ESAB Mag C201 User manual

Mig C141/C151 Mag C171/C201/C251

Origo

 Service manual 0349 300 076 080529 Valid for serial no. 736--xxx--xxxx

READ THIS FIRST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM, Mig C141 / C151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Component description Mig C141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Mig C151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DESCRIPTION OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1 Control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:1 Control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:2 Thermal overload cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:3 RFI suppression and base load resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:4 Motor drive circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1 -- Mig C141 / C151 component positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM, Mag C171 / C201 Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Mag C171 Mag C201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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DESCRIPTION OF OPERATION AP1 Control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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AP1:1 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:2 Reference circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:3,4,5 Start / Stop, Thermal overload, Spot welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:6 Burnback time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:7 Control amplifier and pulse width modulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:8,9 Motor driving / braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1 -- Mag C171 / C201 component positions WIRING DIAGRAM, Mag C251 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Component description Mag C251 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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DESCRIPTION OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1 Control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:1 Power supply AP1:2 Start / Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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AP1:3 Spot welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:4 Wire feed speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:5 Motor driving / braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AP1:6 Burnback time, contactor, gas valve AP1:7 Thermal overload cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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AP1 -- Mag C251 component positions SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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What is ESD?

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Thermal switch (thermostat) replacement procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY INSTALLATION Placing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Assembly of components Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Mains power supply OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Connection and control devices Welding without gas Wire feed pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Replacing and inserting wire Overheating protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4 4 5 7 7 8 9 10 10 11 11 11 11 12 13 13 15 16 17 17 19 19 20 21 21 22 23 24 24 26 27 27 27 27 28 28 29 30 30 31 32 32 32 33 33 35 35 35 37 38 38 39 40 40 40 41 TOCe -- 2 --

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULT TRACING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ORDERING OF SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 41 42 42 43 TOCe -- 3 --

READ THIS FIRST

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 May 2008.

The Origo accordance with international and European standard IEC/EN 60974--1 and EN 60974--10.

TM Mig C141/C151, Mag C171/C201/C251 are designed and tested in 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.

INTRODUCTION

Origo

TM

Mig C141/C151, Mag C171/C201/C251

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 by the wire feed unit.

1sC1425 -- 4 - Edition 080529

TECHNICAL DATA

Voltage Permissible load at 100% duty cycle 60 % duty cycle @ % duty cycle 20 % duty cycle Setting range (DC) Open circuit voltage Open circuit power Power factor at max load Control voltage Wire feed speed Burnback time Spot welding Welding gun connection Wire dimension range Max diameter/weight of wire bobin Dimensions lxwxh Weight Operating temperature Enclosure class Application classifica tion Origo TM Mig C141 220--230V, 1 ∼ 50/60Hz 42A/16,1V 54A/16,7V 83A/18,2V @ 25% 100A/17,0V 35A/15,7V--83A/18,2V (130A/13,4) 18,7--25,1V 75W 0,91 220--230V, 50/60Hz 2,0--14m/min - - fixed 0,6--0,8(Fe) 1,0 (Al) 0,8(cored) 0,8(CuSi) 200mm/5kg 650x300x550 25kg --10 ÷ +40 o C IP 23 Origo TM Mig C151 220--230V, 1 ∼ 50/60Hz 67A/17,4V 87A/18,3V 95A/18,7V @ 50% 150A/16,0V 30A/15,5V--95A/18,7V (150A/16,0V) 17,3--24,3V 110W 0,92 220--230V, 50/60Hz 2,0--14m/min - - fixed 0,6--0,8(Fe) 1,0 (Al) 0,8(cored) 0,8(CuSi) 200mm/5kg 650x300x550 37,5kg --10 ÷ +40 o C IP 23 Origo TM Mag C171 220--230V, 1 ∼ 50/60Hz 76A/17,8V 98A/18,9V 155A/21,7V @ 25% 170A/21,0V 30A/15,5V--155A/21,7 V (170A/21,0) 22,4--44,5V 270W 0,91 42V, 50/60Hz 1,0--17m/min 0,02--0,25s 0,2--2,5s EURO 0,6--0,8(Fe) 1,0(Al) 0,8(cored) 0,8--1,0(CuSi) 300mm/15kg 860x420x730 59kg --10 ÷ +40 o C IP 23 Origo TM Mag C251 220--230V, 1 ∼ 50/60Hz Voltage Permissible load at 100% duty cycle 60 % duty cycle @ % duty cycle 20 % duty cycle Setting range (DC) Open circuit voltage Open circuit power Power factor at max load Origo TM Mag C201 220--230V, 1 ∼ 50/60Hz 90A/18,5V 115A19,7V 185A/23,3V @ 23% 200A/23,0V 30A/15,5V--185A/23,3V (200A/23,0V) 19,6--44,9V 120W 0,89 110A/19,5V 140A/21,0V 200A/24,0V @ 30% 250A/21,0V 40A/16,0V--200A/24,0V (250A/21,0V) 19,0--41,5V 200W 0,92 1sC1425 -- 5 - Edition 080529

