ESAB OrigoMag C140 User manual

Valid for serial no. 5070349 301 105 050913
OrigoMag C140
Instruction manual

ENGLISH
−2 −
TOCe
1 DIRECTIVE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 SAFETY 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 INTRODUCTION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Equipment 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 TECHNICAL DATA 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 INSTALLATION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Placing 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Assembly of components 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Electrical installation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Mains power supply 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 OPERATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Connection and control devices 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Functions explanation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 MAINTENANCE 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Inspection and cleaning 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 FAULT TRACING 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 ORDERING OF SPARE PARTS 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGRAM 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WEAR COMPONENTS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

−3 −
OC140e
1 DIRECTIVE
DECLARATION OF CONFORMITY
ESAB Welding Equipment AB, S−695 81 Laxå, Sweden, gives its unreserved guarantee that welding
power source OrigoMag C140 from serial number 507 complies with standard IEC/EN 60974−1, in
accordance with the requirements of directive (73/23/EEC) and addendum (93/68/EEC) and with
standard EN 60974−10 in accordance with the requirements of directive (89/336/EEC) and addendum
(93/68/EEC).
−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−
Henry Selenius
Vice President
ESAB Welding Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924
Laxå 2005−08−31
2 SAFETY
Users of ESAB welding 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 welding equipment. The following recommen-
dations 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 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 be 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:
Sbe suitable for the purpose
Sbe 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, 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.
GB

−4 −
OC140e
WARNING
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-
TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS’ HAZARD DATA.
ELECTRIC SHOCK −Can kill
SInstall and earth the welding 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!
Read and understand the instruction manual
before installing or operating.
Do not use the power source for thawing frozen pipes.
WARNING!
This product is solely intended for arc welding.
GB

−5 −
OC140e
3 INTRODUCTION
OrigoMag C140 are step controlled power sources in a compact design, intended for welding with
solid steel, stainless steel or tubular wire with or without shielding gas.The possibility of welding with
homogeneous wire/shielding gas and welding with gasless tubular wire is obtained 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 14.
3.1 Equipment
The power source is supplied with:
SWelding gun
SReturn cable with return clamp
SInstruction manual
4 TECHNICAL DATA
OrigoMag C140
Voltage 230V, 1∼50/60Hz
Permissible load at
100% duty cycle 42A
60 % duty cycle 54A
20 % duty cycle 100A
Setting range (DC) 35A−130A
Open circuit voltage 20−28V
Open circuit power 90W
Power factor at max load 0,92
Control voltage 230V, 50/60Hz
Wire feed speed 2,0−14m/min
Welding gun connection fixed
Wire dimension range 0,6−0,8(Fe)
0,8(cored)
0,8(CuSi)
Max diameter/weight
of wire bobin 200mm/5kg
Dimensions lxwxh 650x300x550
Weight 25kg
Operating temperature −10 ÷+40oC
Enclosure class IP 23
Application classification
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 by solid
objects or water. Equipment marked IP23 is designed for indoor and outdoor use.
GB

−6 −
OC140e
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
5 INSTALLATION
The installation must be executed by a professional.
5.1 Placing
Position the welding power source such way that its cooling air inlets and outlets are
not obstructed.
5.2 Assembly of components
GB

−7 −
OC140e
5.3 Electrical installation
GB

−8 −
OC140e
5.4 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
OrigoMag C140
Voltage V 230V, 1∼50/60Hz
Current A
at 100% duty cycle 5,4
at 60% duty cycle 7,6
at 20% duty cycle 13,8
Cable area mm23 x 1.5
Fuse slow A 10
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.
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.
WARNING −TIPPING RISK!
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 be provided !
GB

−9 −
OC140e
6.1 Connection and control devices
1Welding voltage switch
OFF + 4 steps (mains ON/OFF) 4Return cable with clamp, fixed
2Orange indicating lamp, overheating 5Knob for wire speed setting
3Welding gun, fixed
6.2 Functions explanation
6.2.1 Overheating protection
If the internal temperature becomes too high, the welding is interrupted and disabled.
This state is indicated by lighting of the orange indicating lamp [2] on the front of the ma-
chine. It resets automatically when the temperature has fallen.
7 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
Note!
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 be regularly blown clean using dry compressed air at reduced
pressure. More frequently in dirty environments. Otherwise the air inlet/outlet may be-
come blocked and cause overheating.
GB

−10 −
OC140e
Welding gun
SCleaning and replacement of the welding gun’s wear parts should take place at
regular intervals in order to achieve trouble−free wire feed. Blow the wire guide
clean regularly and clean the contact tip.
8 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
9 ORDERING OF SPARE PARTS
OrigoMag C140 is designed and tested in accordance with the international and Euro-
pean standards IEC/EN 60974−1 and 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.
GB