ESAB | Mig C250 3ph | Service manual | ESAB Mig C250 3ph User manual

ESAB Mig C250 3ph User manual
Origo™
Mig C170 3ph, Mig C200 3ph,
Mig C250 3ph
Service manual
0349 300 064 GB 20180627
Valid for: serial no. 626-, 744-xxx-xxxx
TABLE OF CONTENTS
READ THIS FIRST ....................................................................................
3
INTRODUCTION .......................................................................................
4
TECHNICAL DATA ...................................................................................
5
WIRING DIAGRAM ...................................................................................
7
Component description .........................................................................
7
Origo™ Mig C170 3ph, 400-415V ..........................................................
8
Origo™ Mig C200 3ph, 400-415 V .........................................................
9
Origo™ Mig C250 3ph, 400-415 V .........................................................
10
Origo™ Mig C250 3ph, 230/400-415 V ..................................................
12
DESCRIPTION OF OPERATION ..............................................................
14
AP1 Control board..................................................................................
14
AP1:1 Power supply .............................................................................
16
AP1:2 Reference circuit........................................................................
16
AP1:3,4,5 Start / Stop, Thermal overload, Spot welding ......................
17
AP1:6 Burnback time............................................................................
17
AP1:7 Control amplifier and pulse width modulator .............................
18
AP1:8,9 Motor driving / braking ............................................................
18
AP1 - component layout .......................................................................
19
SERVICE INSTRUCTIONS .......................................................................
20
What is ESD? ..........................................................................................
20
Thermal switch (thermostat) replacement procedure ........................
20
Rights reserved to alter specifications without notice.
0349 300 064
© ESAB AB 2018
READ THIS FIRST
READ THIS FIRST
The maintenance and repair work should be performed by an experienced person, and
electrical work only by a trained electrician. Use only recommended replacement parts.
This service manual is intended for use by technicians with electrical/electronic training for
help in connection with fault-tracing and repair.
Use the wiring diagram as a form of index for the description of operation. The circuit board
is divided into numbered blocks, which are described individually in more detail in the
description of operation. All component names in the wiring diagram are listed in the
component description.
This manual contains details of all design changes that have been made up to and including
October 2017.
The OrigoTM Mig C170/C200/C250 3ph is designed and tested in accordance with
international and European standard IEC/EN 60974-1 and EN 60974-10.On completion
of service or repair work, it is the responsibility of the person(s) etc. performing the
work to ensure that the product does not depart from the requirements of the above
standard.
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© ESAB AB 2018
INTRODUCTION
INTRODUCTION
OrigoTM Mig C170/C200/C250 3ph is step controlled power source 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 changing -over the welding polarity + and - on the terminal by the
wire feed unit.
NOTE!
Dispose of electronic equipment at the recycling
facility!
In observance of European Directive 2012/19/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.
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© ESAB AB 2018
TECHNICAL DATA
TECHNICAL DATA
Origo™ Mig C170
3ph
Origo™ Mig C200
3ph
Origo™ Mig C250
3ph
400–415 V,
3~ 50/60Hz
400–415 V,
3~ 50/60Hz
230/400–415 V,
3~ 50/60Hz
100 % duty cycle
100 A
120 A
150 A
60 % duty cycle
130 A
150 A
190 A
35 % duty cycle
170 A
200 A
250 A
Setting range (DC)
30–170 A
30–200 A
40–280 A
Open circuit voltage
15.5–30.6 V1),
18.0–34.8 V2)
16.0–31.8 V
15.0–37.0 V
Open circuit power
310 W
210 W
340 W
Power factor at max load
0.97
0.97
0.971), 0.942)
Control voltage
42 V, 50/60 Hz
42 V, 50/60 Hz
42 V, 50/60 Hz
Wire feed speed
1.0–17 m/min
1.0–17 m/min
1.0–17 m/min
Burnback time
0.02–0.25 s
0.02–0.25 s
0.02–0.25 s
Spot welding
0.2–2.5 s
0.2–2.5 s
0.2–2.5 s
Welding torch connection EURO
EURO
EURO
Wire dimension range
0.6–0.8(Fe, SS)
0.6–1.0(Fe, SS)
0.6–1.2(Fe, SS)
1.0(Al)
1.0(Al)
1.0–1.2(Al)
0.8(FCW)
0.8–1.0(FCW)
0.8–1.2(FCW)
0.8–1.0(CuSi)
0.8–1.0(CuSi)
0.8–1.0(CuSi)
Max diameter/weight of
wire bobbin
300 mm/15 kg
300 mm/15 kg
300 mm/15 kg
Dimensions l×w×h
860x420x730 mm
860x420x730 mm
860×420×730 mm
Weight
63.5 kg1), 67.5 kg2) 72.5 kg
82 kg
Operating temperature
-10 to +40 °C
-10 to +40 °C
-10 to +40 °C
Enclosure class
IP 231), IP 212)
IP 231), IP 212)
IP 231), IP 212)
Voltage
Permissible load at
Application classification
1)
Valid for serial number 626-xxx-xxxx
2)
Valid from serial number 744-xxx-xxxx
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 / 104 °F, or below.
