ESAB Origo Mig C420 PRO User manual

Origo™
Instruction manual
0463 272 001 GB 20170310 Valid for: serial no. 627-xxx-xxxx, 120-xxx-xxxx
Mig C420 PRO

TABLE OF CONTENTS
0463 272 001 © ESAB AB 2017
1SAFETY ......................................................................................................... 4
1.1 Meaning of symbols ................................................................................. 4
1.2 Safety precautions ................................................................................... 4
2INTRODUCTION............................................................................................ 7
2.1 Equipment ................................................................................................. 7
3TECHNICAL DATA ........................................................................................ 8
4INSTALLATION.............................................................................................. 10
4.1 Location..................................................................................................... 10
4.2 Assembly of components........................................................................ 10
4.3 Electrical installation ............................................................................... 11
4.4 Mains power supply ................................................................................. 11
5OPERATION .................................................................................................. 13
5.1 Connection and control devices ............................................................. 14
5.2 Start ........................................................................................................... 14
5.3 Overheating protection ............................................................................ 14
5.4 Water connection ..................................................................................... 15
5.5 Water flow guard ...................................................................................... 15
5.6 Idle mode................................................................................................... 15
5.7 Mig C420w PRO / Mig C420 PRO ............................................................ 15
5.8 Polarity change......................................................................................... 16
5.9 Wire feed pressure ................................................................................... 16
5.10 Replacing and inserting wire................................................................... 16
6MAINTENANCE............................................................................................. 18
6.1 Inspection and cleaning........................................................................... 18
6.2 Topping up the coolant ............................................................................ 19
7TROUBLESHOOTING ................................................................................... 20
8ORDERING SPARE PARTS .......................................................................... 21
CLEANING............................................................................................................ 22
DIAGRAM ............................................................................................................. 23
ORDERING NUMBERS........................................................................................ 25
WEAR PARTS....................................................................................................... 26
ACCESSORIES .................................................................................................... 28
Rights reserved to alter specifications without notice.

1 SAFETY
0463 272 001 -4- © ESAB AB 2017
1 SAFETY
1.1 Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of
life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual
and follow all labels, employer´s safety practices and Safety
Data Sheets (SDSs).
1.2 Safety precautions
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 observed 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
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 equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
○ no unauthorised person is stationed within the working area of the equipment
when it is started up
○ no-one is unprotected when the arc is struck or work is started with the
equipment
3. The workplace must:
○ be suitable for the purpose
○ be free from drafts

1 SAFETY
0463 272 001 -5- © ESAB AB 2017
4. Personal safety equipment:
○ Always wear recommended personal safety equipment, such as safety glasses,
flame-proof clothing, safety gloves
○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which
could become trapped or cause burns
5. General precautions:
○ Make sure the return cable is connected securely
○ Work on high voltage equipment may only be carried out by a qualified
electrician
○ Appropriate fire extinguishing equipment must be clearly marked and close at
hand
○ Lubrication and maintenance must not be carried out on the equipment during
operation
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting.
ELECTRIC SHOCK - Can kill
• Install and ground the unit in accordance with instruction manual.
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.
• Insulate yourself from work and ground.
• Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
• Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.
• Exposure to EMF may have other health effects which are unknown.
• Welders should use the following procedures to minimize exposure to
EMF:
○ Route the electrode and work cables together on the same side of
your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or
work cable around your body. Keep welding power source and
cables as far away from your body as possible.
○ Connect the work cable to the workpiece as close as possible to the
area being welded.
FUMES AND GASES - Can be dangerous to health
• Keep your head out of the fumes.
• Use 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
• Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing.
• Protect bystanders with suitable screens or curtains.
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.

1 SAFETY
0463 272 001 -6- © ESAB AB 2017
MOVING PARTS - Can cause injuries
• Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.
• Stop engine before installing or connecting unit.
• Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure that there are no inflammable
materials nearby.
• Do not use on closed containers.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
WARNING!
Do not use the power source for thawing frozen pipes.
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.
NOTE!
Dispose of electronic equipment at the recycling
facility!
In observance of European Directive 2012/19/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 has an assortment of welding accessories and personal protection equipment
for purchase. For ordering information contact your local ESAB dealer or visit us on
our website.

