,

ESAB

OrigoTMEDW 510/610D

Engine driven welder

Service manual

0700 161 101

Valid for OrigoTMEDW 510D serial No. 730-xxx-xxxx

Valid for OrigoTMEDW 610D serial No. 745-xxx-xxxx
CONTENTS Page

1 READ THIS FIRST 3

2 SAFETY 3
3 INTRODUCTION 5
4 TECHNICAL DESCRIPTION 6
5 TECHNICAL DATA 8
Static characteristics 9
Circuit diagram 10
6 OPERATION 12
7 MAINTENANCE 14
8 FAULT TRACING 17
9 SPARE PARTS LIST 23

2
1 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 connection diagram as a form of index for the description of operation. All component names in the
connection diagram are listed in the component description.

2 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.

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 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 person is stationed within the working area of the equipment when it is started
up.
• no-one 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 safely 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 curried out by a qualified electrician.
• Appropriate fire extinguishing equipment must be clearly marked and close at hand.
• Lubrication and maintenance must not be carried out on the equipment during operation.
6. EMF information
To reduce your exposure to electromagnetic fields, use the following procedures:
• Keep cables close together by twisting or taping them.
• Arrange cables to one side and away from the operator.
• Do not coil or drape cables around your body.
• Connect work clamp to workpice as close to the weld as possible.

Do not dispose of electrical equipment together with normal waste!

In observance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation in accordance with national law, electrical equipment that
has reached the end of its life must be collected separately and returned to an
environmentally compatible recycling facility. As the owner of the equipment, you should get
information on approved collection systems from our local representative.
By applying this European Directive you will improve the environment and human health!

3
 WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE
PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH
SHOULD BE BASED ON MANUFACTURER’S HAZARD DATA.

ELECTRICAL SHOCK - Can kill

• Install and earth the welding unit in accordance with applicable standards.
• Do not touch live electrical parts or electrode with bare skin, wet gloves or wet clothing.
• Insulate yourself from earth and the workpiece.
• Ensure your working stance is safe.
FUMES AND GASES – Can be dangerous to health
• Keep your head out of the fumes.
• Use ventilation, extraction at the arc, or both, to keep fumes and gases from your breathing zone and
the general area.
ARC RAYS – Can injure eyes and burn skin.
• Protect your eyes and body. Use the correct welding screen and filter lens and wear protective clothing.
• Protect bystanders with suitable screens or curtains.
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE – Excessive noise can damage hearing
• Protect your ears. Use earmuffs or other hearing protection.
• Warn bystanders of the risk.
MOVING PARTS – Can injure
• Do not operate with guards or covers off.
• Stop engine before servicing.
• Keep away from moving parts.
FUEL – Can cause fire or explosion
• Stop engine and let it cool before checking or adding fuel.
• Do not add fuel while smoking or if unit is near any sparks or open flames.
• Do not spill fuel. If fuel is spilled, clean up before starting engine.
BATTERY EXPLOSION – Can blind
• Always wear a face shield, rubber gloves and protective clothing when working on a battery.
• Stop engine before disconnecting or connecting battery cables or servicing battery.
• Do not allow tools to cause sparks when working on a battery.
• Observe correct polarity (+ and -) on battery.
• Disconnect negative (-) cable first and connect it last.
MALFUNCTION – Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

WARNING!
Read and understand the instruction manual
before installing or operating.

WARNING! Do not use the power source for thawing frozen pipes.

Note! This product is solely intended for arc welding.

4
3 INTRODUCTION

The OrigoTMEDW 510/610D is a combined engine driven welding and electric power unit.
It is designed for working even under the toughest job requirements. It is suitable for MMA
welding with all types of DC electrodes, especially cellulose; scratch start TIG welding or
TIG with additional equipment for high frequency start and for arc air gouging. The
auxiliary power generator provides alternating current for power tools, lighting etc.
Continuous welding and auxiliary power can be used simultaneously.

The OrigoTMEDW 510/610D is ideal for quality welding in assembly work, service and
repair in the field, e.g. pipelines, petrol-chemical plants, off-shore work etc.
Stationary form is a standard design. On request, the welding unit can be provided with
two or four wheel trailer.

Front control panel

1 2 3 4 5 6

23
22
21 7
20
19 A
8
18 STOP

17
16
15 220V 220V

14 13 12 11 10 9

1 Engine control module

2 Fuel level gauge
3 Voltmeter (optional)
4 Ammeter (optional)
5 Current range switch
6 Welding current fine setting
7 Emergency stop push button (optional)
8 Polarity switch (optional)
9 Workpiece connection
10 Welding terminal (MMA and TIG)
11 Gouging terminal
12 Socket 220V,16A (optional 110V)
13 Socket 220V,32A
14 Earth terminal
15 Remote control connection
16 Hot start off switch (optional)
17 Remote control switch
18 LED yellow - overheating
19 Circuit breaker - exciter circuit protection
20 Circuit breaker - fuel solenoid protection
21 Circuit breaker 220V
22 Circuit breaker 220V
23 Circuit breaker 220V (optional 110V)

