ESAB Origo Arc 650c, Origo Arc 410c, Origo Arc 810c Service Manual

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

.

OrigoTMArc 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

OrigoTM 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. OrigoTM 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 electrostatic­sensitive devices.

• Use proper static--proof bags and boxes.

7

OrigoTM Arc 410c

8

OrigoTM Arc 650c

9

OrigoTM 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.