ESAB Origo Mag C171, Service Manual

Page 1: ...0349 300 076 Valid for serial no 736 xxx xxxx 080529 Mig C141 C151 Mag C171 C201 C251 Origo Service manual ...

Page 2: ...rol amplifier and pulse width modulator 21 AP1 8 9 Motor driving braking 22 AP1 Mag C171 C201 component positions 23 WIRING DIAGRAM Mag C251 24 Component description 24 Mag C251 26 DESCRIPTION OF OPERATION 27 AP1 Control board 27 AP1 1 Power supply 27 AP1 2 Start Stop 27 AP1 3 Spot welding 28 AP1 4 Wire feed speed 28 AP1 5 Motor driving braking 29 AP1 6 Burnback time contactor gas valve 30 AP1 7 T...

Page 3: ... 3 TOCe MAINTENANCE 41 Inspection and cleaning 41 FAULT TRACING 42 ORDERING OF SPARE PARTS 42 NOTES 43 ...

Page 4: ...s details of all design changes that have been made up to and including May 2008 The OrigoTM Mig C141 C151 Mag C171 C201 C251 are designed and tested in accordance with international and European standard IEC EN 60974 1 and EN 60974 10 On completion of service or repair work it is the responsibility of the person s etc performing the work to ensure that the product does not depart from the require...

Page 5: ... min Burnback time 0 02 0 25s Spot welding 0 2 2 5s Welding gun connection fixed fixed EURO Wire dimension range 0 6 0 8 Fe 1 0 Al 0 8 cored 0 8 CuSi 0 6 0 8 Fe 1 0 Al 0 8 cored 0 8 CuSi 0 6 0 8 Fe 1 0 Al 0 8 cored 0 8 1 0 CuSi Max diameter weight of wire bobin 200mm 5kg 200mm 5kg 300mm 15kg Dimensions lxwxh 650x300x550 650x300x550 860x420x730 Weight 25kg 37 5kg 59kg Operating temperature 10 40oC ...

Page 6: ...860x420x730 860x420x730 Weight 68kg 94kg Operating temperature 10 40oC 10 40oC Enclosure class IP 23 IP 23 Application classifica tion Duty cycle The duty cycle refers to the time as a percentage of a ten minute period that you can weld at a cer tain load without overloading Enclosure class The IP code indicates the enclosure class i e the degree of protection against penetration by solid objects ...

Page 7: ...40V C150 68mF 40V EV1 Fan KM1 Contactor 230V 50 60Hz L1 Inductor M1 Feed unit motor QF1 Switch ON OFF and C141 4 step welding voltage selector C151 7 step welding voltage selector R13 Potentiometer wire feed speed placed on AP1 R01 R02 Resistor 15Ω 20W R1 Resistor 100kΩ 2W RO Resistor 15Ω 20W ST1 Thermal switch operates at 150oC C141 or at 130oC C151 Thermal switch is mounted on the inductor TC2 T...

Page 8: ...Edition 080529 8 1sC1425 Mig C141 ...

Page 9: ...Edition 080529 9 1sC1425 Mig C151 ...

Page 10: ...Edition 080529 10 1sC1425 DESCRIPTION OF OPERATION AP1 Control board clka0e02 ...

Page 11: ...condary 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 con...

Page 12: ...Edition 080529 12 1sC1425 AP1 Mig C141 C151 component positions clka0e03 ...

Page 13: ...r 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 C171 Switch 12 step welding voltage selector for C201 RO Resistor 15Ω 20W RVS Resistor RP1 Potentiometer wire feed speed RP2 Potentiometer with switch spot welding RI Shunt accessory RL Resistor ST1 C171 Thermal switch operates at 150oC Thermal switch is mounted on th...

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

Page 15: ...Edition 080529 15 1sC1425 Mag C171 ...

Page 16: ...Edition 080529 16 1sC1425 Mag C201 ...

Page 17: ...Edition 080529 17 1sC1425 DESCRIPTION OF OPERATION AP1 Control board clka1e03 ...

Page 18: ...Edition 080529 18 1sC1425 clka1e04 ...

Page 19: ...ply 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 ᐔ0 6 V supply AP1 2 Reference circuit clka1e07 Potentiometer R49 controls the wire feed speed and is connected to te...

Page 20: ...annot be short circuited with the result that wire feed cannot be started When the thermal cutout has operated LED V7 is energised to indicate this via diode D7 Spot welding circuit Potentiometer R50 controls the spot welding time and incorporates a switch When in the zero position the switch is open When the switch in R50 and torch trigger switch SB1 are closed capacitor C22 charges up through re...

Page 21: ...pot 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 val...

