Origo Mig 410 Mig 510 - ESAB
GBOrigo Mig 410Mig 510Instruction manual0463 275 001 GB 20120823Valid for serial no. 627-xxx-xxxx, 122-xxx-xxxx
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1 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.146Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .784.14.24.34.44.5Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Assembly of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Assembly of counter balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mains power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .891010115 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135.15.25.35.45.55.65.7Connection and control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overheating protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Water connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Water flow guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Idle mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inductance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131414141414146 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156.16.2Inspection and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Topping up the coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15157 FAULT TRACING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 ORDERING OF SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CONNECTION INSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ORDER NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161618262728Rights reserved to alter specifications without notice.TOCe-3-
GB1SAFETYUsers of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on ornear the equipment observes all the relevant safety precautions. Safety precautions must meet therequirements 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:S its operationS location of emergency stopsS its functionS relevant safety precautionsS welding and cutting2.The operator must ensure that:S no unauthorised person is stationed within the working area of the equipment when it isstarted up.S no-one is unprotected when the arc is struck3.The workplace must:S be suitable for the purposeS be free from drafts4.Personal safety equipmentS Always wear recommended personal safety equipment, such as safety glasses, flame-proofclothing, safety gloves.S Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could becometrapped or cause burns.5.General precautionsS Make sure the return cable is connected securely.S Work on high voltage equipment may only be carried out by a qualified electrician.S Appropriate fire extinquishing equipment must be clearly marked and close at hand.S Lubrication and maintenance must not be carried out on the equipment during operation.WARNINGDo not use the power source for thawing frozen pipes.-4ba52de ESAB AB 2011
GBWARNINGArc welding and cutting can be injurious to yourself and others. Take precautions when welding andcutting. Ask for your employer's safety practices which should be based on manufacturers' hazarddata.ELECTRIC SHOCK - Can killSInstall 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 healthSKeep your head out of the fumes.SUse ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zoneand 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 protectiveclothing.SProtect bystanders with suitable screens or curtains.FIRE HAZARDSSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.NOISE - Excessive noise can damage hearingSProtect your ears. Use earmuffs or other hearing protection.SWarn bystanders of the risk.MALFUNCTION - Call for expert assistance in the event of malfunction.Read and understand the instruction manual before installing or operating.PROTECT YOURSELF AND OTHERS!CAUTIONClass A equipment is not intended for use in residential locations wherethe electrical power is provided by the public low-voltage supply system.There may be potential difficulties in ensuring electromagneticcompatibility of class A equipment in those locations, due to conductedas well as radiated disturbances.CAUTIONRead and understand the instruction manual beforeinstalling or operating.CAUTIONThis product is solely intended for arc welding.-5ba52de ESAB AB 2011
GBDispose of electronic equipment at the recycling facility!In observance of European Directive 2002/96/EC on Waste Electrical and ElectronicEquipment and its implementation in accordance with national law, electrical and/orelectronic equipment that has reached the end of its life must be disposed of at arecycling facility.As the person responsible for the equipment, it is your responsibility to obtaininformation on approved collection stations.For further information contact the nearest ESAB dealer.ESAB can provide you with all necessary welding protection and accessories.2INTRODUCTIONThe Mig 410 and Mig 510 are step-controlled power sources designed forMIG/MAG-welding together with wire feed units Feed 302, 304, 484 andYardFeed 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 cooledtorches. 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 28.2.1EquipmentThe power source is supplied with:S5m return cable with return clampSShelf for gas cylinderSGuide pin for wire feed unitSInstruction manual-6ba52de ESAB AB 2011
