ESAB Arc 810c Origo™ User manual

Category
Measuring, testing & control
Type
User manual

This manual is also suitable for

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
2
Checking chopper block V0 ............................................................................................................... 33
Overview test ..................................................................................................................................... 35
Rectifier test ....................................................................................................................................... 35
Checking of output stage. .................................................................................................................. 35
Replacing of damaged transistors. .................................................................................................... 36
NOTES .................................................................................................................................................. 37
3
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
TM
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.
4
INTRODUCTION
Origo
TM
Arc 410c, Arc 650c, Arc 810c, are chopper controlled welding rectifiers designed for welding
with coated electrodes, TIG welding and arc air gouging.
Origo
TM
Arc 650c and Arc 810c are delivered with panel A12. Origo
TM
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
5
6
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.
7
Origo
TM
Arc 410c
8
Origo
TM
Arc 650c
9
Origo
TM
Arc 810c
10
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).
11
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.
12
Current and welding voltage meter
The meter has been made on the basis of the application of the ICL7107 integrated circuit. S
3
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
7
and V
8
transistor gates and the V
8
transistor is closed,
shorting the measured voltage signal to ground. V
7
transistor is then open and the current
measurement signal is transmitted to HI measuring input of the ICL7107 integrated circuit. If the S
3
switch is set to position “V”, positive voltage of +5V is switched on for V
7
and V
8
transistor gates; V
7
transistor is shorted and V
8
transistor open. The current measurement signal is transmitted to the
measuring input of the A1 integrated circuit. Simultaneously, the V
9
transistor responsible for switching
on the cutter on the display is polarised via the R
14
resistor. The R6 potentiometer is used for
calibration of the maximum indication of the device for the current measurement. The R
12
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.
13
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
1
, C
21
, R
16
and V
2
make up the +15V voltage power unit, while elements V
3
, C
29
, R
17
, V
4
and C
30
make up the –15V negative voltage power unit.
Elements C
20
, VB1, C
23
, A6, C
24
, C
26
make up the +5V voltage power unit, while on elements R
1
, V
5
,
C
31
the –5V negative voltage power unit is made.
14
LM11 Component positions
15
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
51
and
R
138
.The R01 local setting potentiometer is connected in parallel to the C
51
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.
16
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
2
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
2
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
55
transistor generates the signal. The A11b comparator disables the generator if the
remote regulation peripheral device is disconnected from the device. Elements VB
1
, C
41
, R
114
, R
115
,
R
116
, V
50
, V
51
, V
52
, V
53
, C
42
and C
43
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
57
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
2
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
RP
4
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
RP
2
are connected to the output of this amplifier. The RP
5
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
s
to the minimum value, thus reducing the
output current of the source. In the MMA mode, the C
57
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
17
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
94
transistor is switched on, which results in the high level on the
A15a amplifier output. The C
61
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
61
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
97
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
1
, R
2
, R
5
, R
6
resistors. Next, by means of R
7
, R
8
, R
10
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
17
, R
16
, R
15
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
4
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
19
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
5
transoptor located in the driver circuit.
18
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
1
and CA
1
elements. The welding voltage
measurement signal is carried to the LM11/1 board via the filter composed of RV
1
and CV
1
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
12
diode.
Steering voltage source
The steering voltage is created by rectifying the alternating voltage of 42V via the bridge rectifier made
on diodes V
42
, V
43
, V
44
, V
45
, 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.
19
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
48
transistor off and unblocking
the PWM generator in the A2 integrated circuit. Switching on of the steering voltage via the V
49
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
82
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
2
and V
4
diodes. Closed transistor of the A3a comparator
switches on the H
2
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 810c Origo™ User manual

Category
Measuring, testing & control
Type
User manual
This manual is also suitable for

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