ESAB Mig C240 PRO User manual
- Category
- Welding System
- Type
- User manual
This manual is also suitable for
Valid for serial no. 6270349 301 115 061026
Mig C240 PRO
Mig C240s PRO
Origo
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 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 OPERATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Connection and control devices 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Welding without gas 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Wire feed pressure 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 Replacing and inserting wire 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 Overheating protection 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6 Inductance connection 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7 OrigoTM Mig C240 PRO 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.8 OrigoTM Mig C240s PRO 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 MAINTENANCE 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Inspection and cleaning 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 FAULT TRACING 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 ORDERING OF SPARE PARTS 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGRAM 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-- 3 --
C240Pe
1 DIRECTIVE
DECLARATION OF CONFORMITY
ESAB AB, Welding Equipment, SE--695 81 Laxå, Sweden, gives its unreserved guarantee that weld-
ing power source Origo
TM
Mig C240 PRO, Origo
TM
Mig C240s PRO from serial number 627 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 IEC/EN 60974--10 in accordance with the requirements of
directive (89/336/EEC) and addendum (93/68/EEC).
--------------------------------------------------------------------------------------------------------------------------------------
Kent Eimbrodt
Global Director Equipment and Automation
ESAB AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924
Laxå 2006--09--05
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:
S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding
2. The operator must ensure that:
S no unauthorised person is stationed within the working area of the equipment when it is
started up.
S no--one is unprotected when the arc is struck
3. The workplace must:
S be suitable for the purpose
S be free from draughts
4. Personal safety equipment
S Always wear recommended personal safety equipment, such as safety glasses, flame--proof
clothing, safety gloves.
S Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions
S 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.
GB
-- 4 --
C240Pe
WARNING!
Read and understand the instruction manual
before installing or operating.
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
S Install and earth the welding unit in accordance with applicable standards.
S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
S Insulate yourself from earth and the workpiece.
S Ensure your working stance is safe.
FUMES AND GASES -- Can be dangerous to health
S Keep your head out of the fumes.
S 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.
S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
S Protect bystanders with suitable screens or curtains.
FIRE HAZARD
S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE -- Excessive noise can damage hearing
S Protect your ears. Use earmuffs or other hearing protection.
S Warn bystanders of the risk.
MALFUNCTION -- Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
Do not use the power source for thawing frozen pipes.
WARNING!
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
that has reached the end of its life must be collected separately and returned to an
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!
GB
-- 5 --
C240Pe
3 INTRODUCTION
Origo
TM
Mig C240 PRO & Origo
TM
Mig C240s PRO are step controlled power sources in a compact
design, intended for welding with solid steel, stainless steel or aluminium wire as well as 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 above the wire feed unit.
ESAB’s accessories for the product can be found on page 20.
3.1 Equipment
The power source is supplied with:
S Welding gun PSF 250 -- 3m
S Return cable 3,5m with return clamp
S Shelf for gas cylinder
S Instruction manual
4 TECHNICAL DATA
Origo
TM
Mig C240 PRO Origo
TM
Mig C240s PRO
Voltage 230/400--415V, 3∼ 50/60Hz 230/400--415V, 3∼ 50/60Hz
Permissible load at
100% duty cycle 130A 130A
60 % duty cycle 170A 170A
30 % duty cycle 240A 240A
Setting range (DC) 20A /15V--240A / 23,0V 20A /15V--240A / 23,0V
Open circuit voltage 14 -- 32V 14 -- 32V
Open circuit power 190W 190W
Efficiency 76% 76%
Power factor 0.95 0.95
Control voltage 42 V, 50/60Hz 42 V, 50/60Hz
Wire feed speed 1,9 -- 19m/min 1,4 -- 19m/min
Burnback time 0 -- 0,25s 0 -- 0,25s
Spot welding 0,2 -- 2,5s 0,2 -- 2,5s
Creep start -- + (auto)
2/4 stroke & motor inching -- +
Welding gun connection EURO EURO
Wire dimension range 0,6 -- 1,0mm 0,6 -- 1,0mm
Max diameter of wire bobin 300mm 300mm
Dimensions lxwxh 840x425x830 840x425x830
Weight 103 kg 100 kg
Operating temperature --10 ÷ +40
o
C --10 ÷ +40
o
C
Enclosure class IP 23 IP 23
Application classification
GB
-- 6 --
C240Pe
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.
