ESAB Origo Mig 410 User manual

Valid for serial no. 6270349 301 122 070104
Mig 410
Mig 510
Origo



Instruction manual

ENGLISH
-- 2 --
TOCe
1 DIRECTIVE 3........................................................
2 AFETY 3...........................................................
3 INTRODUCTION 5...................................................
3.1 Equipment 5................................................................
4 TECHNICALDATA 5.................................................
5 IN TALLATION 6....................................................
5.1 Placing 7...................................................................
5.2 Assem lyofcomponents 7...................................................
5.3 Assem lyofcounter alance 8................................................
5.4 Electricalinstallation 8.......................................................
5.5 Mainspowersupply 10........................................................
6 OPERATION 11.......................................................
6.1 Connectionandcontroldevices 11.............................................
6.2 Start 12.....................................................................
6.3 Overheatingprotection 12.....................................................
6.4 Waterconnection 12..........................................................
6.5 Waterflowguard 12..........................................................
6.6 Idlemode 12................................................................
6.7 Inductance 12...............................................................
7 MAINTENANCE 13....................................................
7.1 Inspectionandcleaning 13....................................................
7.2 Toppingupthecoolant 13.....................................................
8 FAULTTRACING 14...................................................
9 ORDERINGOF PAREPART 14......................................
DIAGRAM 15............................................................
ACCE ORIE 20.......................................................

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mi410,510e
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 410 / OrigoTM Mig 510 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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mi410,510e
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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mi410,510e
3 INTRODUCTION
The OrigoTM Mig 410 and OrigoTM Mig 510 are step switched power sources
designed for MIG/MAG--welding together with wire feed units OrigoTM Feed 30x,
OrigoTM Feed 48x and the most of ESAB wire feeders.
The power units are fan--cooled and equipped with thermal overload protection.
The machines can e fitted with an instrument for display of current and voltage. It
incorporates a hold function and can e cali rated.
The machines can e fitted with a flow guard.
E AB’s accessories for the product can be found on page 20.
3.1 Equipment
The power source is supplied with:
SReturn ca le 5m with return clamp
SShelf for gas cylinder
SGuide pin for wire feed unit
SInstruction manual
4 TECHNICAL DATA
OrigoTM Mig 410
Voltage 400--415V, 3∼
∼∼
∼50/60 Hz 230/400--415/500V 3∼
∼∼
∼50 Hz
230/440--460 3∼
∼∼
∼60Hz
Permissible load
at100 % duty cycle 280 A/28 V 280 A/28 V
at 60 % duty cycle 365 A/32 V 365 A/32 V
at 50 % duty cycle 400 A/34 V 400 A/34 V
etting range (DC) 50A/16,5V--400A/34V 50A/16,5V--400A/34V
Open circuit voltage 17--45 V 17--45 V
Open circuit power 360 W 360 W
with cooling unit 600 W 600 W
Efficiency at max current 71% 71%
Power factor at max current 0,98 0,98
Control voltage 42 V, 50/60 Hz 42 V, 50/60 Hz
Dimensions lxwxh 812 x 552 x 925 812 x 552 x 925
Weight 144 kg 145 kg
with cooling unit 158 kg 158 kg
Operating temperature --10 to +40oC --10 to +40oC
Enclosure class IP 23 IP 23
Application classification
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mi410,510e
OrigoTM Mig 510
Voltage 400--415V, 3∼
∼∼
∼50/60 Hz 230/400--415/500V 3∼
∼∼
∼50 Hz
230/440--460 3∼
∼∼
∼60Hz
Permissible load
at100 % duty cycle 390 A/33,5 V 390 A/33,5 V
at 60 % duty cycle 500 A/39 V 500 A/39 V
etting range (DC) 50A/16,5V--500A/39V 50A/16,5V--500A/39V
Open circuit voltage 17--50 V 17--50 V
Open circuit power 440 W 440 W
with cooling unit 620 W 620 W
Efficiency at max current 82% 82%
Power factor at max current 0,92 0,92
Control voltage 42 V, 50/60 Hz 42 V, 50/60 Hz
Dimensions lxwxh 812 x 552 x 925 812 x 552 x 925
Weight 214 kg 215 kg
with cooling unit 228 kg 229 kg
Operating temperature --10 to +40oC --10 to +40oC
Enclosure class IP 23 IP 23
Application classification
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.
Note!
Connect the power source to the electricity mains with a network impedance of 0.230 Ω (Mig 410w),
0.1 Ω (Mig 10w) 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.
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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mi410,510e
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
During transport, the rear wheels of the power source are in their forward position.
Before use, place the wheels in their rear position.
WARNING!
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mi410,510e
5.3 Assembly of counter balance
Assem le the sta ilizer + CB KIT if the counter alance is to e installed on machine.
The sta ilizer + CB KIT is an accessory. Ordering num er you can find on page 21.
Attention! Utilization of counter alance without sta ilizer may cause the machine
tipping over.
5.4 Electrical installation
OrigoTM Mig 410
GB

