ESAB Origo™Cut 36i User manual

Ver 1.0 12/2008

ESAB, Nordic Region

This manual provides service/troubleshooting

instructions for OrigoCut 36i

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Contents

General Precautions..…………………………………………………………………... 3

1. Scope…………………………………………………………………………………… 4

2. Introduction……………………...……………………………………………………. 4

3. Specifications…………………...……………….…………………………………… 5

4. Control Devices and Indicators ……………….………………………………….. 5

5. PT-31XL Torch – HF Ignition………………….………..………………………….. 6

6. PT-31XL Torch - Maintenance………………………..……………………………. 6

7. Common Cutting Problems…………………………….………………………….. 7

8. Sequence of Operation….………………………………………………………….. 8

9. Block Diagram………………………………………………………………………... 8

10. Main Circuit………………………………………………………………………….. 9

10.1 EMI Filter……………………………………………………………………. 9

10.2 Fan VR1……………………………………………………………………… 9

10.3 Air Solenid Valve SV1…………………………………………………….. 9

10.4 Air Flow Switch S2………………………………………………………… 10

10.5 HF Transformer T2………………………………………………………… 10

10.6 Inverter Board………………………………………………………………. 10

10.7 Secondary Rectifier (Bottom Plate)…………………………………….. 11

10.8 Control Board………………………………………………………………. 11

11. Inverter Board………………………………………………………………………. 12

11.1 PFC and Inrush Current Limiter………………………………………… 12

11.2 Power Stage………………………………………………………………… 13

12. Control Board……………………………………………………………………….. 14

12.1 Power Supply……………………………………………………………….. 14

12.2 Preflow 15 sec. (after the power on)…………………………………….

14

12.3 Preflow 2 sec. (after the start signal)…………………………………… 15

12.4 Start…………………………………………………………………………... 15

12.5 HF Control…………………………………………………………………… 16

12.6 Air Flow Sensing…………………………………………………………… 17

12.7 OCV Control………………………………………………………………… 18

13. Troubleshooting…………………………………………………………………….. 19

14. Spare Parts…………………………………………………………………………... 20

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WARNING

ARCWELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE

PRECAUTIONS WHEN WELDING AND CUTTING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES

WHICH SHOULD BE BASED ON MANUFACTURER’S HAZARD DATA.

ELECTRIC SHOCK - Can kill

- Install and earth the welding/cutting unit in accordance with applicable standards.

- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

- Insulate yourself from earth and the workpiece.

- Ensure your working distance is safe.

FUMES AND GASES - Can be dangerous to health

- Keep your head away from of the fumes.

- Use ventilation, extraction at the arc, or both, to take fumes and gases away from your

breathing zone and the general area.

ARC RAYS - Can injure eyes and burn skin.

- Protect your eyes and body. Use the correct welding/cutting screen and filter lens and

wear protective clothing.

- Protect bystanders with suitable screens and curtains.

FIREHAZARD

- Sparks (spatter) can cause fire. Make sure there are no inflammable materials

nearby.

NOISE - Excessive noise can damage hearing.

- Protect your ears. Use earmuffs or other hearing protection.

- Warn bystanders of the risk.

MALFUNCTION - Call for expert assistance in the event of malfunction.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING!

PROTECT YOURSELF AND OTHERS!

WARNING!

Read and understand the instruction

manual before installing and operating

WARNING! Do not use the power source for thawing frozen pipes.

Note! This product is solely intended for plasma cutting

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1. Scope

The purpose of this manual is to provide qualified repair personnel with technical information, which will

assist in trobleshooting and repairing malfunctions. Maintenance and repairs should be performed only

by a trained electrician!

2. Introduction

The OrigoCut 36i is a compact, completely self-contained plasma cutting system. As shipped, the system

is fully assembled and ready to cut after being connected to input power and a source of prefiltered

compressed air 5-10 bar. The OrigoCut 36i package uses the PT-31XL torch to deliver cutting power for

materials up to 9 mm or for severing up to 12 mm. Do not use any other torch than PT-31XL torch with

this power source. Serious injury may occur if used with any other torch!

OrigoCut 36i Cutting Package P/N 0558007873 includes:

 Power source OrigoCut 36i

 PT-31XL torch

 Earth cable 5 m

 Torch Spare Parts Kit, see list below

PT-31XL Spare Parts Kit P/N 0558003462

 3 x 35/40A Nozzle, P/N 0558000508

 2 x Electrode, P/N 0558000507

 1 x Swirl Baffle, P/N 0558000506

 1x Long Heat Shield, P/N 0558000509

PT-31XL Torch P/N 0558001466

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3. Specifications

* 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 equipment.