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.
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.
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 --
C240Pe
During transport, the rear wheels of the power source are in their forward position.
Before use, place the wheels in their rear position.
WARNING!
5.3 Electrical installation
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
Origo
TM
Mig C240 PRO
Origo
TM
Mig C240s PRO
3∼ 50/60 Hz 3∼ 50/60 Hz
Voltage V 230 400/415
Current A
at 100% duty cycle 8.6 5.3
at 60% duty cycle 12.4 7.6
at 30% duty cycle 21 12
Cable area mm
2
22
2
4 x 2.5 4 x 1.5
Fuse slow A 20 16
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.
GB
-- 8 --
C240Pe
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.
To prevent the reel sliding off the hub: Lock the reel in place by turning
the red knob as shown on the warning label attached next to the hub.
WARNING!
WARNING -- TIPPING RISK!
There is a risk of tipping while transportation and operation, if the welding machine leans
more than 10
o
. In that case appropriate securing has to be provided !
6.1 Connection and control devices
Origo
TM
Mig C240 PRO
1 Mains supply switch 7 Connection for return cable (--), high inductance
2 Switch, coarse control 8 Connection for return cable (--), low inductance
3 Switch, precise control 9 Knob for wire speed setting
4 Indicating lamp, power supply ON 10 Knob for spot welding -- ON/OFF and time setting
5 Orange indicating lamp, overhea-
ting
11 Digital instrument -- V / A
(option,see page 20)
6 EURO -- connector for welding gun 12 Knob for burn--back time setting
GB
-- 9 --
C240Pe
Origo
TM
Mig C240s PRO
1 Mains supply switch 11 Digital display for welding parameters
2 Switch, coarse control 12 Switch for display selection -- Volt. or Amp
3 Switch, precise control 13 Switch for display selection -- m/min or mm
4 Indicating lamp, power supply ON 14 Lamp indicating status of synergy control
5 Orange indicating lamp, overheating 15 Lamps indicating recommended (--) current
output -- max/min inductance
6 EURO -- connector (for welding gun) 16 Switch for ”Synergy”-- ON/OFF and ma-
terial/gas selection
7 Connection for return cable (--), high induc-
tance
17 Knob for selection of the wire diameter
8 Connection for return cable (--), low induc-
tance
18 Knob for burn--back time setting
9 Knob for wire speed setting / correction 19
Mode selector 2--stroke / / 4--stroke
10 Knob for spot welding -- ON/OFF and time
setting
GB
-- 10 --
C240Pe
6.2 Welding without gas
6.3 Wire feed pressure
Start by making sure that the wire moves smoothly through the wire guide. Then
set the pressure of the wire feeder’s pressure rollers. It is important that the
pressure is not too great.
Fig 1 Fig 2
To check that the feed pressure is set correctly, you can feed out the wire against
an insolated object, e.g. a piece of wood.
When you hold the gun approx. 5 mm from the piece of wood (fig. 1) the feed
rollers should slip.
If you hold the gun approx. 50 mm from the piece of wood, the wire should be
fed out and bend (fig. 2).
6.4 Replacing and inserting wire
S Open the side panel.
S Disconnect the pressure sensor by folding it backwards, the pressure rollers
slide up.
GB
-- 11 --
C240Pe
S Straighten out the new wire 10--20 cm. File away burrs and sharp edges from the
end of the wire before inserting it into the wire feed unit.
S Make sure that the wire goes properly into the feed roller track and into the outlet
nozzle and the wire guide.
S Secure the pressure sensor.
S Close the side panel.
6.5 Overheating protection
When the machine is switched on with the mains switch [1], indicating lamp [4] is on and
lamp [5] off -- the machine is ready to operate. If the internal temperature becomes too
high, the welding is interrupted and disabled. This state is indicated by lighting of the
orange indicating lamp [5] on the front of the machine. It resets automatically when the
temperature has fallen.
