ESAB Origo™ Arc 250, 300, 400 is a welding power source for coated electrodes that gives direct current. It can weld various metals, including alloy and non-alloy steel, stainless steel, and cast iron. Arc 250 and Arc 300 can weld with coated electrodes from 1.6 to 5mm in diameter. Arc 400 can weld with electrodes up to 6mm in diameter.
ESAB Origo™ Arc 250, 300, 400 is a welding power source for coated electrodes that gives direct current. It can weld various metals, including alloy and non-alloy steel, stainless steel, and cast iron. Arc 250 and Arc 300 can weld with coated electrodes from 1.6 to 5mm in diameter. Arc 400 can weld with electrodes up to 6mm in diameter.
Origo™
Instruction manual
0463 336 001 GB 20140121 Valid for: serial no. 316-303-xxxx
Arc 250, Arc 300, Arc 400
TABLE OF CONTENTS
0463 336 001 © ESAB AB 2014
1 SAFETY ................................................................................................................ 4
2 INTRODUCTION................................................................................................... 7
2.1 Equipment............................................................................................................. 7
2.2 Area of use............................................................................................................ 7
3 TECHNICAL DATA ............................................................................................... 8
4 INSTALLATION..................................................................................................... 9
4.1 Location ................................................................................................................ 9
4.2 Lifting instructions............................................................................................... 9
4.3 Mains power supply.............................................................................................9
4.3.1 Recommended fuse sizes and minimum cable area .......................................10
5 OPERATION ....................................................................................................... 11
5.1 Connections and control devices..................................................................... 11
5.2 At start................................................................................................................. 11
5.3 Overheating protection...................................................................................... 11
6 MAINTENANCE.................................................................................................. 12
6.1 Inspection and cleaning .................................................................................... 12
7 FAULT-TRACING................................................................................................ 13
8 ORDERING SPARE PARTS ............................................................................... 14
DIAGRAM ..................................................................................................................15
STATIC CHARACTERISTICS....................................................................................21
ORDERING NUMBERS.............................................................................................22
Rights reserved to alter specifications without notice.
1 SAFETY
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© ESAB AB 2014
1 SAFETY
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 equpment
3. The workplace must:
○ be suitable for the purpose
○ be free from drafts
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 extinquishing equipment must be clearly marked and close at hand
○ Lubrication and maintenance must not be carried out on the equipment during
operation
1 SAFETY
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© ESAB AB 2014
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting. Ask for your employer's safety practices which should
be based on manufacturers' hazard data.
ELECTRIC SHOCK - Can kill
• Install and earth the unit in accordance with applicable standards
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing
• Insulate yourself from earth and the workpiece
• Ensure your working stance is safe
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
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure therefore that there are no
inflammable materials nearby
NOISE - Excessive noise can damage hearing
• Protect your ears. Use earmuffs or other hearing protection. Protect your
ears. Use earmuffs or other hearing protection
• Warn 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!
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
Read and understand the instruction manual before
installing or operating.
CAUTION!
This product is solely intended for arc welding.
1 SAFETY
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© ESAB AB 2014
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 2002/96/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 can provide you with all necessary welding protection and accessories.
2 INTRODUCTION
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© ESAB AB 2014
2 INTRODUCTION
Arc 250, Arc 300 and Arc 400 are welding power sources intended for use with coated
electrodes.
2.1 Equipment
The power source is supplied with a mains cable (5m) and an instruction manual..
2.2 Area of use
The power source gives direct current which makes it possible to weld most metals to alloy
and non-alloy steel, stainless steel and cast iron. Arc 250 and Arc 300 are suitable for
welding with coated electrodes between 1.6 and 5 mm in diameter and Arc 400 functions
with diameters of up to 6 mm.
3 TECHNICAL DATA
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© ESAB AB 2014
3 TECHNICAL DATA
Arc 250 Arc 300 Arc 400
Mains supply Zmax
(Ω)*
0.18 0.11 0.08
Permissible load
40% duty cycle 250 A / 30 V 285 A / 31.4 V 400 A / 36 V
100% duty cycle 140 A / 25.6 V 150 A / 26 V 230 A / 29.2 V
Setting range 50A/22V -
250A/30V
55A/22.2V -
300A/32V
65A/22.6V -
400A/36V
Open-circuit voltage 65-75 V 65-75 V 70-80 V
No-load power 490 W 590 W 750 W
Power factor
at maximum current
0.52 0.54 0.58
Enclosure class IP23 IP23 IP23
Application class
Weight 98 kg 105 kg 158 kg
Dimensions lxwxh 510x 544x 615 mm 510x 544x 615 mm 570x560x 770 mm
Height with handle 930 mm 930 mm 1.020 mm
Operating
temperature
-10 to +40 °C -10 to +40 °C -10 to +40 °C
Transportation
temperature
-20 to +55 °C -20 to +55 °C -20 to +55 °C
NOTE!
Connect the power source to the electricity mains with a network impedance of
Zmax or lower. If the network impedance is higher, there is a risk of flicker in the
illuminators.
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.
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.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
See section "Static characteristics" for further details.
4 INSTALLATION
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© ESAB AB 2014
4 INSTALLATION
The installation must be carried out by a professional.
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
Place the power source so that its cooling air inlets and outlets are not obstructed.
4.2 Lifting instructions
4.3 Mains power supply
NOTE!