4. Control Devices and Indicators

1. Power On Indicator

2. Output Current Control

3. Air Pressure Indicator

”ON” when the flow switch is closed

4. Over Temperature Indicator

”ON” when the duty cycle has been exceeded

4

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5. PT-31XL Torch – HF Ignition

OrigoCut 36i has a HF type of arc ignition. Arc

strikes when the torch switch is activated and the

cutting tip touches the workpiece or when the HF

strikes between the electrode and workpiece.

6. PT-31XL Torch - Maintenance

Replace the Electrode, when its length is 16 mm.

Replace the Nozzle, when the hole is not round or

performance is poor.

Replace the Heat Shield, when 3 mm has worn-out.

Minimum length 37 mm (new 40 mm).

Check the other parts visually.

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Insufficient Penetration

Uneven Arc

7. Common Cutting Problems

The following list includes the common cutting problems and a probable cause of each.

• Current too low

• Cutting speed too fast

• Damaged cutting nozzle

• Improper air pressure

• Low air flow rate

Main Arc Extinguishes

• Cutting speed too slow

• Worn electrode

Dross Formation

• Current too low

• Cutting speed too fast/slow

• Improper air pressure

• Faulty nozzle or electrode

• Low air flow rate

Double Arcing

• Low air pressure

• Damaged cutting nozzle

• Loose cutting nozzle

• Heavy spatter accumulation on

nozzle

• Damaged cutting nozzle or worn

electrode

Unstable Cutting Conditions

• Incorrect cutting speed

• Loose cable or hose connections

• Electrode and/or cutting nozzle in

poor condition

Main Arc Does Not Strike

• Worn electrode

• Loose connections

• Work cable not attached

Poor Consumable Life

• Improper gas pressure

• Contaminated air supply

• Low air flow rate

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8. Sequence of Operation

NOTE. 1

When the torch switch is closed during the

postflow period, the HF is energized

immediately.

NOTE. 2

If the over temperature light turns on, the

cutting arc is stopped. The postflow time

starts from the moment the torch switch is

released.

9. Block Diagram

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10. Main Circuit

This section includes the descriptions of the main blocks and separate components of the main

circuit.

10.1 EMI Filter

EMI Filter reduces the conducted electromagnetic disturbances to the distribution network.

10.2 Fan VR1

The cooling fan VR1 (+24V) rotates continuously, when the power source is switched on.

10.3 Air Solenid Valve SV1

After ”power on” the air solenoid valve SV1 (230Vac) is controlled ”on” for approx. 15 sec. (=post flow time)

to purge any moisture or dirt out of the system. When the torch switch is pressed the valve is controlled ”on”

immediately and the preflow time is approx. 2 sec.

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10.4 Air Flow Switch S2

Regulator

The regulator inside the unit is preset at the factory. When the flow switch S2 closes the green indicator lamp

on the front panel starts to illuminate and the cutting is enabled.

10.5 HF Transformer T2

The HF transformer T2 steps up the primary voltage, which is controlled and generated by a control board.

10.6 Inverter Board

The inverter board (power board) includes the power factor corrector and primary power stage. The power

stage is a dual switch forward inverter and it is built by using parallel connected discrete transistors.

Operating frequency of the inverter is about 64 kHz and the output power is controlled by a PWM principle.

The power factor corrector (PFC) forces the line current to be sinuous and in phase with the line voltage.

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10.7 Secondary Rectifier (Bottom Plate)

Rectifier

Transformer

Inductor

The secondary voltage of the main transformer T1 is half-wave rectified by the diode D201. Between the

conducting states of the transistors, the secondary current freewheels through the freewheel diodes D202

and D203. The diodes are dumped by the RC-filters. The secondary inductor L2 filters the secondary

current.and prevents the cutting arc to break between the conducting periods of the power transistors.

10.8 Control Board

The control board handles the following control logics:

 Start/Stop control

 HF control

 OCV control

 Solenoid valve control

 Air flow control

 Temperature monitoring

 Output control (control loop)

 Power supply of the control electronics

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11 Inverter Board

This section includes the detailed description of the inverter board (power board).

