Caddy Mig C200i - ESAB Welding & Cutting Products
Contents
1. wire speed reference 4 5V S CADDYMIG C180 2 EIS bewe F519 MMC CNE P614 106 supply inverted 4 1 8373 A318 WIRE ws T FEED n JE av SPEED CMB aT R541 R30 44 107 1 33y ag 8 B Le hH 1 1 4 I R303 1X 4B Iyi i CNB 10 4065 2 1 U MIN 887 E I mm GND INV CNB R52 VOLTAGE 0 REE k C305 CTION CNB 18 SUMMING False only in digital MMC paint B inca diMig 200 j3 219 T gt 105 ex 4 13 to next stage Ov open cut Oper bot T Open circuit circuit Vare u to GND_INV is M Fb14 Hane to current power GND_INV connected 108 GND_INV esl reference PCB to plus output R542 HSV Uare pase ENN Ra 1 to unus una H376 e330 E ti fign zm LARE 1419 ramp 5 U 112 TA a generator J 6V short circuit el l Lj pu 1 GND INV level SHO Er 11 change CIR BEK SNDLINV switch Em off DROP OFF BY drop grounded for aluminum Kr pulse CNB mm ADAPT OFF active 15 20V B The voltage reference is proportional with different coefficients to a wire feed speed reference b voltage on the Umin input c voltage on the Upot input In the previous solution the source a was replaced by the EMF voltage proportional to2. 16 Low Voltage Circuits lt yx nak k ehr 16 AP2 1L Command system kk kk kk kk kk kk kk kk kk kk kk kk kk hh 16 AP2 2L Electromagnetic valve nennen en 18 AP2 3L Short arc control EEN Er ER RA DNS 19 AP2 4L Wire feeder motor speed 22 AP2 Components layout kk kk kk nnns nh nnn nnn 23 iei Ehre Eee PEE Eee 24 AP3 1 2 3 Manual digital and analog input circuits 24 AP3 4 Microprocessor and its circuits l l kk kk kk kk kK KK KK KK kk kk kk kk kk kk kk kk ka 27 AP38 5 Power supplies el qi KA ek ee A 28 AP3 6 Analog outputs xun anak near euren 29 7 Digital outputs x ly yi ARD Ap Lan DES A Ne d lara ra 30 AP3 8 POD display i eso bec engen STD ke 30 Components layout kk kak hh hn 31 SERVICE INSTRUCTIONS tein eet a ee kaka ay a aa 32 What s ESD os deh neo el 32 Before the service work aa ak a aa aa a aa aka ka aa ak ak hn 32 Handling of the control PCB kk kk kk kk kk kk kk kk kk nn nnn 33 Insulation resistance measurement kk kk kk n nn nnn 33 Assembly of the housing
3. kk kk kk kk kk kk kk kak aka ak aa aa aka kaka ak hn 34 Fault tracing ks k ee a e yA A Ka eda Teva 35 General failure of the power block kk kk kk In nnn 36 INSTRUCTIONS kak ERR RIT ERE da mE NER h ra k ye a era rea 37 SA dl Dl GE DIV ce a 37 INSTALLATION 4 3 2 2x 2 ae du eee de keniya aub kr e l 37 Placing scs secu see dac a e T d 38 Mains power supply 4 lll kk kk kk kk kk kk kk kk kk a kk III IH I HI ak m m hn 38 OPERATION DD DD gg Dd 39 Connection and control devices kk kk kk kk kk ak kk kk kak kk kk ka 39 Operation lt s kwa kirk ke k a E IE Red E Ek muc 40 Error codes o _ e e e e eWoasasa vg_gn _ nnnnpggggg_ 42 Setting the dynamics 55 42 Polarity change ce sca cai a ica a n ea de actin ak x jl m 43 Wire feed pressure kk kk kk kk kk kk kk kk kk kk kk kk kk kk kk kk kk kk kk kk 44 Replacing and inserting wire kk kk kk kk kk kk kk ak a ak ak ak ak ak kak ak kaka 44 Shielding gas xx sirk xua KWA ee Rees 45 Overheating protection kk kk kk kk kk k
4. SX unxgo AAS zoa 108 101222 ition Ed s1Cad200 AP1 1 EMI mains filter The EMI mains filter contains capacitors and inductors intended for suppression of the common mode interferences and the differential mode interferences The filter contains following parts LO5 C1 101 102 C5 C8 C16 The resistors R30 R31 provides discharge path the filter s capacitors AP1 2 Pre charge circuit The pre charge circuit contains diodes V01 VO2 and PTC resistors B01 B02 Internal diodes MV3 MV4 of the power module together with diodes V01 V02 create the non controlled rectifier The filter capacitors C2 C21 C22 are charged by this rectifier via non linear resistor BO1 BO2 up to the amplitude value of the mains voltage It is lower then the eventual DC bus voltage nevertheless it protects the supply mains and capacitors from the big inrush currents and makes easier start of the PFC boost converter After charging of the capacitors the auxiliary supply placed on the control PCB starts to work providing also firing pulses to thyristors The main rectifier made of thyristors MV1 MV2 and diodes MV3 MV4 takes over the rectifying role The boost converter created by the inductor 03 switch MV5 and MV6 diodes MV7 MV8 MV9 MV10 starts working charging the DC bus capacitors to 390 400V AP1 3 Two switch forward converter The two switch forward converter is created on transistors MV11 MV18 and diod
5. Caddy i Mig C200 Service manual id for serial no 932 xxx xxxx READ THIS FIRST aus etree eray aa sa 4 INTRODUCTION trend h k xalk dia alye d k ee rk 4 TECHNICAL DATA 4 22 a Dil 5 WIRING DIAGRAM 2 naa Ier a a ne 6 Component 0 kk kk kk kk kk kak kk kk kk kk kk kk kak kk kk ka 6 Caddyr Mig C200 232er en 7 DESCRIPTION OF OPERATION 522 kk ru kk kk pine I kk kk kk ak kk kk kk kak kk kk kk kk kk 8 EM mans Ka dae Kela WO ua dee ds 10 AP1 2 Pre charge circuit ea al ui G avan ad Gana eyane ee 10 AP1 3 Two switch forward converter 10 AP1 4 Current sense transformer 0 KK KK kk kk kk kk kk kk kk 10 AP1 5 High frequency transformer 10 AP1 6 Thermal protection sensors 0 la lk a kall kk ala 11 AP2 Analogue control board Jll k kk kk kk kk kk kk kk kk kk kk kk kk ak kk ak ak aka ak aka nnn 13 High Voltage Circ ts rop iin abe 13 AP2 1H Voltage supervision PFC control 13 AP2 2H Auxiliary power supply kk kk kk kk kk kk kk kk KK kK kK kk kk kk kk kk lk kk kk kk kk kk kk kk ka 14 AP2 3H Thermal protection on the primary side