GB3TECHNICAL DATAVoltageMig 410400-415V, 3 50/60 HzPermissible loadat 100 % duty cycleat 60 % duty cycleat 50 % duty cycleSetting range (DC)Open circuit voltageOpen circuit powerwith cooling unit280 A/28 V365 A/32 V400 A/34 V50A/16.5V-400A/34V17-45 V360 W600 W280 A/28 V365 A/32 V400 A/34 V50A/16.5V-400A/34V17-45 V360 W600 WEfficiency at max currentPower factor at max currentControl voltageDimensions LxWxHWeightwith cooling unit71%0.9842 V, 50/60 Hz812 x 552 x 925144 kg158 kg71%0.9842 V, 50/60 Hz812 x 552 x 925145 kg158 kgOperating temperature-10 to 40 C-10 to 40 CTransportation temperature-20 to 55 C-20 to 55 CEnclosure classIP 23IP 23230/400-415/500V 3 50 Hz230/440-460 3 60HzApplication classificationVoltageMig 510400-415V, 3 50/60 HzPermissible loadat 100 % duty cycleat 60 % duty cycleSetting range (DC)Open circuit voltageOpen circuit powerwith cooling unit390 A/33,5 V500 A/39 V50A/16.5V-500A/39V17-50 V.440 W620 W390 A/33,5 V500 A/39 V50A/16.5V-500A/39V17-50 V440 W620 WEfficiency at max currentPower factor at max currentControl voltageDimensions LxWxHWeightwith cooling unit82%0.9242 V, 50/60 Hz812 x 552 x 925214 kg228 kg82%0.9242 V, 50/60 Hz812 x 552 x 925215 kg229 kgOperating temperature-10 to 40oC-10 to 40oCTransportation temperature-20 to 55 C-20 to 55 CEnclosure classIP 23IP 23230/400-415/500V 3 50 Hz230/440-460 3 60HzApplication classification-7ba52de ESAB AB 2011
GBCooling unit (100 % duty cycle)P1l/min1200 W at 25 CPmax3.5 barCoolantESAB's ready mixed coolantCoolant quantity5.5 lDuty cycleThe duty cycle refers to the time as a percentage of a ten-minute period that you can weld or cut ata certain load without overloading. The duty cycle is valid for 40 C.Enclosure classThe IP code indicates the enclosure class, i. e. the degree of protection against penetration by solidobjects or water. Equipment marked IP23 is designed for indoor and outdoor use.Application classThe symbolindicates that the power source is designed for use in areas with increasedelectrical hazard.4INSTALLATIONThe 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 theilluminators.CAUTIONThis product is intended for industrial use. In a domestic environment this product maycause radio interference. It is the user's responsibility to take adequate precautions.WARNINGStraps must be used when lifting the powersource. The handle is only intended forpulling it.4.1LocationPosition the welding power source in such a way that its cooling air inlets and outletsare not obstructed.-8ba52de ESAB AB 2011
GB4.2Assembly of componentsWARNINGDuring transport, the rear wheels of the power source are in their forward position.Before use, place the wheels in their rear position.-9ba52de ESAB AB 2011
GB4.3Assembly of counter balanceAssemble the stabiliser CB KIT if the counter balance is to be installed on the powersource. The stabiliser CB KIT is an accessory. The order number can be found onpage 28.Attention! Using the counter balance without stabiliser may cause the power sourceto tip over.4.4Electrical installation- 10 ba52de ESAB AB 2011
GB4.5Mains power supplyCheck that the unit is connected to the correct mains power supply voltage, and thatit is protected by the correct fuse size. A protective earth connection must be made,in accordance with regulations.Rating plate with supply connection data- 11 ba52de ESAB AB 2011
GBRecommended fuse sizes and minimum cable areasMig 410Voltage VCurrent Aat 100% duty cycleat 60% duty cycleat 50% duty cycleCable area mm2Fuse, slow A3 50 Hz2303 50/60 Hz400/4153 50 Hz5003 60 Hz2303 60 Hz440/4602842454x6251624284 x 2.5201319204 x 2.5202841454x6251421224 x 2.520Mig 510Voltage VCurrent Aat 100% duty cycleat 60% duty cycleCable area mm2Fuse, slow A3 50 Hz2303 50/60 Hz400/4153 50 Hz5003 60 Hz2303 60 Hz440/46043684 x 166325394x63520314x63543684 x 166323354x625NB: The mains cable areas and fuse sizes as shown above are in accordance with Swedishregulations. They may not be applicable in other countries: make sure that the cable area and fusesizes comply with the relevant national regulations.- 12 ba52de ESAB AB 2011
GB5OPERATIONGeneral safety regulations for handling the equipment can be found onpage 4. Read through before you start using the equipment!WARNINGSecure the equipment - particularly if theground is uneven or sloping.5.1Connection and control devices1Mains supply switch92Main supply switch for cooling unit ELP**103456Switch, precise controlSwitch, coarse controlIndicator lamp, power supply ONOrange indicating lamp, overheating andloss of coolant*Digital instrument V/A111213147815Connection for return cable (-), mediuminductance (Mig 510)Connection for return cable (-), lowinductanceConnection for welding current cable ( )Connection for control cable for wire feederMCBConnection RED for cooling water from thewire feed unitConnection BLUE for cooling water to thewire feed unitConnection for return cable (-), highinductanceNOTE! Cooling water connections only available on certain models.* Indicating loss of coolant, only when water flow guard is used, see point 5.5** ELP ESAB Logic Pump, see point 5.4- 13 ba52de ESAB AB 2011
GB5.2StartWhen switched on, the indicator lamps are checked for 2 seconds. Normally, if thepower source has not overheated, it should start to work in idle mode, which isindicated by the supply-ON lamp flashing. The fan and the coolant pump stop.The fan starts once welding starts. The coolant pump starts at the same time if it isswitched on by means of either the ELP switch on the wire feeder or the pumpsupply switch on the power source.5.3Overheating protectionThe power source has 2-step control of the fan speed and overheating protection.If the temperature crosses the threshold point, the fan starts to operate withincreased speed. If the internal temperature becomes too high, the welding isinterrupted and disabled. This is indicated by the orange indicating lamp on the frontof the unit being permanently lit. The unit resets automatically once the temperaturedrops.5.4Water connectionThe wire