Mig400t Mig500t. Origo. Instruction manual

Transcription

1 Mig400t Mig500t Origo Instruction manual Validforserialno.627

2 ENGLISH 1 DIRECTIVE SAFETY INTRODUCTION Equipment TECHNICAL DATA INSTALLATION Placing Assembly of components Electrical installation Mains power supply OPERATION Connections and control devices Overheating protection Water connection Water flow guard Inductance MAINTENANCE Inspection and cleaning Topping up the coolant FAULT TRACING ORDERING OF SPARE PARTS DIAGRAM ACCESSORIES TOCe - 2 -

3 GB 1 DIRECTIVE DECLARATION OF CONFORMITY ESAB AB, Welding Equipment, SE Laxå, Sweden, gives its unreserved guarantee that weldingpowersourceorigo TM Mig400t/Origo TM Mig500tfromserialnumber627complieswithstandard IEC/EN , in accordance with the requirements of directive(73/23/eec) and addendum (93/68/EEC) and with standard IEC/EN in accordance with the requirements of directive (89/336/EEC) and addendum(93/68/eec) Laxå Kent Eimbrodt Global Director Equipment and Automation ESAB AB 69581LAXÅ SWEDEN Tel: Fax: 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 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 welding equipment. Incorrect operation of the equipment may lead to hazardous situations which can result ininjurytotheoperatoranddamagetotheequipment. 1. Anyone who uses the welding equipment must be familiar with: itsoperation locationofemergencystops itsfunction relevantsafetyprecautions welding 2. The operator must ensure that: nounauthorisedpersonisstationedwithintheworkingareaoftheequipmentwhenitis started up. no--oneisunprotectedwhenthearcisstruck 3. The workplace must: besuitableforthepurpose befreefromdraughts 4. Personal safety equipment Alwayswearrecommendedpersonalsafetyequipment,suchassafetyglasses,flame--proof clothing, safety gloves. Donotwearloose--fittingitems,suchasscarves,bracelets,rings,etc.,whichcouldbecome trapped or cause burns. 5. General precautions Makesurethereturncableisconnectedsecurely. Workonhighvoltageequipmentmayonlybecarriedoutbyaqualifiedelectrician. Appropriatefireextinquishingequipmentmustbeclearlymarkedandcloseathand. Lubricationandmaintenancemustnotbecarriedoutontheequipmentduringoperation. m4050te - 3 -

4 GB WARNING! Read and understand the instruction manual before installing or operating. WARNING 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 Installandearththeweldingunitinaccordancewithapplicablestandards. Donottouchliveelectricalpartsorelectrodeswithbareskin,wetglovesor wetclothing. Insulateyourselffromearthandtheworkpiece. Ensureyourworkingstanceissafe. FUMESANDGASES - Canbedangeroustohealth Keepyourheadoutofthefumes. Useventilation,extractionatthearc,orboth,totakefumesandgasesawayfromyourbreathingzone and the general area. ARCRAYS - Caninjureeyesandburnskin. Protectyoureyesandbody.Usethecorrectweldingscreenandfilterlens andwearprotective clothing. Protectbystanderswithsuitablescreensorcurtains. FIRE HAZARD Sparks(spatter)cancausefire.Makesurethereforethatthereareno inflammablematerialsnearby. NOISE - Excessive noise can damage hearing Protectyourears.Useearmuffsorotherhearingprotection. Warnbystandersoftherisk. MALFUNCTION - Call for expert assistance in the event of malfunction. READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING. PROTECT YOURSELF AND OTHERS! ESAB can provide you with all necessary welding protection and accessories. WARNING! Donotusethepowersourceforthawingfrozenpipes. This product is solely intended for arc welding. Do not dispose of electrical equipment together with normal waste! In observance of European Directive 2002/96/EC on Waste Electrical and Electronic Equipment and its implementation in accordance with national law, electrical equipment thathasreachedtheendofitslifemustbecollectedseparatelyandreturnedtoan environmentally compatible 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! m4050te - 4 -

