ESAB Origo Mig C151 User manual

GB
Valid for serial no. 736-xxx-xxxx0463 326 001 GB 20120528
Origo™
Mig C141/ C151
Mag C171/ C201/ C251
Instruction manual

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Rights reserved to alter specifications without notice.
1 SAFETY 4...........................................................
2 INTRODUCTION 6...................................................
2.1 Equipment 6................................................................
3 TECHNICAL DATA 6.................................................
4 INSTALLATION 8....................................................
4.1 Location 8..................................................................
4.2 Assembly of components 8...................................................
4.2.1 Mig C141 9............................................................
4.2.2 Mig C151 10............................................................
4.2.3 Mag C171/C201/C251 11.................................................
4.3 Electrical installation 11.......................................................
4.4 Mains power supply 12........................................................
4.5 Recommended fuse sizes and minimum cable areas 12...........................
5 OPERATION 12.......................................................
5.1 Connection and control devices 13.............................................
5.2 Welding without gas 14.......................................................
5.3 Wire feed pressure 14........................................................
5.4 Replacing and inserting wire 14................................................
5.5 Overheating protection 15.....................................................
6 MAINTENANCE 15....................................................
6.1 Inspection and cleaning 15....................................................
7 FAULT TRACING 16..................................................
8 ORDERING OF SPARE PARTS 16......................................
DIAGRAM 17............................................................
ORDER NUMBER 23.....................................................
WEAR PARTS 24........................................................
ACCESSORIES 26.......................................................

