ESAB | Origo™Arc 200 | Service manual | ESAB Origo™Arc 200 User manual

ESAB Origo™Arc 200 User manual
Origot Arc 200i
Service manual
0740 800 163
060831
Valid for serial no. 402-xxx-xxxx to 620-xxx-xxxx
READ THIS FIRST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OrigoArc 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2AP1 Power supply board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Primary and secondary circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2AP1
Component positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2AP2 Interference suppressor board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP1 Power board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supply to 2AP1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gate driver stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switching circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP1
Component positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP2 Secondary board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15AP2
Component positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1 Control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:1 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:2 Current reference input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:3 Pulse width modulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:4 Temperature monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:5 Shunt input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1:6 Arc voltage monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20AP1
Component positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What is ESD? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Soft starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking rectifier and freewheel diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the gate pulses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the semiconductor module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting components on the heat sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections and control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overheating protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Rights reserved to alter specifications without notice.
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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 August 2006.
The manual is valid for:
OrigoArc 200 with serial no. 402-xxx-xxxx.
Origot Arc 200i with serial no. 620-xxx-xxxx.
The OrigoArc 200 and Origot Arc 200i are designed and tested in accordance with
international and European standards IEC/EN 60974.
On completion of service or repair work, it is the responsibility of the person(s)
performing the work to ensure that the product still complies with the requirements of
the above standard.
INTRODUCTION
The power source is renamed:
New name
Origot Arc 200i
Old name
OrigoArc 200
The OrigoArc 200 is a welding current power source intended for use with coated
electrodes (MMA welding).
The power module of the power source is a single forward converter, operating at a
switching frequency of 65 kHz. IGBT transistors are used as the switching elements. All
power semiconductors are built into modules.
Schematic diagram of the power source
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TECHNICAL DATA
Mains voltage
Fuse (delayed-action)
Primary current Imax
Primary current Ieff
Voltage/current range (DC)
Maximum permissible load at
25% duty cycle
35% duty cycle
60% duty cycle
100% duty cycle
Power factor at maximum current
Efficiency at maximum current
Open-circuit voltage
Operating temperature
Constant A-weighed sound pressure
Dimensions, l x b x h
Weight
Enclosure class
Application class
230 V $10% 1 50/60 Hz
25 A
45 A
30 A
8 A / 20 V - 180 A / 27 V
180 A / 27 V
160 A / 26.5 V
140 A / 25.5 V
120 A / 25 V
0.58
80%
58 - 75 V
-10° C - +40° C
< 70 db
380 x 180 x 300 mm
8 kg
IP23C
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or cut at
a certain load without overloading. The duty cycle is valid for 40° C.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Equipment marked IP23 is 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.
WIRING DIAGRAM
The power source consists of a number of function modules, which are described in the
component descriptions on the following pages. Wire numbers and component names in
the wiring diagrams show to which module each component belongs.
Wires/cables within modules are marked 100 - 6999.
Circuit boards within each module have names such as 20AP1 - 20AP99.
15 = module association, 1-69
AP = circuit board
1
= individual identification number, 0-99
Components within modules - are named in a similar way.
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CAUTION
STATIC ELECTRICITY can damage circuit
boards and electronic components.
ESD
S
Observe precautions for handling electrostaticsensitive devices.
S
Use proper static-proof bags and boxes.
Component description
1
MMC module.
1D1
LED, lights when the mains switch is on.
1D2
LED, lights when the thermal switches 15ST1 and / or 15ST2 are open due to
overtemperature.
2
Mains module.
2AP1
Power supply board.
2AP2
Interference suppressor board.
2L1
Ferrite ring. The yellow/green cable must be wound two turns through the ferrite
ring.
2L2
Ferrite ring.
2QF1
Mains switch.
2XS1
Flat pin sockets. Important: to obtain a proper electrical connection, the
complete cord set must be replaced if the sockets have to be replaced.
15
Power module.
15AP1
Power board.
15AP2
Secondary board.
15C1
Smoothing capacitor, 2000 uF.
15D1
Diode module with rectifier and freewheel diodes.
15EV1
Fan.
15L1
Inductor.
15RS1
Shunt. 60 mV at 100 A.
15ST1
Thermal switch, fitted in the winding of main transformer 15TM1. See page 15.
15ST2
Thermal switch, fitted on the heat sink. See page 15.
15TM1
Main transformer.
20AP1
Controller circuit board.
20RP1
Potentiometer for setting of welding current.
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OrigoArc 200
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DESCRIPTION OF OPERATION
This description of operation describes the function of circuit boards and other components
in the power source. It is divided into sections, numbered to correspond to the circuit board
numbers and divisions into function blocks.
