ESAB Origo™ Cut 35i User manual

Brand: ESAB

Model: Origo™ Cut 35i

Type: User manual

This manual is also suitable for

Origo™Cut 35i

Service informations:

General

The OrigoCut 35i is an air plasma cutting inverter that operates 230-240Vac (±10%) single phase power

supply. The 2.5m long cable is supplied with a Schucko plug. Circuit bracker with 16A time lag (slow) fuse is

sufficient.

Note:

• At it’s maximum 35A output the primary current is 27A. The open circuit voltage is around 270Vdc and

the maximum cut thickness is 12mm Mild steel.

• The OrigocCut 35i is fitted with the 4.5m long ESAB PT31XL plasma torch. Note: that does not have a

pilot arc and uses HF type arc inition. The safety system utilises an “Air flow sensor” inside the OrigoCut

35i power source in combination with a valve in the PT31XL plasma torch head. If the heat shield is

removed from the torch to access the cutting tip, electrode, etc. the air valve in the torch head shuts off

the air flow. The flow switch in the OrigoCut 35i will not close and no output is available if the torch

switch is accidentally operated.

• An approx. 2 second air preflow is inbuilt when the torch switch is closed, this is overriden if air is already

flowing. Note: there is no air gauge or regulator outside the power source. The regulator is inside the

cover and is preset from the factory.

• When the OrigoCut 35i is first switched on the air will immediately flow for approximately 15 seconds

(the post flow time) to purge any moisture or dirt out of the system.

• There is no test button fitted to this equipment.

• A green LED indicates that air flow switch is activated.

• A yellow LED will indicate that the top temperature of the overtemperature protection has been reached

inside the OrigoCut 35i and the output will be inhibited until the unit has cooled. Make sure that the fan

motor in the back of the unit is operating correctly if this occurs.

Overall OrigoCut 35i circuit arrangement (see fig.1, block diagram):

The OrigoCut 35i uses 2 circuit boards and one bottom plate assembly:

Control The logic, HF generator, air valve PCB top front mounted.

This receive inputs from the torch switch, flow switch, current control potentiometer,

output voltage, etc. and provides the correct control sequencing and interlocks.

Inverter The main inverter PCB.

Bottom plate This carries the main transformer, secondary diodes and chocke.

S1 rocker switch 2x16A R201 resistor 150 ohm 1W

S2 air flow switch 50 l/min R202 resistor 100 ohm 2W

VR1 fan 120x120 220/230V 50/60Hz R203 resistor 6M8

SV1 solenoid valve 230V C201-202 capacitors 1nF 250Vac

T1 main transformer 10/14 C203 capacitor 22nF 250Vac

T2 HF transformer D201-203 diode assembly

L1 coil 500uH CONTROL marked EBPLA3

L2 common mode inductor 1 turn INVERTER marked INV140A v.7

L3 common mode inductor

Fig.1 block diagram OrigoCut 35i:

Fig.2 troubleshooting flow chart OrigoCut 35i:

Spare part list:

ITEM NO. PART NO. DESCRIPTION

1 0459173001 UPPER CASE (LID)

2 0459119001 HANDLE

3 0700156021 TRANSPARENT SWITCH COVER

4 0700156022 CONTROL/HF PCB

5 0700156023 HF GENERATOR

6 0700156006 AIR NIPPLE 1/8” Dia. 8mm, L=20mm

7 0700156007 POWER CABLE 3x1,5 sqmm, L=2,5m

8 0558001466 PT - 31 XL TORCH Ass.ly

9 0700156008 PRESSURE GAUGE

10 0700156009 FAN

11 0700156010 EMC FILTER

12 0558000410 FLOW SWITCH P/N 951202

13 0700156011 INVERTER PCB

14 0700156012 ON/OFF SWITCH

15 0700156013 EARTH CABLE W/CLAMP, L=5m

16 0459172001 PLASTIC FRONT PANEL

17 0700156014 BOTTOM PLATE

18 0700156015 CHOKE (INDUCTANCE)

19 0700156016 TRANSFORMER

20 0700156017 HEAT SINK WITH DIODES

21 0700156024 VENTILATION GRID

22 0700156019 KNOB Dia. 25mm

23 0700156025 Multilanguage user manual

24 0700156020 SOLENOID VALVE

Important circuit details (see Fig.3-4-5-6-7-8):

Primary: The main inverter “INVERTER” rectifies the incomming 230-240V mains

and feeds this to a capacitor bank C101A-B-C via a softstart circuit

comprising relay RL101 and resistor R102 (10 ohm). The relay contact

closes roughly ½ second after switch on, shorting out R102. The dc voltage

across RS101 is roughly 320Vdc.

Auxiliary voltages: The mains rectified voltage is fed to a small PCB vertical mounted on the

main inverter PCB. Inside this a DC/DC step-down converter generates a

24Vdc auxiliary voltage. Other 2 voltage 12Vdc, 5Vdc are derivated from

the main 24Vdc, also.

All these voltages power the various circuits on all the PCB’s.

Thermal overload protection: Is provided by a PTC resistor mounted on a mosfet heatsink on the inverter

PCB. When the temperature has reached the preset high temperature an

overtemperature protection inhibits the main inverter and a signal is sent

out to light the yellow warning LED on the control board PCB.

The inverter: Switching the main mosfet transistor on/off and hence O.C.V. for example

enabling or disabling the main inverter. This is via a signal from the

logic/control PCB to the main inverter PCB it can be measured on Q4

collector.

The current reference: Voltage control up to 5Vdc, is input to the main inverter PCB at CN103 pin

HF and solenoid valves: The control PCB generates the necessary drive for the HF transformer and

controls the air solenoid valve, note these are powered directly by 230-

240V from the mains supply as follows:

• When the torch switch is closed a logic signal immediately drive the relay RL1 in order to give power to

the gas valve.