feed unit has a ELP (ESAB Logic Pump) sensor which senses whether thewater hoses of the welding gun are connected. When a water cooled welding gun isconnected, the water pump is active. For wire feed units with ELP sensor the pumpsupply switch on the power source should be in position ”ELP/0”.It is recommended to switch the power source off by means of the mains switchbefore connecting the cooling water hoses to/from the wire feed unit.The pump supply switch must be in position ”I” exclusively for other types of wirefeeders, when a water cooled welding gun is used. When a self cooled welding gunis used the pump switch must be in position ”ELP/0”.Note, if a water cooled welding gun is used when the pump is inactive, the weldinggun might be damaged.5.5Water flow guardThe water flow guard interrupts and disables welding in the event of loss of coolant.This is indicated by the orange indicating lamp on the front of the power sourceflashing. If there is a lack of coolant flow, the pump is switched off after 1 min andlocks in this state. The pump restarts from this state once welding starts.The water flow guard is an accessory. The order number is on page 28.5.6Idle modeThe machine has an idle mode. The fan switches off 5 min after welding has finishedor 5 min after running at a decreased speed without welding. The pump switches off3 min after welding has finished. Once both the fan and the pump have switched off,the power-supply lamp on the front panel flashes.5.7InductanceHigher inductance produces a more flowing weld and less spatter. Lower inductanceproduces a harsher sound and a stable, concentrated arc.- 14 ba52de ESAB AB 2011
GB6MAINTENANCERegular maintenance is important for safe, reliable operation.CAUTIONAll guarantee undertakings from the supplier cease to apply if the customer attempts anywork to rectify any faults in the product during the guarantee period.6.1Inspection and cleaningPower sourceCheck regularly that the power source is free from dirt.The power source should be regularly blown clean using dry compressed air at reducedpressure, see page 17. This should be done more frequently in dirty environments.Otherwise the air inlet/outlet may become blocked and cause overheating. To avoidthis you can use an air filter.The air filter is an accessory. The order number can be found on page 28.Welding gunSThe welding gun's wear parts should be cleaned and replaced at regularintervals in order to achieve trouble-free wire feed. Blow the wire guide cleanregularly and clean the contact tip.6.2Topping up the coolantESAB's ready mixed coolant is recommended foruse. See accessories on page 28.Note! Coolant must be topped up if connecting awelding torch that is 5 metres in length or longer.When adjusting the water level by topping up, thecoolant hose does not need to be disconnected.CAUTIONThe coolant must be handled as chemical waste.- 15 ba52de ESAB AB 2011
GB7FAULT TRACINGTry these recommended checks and inspections before sending for an authorisedservice technican.Type of faultActionsSSNo arcSSWelding current is interruptedduring weldingSSCheck that the mains power supply switch is turned on.Check that the welding current supply and return cables arecorrectly connected.Check that correct current value is set.Check to see whether the MCB has tripped.Check whether the thermal overload trip has been triggered(indicated by the orange lamp on the front).Check the main power supply fuses.Thermal overload tripstrigger frequentlySSCheck to see whether the air filters are clogged.Make sure that you are not exceeding the rated data for thepower source (i.e. that the unit is not being overloaded).Poor welding performanceSCheck that the welding current supply and return cables arecorrectly connected.Check that the correct current value is set.Check that the correct welding wires are being used.Check the main power supply fuses.SSS8ORDERING OF SPARE PARTSRepair and electrical work should be performed by an authorised ESAB servicetechnician. Use only ESAB original spare and wear parts.Mig 410, Mig 510 is designed and tested in accordance with the international and Euro pean standards IEC/EN 60974-1 and IEC/EN 60974-10. It is the obligation of the servi ce unit which has carried out the service or repair work to make sure that the productstill conforms to the said standard.Spare parts may be ordered through your nearest ESAB dealer, see the last page ofthis publication.- 16 ba52de ESAB AB 2011
Cleaning- 17 ba52clean ESAB AB 2011
DiagramMig 410 (400-415V)- 18 ba52e ESAB AB 2011
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Mig 410 (230-500V)- 20 ba52e ESAB AB 2011
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Mig 510 (400-415V)- 22 ba52e ESAB AB 2011
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Mig 510 (230-500V)- 24 ba52e ESAB AB 2011
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Connection instructionMig 410Mig 510- 26 ba52c ESAB AB 2011
Mig 410, Mig 510Order numberOrder no.TypeNotes0349 303 563 Origo Mig 410400-415 V 3 50Hz with digital instrument0349 312 610 Origo Mig 410230/400-415/500V 3 50Hz; 230/440-460V 3 60Hz with digital instrument0349 303 564 Origo Mig 410w400-415 V 3 50Hz with water cool
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-control
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ESAB's accessories for the product can be found on page 29. 2.1 Equipment The power source Mig C280 PRO is supplied with: Welding gun PSF 250 - 3m ( Mig C280 PRO 4WD - 4,5m) Return cable 3.5m with return clamp (Mig C280 PRO 4WD - 5m) Shelf for gas cylinder Instructi
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