ESAB Origo Mig 410 User manual

GB
Valid for serial no. 627-xxx-xxxx, 122-xxx-xxxx0463 275 001 GB 20120823
Origo™
Mig 410
Mig 510
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 Location 8..................................................................
4.2 Assembly of components 9...................................................
4.3 Assembly of counter balance 10................................................
4.4 Electrical installation 10.......................................................
4.5 Mains power supply 11........................................................
5 OPERATION 13.......................................................
5.1 Connection and control devices 13.............................................
5.2 Start 14.....................................................................
5.3 Overheating protection 14.....................................................
5.4 Water connection 14..........................................................
5.5 Water flow guard 14..........................................................
5.6 Idle mode 14................................................................
5.7 Inductance 14...............................................................
6 MAINTENANCE 15....................................................
6.1 Inspection and cleaning 15....................................................
6.2 Topping up the coolant 15.....................................................
7 FAULT TRACING 16..................................................
8 ORDERING OF SPARE PARTS 16......................................
DIAGRAM 18............................................................
CONNECTION INSTRUCTION 26..........................................
ORDER NUMBER 27.....................................................
ACCESSORIES 28.......................................................

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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.
WARNING
Do not use the power source for thawing frozen pipes.
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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
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.
CAUTION
Read and understand the instruction manual before
installing or operating.
CAUTION
This product is solely intended for arc welding.
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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 Mig 410 and Mig 510 are step-controlled power sources designed for
MIG/MAG-welding together with wire feed units Feed 302, 304, 484 and
YardFeed 200.
The power sources are fan-cooled and equipped with thermal overload protection.
The machines can be fitted with an instrument for display of current and voltage.
This incorporates a hold function and can be calibrated.
Mig 410 and Mig 510 are available with a built-in cooling unit to support liquid cooled
torches. These units can be equipped with a flow guard (option).
The power source comes in different variants, see page 27.
ESAB's accessories for the product can be found on page 28.
2.1 Equipment
The power source is supplied with:
S5m return cable with return clamp
SShelf for gas cylinder
SGuide pin for wire feed unit
SInstruction manual
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3 TECHNICAL DATA
Mig 410
Voltage 400-415V, 3∼50/60 Hz 230/400-415/500V 3∼50 Hz
230/440-460 3∼60Hz
Permissible load
at 100 % 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
Setting 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 +40°C -10 to +40°C
Transportation temperature -20 to +55°C -20 to +55°C
Enclosure class IP 23 IP 23
Application classification
Mig 510
Voltage 400-415V, 3~50/60 Hz 230/400-415/500V 3~50 Hz
230/440-460 3~60Hz
Permissible load
at 100 % duty cycle 390 A/33,5 V 390 A/33,5 V
at 60 % duty cycle 500 A/39 V 500 A/39 V
Setting 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
Transportation temperature -20 to +55°C -20 to +55°C
Enclosure class IP 23 IP 23
Application classification
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Cooling unit (100 % duty cycle)
P1l/min 1200 W at 25°C
Pmax 3.5 bar
Coolant ESAB's ready mixed coolant
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 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.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
4 INSTALLATION
The installation must be carried out by a professional.
Note!
Connect the power source to the electricity mains with a network impedance of 0.230W(Mig 410w),
0.155W(Mig 510w) or lower. If the network impedance is higher, there is a risk of flicker in the
illuminators.
CAUTION
This product is intended for industrial use. In a domestic environment this product may
cause radio interference. It is the user's responsibility to take adequate precautions.
WARNING
Straps must be used when lifting the power
source. The handle is only intended for
pulling it.
4.1 Location
Position the welding power source in such a way that its cooling air inlets and outlets
are not obstructed.
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4.2 Assembly of components
WARNING
During transport, the rear wheels of the power source are in their forward position.
Before use, place the wheels in their rear position.
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4.3 Assembly of counter balance
Assemble the stabiliser + CB KIT if the counter balance is to be installed on the power
source. The stabiliser + CB KIT is an accessory. The order number can be found on
page 28.
Attention! Using the counter balance without stabiliser may cause the power source
to tip over.
4.4 Electrical installation
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4.5 Mains power supply
Check that the unit is connected to the correct mains power supply voltage, and that
it is protected by the correct fuse size. A protective earth connection must be made,
in accordance with regulations.
Rating plate with supply connection data