11.1 PFC and Inrush Current Limiter

After ”power on” the ”STARTUNI” limits the initial charging current of the buss capacitors C1A… C1C and

clamps to a safe level the voltage between these. Relay RL1 closes and short circuits the ”STARTUNI” after

the initial charge. When the charging is completed the PFC circuit starts to operate. The PFC forces the line

current to be sinuous and in phase with the line voltage. The PFC circuit lifts up the rectified line voltage to a

level of +380 V.

Picture 1. Picture 2.

Measured across the buss capacitors Measured across the buss capacitors

without damping (full bandwidth) with damping (10kHz, HF reject)

Note. When the voltage across the capacitors

is measured with the standard multimeter,

the meter shows +300 V before the precharge time.

Then the voltage is pulled up to 380Vdc.

Picture 3.

Power on

Initial charge

PFC starts up

Power on

Initial charge

PFC starts up

+380V

+320V

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11.2 Power Stage

The operating principle of the power stage is dual switch forward. The upper and lower transistors are

controlled to conducting state at the same time and the voltage on the primary side of the main transformer

T001 rises to the voltage level of the boost converter (+380 V). The magnetization current of the main

transformer returns to the intermediate circuit through the return diodes after the conducting state. The

output power is controlled by adjusting the conducting time of the transistors (PWM). The inverter frequency

is about 64 kHz.

The gating signal of the power transistors is buffered and separated galvanically from the control electronics

by the pulse transformer T1.

Picture 1.

Measured across A3 – A4 during the cutting.

Frequency: 64 kHz

Picture 2.

Measured across A3 – A4 during the cutting.

Voltage: +375 V

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12. Control Board

This section includes the detailed description of the control board.

12.1 Power Supply

The auxiliary transformer’s T1 (230 Vac / 2 x 8,5 Vac) secondary voltages are full-wave rectified by the

diodes D1, D2, D4 and D5. Zener diode D3 limits the rectified output to a level of +24 V. The regulator U1

regulates the +24 V supply to a level of +12 V.

12.2 Preflow 15 sec. (after power on)

3. Turns up and controls

relay RL1 and solenoid

valve.

2. Turns down.

1. Turns up for a short

time after ”power on”

activating the post flow

delay circuit.

When ”power” source is switched on for a first time, the air preflow (approx. 15 sec.) is activated

automatically. After ”power on” the output of a inverter circuit U2f turns up for a short time and it activates the

post flow delay circuit. The output of inverter U2e turns down and it turns up the output of inverter U2d, which

controls the transistor Q3 to conducting state and the relay RL1 closes and the solenoid valve (230 Vac) is

energized. After the post flow delay (C9 x R20) the solenoid valve will close. During the preflow the inverter

block is off.

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12.3 Preflow 2 sec. (after the start signal)

Start signal to the power

stage.

5. Q2=non-conducting

when the start is active.

4. Turns down after a

delay.

3. Turns up, the solenoid

valve opens.

2. Turns down when the

torch switch is closed.

1. Turns up when the

torch switch is closed.

When the torch switch is closed (connected to M2) the output of inverter U2f turns up. At the same time the

output of inverter U2d turns up and the solenoid valve opens.

Start of the inverter is delayed (R18 x C6) and when the voltage across capacitor C6 has increased enough,

the output of U2a turns down and optocoupler OC1 turns transistor Q2 to non-conducting state and the

inverter starts up.

12.4 Start

In idle mode the output of the inverter U2a is ”high” and the transistor Q4 is conducting.

When the torch swich is closed (connected to M2), transistor Q4 turns to non-conducting state after a post

flow delay and optocoupler OC1 turns transistor Q2 to non-conducting state > inverter starts up. When the

start is active the voltage at the connector CN2 is about +3,3 V (Note! Connected galvanically to the mains

voltage).

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12.5 HF Control

1. The solenoid valve is activated after the torch switch

is pressed.

3. HF circuit is activated when the OCV has exceeded

the treshold value of the zener diodes D17 and D18.

The HF circuit is deactivated when the cutting arc is

established.

2. The inverter is activated after the preflow and the

OCV is present at the output terminals (+280 V).

The HF circuit is activated when the inverter has started and the OCV (+280 V) is present at the output

terminals. When the voltage between the output terminals exceeds the treshold value of the zener diodes

D17 and D18, the HF generator is activated by a relay RL2. Relay RL2 supplies the gating signal for

thyristor Q5, which controls the HF transformer’s primary. The unit does not produce any HF, if the solenoid

valve is not controlled by relay RL1, because the auxiliary transformer T2 is supplied through relay RL1.