5
4 TECHNICAL DESCRIPTION

The engine F3L912, made by Deutz, drives the three-phase synchronous welding
generator (G), the single-phase auxiliary power generator (G1) and their exciter unit. The
complete rotor assembly is statically and dynamically balanced to assure vibration-free
operation and maximum bearing life.
The brushless exciter unit with two rotating diode bridges is designed for providing the
excitation currents to the rotating fields of welding generator (G) and power generator
(G1). The exciter stator consists of two field windings, which operate separately: eight-pole
winding for welding current adjustment and four-pole winding for auxiliary power. The
exciter rotor consists of two three-phase armatures: eight-pole and four-pole windings.
Two three-phase, full wave rectifier bridges are mounted on the rotor shaft and electrically
connected with appropriate windings.

Description of welding generator operation

This description refers to the circuit diagram .

The welding generator (G) consists of the main generator and the excitation unit. The
exciter stator (F11-F12) is supplied at 12V via the engine control module A2, only while
the engine is running. The excitation current setting is made by the potentiometer
(RP1). The exciter rotor (U-V-W) supplies the rectified current via the diode bridge
(V2.1-V2.6) to the main rotor (F1G-F2G). AC current from the stator (UG-VG-W G) is
rectified via the diode bridge (V1.1-V1.6).

Welding current stabilization is carried by the stabilizer (L2).

The welding coarse settings are carried out by the three-phase inductor (L1) connected to
the generator windings star. The range switch (SA3) is three-positioned. The welding
current fine setting is made by the rheostat (RP1), which allows adjustment of the welding
amperage from minimum to maximum of the coarse range.
6
OCV control circuit provides max open circuit voltage of 92V, regardless of the welding
current setting. The rheostat (RP1) does not affect on OCV because it is shorted when
the arc breaks. When the arc is struck, reed relay (KR1) is operated and allows
adjustment of welding current with the rheostat (RP1).
Optional hot start switch (SA4) disables the max OCV. Switch breaks the max OCV
control circuit and allows the arc striking with open circuit voltage of 65-92V depending
on current setting.
Remote control is available for the fine current setting. For the remote control, place the
switch (SA1) in the remote position and connect the remote control device to the remote
connector (XS6).
The open circuit voltage (92V) is adjusted by the resistor RP2, at factory.
Polarity of the weld output is selected by the polarity switch (SA2).
Polarity switch, ampere meter (PA1) and voltmeter (PV1) can be provided on request.
The thermostat (ST2) prevents the power source from overload. It is placed on the
diode bridge’s heat sink (V1.1-V1.6). When the temperature exceeds 1000C the
thermostat cuts off the excitation current from the exciter stator (F11-F12) and the yellow
LED (V6) lights. The thermostat resets automatically when the temperature falls below
800C.

Description of auxiliary power generator operation

This description refers to the block diagram below.
The single-phase auxiliary power generator (G1) is self-exciting, synchronous, brushless
type machine.The generator consists of the main generator, the excitation unit, which
supplies direct current to the main rotor and an automatic voltage regulator (A1), which
controls the output of the main generator by regulating the current into the exciter field.
The main stator provides power for excitation of the exciter field (F21-F22) via the A1 which
is the controlling device governing the level of excitation provided to the exciter field. The
A1 responds to a voltage sensing signal derived from the main stator winding. By
controlling the low power of the exciter field, control of the high power requirement of the
main field (F1-F2) is achieved through the rectified output (V3) of the exciter stator (U1-V1-
W 1).
The system is excited automatically by means of the residual magnetism of the
magnetic circuit of the generator and exciter, stabilized by the permanent magnets
installed in two of the exciter poles. The remanent voltage, measured on the socket XS4
(or between terminals 1 and 4 on XT2), should be above 5V.

The auxiliary power generator (G1) produces a maximum of 6,2 kVA. Two sockets (220V)
are available on the front panel. The circuit breakers QF1, QF2 and QF3 offer short-circuit
protection, overload protection and earth fault protection.
7
5 TECHNICAL DATA

OrigoTM EDW OrigoTM EDW

Welding generator 510D 610D
Output current range 40-500A 40-700A
Permitted load:
at 25% duty cycle - 700A/25V
at 40% duty cycle 450A/38V 575A/43V
at 60% duty cycle 400A/36V 530A/41,2V
at 100% duty cycle 300A/32V 500A/40V
Open circuit voltage 92 V 92V
Insulation class H (1800C) H (1800C)

Auxiliary power generator

Max. output 6,2kVA, cosφ 0,8 6,2kVA, cosφ 0,8
Voltage 220V, 60Hz 220V, 60Hz
Earth fault protection 30mA 30mA

Simultaneous welding and power loads 300A/32V+6,2kVA 450A/38V+6,2kVA

Diesel engine Deutz F3L 912

Type 3-cylinder
Fuel code Diesel DIN 51601
Prime power at 1800 rpm, ISO 3046-1 32,0 kW
Reference conditions:
Ambient temperature +25oC
Altitude 100m
Relative humidity 30%
Speed:
no-load speed 1890 rpm
load speed 1800 rpm
Displacement 2,827 dm3
Cooling air
Starting system, electrical 3kW/12V
Fuel tank capacity 90 l
Fuel consumption (at 100% duty cycle) 220 g/kWh (approx. 8,4 l/h)
Oil consumption (0,5% of fuel consumption) 0,042 l/h
Battery 12V/100Ah