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Recommended fuse sizes and minimum cable areas
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
at 100% 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 mm24 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
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
at 100% duty cycle 43 25 20 43 23
at 60% duty cycle 68 39 31 68 35
Cable area mm24 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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5 OPERATION
General safety regulations for handling the equipment can be found on
page 4. Read through before you start using the equipment!
WARNING
Secure the equipment - particularly if the
ground is uneven or sloping.
5.1 Connection and control devices
1Mains supply switch 9Connection for return cable (-), medium
inductance (Mig 510)
2Main supply switch for cooling unit ELP** 10 Connection for return cable (-), low
inductance
3Switch, precise control 11 Connection for welding current cable (+)
4Switch, coarse control 12 Connection for control cable for wire feeder
5Indicator 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
7Digital instrument V/A 15 Connection BLUE for cooling water to the
wire feed unit
8Connection for return cable (-), high
inductance
NOTE! Cooling water connections only available on certain models.
* Indicating loss of coolant, only when water flow guard is used, see point 5.5
** ELP = ESAB Logic Pump, see point 5.4
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5.2 Start
When switched on, the indicator lamps are checked for 2 seconds. Normally, if the
power source has not overheated, it should start to work in idle mode, which is
indicated by the supply-ON lamp flashing. The fan and the coolant pump stop.
The fan starts once welding starts. The coolant pump starts at the same time if it is
switched on by means of either the ELP switch on the wire feeder or the pump
supply switch on the power source.
5.3 Overheating protection
The power source has 2-step control of the fan speed and overheating protection.
If the temperature crosses the threshold point, the fan starts to operate with
increased speed. If the internal temperature becomes too high, the welding is
interrupted and disabled. This is indicated by the orange indicating lamp on the front
of the unit being permanently lit. The unit resets automatically once the temperature
drops.
5.4 Water connection
The wire feed unit has a ELP (ESAB Logic Pump) sensor 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 wire feed units with ELP sensor the pump
supply switch on the power source should be in position ”ELP/0”.
It is recommended to switch the power source off by means of the mains switch
before connecting the cooling water hoses to/from the wire feed unit.
The pump supply switch must be 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 be in position ”ELP/0”.
Note, if a water cooled welding gun is used when the pump is inactive, the welding
gun might be damaged.
5.5 Water flow guard
The water flow guard interrupts and disables welding in the event of loss of coolant.
This is indicated by the orange indicating lamp on the front of the power source
flashing. If there is a lack of coolant flow, the pump is switched off after 1 min and
locks in this state. The pump restarts from this state once welding starts.
The water flow guard is an accessory. The order number is on page 28.
5.6 Idle mode
The machine has an idle mode. The fan switches off 5 min after welding has finished
or 5 min after running at a decreased speed without welding. The pump switches off
3 min after welding has finished. Once both the fan and the pump have switched off,
the power-supply lamp on the front panel flashes.
5.7 Inductance
Higher inductance produces a more flowing weld and less spatter. Lower inductance
produces a harsher sound and a stable, concentrated arc.
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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
Power source
Check regularly that the power source is free from dirt.
The power source should be regularly blown clean using dry compressed air at reduced
pressure, see page 17. This should be done more frequently in dirty environments.
Otherwise the air inlet/outlet may become blocked and cause overheating. To avoid
this you can use an air filter.
The air filter is an accessory. The order number can be found on page 28.
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.
6.2 Topping up the coolant
ESAB's ready mixed coolant is recommended for
use. See accessories on page 28.
Note! Coolant must be topped up if connecting a
welding torch that is 5 metres in length or longer.
When adjusting the water level by topping up, the
coolant hose does not need to be disconnected.
CAUTION
The coolant must be handled as chemical waste.
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7 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 cables 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 been triggered
(indicated by the orange lamp on the front).
SCheck the main power supply fuses.
Thermal overload trips
trigger 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 being overloaded).
Poor welding performance SCheck that the welding current supply and return cables are
correctly connected.
SCheck that the correct current value is set.
SCheck that the correct welding wires are being used.
SCheck the main power supply fuses.
8 ORDERING OF SPARE PARTS
Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.
Mig 410, Mig 510 is designed and tested in accordance with the international and Euro
pean standards IEC/EN 60974-1 and IEC/EN 60974-10. It is the obligation of the servi
ce 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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Cleaning
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Diagram
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Mig 410 (400-415V)

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Mig 410 (230-500V)