ESAB | Origo™Mag C170 | Service manual | ESAB Origo™Mag C170 User manual

ESAB Origo™Mag C170 User manual
OrigoMag C150/C170
OrigoMag C200/C250
Service manual
0349 300 049
040607
Valid for serial no. 407/344/343/349−xxx−xxxx
READ THIS FIRST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM, OrigoMag C150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OrigoMag C150, 230V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 − OrigoMag C150 component positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM, OrigoMag C170 / C200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OrigoMag C170, 230V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OrigoMag C200, 230V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1 Control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 − OrigoMag C170 / C200 component positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM, OrigoMag C250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OrigoMag C250, 230V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1 Control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:1 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:2 Start / Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1 − OrigoMag C250 component positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What is ESD? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Placing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mains power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection and control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the wire feed pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUNCTIONS EXPLANATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overheating protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOCe
−2−
4
4
5
7
7
8
9
9
10
10
10
10
11
12
12
14
15
16
16
18
18
19
20
20
21
22
23
23
25
26
26
26
26
27
27
28
29
29
30
31
31
32
32
33
33
33
35
35
36
36
37
37
37
37
37
ORDERING OF SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOCe
−3−
38
39
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 2004.
The OrigoMag C150/C170/C200/C250 are designed and tested in accordance with
international and European standard IEC/EN 60974−1 and EN 50199.
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
OrigoMag C150/C170/C200/C250 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.
1sOC1525
−4−
Edition 040607
TECHNICAL DATA
OrigoMag C150
OrigoMag C170
Voltage
230V, 1∼ 50/60Hz
230V, 1∼ 50/60Hz
Permissible load at
100% duty cycle
67A
76A
60 % duty cycle
86A
98A
30 % duty cycle
122A
139A
20 % duty cycle
150A
170A
Setting range (DC)
35A/15,6V−150A/15,5V
30A/15,5V−170A/19,3V
Open circuit voltage
18,5−30,5V
19,5−35,5V
Open circuit power
145W
145W
Power factor at max load
0,90
0,90
Control voltage
230V, 50/60Hz
42V, 50/60Hz
Wire feed speed
1,0−14m/min
1,0−17m/min
Burnback time
−
0,02−0,25s
Spot welding
−
0,2−2,5s
Welding gun connection fixed
EURO
Wire dimension range
0,6−0,8(Fe)
0,8(cored)
0,6−0,8(Fe)
1,0(Al)
0,8(cored)
Max diameter/weight
of wire bobin
200mm/5kg
300mm/15kg
Dimensions lxwxh
650x300x550
860x420x730
Weight
37,5kg
59kg
+40oC
−10 ÷ +40oC
Operating temperature
−10 ÷
Enclosure class
IP 23
IP 23
OrigoMag C200
OrigoMag C250
Voltage
230V, 1∼ 50/60Hz
230V, 1∼ 50/60Hz
Permissible load at
100% duty cycle
90A
110A
60 % duty cycle
115A
140A
30 % duty cycle
163A
200A
20 % duty cycle
200A
250A
Setting range (DC)
30A/15,5V−200A/18V
40A/16,0V−250A/22,5V
Open circuit voltage
17,5−33,0V
19,5−42,5V
Open circuit power
240W
200W
Power factor at max load
0,83
0,92
Control voltage
42V, 50/60Hz
42V, 50/60Hz
Application classification
1sOC1525
−5−
Edition 040607
Wire feed speed
1,0−17m/min
1,9−19m/min
Burnback time
0,02−0,25s
0−0,25s
Spot welding
0,2−2,5s
0,2−2,5s
Welding gun connection EURO
EURO
Wire dimension range
0,6−1,0(Fe)
1,0(Al)
0,8−1,0(cored)
0,6−1,2(Fe)
1,0−1,2(Al)
0,8−1,2(cored)
Max diameter/weight
of wire bobin
300mm/15kg
300mm/15kg
Dimensions lxwxh
860x420x730
860x420x730
Weight
68kg
94kg
Operating temperature
−10 ÷ +40oC
−10 ÷ +40oC
Enclosure class
IP 23
IP 23
Application classification
Duty cycle
The duty cycle refers to the time as a percentage of a ten−minute period that you can weld at a certain load without overloading.
Enclosure class
The IP code indicates 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.