Control voltage Wire feed speed Burnback time Spot welding Welding gun connection Wire dimension range 42V, 50/60Hz 1,0--17m/min 0,02--0,25s 0,2--2,5s EURO 0,6--1,0(Fe) 1,0(Al) 0,8--1,0(cored) 0,8--1,0(CuSi) 300mm/15kg 42V, 50/60Hz 1,9--19m/min 0--0,25s 0,2--2,5s EURO 0,6--1,2(Fe) 1,0--1,2(Al) 0,8--1,2(cored) 0,8--1,0(CuSi) 300mm/15kg Max diameter/weight of wire bobin Dimensions lxwxh Weight Operating temperature Enclosure class Application classifica tion 860x420x730 68kg --10 ÷ +40 o C IP 23 860x420x730 94kg --10 ÷ +40 o C IP 23 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 electrical hazard.

indicates that the power source is designed for use in areas with increased 1sC1425 -- 6 - Edition 080529

WIRING DIAGRAM, Mig C141 / C151

Component description

ESD SSSS SSSS WARNING !

STATIC ELECTRICITY can damage circuit boards and electronic components.

Observe precautions for handling electrostatic sensitive devices.

Use proper static--proof bags and boxes.

AP1 C1, C2, C3 C4 C5 CO EV1 KM1 L1 M1 QF1 R13 R01, R02 R1 RO ST1 TC2 TM1 V1 V2 VH XTP XT1, XT4 Circuit board Capacitor 0,1uF/250V Capacitor 47uF/275V Capacitor 2,2uF/300V Capacitor, C140: 33mF/40V, C150: 68mF/40V Fan Contactor 230V, 50--60Hz Inductor Feed unit motor Switch, ON/OFF and C141: 4--step welding voltage selector C151: 7--step welding voltage selector Potentiometer, wire feed speed (placed on AP1) Resistor 15 Ω /20W Resistor 100k Ω /2W Resistor 15 Ω /20W Thermal switch, operates at 150 o C (C141) or at 130 o C (C151) .

Thermal switch is mounted on the inductor.

Transformer for CO 2 heater, accessory Main transformer Diode bridge Diode bridge LED yellow indication, thermal overload Main welding current contact, single -- pole Terminal block 1sC1425 -- 7 - Edition 080529

Mig C141

1sC1425 -- 8 - Edition 080529

Mig C151

1sC1425 -- 9 - Edition 080529

DESCRIPTION OF OPERATION

AP1 Control board

1sC1425 clka0e02 -- 10 - Edition 080529

AP1:1 Control circuit

Pressing trigger switch SB1 on the welding torch energises relay RE1 from control power transformer TR1. The contacts on the relay connect main transformer TM1 to the mains power supply.

The power supply to RE1 is half--wave rectified by D1. Resistor R1 is connected in series with the relay and drops the voltage to it. Capacitor C1 (220 µ F) smoothes the voltage. It also delays the drop--off of relay RE1 by about 25 ms, to provide a burnback time.

AP1:2 Thermal overload cutout

In the event of a thermal overload, thermal overload cutout ST1 interrupts the secondary circuit from TR1, causing relay RE1 to drop off and de--energising the welding circuit. When not operated (i.e. with closed contacts), the cutouts short--circuit inputs B6 and B7.