6.6 Inductance connection
Higher inductance produces a more flowing weld and fewer spatters. Lower inductance
produces a harsher sound and a stable, concentrated arc.
6.7 Origo
TM
Mig C240 PRO
The Origo
TM
Mig C240 PRO is equipped with standard control unit. Welder can
manually select and adjust all welding parameters.
S Wire speed (1,9 -- 19m/min).
S Spot--welding time.
S Burn back time.
The machine C240 can be fitted with a digital instrument that displays current and
voltage. It incorporates a hold function (see page 20).
6.8 Origo
TM
Mig C240s PRO
S the standard control (welder can manually select and adjust all welding
parameters) -- switch “SYNERGY” [16] set to OFF
S the synergy control (partly preprogrammed welding parameters) -- switch
“SYNERGY” [16] set to any material/gas group
The stroke control (2/4 stroke) or motor inching (only wire feed motor is activated)
is selected with switch [19]. Burn back time is adjusted with knob [18]. Spot welding
(turning on and time setting 0,5 -- 4s) is activated with knob [10].
For machines C240s digital instrument is included as standard.
6.8.1 Standard control mode
When standard control mode is selected lamps [14, 15] are off and only a lower row
of digital display [11] shows wire speed reference (selector [13] shall be in position
”m/min”).
Operator selects the required voltage [2, 3] and he may set wire speed within full
range (1,4 -- 19m/min) with knob [9].
GB
-- 12 --
C240Pe
During welding process the upper row of display shows actual welding voltage or
current, depending on selection with switch [12]. When welding process is stopped,
displayed values are ”frozen” (dimmed display).
6.8.2 Synergy control mode
In synergy control mode, the operator first has to preselect material/gas [16] and
wire diameter [17].
While changing the voltage (with the voltage selectors [2,3]) digital instrument [11]
and lamps [14,15] on the front panel show welding parameters.
Synergy status lamp [14] is green (only in synergy mode) when correct welding
parameters are set, or red when incorrect or not allowed welding parameters are set
(then machine operation is disabled!).
Note: Lamp is also red (in all control modes):
S if during welding (gun trigger pressed) -- any voltage selector [2, 3]
is operated, then the operation of the machine is disabled immediately until
the trigger is released,
S when the gun trigger is pressed while turning on the machine with switch [1].
One of the lamps [15] points at recommended current outlet (--) with appropriate
inductance [7,8].
Digital display [11] shows values depending on display selectors [12, 13]
and machine status.
Before welding start: the upper display shows expected values of welding current [A]
or voltage [V] (both only in SYNERGY mode); the lower display shows wire speed
reference [m/min] or recommended maximum thickness [mm] of workpiece.
During welding: upper display shows actual welding voltage or current, the lower
display -- as above.
After welding stop: the upper display shows last memorised (HOLD) values of
voltage or current (dimmed display).
Wire speed is set by program (stored in the microprocessor) and the knob [9] shall
be set to middle position ”0”. If necessary the operator may correct the preset speed
reference with that knob within +/-- 20% of the set value.
GB
-- 13 --
C240Pe
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 become blocked and cause overheating. To avoid
this you can use an airfilter.
The airfilter is an accessory. Ordering number can be found on page 20.
Welding gun
S Cleaning 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.
The brake hub
The hub is adjusted when delivered, if
readjustment is required, follow the instructions
below. Adjust the brake hub so that wire is slightly
slack when wire feed stops.
S Adjusting the braking torque:
S Turn the red handle to the locked position.
S Insert a screwdriver into the springs in the hub.
Turn the springs clockwise to reduce the braking torque
Turn the springs anticlockwise to increase the braking torque. NB: Turn both
springs through the same amount.
GB
-- 14 --
C240Pe
8 FAULT TRACING
Try these recommended checks and inspections before sending for an authorised service technican.
Type of fault
Actions
No arc S Check that the mains power supply switch is turned on.
S Check that the welding current supply and return cables are
correctly connected.
S Check that correct current value is set.
Welding current is interrupted
during welding
S Check whether the thermal overload trip has operated
(indicated by the orange lamp on the front).
S Check the main power supply fuses.
