R-Tech I-MIG160 MIG Manuale di Servizio

0349 300 094 Valid for serial no. 924--xxx--xxxx101222CaddyRRRRMig C160iServicemanual

Edition 101222-- 10 --s1Cad160AP1 Power board (one power module version)

Edition 101222-- 11 --s1Cad160AP1:1. EMI mains filterThe EMI mains filter contains capacitors and inductors intended for suppression ofthe common--mod

Edition 101222-- 12 --s1Cad160Power transformer outlets numberingAP1:6. Thermal protection sensorsThe thermal protection sensors are placed inside the

Edition 101222-- 13 --s1Cad160AP1 Components layout (two power module version)

Edition 101222-- 14 --s1Cad160AP1 Components layout (one power module version)

Edition 101222-- 15 --s1Cad160AP2 Analogue control boardThe analogue control PCB contains circuits connected to the input (high voltage,primary) and c

Edition 101222-- 16 --s1Cad160PFC control is built on the specialised integrated circuit IC3. PFC control sensesthe DC bus voltage, input current (5,6

Edition 101222-- 17 --s1Cad160The auxiliary power supply is built as flyback converter. Estimated maximum powerof it is 25W. The most loaded output is

Edition 101222-- 18 --s1Cad160AP2:3H. Thermal protection on the primary sideAs temperature sensors (sensor) are on the high voltage potential, the the

Edition 101222-- 19 --s1Cad160The start signal from the welding torch is the basic input of the command system.As shown on the fig. the start signal c

-- 2 --TOCeREAD THIS FIRST 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Edition 101222-- 20 --s1Cad160As shown, there is 0,2 gas pre--flow delay. The power source is kept on until themotor is running.AP2:2L. Electromagneti

Edition 101222-- 21 --s1Cad160AP2:3L. Short arc controlThe voltage reference is proportional with different coefficients to:a. wire feed speed referen

Edition 101222-- 22 --s1Cad160Voltage feedback is given on the CN4.1. Note that low voltage ground (GND_INV)is connected via CN4.2 to the power supply

Edition 101222-- 23 --s1Cad160The current reference signal IREF_IN from the voltage regulator is delivered via 2diodes to the current input (COMP) of

Edition 101222-- 24 --s1Cad160AP2:4L. Wire feeder motor speed controllerThe motor drive is supplied from the auxiliary winding on the main trafo as sh

Edition 101222-- 25 --s1Cad160AP2 Components layout

Edition 101222-- 26 --s1Cad160MMC panelThe front panel contains two potentiometers and 2 LED indicators. Schematicdiagram and assembly drawing are sho

Edition 101222-- 27 --s1Cad160SERVICE INSTRUCTIONSWhat is ESD?A sudden transfer or discharge of static electricity from one object to another. ESD sta

Edition 101222-- 28 --s1Cad160It is recommended to discharge capacitors entirely. When the voltage is less then 50V a1kW 0,5W resistor may be used for

Edition 101222-- 29 --s1Cad160Assembly of the housingTwo main parts of plastic housing are assembled together by means of bolts.There are tongue--and-

-- 3 --TOCeNOTES 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Edition 101222-- 30 --s1Cad160Fault tracingType of fault ActionsMachine is dead.LED is off (display is off).Fan is not working.S Check that the mains

Edition 101222-- 31 --s1Cad160General failure of the power blockFailure in the power block frequently means the short--circuit of the DC bus. Unfortun

Edition 101222-- 32 --s2Cad160INSTRUCTIONSThis chapter is an extract from the instructions forCaddyr Mig C160i.SAFETYUsers of ESAB welding equipment h

Edition 101222-- 33 --s2Cad160INSTALLATIONWARNING!This product is intended for industrial use. In a domestic environment this product may cause radioi

Edition 101222-- 34 --s2Cad160Supply from power generatorsThe machine can be supplied from different types of generators. However, somegenerators may

Edition 101222-- 35 --s2Cad160Connection and control devices1 Mains supply switch 6 Knob for thickness setting2 Indicating lamp, power supply ON 7 Kno

Edition 101222-- 36 --s2Cad160Polarity change+/-- TERMINALSThe machine is delivered with the welding wire connected to the plus pole. Somewires, e.g.

Edition 101222-- 37 --s2Cad160Wire feed pressureStart by making sure that the wire moves smoothly through the wire guide. Thenset the pressure of the

Edition 101222-- 38 --s2Cad160WARNING!Do not keep the torch near the ears or the face during wire feeding, as this mayresult in personal injury.1.1.1

Edition 101222-- 39 --s2Cad160Welding gunS Cleaning and replacement of the welding gun’s wear parts should take place atregular intervals in order to

Edition 101222-- 4 --s1Cad160READ THIS FIRSTMaintenance and repair work should be performed by an experienced person, andelectrical work only by a tra

-- 40 --notesNOTES

-- 41 --notes

ESAB ABSE--695 81 LAXÅSWEDENPhone +46 584 81 000www.esab.com081016ESAB subsidiaries and representative officesEuropeAUSTRIAESAB Ges.m.b.HVienna--Liesi

Edition 101222-- 5 --s1Cad160TECHNICAL DATAVoltage 230 V, 1∼ 50/60 HzPermissible load at100% duty cycle 100 A / 19 V60 % duty cycle 120 A / 20 V35 % d

Edition 101222-- 6 --s1Cad160WIRING DIAGRAMComponent descriptionWARNING !STATIC ELECTRICITY can damage circuitboards and electronic components.SSSS Ob

Edition 101222-- 7 --s1Cad160Caddyrrrr Mig C160i

Edition 101222-- 8 --s1Cad160DESCRIPTION OF OPERATIONCaddyr Mig C160iis a set of following modules:S power PCB -- AP1S control PCB -- AP2S MMC panel -

Edition 101222-- 9 --s1Cad160AP1 Power board (two power module version)