2AP1 Power supply board
The power supply board generates internal supply voltages for the machine.
Primary and secondary circuit
WARNING! Dangerous voltage - mains voltage.
The primary circuit is supplied with 325 V DC from the power board, 15AP1. S1 is a fuse
with high rupturing capacity.
Transistor Q3 is the switching element in a switched voltage supply. The secondary voltage,
+24 V, is sensed by IC2 and controlled by IC1. It has a tolerance of $0.6 V.
The isolation voltage of transformer T1 and optocoupler IC3 is 4 kV.
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2AP1
Component positions
WARNING! Dangerous voltage - mains voltage.
2AP2 Interference suppressor board
This circuit board filters the mains voltage and reduces mains-borne interference to/from the
power source. Power board 15AP1 rectifies the mains voltage.
WARNING! Dangerous voltage - mains voltage.
Circuit diagram of the interference suppressor board (EMC mains filter)
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15AP1 Power board
WARNING!
Dangerous voltage - mains voltage.
Never make any measurements on this
board when the machine is connected to
the mains supply.
The power module is a single forward converter, operating at a switching frequency of
65 kHz. IGBT transistors are used as the switching elements. See page 21 and 22 for
screen traces of waveforms and measurement instructions.
If the power board has failed, a replacement board must be mounted in accordance with the
instructions on page 23.
The power board carries the mains rectifier, the charging circuit, the switching circuit and
the gate circuit.
The mains rectifier and the switching transistors are integrated in a semiconductor module,
PM1, which is part of the power board.
Charging circuit
When the mains power supply is turned on, the rectified mains voltage charges smoothing
capacitor 15C1 via resistor R31. Thyristor TY1 short-circuits charge resistor R31 when the
machine is loaded. If TY1 did not conduct, resistor R31 would burn out when the unit is on
load.
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Supply to 2AP1
The board supplies power supply board 2AP1 with 325 V DC (pins F1 and F3, connector
15XS1).
Gate driver stages
Transformer TR1 is a gate driver transformer for galvanic isolation of the drive circuits from
controller board 20AP1. Fuses S10 and S20 protect the gate driver circuit if the IGBT
transistors fail.
Switching circuit
The switching transistors are integrated in the semiconductor module. They are parallelconnected four and four.
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15AP1
Component positions
Pin positions of the semiconductor module
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15AP2 Secondary board
The secondary board is fitted on the main transformer 15TM1, diode module 15D1 and
inductor 15L1.
Diode module 15D1 comprises two diodes, rectifier and freewheel diode. During the time
interval between two voltage pulses from transformer 15TM1, the freewheel diode maintain
the welding current from inductor 15L1.
If the diode module has failed, a replacement module must be fitted in accordance with the
instructions on page 23.
Inductor L1 forms an LC circuit with C3//C4 and D1 to reduce the risk of arc extinction at low
welding currents. When rectifier diode 15D1 conducts, the LC circuit charges up. The circuit
is capable of temporarily maintaining a high arc voltage at low current, thus reducing the
risk of arc extinction. Diode D1 prevents capacitor C3//C4 from going negative.
15AP2
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Component positions
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20AP1 Control board
The control board monitors and controls the various functions of the power source.
If the board is faulty, it must be replaced. After replacing the board, soft-start the machine.
See the instructions on page 18.
20AP1:1
Power supply
Voltage regulator VR1 produces an output voltage of +20 1.0 V. All circuits
on the control board, except the current reference, are supplied from VR1.
20AP1:2
Current reference input
The reference input is supplied with +5.1 V generated by IC3, the pulse width
modulator.
Potentiometer R1 adjusts the reference voltage from potentiometer 20RP1 for
correct maximum current value.
20AP1:3
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Pulse width modulator
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The pulse width modulator determines the frequency and pulse duration of the
switch transistors' control pulses. IC3 controls the pulse frequency, the pulse
time and inhibition of pulses.
The pulse frequency is 65 kHz +/-1 kHz, with a maximum pulse width of 42 - 44
% of the cycle width. See page 21 for screen traces of waveforms and
measurement instructions.
Transistor Q5 controls the primary winding of the pulse transformer on circuit
board 15AP1.
The reference voltage, +5.1 V, from IC3 is used as reference for the shunt
voltage and the current reference input.
20AP1:4
Temperature monitoring
The thermal overload switches, 15ST1 and 15ST2, are normally closed, which
means that input T2 is at about 9 V.
15ST2 opens at 75 _C, and is fitted on the heat sink. 15ST1 opens at 130 _C,
and is fitted in the winding of the main transformer, 15TM1.