2 INTRODUCTION
0463 272 001 -7- © ESAB AB 2017
2 INTRODUCTION
The Mig C420 PRO is a step-controlled compact welding power source incorporating wire
feed mechanism intended for MIG/MAG welding with solid wires of steel, stainless steel or
aluminium, and cored wires with or without shielding gas.
The Mig C420w PRO is equipped with a cooling liquid system for welding torches. The Mig
C420 PRO is not equipped with a cooling system and can operate only with appropriate gas
cooled torches.
The power units are fan-cooled and equipped with thermal overload protection.
The power sources can be fitted with a flow guard (Mig C420w PRO).
The power source comes in different variants, see "ORDERING NUMBERS" chapter.
ESAB accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
2.1 Equipment
The power source is supplied with:
• Welding torch PSF 405/410w - 4.5 m
• Return cable 5 m with return clamp
• Shelf for gas cylinder
• Instruction manual

3 TECHNICAL DATA
0463 272 001 -8- © ESAB AB 2017
3 TECHNICAL DATA
Mig C420 PRO
Voltage 400 - 415 V, 3~50Hz
Permissible load
at 100% duty cycle 315 A/30 V
at 60% duty cycle 400 A/34 V
at 50% duty cycle 420 A/35 V
Setting range (DC) 50 A/16.5 V - 420 A/35 V
Open circuit voltage 14 - 47 V
Open circuit power 520 W
with cooling unit 730 W
Efficiency 77%
Power factor 0.92
Control voltage 42 V, 50/60 Hz
Wire feed speed 1.9 - 25.0 m/min
Burnback time 0 - 0.5 s
Creep start OFF / ON
2/4 stroke 2/4
Welding torch connection EURO
Max diameter of wire bobbin 300 mm
Wire dimension range 0.6 - 1.6 mm
Dimensions LxWxH 935 x 640 x 800 mm
Weight 215 kg
with cooling unit 230 kg
Operating temperature -10 to +40 °C
Transportation temperature -20 to +55 °C
Enclosure class IP 23
Application class
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/104°F, or below.
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 intended for indoor and outdoor use.

3 TECHNICAL DATA
0463 272 001 -9- © ESAB AB 2017
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.

4 INSTALLATION
0463 272 001 - 10 - © ESAB AB 2017
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
0.268 W 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 in source such a way that its cooling air inlets and outlets are not
obstructed.
WARNING!
Straps must be used when lifting the
power source. The handle is only
intended for pulling it.
4.2 Assembly of components

4 INSTALLATION
0463 272 001 - 11 - © ESAB AB 2017
WARNING!
During transport, the rear wheels of the power source are in their forward
position. Before use, place the wheels in their rear position.
4.3 Electrical installation
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
Recommended fuse sizes and minimum cable areas
Mig C420 PRO 3~ 50 Hz
Voltage V 400 - 415
Current A
at 100% duty cycle 19
at 60% duty cycle 27
at 50% duty cycle 30
Cable area mm24x4
Fuse, slow A 25

4 INSTALLATION
0463 272 001 - 12 - © ESAB AB 2017
NOTE!
The mains cable areas and fuse sizes as shown above are in accordance with
Swedish regulations. For other regions, supply cables must be suitable for the
application and meet local and national regulations.

5 OPERATION
0463 272 001 - 13 - © ESAB AB 2017
5 OPERATION
General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it 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.
WARNING!
Secure the equipment - particularly if
the ground is uneven or sloping.

5 OPERATION
0463 272 001 - 14 - © ESAB AB 2017
5.1 Connection and control devices
1. Mains supply switch 10. Connection for return cable (-), medium
inductance
2. Switch, coarse control 11. Connection for return cable (-), low
inductance
3. Switch, precise control 12. Knob for wire speed setting
4. Indicator lamp, power supply ON 13. Knob for selecting 2/4-stroke control mode
5. Orange indicating lamp, overheating and
loss of coolant*
14. Knob for selecting - creep start - ON/OFF
6. EURO - connector (for welding torch) 15. Knob for burn-back time setting
7. Connection for cooling water to the
welding torch (Blue - with ELP** switch)
16. Digital instrument - V / A
8. Connection for cooling water from the
welding torch (Red)
17. Water flow guard (option, see
"ACCESSORIES" chapter)
9. Connection for return cable (-), high
inductance
* Indicating loss of coolant, only when water flow guard is used, see "Water flow guard"
section.
** ELP = ESAB Logic Pump, see "Water connection" section.
5.2 Start
When switched on, indicator lamps [4,5] are on for 2 seconds. Normally, if the power source
is not overheated, it should start to work in idle mode, which is indicated by blinking of the
supply ON lamp. The fan and the coolant pump are stopped. The fan starts at the first start of
welding. The coolant pump starts at the same moment, if it is switched on with ELP switch on
the water outlet [7].
5.3 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 run with increased speed. If the internal