• After a little delay from the closed t.s. the inverter is enabled and an open circuit voltage appairs between

A7, A9 connections on the control PCB enegising RL2 which starts the HF generator stage.

Note:

If the gas relay RL1 is not energised it is not possible to get HF as this relay is used to supply 230-240Vac

to the primary of the HF drive stage power supply transformer T2 placed on the control PCB.

Sequencing and interlocks: The main sequencing and interlocking signals required by the control PCB

are:

• O.C.V./arc voltage (measured between A7, A9 connections on the control PCB) is used to both

enable/disable the HF and to limit the O.C.V. of the main inverter to around 270Vdc.

• The air flow switch prevents cutting power from enabling if no air flows, a green LED is illuminated if the

flow switch is operating.

Note:

If the green LED is on and yet no air is flowing, do not use the unit before the fault has been found (flow

switch might be stuck).

OrigoCut 35i – PCB schematics:

Fig.3 CONTROL PCB SCHEMATIC

Fig.4 INVERTER PCB SCHEMATIC

OrigoCut 35i – PCB layouts:

Fig.5 CONTROL PCB LAYOUT

Fig.6 INVERTER PCB LAYOUT

OrigoCut 35i – PCB bill of materials:

QTY COMPONENT REFERENCE TYPE/VALUE

7 A1, A2, A3, A4, A5, A6, A7, A8, A9, A10, A11 FASTON

1 C14 22nF 250Vac CL Y

1 C4 NOT MOUNTED

1 C13 47nF 630V

2 C3, C5 0.1uF

1 C7 0.1uF 1000V

5 C2, C6, C8, C10, C11 10uF

1 C12 10uF 400V

1 C9 22uF

1 C1 470uF 25V

1 CN2 CONN. 2 PIN

1 CN1 CONN. 6 PIN

1 CN3 NOT MOUNTED

1 D20 ZENER 15V 1W

1 D16 DIODE 1N4007

10 D1, D2, D4, D5, D7, D8, D9, D12, D13, D14 DIODE 1N4148

1 D6 ZENER 24V 0.5W

1 D3 ZENER 24V 1W

2 D17, D18 ZENER 68V 1W

2 D15, D19 DIODE BAT46

1 D11 DIODE BYT12P1000

1 D10 DIODE EM518

1 DL1 LED YELLOW

2 DL2, DL3 LED GREEN

2 M1, M2 MORS. 2 PIN

1OC1 OPTO TLP621

1 P1 POT. 100K

1 Q5 SCR IRC 30TPS12

4 Q1, Q2, Q3, Q4 TRANS.BC337 - 25

2 R1, R24 NOT MOUNTED

1 R32 6M8 0,5W 5%

2 R3, R31 10R 0,25W 5%

2 R26, R27 10R 10W 5%

2 R14, R22 100R 0,25W 5%

1 R28 100R 2W 5% WIREWOUND

3 R13, R15, R17 1K 0,25W 5%

1 R30 2K2 0,25W 5%

2 R7, R23 4K7 0,25W 5%

1 R9 8K2 0,25W 5%

6 R8, R10, R16, R19, R21, R25 10K 0,25W5%

1 R11 22K 0,25W 5%

3 R4, R5, R6 27K 0,25W 5%

1 R12 47K 0,25W 5%

2 R2, R18 100K 0,25W 5%

1 R29 100K 1W 5%

1 R20 680K 0,25W 5%

1 RL2 RELE 110V 16A

1 RL1 RELE 24V 16A

1 T1 TRA.002.004.XX

1 T2 TRA.002.001.XX

1 U2 40106

1 U1 7812

1 Z1 VARISTOR 275V

Fig.7 CONTROL PCB BILL OF MATERIALS

QTY COMPONENT REFERENCE TYPE/VALUE

4 A101 A102 A103 A104 FASTON

1 C102 47F 25V

3 C101A C101B C101C 470F 400V

2 CN101 CN102 SC.100ASMT.00.00.XX

1 CN103 CONN. 6 PINS

2 D102 D103 DIODE 1N4148

1 D101 ZENER 47V 1W

2 D104 D105 DIODE MUR1560

2 DL101 DL102 NOT MOUNTED

1 M101 NOT MOUNTED

1 P101 NOT MOUNTED

1 PTC MESP00100

2 Q102 Q108 TRANS. BC327-25

1 Q101 MOSFET IRFD110

4 Q105 Q106 Q107 Q111 Q112 Q113 IGBT SGW30N60

6 Q103 Q104 Q109 Q110 NOT MOUNTED

1 R102 10R 10W

10 R105 R106 R107 R108 R109 R111 R112 R113 R114 R115 15R 0,25W

1 R120 27R 0,25W

2 R118 R119 100R 0,25W

2 R104 R110 1K 0,25W

1 R116 2K2 0,25W

1 R117 4K7 0,25W

1 R103 10K 0,25W

1 R101 68K 1W

1 RL101 RELE 21V 16A

1 RS101 BRIDGE 35A 600V

1 RV101 TRIMMER 50R

2 RX1 RX2 150R 2W

1 T101 TRA.002.006.00

1 TA101 TRA.003.001.00

3 TP1 TP2 STRIP 2 PINS

1TP3 CONN. 2 PINS

1 Z101 VARISTOR 275V

Fig.6 INVERTER PCB BILL OF MATERIALS

ESAB Origo™ Cut 35i User manual

Brand: ESAB

Model: Origo™ Cut 35i

Type: User manual

This manual is also suitable for

Origo™Cut 35i

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ESAB Origo™ Cut 35i User manual

This manual is also suitable for

ESAB Origo™ Cut 35i User manual

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