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12.6 Air Flow Sensing

1. Turns up when the flow switch is

closed > the start of the inverter is

enabled.

2. Turns up when the flow switch is

closed > controls the green ”led” on

the front panel.

3. ”High” = Inverter ”on”. ”Low” =

Inverter ”off”.

The air flow is sensed by a flow switch (connected to M1). If the air flow switch does not close during the

preflow (2 sec.), the start signal of the power stage is disabled (= output of the inverter U2b is low).

When the flow switch closes the start signal for the inverter is enabled and the green ”led” DL2 on the front

panel is controlled ”on” (= output of the inverter U2c is high). If the air flow switch opens during the cutting,

the inverter will be stopped immediately.

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1. Q1 conducts when the maximum

limit value of OCV is exceeded.

2. Q2 conducts when the maximum

limit value of OCV is exceeded.

Q2 on = Power stage off

Q2 off = Power stage on

12.7 OCV Control

The OCV is limited to a level of +280 V. When the OCV exceeds the maximum limit, the transistor Q1 is

controlled to conducting state. When the transistor Q1 starts to conduct the optocoupler OC1 turns to non-

conducting state and the transistor Q2 starts to conduct, which regulates the power stage control voltage in

order to limit the O.C.V.

How to measure the OCV?

Warning! High voltage!

1. Disconnect the unit from the mains supply.

2. Disable the HF circuit by removing the connector A5 or A6 from the control board (HF transformer’s

primary winding)!

3. Connect the air supply.

4. Connect a meter across the output terminals.

5. Connect the unit to the mains supply and turn the main switch to position 1.

6. Press the torch switch.

Picture 1.

The OCV +280 V at the output terminals.

High voltage!

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13. Troubleshooting

Check the problem against the symptoms in the following troubleshooting quide. Start the troubleshooting by

checking that the mains supply, the wear parts of the torch and the air supply are ok. See also the chapter;

7. Common Cutting Problems.

Voltages in the plasma cutting equipment are high enough to cause serious injury or possible death!

If the cause cannot be quickly located, turn the main switch to position 0, remove the covers and perform a

simple visual inspection of all the components and wiring. Check the terminal connections, loose or burned

wiring or components, bulged or leaking capacitors, or any other sign of damage.

Symptom Possible cause Check

Main fuse trips immediately

after the power on or when

the torch switch is pressed.

Short circuit in the power stage.

Check the semiconductors of the

primary circuit. See chapter; 11.

Inverter Board.

Preflow 15 sec. is missing

after ”power on”.

1. The solenoid valve is

defective.

2. The power supply for the

control electronics is missing.

3. The control board is defective.

Check the solenoid valve and its

wiring.

See chapter; 12.1 Power

Supply.

See chapter; 12.2 Preflow 15

sec.

Nothing happens when the

torch switch is activated.

1. The switch or the control wires

are broken in the torch.

2. The control board is defective.

Check the torch switch and its

wiring.

See chapter; 12.4 Start.

The preflow starts, but the

cutting arc does not strike

when the torch switch is

activated.

1. The OCV is missing.

2. The power stage is defective.

3. The HF circuit is defective.

See chapter; How to measure

OCV?

If the OCV is missing, check the

operation of power stage and

the condition of the secondary

diodes on the bottom plate. See

chapters; 11.2 Power Stage and

10.7 Secondary Rectifier.

See chapter; 12.5 HF Control.

The air flow indicator on the

front panel does not turn ”on”

when the torch switch is

activated even though the air

supply is ok.

1. The air flow sensor is

defective.

2. The control board is defective.

See the chapters; 10.4 Air Flow

Switch and 12.6 Air Flow

Sensing.

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14. Spare Parts

Item Ordering number Description

5 0700156023

HF GENERATOR

8

0558001466 PT-31XL TORCH Assembly

9 0700156008 PRESSURE GAUGE

10 0558008095 FAN

11

0700156010 EMC FILTER

12

0558000410 FLOW SWITCH

13

0558008066 INVERTER PCB

15

0700156013 EARTHCABLEW/CLAMP, L=5m

16

0459172001 PLASTIC FRONT PANEL

17 0558008068 BOTTOM PLATE

22 0700156019 KNOB Dia. 25mm

24

0700156020 SOLENOID VALVE

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