ESAB Origo Mig C141 User manual

0349 300 076 Valid for serial no. 736--xxx--xxxx080529
Mig C141/C151
Mag C171/C201/C251
Origo
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REA THISFIRST 4.................................................................
INTRO UCTION 4...................................................................
TECHNICAL ATA 5.................................................................
WIRING IAGRAM,MigC141/C151 7................................................
Componentdescription 7..........................................................
MigC141 8.......................................................................
MigC151 9.......................................................................
ESCRIPTIONOFOPERATION 10.....................................................
AP1Controlboard 10..............................................................
AP1:1Controlcircuit 11..............................................................
AP1:2Thermaloverloadcutout 11.....................................................
AP1:3 RFI suppression and base load resistors 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:4 otordrivecircuit 11..........................................................
AP1-- igC141/C151componentpositions 12........................................
WIRING IAGRAM,MagC171/C201 13................................................
Componentdescription 13..........................................................
MagC171 15.......................................................................
MagC201 16.......................................................................
ESCRIPTIONOFOPERATION 17.....................................................
AP1Controlboard 17..............................................................
AP1:1Powersupply 19..............................................................
AP1:2Referencecircuit 19...........................................................
AP1:3,4,5 Start / Stop, Thermal overload, Spot welding 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:6Burnbacktime 21.............................................................
AP1:7 Control amplifier and pulse width modulator 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:8,9 otordriving/braking 22.....................................................
AP1-- agC171/C201componentpositions 23........................................
WIRING IAGRAM,MagC251 24......................................................
Componentdescription 24..........................................................
MagC251 26.......................................................................
ESCRIPTIONOFOPERATION 27.....................................................
AP1Controlboard 27..............................................................
AP1:1Powersupply 27..............................................................
AP1:2Start/Stop 27................................................................
AP1:3Spotwelding 28...............................................................
AP1:4Wirefeedspeed 28............................................................
AP1:5 otordriving/braking 29......................................................
AP1:6Burnbacktime,contactor,gasvalve 30...........................................
AP1:7Thermaloverloadcutout 30.....................................................
AP1-- agC251componentpositions 31..............................................
SERVICEINSTRUCTIONS 32..........................................................
WhatisES ? 32...................................................................
Thermal switch (thermostat) replacement procedure 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTIONS 33...................................................................
SAFETY 33..........................................................................
INSTALLATION 35....................................................................
Placing 35.........................................................................
Assemblyofcomponents 35........................................................
Electricalinstallation 37............................................................
Mainspowersupply 38.............................................................
OPERATION 38....................................................................
Connectionandcontroldevices 39..................................................
Weldingwithoutgas 40............................................................
Wirefeedpressure 40..............................................................
Replacingandinsertingwire 40.....................................................
Overheatingprotection 41..........................................................

-- 3 --TOCe
MAINTENANCE 41....................................................................
Inspectionandcleaning 41.........................................................
FAULTTRACING 42..................................................................
OR ERINGOFSPAREPARTS 42......................................................
NOTES 43...........................................................................

Edition 080529
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1sC1425
REA THIS FIRST
aintenance 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 ay 2008.
The OrigoTM Mig C141/C151, Mag C171/C201/C251 are 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.
INTRO UCTION
OrigoTM Mig C141/C151, Mag C171/C201/C251 are step controlled power sources
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 switching the + and -- connections on the
switching terminal by the wire feed unit.

