ESAB Origo Mig L305 User manual

Origo™
Service manual
0349 300 067 GB 20200225
Valid for:
MigL305:serialno.628-,647-,211-,331-,746-xxx-xxxx
MigL405:serialno.628-,647-,211-,331-,730-xxx-xxxx
MigL305, MigL405

TABLE OF CONTENTS
0349 300 067 © ESAB AB 2020
READ THIS FIRST.................................................................................... 3
INTRODUCTION....................................................................................... 4
TECHNICAL DATA ................................................................................... 5
WIRING DIAGRAM................................................................................... 8
Component description ......................................................................... 8
Origo™ Mig L305 .................................................................................... 8
Origo™ Mig L405 .................................................................................... 10
DESCRIPTION OF OPERATION.............................................................. 13
P1 Digital instrument.............................................................................. 13
P1:1 Calibration and voltage correction ............................................... 13
P1:2 Connections to the digital instrument........................................... 14
SERVICE INSTRUCTIONS....................................................................... 15
What is ESD? .......................................................................................... 15
Thermal switch (thermostat) replacement procedure ........................ 15
Rights reserved to alter specifications without notice.

READ THIS FIRST
0349 300 067 -3- © ESAB AB 2020
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
November 2017.
The Origo™ Mig L305, Mig L405 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.

INTRODUCTION
0349 300 067 -4- © ESAB AB 2020
INTRODUCTION
The Origo™ Mig L305, Mig L405 are step switched power sources designed for
MIG/MAG-welding together with wire feed units OrigoFeed.
The power units are fan-cooled and equipped with thermal overload protection.
The equipments can be fitted with an instrument that displays current and voltage.
It incorporates a hold function and can be calibrated.

TECHNICAL DATA
0349 300 067 -5- © ESAB AB 2020
TECHNICAL DATA
Valid for serial no. 628-,647-,211- and 331-xxx-xxxx
Mig L305 Mig L405 Mig L405
Voltage 400-415 V,
3~50/60Hz
400-415 V,
3~50/60Hz
230/400-415/500V 3~50Hz
230/440-460V 3~60Hz
Permissible load
at 100% duty cycle 150 A 280 A/28 V 280 A/28 V
at 60% duty cycle 190 A 365 A/32 V 365 A/32 V
at 50% duty cycle - 400 A/34 V 400 A/34 V
at 25% duty cycle 300 A - -
Setting range (DC) 30 A/15 V-300A/29V 50A/16.5V -
400A/34V
50A/16.5V - 400A/34V
Open circuit voltage 17-40 V 17-45 V 17-45 V
Open circuit power 190 W 360 W 360 W
with cooling unit - 600 W 600 W
Efficiency at max
current
69% 71% 71%
Power factor at max
current
0.97 0.98 0.98
Control voltage 42 V, 50/60 Hz 42 V, 50/60 Hz 42 V, 50/60 Hz
Dimensions l×w×h 782 × 425 × 830 812 × 552 × 925 812 × 552 × 925
Weight 89 kg 142 kg 143 kg
with cooling unit - 156 kg 156 kg
Operating
temperature
-10 to +40 °C -10 to +40 °C -10 to +40 °C
Transportation
temperature
-20 to +55 °C -20 to +55 °C -20 to +55 °C
Enclosure class IP 23 IP 23S IP 23S
Application class
Cooling unit (100% duty cycle) for Mig L405
25°C 40°C
P1L/min for 400–415 V 970 W 440 W
P1L/min for 230 V 940 W 430 W
Pmax 3.5 bar
Coolant ESAB ready mixed coolant (see the "ACCESSORIES" chapter in
the instruction manual)
Coolant quantity 5.5 l

TECHNICAL DATA
0349 300 067 -6- © ESAB AB 2020
Valid for serialno.730-xxx-xxxx and 746-xxx-xxxx
Mig L305 Mig L405 Mig L405
Voltage 400-415 V,
3~50/60Hz
400-415 V,
3~50/60Hz
230/400-415/500V 3~50Hz
230/440-460V 3~60Hz
Permissible load
at 100% duty cycle 150 A 280 A/28 V 280 A/28 V
at 60% duty cycle 190 A 365 A/32 V 365 A/32 V
at 50% duty cycle - 400 A/34 V 400 A/34 V
at 20% duty cycle 300 A - -
Setting range (DC) 30 A/15 V-300A/29V 50A/16.5V -
400A/34V
50A/16.5V - 400A/34V
Open circuit voltage 17-40 V 17-45 V 17-45 V
Open circuit power 190 W 360 W 360 W
with cooling unit - 600 W 600 W
Efficiency at max
current
69% 71% 71%
Power factor at max
current
0.97 0.98 0.98
Control voltage 42 V, 50/60 Hz 42 V, 50/60 Hz 42 V, 50/60 Hz
Dimensions l×w×h 782 × 425 × 830 812 × 552 × 925 812 × 552 × 925
Weight 79.5 kg 142 kg 143 kg
with cooling unit - 156 kg 156 kg
Operating
temperature
-10 to +40 °C -10 to +40 °C -10 to +40 °C
Transportation
temperature
-20 to +55 °C -20 to +55 °C -20 to +55 °C
Enclosure class IP 23S IP 23S IP 23S
Application class
Cooling unit (100% duty cycle) for Mig L405
25°C 40°C
P1L/min for 400–415 V 970 W 440 W
P1L/min for 230 V 940 W 430 W
Pmax 3.5 bar
Coolant ESAB ready mixed coolant (see the "ACCESSORIES" chapter in
the instruction manual)
Coolant quantity 5.5 l
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.