Thermal overload trips
operate frequently
S Check to see whether the air filters are clogged.
S Make 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 S Check that the welding current supply and return cables are
correctly connected.
S Check that the correct current value is set.
S Check that the correct welding wires are being used.
S Check the main power supply fuses.
S Check 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
Origo
TM
Mig C240 PRO, Origo
TM
Mig C240s PRO is designed and tested in accordance
with the international and European 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
Diagram
-- 15 --
dC240P
Origo
TM
Mig C240 PRO, 230/400--415V
-- 16 --
dC240P
Origo
TM
Mig C240s PRO, 230V
-- 17 --
dC240P
Origo
TM
Mig C240s PRO, 400--415V
Origo
T
M
Mig C240 PRO, Origo
T
M
Mig C240s PRO
Edition 061026
-- 18 --
oC240P
Valid for serial no. 627--XXX--XXXX
Ordering numbers
0349 304 657 Origo
TM
Mig C240 PRO 400--415V 3∼
∼∼
∼50/60Hz (welding gun PSF 250, 3m)
0349 304 658 Origo
TM
Mig C240 PRO 230V 3∼
∼∼
∼50/60Hz (welding gun PSF 250, 3m)
0349 304 659 Origo
TM
Mig C240s PRO 400--415V 3∼
∼∼
∼50/60Hz (welding gun PSF 250, 3m)
0349 304 660 Origo
TM
Mig C240s PRO 230V 3∼
∼∼
∼50/60Hz (welding gun PSF 250, 3m)
0349 305 983 Origo
TM
Mig C240 PRO 400--415V 3∼
∼∼
∼50/60Hz (welding gun PSF 250, 4,5m)
0349 305 984 Origo
TM
Mig C240 PRO 230V 3∼
∼∼
∼50/60Hz (welding gun PSF 250, 4,5m)
0349 305 985 Origo
TM
Mig C240s PRO 400--415V 3∼
∼∼
∼50/60Hz (welding gun PSF 250, 4,5m)
0349 305 986 Origo
TM
Mig C240s PRO 230V 3∼
∼∼
∼50/60Hz (welding gun PSF 250, 4,5m)
Origo
T
M
Mig C240 PRO, Origo
T
M
Mig C240s PRO
Edition 061026
-- 19 --
wC240P
W. F. Mechanism 0455 890 882
Item Denomination Ordering no. Notes
A Pressure roller 0455 907 001
B Feed roller
0367 556 001
0367 556 002
0367 556 006
0367 556 004
Ø 0.6--0.8mm Fe, Ss, cored wire.
Ø 0.8--1.0mm Fe, Ss, cored wire.
Ø 1.0--1.2mm cored wire.
Ø 1.0--1.2mm Al wire.
C Inlet nozzle 0466 074 001
D Insert tube
0455 894 001
0455 889 001
Plastic, must be used together with item 0455 885 001,
for welding with Al wire.
Steel, must be used together with item 0455 886 001.
E Outlet nozzle
0455 885 001
0455 886 001
Must be used together with item 0455 894 001,
for welding with Al wire.
Must be used together with item 0455 889 001.
The rollers are marked with wire dimension in mm, some are also marked with inch.
Welding with aluminium wires.
In order to weld with aluminium wires, proper rollers, nozzles and liners for aluminium wires MUST be
used. It is recommended to use 3m long welding gun for aluminium wires, equipped with appropriate
wear parts.
Origo
T
M
Mig C240 PRO, Origo
T
M
Mig C240s PRO
Edition 061026
Accessories
-- 20 --
aC240P
Digital meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0349 302 598
Transformer kit for CO
2
heater . . . . . . . . . . . 0349 302 250
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0349 302 599
Cable holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0349 303 362
Page is loading ...
-
1
-
2
-
3
-
4
-
5
-
6
-
7
-
8
-
9
-
10
-
11
-
12
-
13
-
14
-
15
-
16
-
17
-
18
-
19
-
20
-
21
ESAB Mig C240 PRO User manual
- Category
- Welding System
- Type
- User manual
- This manual is also suitable for
Ask a question and I''ll find the answer in the document
Finding information in a document is now easier with AI