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mi410,510e
OrigoTM Mig 510
GB

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mi410,510e
5.5 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 Mig 410 3∼50 Hz 3∼50/60 Hz 3∼50 Hz 3∼60 Hz 3∼60 Hz
Voltage V 230 400/415 500 230 440/460
Current A
at100% duty cycle 28 16 13 28 14
at 60% duty cycle 42 24 19 41 21
at 50% duty cycle 45 28 20 45 22
Cable area mm2
22
24 x 6 4 x 2,5 4 x 2,5 4 x 6 4 x 2,5
Fuse, slow A 25 20 20 25 20
OrigoTM Mig 510 3∼50 Hz 3∼50/60 Hz 3∼50 Hz 3∼60 Hz 3∼60 Hz
Voltage V 230 400/415 500 230 440/460
Current A
at100% duty cycle 43 25 20 43 23
at 60% duty cycle 68 39 31 68 35
Cable area mm2
22
24 x 16 4 x 6 4 x 6 4 x 16 4 x 6
Fuse, slow A 63 35 35 63 25
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.
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mi410,510e
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 -- 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 9Connection for return ca le (--), medium in-
ductance
2Main supply switch for cooling unit ELP** 10 Connection for return ca le (--), low induc-
tance
3Switch, precise control 11 Connection for welding current ca le (+)
4Switch, coarse control 12 Connection for control ca le for wire feeder
5Indicating lamp, power supply ON 13 MCB
6Orange indicating lamp, overheating and
loss of coolant* 14 Connection RED for cooling water from the wire feed unit
7Space for digital meter (optional), see page
20 15 Connection BLUE for cooling water to the wire feed unit
8Connection for return ca le (--), high induc-
tance
NOTE! Cooling water connections only availa le on certain models.
* Indicating loss of coolant, only when water flow guard is used, see point 6.5
** ELP = ESAB Logic Pump, see point 6.4.
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mi410,510e
6.2 tart
When switched on, indicating lamps are checked for 2 seconds. Normally, if the
machine is not overheated, it should start to work in idle mode, which is indicated y
linking of the supply--ON lamp. The fan and the coolant pump are stopped.
The fan starts from the first start of welding. The coolant pump starts at the same
moment, if it is switched on y means of either the ELP switch on the wire feeder,
or the pump supply switch on the power source.
6.3 Overheating protection
The power source has 2--step control of fan speed and overheating protection.
If temperature crosses the threshold point, the fan starts to operate with increased
speed. If the internal temperature ecomes too high, the welding is interrupted and
disa led. This state is indicated y permanent lighting of the orange indicating lamp
on the front of the unit. It resets automatically when the temperature falls down.
6.4 Water connection
The OrigoTM Feed has a sensor ELP, E AB Logic Pump, which senses whether the
water hoses of the welding gun are connected. When a water--cooled welding gun is
connected, the water pump is active. For the Feeds the pump supply switch on the
power source should e left in position ”0/ELP”.
It is recommended to switch the power source off y means of the mains switch
ON/OFF for connecting the cooling water hoses to/from the Feed wire feed unit.
The pump supply switch must e in position ”I” exclusively for other types of wire
feeders, when a water--cooled welding gun is used. When a self--cooled welding gun
is used the pump switch must e in position ”ELP/0”.
Note, if a water--cooled welding gun is used when the pump is inactive, the welding
gun might e damaged.
6.5 Water flow guard
The water flow guard interrupts and disa les the welding in the event of loss of
coolant. This state is indicated y linking of the orange indicating lamp on the front
of the power source. If there is a lack of coolant flow, after 1 min the pump is
switched off and latched in this state. The pump restarts from this state along with
starting of welding.
The water flow guard is an accessory. Ordering num er see on page 20.
6.6 Idle mode
The machine has an idle mode. The fun is switched off 5 min after the last welding
or after 5 min of work with decreased speed without welding. The pump is switched
off 3 min after the last welding. When oth fan and pump are switched off the
power--supply lamp on the front panel is linking.
6.7 Inductance
Higher inductance produces a more flowing weld and fewer spatters. Lower
inductance produces a harsher sound and a sta le, concentrated arc.
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mi410,510e
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 ecome locked and cause overheating. To avoid
this you can use an airfilter.
The airfilter is an accessory. Ordering num er can e found on page 21.
7.2 Topping up the coolant
We recommend a 50/50 % mixture of water and ethylene glycol.
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mi410,510e
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.
SCheck to see whether the MCB has tripped.
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 filters 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.
9 ORDERING OF PARE PART
OrigoTM Mig 410 & OrigoTM Mig 510 is designed and tested in accordance with the in-
ternational and European standards IEC/EN 60974--1 and EN 60974--10. It is the obliga-
tion 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.
GB

