ESAB Arc 410c User manual

Brand: ESAB

Model: Arc 410c

Category: Measuring, testing & control

Type: User manual

This manual is also suitable for

ESAB Arc 410c is a compact and powerful welding inverter that offers versatility for various welding tasks. It's suitable for MMA, TIG, and ARC gouging applications. The device ensures precise welding performance with its advanced control system and features like Hot Start, Arc Force, and Anti-Stick for optimized arc stability and weld quality.

0349 300 082 Valid for serial no. 734, 749, 751--xxx--xxxx080623

Arc 410c

Arc 650c

Arc 810c

Origo

™

™™

™

Service manual

READ THIS FIRST .................................................................................................................................. 3

INTRODUCTION ..................................................................................................................................... 4

Design structure of the power source .................................................................................................. 4

TECHNICAL DATA.................................................................................................................................. 5

WIRING DIAGRAM.................................................................................................................................. 6

Component description ........................................................................................................................ 6

OrigoArc 410c ...................................................................................................................................... 7

OrigoArc 650c ...................................................................................................................................... 8

OrigoArc 810c ...................................................................................................................................... 9

DESCRIPTION OF OPERATION.......................................................................................................... 10

MMC module...................................................................................................................................... 10

Control panel A11 .............................................................................................................................. 10

Control panel A12 .............................................................................................................................. 11

Current and welding voltage meter .................................................................................................... 12

Remote wireless welding current setting receiver circuit................................................................... 13

A12 panel supply................................................................................................................................ 13

LM11 Component positions ............................................................................................................... 14

CH21 Control circuit board .................................................................................................................... 15

Welding current setting circuit............................................................................................................ 15

ANTISTIC, HOTSTART, ARC FORCE functions .............................................................................. 16

Current loop control system ............................................................................................................... 17

Circuit reducing the current required for activating the device .......................................................... 18

Steering voltage source ..................................................................................................................... 18

Activation in TIG method.................................................................................................................... 19

Selecting the welding method ............................................................................................................ 19

Signalling and protecting systems ..................................................................................................... 19

Power transistors control system (driver) .......................................................................................... 20

Power unit .......................................................................................................................................... 20

CH21 Component positions ............................................................................................................... 21

K69 Suppression circuit board............................................................................................................... 22

Circuit diagram................................................................................................................................... 22

Component positions ......................................................................................................................... 22

REMOTE CONTROLS .......................................................................................................................... 23

SERVICE INSTRUCTION ..................................................................................................................... 23

What is ESD?..................................................................................................................................... 23

Service aid ............................................................................................................................................. 24

Antistatic service kit ........................................................................................................................... 24

Checking power board CH21 ................................................................................................................ 24

Checking signal LEDs........................................................................................................................ 24

Checking supply and reference voltages........................................................................................... 25

Calibrating the remote wire current setting circuit.............................................................................. 26

Calibrating of the source in MMA, ARC GOUGING and TIG mode .................................................. 27

Checking the HOT START function................................................................................................... 27

Checking the ARC FORCE function .................................................................................................. 27

Checking the ANTISTICK function..................................................................................................... 27

Checking the ANTISTICK function in MMA mode...................................................................... 27

Checking the ANTISTICK function in TIG mode ........................................................................ 28

Setting the maximum current ............................................................................................................. 28

Checking the operation of thermal protections .................................................................................. 28

Checking the operation of PWM driver .............................................................................................. 29

Checking the PWM signal.................................................................................................................. 29

Checking the gate pulses................................................................................................................... 29

Checking display board LM11............................................................................................................ 30

Checking supply and reference voltages ....................................................................................... 30

Current meter calibration................................................................................................................ 30

Calibration of the current value set with the remote wireless current setting receiver. ..................... 31

Voltage meter calibration ................................................................................................................... 32

Checking the remote current setting circuits...................................................................................... 33

Checking the wire remote setting circuit..................................................................................... 33

Checking the wireless remote current setting circuit .................................................................. 33

Checking chopper block V0 ............................................................................................................... 33

Overview test ..................................................................................................................................... 35

Rectifier test ....................................................................................................................................... 35

Checking of output stage. .................................................................................................................. 35

Replacing of damaged transistors. .................................................................................................... 36

NOTES .................................................................................................................................................. 37

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

boards are 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

June 2008.

The manual is valid for:

OrigoArc 410c/650c/810c with serial no.

734, 749, 751--xxx--xxxx

Origo

Arc 410c/650c/810c has been designed and tested in accordance with international and

European standards IEC/EN 60974.

On completion of service or repair, the service organisation that has performed the

work must make sure that the equipment still complies with the above standards.

INTRODUCTION

Origo

Arc 410c, Arc 650c, Arc 810c, are chopper controlled welding rectifiers designed for welding

with coated electrodes, TIG welding and arc air gouging.