Complete unit
Enclosure class IP23
Working ambient temperature -10oC to +40oC
Dimensions (LxWxH) 1610x850x990 mm
Standard EN 60974-1
Weight (dry) 775kg 795kg

Duty cycle
The duty cycle refers to the time as a percentage of a ten–minute period that you can
weld at a certain load without overloading.
Enclosure class
The IP code indicates enclosure class, i.e. the degree of protection against penetration by
solid objects and water. Equipment marked IP23 is designed for indoor and outdoor use.

8
5.1 Static characteristics

Static characteristics OrigoTM EDW 510D

100
Welding current range for
90 MMA:
Step I 40-85A
80
Step II 60-200A
Step III 110-450A
70

60
U (V)

50
III
40

30 II

20
I
10

0
0 100 200 300 400 500 600 700
I (A)

Static characteristics OrigoTM EDW 610D

100
Welding current range for
90 MMA:
Step I 40-90A
Step II 75-235A
80 Step III 140-575A

70

60
U (V)

50
III
40

30 II

20
I

10

0
0 100 200 300 400 500 600 700
I (A)

9
5.2 Circuit diagram Diesel welder 510D/610D

y.-green

brown
black
blue

10
A1 Voltage regulator (for G1)
A2 Engine control module (DSE 702)
E1* Earth rod (optional)
EV1 Fan (only for Diesel 610D)
FR1-FR2 Thermal circuit breaker (16A)
G Welding generator
G1 Auxiliary generator
G2 Alternator
GB1 Battery (12V, 100Ah)
KA1-2 Relay 12V (NO)
KA3 Relay 12V (NC)
KR1 Reed relay
L1 Inductor
L2 Stabilizer
M1 Electric starter
P1 Fuel level gauge
PA1* Ampere meter (600A, 60mV) - optional
PV1* Voltmeter (100V) - optional
QF1 Circuit breaker (220V, 25A,
I=30mA)
QF2 Circuit breaker (220V, 25A)
QF3 Circuit breaker (220V)
R4 Resistor (100 Ω, 2W)
RP1 Fine setting rheostat (8 Ω, 200W)
RP2 Resistor (0,6 Ω, 30W)
RS1* Shunt (600A, 60mV) - optional
RV1 Varistor
SA1 Switch (remote control)
SA2* Polarity switch (optional)
SA3 Current range switch
SA4* Hot start off switch (optional)
SB1* Emergency stop push button (optional)
SL1 Fuel level indicator
SP1 Oil pressure indicator
ST1 Oil temperature indicator
ST2 Thermostat (1000C/800C)
V1.1-V1.6 Diode bridge
V2.1-V2.6 Diode bridge (SKD30/08A1)
V3.1-V3.6 Diode bridge (SKD30/08A1)
V4 Diode (MR754)
V6 LED yellow
XS1.+ Welding terminal with stabilizer
XS2.+ Welding terminal without stabilizer
XS3.- Welding terminal
XS4 Socket (220V, 32A)
XS5 Socket (220V, 16A)
XS6 Remote control connector (3-pole)
XT1 Connection block
XT2 Connection block
YA1 Fuel solenoid valve
Z1* HF-filter (optional for TIG-HF ignition unit)

11
 6 OPERATION

6.1 Starting the engine

• Disconnect all weld and power load from the generator.

• Turn the ignition key to the hand position.
• Press the pre-heat (yellow) button for required time (optional: cold starting aid –170C).
• Press and hold the START (green) button for few seconds to crank the engine.
• The starter motor is disengaged automatically when the engine fires or when the START
button is released.
• The control module indicates fault conditions by LED: low oil pressure, high cylinder head
temperature and low battery charging.
• The module automatically shuts down the engine if any of following alarms are operated:
low oil pressure and high cylinder head temperature.
• The alarm output and relevant LED will remain active until the unit is reset by turning the
key to the “0” position.
• The module is provided with the LCD hours run counter which is incremented whenever
the engine is running.
• Let the engine idle for a few minutes before applying load.

6.2 Stopping the engine

• Disconnect all weld and power load from generator.

• Turn the ignition key to the off position.
• Press the emergency stop button (optional).
• When engine is not running ignition key must be in position 0 to protect battery from
discharging.

6.3 Welding output

• Select suitable welding and return cables and connect them to the welding terminals.
• Connect welding cable to the terminal marked for MMA/TIG welding or to the terminal
marked for arc air gouging.
• Select either Electrode Positive or Electrode Negative by the polarity switch.
• Connect the return cable to the work piece.
• Set the welding current range using the range switch. Current fine setting is made by a
rheostat which allows adjustment of welding amperage from minimum to maximum of the
current range.
• Remote control is available only for fine current setting. For remote control, place switch in
Remote position and connect remote control to the remote control connector.
• The current range switch and the polarity switch should not be switched over during
welding operation!
• The FINE CURRENT control may be adjusted while welding!
• Check that the electrode holder has no electric connection with the return clamp!
• Do not weld anything on the welder machine!
• The thermostat mounted on the diode bridge prevents the power source from overload.
The thermostat reset automatically.