TECHNICAL DATA
0349 300 067 -7- © ESAB AB 2020
Equipment marked IP23 is intended for indoor and outdoor use.
Equipment marked IP 23S is intended for indoor and outdoor use; however, should not be
operated in precipitation.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.

WIRING DIAGRAM
0349 300 067 -8- © ESAB AB 2020
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.
Origo™ Mig L305
Component Description
C1, C2, CES Capacitor, 0.1 μF 250 V
EV1 Fan
HL1 Lamp, green, On/Off
HL2 Lamp, yellow. Thermal overload cutout
KM1 Main contactor 42 V, 50-60 Hz
L1 Inductor
AP2 Digital instrument, accessory
QF1 Switch, ON/OFF
R1 Resistor
R2 Varistor
RS1 Shunt, accessory
SA1 10-step switch, selection of welding voltage
ST1 Thermal overload cutout, opens at 120 °C. Mounted at the cooling fins of
the diode bridge.
ST2 Thermal overload cutout, opens at 160 °C. Mounted in the winding of
transformer TM1.
TC1 Control transformer.
TC2 Transformer for CO2heater, accessory.
TC3 Transformer for digital instrument, accessory.
TM1 Main transformer.
V1-V6 Diode bridge.
XS1 Connector, 15-pole. For connection to/from the wire feed unit.
XT1 3-pole terminal block.
XT2, XT3 Connector, flat pin.

WIRING DIAGRAM
0349 300 067 -9- © ESAB AB 2020
Origo™ Mig L305, 400-415 V

WIRING DIAGRAM
0349 300 067 - 10 - © ESAB AB 2020
Origo™ Mig L405
Component Description
C1-C3 Suppression capacitors 2 μF 450 V
C4 Capacitor, 3 μF 400V. Start and run capacitor for fan motor EV1.
C6, C7 Suppression capacitors, 0.1 μF 250V
EV1 Fan
HL1 Indicating lamp 42 V, white. Lights when switch QF1 is in the ON position.
HL2 Indicating lamp 42 V, yellow. Lights to indicate operation of the thermal
cutouts.
KM1 Contactor 42 V 50 Hz. Main contactor.
L1 Inductor.
M1 Pump, 230 V 50 Hz 0.2 kW. Only power sources with water cooling.
P1 Digital instrument.
QF1 Main ON/OFF switch.
QF2 Switch, for selecting welding voltage, 4-step.
QF3 Switch, for selecting welding voltage, 10-step.
R1 Resistor
RS1 Shunt 60 mV / 400 A, accessory.
SA1 Cooling water pump switch. Only on power sources with water cooling.
ST1 Thermal switch. 150 °C Protects the equipment against excessive
temperature. Mounted on inductor.
TC1 Control transformer.
TC2 Transformer for CO2heater, accessory.
TM1 Main transformer.
V1-V6 Diode bridge.
XS1 Connector, 15-pole. For connection to/from the wire feed unit.
XS2-XS5 Main welding current contact, single-pole.
XT1 3-pole terminal block.
XT2 9-pole terminal block.

WIRING DIAGRAM
0349 300 067 - 11 - © ESAB AB 2020
Origo™ Mig L405, 400-415 V

WIRING DIAGRAM
0349 300 067 - 12 - © ESAB AB 2020
Origo™, Mig L405, 230-500 V

DESCRIPTION OF OPERATION
0349 300 067 - 13 - © ESAB AB 2020
DESCRIPTION OF OPERATION
P1 Digital instrument
P1:1 Calibration and voltage correction
The meter has a possibility of the voltage and current calibration, as well as a possibility of
the current-dependant voltage correction, to show a voltage approximately equal to the
actual arc voltage.
Since all meters are factory calibrated it is recommended to carry out a second calibration
only if it’s needed. In most applications a zero voltage correction (no correction) is factory
adjusted.
For the calibration an accurate reference meter and a resistance load are required. The
resistance load should force at least 100 A current flow.
For calibration following actions should be done:
1. Switch the power source on and load it. The meter should indicate voltage and current
presence.
2. Press simultaneously both pushbuttons placed on the meter PC board. In sequence,
symbols of the calibration modes appear: ”U” - voltage calibration, ”I” - current
calibration, ”dU” - voltage correction. Release the buttons as the required mode
appears.
3. Adjust the voltage or the current value equal to the value shown by the reference
meter by means of the pushbuttons: S1 - ”+”, S2 - ”- ”.
Voltage calibration mode
The reference meter should be connected to the same potentials as a calibrated meter.
Exclusively in this mode a voltage without correction is shown on display.
Voltage correction mode
The reference meter should be connected to the end of mass cable and to the torch current
tip, which are connected to the external load. In this mode, as well as during the regular
work, the meter shows a voltage taking in account voltage drops on cables and welding
torch. An adjustment of the voltage correction should be carried out only in assumption of the
proper voltage calibration and in the presence of load current above 100 A.

DESCRIPTION OF OPERATION
0349 300 067 - 14 - © ESAB AB 2020
P1:2 Connections to the digital instrument

SERVICE INSTRUCTIONS
0349 300 067 - 15 - © ESAB AB 2020
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.

For contact information visit esab.com
ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone [phone]
http://manuals.esab.com