1sOC1525
−6−
Edition 040607
WIRING DIAGRAM, OrigoMag C150
Component description
WARNING !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
ESD
S
Observe precautions for handling electrostatic
sensitive devices.
S
Use proper static−proof bags and boxes.
AP1
Circuit board
C1, C2, C3
Capacitor 0,1uF/250V
CO
Capacitor 68mF/40V
EV1
Fan
KM1
Contactor 230V, 50−60Hz
L1
Inductor
M1
Feed unit motor
QF1
Switch, ON/OFF and 7−step welding voltage selector
R13
Potentiometer, wire feed speed (placed on AP1)
RO
Resistor 15Ω/20W
ST1
Thermal oveload cutout, operates at 120oC. The cutout is mounted at
the cooling fins of the diode bridge.
TC2
Transformer for CO2 heater, accessory
TM1
Main transformer
V1
Diode bridge
V2
Diode bridge
VH
LED yellow indication, thermal overload
XTP
Main welding current contact, single − pole
XT1, XT4
Terminal block
1sOC1525
−7−
Edition 040607
OrigoMag C150, 230V
1sOC1525
−8−
Edition 040607
DESCRIPTION OF OPERATION
AP1 Control board
clka0e02
1sOC1525
−9−
Edition 040607
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
(220µF) 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 cutouts ST1 or ST2
interrupt 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.
1sOC1525
− 10 −
Edition 040607
AP1 − OrigoMag C150 component positions
clka0e03
1sOC1525
− 11 −
Edition 040607
WIRING DIAGRAM, OrigoMag C170 / C200
Component description
WARNING !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
ESD
S
Observe precautions for handling electrostatic
sensitive devices.
S
Use proper static−proof bags and boxes.
AP1
Circuit board
AP2
Digital instrument, accessory
C1, C2, CVS
Capacitor 0,1uF/250V
EV1
Fan
KM1
Contactor 42V, 50−60Hz
L1
Inductor
L2, L3
Ferrite core
LF1
Lamp, white, On/Off, 230V
M1
Feed unit motor
QF1
Switch, ON/OFF
QF2
Switch, 8−step welding voltage selector for C170
Switch, 12−step welding voltage selector for C200
RO
Resistor 15Ω/20W
RVS
Resistor
RP1
Potentiometer, wire feed speed
RP2
Potentiometer with switch, spot welding
RI
Shunt, accessory
RL
Resistor
ST1
Thermal oveload cutout, operates at 130oC. The cutout is mounted at
the cooling fins of the diode bridge.
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
1sOC1525
− 12 −
Edition 040607
XTP
Main welding current contact, single − pole
XT1, XT4
Terminal block
YV1
Gas valve
1sOC1525
− 13 −
Edition 040607
OrigoMag C170, 230V
1sOC1525
− 14 −
Edition 040607
OrigoMag C200, 230V
1sOC1525
− 15 −
Edition 040607
DESCRIPTION OF OPERATION
AP1 Control board
clka1e03
1sOC1525
− 16 −
Edition 040607
clka1e04
1sOC1525
− 17 −
Edition 040607
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 "0.6 V supply.
AP1:2 Reference circuit
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.
1sOC1525
− 18 −
Edition 040607
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 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%.
1sOC1525
− 19 −
Edition 040607
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.
1sOC1525
− 20 −
Edition 040607
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 "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.
1sOC1525
− 21 −
Edition 040607
AP1 − OrigoMag C170 / C200 component positions
clka1e05
1sOC1525
− 22 −
Edition 040607
WIRING DIAGRAM, OrigoMag C250
Component description
WARNING !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
ESD
S
Observe precautions for handling electrostatic
sensitive devices.
S
Use proper static−proof bags and boxes.
AP1
Circuit board
AP2
Digital instrument, accessory
C1, C2, CVS
Capacitor 0,1uF/250V
EV1
Fan
KM1
Contactor 42V, 50−60Hz
L1
Inductor
L2, L3
Ferrite core
LF1
Lamp, white, On/Off
M1
Feed unit motor
QF1
Switch, ON/OFF
QF2
Switch, 12−step welding voltage selector
RO
Resistor 15Ω/20W
RVS
Resistor
RP1
Potentiometer, wire feed speed
RP2
Potentiometer with switch, spot welding
RI
Shunt, accessory
RL
Resistor
ST1
Thermal oveload cutout, operates at 130oC. The cutout is mounted at
the cooling fins of the diode bridge.