12
6.3.1 Selecting weld cable sizes
The following current load is recommended for the individual sectional areas, duty factors
and cable length up to 30m. For cable distance longer than 30m, use next size larger cable.

Maximum permissible current (A)

2
Sectional copper cable area (mm ) for duty factor
100% 60% 35%

35 225 243 279

50 285 316 371
70 355 403 482
95 430 498 606

6.4 Auxiliary power output

The auxiliary power generator provides alternating current for power tools, lighting etc.
Two sockets 220V are available on the front panel.
The circuit breaker offers short-circuit protection, overload protection and earth fault
protection.
If the generator is overloaded circuit breaker will automatically stop supplying electricity. If this
happens disconnect your equipment, let the motor idle for a while, and then reconnect again.
The circuit breaker will cut off supply in case of an earth fault (residual current I ∆N≤ 30mA). If
this happens check for faulty tools and reset switch.
This protective device will not protect the operator unless there is a good ground. It is
responsibility of person to use a good quality earth cable and connect it to the earth terminal
of the machine.
All tools must be earthed to the machine frame using an earthed type plug or should be
double insulated.

6.4.1 Testing the earth fault protection

Set the residual current circuit breaker to the position 1. Test by pressing the test button
while the engine is running. The circuit breaker should cut out and the breaker return to
position 0. Reset the breaker to position 1.

6.4.2 Grounding
• Always ground machine frame to transport vehicle frame to prevent electric shock and
static electricity hazards.
• Always ground machine frame to system earth ground if supplying power to a premises
(home, shop…)

13
7 7 MAINTENANCE

7.1 Generator maintenance

The generator requires minimum of maintenance. Under normal operating conditions it is
sufficient to blow dust with dry, low pressure air once a week.

7.1.1 Removal of exciter rotor

- Disconnect all leads from the rotating rectifier bridges.
- Remove the bolts M4x15 and remove the rectifier bridges.
- Remove two bolts M6x25 and remove the support from the shaft.

- Remove exciter rotor from the shaft with adequate tool as follows:
- Place the tool on two existing bolts M8x90.
- Tighten two nuts M6 and the tool will be fixed to the rotor package.
- Screw two bolts M8x135 alternately through the tool, so that the end of bolts press the
end of the shaft.
- In that way the exciter rotor will be removed horizontally.

14
7.2 Engine maintenance
The engine requires a certain amount of maintenance (see the engine instructions).
Recommended service intervals must be observed and maintenance work carried out
conscientiously. Special care should be taken under extra demanding operating conditions.

7.2.1 Installing spark arrestor (optional)

A suitable spark arrestor must be installed when the diesel welding unit is operated in
certain locations where unarrested sparks may present a fire hazard.

Do not touch hot muffler or exhaust pipe!

• Stop the engine and let cool.
• Remove the exhaust pipe.
• Install the spark arrestor on the exhaust pipe.
• Tighten the clamp.

15
 7.2.2 Recommended maintenance schedule:

1)
Operation hours check
every clean
change
Once Every
2)
after 10H or 125 250 500 1000 2000 3000 5000 Operation
50-150 daily
● ● Oil level in engine/separate container
● ● Engine leaks
● ● Oil bath and dry type air cleaners 3) 4)
● ● Battery and cable connectors
● ● ● ● Cooling system 3) 6)
● ● ● ● ● ● Engine oil (depending of engine use) 5)
● ● ● Oil filter cartridge
● ● ● Fuel filter cartridge
● ● ● ● Valve clearance (adjust if necessary)
● ● ● Engine mounts (retighten if necessary)
● ● ● V-belts (retension if necessary)
● ● Warning system
● ● Fuel precleaner
● ● ● Mountings
● ● Flame glow plugs 4)
● ● Partial –flow oil filter
● ● Sheathed element heater plugs
● ● Injection valve

The specified engine maintenance times are maximum values. Depending on the operating environment, shorter maintenance intervals may be required. Please observe
the operating instructions of the engine manufacturer.