Edition 080529
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TECHNICAL ATA
OrigoTM Mig C141 OrigoTM Mig C151 OrigoTM Mag C171
Voltage 220--230V, 1∼50/60Hz 220--230V, 1∼50/60Hz 220--230V, 1∼50/60Hz
Permissible load at
100% duty cycle 42A/16,1V 67A/17,4V 76A/17,8V
60 % duty cycle 54A/16,7V 87A/18,3V 98A/18,9V
@ % duty cycle 83A/18,2V @ 25% 95A/18,7V @ 50% 155A/21,7V @ 25%
20 % duty cycle 100A/17,0V 150A/16,0V 170A/21,0V
Setting range ( C) 35A/15,7V--83A/18,2V
(130A/13,4)
30A/15,5V--95A/18,7V
(150A/16,0V)
30A/15,5V--155A/21,7
V (170A/21,0)
Open circuit voltage 18,7--25,1V 17,3--24,3V 22,4--44,5V
Open circuit power 75W 110W 270W
Power factor at max load 0,91 0,92 0,91
Control voltage 220--230V, 50/60Hz 220--230V, 50/60Hz 42V, 50/60Hz
Wire feed speed 2,0--14m/min 2,0--14m/min 1,0--17m/min
Burnback time -- -- 0,02--0,25s
Spot welding -- -- 0,2--2,5s
Welding gun connection fixed fixed EURO
Wire dimension range 0,6--0,8(Fe)
1,0 (Al)
0,8(cored)
0,8(CuSi)
0,6--0,8(Fe)
1,0 (Al)
0,8(cored)
0,8(CuSi)
0,6--0,8(Fe)
1,0(Al)
0,8(cored)
0,8--1,0(CuSi)
Max diameter/weight
of wire bobin 200mm/5kg 200mm/5kg 300mm/15kg
imensions lxwxh 650x300x550 650x300x550 860x420x730
Weight 25kg 37,5kg 59kg
Operating temperature --10 ÷+40oC --10 ÷+40oC --10 ÷+40oC
Enclosure class IP 23 IP 23 IP 23
Application classifica-
tion
OrigoTM Mag C201 OrigoTM Mag C251
Voltage 220--230V, 1∼50/60Hz 220--230V, 1∼50/60Hz
Permissible load at
100% duty cycle 90A/18,5V 110A/19,5V
60 % duty cycle 115A19,7V 140A/21,0V
@ % duty cycle 185A/23,3V @ 23% 200A/24,0V @ 30%
20 % duty cycle 200A/23,0V 250A/21,0V
Setting range ( C) 30A/15,5V--185A/23,3V
(200A/23,0V)
40A/16,0V--200A/24,0V
(250A/21,0V)
Open circuit voltage 19,6--44,9V 19,0--41,5V
Open circuit power 120W 200W
Power factor at max load 0,89 0,92

Edition 080529
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1sC1425
Control voltage 42V, 50/60Hz 42V, 50/60Hz
Wire feed speed 1,0--17m/min 1,9--19m/min
Burnback time 0,02--0,25s 0--0,25s
Spot welding 0,2--2,5s 0,2--2,5s
Welding gun connection EURO EURO
Wire dimension range 0,6--1,0(Fe)
1,0(Al)
0,8--1,0(cored)
0,8--1,0(CuSi)
0,6--1,2(Fe)
1,0--1,2(Al)
0,8--1,2(cored)
0,8--1,0(CuSi)
Max diameter/weight
of wire bobin 300mm/15kg 300mm/15kg
imensions lxwxh 860x420x730 860x420x730
Weight 68kg 94kg
Operating temperature --10 ÷+40oC --10 ÷+40oC
Enclosure class IP 23 IP 23
Application classifica-
tion
uty cycle
The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer-
tain load without overloading.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Equipment marked IP23 is designed for indoor and outdoor use.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.

Edition 080529
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WIRING IAGRAM, Mig C141 / C151
Component description
WARNING !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
S
SS
SObserve precautions for handling electrostatic
sensitive devices.
S
SS
SUse proper static--proof bags and boxes.
ES
AP1 Circuit board
C1, C2, C3 Capacitor 0,1uF/250V
C4 Capacitor 47uF/275V
C5 Capacitor 2,2uF/300V
CO Capacitor, C140: 33mF/40V, C150: 68mF/40V
EV1 Fan
KM1 Contactor 230V, 50--60Hz
L1 Inductor
M1 Feed unit motor
QF1 Switch, ON/OFF and
C141: 4--step welding voltage selector
C151: 7--step welding voltage selector
R13 Potentiometer, wire feed speed (placed on AP1)
R01, R02 Resistor 15Ω/20W
R1 Resistor 100kΩ/2W
RO Resistor 15Ω/20W
ST1 Thermal switch, operates at 150oC (C141) or at 130oC (C151) .
Thermal switch is mounted on the inductor.
TC2 Transformer for CO2heater, accessory
TM1 ain transformer
V1 Diode bridge
V2 Diode bridge
VH LED yellow indication, thermal overload
XTP ain welding current contact, single -- pole
XT1, XT4 Terminal block

Edition 080529
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1sC1425
Mig C141

Edition 080529
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Mig C151

Edition 080529
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ESCRIPTION OF OPERATION
AP1 Control board
clka0e02