Operation of either of the cutouts is indicated by LED V1. Interruption of the cutout circuit energises the LED via D2, R3 and D3. D2 is a half--wave rectifier, R3 limits the current through the LED and D3 protects it against reverse voltage.

AP1:3 RFI suppression and base load resistors

Capacitors C4 -- C6 protect against RFI. Resistors R12 and R15 provide a minimum base load for the rectifier bridge: in addition, they act as discharge resistors for the capacitors.

AP1:4 Motor drive circuit

The wire feed motor is powered by the rectified secondary voltage from main transformer TM1.

Pressing the welding torch trigger switch SB1 provides a supply to thyristor TY1 via contact B4 from the positive side of the main power rectifier VC1.

Resistors R10 and R14 limit the motor starting current: excessive starting current would demagnetise the motor. D9 is a squelch diode protecting against back--emf from the motor.The ignition circuit for TY1 consists of R2, R4, R5, D5 and C2.

When Q1 is not conducting, operation of the circuit is as follows: If the voltage at B4 exceeds the motor voltage, C2 charges via R2, R4 and R5.

When the voltage on C2 reaches the trigger voltage (0.5 -- 1.5 V), thyristor TY1 fires. This means that TY1 conducts each half--cycle when Q1 is not conducting.

D5 protects C2 against negative voltage when Q1 conducts.

Motor voltage control C3, R11 and potentiometer R13 form a low--pass filter circuit for the motor supply. R13 picks off a suitable fraction of the motor voltage for connection to the base of Q1 via diode D6. Q1 starts to conduct at a bases voltage of 0.7 V.

C2 charges more slowly, which means that thyristor TY1 fires later. Motor voltage is lowest when R13 is in its upper position, the minimum position.

The base voltage is then high and Q1 conducts. The charging time for C2 becomes so long that thyristor TY1 misses some half cycles, firing only (for example) on every third cycle.

When R13 is in its lower (= maximum) position, the base voltage on Q1 is low and Q1 does not conduct. In this state, zener diode D7 determines the maximum motor voltage.

1sC1425 -- 11 - Edition 080529

AP1 -- Mig C141 / C151 component positions

clka0e03 1sC1425 -- 12 - Edition 080529

WIRING DIAGRAM, Mag C171 / C201

RO RVS RP1 RP2 RI RL ST1






AP1 AP2 C1, C2, CVS EV1 KM1 L1 L2, L3 LF1 M1 QF1 QF2 TC1 TC2 TC3 Circuit board Digital instrument, accessory Capacitor 0,1uF/250V Fan Contactor 42V, 50--60Hz Inductor Ferrite core Lamp, white, On/Off, 230V Feed unit motor Switch, ON/OFF Switch, 8--step welding voltage selector for C171 Switch, 12--step welding voltage selector for C201 Resistor 15 Ω /20W Resistor Potentiometer, wire feed speed Potentiometer with switch, spot welding Shunt, accessory Resistor C171: Thermal switch, operates at 150 o C. Thermal switch is mounted on the inductor.

C201: Thermal switch, operates at 130 o C. Thermal switch is mounted on the transformer.

Control transformer Transformer for CO 2 heater, accessory Transformer for digital instrument, accessory 1sC1425 -- 13 - Edition 080529

TM1 V1 VH XTP XT1, XT4 YV1 Main transformer Diode bridge LED yellow indication, thermal overload Main welding current contact, single -- pole Terminal block Gas valve 1sC1425 -- 14 - Edition 080529

Mag C171

1sC1425 -- 15 - Edition 080529

Mag C201

1sC1425 -- 16 - Edition 080529


AP1 Control board

1sC1425 -- 17 - clka1e03 Edition 080529

1sC1425 clka1e04 -- 18 - Edition 080529

AP1:1 Power supply

clka1e06 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 in the fan--cooled machines and somewhat higher in the 3--phase LKA 180. This supply powers fan EV1 in the fan--cooled machines. Voltage regulator VR1 is supplied via diode D1 to provide a regulated 15 ᐔ 0.6 V supply.

AP1:2 Reference circuit

1sC1425 clka1e07 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.

-- 19 - Edition 080529

AP1:3,4,5 Start / Stop, Thermal overload, Spot welding

clka1e08 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 machine contains thermal overload cutout, connected to inputs T8 and T9.

