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B
AE
2ULJR
Engine driven welder
Instruction manual and spare parts list
0700 161 100
Valid for Origo
70
(':'
Valid for OrigoTMEDW 510D serial No. 730-xxx-xxxx
TM
EDW 610D serial No. 745-xxx-xxxx
CONTENTS Page
1 SAFETY 2
2 INTRODUCTION 4
3 TECHNICAL DATA 6
4 INSTALLATION 8
5 OPERATION 9
6 MAINTENANCE 10
7 FAULT TRACING 13
8 CIRCUIT DIAGRAM 14
9 SPARE PARTS LIST 15
1 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 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:
• its operation
• location of emergency stops
• its function
• relevant safety precautions
• welding
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
3. The workplace must:
• be suitable for the purpose
• be free from draughts
4. Personal safety equipment
• Always wear recommended personal safely 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
• Appropriate fire extinguishing equipment must be clearly marked and close at hand.
• Lubrication and maintenance must
6. EMF information
To reduce your exposure to electromagnetic fields, use the following procedures:
• Keep cables close together by twisting or taping them.
• Arrange cables to one side and away from the operator.
• Do not coil or drape cables around your body.
• Connect work clamp to workpice as close to the weld as possible.
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!
may only be curried out by a qualified electrician.
not
be carried out on the equipment during operation.
2
WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE
PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH
SHOULD BE BASED ON MANUFACTURER’S HAZARD DATA.
ELECTRICAL SHOCK - Can kill
•
Install and earth the welding unit in accordance with applicable standards.
•
Do not touch live electrical parts or electrode 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 keep fumes and gases 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.
•
Warn bystanders of the risk.
MOVING PARTS – Can injure
• Do not operate with guards or covers off.
• Stop engine before servicing.
• Keep away from moving parts.
FUEL – Can cause fire or explosion
• Stop engine and let it cool before checking or adding fuel.
• Do not add fuel while smoking or if unit is near any sparks or open flames.
• Do not spill fuel. If fuel is spilled, clean up before starting engine.
BATTERY EXPLOSION – Can blind
• Always wear a face shield, rubber gloves and protective clothing when working on a battery.
• Stop engine before disconnecting or connecting battery cables or servicing battery.
• Do not allow tools to cause sparks when working on a battery.
• Observe correct polarity (+ and -) on battery.
• Disconnect negative (-) cable first and connect it last.
MALFUNCTION – Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
WARNING!
Read and understand the instruction manual
before installing or operating.
Note! This product is solely intended for arc welding.
WARNING!
3
Do not use the power source for thawing frozen pipes.
2 INTRODUCTION
The Origo
TM
EDW 510/610D is a combined engine driven welding and electric power unit.
It is designed for working even under the toughest job requirements. It is suitable for MMA
welding with all types of DC electrodes, especially cellulose; scratch start TIG welding or
TIG with additional equipment for high frequency start and for arc air gouging. The
auxiliary power generator provides alternating current for power tools, lighting etc.
Continuous welding and auxiliary power can be used simultaneously.
The Origo
TM
EDW 510/610D is ideal for quality welding in assembly work, service and
repair in the field, e.g. pipelines, petrol-chemical plants, off-shore work etc.
Stationary form is a standard design. On request, the welding unit can be provided with
two or four wheel trailer.
Front control panel
213456
22
21
20
19
18
17
16
15
14
STOP
220V 220V
$
7
13
12
11
910
8
1 Engine control module
2 Fuel level gauge
3 Voltmeter (optional)
4 Ammeter (optional)
5 Current range switch
6 Welding current fine setting
7 Polarity switch (optional)
8 Workpiece connection
9 Welding terminal (MMA and TIG)
10 Gouging terminal
11 Socket 220V,16A (optional 110V)
12 Socket 220V,32A
13 Earth terminal
14 Remote control connection
15 Hot start off switch (optional)
16 Remote control switch
17 LED yellow - overheating
18 Circuit breaker - exciter circuit protection
19 Circuit breaker - fuel solenoid protection
20 Circuit breaker 220V
21 Circuit breaker 220V (optional 110V)
22 Emergency stop push button (optional)
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The engine is the F3L912, made by Deutz, a well known manufacturer with a world wide
service network.