Edition 080529
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AP1:1 Control circuit
Pressing trigger switch SB1 on the welding torch energises relay RE1 from
control power transformer TR1. The contacts on the relay connect main
transformer T 1 to the mains power supply.
The power supply to RE1 is half--wave rectified by D1. Resistor R1 is
connected in series with the relay and drops the voltage to it. Capacitor C1
(220µF) smoothes the voltage. It also delays the drop--off of relay RE1 by
about 25 ms, to provide a burnback time.
AP1:2 Thermal overload cutout
In the event of a thermal overload, thermal overload cutout ST1 interrupts the
secondary circuit from TR1, causing relay RE1 to drop off and de--energising
the welding circuit. When not operated (i.e. with closed contacts), the cutouts
short--circuit inputs B6 and B7.
Operation of either of the cutouts is indicated by LED V1. Interruption of the
cutout circuit energises the LED via D2, R3 and D3. D2 is a half--wave
rectifier, R3 limits the current through the LED and D3 protects it against
reverse voltage.
AP1:3 RFI suppression and base load resistors
Capacitors C4 -- C6 protect against RFI. Resistors R12 and R15 provide a
minimum base load for the rectifier bridge: in addition, they act as discharge
resistors for the capacitors.
AP1:4 Motor drive circuit
The wire feed motor is powered by the rectified secondary voltage from main
transformer T 1.
Pressing the welding torch trigger switch SB1 provides a supply to thyristor
TY1 via contact B4 from the positive side of the main power rectifier VC1.
Resistors R10 and R14 limit the motor starting current: excessive starting
current would demagnetise the motor. D9 is a squelch diode protecting
against back--emf from the motor.The ignition circuit for TY1 consists of R2,
R4, R5, D5 and C2.
When Q1 is not conducting, operation of the circuit is as follows:
If the voltage at B4 exceeds the motor voltage, C2 charges via R2, R4 and R5.
When the voltage on C2 reaches the trigger voltage (0.5 -- 1.5 V), thyristor TY1
fires. This means that TY1 conducts each half--cycle when Q1 is not
conducting.
D5 protects C2 against negative voltage when Q1 conducts.
Motor voltage control
C3, R11 and potentiometer R13 form a low--pass filter circuit for the motor
supply. R13 picks off a suitable fraction of the motor voltage for connection to
the base of Q1 via diode D6. Q1 starts to conduct at a bases voltage of 0.7 V.
C2 charges more slowly, which means that thyristor TY1 fires later. otor
voltage is lowest when R13 is in its upper position, the minimum position.
The base voltage is then high and Q1 conducts. The charging time for C2
becomes so long that thyristor TY1 misses some half cycles, firing only (for
example) on every third cycle.
When R13 is in its lower (= maximum) position, the base voltage on Q1 is low
and Q1 does not conduct. In this state, zener diode D7 determines the
maximum motor voltage.

Edition 080529
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1sC1425
AP1 -- Mig C141 / C151 component positions
clka0e03

Edition 080529
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WIRING IAGRAM, Mag C171 / C201
Component description
WARNING !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
S
SS
SObserve precautions for handling electrostatic
sensitive devices.
S
SS
SUse proper static--proof bags and boxes.
ES
AP1 Circuit board
AP2 Digital instrument, accessory
C1, C2, CVS Capacitor 0,1uF/250V
EV1 Fan
KM1 Contactor 42V, 50--60Hz
L1 Inductor
L2, L3 Ferrite core
LF1 Lamp, white, On/Off, 230V
M1 Feed unit motor
QF1 Switch, ON/OFF
QF2 Switch, 8--step welding voltage selector for C171
Switch, 12--step welding voltage selector for C201
RO Resistor 15Ω/20W
RVS Resistor
RP1 Potentiometer, wire feed speed
RP2 Potentiometer with switch, spot welding
RI Shunt, accessory
RL Resistor
ST1 C171:
Thermal switch, operates at 150oC. Thermal switch is mounted on the
inductor.
C201:
Thermal switch, operates at 130oC. Thermal switch is mounted on the
transformer.
TC1 Control transformer
TC2 Transformer for CO2heater, accessory
TC3 Transformer for digital instrument, accessory

Edition 080529
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TM1 ain transformer
V1 Diode bridge
VH LED yellow indication, thermal overload
XTP ain welding current contact, single -- pole
XT1, XT4 Terminal block
YV1 Gas valve

Edition 080529
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Mag C171

Edition 080529
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1sC1425
Mag C201

Edition 080529
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ESCRIPTION OF OPERATION
AP1 Control board
clka1e03

Edition 080529
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1sC1425
clka1e04

Edition 080529
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AP1:1 Power supply
clka1e06
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 in the fan--cooled machines and
somewhat higher in the 3--phase LKA 180. This supply powers fan EV1 in the
fan--cooled machines. Voltage regulator VR1 is supplied via diode D1 to
provide a regulated 15 ᐔ0.6 V supply.
AP1:2 Reference circuit
clka1e07
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.

Edition 080529
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1sC1425
AP1:3,4,5 Start / Stop, Thermal overload, Spot welding
clka1e08
Start / Stop circuit
When the torch trigger switch SB1 is not activated, the voltage between 3
and 4 is 24 V. Pressing the trigger switch shorts the circuit, producing a
voltage of 0 V between 3 and 4.
Thermal overload circuit
The machine contains thermal overload cutout, connected to inputs T8 and T9.
If it operates, the torch trigger switch circuit cannot be short--circuited, with the
result that wire feed cannot be started. When the thermal cutout 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 ᐔ30%.