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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.
CAUTION
Read and understand the instruction manual before
installing or operating.
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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!
WARNING
Do not use the power source for thawing frozen pipes.
CAUTION
This product is solely intended for arc welding.
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.
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2 INTRODUCTION
Mig C141, Mig C151, Mag C171, Mag C201 and Mag C251 are step controlled power sources of a
compact design, intended for welding with solid steel, stainless steel or aluminium wire as well as
tubular wire with or without shielding gas.It is possible to weld with homogeneous wire/shielding gas
and weld with gasless tubular wire by switching the + and - connections on the switching terminal by
the wire feed unit.
ESAB's accessories for the product can be found on page 26.
2.1 Equipment
The power source is supplied with:
SWelding gun
SReturn cable with return clamp
SShelf for gas cylinder (C151-C251)
SInstruction manual
3 TECHNICAL DATA
Mig C141 Mig C151 Mag C171
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 87A/18.3V 98A/18.9V
50 % duty cycle - 95A/18.7V -
25 % duty cycle 83A/18.2V - 155A/21.7V
20 % duty cycle 100A/17.0V 150A/16.0V 170A/21.0V
Setting range (DC) 35A/15.7V-83A/18.2V
(130A/13.4)
30A/15.5V-95A/18.7V
(150A/16.0V)
30A/15.5V-155A/21.7
V (170A/21.0)
Open circuit voltage 18.7-25.1V 17.3-24.3V 22.4-44.5V
Open circuit power 75W 110W 270W
Power factor at max load 0.91 0.92 0.91
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
Spot welding - - 0.2-2.5s
Welding gun connection fixed fixed EURO
Wire dimension range 0.6-0.8(Fe)
1.0(Al)
0.8(cored)
0.8(CuSi)
0.6-0.8(Fe)
1.0(Al)
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 bobbin
200mm/5kg 200mm/5kg 300mm/15kg
Dimensions lxwxh 650x300x550 650x300x550 860x420x730
Weight 25kg 37,5kg 59kg
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Mag C171Mig C151Mig C141
Operating temperature -10 ÷+40oC -10 ÷+40oC -10 ÷+40oC
Enclosure class IP 23 IP 23 IP 23
Application classifica
tion
Mag C201 Mag C251
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
30 % duty cycle - 200A/24.0V
23 % duty cycle 185A/23.3V -
20 % duty cycle 200A/23.0V 250A/21.0V
Setting range (DC) 30A/15.5V-185A/23.3V
(200A/23.0V)
40A/16.0V-200A/24.0V
(250A/21.0V)
Open circuit voltage 19.6-44.9V 19.0-41.5V
Open circuit power 120W 200W
Power factor at max load 0.89 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
Spot 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 bobbin
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 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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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 (C141 - 0.41; C151 -
N/A; C171 - N/A; C201 - 0.32; C251 - 0.212) ohm 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.
4.1 Location
Position the welding power source in such a way that its cooling air inlets and outlets
are not obstructed.
4.2 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!
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4.2.1 Mig C141
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4.2.2 Mig C151
1.
3.
2.
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4.2.3 Mag C171/C201/C251
1.
3.
2.
4.3 Electrical installation
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4.4 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
4.5 Recommended fuse sizes and minimum cable areas
Mig C141 Mig C151 Mag C171 Mag C201 Mag C251
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 5.1 8.3 12.0 13.0 16.6
at 60% duty cycle 7.0 12.0 15.7 18.2 23.4
at % duty cycle 11.5 at 25% 13.0 at 50% 27.8 at 25% 36.2 at 23% 38.7 at 30%
at 20% duty cycle 13.8 20.4 29.7 39.0 47.5
Cable area mm23 x 1.5 3 x 1.5 3 x 1.5 3 x 2.5 3 x 4.0
Fuse slow A 10 10 (16*) 16 20 35
NB: The mains cable areas and fuse sizes 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.
*- In the supply networks of high level of short circuit power (low impedance of network) it is
recommended to use 16A fuse.
5 OPERATION
General safety regulations for handling the equipment can be found on
page 4. Read through before you start using the equipment!
WARNING
Rotating parts can cause injury, take great care.
WARNING
To prevent the reel from sliding off the hub: Lock the
reel in place by turning the red knob as shown on the
warning label attached next to the hub.
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WARNING
Secure the equipment - particularly if the
ground is uneven or sloping.
5.1 Connection and control devices
1Mains supply switch with indicator lamp,
only in C171/C201/C251
5a Return cable with clamp, fixed,
only in C140/C150/C170/C200
2Orange indicator lamp, overheating 6Knob for spot welding - ON/OFF and time
setting, only in C171/C201/C251
3Welding voltage switch
C141: OFF + 4 steps (mains ON/OFF)
C151: OFF + 7 steps (mains ON/OFF)
C171: 8 steps
C201: 12 steps
C251: 12 steps
7Knob for wire speed setting
4EURO - connector for welding gun,
only in C171/C201/C251
8Digital instrument - V / A, only in
C171/C201/C251 (option,see page 26)
4a Welding gun, fixed,
only in C141/C151
9Knob for burn-back time setting.
In C251 located in wire feeder compartment.
In C171/C201 located on control board.
5Connection for return cable (-),only in
C251
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5.2 Welding without gas
(cored)
(Fe) (Al) (cored)
(CuSi)
connected when delivered
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 the new wire for 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 track and into the outlet
nozzle and the wire guide.
SSecure the pressure sensor.
SClose the side panel.
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5.5 Overheating protection
When the machine is switched on with the mains switch, [1] or [3] depending on machine
model, indicator lamp [1] is on and lamp [2] off - the machine is ready to operate. If the
internal temperature becomes too high, the welding is interrupted and disabled. This
state is indicated by lighting of the orange indicator lamp [2] on the front of the machine.
It resets automatically when the temperature has fallen.
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
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. It should be cleaned more frequently in dirty environments. Otherwise the air
inlet/outlet may become blocked and cause overheating.
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.
The brake hub
The hub is adjusted when delivered, if
readjustment is required, follow the instructions
below. Adjust the brake hub 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 hub.
Turn the springs clockwise to reduce the braking torque
Turn the springs counter-clockwise to increase the braking torque. NB: Turn
both springs the same amount.
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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.
Welding current is interrupted
during welding
SCheck whether the thermal overload trip has operated
(indicated by 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 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.
SCheck the wire feed unit - if proper rolls are applied and
properly set the pressure of the wire feeder's pressure rollers
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 C141/ C151 Mag C171/ C201/ C251 is designed and tested in accordance with the inter
national and European standards IEC-/ EN 60974-1, IEC-/ 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 2012
Diagram
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© ESAB AB 2012
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© ESAB AB 2012
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© ESAB AB 2012
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