6. The auxiliary power supply provides power for primary and secondary control circuits Basically it produces 15V supply for the primary circuits and galvanically separated 24V supply for secondary circuit In addition it provides firing pulses to the thyristor in the input rectifier The auxiliary power supply is switched off by means of the voltage control circuit HV ENABLE Therefore thyristor firing pulses are not delivered until DC bus capacitors are charged to the peak input voltage s1Cad200 14 Edition 101222 AUXILIARY POWER SUPPLY to thyristor gates 5v DCBUS C130 1nFY2 GND INV TPS GND The auxiliary power supply is built as flyback converter Estimated maximum power of it is 25W The most loaded output is the 24V secondary side It provides the power for all low voltage control circuits and also power for the fan and the gas valve The wire feeder motor is supplied from the auxiliary winding of the power transformer However it s energy storage capacitor is pre charged from the 24V to provide power for uninterrupted start of the motor s1Cad200 15 Edition 101222 AP2 3H Thermal protection on the primary side iSV_PFE 5Vref As temperature sensors sensor are on the high voltage potential the thermal protection circuit fig is placed on the high voltage side then the 0 1 signal is transferred via the optocoupler IC2 with extended isolation to
7. Current A at 100 duty cycle at 60 duty cycle at 25 duty cycle Cable area mm2 Fuse slow A The mains cable areas and fuse sizes as shown above are in accordance with Swedish regulations They may not be applicable in other countries make sure that the cable area and fuse sizes comply with the relevant national regulations PFC The machine is equipped with Power Factor Correction converter and has near to unity power factor It complies with standard EN 61000 3 12 2005 04 Electromagnetic compatibility EMC Part 3 12 Limits harmonic currents produced by equipment connected to public low voltage systems with input current gt 16 A and lt 75 A per phase Extension cord If extension cord is needed it is recommended to use cord 3x2 5mm of maximum length 50m Supply from power generators The machine can be supplied from different types of generators However some generators may not provide sufficient power for welding The generators with AVR equivalent or better type of regulation with rated power 5 5 6 5 kW are recommended to supply the Caddy Mig C200i semiautomatic welder within it s full capacity It is also possible to use generators with lower rated power starting from 3 0kW but in that case the machine setting must be proportionally limited The s2Cad200 38 Edition 101222 machine is protected against undervoltage If the power supplied by the generator is not sufficient the welding is
8. 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 Caddy Mig C200i is an inverter based portable semiautomatic welder in a compact design intended for MIG MAG welding 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 close to the wire feed unit The machine operates with wire diameters from 20 6 to 21 0 mm As shielding gas pure argon mixed gas or pure CO may be used The Caddy Mig C200i draws current with near unity power factor which produces very low level harmonics in the mains s1Cad200 4 Edition 101222 TECHNICAL DATA Permissible load at 100 duty cycle 60 duty cycle 25 duty cycle Setting range DC Open circuit voltage Open circuit power Efficiency Power factor Wire feed speed Wire diameter Bobbin size Dimensions Ixwxh Weight Operating temperature Enclosure class Application classification Duty cycle 230 V 1 50 60 Hz 100 A 120 A 180 A 30 200 A 60 V 15 82 0 99 2 12m min 20 6 1 0 20 8 1 0 20 8 1 0 21 0 2200 mm 449x198x347 12 kg 10 to 40 C IP 23C S The duty cycle refers to the time as a percentage of ten minute period that you can weld at a
9. R523 CN1 8 END 24V_INV CN1 1 CN1 2 notused in the current cnt 18 solution removed grounded CN1 20 E or left untouched s1Cad200 26 Edition 101222 AP3 4 Microprocessor and its circuits The programming is available through the standard serial connector RS232 connected to CN4 via buffer PCB Program updating can be carried out via this way JTAG connector is not mounted microprocessor m JTMSISWDIO Io JTCK SWCLK w gt Bese 2 WD CD 4 Cb m Rum m 4 why ja Js je sp l l m e 5 eR WR j Boot ad To 65232 adapter e Cn 11 28 50 75 100 3 3V 10 27 49 99 CND 33 s1Cad200 27 Edition 101222 AP3 5 Power supplies The MMC panel is supplied from the 24V delivered by the power supply placed on the analog PCB 5V power 15 built as the pulse buck converter The integrated regulator VR2 together with the inductor L500 and the diode 0520 composes a simple buck converter 3 3V supply is created from the 5V by means of the low drop regulator VR3 Operational amplifiers are supplied from the 20V supply created on the VR1 regulator m Supply lines 24V 24V_INV 530 b 519 3 3 nf C555 10 uF 573 470uF TL434AID 3 3V ref C531 220ur T 10k C572 1 5 CSG 330nf 6551 330nF C534 s1Cad200
10. When the power PCB is replaced only the fully functional control PCB could be applied Verify the control PCB by checking the resistance of R125 and R151 on the CN1 connector Both resistors should have 10 Ohm resistance To check the power block measure the DC bus voltage and or check the PCB using ohmmeter The DC bus must be completely discharged before using the ohmmeter Use diode check mode Presence of the big capacitor is showed by the growing resistance s1Cad200 36 Edition 101222 INSTRUCTIONS This chapter is an extract from the instructions for Caddy Mig C200i SAFETY Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions Safety precautions must meet the requirements that apply to this type of welding equipment The following recommen dations should be observed in addition to the standard regulations that apply to the workplace All work must be carried out by trained personnel well acquainted with the operation of the welding equipment Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the operator and damage to the equipment 1 Anyone who uses the welding equipment must be familiar with its operation location of emergency stops its function relevant safety precautions welding 2 The operator must ensure that no unauthorised perso