1) Recommended maximum
2) Commissioning new or reconditioned engines
3) Clean if needed
4) Change if necessary. If fitted, service after service indicator.
5) Oil change interval
6) Clean system /cooling fins

16
7 8 FAULT TRACING

8.1 Welding generator G

Type of fault Measure

No arc • Check that the welding and return cables
are properly connected
• Check if circuit breakers (FR1, FR2) are
open
• Check position of remote switch (SA1)
The welding current is interrupted • Check if the thermal cut-out has tripped
during welding (The thermostat resets automatically)
The thermal cut-out trips frequently • Check that the ratings of the welding
power source have not been exceeded
(overload of the power source)
Poor welding result • Check that the welding and return cables
are properly connected
• Make sure the welding current set is
correct
• Check that the correct electrodes are
being used
Excessive spatter from the arc ● Damp or defective electrode
● Incorrect electrode polarity
● Incorrect terminal connection: gauging
instead of welding terminal

8.2 Auxiliary generator G1

Type of fault Measure

No voltage build-up • Check that the circuit breaker QF1, QF2
and QF3 are switched On

8.3 Engine

Type of fault Measure

Engine will not crank • Check battery
• Check battery connections
Engine cranks but does not start • Check if circuit breaker (FR2) is open
• Check fuel level
• Check fuel filter
• Check oil level
• Check oil temperature

• Check oil temperature

Engine shuts down shortly after starting • Check oil level
Engine runs rough and slowly stopped • Dirty fuel or air filters
• Water in fuel

17
8.4 Winding resistance for OrigoTMEDW 510D

ZX 020 - Welding generator (G) resistance values at 200C

Stator: U-x, V-y, W-z 0,00504W (0,004 - 0,006)
Rotor: F1G - F2G 0.93413W (0.8 -1,0)

FX005 – Auxiliary generator (G1)

Stator: U1-x1, V1-y1 0,36354W (0,3 - 0,4)
Rotor: F1 - F2 0,65172W (0,6 - 0,7)

Exciter
Exciter stator (ZX-generator)
F11-F12 1.48W (1,3 - 1,6)
Exciter stator (FX-generator)
F21-F22 18W (16 -19)
Exciter rotor (ZX-generator)
U-V, V-W, U-W 0,1236W (0,10-0,15)
Exciter rotor (FX-generator) 0.336W (0.3-0,40)
U1-V1, V1-W 1, U1-W 1

8.5 Winding resistance for OrigoTMEDW 610D

ZX 025 - Welding generator (G) resistance values at 200C

Armature: U-x, V-y, W-z 0,0033W (0,003 - 0,004)
Field: F1G - F2G 1,0862W (1.05-1,15)

FX005 – Auxiliary generator (G1)

Stator: U1-x1, V1-y1 0,36354W (0,3 - 0,4)
Rotor: F1 - F2 0,65172W (0,6 - 0,7)

Exciter
Exciter stator (ZX-generator)
F11-F12 1.48W (1,3 - 1,6)
Exciter stator (FX-generator)
F21-F22 18W (16 -19)
Exciter rotor (ZX-generator)
U-V, V-W, U-W 0,1236W (0,10-0,15)
Exciter rotor (FX-generator) 0.336W (0.3-0,40)
U1-V1, V1-W 1, U1-W 1

8.6 Insulation resistance

The insulation resistance shall be not less than 5MΩ between windings and earthed parts.
Conformity shall be checked by the stabilized measurement of the insulation resistance by
application of a d.c. voltage of 500V at room temperature.

18
8.7 Dielectric strength

The a.c. test voltage shall be of an approximate sine wave-form, having a frequency of
approximately 50Hz or 60Hz.
Conformity shall be checked by application of the test voltage for 5 sec.
The test voltages may be raised to the full value slowly.
The insulation shall whitstand the following test voltages without any flashover or
breakdown.
1600V Stator winding (Auxiliary generator)
1200V Stator winding (Welding generator)
1200V Rotor winding (Auxiliary generator)
1200V Rotor winding (Welding generator)
1200V Rotor winding & pole winding (Exciter)
800V Inductor windings

8.8 Testing rotating diode bridge

The moulded bridge rectifiers V2.1-V2.6 and V3.1-V3.6 consist of 6 diodes.

The diodes can be checked with a digital multimeter. Set the digital multimeter to the diode
measurement scale. A diode in a good condition enables the current to flow in only one
direction, from anode to cathode, because of low resistance. In reverse direction the resistance
is very high. See diagram 1, 2 and 3.

1. Connect black lead of multimeter to the diode bridge terminal marked (+) and red lead to
the first terminal marked (∼) for testing the diode V2.1.
For testing the diode V2.3 connect red lead to the second terminal marked (∼).
For testing the diode V2.5 connect red lead to the third terminal marked (∼).
The diodes are good if the voltage readings are 0,4-0,6V dc.
If the black and red leads are changed multimeter reading is OVER.
2. Connect red lead of multimeter to the diode bridge terminal marked (-) and black lead to
the first terminal marked (∼) for testing the diode V2.2.
For testing the diode V2.4 connect red lead to the second terminal marked (∼).
For testing the diode V2.6 connect red lead to the third terminal marked (∼).
The diodes are good if the voltage readings are 0,4-0,6V dc.
If the black and red leads are changed multimeter reading is OVER.

19
3. Connect red lead of multimeter to the diode bridge terminal marked (-) and black lead to
the terminal marked (+).
The diodes are good if the voltage reading is 0,8-1,2 V .
If black and red leads are changed multimeter reading is OVER.

8.9 Restoring residual magnetism

Residual magnetism of the exciter field poles may be lost or weakened by momentary reversal of
the field connection or if the generator is not operated for a long period of time. In such cases no
voltage is built-up. The regeneration process is carried out as follows:
- Engine runs at 1890 rpm / no load.
- Strike the arc and change welding current with rheostat RP1 from minimum to maximum of
the coarse range.
- Check if the voltage is built-up.