Diagram
-- 15 --mi410,510di
OrigoTM Mig 410 (400--415V)

-- 16 --mi410,510di
OrigoTM Mig 410 (230--500V)

-- 17 --mi410,510di
OrigoTM Mig 510 (400--415V)

-- 18 --mi410,510di
OrigoTM Mig 510 (230--500V)

Origo
T
M
Mig 410, Origo
T
M
Mig 510
Edition 070104
-- 19 --mi410,510or
Valid for serial no. 627--XXX--XXXX
Ordering numbers
0349 302 408 OrigoTM Mig 410 400--415V 3∼
∼∼
∼50Hz
0349 302 713 OrigoTM Mig 410 230/400--415/500V 3∼
∼∼
∼50Hz; 230/440--460V 3∼
∼∼
∼60Hz
0349 302 407 OrigoTM Mig 410w 400--415V 3∼
∼∼
∼50Hz; with water cooler
0349 302 711 OrigoTM Mig 410w 230/400--415/500V 3∼
∼∼
∼50Hz; 230/440--460V 3∼
∼∼
∼60Hz; with water cooler
0349 303 563 OrigoTM Mig 410 400--415V 3∼
∼∼
∼50Hz; with digital instrument
0349 303 564 OrigoTM Mig 410w 400--415V 3∼
∼∼
∼50Hz; with water cooler, with digital instrument
0349 302 404 OrigoTM Mig 510 400--415V 3∼
∼∼
∼50Hz
0349 302 436 OrigoTM Mig 510 230/400--415/500V 3∼
∼∼
∼50Hz; 230/440--460V 3∼
∼∼
∼60Hz
0349 302 403 OrigoTM Mig 510w 400--415V 3∼
∼∼
∼50Hz; with water cooler
0349 302 435 OrigoTM Mig 510w 230/400--415/500V 3∼
∼∼
∼50Hz; 230/440--460V 3∼
∼∼
∼60Hz; with water cooler
0349 303 565 OrigoTM Mig 510 400--415V 3∼
∼∼
∼50Hz; with digital instrument
0349 303 566 OrigoTM Mig 510w 400--415V 3∼
∼∼
∼50Hz; with water cooler, with digital instrument

Origo
T
M
Mig 410, Origo
T
M
Mig 510
Edition 070104
Accessories
-- 20 --mi410,510ac
NO TAG
Feeder with capsulated bobbin, M11 panel
OrigoTM Feed302 ........................
OrigoTM Feed 302 with water . . . . . . . . . . . . . .
0459 116 781
0459 116 791
Feeder with capsulated bobbin, M12 panel
OrigoTM Feed304 ........................
OrigoTM Feed 304 with water . . . . . . . . . . . . . .
OrigoTM Feed484 ........................
OrigoTM Feed 484 with water . . . . . . . . . . . . . .
0459 116 882
0459 116 892
0459 116 982
0459 116 992
Feeder for Marathon Pact
tt
t, M12 panel
OrigoTM Feed304 ........................
OrigoTM Feed 304 with water . . . . . . . . . . . . . .
OrigoTM Feed484 ........................
OrigoTM Feed 484 with water . . . . . . . . . . . . . .
0459 114 882
0459 114 892
0459 114 982
0459 114 992
Digital meter
for OrigoTM Mig410 ......................
for OrigoTM Mig510 ......................
0349 302 451
0349 302 424
Transformer kit for CO2heater ........... 0349 302 250
Waterflowguard ........................ 0349 302 251