11. m amp g m 5 arm 2 m Rshunt al E 3 D amp wo 4 5 fei jf id 5 5 a Hayes high voltage controller BAe circuits enable T a ANA SH grounded on Ho He B 8 a any undervoltage P504 ENE T De 4 psr H2 104 HV ENABLE gy c 3 d c bus 8 amp ln Riga OTS charged 7 e Heemse MA as GND U 4 2 sense reser 4 l f switching off kesa undervoltage 4 ds SY 1 T protection 80 RESET me 8 5 8 GND 9 B 8 aL RLS uam EN E 3 CNi 2 GND Voltage supervision circuits senses the DC bus voltage inputs 19 20 CN1 and the rectified input voltage input 15 CN1 As long as voltage are not within limits high voltage enable line HV_ENABLE is grounded by means of transistor Q1 Operation of the PFC and auxiliary power supply is disabled The reset IC4 is used for the voltage control Two of inputs are connected to the rectified input voltage one to the DC bus Operation of the machine is disabled as long as the a c voltage is less then 188 Vrms or drops under 177 Vrms SENSE3 and DC bus voltage is less then 259V or drops below 173V SENSE1 Another sense input SENSE2 has very low time constant along with voltage limitati
12. 28 Edition 101222 AP3 6 Analog outputs All outputs are slow response PWM outputs PWM signal are filtered and conditioned to the required level by means of the operational amplifiers The di dt output has a form of the sinking current source where the npn transistor Q504 with resistor R570 in emitter is placed in the feedback of the operational amplifier di dt analog outputs BC817 16 DNE C4 yr Q504 7 i a _j END 220k R558 R560 Snp not used HE e s1Cad200 29 Edition 101222 AP3 7 Digital outputs Digital outputs are created in form of the npn and pnp open collectors connecting adequate output lines to ground and to 20V respectively DROP OFF Q503 551 digital outputs x e 10501 ADAPT OFF 6 AP3 8 LCD display LCD display is connected directly to the microprocessor lines Group lines are connected to the voltage dividers on resistors R587 594 which are necessary to create a c voltage on particular segments The d c fraction is not allowed as it would damage the display The display background is highlighted by means of the edge white LED diodes Backlight diodes are switched off during the power down sequence by means of the microprocessor and the transistor Q506 LED display to microcontroller 56 7 8 0 10 11 12 13 14 15 to microcontroller 30 to
13. 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 IP23C is designed for indoor and outdoor use Application class The symbol 5 electrical hazard indicates that the power source is s1Cad200 designed for use in areas with increased Edition 101222 WIRING DIAGRAM Component description WARNING STATIC ELECTRICITY can damage circuit boards and electronic components Observe precautions for handling electrostatic sensitive devices e Use proper static proof bags and boxes WARNING High DC voltage may remain on the electrolytic capaci tors on the power board Check the voltage and discharge capacitors if needed AP1 Power board AP2 Control board AP3 MMC board K1 Gas valve M1 Wire feeding motor M2 Fan S1 Torch switch Q1 Mains switch s1Cad200 6 Edition 101222 Caddy Mig C200i CONTROL BOARD 230V 50 60Hz 7 K1 51 200 7 Edition 101222 DESCRIPTION OF OPERATION Caddy Mig C200i is a set of following modules e power PCB AP1 e control PCB AP2 MMC panel e gas valve K1 e wire feeding motor M1 e fan M2 POWER PCB AP1 230V 50 60Hz CONTROL PCB AP2 CONTROL SYSTEM Ki PANEL vbe e z A 3 1 pog A
14. delivered via 2 diodes to the current input COMP of the PWM controller 1011 Diodes were applied to compensate voltage drop on diodes embedded in the IC11 Current feedback is provided by means of the current transformer TOO2 placed on the power PCB Pulsed current signal is delivered to the current sense input Isense of the IC11 As the voltage on the DC bus is stable the average primary current is proportional to the drawn power Therefore the signal from the current transformer is also given the input of the integrator on IC9 8 9 10 providing the power limitation s1Cad200 21 Edition 101222 AP2 4L Wire feeder motor speed controller The motor drive is supplied from the auxiliary winding on the main trafo as shown on the figure below main power transformer yyy i e 2 turns C 3E 3 013 wire speed reference R231 R546 551 M4 IF C344 GND_INV R252 R255 The wire speed motor controller is built on the peak current mode PWM controller IC This IC does not provide the reference input the internal reference is 2 5V In this case the negative voltage feedback is provided in the form of the sourcing current and the reference value is provid
15. microcontroller s1Cad200 30 Edition 101222 AP3 Components layout area under the LCD display Edition 101222 31 s1Cad200 SERVICE INSTRUCTIONS WARNING 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 an
16. on The command system is not shown entirely The sequence of operation of the subassemblies of the semiautomatic welder is shown on the fig Note that there are no proportions on this drawings s1Cad200 17 Edition 101222 TORCH SWITCH 9 Ye FEEDING SPEED T t POWER EN ptis SUPPLY Ng 1 200A ON OFF i 1 110 25 _ VALVE 50 20kHz ME VOLTAGE nun As shown there is 0 2 gas pre flow delay The power source is kept on until the motor is running AP2 2L Electromagnetic valve The electromagnetic valve control works in a specific mode TP42 24v_INV K 1 CN7 2 M2 24V INV 7 1 GND_INW As shown on the diagram the first 0 2 s coil of the valve is supplied from 24 volts d c Then the generator starts running providing 50 20kHz 24V amplitude supply ofthe gas welding In result the drawn power is reduced down t01 4 ofthe rated power but the valve due to its relay type characteristics is kept open s1Cad200 18 Edition 101222 AP2 3L Short arc control
17. plate thickness for the set wire feed speed is displayed simultaneously D The plate thickness recommendation is calculated for a fillet weld using the following wire dimensions Fe Ss and CuSi 20 8mm Al 21 0mm If you use a smaller diameter wire you should set a slightly higher value for plate thickness than what you are going to weld If you use a larger diameter wire set a slightly lower value Heat input adjustment The heat input can be adjusted with the QSet knob F in steps from 9 to 9 to make the weld hotter or colder A higher value gives a hotter more concave weld longer arc length for more penetration A lower value gives a colder more convex weld shorter arc length to prevent burning through the welded material Typically the QSet value should be set 0 which gives you an average heat input that is s2Cad200 41 Edition 101222 suitable in most cases The heat input setting is symbolised with thermometer indicating hotter or colder settings Error codes If an error occurs only the error code will be visible Description CHSUM program related error Switch the machine OFF wait POWER_SUPPLY_5V hardware related error 130 sec and switch it ON POWER_SUPPLY_24V hardware related error Call for service if the error remains WATCHDOG_ERROR program related error HIGH TEMP thermal protection Do not switch the machine OFF let it to cool down Setting the dynam
