ESAB Mig L305 User manual

0349 300 067 Valid for serial no. 647, 628--xxx--xxxx071022

Mig L305

Mig L405

Origo







-- 2 --TOCe

READ THIS FIRS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INTRODUCTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TECHNICAL DATA 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Component description 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OrigoTM Mig L305 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OrigoTM Mig L405 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DESCRIPTION OF OPERATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

P1 Digital instrument 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

P1:1 Calibration and voltage correction 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

P1:2 Connections to the digital instrument 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE INSTRUCTIONS 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

What is ESD? 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thermal switch (thermostat) replacement procedure 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTRUCTIONS 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Placing 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly of counter balance 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly of components 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical installation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mains power supply 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connection and control devices 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overheating protection 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inductance connection 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection and cleaning 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Topping up the coolant 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULT TRACING 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ORDERING OF SPARE PARTS 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NOTES 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Edition 071022

-- 3 --1sO3545

READ THIS FIRS

The 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 October 2007.

The Origo

Mig L305, Mig L405 are designed and tested in accordance with interna-

tional 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 requirements

of the above standard.

INTRODUCTION

The Origo

Mig L305, Mig L405 are step switched power sources designed for

MIG/MAG--welding together with wire feed units OrigoFeed.

The power units are fan--cooled and equipped with thermal overload protection.

The machines can be fitted with an instrument that displays current and voltage.

It incorporates a hold function and can be calibrated.

Edition 071022

-- 4 --

1sO3545

TECHNICAL DATA

Origo

Mig L305 Origo

Mig L405 Origo

Mig L405

Voltage 400--415V, 3∼

∼∼

∼50/60 Hz 400--415V, 3∼

∼∼

∼50/60 Hz 230/400--415/500V

3∼

∼∼

∼50 Hz 230/440--460

3∼

∼∼

∼60Hz

Permissible load

at100 % duty cycle 150A 280 A/28 V 280 A/28 V

at 60 % duty cycle 190A 365 A/32 V 365 A/32 V

at 50 % duty cycle -- 400 A/34 V 400 A/34 V

at 25 % duty cycle 300A -- --

Setting range (DC) 30A/15V--300A/29V 50A/16,5V--400A/34V 50A/16,5V--400A/34V

Open circuit voltage 17--40V 17--45 V 17--45 V

Open circuit power 190 W 360 W 360 W

with cooling unit -- 600 W 600 W

Efficiency at max cur-

rent

69% 71% 71%

Power factor at max

current

0,97 0,98 0,98

Control voltage 42 V, 50/60 Hz 42 V, 50/60 Hz 42 V, 50/60 Hz

Dimensions lxwxh 782 x 425 x 830 812 x 552 x 925 812 x 552 x 925

Weight 89 kg 142 kg 143 kg

with cooling unit -- 156 kg 156 kg

Operating temperatu-

--10 to +40

C --10 to +40

Enclosure class IP 23 IP 23 IP 23

Application classifi-

cation

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 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.

Edition 071022

-- 5 --1sO3545

WIRING DIAGRAM

Component description

WARNING !

STATIC ELECTRICITY can damage circuit

boards and electronic components.

S Observe precautions for handling electrostatic

sensitive devices.

S Use proper static--proof bags and boxes.

ESD

Origo

Mig L305

C1, C2, CES

Capacitor, 0,1 uF 250V

EV1

Fan

HL1

Lamp, green, On/Off

HL2

Lamp, yellow. Thermal overload cutout

KM1

Main contactor 42V, 50--60Hz

Inductor

AP2

Digital instrument, accessory

QF1

Switch, ON/OFF

Resistor

Varistor

RS1

Shunt, accessory

SA1

10--step switch, selection of welding voltage

ST1

Thermal overload cutout, opens at 120

C. Mounted at the cooling fins of

the diode bridge.

ST2

Thermal overload cutout, opens at 160

C. Mounted in the winding of

transformer TM1.

TC1

Control transformer.

TC2

Transformer for CO2 heater, accessory.

TC3

Transformer for digital instrument, accessory

TM1

Main transformer.

V1--V6

Diode bridge

Edition 071022

-- 6 --

1sO3545

XS1

Connector, 15--pole. For connection to/from the wire feed unit.

XT1

3--pole terminal block.

XT2, XT3

connector, flat pin.

Edition 071022

-- 7 --1sO3545

Origo

Mig L305, 400--415V

Edition 071022

-- 8 --

1sO3545

Origo

Mig L405

C1--C3

Suppression capacitors 2uF 450V.

Capacitor, 3uF 400V. Start and run capacitor for fan motor EV1.

C6, C7

Suppression capacitors 0.1uF 250V.

EV1

Fan

HL1

Indicating lamp 42V, white. Lights when switch QF1 is in the ON position.

HL2

Indicating lamp 42V, yellow. Lights to indicate operation of the thermal

cutouts.

KM1

Contactor 42V 50Hz. Main contactor.

Inductor.

Pump, 230V 50Hz 0.2kW. Only machines with water cooling.

Digital instrument.

QF1

Main ON/OFF switch.

QF2

Switch, for selecting welding voltage, 4--step.

QF3

Switch, for selecting welding voltage, 10--step.

Resistor

RS1

Shunt 60mV / 400A, accessory.

SA1

Cooling water pump switch. Only on machines with water cooling.

ST1

Thermal switch. 150_C Protects the machine against excessive

temperature. Mounted on inductor.

TC1

Control transformer.

TC2

Transformer for CO2 heater, accessory.

Main transformer.

V1--V6

Diode bridge

XS1

Connector, 15--pole. For connection to/from the wire feed unit.

XS2--XS5

Main welding current contact, single--pole.

XT1

3--pole terminal block.

XT2

9--pole terminal block.