5 GB 3 INTRODUCTION Origo TM Mig400tandOrigo TM Mig500tarethyristorpowersourcesdesignedfor MIG/MAG--weldingtogetherwithwirefeedunitsOrigo TM Feed30x, Origo TM Feed48xandthemostofESABwirefeeders. The power sources are fan--cooled an equipped with thermal overload protection. ESAB saccessoriesfortheproductcanbefoundonpage Equipment The power source is supplied with: Returncable5mwithreturnclamp Shelfforgascylinder Attachmentchainforgascylinder Guidepinforwirefeedunit Instructionmanual 4 TECHNICAL DATA Origo TM Mig400t Origo TM Mig400t Mains voltage 400/415 V 3 50 Hz 230/400/415/500 V, 3 50 Hz 230/440/460V,3 60Hz Permissible load at 45% duty cycle 60%dutycycle 100% duty cycle Setting range(dc) 400A/34V 350A/32V 280A/28V 400A/34V 350A/32V 280A/28V 50A/16.5V--400A/34V 50A/16.5V--400 A/34V Open circuit voltage V V Open circuit power with cooling unit 590W 790W 640W 840W Power factor at maximum current 0,86 0,86 Efficiency at maximum current 74% 76% Control voltage 42 V, 50/60 Hz 42 V, 50/60 Hz Dimensionslxwxh 800x640 x835mm 800x640 x835mm Weight with cooling unit 209kg 223kg 210kg 224kg Operating temperature --10 to +40 C --10 to +40 C Enclosure class IP 23 IP 23 Application classification m4050te - 5 -

6 GB Origo TM Mig500t Origo TM Mig500t Mains voltage 400/415 V 3 50 Hz 230/400/415/500 V, 3 50 Hz 230/440/460V,3 60Hz Permissible load at 60% duty cycle 80%dutycycle 100% duty cycle 500A/39V 450A/37V 400A/34V 500A/39V 435A/36V 390A/33,5V Setting range(dc) 50A/16.5V--500A/39V 50A/16.5V--500A/39V Open circuit voltage V V Open circuit power with cooling unit 670W 870W 720W 920W Power factor at maximum current 0,90 0,90 Efficiency at maximum current 78% 78% Control voltage 42 V, 50/60 Hz 42 V, 50/60 Hz Dimensionslxwxh 800x640 x835mm 800x640 x835mm Weight with cooling unit 235kg 249kg 237kg 251kg Operating temperature --10 to +40 C --10 to +40 C Enclosure class IP 23 IP 23 Application classification Cooling unit Cooling power Coolant 2500 W at40 C temp. difference and flow 1,5l/min 2500 W at40 C temp. differenceandflow 1,5l/min 50%water/50%glycol 50%water/50%glycol Coolant quantity 5,5 l 5,5 l Maximum water flow 2,0 l/min 2,0 l/min Duty cycle Thedutycyclereferstothetimeasapercentageofaten--minuteperiodthatyoucanweldatacertain 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. Application class The symbol indicates that the power source is designed for use in areas with increased electrical hazard. m4050te - 6 -

7 GB 5 INSTALLATION The installation must be executed by a professional. Note! Connect the power source to the electricity mains with a network impedance of 0.243Ω (Mig 400tw), 0.136Ω(Mig500tw)orlower.Ifthenetworkimpedanceishigher,thereisariskofflickerintheilluminators. WARNING! 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. Lifting instructions Thepowersupplyshouldbeliftedbymeansofitslifting eye.thehandleisonlyintendedforpullingitalongthe ground. 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 m4050te - 7 -

8 GB WARNING! During transport, the rear wheels of the power source are in their forward position. Before use, place the wheels in their rear position. 5.3 Electrical installation m4050te - 8 -