8.10 Open circuit voltage

- Adjust resistor RP2 that the open circuit voltage is 90-92V.

- Voltage measured between terminals 1 and 3 on connection block XT1 is 11-12V. In that
case the current through exciter winding (F11 - F12) is about 7A.
- Open circuit voltage is independent of the current setting because the rheostat RP1 is
shorted by relay KA3.
- Open circuit voltage measurement between the welding terminals XS1 and XS3:

If the open circuit voltage isn’t within the tolerance range 90-92V, check the voltage
between output generator terminals (UG-VG-W G). The voltage should be about 67V. If the
voltage is correct, the rectifier bridge V1.1-V1.6 is incorrect. If the voltage between output
generator terminals isn’t correct the fault could be in inductor L1, switch SA3, or welding
generator G. Check the winding resistance.
20
8.11 Welding output
When the arc is struck, reed relay KR1 and relay KA3 are operated, rheostat RP1 is not
shorted and RP1 adjusts current through exciter winding (F11 - F12) i.e. welding current.
When the RP1 is at min. position the exciter current is min. value (1,4A). Voltage measured
between terminals 1 and 2 on connection block XT1 is 1,9-2,0 V.
When the RP1 is at max. position the exciter current is max. value (7A). Voltage measured
between terminals 1 and 2 on connection block XT1 is 9,2-9,5 V.

- Set the current range switch SA3 at third range.

- Adjust welding current 450A by rheostat RP1.
- Start weld (450A / 38V).
- Voltage and amperage measurements between the welding terminals marked
(+XS1) and (-XS3 ):

- Set the current range switch SA3 at third range.

- Adjust welding current 450A by potentiometer RP1.
- Start weld (450A / 38V).
- Voltage and amperage measurements between the welding terminals marked
(+XS2 without stabilizer L2) and (-XS3):

21
8.12 Auxiliary power output

The AC curves show the generator power available in amperes:

U=f(I)

250

200

150
cos 1
U(V)

cos 0,8
100

50

0
0 5 10 15 20 25 30 35 40
I(A)

Auxiliary voltage measurement at connection block XT2 or socket XS4:

22
7 9 ORDERING OF SPARE PARTS

Spare parts may be ordered through your nearest ESAB dealer, see the last page of this publication. When
ordering, please state product type, serial number, designation and spare part number in accordance with
the spare parts list. This facilitates dispatch and ensures correct delivery.

Accessories Ordering no.

Remote control, 15 m 0700161041
Spark arrestor 0700161043
Earth rod 0700161042
2-wheel trolley, off road 0700161045
2-wheel trolley, highway 0700161096
4-wheel trolley, off road 0700161046
4-wheel trolley, off road heavy duty with leaf springs 0700161084
Cable holders, side assembled 0700161129

Wear parts Ordering no.

Engine maintenance set, 2000h operation 0700161087

Control panel

FRONT SIDE 1 2 3 4 5 6 7 BACK SIDE 18 19

17
RP1 PA1 PV1 A2
P1
25
16 20
KA3 KA2 KA1
15 A
SB1 A2
14 STOP
SA2 SA3

FR2 FR1 RP2

21
13 V6
QF2 QF3 QF1
12 220V 220V
XS5 XS4 SA1 SA4
11 XS3 XS1 XS2
XT1
XT2
Z1
XS6

10 9 8 24 23 22

C=component designation in the circuit diagram

Item Quantity Ordering no. Denomination C

no. OrigoTM OrigoTM
EDW510D EDW610D
1 1 1 0700161064 Engine control module (DSE702) A2
2 1 1 0700161116 Fuel level gauge P1
3 1 1 0700161070 Voltmeter (optional) PV1
23
4 1 1 0700161071 Ampere meter (optional) PA1
1 1 0700161097 Shunt (optional) RS1
1 1 0700161066 A/V meter kit (optional) PA1,PV1,
RS1
5 1 1 0700161009 Current range switch SA3
1 1 0700161062 Current range switch handle
6 1 1 0700161050 Rheostat (8Ω, 200W) RP1
1 1 0700161063 Rheostat knob
7 1 1 0700161072 Polarity switch (optional) SA2
8 3 3 0700161010 Welding terminal XS1-XS3
9 1 1 0700161012 Socket 220V, 16A XS5
1 1 0700161011 Socket 110V, 16A (optional) XS5
1 1 0700161118 110V socket/breaker kit (optional)
10 1 1 0700161102 Socket 220V, 32A XS4
11 1 1 0700161007 Remote control connector (3-pole) XS6
12 1 1 0700161119 Hot start off switch (optional) SA4
13 1 1 0700161006 Remote control switch SA1
14 1 1 LED yellow V6
15 2 2 0700161113 Thermal circuit breaker (16A) FR1, FR2
16 1 1 0700161002 Circuit breaker (220V, 25A/0,03A) QF1
17 1 1 0700161137 Circuit breaker (220V, 25A + U<) QF2,QF3
1 1 0700161123 Circuit breaker (110V, 16A/0,03A)
(optional)
18 1 1 0700161085 Relay KA3
19 2 2 0700161065 Relay KA1, KA2
20 1 1 0700161015 Voltage regulator A1
21 1 1 0700161112 Resistor (0,6Ω, 30W) RP2
22 1 1 Connection block XT1
23 1 1 Connection block XT2
24 1 1 0700161121 TIG-HF filter (optional) Z1
25 1 1 0700161120 Emergency stop button (optional) SB1

