ESAB Mig C200 3ph User manual

Brand: ESAB

Model: Mig C200 3ph

Category: Welding System

Type: User manual

This manual is also suitable for

The ESAB Mig C200 3ph is a step controlled power source designed for welding with solid steel, stainless steel, or aluminum wire as well as tubular wire with or without shielding gas. With a 100% duty cycle at 120 A, it offers reliable welding performance for various applications. The device's compact design makes it portable and suitable for use in tight spaces. Its adjustable wire feed speed, burnback time, and spot welding capabilities provide precise control over the welding process.

Origo™

Service manual

0349 300 064 GB 20180627

Valid for: serial no. 626-, 744-xxx-xxxx

MigC1703ph, MigC2003ph,

MigC2503ph

TABLE OF CONTENTS

0349 300 064 © ESAB AB 2018

READ THIS FIRST

....................................................................................

INTRODUCTION

.......................................................................................

TECHNICAL DATA

...................................................................................

WIRING DIAGRAM

...................................................................................

Component description

.........................................................................

Origo™ Mig C170 3ph, 400-415V

..........................................................

Origo™ Mig C200 3ph, 400-415 V

.........................................................

Origo™ Mig C250 3ph, 400-415 V

.........................................................

Origo™ Mig C250 3ph, 230/400-415 V

..................................................

DESCRIPTION OF OPERATION

..............................................................

AP1 Control board

..................................................................................

AP1:1 Power supply ............................................................................. 16

AP1:2 Reference circuit........................................................................ 16

AP1:3,4,5 Start / Stop, Thermal overload, Spot welding ...................... 17

AP1:6 Burnback time............................................................................ 17

AP1:7 Control amplifier and pulse width modulator ............................. 18

AP1:8,9 Motor driving / braking ............................................................ 18

AP1 - component layout ....................................................................... 19

SERVICE INSTRUCTIONS

.......................................................................

What is ESD?

..........................................................................................

Thermal switch (thermostat) replacement procedure

........................

Rights reserved to alter specifications without notice.

READ THIS FIRST

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READ THIS FIRST

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 2017.

The Origo

Mig C170/C200/C250 3ph is 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 requirements of the above

standard.

INTRODUCTION

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INTRODUCTION

Origo

Mig C170/C200/C250 3ph is step controlled power source in a compact design,

intended for welding with solid steel, stainless steel or aluminium wire as well as tubular wire

with or without shielding gas.

The possibility of welding with homogeneous wire/shielding gas and welding with gasless

tubular wire is obtained by changing -over the welding polarity + and - on the terminal by the

wire feed unit.

NOTE!

Dispose of electronic equipment at the recycling

facility!

In observance of European Directive 2012/19/EC on Waste

Electrical and Electronic Equipment and its implementation

in accordance with national law, electrical and/or electronic

equipment that has reached the end of its life must be

disposed of at a recycling facility.

As the person responsible for the equipment, it is your

responsibility to obtain information on approved collection

stations.

For further information contact the nearest ESAB dealer.

TECHNICAL DATA

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TECHNICAL DATA

Origo™ Mig C170

3ph

Origo™ Mig C200

3ph

Origo™ Mig C250

3ph

Voltage 400–415 V,

3~50/60Hz

400–415 V,

3~50/60Hz

230/400–415 V,

3~50/60Hz

Permissible load at

100 % duty cycle 100 A 120 A 150 A

60 % duty cycle 130 A 150 A 190 A

35 % duty cycle 170 A 200 A 250 A

Setting range (DC) 30–170 A 30–200 A 40–280 A

Open circuit voltage

15.5–30.6V

18.0–34.8V

16.0–31.8 V 15.0–37.0 V

Open circuit power 310 W 210 W 340 W

Power factor at max load 0.97 0.97

0.97

, 0.94

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

Wire feed speed 1.0–17 m/min 1.0–17 m/min 1.0–17 m/min

Burnback time 0.02–0.25 s 0.02–0.25 s 0.02–0.25 s

Spot welding 0.2–2.5 s 0.2–2.5 s 0.2–2.5 s

Welding torch connection EURO EURO EURO

Wire dimension range 0.6–0.8(Fe, SS) 0.6–1.0(Fe, SS) 0.6–1.2(Fe, SS)

1.0(Al) 1.0(Al) 1.0–1.2(Al)

0.8(FCW) 0.8–1.0(FCW) 0.8–1.2(FCW)

0.8–1.0(CuSi) 0.8–1.0(CuSi) 0.8–1.0(CuSi)

Max diameter/weight of

wire bobbin

300 mm/15 kg 300 mm/15 kg 300 mm/15 kg

Dimensions l×w×h 860x420x730 mm 860x420x730 mm 860×420×730 mm

Weight

63.5kg

, 67.5 kg

72.5 kg 82 kg

Operating temperature -10 to +40 °C -10 to +40 °C -10 to +40 °C

Enclosure class

IP23

, IP21

IP23

, IP21

IP23

, IP21

Application classification

Valid for serialnumber626-xxx-xxxx

Valid fromserialnumber744-xxx-xxxx

Duty cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or

cut at a certain load without overloading. The duty cycle is valid for 40°C/104°F, or below.

Enclosure class

The IP code indicates the enclosure class, i.e. the degree of protection against penetration

by solid objects or water.

Equipment marked IP21 is intended for indoor use.