18. the actual wire feed speed i e the EMF voltage was 0 when the motor was stopped In one or either way the voltage reference was in relation to the wire feed speed In the actual solution it is achieved by grounding pin 18 of CN6 In previous solution the EMF signal was delivered to micro controlled and then subtracted from the reference with adequate coefficient s1Cad200 19 Edition 101222 s1Cad200 CADDYMIG C1601 WIRE voltage BEER proportional to the voltage on the WF motor VOLTAGE CORRE CTION 18 a EMF CNG R307 R306 R511 ICT Uarc GND Voltage feedback is given on the CN4 1 Note that low voltage ground GND_INV is connected via CN4 2 to the power supply It enables creation of the summing point in system with unipolar supply Nevertheless the voltage feedback inverting amplifier gives the signal in opposite phase This signal is delivered to the next inverting amplifier which is not shown on the drawing This amplifier also adds the fraction proportional to the ramp signal created during short circuit In his way current reference signal is delivered to the peak current mode PWM integrated circuit IC11 20 Edition 101222 i5V C318 GND INV Re C m K 8 TO 02 CES 4 7 N R366 372 8 GND_INV power limitation GND_INV The current reference signal IREF_IN from the voltage regulator is
19. the secondary circuits Low Voltage Circuits Low voltage circuits secondary side are placed on the left part of the PCB and they are connected to the external circuits by means of the connector existed connectors except the CN1 Low voltage circuits include e command system of the semiautomatic welder e short arc control system wire feeder motor speed control circuit e low energy control of the electromagnetic AP2 1L Command system Command system produces assumed program control on discrete inputs and outputs In particular it provides logic dependencies and generates the sequence control of parts of the semiautomatic welder s1Cad200 16 Edition 101222 n201 Reo ji C O5 6 KHH HEN Start 7 sequence An 3599 7 4O4V ENABLE GND_INV ENABLE GND INV The start signal from the welding torch is the basic input of the command system As shown on the fig the start signal can be disabled in several cases e thermal protection from the primary side 122 e thermal protection form the secondary side CN4 5 6 e torch switch is pressed during the power up charging of the C342 hold by the pressed switch e lack of the 24V ENABLE signal As shown any of listed cases keeps the ENABLE line low Note that even after removal all listed error signals the machine is kept in disable state until the torch Switch is released This is additional protection of unintentional switching
20. 12V DC average Note that any failure is latched when the torch button is on Release it if pressed Overheating should disappear after 3 4 minutes Wait Switch the equipment off and switch on again after 2 minutes If it is still disabled look for failure in the control PCB Lack of any voltage may cause permanent disability 35 Edition 101222 General failure of the power block intrinsic nk amnia body diode FR N Shunt An B AN ji um Control resistors R125 R151 lIT Loo reference R139 R138 LHH 3143 Riss Ri II HJ R140 L1 Riss Rasy 330k m C104 22056 GND Failure in the power block frequently means the short circuit of the DC bus Unfortunately it causes an avalanche of further failures Mechanism of the avalanche of failures is shown on the picture DC bus short circuit causes damage and disconnection of the shunt resistor inside the module Consequently resistors R125 R151 on the control PCB damaged into the disconnection It leads to further failures in particular of the PFC control circuit To avoid the damage of the control circuit the protective fuse and transient suppressor were implemented However it does not guarantee 100 of the control PCB protection WARNING
21. 974 1 5 EN 61000 3 12 and EN 60974 10 It is the obligation of the service unit which has carried out the service or repair work to make sure that the product still conforms to the said standard Spare parts may be ordered through your nearest ESAB dealer see the last page of this publication s2Cad200 47 Edition 101222 NOTES notes 48 notes 49 ESAB subsidiaries and representative offices Europe AUSTRIA ESAB Ges m b H Vienna Liesing Tel 43 1 888 25 11 Fax 43 1 888 25 11 85 BELGIUM S A ESAB N V Brussels Tel 32 2 745 11 00 Fax 32 2 745 11 28 THE CZECH REPUBLIC ESAB VAMBERK s r o Vamberk Tel 420 2 819 40 885 Fax 420 2 819 40 120 DENMARK Aktieselskabet ESAB Herlev Tel 45 36 30 01 11 Fax 45 36 30 40 03 FINLAND ESAB Oy Helsinki Tel 358 9 547 761 Fax 358 9 547 77 71 FRANCE ESAB France S A Cergy Pontoise Tel 33 1 30 75 55 00 Fax 33 1 30 75 55 24 GERMANY ESAB GmbH Solingen Tel 49 212 298 0 Fax 49 212 298 218 GREAT BRITAIN ESAB Group UK Ltd Waltham Cross Tel 44 1992 76 85 15 Fax 44 1992 71 58 03 Automation Ltd Tel 44 1264 33 22 33 44 1264 33 20 74 HUNGARY ESAB Kft Budapest Tel 36 1 20 44 182 Fax 36 1 20 44 186