9 GB 5.4 Mains power supply Checkthattheunitisconnectedtothecorrectmainspowersupplyvoltage,andthat 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 Origo TM Mig400t 3µ50Hz 3µ50Hz 3µ50Hz 3µ60Hz 3µ60Hz Mainsvoltage 230V 400/415V 500V 230V 440/460V Primary current 45% duty cycle 60% duty cycle 100% duty cycle 51A 47A 39A 31A 28A 23A 25A 22A 19A 51A 45A 37A 30A 27A 22A Mainscablearea 4x10mm 2 4x4mm 2 4x4mm 2 4x10mm 2 4x4mm 2 Fuseanti--surge 35A 25A 20A 35A 20A Origo TM Mig500t 3µ50Hz 3µ50Hz 3µ50Hz 3µ60Hz 3µ60Hz Mainsvoltage 230V 400/415V 500V 230V 440/460V Primary current 60% duty cycle 80% duty cycle 100% duty cycle 69A 63A 59A 42A 38A 34A 33A 29A 27A 69A 61A 56A 42A 37A 33A Mainscablearea 4x16mm 2 4x6mm 2 4x6mm 2 4x16mm 2 4x6mm 2 Fuseanti--surge 63A 35A 35A 50A 25A NB:ThemainscableareasandfusesizesasshownaboveareinaccordancewithSwedish regulations. They may not be applicable in other countries: make sure that the cable area and fuse sizes comply with the relevant national regulations. m4050te - 9 -

10 GB 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 - TIPPING RISK! Fasten the equipment -- particularly if the ground is uneven or sloping. 6.1 Connections and control devices 1 Connection for control cable to the wire feed unit 8 Connection for return cable(--), low inductance 2 MCB 9 Connection for return cable(--), medium inductance 3 Display(digital meters) is an accessory seeonpage19. 4 Orange indicating lamp, overheating and loss of coolant* 10 Connection for return cable(--), high inductance 11 Connection RED for cooling water from thewirefeedunit 5 White indicating lamp, power supply ON 12 Connection BLUE for cooling water to the wire feed unit 6 Main supply switch 13 Connection for weldng current cable(+) 7 Main supply switch for cooling unit ELP** NOTE! Cooling water connections only available on certain models. *Indicatinglossofcoolant,onlywhenwaterflowguardisused,seepoint6.4 **ELP=ESABLogicPump,seepoint6.3. m4050te

11 GB 6.2 Overheating protection The power source has one thermal overload trip which operates if the internal temperature becomes too high, interrupting the welding current and lighting the orange indicating lamp on the front of the unit. It resets automatically when the temperature has fallen and the indicating lamp will go out. 6.3 Water connection TheOrigo TM FeedhasasensorELP,ESABLogicPump,thatsensesifthewater hosesoftheweldinggunareconnected.whenawatercooledweldinggunis connected, the water pump starts. Whenusingotherwirefeedunits,thewaterpumpswitchmustbeinposition I when awatercooledweldinggunisused. When connecting the cooling water hoses to/from the Feed wire feed unit, the mains ON/OFFswitchoftheOrigo TM MigmustbeintheOFFposition. Whenaselfcooledweldinggunisusedthepumpswitchmustbeinposition ELP/0. Note,ifawatercooledweldinggunisusedwhenthepumpisinactive,thewelding gun might be damaged. 6.4 Water flow guard Thewaterflowguardinterruptstheweldingcurrentintheeventoflossofcoolant andanorangeindicatinglamponthefrontofthepowersourcelightsup. Thewaterflowguardisanaccessory.Orderingnumberseeonpage Inductance Higher inductance produces a more flowing weld and less spatter. Lower inductance produces a harsher sound and a stable, concentrated arc. 7 MAINTENANCE Regular maintenance is important for safe, reliable operation. Maintenance must be executed by a professional. Only those persons who have appropriate electrical knowledge(authorised personnel) may remove the safety plates. Note! All guarantee undertakings from the supplier cease to apply if the customer himself attemptsanyworkintheproductduringtheguaranteeperiodinordertorectifyany faults. m4050te