Equipment marked IP23 is intended for indoor and outdoor use.

TECHNICAL DATA

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Application class

The symbol indicates that the power source is designed for use in areas with increased

electrical hazard.

WIRING DIAGRAM

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WIRING DIAGRAM

Component description

CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling electrostatic

sensitive devices.

• Use proper static-proof bags and boxes.

AP1 Control circuit board

AP2 Digital instrument, accessory

C1, C2,

CVS

Capacitor 0,1 μF/250 V

EV1 Fan

KM1 Contactor 42V, 50-60Hz

L1 Inductor

L2, L3 Ferrite core

HL1 Lamp, white, On/Off, 42V

M1 Feed unit motor

QF1 Switch, ON/OFF

QF2 Switchweldingvoltageselector: 8-stepforOrigomagC1703ph,

10-stepforOrigomagC200/C2503ph

RVS Resistor

RP1 Potentiometer, wire feed speed 10k

RP2 Potentiometer with switch, spot welding 470k

RI Shunt, accessory

RL Resistor

ST1,

ST2

Thermal overload cutout, operates at 150 °C. ST1 is mounted on secondary winding

of TM1. ST2 is mounted in the rectifier bridge (from serial no. 744-xxx-xxxx).

TC1 Control transformer

TC2 Transformer for CO

heater, accessory

TC3 Transformer for digital instrument, accessory

TM1 Main transformer

V1 Diode bridge

VH LED yellow indication, thermal overload

XTP Welding current contact, welding polarity change-over

XT4 Terminal block, accessory

YV1 Gas valve

WIRING DIAGRAM

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Origo™ Mig C170 3ph, 400-415V

WIRING DIAGRAM

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Origo™ Mig C200 3ph, 400-415 V

WIRING DIAGRAM

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Origo™ Mig C250 3ph, 400-415 V

Valid for serial no. 626-xxx-xxxx

WIRING DIAGRAM

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Valid from serial no. 744-xxx-xxxx

WIRING DIAGRAM

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Origo™ Mig C250 3ph, 230/400-415 V

Valid for serial no. 626-xxx-xxxx

WIRING DIAGRAM

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Valid from serial no. 744-xxx-xxxx

DESCRIPTION OF OPERATION

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DESCRIPTION OF OPERATION

AP1 Control board

DESCRIPTION OF OPERATION

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DESCRIPTION OF OPERATION

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AP1:1 Power supply

Transformer TC1 supplies indicating lamp HL1 and rectifier bridge BR1 with 27 V AC. The

unsmoothed DC output from BR1 is smoothed by capacitors C5 and C25 to produce an

open-circuit voltage of 38 V ±10%.

This provides the power supply for the wire feeder motor.

Connections T6 and T7 supply 20 V AC from transformer TC1 to diodes D18 - D21. The

rectified voltage is about 24 V, voltage regulator VR1 is supplied via diode D1 to provide a

regulated 15 ±0.6 V supply.

AP1:2 Reference circuit

Potentiometer R49 controls the wire feed speed and is connected to terminals P1 - P3. It is

energised via resistors R51 - R55 and R23. The reference voltage is supplied through

resistor R20 to the error amplifier.

DESCRIPTION OF OPERATION

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AP1:3,4,5 Start / Stop, Thermal overload, Spot welding

Start / Stop circuit

When the torch trigger switch SB1 is not activated, the voltage between M3 and M4 is 24 V.

Pressing the trigger switch shorts the circuit, producing a voltage of 0 V between M3 and M4.

Thermal overload circuit

The power source contains two thermal overload cutouts, wired in series and connected to

inputs T8 and T9. If either of them operates, the torch trigger switch circuit cannot be short

-circuited, with the result that wire feed cannot be started. When either of the thermal cutouts

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 resistors R32 and R50. Wire feed stops when the voltage on C22 reaches 8.8 V. The

trigger switch must be released and then pressed again before a new spot weld can be

made.

The spot welding time can be adjusted between 0.2 and 2.5 seconds ±30%.

AP1:6 Burnback time

DESCRIPTION OF OPERATION

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The burn-back time is the time from when wire feed ceases until contactor KM1 drops off.

During welding, the voltage at pin 13 of IC2 is low. The output of the inverter at pin 14 is

therefore high, turning on transistor Q2 and activating relay RE1.

When the torch trigger switch is released, or when the spot 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 value speed signal is provided by

measuring the motor voltage.

The pulse width modulator controls the frequency and pulse time of current to the wire feed

motor.

AP1:8,9 Motor driving / braking

Motor driving circuit

The output stage of the pulse width modulator is connected to transistor Q1 via resistor R16.

A motor current signal is provided by measuring the voltage across resistor R4, connected to

transistor Q1. If the voltage across R4 exceeds 1.1 V ±60 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 resistor R47 and diode D17.

DESCRIPTION OF OPERATION

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AP1 - component layout

SERVICE INSTRUCTIONS

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SERVICE INSTRUCTIONS

CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling electrostatic

sensitive devices.

• Use proper static-proof bags and boxes.

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.

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 10 mm 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 °C

or higher.

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ESAB Mig C200 3ph User manual

Brand: ESAB

Model: Mig C200 3ph

Category: Welding System

Type: User manual

This manual is also suitable for

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ESAB Mig C200 3ph User manual

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ESAB Mig C200 3ph User manual

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