Origo

Arc 650c and Arc 810c are delivered with panel A12. Origo

Arc 410c may be delivered with

panel A11 or A12. A12 is version with display that allows current setting to be read from the front of

the rectifier.

Design structure of the power source

The power source is transistor-controlled, operating on the chopper principle. It consists of a

number of function modules, as shown in the schematic diagram on next pages.

Block diagram

WIRING DIAGRAM

The power source consists of a number of function modules, which are described in the

component descriptions on the following pages.

Component description

A11 A11 MMC Panel.

A12 A12 MMC Panel.

B1 Thermal switch. Protects the main transformer against excessive temperature.

B2 Thermal switch. Protects the chopper block against excessive temperature.

C1 Capacitor, 3uF 450V/500V. Start and run capacitor for fan motor M1.

C3, C4, C5 Suppression capacitors, 0,1uF 250V.

CH21 Control circuit board.

H1 White indicating lamp, power supply ON.

H2 Orange indicating lamp, overheating.

K1 Main contactor.

K69 Suppression circuit board

L1 Inductor.

M1 Fan 230V 50Hz

Q01 Main ON/OFF switch.

R2 Resistor, 100 /50W

R3 Resistor, 22 /50W

RB Shunt, 60 mV / 600 A

TC1 Control power transformer.

TR1 Main transformer.

V0 Chopper module.

VB1 Rectifier.

X01 Remote control connector.

X03 Optional TIG connector.

X40, X50 Plug connector.

X60, X70 Plug connector.

XT1, XT4 9 pole terminal block.

WARNING !

STATIC ELECTRICITY can damage circuit

boards and electronic components.

• Observe precautions for handling electrostatic-

sensitive devices.

• Use proper static--proof bags and boxes.

Origo

Arc 410c

Origo

Arc 650c

Origo

Arc 810c

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.

MMC module

The MMC module consists of an operator’s control panel.

Control panel A11

A0 is intended only for OrigoArc410c.

A11 panel carries out basic functions required for MMA welding, AG arc gouging and TIG welding with

contact arc ignition.

Electric part of this panel consists of three potentiometers for welding current setting (R01), HOT

START time (R02) and ARC FORCE penetration depth (R03) as well as of welding method selection

switch (S1).

Control panel A12

Diagram of A12

Apart from potentiometers for current setting (R01), HOT START time (R02), ARC FORCE penetration

depth (R03) and welding method switch (S1), A12 panel also consists of current setting location

selection switch (S2), current and welding voltage meter and remote wireless current setting receiver.

Current and welding voltage meter

The meter has been made on the basis of the application of the ICL7107 integrated circuit. S

switch is

used for selecting the measured quantity (current or voltage). If the switch is set to position “A”,

negative voltage of – 5V is switched on for V

and V

transistor gates and the V

transistor is closed,

shorting the measured voltage signal to ground. V

transistor is then open and the current

measurement signal is transmitted to HI measuring input of the ICL7107 integrated circuit. If the S

switch is set to position “V”, positive voltage of +5V is switched on for V

and V

transistor gates; V

transistor is shorted and V

transistor open. The current measurement signal is transmitted to the

measuring input of the A1 integrated circuit. Simultaneously, the V

transistor responsible for switching

on the cutter on the display is polarised via the R

resistor. The R6 potentiometer is used for

calibration of the maximum indication of the device for the current measurement. The R

potentiometer is used for calibration of the device for the current measurement. The device is

calibrated first for the current and then for the voltage – according to the procedure included at the end

of the manual.

Remote wireless welding current setting receiver circuit

Circuits D1 and D2 form an 8-bit meter recording the set value of welding current in binary numbers.

A3 and A4 integrated circuits form the C/A converter which transforms the binary value of the current

into the setting voltage of the value within the range of 0 – REF1.

The A5a comparator shapes the impulses of the signal sent by the N02 transmitter. The received

signal is processed in the circuit of impulses selector and separator. As a result of such process, the

following impulses are sent: RESET impulse and COUNT impulse, with the duration proportional to the

set welding current. The D3a gate generates the impulse which resets D4 and D5 meters.

The flip-flop consisting of D3b and D3c controls the process of counting impulses while the information

concerning the set welding current is sent by the transmitter. The A5b comparator blocks the receiver

during welding. R24 potentiometer is used for calibrating the setting voltage range. Calibration of the

setting voltage for the receiving part of the remote wireless welding current setting is described in the

procedure of the A12 panel checking and calibrating and included at the and of the manual.

A12 panel supply

Power unit made on the TS1 transformer is used for supplying the panel. The TS1 transformer is

connected to alternating voltage of 42V. The power unit provides +15V and –15V voltage for supplying

integrated circuits of the wireless current setting receiver as well as +5V and –5V voltage for supplying

the meter.