22. ITALY ESAB Saldatura S p A Mesero Mi Tel 39 02 97 96 81 Fax 39 02 97 28 91 81 THE NETHERLANDS ESAB Nederland B V Amersfoort Tel 31 33 422 35 55 Fax 31 33 422 35 44 NORWAY AS ESAB Larvik Tel 47 33 12 10 00 Fax 47 33 11 52 03 POLAND ESAB Sp zo o Katowice Tel 48 32 351 11 00 Fax 48 32 351 11 20 PORTUGAL ESAB Lda Lisbon Tel 351 8 310 960 Fax 3511 859 1277 SLOVAKIA ESAB Slovakia s r o Bratislava Tel 421 7 44 88 24 26 Fax 421 7 44 88 87 41 SPAIN ESAB Ib rica S A de Henares MADRID Tel 34 91 878 3600 Fax 34 91 802 3461 SWEDEN ESAB Sverige AB Gothenburg Tel 46 31 50 95 00 Fax 46 31 50 92 22 ESAB international AB Gothenburg Tel 46 31 50 90 00 Fax 46 31 50 93 60 SWITZERLAND ESAB AG Dietikon Tel 41 1 744 25 25 Fax 41 1 740 30 55 North and South America ARGENTINA CONARCO Buenos Aires Tel 54 11 4 753 4039 Fax 54 11 4 753 6313 BRAZIL ESAB S A Contagem MG Tel 55 31 2191 4333 Fax 55 31 2191 4440 CANADA ESAB Group Canada Inc Missisauga Ontario Tel 1 905 670 02 20 Fax 1 905 670 48 79 MEXICO ESAB Mexico S A Monterrey Tel 52 8 350 5959 Fax 52 8 350 7554 USA ESAB Welding amp Cutting Products Florence SC Tel 1 843 669 44 11 Fax 1 843 664 57 48 Asia Pacific CHINA Shanghai ESAB A P Shanghai Tel 86 21 2326 3000 Fax 86 21 6566 6622 INDIA ESAB India Ltd Ca
23. P3 The power PCB contains all the track of energy conversion It is supplied from the 230V 50 60Hz mains There is the EMI filter on the input then half controlled thyristor bridge Thyristor are not fired until DC bus capacitors are not charged via pre charge circuit Between the rectifier and the DC bus capacitors the boost converter is placed It contains the high frequency inductor the switch MOSFET and the diode Control system of the boost converter is placed on the control PCB AP2 The switch in boost converter control provides a sinusoidal shape of the input mains current b stabilised voltage on the DC bus By the principle the voltage is higher the amplitude value of the AC input voltage In the CaddyMigs it is 390 400V The boost converter s frequency is 70 kHz The converter that provides the power to welding has two switch forward topology The switching frequency is 70 kHz By the principle the maximum converter s duty cycle is less then 50 Transformer ratio is 5 5 1 what means that peak voltage in secondary winding of the power transformer is about 70V The high frequency rectifier inductor are connected to the transformer s secondary winding The control circuits of the forward converter are included in the control PCB Beyond the both converters control circuits the control PCB contains also the rest of needed circuits On the primary side it includes voltage supervisor auxiliary power supply primary circu
24. ainst overheating by disabling the welding if overheating occurs The cutout resets automatically when the unit has cooled down s2Cad200 45 Edition 101222 MAINTENANCE Regular maintenance is important for safe reliable operation Note All guarantee undertakings from the supplier cease to apply if the customer himself attempts any work in the product during the guarantee period in order to rectify any faults Inspection and cleaning Check regularly that the power source is free from dirt The power source should be regularly blown clean using dry compressed air at reduced pressure More frequently in dirty environments Otherwise the air inlet outlet may become blocked and cause overheating Welding gun e Cleaning and replacement of the welding gun s wear parts should take place at regular intervals in order to achieve trouble free wire feed Blow the wire guide clean regularly and clean the contact tip Changing the wire liner A Loosen the fixing screw and take the roller off the axle B Loosen the adaptor nut straighten the torch and remove the liner C Insert the replacement liner into the straightened torch until it touches the contact tip s2Cad200 46 Edition 101222 D Lock the liner with adaptor nut Cut excess of liner so it sticks 7mm out of adaptor nut ORDERING OF SPARE PARTS CaddyTM Mig C200i is designed and tested in accordance with the international and European standards IEC EN 60
25. ak kk kk kk kk kk kk kk kk kk ka 45 TOCe MAINTENANCE oaeen E Ree e erate We a dana ases rk re eR EE a Ea a 46 Inspection and cleaning kk kk kk kk kk kk kk ka a a a aka ak ak aka ak aa aka ak aka a aka 46 Changing the wire liner kk kk kk kk kk kk kk kk kk kk kk hh nnn 46 ORDERING OF SPARE PARTS kk kk kk kk kk kk a nn kk kk kk lk kk kk kk kk 47 NOTES a k na ea ines cel y r ep etal c D andi a e b wd E el l Aie a a 48 TOCe 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 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 December 2010 The Caddy Mig C200i is designed and tested in accordance with international and European standard IEC EN 60974 1 5 10 and EN 61000 3 12
26. ata for suitable wire dimensions for each wire type Use only 2200mm spools 2100 spools are not applicable Open the side panel Place the spool the hub and secure it with the lock Disconnect the pressure arm by folding it sidewards the pressure roller slides away e Straighten out the new wire 10 20 cm File away burrs and sharp edges from the end of the wire before inserting it into the wire feed unit e sure that wire goes properly into the feed roller track and into the outlet nozzle and the wire guide e Secure the pressure arm e Close the side panel Feed the wire through the welding torch until it comes out of the current tip This operation should be carried out carefully as the wire is on the welding potential and unintentional arc may occur Keep the torch off conducting parts during feeding the s2Cad200 44 Edition 101222 wire through and terminate wire feeding instantly when the wire comes out of the current tip WARNING Do not keep the torch near the ears or the face during wire feeding as this may result in personal injury NOTE Remember to use the correct contact tip in the torch for the wire diameter used The torch is fitted with a contact tip for 0 8mm wire If you use another diameter you must change the contact tip The wire liner fitted in the torch is recommended for welding with Fe and Ss wires Change the liner to the PTFE type for welding Al or Brazi
