ESAB Origo Mig C170 3ph User manual

Valid for serial no. 6260349 301 116 070103
Mig C170 3ph
Mig C200 3ph
Mig C250 3ph
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 6...................................................................
5.2 Assem lyofcomponents 6...................................................
5.3 Electricalinstallation 7.......................................................
5.4 Mainspowersupply 7........................................................
6 OPERATION 8.......................................................
6.1 Connectionandcontroldevices 8.............................................
6.2 Weldingwithoutgas 9.......................................................
6.3 Wirefeedpressure 9........................................................
6.4 Replacingandinsertingwire 9................................................
6.5 Overheatingprotection 10.....................................................
7 MAINTENANCE 10....................................................
7.1 Inspectionandcleaning 10....................................................
8 FAULTTRACING 11...................................................
9 ORDERINGOF PAREPART 11......................................
DIAGRAM 12............................................................
WEARCOMPONENT 17.................................................
ACCE ORIE 18.......................................................

-- 3 --
C17253e
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 C170 3ph/C200 3ph/C250 3ph from serial num er 626 complies with
standard IEC/EN 60974--1, in accordance with the requirements of directive (73/23/EEC) and adden-
dum (93/68/EEC) and with standard IEC/EN 60974--10 in accordance with the requirements of direc-
tive (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--07--07
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.
GB

-- 4 --
C17253e
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!
GB

-- 5 --
C17253e
3 INTRODUCTION
OrigoTM Mig C170 3ph/C200 3ph/C250 3ph 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 18.
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 Mig C170
3ph OrigoTM Mig C200 3ph OrigoTM Mig C250 3ph
Voltage 400--415V
3∼50/60 Hz 400--415V 3∼50/60 Hz 230/400--415V 3∼50/60 Hz
Permissible load at
100% duty cycle 100A 120A 150A
60 % duty cycle 130A 150A 190A
35 % duty cycle 170A 200A 250A
etting range (DC) 30--170A 30--200A 40--280A
Open circuit voltage 15,5--30,6V 16,0--31,8V 15,0--37,0V
Open circuit power 310W 210W 340W
Power factor at max load 0,97 0,97 0,97
Control voltage 42V, 50/60Hz 42V, 50/60Hz 42V, 50/60Hz
Wire feed speed 1,0--17m/min 1,0--17m/min 1,0--17m/min
Burnback time 0,02--0,25s 0,02--0,25s 0,02--0,25s
pot welding 0,2--2,5s 0,2--2,5s 0,2--2,5s
Welding gun connection EURO EURO EURO
Wire dimension range 0,6--0,8(Fe, SS)
1,0(Al)
0,8(FCW)
0,8--1,0(CuSi)
0,6--1,0(Fe, SS)
1,0(Al)
0,8--1,0(FCW)
0,8--1,0(CuSi)
0,6--1,2(Fe, SS)
1,0--1,2(Al)
0,8--1,2(FCW)
0,8--1,0(CuSi)
Max diameter/weight
of wire bobin 300mm/15kg 300mm/15kg 300mm/15kg
Dimensions lxwxh 860x420x730 860x420x730 860x420x730
Weight 63,5kg 72,5kg 82kg
Operating temperature --10 ÷+40oC --10 ÷+40oC --10 ÷+40oC
Enclosure class IP 23 IP 23 IP 23
Application classification
GB

-- 6 --
C17253e
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.
ote!
Connect the power source to the electricity mains with a network impedance of 0.268 (C250 3ph) 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!
1.
3.
2.
GB

-- 7 --
C17253e
5.3 Electrical installation
C200 3ph
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 Mig C170 3ph OrigoTM Mig C200 3ph OrigoTM Mig C250 3ph
Voltage V 400--415V, 3∼50/60 Hz 400--415V, 3∼50/60 Hz 230/400--415V, 3∼50/60 Hz
Current A
at 100% duty cycle 4,0 5,3 12,1/7,0
at 60% duty cycle 6,1 6,8 17,6/10,2
at 35% duty cycle 8,9 10,1 25,3/14,6
Cable area mm2
22
24 x 1,5 4 x 1,5 4 x 2,5/4 x 1,5
Fuse slow A10 10 25/16
B: 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.
GB

-- 8 --
C17253e
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!
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 7Connection for return ca le (--), low inductan-
ce
2Indicating lamp, power ON/OFF 8Kno for spot welding -- ON/OFF and time set-
ting
3Orange indicating lamp, overheating 9Kno for wire speed setting
4Welding voltage switch 10 Digital instrument -- V/A (option,see page 18)
5EURO -- connector for welding gun 11 Return ca le with return clamp
6Connection for return ca le (--), high in-
ductance *Kno for urn-- ack time setting (located on control oard)
C250 3phC170 3ph
C200 3ph
GB

-- 9 --
C17253e
6.2 Welding without gas
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.
GB

-- 10 --
C17253e
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.
SSecure the pressure sensor.
SClose the side panel.
6.5 Overheating protection
When the machine is switched on with the mains switch [1], indicating lamp [2] is on and
lamp [3] 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 [3] on the front of the machine. It resets automatically when the
temperature has fallen.
7 MAINTENANCE
Regular maintenance is important for safe reliable operation.
ote!
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.
GB