If it operates, the torch trigger switch circuit cannot be short--circuited, with the result that wire feed cannot be started. When the thermal cutout 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 ᐔ 30%.

1sC1425 -- 20 - Edition 080529

AP1:6 Burnback time

clka1e09 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.

1sC1425 -- 21 - Edition 080529

AP1:8,9 Motor driving / braking

clka1e10 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 ᐔ 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.

1sC1425 -- 22 - Edition 080529

AP1 -- Mag C171 / C201 component positions

clka1e05 1sC1425 -- 23 - Edition 080529

WIRING DIAGRAM, Mag C251






AP1 AP2 C1, C2, CVS EV1 KM1 L1 L2, L3 LF1 M1 QF1 QF2 RO RVS RP1 RP2 RI RL ST1 TC1 TC2 TC3 TM1 V1 VH Circuit board Digital instrument, accessory Capacitor 0,1uF/250V Fan Contactor 42V, 50--60Hz Inductor Ferrite core Lamp, white, On/Off Feed unit motor Switch, ON/OFF Switch, 12--step welding voltage selector Resistor 15 Ω /20W Resistor Potentiometer, wire feed speed Potentiometer with switch, spot welding Shunt, accessory Resistor Thermal switch, operates at 130 o C. Thermal switch is mounted on the transformer.

Control transformer Transformer for CO 2 heater, accessory Transformer for digital instrument, accessory Main transformer Diode bridge LED yellow indication, thermal overload -- 24 - Edition 080529 1sC1425

XTP XT1, XT4 YV1 Main welding current contact, single -- pole Terminal block Gas valve 1sC1425 -- 25 - Edition 080529

Mag C251

1sC1425 -- 26 - Edition 080529


AP1 Control board AP1:1 Power supply

The circuit board uses two different supply voltages: 16 V for the electronics and 42 V for power supply to the motor, contactor and gas valve.

clkb0e05 Power supply to the electronic circuitry The 16 V power supply from transformer TC1 is rectified by diodes D3--D6 and regulated to 15 V by voltage regulator VR1.

42 V power supply A_42VAC and B_42VAC are used as control power supplies for the contactor and gas valve. Indicating lamp HL1 is mounted on the front of the machine and shows that the power is turned on.

The supply is rectified by diode bridge BR1. The output voltage (60 V) supplies the wire feed unit motor.

AP1:2 Start / Stop

clkb0e07 Closing contact SB1 on the welding torch starts the welding process.

1sC1425 -- 27 - Edition 080529

Welding gun trigger switch Gas valve Wire feed Contactor Start-- stop sequence.

AP1:3 Spot welding

T 1 0 1 T 1 0 T1 = Burn--back time 1 0 1 0 1 clkb0e08 Spot welding is active when the switch in potentiometer RP2 is closed. Spot welding time is adjustable between 0.2 and 2.5 seconds.

If the welding torch trigger switch is released while a spot weld is being made, the welding sequence will be interrupted.. If the switch is held closed for longer than the spot weld time, welding stops when the spot weld time is up.

To restart, the switch must be released and then operated again.

AP1:4 Wire feed speed

The wire feed speed adjustment range is 1.9 to 19 metre/minute.

clkb0e06 The +5.1 V reference voltage ( ± 1 %) is derived from the PWM circuit, which generates gate pulses for the motor drive transistor.

1sC1425 -- 28 - Edition 080529

AP1:5 Motor driving / braking

black red 1sC1425 clkb0e12 The motor is powered by the smoothed +60 V supply. Pulse width modulation of transistor Q5 controls the motor voltage. The pulse frequency is about 9 kHz, and maximum conduction time of the pulses is about 98 % of the pulse cycle time.

During the Off parts of the pulse cycle, the motor current freewheels through diode D35.

At 24 V motor supply voltage, the wire feed roller speed is 160 r/min a roller speed of 200 r/min, the wire feed speed is 19 m/min ± 5 %.

± 5 %. At Speed control The gate pulses to transistor Q5 are generated by a PWM circuit. Resistors R84 and R85 form a potential divider, providing a voltage signal that is proportional to the wire speed. The PWM circuit compares the set speed with the actual speed.

