CaddyR Mig C160i Service manual 0349 300 094 101222 Valid for serial no.
READ THIS FIRST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
TECHNICAL DATA Voltage 230 V, 1∼ 50/60 Hz Permissible load at 100% duty cycle 100 A / 19 V 60 % duty cycle 120 A / 20 V 35 % duty cycle 150 A / 21.5 V Setting range (DC) 30A / 15.5 V--160A / 22 V Open circuit voltage 60 V Open circuit power 15 W Efficiency 82% Power factor 0.99 Wire feed speed 2 -- 11m/min Wire diameter Fe 0.8 (0.6--1.0) CW 0.8--1.
WIRING DIAGRAM Component description WARNING ! STATIC ELECTRICITY can damage circuit boards and electronic components. ESD S Observe precautions for handling electrostatic sensitive devices. S Use proper static--proof bags and boxes. WARNING ! High DC voltage may remain on the electrolytic capacitors on the power board. Check the voltage and discharge capacitors if needed.
Caddyr r Mig C160i s1Cad160 -- 7 -- Edition 101222
DESCRIPTION OF OPERATION Caddyr Mig C160i is a set of following modules: S power PCB -- AP1 S control PCB -- AP2 S MMC panel -- AP3 S gas valve -- K1 S wire feeding motor -- M2 S fan -- M1. 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.
AP1 Power board (two power module version) s1Cad160 -- 9 -- Edition 101222
AP1 Power board (one power module version) s1Cad160 -- 10 -- Edition 101222
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 EMI filter contains following parts: L05, C1, L02, C5, C8, C16. The resistors R30, R31 provides discharge path for the filter’s capacitors. AP1:2. Pre-- charge circuit The pre--charge circuit contains diodes V01, V02 and PTC resistors B01, B02.
Power transformer outlets numbering 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 -- 22kΩ @ 25_C, while on the output rectifier the PTC (positive temperature coefficient) 1,0 kΩ @ 25_C linear sensor is installed.
AP1 Components layout (two power module version) s1Cad160 -- 13 -- Edition 101222
AP1 Components layout (one power module version) s1Cad160 -- 14 -- Edition 101222
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.
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.
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.
AP2:3H. Thermal protection on the primary side 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 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.
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: S thermal protection from the primary side (IC2), S thermal protection form the secondary side (CN4.5,6), S torch switch is pressed during the power up (charging of the C342, hold by the pressed switch) S lack of the +24V_ENABLE signal As shown any of listed cases keeps the ENABLE line low.
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. 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 of the gas welding.
AP2:3L. Short arc control 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 to 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.
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.
The current reference signal IREF_IN from the voltage regulator is delivered via 2 diodes to the current input (COMP) of the PWM controller IC11. Diodes were applied to compensate voltage drop on diodes embedded in the IC11. Current feedback is provided by means of the current transformer TO02, 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.
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. 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 provided in the form of the sinking current.
AP2 Components layout s1Cad160 -- 25 -- Edition 101222
MMC panel The front panel contains two potentiometers and 2 LED indicators. Schematic diagram and assembly drawing are shown below.
SERVICE INSTRUCTIONS WARNING ! STATIC ELECTRICITY can damage circuit boards and electronic components. ESD S Observe precautions for handling electrostatic sensitive devices. S 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.
It is recommended to discharge capacitors entirely. When the voltage is less then 50V a 1kW 0,5W resistor may be used for the final discharge. Handling of the control 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.
Assembly of the housing Two main parts of plastic housing are assembled together by means of bolts. 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 Type of fault Machine is dead. LED is off (display is off). Fan is not working. The machine is dead. LED is off (display is off). Fan is not working. Mains fuse tripped. Actions S Check that the mains power supply switch is turned on. S Check that the welding current supply and return cables are correctly connected. S Check that correct current value is set. General failure in the power block. S Check the power PCB according to the description on the next page.
General failure of the power block 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 are damaged into the disconnection. It leads to further failures, in particular of the PFC control circuit.
INSTRUCTIONS This chapter is an extract from the instructions for Caddyr Mig C160i. 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 recommendations should be observed in addition to the standard regulations that apply to the workplace.
INSTALLATION WARNING! This product is intended for industrial use. In a domestic environment this product may cause radio interference. It is the user’s responsibility to take adequate precautions. Placing Position the welding power source such way that its cooling air inlets and outlets are not obstructed. Mains power supply Check that the unit is connected to the correct mains power supply voltage, and that it is protected by the correct fuse size.
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 160 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.
Connection and control devices 1 Mains supply switch 6 Knob for thickness setting 2 Indicating lamp, power supply ON 7 Knob for arc correction 3 4 5 Orange indicating lamp, overheating Welding gun Return cable 8 9 Gas connection Mains cable 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 1, the green lamp 2 indicates that machine is ready.
Polarity change +/-- TERMINALS The machine is delivered with the welding wire connected to the plus pole. Some 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: 1. Switch off the machine and disconnect the mains cable. 2.
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. 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.
WARNING! Do not keep the torch near the ears or the face during wire feeding, as this may result in personal injury. 1.1.1 Changing the feed roller groove The machine is delivered with the feed roller set for ∅0.8/1.0mm 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.
Welding gun S 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. D. Lock the liner with adaptor nut.
NOTES notes -- 40 --
notes -- 41 --
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.
