Service manual
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INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections and control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overheating protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TOCe
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The OrigoArc 200 is designed and tested in accordance with international and
European standards IEC/EN 60974--1 and EN 50199.
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 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.
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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
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.
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
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WARNING !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
ESD
Component description
1
MMC module.
1D1
1D2
LED, lights when the thermal switches 15ST1 and / or 15ST2 are open due to
overtemperature.
Mains module.
2AP1
2AP2
2L1
Ferrite ring. The yellow/green cable must be wound two turns through the ferrite
ring.
2L2
Ferrite ring.
2QF1
Mains switch.
2XS1
15
Power module.
15AP1
Power board.
15AP2
Secondary board.
15C1
15D1
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
15TM1
Main transformer.
20AP1
20RP1
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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.
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2AP1
Component positions
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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).
Switching circuit
The switching transistors are integrated in the semiconductor module. They are parallel-connected four and four.
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15AP1
Component positions
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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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20AP1:1
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
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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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
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20AP1:6
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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Component positions
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SERVICE INSTRUCTIONS
WARNING !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
ESD
What is ESD?
A sudden transfer or discharge of static electricity from one object to another. ESD stands for
Electrostatic Discharge.
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.
2.
Connect the 230 V AC input of the SST 1 to terminals C1 and C3 on circuit board
2AP2.
3.
Connect the 325 V DC output of the SST 1 to terminals F1 and F3 on circuit board
2AP1.
4.
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.
5.
Connect the power source to the mains and turn on the mains switch.
6.
Verify the output voltage from 2AP1, the +24 V LED must light.
(The voltage must be +24 V 0.6 V.)
7.
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.
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.
9.
Connect the 24 V DC output of the SST 1 to terminals N1:1 and N2:1 of power board
15AP1.
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2.
3.
Use a Torx key no. T25 to unscrew and remove five screws from circuit board 15AP2.
The screws are marked
on the picture below,
4.
Bend out the circuit board so that it has no contact with the connections of the diode
module.
5.
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.
6.
If the diode module has to be replaced, follow the instructions on page 23.
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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.
2.
3.
4.
5.
6.
7.
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.
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.
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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.
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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Fitting instructions
15AP1
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
15ST2
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Diode module
1.
Clean the heat sink and apply thermal conducting paste to the diode
module as described above.
2.
Fit the module and tighten the screws to a torque of 2.5 Nm, and then
further tighten them to 4.5 Nm.
3.
4.
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.
2.
Fit the thermal overload switch and tighten the screw to 2 Nm.
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INSTRUCTIONS
This chapter is an extract from the instructions for the OrigoArc 200.
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.
2.
3.
4.
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.
WARNING!
Do not use the power source for thawing frozen pipes.
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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 users 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.
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
180 A 25% duty cycle
10 A
16 A
20 A
25 A
3 x 4 mm2
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.
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OPERATION
General safety regulations for the handling of the equipment can be found on
page 24. Read through before you start using the equipment!
Mains switch
Mains cable
Return cable connection(--)
5
6
7
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 OrigoArc 200 is published in a separate document with filename
/ ordering no. 0459 261 990.
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NOTES
notes
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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 Ibrica 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
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
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 LAX
SWEDEN
Phone +46 584 81 000
www.esab.com
031021