Mains supply requirements
High power equipment may, due to the primary current drawn from the mains
supply, influence the power quality of the grid. Therefore connection restrictions
or requirements regarding the maximum permissible mains impedance or the
required minimum supply capacity at the interface point to the public grid may
apply for some types of equipment (see technical data). In this case it is the
responsibility of the installer or user of the equipment to ensure, by consultation
with the distribution network operator if necessary, that the equipment may be
connected.
• Ensure that the power source is set for the correct mains supply.
• The mains cable is connected to terminal block XT1 (via connection L1, L2 and L3) and
PE connection.
• Ensure that the terminal blocks XT1 and XT2 are correctly connected to the mains
supply that is used. (At delivery the power source is connected for a mains voltage of 3 x
400-415 V, 50 Hz).
• Make sure that the welding power source is connected to the correct supply voltage and
that it is protected by the correct fuse rating. A protective earth connection must be made
in accordance with regulations.
4 INSTALLATION
0463 336 001
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© ESAB AB 2014
A. Rating plate with supply connection data
4.3.1 Recommended fuse sizes and minimum cable area
Arc 250 50/60 Hz 50 Hz 60 Hz 50 Hz 60 Hz
Mains voltage (V) 230 400-415 440-460 500 550
Mains cable area (mm
2
)
4x6 4x4 4x4 4x2.5 4x2.5
Fuse anti-surge (A) 35 20 20 16 16
Arc 300 50/60 Hz 50 Hz 60 Hz 50 Hz 60 Hz
Mains voltage (V) 230 400-415 440-460 500 550
Mains cable area (mm
2
)
4x6 4x4 4x4 4x2.5 4x2.5
Fuse anti-surge (A) 35 25 20 16 16
Arc 400 50/60 Hz 50 Hz 60 Hz 50 Hz 60 Hz
Mains voltage (V) 230 400-415 440-460 500 550
Mains cable area (mm
2
)
4x10 4x6 4x6 4x4 4x4
Fuse anti-surge (A) 63 35 35 25 25
5 OPERATION
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© ESAB AB 2014
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!
5.1 Connections and control devices
1. Main power supply switch 0 / 1 4. Connection (-)
2. Display of welding current 5. Connection (+)
3. Knob for adjusting the current
5.2 At start
• Start the power source by setting the main switch to “I". The white indicator lights and the
fan starts.
• Set the welding current using the knob on the front. The current that you have selected is
shown on the display. Follow the instructions on the electrode packaging for the
recommended welding current.
• Connect the welding and return cable to the outputs marked + and - on the front of the
power source. Pole reversal occurs if you switch the welding and return cables. Connect
the return cable connector clamp to the workpiece.
• The power source is now ready for welding.
5.3 Overheating protection
The thermostat prevents the power source from overheating. The yellow LEDs light in the
event of overheating. The settings are automatically reset when the power source has
cooled.
6 MAINTENANCE
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© ESAB AB 2014
6 MAINTENANCE
NOTE!
Regular maintenance is important for safe, reliable operation.
Only those persons who have appropriate electrical knowledge (authorised personnel) may
remove the safety plates to connect or carry out service, maintenance or repair work on
welding equipment.
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
In normal cases it is sufficient to regularly blow the power source clean with dry compressed
air (reduced pressure). In dirty and dusty conditions the power source must be cleaned at
shorter intervals.
If necessary the chain and gears must be lubricated with a heat resistant lubricant. If
necessary the sliding surfaces and leakage cores must be lubricated with a thin layer of the
same lubricant.
7 FAULT-TRACING
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© ESAB AB 2014
7 FAULT-TRACING
Try these recommended checks and inspections before sending for an authorised service
technician.
Type of fault Corrective action
No arc. • Check that the mains power supply switch is turned on.
• Check that the welding and return cables are correctly
connected.
• Check that the correct current value is set.
• Check the mains power supply fuses.
The welding current is
interrupted during
welding.
• Check whether the thermal overload trips have operated
(indicated by the yellow LED on the front panel).
• Check the mains power supply fuses.
The overheating
protection trips
frequently.
• Make sure that you are not exceeding the rated data for the
welding power source (i.e. that the unit is not being
overloaded).
• Check that the welding power source is not clogged with dirt.
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 electrodes are being used.
8 ORDERING SPARE PARTS
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© ESAB AB 2014
8 ORDERING SPARE PARTS
CAUTION!
Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.
Arc 250, Arc 300, Arc 400 is designed and tested in accordance with the international and
European standards IEC-/EN 60974-1, IEC-/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.
The spare parts list is published in a separate document that can be downloaded from the
Internet: www.esab.com
DIAGRAM
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© ESAB AB 2014
DIAGRAM
Arc 250/300
DIAGRAM
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© ESAB AB 2014
DIAGRAM
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© ESAB AB 2014
Arc 400 (400V)
DIAGRAM
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© ESAB AB 2014
DIAGRAM
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© ESAB AB 2014
Arc 400 (500V)
DIAGRAM
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© ESAB AB 2014
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ESAB Origo™ Arc 250, 300, 400 is a welding power source for coated electrodes that gives direct current. It can weld various metals, including alloy and non-alloy steel, stainless steel, and cast iron. Arc 250 and Arc 300 can weld with coated electrodes from 1.6 to 5mm in diameter. Arc 400 can weld with electrodes up to 6mm in diameter.
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