wire feed unit.
E AB’s accessories for the product can be found on page 23.
3.1 Equipment
The power source is supplied with:
SWelding gun
SReturn ca le with return clamp
SShelf for gas cylinder
SInstruction manual
4 TECHNICAL DATA
OrigoTM Mag C140 OrigoTM Mag C150 OrigoTM Mag C170
Voltage 220--230V, 1∼50/60Hz 220--230V, 1∼50/60Hz 220--230V, 1∼50/60Hz
Permissible load at
100% duty cycle 42A/16,1V 67A/17,4V 76A/17,8V
60 % duty cycle 54A/16,7V 86A/18,3V 98A/18,9V
@ % duty cycle 67A/17,4V @ 40% 95A/18,7V @ 50% 150A/21,8V @ 25%
20 % duty cycle 100A/13,0V 150A/13,8V 170A/19,3V
etting range (DC) 35A/15,7V--67A/17,4V
(100A/13,0V)
35A/15,7V--95A/18,7V
(150A/13,8V)
30A/15,5V--150A/19,3
V (170A/19,3V)
Open circuit voltage 19,6--27,5V 18,5--30,5V 15,5--30,6V
Open circuit power 90W 100W 145W
Power factor at max load 0,92 0,91 0,90
Control voltage 220--230V, 50/60Hz 220--230V, 50/60Hz 42V, 50/60Hz
Wire feed speed 2,0--14m/min 2,0--14m/min 1,0--17m/min
Burnback time -- -- 0,02--0,25s
pot welding -- -- 0,2--2,5s
Welding gun connection fixed fixed EURO
Wire dimension range 0,6--0,8(Fe)
0,8(cored)
0,8(CuSi)
0,6--0,8(Fe)
0,8(cored)
0,8(CuSi)
0,6--0,8(Fe)
1,0(Al)
0,8(cored)
0,8--1,0(CuSi)
Max diameter/weight
of wire bobin 200mm/5kg 200mm/5kg 300mm/15kg
Dimensions lxwxh 650x300x550 650x300x550 860x420x730
Weight 25kg 37,5kg 59kg
Operating temperature --10 ÷+40oC --10 ÷+40oC --10 ÷+40oC
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Enclosure class IP 23 IP 23 IP 23
Application classifica-
tion
OrigoTM Mag C200 OrigoTM Mag C250
Voltage 220--230V, 1∼50/60Hz 220--230V, 1∼50/60Hz
Permissible load at
100% duty cycle 90A/18,5V 110A/19,5V
60 % duty cycle 115A19,7V 140A/21,0V
@ % duty cycle 150A/21,5V @ 35% 200A/24,0V @ 30%
20 % duty cycle 200A/18,0V 250A/21,0V
etting range (DC) 30A/15,5V--150/21,5
(200A/18V)
40A/16,0V--200A/24,0V
(250A/21,0V)
Open circuit voltage 17,5--33,0V 19,0--41,5V
Open circuit power 240W 200W
Power factor at max load 0,83 0,92
Control voltage 42V, 50/60Hz 42V, 50/60Hz
Wire feed speed 1,0--17m/min 1,9--19m/min
Burnback time 0,02--0,25s 0--0,25s
pot welding 0,2--2,5s 0,2--2,5s
Welding gun connection EURO EURO
Wire dimension range 0,6--1,0(Fe)
1,0(Al)
0,8--1,0(cored)
0,8--1,0(CuSi)
0,6--1,2(Fe)
1,0--1,2(Al)
0,8--1,2(cored)
0,8--1,0(CuSi)
Max diameter/weight
of wire bobin 300mm/15kg 300mm/15kg
Dimensions lxwxh 860x420x730 860x420x730
Weight 68kg 94kg
Operating temperature --10 ÷+40oC --10 ÷+40oC
Enclosure class IP 23 IP 23
Application classifica-
tion
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.
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5 IN TALLATION
The installation must be executed by a professional
Note!
Connect the power source to the electricity mains with a network impedance of (C150 -- 0,419, C170 --
0,28 , C200 -- 0,203, C250 -- 0,212) ohm 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.
5.2 Assembly of components
For packing and shipment of the machine the wheels are detached from the unit.
Before use attach the wheels according to instruction.
WARNING!
5.2.1 OrigoTM Mag C140
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5.2.2 OrigoTM Mag C150
1.
3.
2.
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5.2.3 OrigoTM Mag C170/C200/C250
1.
3.
2.
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 y
the correct fuse size. A protective earth connection must e made, in accordance with regulations.
Rating plate with supply connection data
OrigoTM
Mag C140 OrigoTM Mag C150 OrigoTM Mag C170 OrigoTM Mag C200 OrigoTM Mag C250
Voltage V 220--230V,
1∼50/60Hz
220--230V,
1∼50/60Hz
220--230V,
1∼50/60Hz
220--230V,
1∼50/60Hz
220--230V,
1∼50/60Hz
Current A
at 100% duty cycle 5,4 9,6 10,4 14,3 16,6
at 60% duty cycle 7,6 12,9 15,0 17,6 23,4
at @% duty cycle 10,2A @40% 15,2 @ 50% 26,5 @ 25% 26,2 @ 35% 38,7 @ 30%
at 20% duty cycle 13,8 22,6 29 32,5 47,5
Cable area mm2
22
23 x 1.5 3 x 1.5 3 x 1.5 3 x 2.5 3 x 4,0
Fuse slow A10 10 16 16 35
NB: The mains cable areas and fuse sizes 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
sizes 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 with indicating lamp,
only in C170/C200/C250
5a Return ca le with clamp, fixed,
only in C140/C150/C170/C200
2Orange indicating lamp, overheating 6Kno for spot welding -- ON/OFF and time
setting
3Welding voltage switch
C140: OFF + 4 steps (mains ON/OFF)
C150: OFF + 7 7 steps (mains ON/OFF)
C170: 8 steps
C200: 12 steps
C250: 12 steps
7Kno for wire speed setting
4EURO -- connector for welding gun,
only in C170/C200/C250
8Digital instrument -- V / A, only in
C170/C200/C250 (option,see page 23)
4a Welding gun, fixed,
only in C140/C150
9Kno for urn-- ack time setting.
In C250 located in wire feeder compartment,