Page 22: ...suring the voltage across resistor R4 connected to transistor Q1 If the voltage across R4 exceeds 1 1 V ᐔ60 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 resi...

Page 23: ...Edition 080529 23 1sC1425 AP1 Mag C171 C201 component positions clka1e05 ...

Page 24: ...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 switch operates at 130oC Thermal switch is mounted on the transformer TC1 Control transform...

Page 25: ...Edition 080529 25 1sC1425 XTP Main welding current contact single pole XT1 XT4 Terminal block YV1 Gas valve ...

Page 26: ...Edition 080529 26 1sC1425 Mag C251 ...

Page 27: ...ply 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 m...

Page 28: ...f 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 refer...

Page 29: ...WM 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 t...

Page 30: ...rd 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 switc...

Page 31: ...Edition 080529 clkb0e13 31 1sC1425 AP1 Mag C251 component positions ...

Page 32: ...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 se...

Page 33: ...ith 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 wea...

Page 34: ...wear protective clothing S Protect bystanders with suitable screens or curtains FIRE HAZARD S Sparks spatter can cause fire Make sure therefore that there are no inflammable materials nearby NOISE Excessive noise can damage hearing S Protect your ears Use earmuffs or other hearing protection S Warn bystanders of the risk MALFUNCTION Call for expert assistance in the event of malfunction PROTECT YO...

Page 35: ...cker in the illuminators WARNING This product is intended for industrial use In a domestic environment this product may cause radio interference It is the user s responsibility to take adequate precautions Placing Position the welding power source such way that its cooling air inlets and outlets are not obstructed Assembly of components For packing and shipment of the machine the wheels are detach...

Page 36: ...Edition 080529 36 2sC1425 OrigoTM Mig C151 1 3 2 ...

Page 37: ...Edition 080529 37 2sC1425 OrigoTM Mag C171 C201 C251 1 3 2 Electrical installation ...

Page 38: ... duty cycle 13 8 20 4 29 7 39 0 47 5 Cable area mm2 2 2 2 3 x 1 5 3 x 1 5 3 x 1 5 3 x 2 5 3 x 4 0 Fuse slow A 10 10 16 16 20 35 NB The mains cable areas and fuse sizes as shown above are in accordance with Swedish regulations They may not be applicable in other countries make sure that the cable area and fuse sizes comply with the relevant national regulations in the supply networks of high level ...

Page 39: ...dicating lamp overheating 6 Knob for spot welding ON OFF and time setting only in C171 C201 C251 3 Welding voltage switch C141 OFF 4 steps mains ON OFF C151 OFF 7 steps mains ON OFF C171 8 steps C201 12 steps C251 12 steps 7 Knob for wire speed setting 4 EURO connector for welding gun only in C171 C201 C251 8 Digital instrument V A only in C171 C201 C251 option see user manual 4a Welding gun fixed...

Page 40: ...t the wire against an insolated object e g a piece of wood When you hold the gun approx 5 mm from the piece of wood fig 1 the feed rollers should slip If you hold the gun approx 50 mm from the piece of wood the wire should be fed out and bend fig 2 Replacing and inserting wire S Open the side panel S Disconnect the pressure sensor by folding it backwards the pressure rollers slide up S Straighten ...

Page 41: ...guarantee period in order to rectify any faults Inspection and cleaning Check regularly that the power source is free from dirt The power source should be regularly blown clean using dry compressed air at reduced pressure More frequently in dirty environments Otherwise the air inlet outlet may be come blocked and cause overheating Welding gun S Cleaning and replacement of the welding gun s wear pa...

Page 42: ...pply fuses Thermal overload trips operate frequently S Check to see whether the air inlets outlets are clogged S Make sure that you are not exceeding the rated data for the power source i e that the unit is not being overloaded Poor welding performance S Check that the welding current supply and return cables are correctly connected S Check that the correct current value is set S Check that the co...

Page 43: ... 43 notes NOTES ...

Page 44: ... 44 notes ...

Page 45: ...50 92 22 ESAB international AB Gothenburg Tel 46 31 50 90 00 Fax 46 31 50 93 60 SWITZERLAND ESAB AG Dietikon Tel 41 1 741 25 25 Fax 41 1 740 30 55 North and South America ARGENTINA CONARCO Buenos Aires Tel 54 11 4 753 4039 Fax 54 11 4 753 6313 BRAZIL ESAB S A Contagem MG Tel 55 31 2191 4333 Fax 55 31 2191 4440 CANADA ESAB Group Canada Inc Missisauga Ontario Tel 1 905 670 02 20 Fax 1 905 670 48 79 ...