Current limit The current limit is set at 5.5 A. The motor current is measured by resistor R68, which produces a voltage drop proportional to the current (1 A = 100 mV).

The current limit restricts the conduction time of the gate pulses to transistor Q5.

Braking When the motor starts, capacitor C22 charges via diode D18. The voltage is limited to 15 V by zener diode D13. The LED in optocoupler IC4 is activated when braking is required, connecting C22 (15 V) to the gate of transistor Q3.

The transistor conducts and short--circuits the motor voltage via resistors R69 and R70, which limit the braking current to about 20 A.

-- 29 - Edition 080529

AP1:6 Burnback time, contactor, gas valve

clkb0e11 Burnback time The burn--back time is the time from when motor braking starts until the main contactor opens. When welding stops, capacitor C38 is discharged through potentiometer R21. The time can be adjusted from 0 to 0.25 seconds.

Energising the contactor The contactor is controlled by triac TC2.

Gas valve The gas valve is connected to board contacts A5 and A6, it receives its power supply from triac TC2 via resistor R20 (0 Ω ).

AP1:7 Thermal overload cutout

1sC1425 The thermal overload cutout ST1 is mounted on the cooling fins of the diode bridge, and operates at a temperature of 130 ° C.

A current normally flows through the cutouts from the +20 V supply via R2 and D2, and from the +15 V supply via R8. The voltage at contact C1 is kept low by the switch. If a cutout operates, C1 goes high and the output signals from the board are disabled.

Operation of the cutout causes a current to flow from +20 V to 0 V via R2, D1 and LED V7, which indicates operation of the cutout.

-- 30 - Edition 080529

AP1 -- Mag C251 component positions

clkb0e13 1sC1425 -- 31 - Edition 080529

SERVICE INSTRUCTIONS





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 10mm or less from broken thermostat. If it’s possible and safe for transformer/inductor 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 o C or higher.

-- 32 - Edition 080529 1sC1425

INSTRUCTIONS

This chapter is an extract from the instructions for Mig C141/151, Mag C171/C201/C251.

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.

2.

3.

4.

Anyone who uses the welding equipment must be familiar with: S S S S S its operation location of emergency stops its function relevant safety precautions welding 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 The workplace must: S be suitable for the purpose S be free from draughts 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 S 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.

WARNING!

Read and understand the instruction manual before installing or operating.

2sC1425 -- 33 - Edition 080529

WARNING

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 S S Install and earth the welding 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.

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.

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.

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!

-- 34 - Edition 080529 2sC1425

INSTALLATION

The installation must be executed by a professional.

Note!

Connect the power source to the electricity mains with a network impedance of (C141 -- 0,41; C151 -- N/A; C171 -- N/A; C201 -- 0,32; C251 -- 0,212) ohm or lower. If the network impedance is higher, there is a risk of flicker in the illuminators.

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.

Placing

Position the welding power source such way that its cooling air inlets and outlets are not obstructed.

Assembly of components WARNING!

For packing and shipment of the machine the wheels are detached from the unit.

Before use attach the wheels according to instruction.

Origo

TM

Mig C141

2sC1425 -- 35 - Edition 080529

Origo

TM

Mig C151 1.

2.

3.

2sC1425 -- 36 - Edition 080529

Origo

TM

Mag C171/C201/C251 1.

2.

3.

Electrical installation

2sC1425 -- 37 - Edition 080529

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 Voltage V Current A at 100% duty cycle at 60% duty cycle at @% duty cycle at 20% duty cycle Cable area mm 2 Fuse slow A Origo TM Mig C141 220--230V, 1 ∼ 50/60Hz 5,1 7,0 11,5A @25% 13,8 3 x 1.5

10 Origo TM Mig C151 220--230V, 1 ∼ 50/60Hz 8,3 12,0 13,0 @50% 20,4 3 x 1.5

10 (16*) Origo TM Mag C171 220--230V, 1 ∼ 50/60Hz 12,0 15,7 27,8 @ 25% 29,7 3 x 1.5

16 Origo TM Mag C201 220--230V, 1 ∼ 50/60Hz 13,0 18,2 36,2 @ 23% 39,0 3 x 2.5

20 Origo TM Mag C251 220--230V, 1 ∼ 50/60Hz 16,6 23,4 38,7 @ 30% 47,5 3 x 4,0 35 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.