in C170/C200 located on control oard.
5Connection for return ca le (--),only in
C250
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6.2 Welding without gas
(cored)
(cored)
(Fe) (Al) (cored)
(Cu i)
connected when delivered
(Fe) (Al) (cored)
(Cu i)
connected when delivered
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.
SStraighten out the new wire 10--20 cm. File away urrs and sharp edges from the
end of the wire efore inserting it into the wire feed unit.
SMake sure that the wire goes properly into the feed roller track and into the outlet
nozzle and the wire guide.
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SSecure the pressure sensor.
SClose the side panel.
6.5 Overheating protection
When the machine is switched on with the mains switch [1] or [3] depending on machine
model, indicating lamp [1] is on and lamp [2] off -- the machine is ready to operate. If the
internal temperature ecomes too high, the welding is interrupted and disa led. This
state is indicated y lighting of the orange indicating lamp [2] on the front of the machine.
It resets automatically when the temperature has fallen.
7 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
Note!
All guarantee undertakings from the supplier cease to apply if the customer himself
attempts any work in the product during the guarantee period in order to rectify any
faults.
7.1 Inspection and cleaning
Check regularly that the power source is free from dirt.
The power source should e regularly lown clean using dry compressed air at reduced
pressure. More frequently in dirty environments. Otherwise the air inlet/outlet may e-
come locked and cause overheating.
Welding gun
SCleaning and replacement of the welding gun’s wear parts should take place at
regular intervals in order to achieve trou le--free wire feed. Blow the wire guide
clean regularly and clean the contact tip.
The brake hub
The hu is adjusted when delivered, if
readjustment is required, follow the instructions
elow. Adjust the rake hu so that wire is slightly
slack when wire feed stops.
SAdjusting the braking torque:
STurn the red handle to the locked position.
SInsert a screwdriver into the springs in the hu .
Turn the springs clockwise to reduce the raking torque
Turn the springs anticlockwise to increase the raking torque. NB: Turn oth
springs through the same amount.
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8 FAULT TRACING
Try these recommended checks and inspections before sending for an authorised service technican.
Type of fault Actions
No arc SCheck that the mains power supply switch is turned on.
SCheck that the welding current supply and return ca les are
correctly connected.
SCheck that correct current value is set.
Welding current is interrupted
during welding
SCheck whether the thermal overload trip has operated
(indicated y the orange lamp on the front).
SCheck the main power supply fuses.
Thermal overload trips
operate frequently
SCheck to see whether the air inlets/outlets are clogged.
SMake sure that you are not exceeding the rated data for the
power source (i.e. that the unit is not eing overloaded).
Poor welding performance SCheck that the welding current supply and return ca les are
correctly connected.
SCheck that the correct current value is set.
SCheck that the correct welding wires are eing used.
SCheck the main power supply fuses.
SCheck the wire feed unit -- if proper rolls are applied and
properly set the pressure of the wire feeder’s pressure rollers
9 ORDERING OF PARE PART
OrigoTM Mag C140/C150/C170/C200/C250 is designed and tested in accordance with
the international and European standards IEC/EN 60974--1 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 e ordered through your nearest ESAB dealer, see the last page of
this pu lication.
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Diagram
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OrigoTM Mig C140, 230V

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dC1425
OrigoTM Mig C150, 230V

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dC1425
OrigoTM Mig C170, 230V

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OrigoTM Mig C200, 230V

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dC1425
OrigoTM Mig C250, 230V

Origo
T
M
Mag C140/C150/C170/C200/C250
Edition 071119
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oC1425
Valid for serial no. 626--XXX--XXXX
Ordering numbers
0349 306 220 OrigoTM Mig C140 230V 1∼
∼∼
∼50/60Hz
0349 306 532 OrigoTM Mig C150 230V 1∼
∼∼
∼50/60Hz
0349 305 236 OrigoTM Mig C170 230V 1∼
∼∼
∼50/60Hz
0349 306 560 OrigoTM Mig C200 230V 1∼
∼∼
∼50/60Hz
0349 305 238 OrigoTM Mig C250 230V 1∼
∼∼
∼50/60Hz