The engine drives three-phase synchronous welding generator, single-phase auxiliary
power generator and their exciter unit. The complete rotor assembly is statically and
dynamically balanced to assure vibration-free operation and maximum bearing life.
Bearing is fully sealed, so that no lubrication is required during the exploitation. There are
no slip rings or brushes to maintain.
The welding unit canopy is designed for single side servicing and protects the machine. It
ensures correct air flow around the engine and the generator.
The front panel is fitted with engine starting controls, welding controls and auxiliary power
outputs. The engine control module (A2) is used to start and stop the engine and indicate
fault conditions: low oil pressure, high cylinder head temperature and low battery
charging. The module automatically shuts down the engine if the oil pressure is low or the
temperature is too high.
The module has an integral tamperproof LDC hours run counter to indicate total engine
run time.
Welding coarse settings are carried out by a three-phase inductor (L1) connected to the
generator windings star (G). The range switch (SA3) is three-positioned. AC current from
the generator (G) is rectified via the diode bridge (V1.1-V1.6), and the welding current
stabilization is carried by stabilizer (L2).
Welding current fine setting is made by a rheostat (RP1), which allows adjustment of
welding amperage from minimum to maximum of the coarse range.
OCV control circuit provides max open circuit voltage of 92V, regardless of the welding
current setting. The rheostat (RP1) does not affect on OCV because it is shorted when
the arc breaks. When the arc is struck, reed relay (KR1) is operated and allows
adjustment of welding current with the rheostat (RP1).
Optional hot start switch (SA4) disables the max OCV. Switch breaks the max OCV
control circuit and allows the arc striking with open circuit voltage of 65-92V depending
on current setting.
Optional remote control is available for fine current setting.
Polarity of weld outputs is selected by an optional polarity switch.
Optional voltmeter displays voltage at the weld output terminals.
Optional ammeter displays amperage output of the unit.
The thermostat (ST2) is placed on the diode bridge’s heat sink. It prevents the power
source from overheating. The thermostat reset automatically. The yellow LED lights up in
case of overheating.
The auxiliary power generator (G1) produces a maximum of 6,2 kVA. Two sockets (220V)
are available on the front panel (one socket 110V optional). The circuit breakers QF1 and
QF2 offer short-circuit protection, overload protection and earth fault protection
.
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3 TECHNICAL DATA
Origo
TM
EDW Origo
TM
EDW
Welding generator 510D 610D
Output current range 40-500A 40-700A
Permitted load:
at 25% duty cycle - 650A/25V
at 40% duty cycle 450A/38V 575A/43V
at 60% duty cycle 400A/36V 530A/41,2V
at 100% duty cycle 300A/32V 500A/40V
Open circuit voltage 92 V 92V
Insulation class H (180
0
C) H (1800C)
Auxiliary power generator
Max. output 6,2kVA, cosij 0,8 6,2kVA, cosij 0,8
Voltage 220V, 60Hz 220V, 60Hz
Earth fault protection 30mA 30mA
Simultaneous welding and power loads
300A/32V+6,2kVA 450A/38V+6,2kVA
Diesel engine Deutz F3L 912
Type 3-cylinder
Fuel code Diesel DIN 51601
Prime power at 1800 rpm, ISO 3046-1 32,0 kW
Reference conditions:
Ambient temperature +25
o
C
Altitude 100m
Relative humidity 30%
Speed:
no-load speed 1890 rpm
load speed 1800 rpm
Displacement 2,827 dm
3
Cooling air
Starting system, electrical 3kW /12V
Fuel tank capacity 90 l
Fuel consumption (at 100% duty cycle) 220 g/kWh (approx. 8,4 l/h)
Oil consumption (0,5% of fuel consumption) 0,042 l/h
Battery 12V/100Ah
Complete unit
Enclosure class IP23
Working ambient temperature -10
o
C to +40oC
Dimensions (LxWxH) 1610x850x990 mm
Standard EN 60974-1
Weight (dry) 775kg 795kg
Duty cycle
The duty cycle refers to the time as a percentage of a ten–minute period that you can weld
at a certain load without overloading.
Enclosure class
The IP code indicates enclosure class, i.e. the degree of protection against penetration by
solid objects and water. Equipment marked IP23 is designed for indoor and outdoor use.
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