5 OPERATION
0463 272 001 - 15 - © ESAB AB 2017
temperature becomes too high, the welding is interrupted and disabled. This state is
indicated by permanent lighting of the orange indicating lamp on the front of the unit. It resets
automatically when the temperature falls down.
5.4 Water connection
The Mig C420w PRO has a sensor ELP, ESAB Logic Pump, which senses whether the water
hoses of the welding torch are connected. When a water-cooled welding torch is connected,
the water pump is active.
It is recommended to switch the power source off by means of the mains switch ON/OFF [1]
for connecting the cooling water hoses to/from the Mig C420w PRO.
5.5 Water flow guard
The power sources with cooling unit (Mig C420w PRO) can be fitted with a water flow guard
(option - see "ACCESSORIES" chapter).
The water flow guard interrupts and disables welding in event of loss of coolant. This state is
indicated by the orange indicating lamp on the front of the power source flashing. If there is a
lack of coolant flow, after 1 min the pump is switched off and locked in this state. The pump
restarts from that state along with start of welding.
5.6 Idle mode
The power source has an idle mode. The fan is switched off 5 min after the end of 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 both fan and pump are switched off the power supply
lamp [4] on the front panel flashes.
5.7 Mig C420w PRO / Mig C420 PRO
The Mig C420w PRO / Mig C420 PRO is equipped with a standard control unit. The welder
can manually select and adjust all welding parameters.
• Wire speed (1.9 - 25 m/min) is set with knob [12].
• The stroke control (2/4 stroke) is selected with switch [13].
• Creep start i.e. start with 50% wire speed is toggled ON/OFF with switch [14].
• Burn back time is set with knob [15].
Mig C420w PRO / Mig C420 PRO can be fitted with a digital instrument that displays current
and voltage. It incorporates a hold function (see "ACCESSORIES" chapter).

5 OPERATION
0463 272 001 - 16 - © ESAB AB 2017
5.8 Polarity change
The power source is delivered with the welding wire connected to the plus pole. Some wires,
e.g self shielded cored wires, are recommended for welding with negative polarity. Negative
polarity means that the wire is connected to the minus pole and the return cabel to the plus
pole.
Check the recommended polarity for the welding wire you want to use.
5.9 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 torch approx. 5 mm from the piece of wood (fig. 1) the feed rollers should
slip.
If you hold the torch approx. 50 mm from the piece of wood, the wire should be fed out and
bend (fig. 2).
5.10 Replacing and inserting wire
• Open the side panel.
• Disconnect the pressure sensor by folding it backwards, the pressure rollers slide up.

5 OPERATION
0463 272 001 - 17 - © ESAB AB 2017
• Straighten out 10-20 cm of new wire. File off any burrs and sharp edges from the end
of the wire before inserting it into the wire feed unit.
• Make sure that the wire goes properly into the feed roller track and into the outlet
nozzle and the wire guide.
• Secure the pressure sensor.
• Close the side panel.

6 MAINTENANCE
0463 272 001 - 18 - © ESAB AB 2017
6 MAINTENANCE
NOTE!
Regular maintenance is important for safe and reliable operation.
CAUTION!
Only those persons who have appropriate electrical knowledge (authorized
personnel) may remove the safety plates.
CAUTION!
All warranty undertakings from the supplier cease to apply if the customer
attempts any work to rectify any faults in the product during the warranty 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 "CLEANING" chapter. 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 airfilter.
The airfilter is an accessory. Order number can be found in the "ACCESSORIES" chapter.
Welding torch
The welding torch'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.
•Adjusting the braking torque:
○ Turn the red handle to the locked
position.
○ Insert 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.
Note: Make sure you turn both springs
the same amount.

6 MAINTENANCE
0463 272 001 - 19 - © ESAB AB 2017
6.2 Topping up the coolant
ESAB's ready mixed coolant is recommended for use.
See accessories in the "ACCESSORIES" chapter.
NOTE!
Coolant must be topped up if connecting a Push-Pull
welding torch that is 6 meters 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.

7 TROUBLESHOOTING
0463 272 001 - 20 - © ESAB AB 2017
7 TROUBLESHOOTING
Try these recommended checks and inspections before sending for an authorised service
technican.
Type of fault Actions
No arc • Check that the mains power supply switch is turned on.
• Check that the welding current supply and return cables
are correctly connected.
• Check that correct current value is set.
Welding current is
interrupted during welding
• Check whether the thermal overload trip has operated
(indicated by the orange lamp on the front).
• Check the main power supply fuses.
Thermal overload trips
operate frequently
• Check to see whether the air filters are clogged.
• Make 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 • Check that the welding current supply and return cables
are correctly connected.
• Check that the correct current value is set.
• Check that the correct welding wires are being used.
• Check the main power supply fuses.
• Check the wire feed unit - that proper rolls are applied and
properly set the pressure of the wire feeder's pressure
rollers.