If either of the switches operates, the power source is stopped and 1D2, the
yellow LED on the front panel lights. The power source cannot be restarted
until it has cooled sufficiently for the switch(es) to reclose.
20AP1:5
Shunt input
The shunt produces 60 mV at a welding current of 100 A. The shunt response
is linear to the welding current.
If the shunt is not connected to the circuit board, resistor R67 supplies about
0.6 to 0.9 V at the shunt input. This blocks the current control amplifier, i.e. the
machine does not deliver any welding current.
Note: the reference level for the shunt voltage is +5.1 V, voltages mentioned
above are measured between terminals S1 and S2.
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20AP1:6
Arc voltage monitoring
The open-circuit voltage controller senses the voltage at the welding current
terminals and limits it to a level between 60 and 71 V. This function is inactive
during welding, i.e. when the shunt voltage is higher than 2.1 mV.
When the OrigoArc is in welding mode, the maximum output voltage is 110 V.
20AP1
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Edition
© ESAB060831
AB 2004
SERVICE INSTRUCTIONS
CAUTION
STATIC ELECTRICITY can damage circuit
boards and electronic components.
ESD
S
Observe precautions for handling electrostaticsensitive devices.
S
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.
Special tools
Torx key
Torx key no. T10 and T25
Soft-starting tool SST 1
The soft-starting tool SST 1 is made for the CaddyArc, CaddyTig, OrigoTig and OrigoArc. It
can be ordered from ESAB, ordering no. 0459 534 880.
The tool includes: Soft starting rectifier, cable set, voltage test board, gate pulse load and
shunt voltage resistor for the OrigoArc.
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Soft starting
We recommend soft starting of the machine after replacing control circuit board 20AP1,
power supply board 2AP1 and circuit boards or components in the power module. Soft
starting supplies the power module with a low voltage in order to avoid injury to persons or
damage to components.
It is a good idea to use soft starting when fault tracing.
Special equipment
To soft-start the machine you need soft-starting tool SST 1, this is described on page 17.
Instructions
1.
Disconnect wires 1501, 1502, 1505, 1506, 1503 and 1504 from circuit boards 2AP2,
2AP1 and 15AP1.
Disconnections prior to soft starting
2.
3.
Connect the 230 V AC input of the SST 1 to terminals C1 and C3 on circuit board
2AP2.
Connect the 325 V DC output of the SST 1 to terminals F1 and F3 on circuit board
2AP1.
The SST 1 connected to 2AP2 and 2AP1
4.
5.
6.
7.
Disconnect connector 20XS4 from terminal PS of power supply board 2AP1. Connect
the voltage test cable of the SST 1 to terminal PS of power supply board 2AP1.
Connect the power source to the mains and turn on the mains switch.
Verify the output voltage from 2AP1, the +24 V LED must light.
(The voltage must be +24 V $0.6 V.)
Switch off the machine. Disconnect the voltage test cable and reconnect connector
20XS4 to terminal PS of power supply board 2AP1.
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8.
9.
Disconnect connector 15XS3 (supply to the fan) from terminal E of circuit board 2AP1.
Connect the 24 V DC input of the SST 1 to terminal E of circuit board 2AP1.
Connect the 24 V DC output of the SST 1 to terminals N1:1 and N2:1 of power board
15AP1.
Circuit connections and measuring points for soft starting
10.
11.
12.
13.
Switch on the machine.
Check that the DC voltage across smoothing capacitor 15C1 is 22-24 V.
Check that the DC voltage at the welding terminals is 7-8 V.
If all the measurements are as described above, reconnect the wires to restore the
power source to normal operation mode and make a test weld.
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Checking rectifier and freewheel diodes
1.
2.
3.
4.
5.
6.
Disconnect the machine from the mains.
Dismantle the housing of the machine.
Use a Torx key no. T25 to unscrew and remove five screws from circuit board 15AP2.
The screws are marked
on the picture below,
Bend out the circuit board so that it has no contact with the connections of the diode
module.
Use a multimeter in diode test position to measure the forward voltage drop of the two
diodes: see the picture below. The voltage drop must be 0.3 to 0.5 V.
If the diode module has to be replaced, follow the instructions on page 23.
Measuring points, circuit board 15AP2
Circuit diagram and measuring points, circuit board 15AP2
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Checking the gate pulses
When checking the gate pulses, the machine can either be in soft-start mode or in normal
operation mode.
Special equipment
To measure the gate pulses, you need a gate pulse load and a shunt voltage resistor. This
is included in soft-starting tool SST 1, which is described on page 17.
Instructions
1.