27. e wires e g gasless cored wires are recommended to be welded with negative polarity welding wire connected to the minus pole and return cable connected to the plus pole Check the recommended polarity for the welding wire you want to use The polarity can be changed inside the wire feed cabinet Switch off the machine and disconnect the mains cable Bend the rubber covers back to give access to the cable lugs Remove the nuts and washers Note the correct order of the washers Change the position of the cables to the desired polarity see marking Install the washers in correct order and tighten the nuts to spanner tightness Make sure the rubber covers are covering the cable lugs WE I s2Cad200 43 Edition 101222 Wire feed pressure Start by making sure that the wire moves smoothly through the wire guide Then set the pressure of the wire feeder s pressure rollers It is important that the pressure is not too great A gt gt K 50mm 10 Fig 1 Fig 2 To check that the feed pressure is set correctly you can feed out the wire against an insolated object e g a piece of wood When you hold the gun approx 5 mm from the piece of wood fig 1 the feed rollers should slip If you hold the gun approx 50 mm from the piece of wood the wire should be fed out and bend fig 2 Replacing and inserting wire To prepare the machine a spool with wire should be installed See technical d
28. ed in the form of the sinking current PWM controller commands the MOSFET Q17 which delivers PW modulated voltage to the motor When the motor must be switched off the Q26 MOSFET short circuits the motor providing effective way of fast stopping of the motor s1Cad200 22 Edition 101222 2 Components layout prora eoru rors BE mz 2 20 orza JU uz RU Jr a El 101222 ition Ed 23 s1Cad200 AP3 MMC panel Man machine communication panel MMC provides controls for process settings and machine operation as well as feedback from the process and the machine condition Physically the MMC is printed circuit board PCB which consist of e microprocessor system e manual controls pushbutton rotary encoders LCD display The MMC is connected to the analog control PCB via connector CN1 AP3 1 2 3 Manual digital and analog input circuits s1Cad200 Circuits do not need special explanations Both manual and digital inputs have input filters and Schmidt trigger buffers to protect signal lines from interferences Analog inputs also consist of filters Voltage followers on the operational amplifiers are added as buffers Manual inputs 24 Edition 101222 Digital inputs digital inputs 24V_ENABLE s1Cad200 25 Edition 101222 Analog inputs analog inputs Vcn1 18 0 IREF OUT
29. es MV14 MV15 Others diodes and transistors if exists are not activated There is the current sense resistor MR1 placed on the placed before the PFC converter It S purpose is to provide information of the momentary current to the PFC control system what is needed for creation of the average current control loop in the PFC control Drivers for the switches in the PFC and forward converters are placed on the power PCB AP1 4 Current sense transformer The current sense transformer 2 is placed on the line It senses the pulse current which is needed for creation of the peak current control loop in the inverter s control system AP1 5 High frequency transformer The high frequency transformer is mounted on the power PCB Due to high power soldering and anticipated high reliability replacement of the transformer is not subject of service routines s1Cad200 10 Edition 101222 Numbers of outlets of the power transformer AP1 6 Thermal protection sensors The thermal protection sensors are placed inside the power modules or module and on the heatsink of the output rectifier In the power module there are is NTC negative temperature coefficient non linear sensor 22k 25 C while on the output rectifier the positive temperature coefficient 1 0 25 C linear sensor is installed The replacement of the sensor in the heatsink can be carried out only along with damaging the old sensor The new one
30. ics Fe SS In certain cases especially for mild steel welding in different gases the quality of welding may be improved by changing the dynamics of the Caddy Mig C200i Setting of the dynamics function is normally hidden but can be invoked by the pressing and keeping pressed the pushbutton 7 for 5s or more When this setting is available all graphics from the right side of the display disappears and only number from 00 to 10 is displayed This number corresponds to the virtual inductance 00 means that virtual inductance is small and the welding arc is sharp 10 means that the virtual inductance is high and the welding arc is soft The value of the virtual inductance can be set by means of the knob 8 Default setting is 05 Recommendations e When the is used it is recommended to set set lower inductance then 05 for instance from 03 down to 00 e When the Ar CO mixture is used the operator should set higher inductance from 05 up to 10 The interface goes back to the regular appearance 10s after the last movement of the knob 8 or pressing pushbutton 7 Operator can accelerate the return to the regular mode by again pressing and keeping pressed the pushbutton 7 for 5s s2Cad200 42 Edition 101222 Polarity change TERMINALS 45 M3 GF 7 0 agg Zen H ml v e Dr KI EE The machine is delivered with the welding wire connected to the plus pole Som
31. interrupted by the undervoltage protection Especially welding start could be disturbed The generator should be replaced with a more powerful one or welding parameters be decreased if operator finds the welding process disturbed OPERATION General safety regulations for the handling of the equipment appear from page 37 Read through before you start using the equipment WARNING gt a Rotating parts can cause injury take great care VAN WARNING Lock the bobbin in order to prevent it from sliding off the hub Connection and control devices 1 Mains supply switch 4 Return cable 2 LCD see Manual QSet mode 5 Mains cable 3 Welding torch 6 connection s2Cad200 39 Edition 101222 Operation Once the machine is turned on it is not powered instantly Approximately 2 seconds after switching the machine on by means of the mains switch the LCD display indicates that the machine is ready The machine is protected against welding start during power on If the torch pushbutton is pressed while the machine is being turned on the operation is disabled until the torch button is released The return cable must be reliably connected to the workpiece or to the welding table The wire spool section must be closed prior to the welding Machine is instantly switched off by means of the mains switch Manual mode Caddy ms A welding voltage F wire feed speed B welding current A TV F vol
