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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