*-- in the supply networks of high level of short circuit power (low impedance of network) it is recommended to use 16A fuse.

OPERATION

General safety regulations for the handling of the equipment appear from page 33. Read through before you start using the equipment!

WARNING!

Rotating parts can cause injury, take great care.

WARNING!

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.

2sC1425 -- 38 - Edition 080529

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 !

Connection and control devices

1 2 Mains supply switch with indicating lamp, only in C171/C201/C251 Orange indicating lamp, overheating 5a 6 7 Return cable with clamp, fixed, only in C140/C150/C170/C200 Knob for spot welding -- ON/OFF and time setting, only in C171/C201/C251 Knob for wire speed setting 3 4 4a Welding voltage switch C141: OFF + 4 steps (mains ON/OFF) C151: OFF + 7 steps (mains ON/OFF) C171: 8 steps C201: 12 steps C251: 12 steps EURO -- connector for welding gun, only in C171/C201/C251 Welding gun, fixed, only in C141/C151 8 9 Digital instrument -- V / A, only in C171/C201/C251 (option,see user manual) Knob for burn--back time setting.

In C251 located in wire feeder compartment.

In C171/C201 located on control board.

5 Connection for return cable (--),only in C251 2sC1425 -- 39 - Edition 080529

Welding without gas 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).

S S

Replacing and inserting wire

S Open the side panel.

Disconnect the pressure sensor by folding it backwards, the pressure rollers slide up.

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.

2sC1425 -- 40 - Edition 080529

S S S Make sure that the wire goes properly into the feed roller track and into the outlet nozzle and the wire guide.

Secure the pressure sensor.

Close the side panel.

Overheating protection

When the machine is switched on with the mains switch [1] or [3] depending on machine model, indicating lamp [1] is on and lamp [2] 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 [2] on the front of the machine.

It resets automatically when the temperature has fallen.

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.

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 be come blocked and cause overheating.

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.

springs through the same amount.

NB:

Turn both 2sC1425 -- 41 - Edition 080529

FAULT TRACING

Try these recommended checks and inspections before sending for an authorised service technican.

No arc Type of fault Welding current is interrupted during welding Thermal overload trips operate frequently Poor welding performance S S S S S S S S S S S S Actions Check that the mains power supply switch is turned on.

Check that the welding current supply and return cables are correctly connected.

Check that correct current value is set.

Check whether the thermal overload trip has operated (indicated by the orange lamp on the front).

Check the main power supply fuses.

Check to see whether the air inlets/outlets are clogged.

Make sure that you are not exceeding the rated data for the power source (i.e. that the unit is not being overloaded).

Check that the welding current supply and return cables are correctly connected.

Check that the correct current value is set.

Check that the correct welding wires are being used.

Check the main power supply fuses.

Check the wire feed unit -- if proper rolls are applied and properly set the pressure of the wire feeder’s pressure rollers

ORDERING OF SPARE PARTS

Spare parts may be ordered through your nearest ESAB dealer, see the last page of this publication.

2sC1425 -- 42 - Edition 080529

NOTES

notes -- 43 --

notes -- 44 --

ESAB subsidiaries and representative offices

Europe AUSTRIA ESAB Ges.m.b.H

Vienna--Liesing Tel: +43 1 888 25 11 Fax: +43 1 888 25 11 85 BELGIUM S.A. ESAB N.V.

Brussels Tel: +32 2 745 11 00 Fax: +32 2 745 11 28 THE CZECH REPUBLIC ESAB VAMBERK s.r.o.

Vamberk Tel: +420 2 819 40 885 Fax: +420 2 819 40 120 DENMARK Aktieselskabet ESAB Herlev Tel: +45 36 30 01 11 Fax: +45 36 30 40 03 FINLAND ESAB Oy Helsinki Tel: +358 9 547 761 Fax: +358 9 547 77 71 FRANCE ESAB France S.A.