Disconnect the machine from
the mains.
2. Disconnect connector 15XS8
from terminal S on control
board 20AP1.
3. Connect the cable marked
“20AP1 S1, S2” to terminal S.
Shunt voltage resistor connected to terminal S
4. Disconnect connector 20XS5
from terminal G on control
board 20AP1.
5. Connect the gate pulse test
cable of the SST 1 to terminal
G on control board 20AP1.
6. Switch on the machine.
7. Connect an oscilloscope to the
SST 1, with the probe to
terminal G2 and the screen to
Measuring connection for the gate pulses
terminal G1.
8. Set the current reference to 70 A or more. This will set the pulses to maximum pulse
width. At minimum current reference, there are no pulses.
9. Measure the pulse frequency. It must be 65 kHz +/- 1kHz.
10. Measure the duration of the negative pulse. It must be 41 - 43 % of the cycle time,
measured at a voltage level of -10 V.
11. The waveform of the pulses must be as shown below.
Gate pulses from circuit board 20AP1
ch25bf5gate
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© ESAB AB 2004
Checking the semiconductor module
Rectifier diodes and thyristor
IGBT transistors and
freewheel diodes
Measuring points for the semiconductor module
Disconnect the machine from the mains and follow the instructions below.
Measurements 2 - 5: Use a multimeter in diode test position to measure the diodes.
Measure with the positive and negative of the multimeter connected as shown in the picture
above. The main transformer must be connected to terminals T1 and T2.
1. Resistor R31 (and thyristor TY1 in parallel): measure the resistance of R31. It must be
12 ohm (on some boards the resistance of R31 is 6.8 or 10 ohm, which are also
approved values).
2. Diode P1D: measure between resistor R31 and terminal N1.
Diode P2D: measure between resistor R31 and terminal N2.
The forward voltage drop must be 0.4 to 0.6 V.
3. Diode N1D: measure between the negative of capacitor 15C1 and terminal N1.
Diode N2D: measure between the negative of capacitor 15C1 and terminal N2.
The forward voltage drop must be 0.4 to 0.6 V.
4. Diode D1 connected in parallel with D4: measure between the negative of capacitor
15C1 and terminal T2. The forward voltage drop must be 0.3 to 0.5 V.
5. Diode D2 connected in parallel with D3: measure between the positive of capacitor
15C1 and terminal T2. The forward voltage drop must be 0.3 to 0.5 V.
6. Transistors Q1.1, Q1.2, Q1.3 and Q1.4: measure the resistance between collector,
R31, and gate, pin 16 of the module. The resistance must be higher than 500 kohm.
7. Transistors Q2.1, Q2.2, Q2.3 and Q2.4: measure the resistance between collector,
terminal T2, and gate, pin 11 of the module. The resistance must be higher than 500
kohm.
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© ESAB AB 2004
Mounting components on the heat sink
Thermal paste
Apply thermal conducting paste to the components before fitting them to the heat sink.
Start by cleaning the heat sink, and then apply a very thin, even layer of thermal paste to
the contact surfaces of the components. The purpose of the paste is to fill out any hollows
in the surfaces of the components and the heat sink. Those parts of the component and the
heat sink that are in true metallic contact may already have good thermal contact.
Mount the components as described below.
See the spare parts list for the order number for thermal paste. Use only the paste
recommended by us.
Fitting instructions
15AP1
Power board with semiconductor module
1.
Clean the heat sink and apply thermal conducting paste to the
semiconductor module as described above.
2. Fit the board and tighten the screws to a torque of 2.5 Nm, and then further
tighten them to 4.5 Nm.
3. Tighten the screws that connect transformer 15TM1 and capacitor 15C1 to
circuit board 15AP1 to a torque of 4.5 Nm.
Warning: Incorrectly fitted components can cause failure. Do not tighten the
screws to more than 4.5 Nm.
Note: If capacitor 15C1 or transformer 15TM1 have to be replaced, the power
board must be removed and then refitted as described above.
15D1
Diode module
1.
2.
3.
4.
15ST2
Thermal overload switch
1.
2.
ch25ba1heat
Clean the heat sink and apply thermal conducting paste to the diode
module as described above.
Fit the module and tighten the screws to a torque of 2.5 Nm, and then
further tighten them to 4.5 Nm.
Tighten the connections to circuit board 15AP2 to 4.5 Nm.
Tighten the screws that connect transformer 15TM1 and inductor 15L1 to
circuit board 15AP2 to a torque of 4.5 Nm.
Clean the heat sink and apply thermal conducting paste to the thermal
overload switch as described above.
Fit the thermal overload switch and tighten the screw to 2 Nm.