32. its overheating and overvoltage protection On the secondary side there are process sequence and control short arc control overheating protection wire feed speed regulator and gas valve controller s1Cad200 8 Edition 101222 uue 5e p 5 2 2 Big L t 5 8 ER T n 6 9 9 9 1 11 p 9X r sx z asan 1 163 2 z 5 E 8 i 2 5 2 2 g 5 5 1 unx SAAS jo 9 96 ans gin x oF tr vOA nx lt ala ala oc BASAL ran 01 19 OLA PLAN AN M Y a Nz sour sanb OE 2 60A 3 T SAW LAW VA T 3 1 Erd zan 1 ZAN NZ EI 2 un T T Hd d LLAN ME ji AX 920 LI a CER 2 Den ssopeq ss NE 8 LOV Z L v LOV Z L TOA 02 A00F 06 on sen g9 108 4 I4 Sr 62 ro 908 23 b
33. lay is off Fan is not working The machine is dead LED is off display is off Fan is not working Mains fuse tripped No wire feeding Fan is working LED or display is on The equipement seems to work properly however the welding seems to be imposs ible No shielding gas The equipement seems to work but it is permanently blocked by some error The yellow diode is on the display shows error s1Cad200 Check that the mains power supply switch is turned on Check that the welding current supply and return cables are correctly connected Check that correct current value is set General failure in the power block Check the power PCB according to the description on the next page Replace damaged parts NOTE Insufficient check may cause another failure of the new part Check torch switch circuit Check lack of the indicated failure Press the torch pushbutton and check the open circuit voltage If it is proper cca 58V search failure in the control PCB Check the open circuit voltage If it is significantly less then 58V check the DC bus voltage 390 400V Search for the failure in the PFC part Check the gas supply Visually check the quality of the wire feeding Correct wire placement roll etc Check gas connection Check the gas valve operation by listening to the sound of the tripping Check the voltage on the solenoid In the steady state it should amount approx
34. lcutta Tel 91 33 478 4517 Fax 91 33 468 18 80 INDONESIA ESABindo Pratama Jakarta Tel 62 21 460 0188 Fax 62 21 461 2929 JAPAN ESAB Japan Tokyo Tel 81 45 670 7073 Fax 81 45 670 7001 MALAYSIA ESAB Malaysia Snd Bhd USJ Tel 603 8023 7835 Fax 603 8023 0225 SINGAPORE ESAB Asia Pacific Pte Ltd Singapore Tel 65 6861 43 22 Fax 65 6861 31 95 SOUTH KOREA ESAB SeAH Corporation Kyungnam Tel 82 55 269 8170 Fax 82 55 289 8864 UNITED ARAB EMIRATES ESAB Middle East FZE Dubai Tel 971 4 887 21 11 Fax 971 4 887 22 63 Representative offices BULGARIA ESAB Representative Office Sofia Tel Fax 359 2 974 42 88 EGYPT ESAB Egypt Dokki Cairo Tel 20 2 390 96 69 Fax 20 2 393 32 13 ROMANIA ESAB Representative Office Bucharest Tel Fax 40 1 322 36 74 RUSSIA LLC ESAB Moscow Tel 7 095 543 9281 Fax 7 095 543 9280 LLC ESAB St Petersburg Tel 7 812 336 7080 Fax 7 812 336 7060 Distributors For addresses and phone numbers to our distributors in other countries please visit our home page www esab com ESAB AB j SE 695 81 LAX SWEDEN Phone 46 584 81 000 www esab com 081016
35. n is stationed within the working area of the equipment when it is started up is unprotected when the arc is struck 3 The workplace must be suitable for the purpose be free from draughts 4 Personal safety equipment Always wear recommended personal safety equipment such as safety glasses flame proof clothing safety gloves Do not wear loose fitting items such as scarves bracelets rings etc which could become trapped or cause burns 5 General precautions Make sure the return cable is connected securely Work on high voltage equipment may only be carried out by a qualified electrician Appropriate fire extinquishing equipment must be clearly marked and close at hand Lubrication and maintenance must not carried out on the equipment during operation INSTALLATION A WARNING This product is intended for industrial use In domestic environment this product may cause radio interference It is the user s responsibility to take adequate precautions s2Cad200 37 Edition 101222 Placing Position the welding power source such a way that its cooling air inlets and outlets are not obstructed Mains power Check that the unit is connected to the correct mains power supply voltage and that it is protected by the correct fuse size A protective earth connection must be made in accordance with regulations Rating plate with supply connection data Voltage V
36. ng CuSi See 7 2 regarding how to change the wire liner Changing the feed roller groove The machine is delivered with the feed roller set for 20 8 1 0mm welding wire If you want to use it for 0 6mm wire you must change the groove in the feed roller 1 Fold back the pressure device to release the pressure roller 2 Switch on the machine and press the torch trigger to position the feed roller so that the locking screw is visible 3 Switch off the machine Use a 2mm Allen key to open the locking screw about half a turn 5 Pull the feed roller off the shaft and turn it around See marking on the side of the feed roller for suitable wire diameters 6 Putthe roller back on the shaft and make sure it goes all the way in You may need to turn the roller to position the locking screw over the flat surface of the shaft 7 Tighten the locking screw Shielding gas The choice of suitable shielding gas depends on the material Typically mild steel is welded with mixed gas Ar CO2 or carbon dioxide Stainless steel can be welded with mixed gas Ar CO2 or O2 and Aluminium with pure argon MIG MAG brazing CuSi uses pure argon or mixed gas Ar O2 Check the recommended gas for the welding wire you want to use QSet mode see 6 2 2 will automatically set the optimal welding arc with the gas you use Overheating protection Overheating is indicated on the LCD with error code E4 A thermal overload cutout pro tects the unit ag