12 GB 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 become blocked and cause overheating. To avoid thisyoucanuseanairfilter. The airfilter is an accessory. Ordering number on page Topping up the coolant Werecommenda50/50%mixtureofwaterandethyleneglycol. 8 FAULT TRACING Try these recommended checks and inspections before sending for an authorised service technican. Noarc. Type of fault Welding current is interrupted during welding The thermal overload trips operate frequently Poorweldingperformance. Actions Checkthatthemainspowersupplyswitchisturnedon. Checkthattheweldingcurrentsupplyandreturncablesare correctly connected. Checkthatthecorrectcurrentvalueisset. ChecktoseewhethertheMCBhastripped. Checkwhetherthethermaloverloadtriphasoperated (indicated by the orange lamp on the front) Checkthemainpowersupplyfuses. Checktoseewhethertheairfiltersareclogged. Makesurethatyouarenotexceedingtherateddataforthe power source(i.e. that the unit is not being overloaded). Checkthattheweldingcurrentsupplyandreturncablesare correctly connected. Checkthatthecorrectcurrentvalueisset. Checkthatthecorrectweldingwiresarebeingused. Checkthemainpowersupplyfuses. m4050te

13 GB 9 ORDERING OF SPARE PARTS Origo TM Mig400t/Origo TM Mig500tisdesignedandtestedinaccordancewiththeinternational and European standards IEC/EN and EN It is the obligationoftheserviceunitwhichhascarriedouttheserviceorrepairworktomakesure that the product still conforms to the said standard. SparepartsmaybeorderedthroughyournearestESABdealer,seethelastpageof this publication. m4050te

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18 Origo TM Mig400t/Origo TM Mig500t Validforserialno.627-XXX-XXXX Ordering numbers Origo TM Mig400t 400V/415V,3~50Hz Origo TM Mig400t 230V/400V/415V/500V3~50Hz,230V/440V/460V3~60Hz Origo TM Mig400tw 400V/415V,3~50Hz;withwatercooler Origo TM Mig400tw 230V/400V/415V/500V3~50Hz,230V/440V/460V3~60Hz; with water cooler Origo TM Mig500t 400V/415V,3~50Hz Origo TM Mig500t 230V/400V/415V/500V3~50Hz,230V/440V/460V3~60Hz Origo TM Mig500tw 400V/415V,3~50Hz;withwatercooler Origo TM Mig500tw 230V/400V/415V/500V3~50Hz,230V/440V/460V3~60Hz; with water cooler Origo TM Mig500tw 400V/415V,3~50Hz;withwatercooler,withcircuitbreaker om4050t Edition

19 Origo TM Mig400t/Origo TM Mig500t Accessories Origo TM FeedforMarathonPac TM, M13 panel Origo TM Feed304M13... Origo TM Feed304M13withdisplay... Origo TM Feed304M13withwater... Origo TM Feed304M13withdisplayandwater Origo TM Feed484M13... Origo TM Feed484M13withdisplay... Origo TM Feed484M13withwater... Origo TM Feed484M13withdisplayandwater Origo TM Feedwithcapsulatedbobbin, M13 panel Origo TM Feed304M13... Origo TM Feed304M13withdisplay... Origo TM Feed304M13withwater... Origo TM Feed304M13withdisplayandwater Origo TM Feed484M13... Origo TM Feed484M13withdisplay... Origo TM Feed484M13withwater... Origo TM Feed484M13withdisplayandwater Origo TM FeedforMarathonPac TM, M14 panel Origo TM Feed304M13withdisplayandwater Origo TM Feed484M13withdisplayandwater Origo TM Feedwithcapsulatedbobbin, M14panel... Origo TM Feed304M13withdisplayandwater Origo TM Feed484M13withdisplayandwater Digitalinstrument am4050t Edition

