ESAB Origo™ Arc 250 User manual

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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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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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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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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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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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 50A/22V -

250A/30V

55A/22.2V -

300A/32V

65A/22.6V -

400A/36V

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 510x 544x 615 mm 510x 544x 615 mm 570x560x 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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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

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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

)

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

)

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

)

4x10 4x6 4x6 4x4 4x4

Fuse anti-surge (A) 63 35 35 25 25

5 OPERATION

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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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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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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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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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DIAGRAM

Arc 250/300

DIAGRAM

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DIAGRAM

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Arc 400 (400V)

DIAGRAM

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DIAGRAM

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Arc 400 (500V)

DIAGRAM

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ESAB Origo™ Arc 250, 300, 400, Origo™ Arc 250, 300, 400 User manual

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