Cergy Pontoise Tel: +33 1 30 75 55 00 Fax: +33 1 30 75 55 24 GERMANY ESAB GmbH Solingen Tel: +49 212 298 0 Fax: +49 212 298 218 GREAT BRITAIN ESAB Group (UK) Ltd Waltham Cross Tel: +44 1992 76 85 15 Fax: +44 1992 71 58 03 ESAB Automation Ltd Andover Tel: +44 1264 33 22 33 Fax: +44 1264 33 20 74 HUNGARY ESAB Kft Budapest Tel: +36 1 20 44 182 Fax: +36 1 20 44 186 ITALY ESAB Saldatura S.p.A.

Mesero (Mi) Tel: +39 02 97 96 81 Fax: +39 02 97 28 91 81 THE NETHERLANDS ESAB Nederland B.V.

Amersfoort Tel: +31 33 422 35 55 Fax: +31 33 422 35 44 NORWAY AS ESAB Larvik Tel: +47 33 12 10 00 Fax: +47 33 11 52 03 POLAND ESAB Sp.zo.o.

Katowice Tel: +48 32 351 11 00 Fax: +48 32 351 11 20 PORTUGAL ESAB Lda Lisbon Tel: +351 8 310 960 Fax: +351 1 859 1277 SLOVAKIA ESAB Slovakia s.r.o.

Bratislava Tel: +421 7 44 88 24 26 Fax: +421 7 44 88 87 41 SPAIN ESAB Ibérica S.A.

Alcalá de Henares (MADRID) Tel: +34 91 878 3600 Fax: +34 91 802 3461 SWEDEN ESAB Sverige AB Gothenburg Tel: +46 31 50 95 00 Fax: +46 31 50 92 22 ESAB international AB Gothenburg Tel: +46 31 50 90 00 Fax: +46 31 50 93 60 SWITZERLAND ESAB AG Dietikon Tel: +41 1 741 25 25 Fax: +41 1 740 30 55 North and South America ARGENTINA CONARCO Buenos Aires Tel: +54 11 4 753 4039 Fax: +54 11 4 753 6313 BRAZIL ESAB S.A.

Contagem--MG Tel: +55 31 2191 4333 Fax: +55 31 2191 4440 CANADA ESAB Group Canada Inc.

Missisauga, Ontario Tel: +1 905 670 02 20 Fax: +1 905 670 48 79 MEXICO ESAB Mexico S.A.

Monterrey Tel: +52 8 350 5959 Fax: +52 8 350 7554 USA ESAB Welding & Cutting Products Florence, SC Tel: +1 843 669 44 11 Fax: +1 843 664 57 48 Asia/Pacific CHINA Shanghai ESAB A/P Shanghai Tel: +86 21 5308 9922 Fax: +86 21 6566 6622 INDIA ESAB India Ltd Calcutta Tel: +91 33 478 45 17 Fax: +91 33 468 18 80 INDONESIA P.T. ESABindo Pratama Jakarta Tel: +62 21 460 0188 Fax: +62 21 461 2929 JAPAN ESAB Japan Tokyo Tel: +81 3 5296 7371 Fax: +81 3 5296 8080 MALAYSIA ESAB (Malaysia) Snd Bhd Selangor Tel: +60 3 8027 9869 Fax: +60 3 8027 4754 SINGAPORE ESAB Asia/Pacific Pte Ltd Singapore Tel: +65 6861 43 22 Fax: +65 6861 31 95 SOUTH KOREA ESAB SeAH Corporation Kyungnam Tel: +82 55 269 8170 Fax: +82 55 289 8864 UNITED ARAB EMIRATES ESAB Middle East FZE Dubai Tel: +971 4 887 21 11 Fax: +971 4 887 22 63 ESAB AB SE--695 81 LAXÅ SWEDEN Phone +46 584 81 000 www.esab.com

Representative offices BULGARIA ESAB Representative Office Sofia Tel/Fax: +359 2 974 42 88 EGYPT ESAB Egypt Dokki--Cairo Tel: +20 2 390 96 69 Fax: +20 2 393 32 13 ROMANIA ESAB Representative Office Bucharest Tel/Fax: +40 1 322 36 74 RUSSIA LLC ESAB Moscow Tel: +7 095 543 9281 Fax: +7 095 543 9280 LLC ESAB St Petersburg Tel: +7 812 336 7080 Fax: +7 812 336 7060 Distributors For addresses and phone numbers to our distributors in other countries, please visit our home page www.esab.com

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