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© ESAB AB 2004
INSTRUCTIONS
This chapter is an extract from the instructions for the Origo Arc 200i.
SAFETY
Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on or
near the equipment observes all the relevant safety precautions. Safety precautions must meet the
requirements that apply to this type of equipment. The following recommendations should be ob­
served 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 equip­
ment. Incorrect operation of the equipment may lead to hazardous situations which can result in in­
jury to the operator and damage to the equipment.
1.
Anyone who uses the equipment must be familiar with:
S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding and cutting
2.
The operator must ensure that:
S no unauthorized 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 drafts
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.
CAUTION
Read and understand the instruction manual before
installing or operating.
CAUTION
This product is solely intended for arc welding.
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© ESAB AB 2004
INSTALLATION
CAUTION
This product is intended for industrial use. In a domestic environment this product may
cause radio interference. It is the user's responsibility to take adequate precautions.
Placing
Place the welding power source so that its cooling air inlets and outlets are not obstructed.
Rating plate
The rating plate is located on the underside of the power source.
Mains power supply
Make sure that the welding power source is connected to the correct supply voltage and
that it is protected by the correct fuse rating. The standards for the country in question must
be complied with as regards the mains cable area. A protective earth connection must be
made in accordance with regulations.
Recommended fuse ratings and minimum cable areas
Mains voltage
230 V 10 %, 1-phase
Mains frequency
50 - 60 Hz
Fuse (delayed-action)
85A 35% duty cycle
120A 20% duty cycle
160A 35% duty cycle
10 A
16 A
20 A
180 A 25% duty cycle
25 A
Mains cable area
3 x 4 mm2
Welding cable area
25 mm2
The cable area and fuse rating above comply with Swedish regulations. Use the welding power source
in accordance with the relevant national regulations.
ch25bie1
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S0740 800 163/E060831/P28
© ESAB AB 2004
OPERATION
General safety regulations for the handling of the equipment can be found on
page 24. Read through before you start using the equipment!
Connections and control devices
1
2
3
Mains switch
Mains cable
Return cable connection(-)
4
Welding cable connection (+)
5
6
7
Knob for current setting
Mains voltage indicator (green)
Thermal overload indicator (yellow)
Welding
The OrigoArc 200 gives direct current, and you can weld most metals to alloy and non-alloy
steel, stainless steel and cast iron. The OrigoArc 200 allows you to weld most coated
electrodes from ∅ 1.6 to ∅ 4.0 mm.
Overheating protection
The welding power source has a thermal overload trip which operates if the temperature
becomes too high, interrupting the welding current and lighting a yellow indicating lamp on
the front of the power source. The thermal overload trip 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.
The OrigoArc 200 requires little maintenance. In normal cases, it is sufficient to blow it clean
using dry compressed air once a year, but this should be done more often if it is set up in a
dusty, dirty area.
SPARE PARTS
The spare parts list for the Origo Arc 200i is published in a separate document with filename
0459 261 990.
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© ESAB AB 2004
emptypage
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S0740 800 163/E060831/P28
© ESAB AB 2004
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
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
BULGARIA
ESAB Kft Representative Office
Sofia
Tel/Fax: +359 2 974 42 88
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 8 310 960
Fax: +351 1 859 1277
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
ROMANIA
ESAB Romania Trading SRL
Bucharest
Tel: +40 316 900 600
Fax: +40 316 900 601
DENMARK
Aktieselskabet ESAB
Herlev
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
RUSSIA
LLC ESAB
Moscow
Tel: +7 (495) 663 20 08
Fax: +7 (495) 663 20 09
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
SPAIN
ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 218
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
ESAB international AB
Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
SWITZERLAND
ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
UKRAINE
ESAB Ukraine LLC
Kiev
Tel: +38 (044) 501 23 24
Fax: +38 (044) 575 21 88
ITALY
ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: +39 02 97 96 8.1
Fax: +39 02 97 96 87 01
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
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
Africa
EGYPT
ESAB Egypt
Dokki-Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
SOUTH AFRICA
ESAB Africa Welding & Cutting Ltd
Durbanvill 7570 - Cape Town
Tel: +27 (0)21 975 8924
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 2326 3000
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 45 670 7073
Fax: +81 45 670 7001
MALAYSIA
ESAB (Malaysia) Snd Bhd
USJ
Tel: +603 8023 7835
Fax: +603 8023 0225
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 6861 43 22
Fax: +65 6861 31 95
THE NETHERLANDS
ESAB Nederland B.V.
Amersfoort
Tel: +31 33 422 35 55
Fax: +31 33 422 35 44
www.esab.com
© ESAB AB
110426
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