Enclosure class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration
by solid objects or water.
Equipment marked IP21 is intended for indoor use.
Equipment marked IP23 is intended for indoor and outdoor use.
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© ESAB AB 2018
TECHNICAL DATA
Application class
The symbol
indicates that the power source is designed for use in areas with increased
electrical hazard.
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© ESAB AB 2018
WIRING DIAGRAM
WIRING DIAGRAM
Component description
CAUTION!
STATIC ELECTRICITY can damage circuit boards and
electronic components.
•
•
Observe precautions for handling electrostatic
sensitive devices.
Use proper static-proof bags and boxes.
AP1
Control circuit board
AP2
Digital instrument, accessory
C1, C2, Capacitor 0,1 μF/250 V
CVS
EV1
Fan
KM1
Contactor 42V, 50-60Hz
L1
Inductor
L2, L3 Ferrite core
HL1
Lamp, white, On/Off, 42V
M1
Feed unit motor
QF1
Switch, ON/OFF
QF2
Switch welding voltage selector: 8-step for Origomag C170 3ph,
10-step for Origomag C200/C250 3ph
RVS
Resistor
RP1
Potentiometer, wire feed speed 10k
RP2
Potentiometer with switch, spot welding 470k
RI
Shunt, accessory
RL
Resistor
ST1,
ST2
Thermal overload cutout, operates at 150 °C. ST1 is mounted on secondary winding
of TM1. ST2 is mounted in the rectifier bridge (from serial no. 744-xxx-xxxx).
TC1
Control transformer
TC2
Transformer for CO2 heater, accessory
TC3
Transformer for digital instrument, accessory
TM1
Main transformer
V1
Diode bridge
VH
LED yellow indication, thermal overload
XTP
Welding current contact, welding polarity change-over
XT4
Terminal block, accessory
YV1
Gas valve
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© ESAB AB 2018
WIRING DIAGRAM
Origo™ Mig C170 3ph, 400-415V
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© ESAB AB 2018
WIRING DIAGRAM
Origo™ Mig C200 3ph, 400-415 V
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© ESAB AB 2018
WIRING DIAGRAM
Origo™ Mig C250 3ph, 400-415 V
Valid for serial no. 626-xxx-xxxx
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© ESAB AB 2018
WIRING DIAGRAM
Valid from serial no. 744-xxx-xxxx
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© ESAB AB 2018
WIRING DIAGRAM
Origo™ Mig C250 3ph, 230/400-415 V
Valid for serial no. 626-xxx-xxxx
0349 300 064
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© ESAB AB 2018
WIRING DIAGRAM
Valid from serial no. 744-xxx-xxxx
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© ESAB AB 2018
DESCRIPTION OF OPERATION
DESCRIPTION OF OPERATION
AP1 Control board
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© ESAB AB 2018
DESCRIPTION OF OPERATION
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© ESAB AB 2018
DESCRIPTION OF OPERATION
AP1:1 Power supply
Transformer TC1 supplies indicating lamp HL1 and rectifier bridge BR1 with 27 V AC. The
unsmoothed DC output from BR1 is smoothed by capacitors C5 and C25 to produce an
open-circuit voltage of 38 V ±10%.
This provides the power supply for the wire feeder motor.
Connections T6 and T7 supply 20 V AC from transformer TC1 to diodes D18 - D21. The
rectified voltage is about 24 V, voltage regulator VR1 is supplied via diode D1 to provide a
regulated 15 ±0.6 V supply.
AP1:2 Reference circuit
Potentiometer R49 controls the wire feed speed and is connected to terminals P1 - P3. It is
energised via resistors R51 - R55 and R23. The reference voltage is supplied through
resistor R20 to the error amplifier.
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© ESAB AB 2018
DESCRIPTION OF OPERATION
AP1:3,4,5 Start / Stop, Thermal overload, Spot welding
Start / Stop circuit
When the torch trigger switch SB1 is not activated, the voltage between M3 and M4 is 24 V.