24
Generator

C=component designation in the circuit diagram

Item Quantity Ordering no. Denomination C

no. OrigoTM OrigoTM
EDW510D EDW610D
1 1 1 Coupling disc SAE 8
2 1 Fan
3 1 Fan support
4 1 0700161114 Axle
5 1 Welding generator rotor G
6 1 Auxiliary generator rotor G1
2 1 Fan
3 1 Fan support
4 1 0700161104 Axle
5 1 Welding generator rotor G
6 1 Auxiliary generator rotor G1
7 1 1 0700161023 Bearing (6210-2RS C3)
8 1 1 0700161024 Exciter rotor
9 2 2 0700161025 Diode bridge (SKD30/08 A1) V2, V3
10 1 1 Air outlet cover
11 1 1 Welding generator stator G
12 2 2 Foot
13 1 1 Stator cover
14 1 1 0700161125 Auxiliary generator stator G1
15 1 1 Exciter stator support
16 1 1 0700161029 Exciter stator
17 1 1 Air inlet cover

25
Diesel welder

C=component designation in the circuit diagram

Item Quantity Ordering no. Denomination C

no. OrigoTM OrigoTM
EDW510D EDW610D
1 Control panel
2 1 0700160051 Fan EV1
1 0700161105 Generator G, G1
3
1 0700161115 Generator G, G1
4 2 2 0700161134 Shock absorber
1 1 0700161032 Diode bridge V1.1-V1.6
5
1 1 0700160048 Thermostat (1000C/800C) ST2
1 0700161051 Inductor L1
6
1 0700161074 Inductor L1
1 0700161106 Welding stabilizer L2
7
1 0700161075 Welding stabilizer L2
8 1 1 0700161111 Oil drainage valve (optional)
9 1 1 Battery 100Ah,12V, DIN540A GB1
10 2 2 0700161107 Shock absorber
11 1 1 Deutz engine F3L912
12 2 2 Service door
13 4 4 0216704801 Key lock latch
26
 14 2 2 0700161098 Hinge
15 1 1 0700161110 Latch
16 1 1 Door
17 1 1 Exhaust pipe
18 1 1 0700161117 Fuel cap
19 1 1 0700161122 Fuel filter
1 1 0700161108 Fuel tank (90l)
20
1 1 0700161109 Fuel level indicator SL1
21 1 1 0700161042 Earth rod (optional) E1

Remote control

2
1

C=component designation in the circuit diagram

Item Quantity Ordering no. Denomination C

no. OrigoTM OrigoTM
EDW510D EDW610D
1 1 1 0700161041 Remote control, 15 m
2 1 1 0700161050 Potentiometer (8Ω, 200W)
3 1 1 0700161047 Connector (3-pole, male)

27
Voltage regulator VR 3.1

Technical data
The VR 3.1 is a half wave voltage regulator designed for brushless alternators whose nominal phase or
line voltage is in the 180-260Vac range, 50 or 60 Hz and exciter current does not exceed 4A dc.

Specifications:
• Power input voltage range 180-260Vac, 50 or 60 Hz
• Sensing voltage 180-260Vac, 50 or 60 Hz
• DC output current 4A dc at 63Vdc continuous
• DC max. output current 6,32A at 240Vac input (max 30sec)
• Min. field DC resistance 15,75 Ω
• Regulation accuracy better than ± 1% no load to full load
• Frequency compensation 8 V/Hz voltage drop below 45 or 55Hz
• Automatic voltage build-up 5Vac remanent voltage
• Remote voltage adjusting rheostat 2k Ω , 2W
• EMI suppression internal, 220nF X2 capacitor
• Operating temperature -40 to +60oC
• Dimensions 125x75x27
• Weight 220g

The AVR is connected to the terminals of the generator and to the exciter through eight – pole
terminals.
Max. wire section is 2,5 mm2.
It is recommended that fast-blow fuses with high interruption capability (10A, 240V) are installed to
protect wiring from faults.
Voltage regulator is adjusted at manufacturer to regulate 220V on terminals ~ and ~.
Voltage correction is possible by screwdriver adjustable 25-turn potentiometer between 180 and 260V.
In the case that the customer would like to be able to regulate voltage from the control panel it is
necessary to disconnect both Var terminals and reconnect them to the potentiometer (2kΩ, 2W, to
obtain ± 5% voltage range).
Potentiometer for low speed protection is set in order to reduce the excitation when the speed is 10%
below the rated value at 50 or 60 Hz.