Edition 071022

-- 9 --1sO3545

Origo

Mig L405, 400--415V

Edition 071022

-- 10 --

1sO3545

Origo

Mig L405, 230--500V

Edition 071022

-- 11 --1sO3545

DESCRIPTION OF OPERATION

P1 Digital instrument

P1:1 Calibration and voltage correction

The meter has a possibility of the voltage and current calibration, as well as a possibility

of the current--dependant voltage correction, to show a voltage approximately equal to

the actual arc voltage.

Since all meters are factory calibrated it is recommended to carry out a second

calibration only if it’s needed. In most applications a zero voltage correction (no

correction) is factory adjusted.

For the calibration an accurate reference meter and a resistance load are required. The

resistance load should force at least 100A current flow.

For calibration following actions should be done:

1 Switch the machine on and load it. The meter should indicate voltage and current

presence.

2 Press simultaneously both pushbuttons placed on the meter PC board. In sequence,

symbols of the calibration modes appear: ”U” -- voltage calibration, ”I” -- current

calibration, ”dU” -- voltage correction. Release the buttons as the required mode

appears.

3 Adjust the voltage or the current value equal to the value shown by the reference meter

by means of the pushbuttons: S1 -- ”+”, S2 -- ”--”.

Voltage calibration mode

The reference meter should be connected to the same potentials as a calibrated meter.

Exclusively in this mode a voltage without correction is shown on display.

Voltage correction mode

The reference meter should be connected to the end of mass cable and to the torch

current tip, which are connected to the external load. In this mode, as well as during the

regular work, the meter shows a voltage taking in account voltage drops on cables and

welding torch. An adjustment of the voltage correction should be carried out only in

assumption of the proper voltage calibration and in the presence of load current above

100A.

Edition 071022

-- 12 --

1sO3545

P1:2 Connections to the digital instrument

SERVICE INSTRUCTIONS

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.

WARNING !

STATIC ELECTRICITY can damage circuit

boards and electronic components.

S Observe precautions for handling electrostatic

sensitive devices.

S Use proper static--proof bags and boxes.

ESD

Edition 071022

-- 13 --1sO3545

Thermal switch (thermostat) replacement procedure

1. Spare thermostat must be the same type as replaced one.

2. Spare thermostat should be mounted within radius of 10mm or less from broken

thermostat. If it’s possible and safe for transformer winding, broken thermostat may be

removed. Then the spare thermostat is to be mounted right in place of broken one.

3. Spare thermostat should adjoin protected winding as tight as possible.

4. Spare thermostat must be secured with silicone glue of working temperature of 200

or higher.

Edition 071022

-- 14 --

2sO3545

INSTRUCTIONS

This chapter is an extract from the instructions for Origo

Mig L305, Mig L405.

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 recommen-

dations 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.

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.

Edition 071022

-- 15 --2sO3545

The power supply should be lifted by means of its lifting

eye. The handle is only intended for pulling it along the

ground.

Lifting instructions

Placing

Position the welding power source such way that its cooling air inlets and outlets are

not obstructed.

Assembly of counter balance

Assemble the stabilizer + CB KIT if the counter balance is to be installed on machine.

The stabilizer + CB KIT is an accessory. Ordering number you can find in user manual.

Attention! Utilization of counter balance without stabilizer may cause the machine

tipping over.

Edition 071022

-- 16 --

2sO3545

Assembly of components

During transport, the rear wheels of the power source are in their forward position.

Before use, place the wheels in their rear position.

WARNING!

Edition 071022

-- 17 --2sO3545

Electrical installation

L405

Edition 071022

-- 18 --

2sO3545

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

L305 3∼ 50/60 Hz

Voltage V 400/415

Current A

at100% duty cycle 7

at 60% duty cycle 10

at 25% duty cycle 18

Cable area mm

4 x 2,5

Fuse, slow A 16

L405 3∼ 50 Hz 3∼ 50/60 Hz 3∼ 50 Hz 3∼ 60 Hz 3∼ 60 Hz

Voltage V 230 400/415 500 230 440/460

Current A

at100% duty cycle 28 16 13 28 14

at 60% duty cycle 42 24 19 41 21

at 50% duty cycle 45 28 20 45 22

Cable area mm

4 x 6 4 x 2,5 4 x 2,5 4 x 6 4 x 2,5

Fuse, slow A 25 20 20 25 20

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.

OPERATION

General safety regulations for the handling of the equipment appear from page

14. Read through before you start using the equipment!

WARNING -- TIPPING RISK!

There is a risk of tipping while transportation and operation, if the welding machine leans

more than 10

. In that case appropriate securing has to be provided !

Edition 071022

-- 19 --2sO3545

Connection and control devices

1 Mains supply switch 8 Connection for return cable (--), high induc-

tance

2 Main supply switch for cooling unit 9 Connection for return cable (--), low induc-

tance

3 Switch, precise control 10 Connection for welding current cable (+)

4 Switch, coarse control 11 Connection for control cable for wire feeder

5 Indicating lamp, power supply ON 12 Connection RED for cooling water from the

wire feed unit

6 Orange indicating lamp, overheating 13 Connection BLUE for cooling water to the

wire feed unit

7 Space for digital meter (optional),

see user manual

Overheating protection

A thermal overload cutout protects against overheating. The cutout resets automatically

when the unit has cooled.

Inductance connection

Higher inductance produces a more flowing weld and fewer spatters. Lower inductance

produces a harsher sound and a stable, concentrated arc.

Edition 071022

-- 20 --

2sO3545

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.

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 become blocked and cause overheating.

Topping up the coolant

We recommend a 50/50 % mixture of water and ethylene glycol.

Page is loading ...

ESAB Mig L305, Mig L405 Origo™ User manual

Related papers

Other documents