Pressing the trigger switch shorts the circuit, producing a voltage of 0 V between M3 and M4.
Thermal overload circuit
The power source contains two thermal overload cutouts, wired in series and connected to
inputs T8 and T9. If either of them operates, the torch trigger switch circuit cannot be short
-circuited, with the result that wire feed cannot be started. When either of the thermal cutouts
has operated, LED V7 is energised to indicate this via diode D7.
Spot welding circuit
Potentiometer R50 controls the spot welding time and incorporates a switch. When in the
zero position, the switch is open.
When the switch in R50 and torch trigger switch SB1 are closed, capacitor C22 charges up
through resistors R32 and R50. Wire feed stops when the voltage on C22 reaches 8.8 V. The
trigger switch must be released and then pressed again before a new spot weld can be
made.
The spot welding time can be adjusted between 0.2 and 2.5 seconds ±30%.
AP1:6 Burnback time
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© ESAB AB 2018
DESCRIPTION OF OPERATION
The burn-back time is the time from when wire feed ceases until contactor KM1 drops off.
During welding, the voltage at pin 13 of IC2 is low. The output of the inverter at pin 14 is
therefore high, turning on transistor Q2 and activating relay RE1.
When the torch trigger switch is released, or when the spot welding time expires, capacitor
C23 charges up via resistors R36, R37 and R38. When the voltage across C23 reaches
8.8 V, output 14 of IC2 goes low, turning off Q2 and causing relay RE1 to drop off.
AP1:7 Control amplifier and pulse width modulator
The control amplifier compares the set value speed signal with the actual speed and supplies
a control signal to the pulse width modulator. The actual value speed signal is provided by
measuring the motor voltage.
The pulse width modulator controls the frequency and pulse time of current to the wire feed
motor.
AP1:8,9 Motor driving / braking
Motor driving circuit
The output stage of the pulse width modulator is connected to transistor Q1 via resistor R16.
A motor current signal is provided by measuring the voltage across resistor R4, connected to
transistor Q1. If the voltage across R4 exceeds 1.1 V ±60 mV, the gate pulses to Q1 are
inhibited. This provides a current limit of about 11 A.
Motor braking circuit
When wire feed is to stop, the pulse width modulator turns off the pulses to Q1.
Transistors Q3 and Q4 turn on: transistor Q4 provides a path for dynamic braking current to
flow through resistor R47 and diode D17.
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© ESAB AB 2018
DESCRIPTION OF OPERATION
AP1 - component layout
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© ESAB AB 2018
SERVICE INSTRUCTIONS
SERVICE INSTRUCTIONS
CAUTION!
STATIC ELECTRICITY can damage circuit boards and
electronic components.
•
•
Observe precautions for handling electrostatic
sensitive devices.
Use proper static-proof bags and boxes.
What is ESD?
A sudden transfer or discharge of static electricity from one object to another. ESD stands
for Electrostatic Discharge.
How does ESD damage occur?
ESD can cause damage to sensitive electrical components but is not dangerous to people.
ESD damage occurs when an ungrounded person or object with a static charge comes into
contact with a component or assembly that is grounded. A rapid discharge can occur,
causing damage. This damage can take the form of immediate failure, but it is more likely
that system performance will be affected and the component will fail prematurely.
How do we prevent ESD damage?
ESD damage can be prevented by awareness. If static electricity is prevented from building
up on you or on anything at your work station, then there cannot be any static discharges.
Nonconductive materials (e.g. fabrics), or insulators (e.g. plastics) generate and hold static
charge, so you should not bring unnecessary nonconductive items into the work area. It is
obviously difficult to avoid all such items, so various means are used to drain off any static
discharge from persons to prevent the risk of ESD damage. This is done by simple devices:
wrist straps, connected to ground, and conductive shoes.
Work surfaces, carts and containers must be conductive and grounded. Use only antistatic
packaging materials. Overall, handling of ESD-sensitive devices should be minimized to
prevent damage.
Thermal switch (thermostat) replacement procedure
1.
2.
3.
4.
Spare thermostat must be the same type as replaced one.
Spare thermostat should be mounted within radius of 10 mm or less from broken
thermostat. If it's possible and safe for transformer winding, broken thermostat may be
removed. Then the spare thermostat is to be mounted right in place of broken one.
Spare thermostat should adjoin protected winding as tight as possible.
Spare thermostat must be secured with silicone glue of working temperature of 200 °C
or higher.
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© ESAB AB 2018
SERVICE INSTRUCTIONS
0349 300 064
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© ESAB AB 2018
For contact information visit esab.com
http://manuals.esab.com
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