28
 ESAB ESAB subsidiaries and representative offices

Europe North and South Asia / Pacific

AUSTRIA NORWAY America CHINA
ESAB Ges.m.b.H AS ESAB Shanghai ESAB A/P
Larvik ARGENTINA
Vienna-Liesing Shanghai
Tel: +47 33 12 10 00 CONARCO Tel: +86 21 6539 7124
Tel: +43 1 888 25 11
Fax: +47 33 11 52 03 Buenos Aires Fax: +86 21 6543 6622
Fax: +43 1 888 25 11 85
Tel: +54 11 4 753 4039
INDIA
POLAND Fax: +54 11 4 753 6313
BELGIUM ESAB India Ltd
BRAZIL
S.A. ESAB N.V. ESAB Sp.z.o.o Calcutta
ESAB S.A.
Brussels Warszaw Tel: +91 33 478 45 17
Contagem -MG Fax: +91 33 468 18 80
Tel: +32 2 745 11 00 Tel: +48 22 813 99 63 Tel: +55 31 3369 4333
Fax: +32 2 726 80 05 Fax: +48 22 813 98 81 INDONESIA
Fax: +55 31 3369 4440
P.T. Esabindo Pratama
THE CZECH REPUBLIC Jakarta
PORTUGAL CANADA
ESAB VAMBERK s.r.o. ESAB Group Canada Inc. Tel: +62 21 460 01 88
Prague ESAB Lda Mississauga, Ontario
Lisbon Fax: +62 21 461 29 29
Tel: +420 2 819 40 885 Tel: +1 905 670 02 20
Fax: +420 2 819 40 120 Tel: +351 1 837 1527 Fax: +1 905 670 48 79 MALAYSIA
Fax: +351 1 859 1277 ESAB (Malaysia) Snd Bhd
DENMARK MEXICO Selangor
Aktieselskabet ESAB SLOVAKIA ESAB Mexico S.A. Tel: +60 3 703 36 15
Copenhagen-Valby ESAB Slovakia s.r.o Monterrey
Bratislava Fax: +60 3 703 35 52
Tel: +45 36 30 01 11 Tel: +52 8 350 5959
Tel: +421 7 44 88 24 26 Fax: +52 8 350 7554 SINGAPORE
Fax: +45 36 30 40 03 Fax: +421 7 44 88 87 41 ESAB Singapore Pte Ltd
USA Singapore
FINLAND SPAIN ESAB Welding & Cuting
ESAB Oy ESAB IbErica S.A. Tel: +65 861 43 22
Products Fax: +65 861 31 95
Helsinki Alcobendas (Madrid)
Tel: +34 91 623 11 00 Florence, SC
Tel: +358 9 547 761 Tel: +1 843 669 44 11 ESAB Asia/Pacific Pte Ltd
Fax: +34 91 661 51 83
Fax: +358 9 547 77 71 Fax: +1 843 664 44 58 Singapore
SWEDEN Tel: +65 861 74 42
FRANCE Fax: +65 863 08 39
ESAB Sverige AB
ESAB France S.A. Gothenburg SOUTH KOREA
Cergy Pontoise Tel: +46 31 50 95 00 ESAB SeAH Corporation
Tel: +33 1 30 75 55 00 Fax: +46 31 50 92 22 Kyng-Nam
Fax: +33 1 30 75 55 24 Tel: +82 551 289 81 11
SWITZERLAND Fax: +82 551 289 88 63
GERMANY ESAB AG
Dietikon UNITED ARAB EMIRATES
ESAB GmbH
Tel: +41 1 741 25 25 ESAB Middle East
Solingen
Fax: +41 1 740 30 55 Dubai
Tel: +49 212 298 0
Fax: +49 212 298 204 Tel: +971 4 338 88 29
Fax: +971 4 338 87 29
GREAT BRITAIN
ESAB Group (UK) Ltd Representative
Waltham Cross
Tel: +44 1992 76 85 15 offices
Fax: +44 1992 71 58 03
BULGARIA
ESAB Automation Ltd ESAB Representative Office
Andover Sofia
Tel: +44 1264 33 22 33 Tel/Fax: +359 2 974 42 88
Fax: +44 1264 33 20 74 EGYPT
ESAB Egypt
Dokki-Cairo
HUNGARY Tel: +20 2 390 96 69
ESAB Kft
Budapest Fax: +20 2 393 32 13
Tel: +36 1 20 44 182 ROMANIA
Fax: +36 1 20 44 186 ESAB Representative Office
Bucharest
ITALY
ESAB Saldatura S.p.A. Tel/Fax: +40 1 322 36 74
Mesero (Mi) RUSIJA-CIS
Tel: +39 02 97 96 81 ESAB Representative Office
Fax: +39 02 97 28 91 81 Moscow
Tel: +7 095 937 98 20
THE NETHERLANDS Fax: +7 095 937 95 80
Esab Nederland B.V.
Utrecht ESAB Representative Office
Tel: +31 30 248 59 22 St Petersburg
Fax: +31 30 248 52 60 Tel: +7 812 325 43 62
Fax: +7 812 325 66 85

29