37. ol PCB Carefully put the control PCB in place Try to avoid touching the wrong pins during placement of the PCB The slit in the control PCB and the diode on the power PCB should help with positioning Nevertheless remove and place the control PCB carefully Insulation resistance measurement MMC BOARD CONTROL BOARD 51 M2 Secondary circuits 478 Q1 1 Pr HH pa CL 1 s1Cad200 33 Edition 101222 ATTENTION All primary and secondary circuits must be short circuited to protect semiconductor devices The insulation resistance between welding circuits secondary circuits and primary circuits should be more then 5MQ It is recommended to carry out the insulation resistance test during periodical survey dependently on the environmental conditions not less then once a year If needed the inside of the equipment should be cleaned by means of the compressed air Assembly of the housing S aw AY AY AV 1 N ZI Two main parts of plastic housing are assembled together by means of bolts s1Cad200 34 Edition 101222 There are tongue and groove joints in the upper part of housing To avoid damaging of the joint and achieve good connection it is strongly recommended to follow the bolts insertion sequence presented on the drawing Fault tracing Machine is dead LED is off disp
38. on It provides fast disable during the machine switching off s1Cad200 13 Edition 101222 PFC control is built on the specialised integrated circuit IC3 PFC control senses the DC bus voltage input current 5 6 CN1 and input voltage providing the constant 390 400V on the DC bus along with sinusoidal form of the input current This goal is achieved by the control of the switch in the boost converter placed on the power PCB Actually the control circuit placed on the control PCB produces the drive signal for PFC switch OVERVOLTAGE PROTECTION 45V_PF D101 R109 to PFC I witch 7 4 0 4 TL 1015 2 41 TI 440 420V rom output f the control IC Dmax 95 IC1 second level 460V overvoltage protection reset PFC control aH Specialised PFC controller IC3 used in the present solution does not provide overvoltage protection Therefore extra two comparators were applied to control the DC bus voltage There is a two step overvoltage protection First on the lower level simply cuts off the drive signal from the PFC control IC by means of the logic AND gate Second level is higher the first and it resets the PFC control IC via it s soft start input The system of overvoltage protection is needed especially for work with engine driven generator where the voltage surges occur at the end of the welding AP2 2H Auxiliary power supply
39. should be installed by means of the electrically non conductive and thermally conductive silicon rubber Fixing of the PTC thermal sensor s1Cad200 11 Edition 101222 lqwasse Zr 614 ELO Jepjos aU 1012 1018 4uIs esy 105195 eJnjejedue Edition 101222 12 s1Cad200 AP2 Analogue control board The analogue control PCB contains circuits connected to the input high voltage primary and circuits connected to the output low voltage secondary High Voltage Circuits High voltage circuits primary side are placed on the right part of the PCB and they are connected to the external circuits by means of the connector CN1 High voltage circuits contains e voltage supervision circuits PFC control circuits e auxiliary power supply e temperature sensors circuits AP2 1H Voltage supervision and PFC control DCBUS 390 400V d c CNi 20 EEE Y2 x Uin NN CNi 10H VOLTAGE CONTROL 168 R167 R174 R473 as mr al 8 m
40. tage setting knob Ben V QSet G Manual QSet mode button A H dynamics setting button I wire feed speed setting knob mimin ob QSet The operator must set appropriate values for the wire feed speed and welding voltage s2Cad200 40 Edition 101222 QSet mode A welding voltage B welding current wire feed speed D workpiece thickness E QSet value F QSet value setting knob G Manual QSet mode button H material selection dynamics setting button plate thickness setting knob In QSet mode the appropriate welding voltage is automatically set by the machine QSet monitors the welding arc and continuously adjusts the voltage to maintain the optimal setting Calibration The first time you use QSet mode and when you change welding wire material or shielding gas you need to allow QSet to calibrate This is done by making a test weld min 6 seconds Simply start welding and let QSet find the correct parameter settings Material selection Since different materials have different heat dispersion it is necessary to select the right material group H so that a correct plate thickness value can be calculated Plate thickness setting Set the plate thickness of the object you want to weld using the plate thickness setting knob 1 This knob sets the wire feed speed C A suitable voltage setting is automatically calculated by QSet The recommended
41. y 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 Before the service work WARNING High DC voltage may remain on the electrolytic capaci tors on the power board Check the voltage and discharge capacitors if needed Disconnect the equipment from the mains before opening the housing The capacitors of the PFC filters are charged up to 400V and collect significant charge It is recommended to wait 5 min after switching the equipment off and disconnecting it from mains This time may include the time of unscrewing all screws of the housing Check the voltage on the capacitors on the X8 pads Openings have standard 2 0mm diameter as standard multimeter s probes If accelerated discharge of the high voltage is required use 10kW 5W resistor with safe outlets i e cables with 2 0 mm probes Note that the time constant is still 15 s It is recommended to discharge capacitors entirely s1Cad200 32 Edition 101222 When the voltage is less then 50V a 1kW 0 5W resistor may be used for the final discharge EHE i 10kQ _ m C E 4 5W m 1280 iti WARNING NU HIGH DC VOLTAGE Handling of the contr
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