20 Origo TM Mig400t/Origo TM Mig500t TransformerforCO 2 heater Guidepin Waterflowguard Filter Holderforweldinggunandcables am4050t Edition

21 Origo TM Mig400t/Origo TM Mig500t Connection set for 400 A power sources Connectionset1.7m... Connectionset10m... Connectionset15m... Connectionset25m... Connectionset35m... Connectionset1.7m,water... Connectionset10m,water... Connectionset15m,water... Connectionset25m,water... Connectionset35m,water... Connection set for 500 A power sources Connectionset1.7m... Connectionset10m... Connectionset15m... Connectionset25m... Connectionset35m... Connectionset1.7m,water... Connectionset10m,water... Connectionset15m,water... Connectionset25m,water... Connectionset35m,water For more information of the accessories contact the nearest ESAB agency. am4050t Edition

22 ESAB subsidiaries and representative offices Europe AUSTRIA ESAB Ges.m.b.H Vienna-Liesing Tel: Fax: BELGIUM S.A. ESAB N.V. Brussels Tel: Fax: THE CZECH REPUBLIC ESAB VAMBERK s.r.o. Vamberk Tel: Fax: DENMARK Aktieselskabet ESAB Herlev Tel: Fax: FINLAND ESAB Oy Helsinki Tel: Fax: FRANCE ESAB France S.A. Cergy Pontoise Tel: Fax: GERMANY ESAB GmbH Solingen Tel: Fax: GREAT BRITAIN ESAB Group(UK) Ltd Waltham Cross Tel: Fax: ESAB Automation Ltd Andover Tel: Fax: NORWAY AS ESAB Larvik Tel: Fax: POLAND ESAB Sp.zo.o. Katowice Tel: Fax: PORTUGAL ESAB Lda Lisbon Tel: Fax: SLOVAKIA ESAB Slovakia s.r.o. Bratislava Tel: Fax: SPAIN ESAB Ibérica S.A. Alcalá de Henares (MADRID) Tel: Fax: SWEDEN ESAB Sverige AB Gothenburg Tel: Fax: ESAB international AB Gothenburg Tel: Fax: SWITZERLAND ESAB AG Dietikon Tel: Fax: North and South America ARGENTINA CONARCO Buenos Aires Tel: Fax: Asia/Pacific CHINA Shanghai ESAB A/P Shanghai Tel: Fax: INDIA ESAB India Ltd Calcutta Tel: Fax: INDONESIA P.T. ESABindo Pratama Jakarta Tel: Fax: JAPAN ESAB Japan Tokyo Tel: Fax: MALAYSIA ESAB(Malaysia) Snd Bhd Selangor Tel: Fax: SINGAPORE ESAB Asia/Pacific Pte Ltd Singapore Tel: Fax: SOUTH KOREA ESAB SeAH Corporation Kyungnam Tel: Fax: UNITED ARAB EMIRATES ESAB Middle East FZE Dubai Tel: Fax: Representative offices BULGARIA ESAB Representative Office Sofia Tel/Fax: EGYPT ESAB Egypt Dokki-Cairo Tel: Fax: ROMANIA ESAB Representative Office Bucharest Tel/Fax: RUSSIA LLC ESAB Moscow Tel: Fax: LLC ESAB St Petersburg Tel: Fax: Distributors For addresses and phone numbers to our distributors in other countries, please visit our home page HUNGARY ESAB Kft Budapest Tel: Fax: BRAZIL ESAB S.A. Contagem-MG Tel: Fax: ITALY ESAB Saldatura S.p.A. Mesero(Mi) Tel: Fax: THE NETHERLANDS ESAB Nederland B.V. Utrecht Tel: Fax: CANADA ESAB Group Canada Inc. Missisauga, Ontario Tel: Fax: MEXICO ESAB Mexico S.A. Monterrey Tel: Fax: USA ESAB Welding& Cutting Products Florence, SC Tel: Fax: ESAB AB SE-69581LAXÅ SWEDEN Phone