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
1sOC1525
− 23 −
Edition 040607
XTP
Main welding current contact, single − pole
XT1, XT4
Terminal block
YV1
Gas valve
1sOC1525
− 24 −
Edition 040607
OrigoMag C250, 230V
1sOC1525
− 25 −
Edition 040607
DESCRIPTION OF OPERATION
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.
1sOC1525
− 26 −
Edition 040607
Welding gun
trigger switch
1
0
1
Gas valve
T1
0
1
Wire feed
0
1
Contactor
T1
0
T1 = Burn−back time
Start− stop sequence.
AP1:3 Spot welding
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.
1sOC1525
− 27 −
Edition 040607
AP1:5 Motor driving / braking
black
red
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 ±5 %. At
a roller speed of 200 r/min, the wire feed speed is 19 m/min ± 5 %.
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.
1sOC1525
− 28 −
Edition 040607
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 (0Ω).
AP1:7 Thermal overload cutout
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.
1sOC1525
− 29 −
Edition 040607
AP1 − OrigoMag C250 component positions
clkb0e13
1sOC1525
− 30 −
Edition 040607
SERVICE INSTRUCTIONS
WARNING !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
ESD
S
Observe precautions for handling electrostatic
sensitive 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.
1sOC1525
− 31 −
Edition 040607
INSTRUCTIONS
This chapter is an extract from the instructions for OrigoMag C150/C170/C200/C250.
SAFETY
Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety precautions
must meet the requirements that apply to this type of welding equipment. The following recommendations should be observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well−acquainted with the operation of the welding
equipment. Incorrect operation of the equipment may lead to hazardous situations which can result
in injury to the operator and damage to the equipment.
1.
Anyone who uses the welding equipment must be familiar with:
S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding
2.
The operator must ensure that:
S no unauthorised person is stationed within the working area of the equipment when it is
started up.
S no−one is unprotected when the arc is struck
3.
The workplace must:
S be suitable for the purpose
S be free from draughts
4.
Personal safety equipment
S Always wear recommended personal safety equipment, such as safety glasses, flame−proof
clothing, safety gloves.
S Do not wear loose−fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5.
General precautions
S Make sure the return cable is connected securely.
S Work on high voltage equipment may only be carried out by a qualified electrician.
S Appropriate fire extinquishing equipment must be clearly marked and close at hand.
S Lubrication and maintenance must not be carried out on the equipment during operation.
WARNING!
Read and understand the instruction manual
before installing or operating.
1sOC1525
− 32 −
Edition 040607
INSTALLATION
INSTALLATION
The installation must be executed by a professional.
WARNING!
This product is intended for industrial use. In a domestic environment this product may cause radio
interference. It is the user’s responsibility to take adequate precautions.
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.
OrigoMag C150
1.
2.
3.
1sOC1525
− 33 −
Edition 040607
INSTALLATION
OrigoMag C170/C200/C250
1.
2.
3.
1sOC1525
− 34 −
Edition 040607
INSTALLATION
Electrical installation
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
OrigoMag C150
OrigoMag C170
OrigoMag C200
OrigoMag C250
Voltage V
230V, 1∼ 50/60Hz
230V, 1∼ 50/60Hz
230V, 1∼ 50/60Hz
230V, 1∼ 50/60Hz
Current A
at 100% duty cycle
9,6
10,4
14,3
16,6
at 60% duty cycle
12,9
15,0
17,6
23,4
at 20% duty cycle
22,6
29
32,5
47,5
3 x 1.5
3 x 1.5
3 x 2.5
3 x 4,0
10
16
16
35
Cable area
mm2
Fuse slow A
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.
1sOC1525
− 35 −
Edition 040607
OPERATION
OPERATION
General safety regulations for the handling of the equipment can be found on
page 32. Read through before you start using the equipment!
WARNING!
Rotating parts can cause injury, take great care.
WARNING − TIPPING RISK!
There is a risk of tipping while transportation and operation, if the welding machine leans
more than 10o. In that case appropriate securing has to be provided !