Elements V

, C

, R

and V

make up the +15V voltage power unit, while elements V

, C

, R

, V

and C

make up the –15V negative voltage power unit.

Elements C

, VB1, C

, A6, C

, C

make up the +5V voltage power unit, while on elements R

, V

the –5V negative voltage power unit is made.

LM11 Component positions

CH21 Control circuit board

Welding current setting circuit

Reference voltage of 5.1V from the A2 integrated circuit is the source of the reference voltage for the

setting circuit. In order to obtain the reference voltage required for setting the current – the 5.1V

voltage is separated in the follower circuit consisting of the following elements: A13a, R

137

, C

and

138

.The R01 local setting potentiometer is connected in parallel to the C

capacitor. The voltage of

+10V on the A13b operational amplifier output is the reference voltage for the remote wire current

setting in this circuit. The system of three keys of the A17 integrated system makes up an electronic

switch which switches on the remote or local welding current setting. When the local setting is on, the

welding current setting signal is transmitted from the R01 potentiometer slide via the R

142

resistor and

the shorted A17c key onto the input of the separating follower, made on the A13d operating amplifier.

Switching to the remote wire supply mode is performed automatically after fixing the peripheral device

to the X01 socket on the cap board of the device. The electronic system of remote setting is

galvanically separated from the remaining electronic circuits controlling the source operation.

The VC

transoptor carries a signal which switches off the A17c key and switches on the A17d key,

transmitting the signal from the A12b amplifier output onto the A13d separating follower input, thus

activating the remote setting. The VC

transoptor transmits the signal of the welding current value.

This is a signal with a variable pulse-duty factor for a rectangular wave, proportional to the value set by

the potentiometer on the remote regulation peripheral device. The circuit made of the A11a

comparator and V

transistor generates the signal. The A11b comparator disables the generator if the

remote regulation peripheral device is disconnected from the device. Elements VB

, C

, R

114

, R

115

116

, V

, C

and C

make up the power unit for the galvanically separated part of the

remote setting circuit. The rectangular wave of the stable voltage amplitude and of time parameters

depending on the set welding current is obtained on the V

transistor collector. This signal is

averaged by means of a low-pass filter made on the A12a operational amplifier. The function of the

circuit made on the A12b operational amplifier is to set the changes range of the voltage setting the

welding current. The RP

potentiometer is used for resetting the setting signal for the current setting

potentiometer on the peripheral device to the minimum value. R

114

potentiometer is designed for

setting the maximum value of the setting signal for the current setting potentiometer on the peripheral

device to the maximum value. Calibration procedure is described in detail in item 2 – Procedures for

checking and calibration of the source. The A13d follower output is connected to the R

184

resistor and

potentiometer used for calibrating the maximum welding current in MMA, AG and TIG methods.

An amplifier with amplification 2 is made on the A13c operational amplifier. Potentiometers R

114

and

are connected to the output of this amplifier. The RP

potentiometer sets the minimum current. I

sol

voltage signal is the current setting in MMA, AG and TIG methods and it is transmitted onto the non-

inverting input of the A16a amplifier.

ANTISTIC, HOTSTART, ARC FORCE functions

The ANTISTICK function is carried out by the A14 integrated circuit.In the event that the electrode

sticks and the welding voltage is reduced to the value below the threshold of activating the ANTISTICK

function, the transistor in the A14c compactor is closed, which results in a delayed closure of the

transistor in A14d comparator. Closing this transistor will result in opening the A17a key and in

reduction of the voltage of the welding current setting I

to the minimum value, thus reducing the

output current of the source. In the MMA mode, the C

capacitor and R

160

+ R

161

resistors are

responsible for the delay of the ANTISTICK function activation. In the TIG mode, the delay of the

ANTISTICK function activation is switched off by means of a TIG signal transmitted by the R

162

resistor

onto the non-inverting input of A14d comparator. In the AG mode, the ANTISTICK function is switched

off by means of shorting the A14b comparator output with the activated output transistor of the A14a

comparator.

The HOT START function is carried out by A15 and D1 integrated circuits. When the welding starts

and the arc ignition takes place, V

transistor is switched on, which results in the high level on the

A15a amplifier output. The C

capacitor is charged via the R

197

resistor. The charging time of this

capacitor up to the voltage set by the HOT START potentiometer and sent to the non-inverting input of

A15b amplifier defines the HOT START operating time. As long as the voltage on the C

capacitor is

lower than the voltage set with the HOT START potentiometer, the level at the A15b output is high,

while the D1a circuit output transistor connects the R

173

resistor to the ground. Connecting the resistor

to the ground will result in the rise of voltage by 50% on the A16a operational amplifier output with

reference to the voltage at the non-inverting input, thus increasing the welding current setting value.

The HOT START function is blocked in the TIG mode. It is also deactivated if the HOT START

potentiometer is set to the minimum value.

The ARC FORCE function is carried out by the A16 operational amplifier. After reducing the initial

voltage to the value below the threshold of activating the ARC FORCE function, voltage on the A16b

output is decreasing. Reduction of this voltage results in the increase of the amount of current flowing

through the V

transistor and the increase of voltage at the A16a output, thus increasing the value of

the welding current. Maximum increase in the value of the welding current accompanying the arc

shortening may be regulated using the ARC FORCE potentiometer.

Current loop control system

Feedback signal from the shunt is amplified 100x by means of a differential amplifier made on the A1

operational amplifier and R

, R

resistors. Next, by means of R

, R

resistors it is carried

onto the input of the PI type regulator made on the operational amplifier included in the A2 integrated

circuit. Voltage signal proportional to the welding current is transmitted onto the non-inverting input of

this amplifier via R

, R

resistors. Output voltage from the PI regulator controls the operation of

the PWM modulator included in the A2 integrated circuit. Operation of the PWM modulator may be

blocked by means of a low logical level of a signal on the V

diode cathode, coming from the

protecting systems (thermal, lack of liquid circulation, too low supply voltage) and from the source

switch on/off control system. The electronic circuit made on the V

transistor is the limiter of the

maximum current source. The value of the current is set using the RP1 potentiometer. The PWM

output signal controls diodes of the VC

transoptor located in the driver circuit.

A voltage measurement signal proportional to the welding current is transmitted to the LM11/1 board

located on the A12 panel via the RC filter composed of RA

and CA

elements. The welding voltage

measurement signal is carried to the LM11/1 board via the filter composed of RV

and CV

elements.

Circuit reducing the current required for activating the device

Circuit reducing the current value required for activating the device switches on the K1 main contactor

only after the capacitor batteries in the chopper have been charged. This circuit is a typical Schmitt

trigger made on the A3a comparator, controlled by the voltage of a charging capacitors battery and

performing the switching on of the K1 contactor with delay in relation to the moment of switching on

the source via the Q01 switch. Activation of this circuit after the battery has been charged is signalled

by the V

diode.

Steering voltage source

The steering voltage is created by rectifying the alternating voltage of 42V via the bridge rectifier made

on diodes V

, V

, and then filtered by C

106

and C

107

capacitors. The voltage is connected in

parallel to output terminals of the source via the R2 resistor, which serves as a detector of the level of

contact of the electrode and the welded material as well as the detector of the signal sent by the N02

transmitter. In the TIG method, the steering voltage is switched on by the K2 transmitter when the

button on the welding torch is pressed, while in MMA and AG methods, it is switched on permanently,

providing the source resting voltage of approx. 56V.

Activation in TIG method

After pressing the button on the torch, the current flow through the VC3 transoptor takes place.

Switching on the transistor of the VC3 transoptor results in cutting the V

transistor off and unblocking

the PWM generator in the A2 integrated circuit. Switching on of the steering voltage via the V

transistor switching on the K2 transmitter also takes place.

Selecting the welding method

The system of selecting the welding method cooperates with the S1 welding method selecting switch

located on the A11 or A12 panel and connected to the CH21/1 board via the X2.8B connector. If the

S1 switch is set to the MMA mode, the steering voltage source is switched on permanently via the V

diode and the PWM circuit is unblocked. The ANTISTICK function is also switched on, along with the

delay of activating this function. If the S1 switch is set to the AG mode, the steering voltage source and

the PWM circuit are still switched on in the standby mode. The ANTISTICK function is switched off by

means of shorting the A14b comparator output via the switched on A14a comparator. In the TIG

mode, the steering voltage source is switched off and the PWM circuit is blocked until the button

located on the welding torch is pressed. The ANTISTICK function activation delay is also switched off.

Signalling and protecting systems

Activation status of the source is signalled by means of the H1 signal lamp located on the cap board.

Overheating protection of the device is carried out on the A3a comparator. This system cooperates

with bimetallic switches which open after the nominal temperature has been exceeded. Opening of

any of the switches (on the transformer or on the rectifying bridge) results in setting of the A3a

comparator inverting input with the voltage of +15V and closing its output transistor, which results in

blocking the PWM modulator operation via V

and V

diodes. Closed transistor of the A3a comparator

switches on the H

signal lamp.

Via V3 and V4 diodes, the A4a comparator carries out the blocking of the PWM circuit in case there is

no voltage readiness on the chopper capacitors battery or in case there is no voltage supplying the

driver.

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ESAB Arc 410c User manual

Brand: ESAB

Model: Arc 410c

Category: Measuring, testing & control

Type: User manual

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ESAB Arc 410c User manual

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ESAB Arc 410c User manual

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