Connection and control devices
1
Mains supply switch with indicating lamp,
only in C170/C200/C250
5a
Return cable with clamp, fixed,
only in C150/C170/C200
2
Orange indicating lamp, overheating
6
Knob for spot welding − ON/OFF and time
setting
3
Welding voltage switch
C150: OFF + 7 steps (mains ON/OFF)
C170: 8 steps
C200: 12 steps
C250: 12 steps
7
Knob for wire speed setting
4
EURO − connector for welding gun,
only in C170/C200/C250
Welding gun, fixed,
only in C150
8
Digital instrument − V / A, only in
C170/C200/C250, option
Knob for burn−back time setting.
In C250 located in wire feeder compartment,
in C170/C200 located on control board.
4a
5
9
Connection for return cable (−),only in C250
1sOC1525
− 36 −
Edition 040607
OPERATION
Setting the 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.
ÏÏ
ÏÏ
ÏÏ
ÏÏ
ÏÏ
ÏÏ
Fig 1
ÏÏ
ÏÏ
ÏÏ
ÏÏ
ÏÏ
Fig 2
To check that the feed pressure is set correctly, you can feed out the wire against an
insulated object, e.g. a piece of wood.
When you hold the welding gun approx. 5 mm from the piece of wood (fig. 1) the feed
rollers should slip. If you hold the welding gun approx. 50 mm from the piece of wood, the
wire should be fed out and bend (fig. 2).
FUNCTIONS EXPLANATION
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.
Maintenance must be executed by a professional.
Only those persons who have appropriate electrical knowledge (authorised
personnel) may remove the safety plates.
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.
1sOC1525
− 37 −
Edition 040607
OPERATION
Otherwise the air inlet/outlet may become blocked and cause overheating. To avoid
this you can use an airfilter.
Welding gun
S
Cleaning and replacement of the welding gun’s wear parts should take place at
regular intervals in order to achieve trouble−free wire feed. Blow the wire guide
clean regularly and clean the contact tip.
The brake hub
The hub is adjusted when delivered, if
readjustment is required, follow the instructions
below. Adjust the brake hub so that wire is slightly
slack when wire feed stops.
S
Adjusting the braking torque:
S
Turn the red handle to the locked position.
S
Insert a screwdriver into the springs in the hub.
Turn the springs clockwise to reduce the braking torque
Turn the springs anticlockwise to increase the braking torque. NB: Turn both
springs through the same amount.
Wire feed unit
Check regularly that the wire feed unit is not clogged with dirt.
S
Cleaning and replacement of the wire feed unit mechanism’s worn parts should
take place at regular intervals in order to achieve trouble−free wire feed. Note
that if pre−tensioning is set too hard, this can result in abnormal wear on the
pressure roller, feed roller and wire guide.
ORDERING OF SPARE PARTS
Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication.
1sOC1525
− 38 −
Edition 040607
NOTES
notes
− 39 −
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 2 726 80 05
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Prague
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Copenhagen−Valby
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: +49 212 298 204
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.
Utrecht
Tel: +31 30 248 59 22
Fax: +31 30 248 52 60
NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
POLAND
ESAB Sp.z.o.o
Warszaw
Tel: +48 22 813 99 63
Fax: +48 22 813 98 81
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 1 837 1527
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.
Alcobendas (Madrid)
Tel: +34 91 623 11 00
Fax: +34 91 661 51 83
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
Asia/Pacific
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 6539 7124
Fax: +86 21 6543 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 01 88
Fax: +62 21 461 29 29
MALAYSIA
ESAB (Malaysia) Snd Bhd
Selangor
Tel: +60 3 703 36 15
Fax: +60 3 703 35 52
SINGAPORE
ESAB Singapore Pte Ltd
Singapore
Tel: +65 861 43 22
Fax: +65 861 31 95
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 861 74 42
Fax: +65 863 08 39
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−CIS
ESAB Representative Office
Moscow
Tel: +7 095 937 98 20
Fax: +7 095 937 95 80
ESAB Representative Office
St Petersburg
Tel: +7 812 325 43 62
Fax: +7 812 325 66 85
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
SOUTH KOREA
ESAB SeAH Corporation
Kyung−Nam
Tel: +82 551 289 81 11
Fax: +82 551 289 88 63
UNITED ARAB EMIRATES
ESAB Middle East
Dubai
Tel: +971 4 338 88 29
Fax: +971 4 338 87 29
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 3369 4333
Fax: +55 31 3369 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 44 58
ESAB AB
SE−695 81 LAXÅ
SWEDEN
Phone +46 584 81 000
www.esab.com
031021
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising