C.so E. Filiberto, 27 - 23900 LECCO ITALY
Tel. ++39.0341.22322 - Fax ++39.0341.422646
Cas. Post. (P.O.BOX) 205
e-mail: cea@ceaweld.com - web: www.ceaweld.com
1020h453/A
Strictly confidential
INDEX:
1) Purpose of Manual
2) Machine description
3) Available spare parts
4) Instruments required for testing and repairing
5) Testing procedure
6) Warranty conditions
7) Technical data
8) Technical assistance procedure request
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1. PURPOSE OF THE MANUAL
The purpose of this manual is to give useful information on repairing RAINBOW 180E to
authorised Service Centres. This manual must only be used by qualified technicians to
avoid running risks of serious damage to persons or objects.
It is better to read and understand the contents of this manual before repair work.
Repairing a machine means opening it up to gain access to the parts inside after removing
some of the safety guards. For this reason there are certain precautions to be taken, other
than those for just using it for welding, aimed at avoiding being harmed by contact with:
- live parts;
- moving parts;
- parts with elevated temperatures.
WARNING! : Always unplug from the socket before handling parts inside the
machine, as switching on the switch does not prevent danger of being electrocuted.
Always wait for about five minutes before working on the inside parts as some of
the capacitors may still be charged at a high voltage.
Always use original spare parts supplied by CEA
The subject matters in this manual have been organised into a successive logic gradually
leading the operator into gaining a working knowledge of the general characteristics of the
machine (chapter 2) and making it possible to identify the damaged component.
Repairs consist in identifying the damaged part and replacing it only for the parts listed at
chapter 3.
At chapter 4 you’ll find a list with all the necessary instruments for making the correct
diagnosis and repairing.
At chapter 5 you’ll find how to find out the faulty component.
In case you are not able to solve the problem by following the instructions given in this
book, the machine must be sent back to CEA for repairing.
Should you have any doubt or problem when repairing the equipment, you can contact
CEA SpA at any time: we’ll be glad to help you (see chapter 8).
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2) MACHINE DESCRIPTION
The RAINBOW 180 welder is based on INVERTER technology. By using a high frequency
intermediate section it is possible to use a transformer considerably smaller in size and
weight than standard machines. There are other important factors related to using this
system such as greater efficiency and improved welding quality resulting from the rapid
response from the system.
Figure 2.1 block diagram shows the working principle of the above machine.
The technology used for the RAINBOW 180 greatly adds to these characteristics. In fact, a
totally controlled single-phase inverter is used, which, due to its rapid response, controls
the weld current far more rapidly and effectively: in TIG immediate arc striking (ignition) is
obtained just by lightly touching the work piece (touch and start) and MMA welding
performance is particularly efficient and stable both with basic and steel electrodes. This is
all possible due to the 100 kHz working frequency, IGBT technology and the kind of used
inverter (zero voltage switching inverter). In addition to the above, a microprocessor
control grants an easy but precise machine adjustment.
Figure 2.1 block diagram shows the working principle of the above machine.
°t
+
1- Radiodisturbance mains filter
2- Line switch
3- Electrolytic capacitors charge circuit
4- Primary rectifier
5- Electrolytic capacitors
6- Power inverter
7- Main current reading transformer
8- Main transformer
9- Secondary bridge with thermostat
10- Doubler PCB and snubber circuits
11- Inverter control PCB
12- Analogic front controls card
13- Current reading shunt
14- Mains supply circuit
Figure 2.1
We are also giving you two side views showing the component position in respect to the
number given on the block diagram (see figure 2.2)
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2
12
3
1
6
7
13
10
9
11
14
5
6
4
8
Figure 2.2
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The following points give a general description of each item in the block diagram:
1. Radiodisturbance filter. This is a passive component with the dual task of limiting
machine frequency output as required by EEC norms and making the RAINBOW 180
E immune from problems caused by eventual electronic devices connected to the
same mains supply.
2. Main switch. This has the simple task of switching the machine on and off and is
located on the back panel at the exit of the mains cable.
WARNING! The switch is connected after the radiodisturbance filter so that switching
on power to the mains cable also automatically means supplying the filter, i.e. a part of
the machine is live.
3. Electrolytic capacitors charging circuit. This is a simple circuit required for initially
charging the electrolytic capacitors. In fact, an uncharged capacitor at the initial
moment of the charge transient has the effect of a real short-circuit with very high
currents. Apart from damaging the capacitors themselves, this could also damage the
primary bridge where the entire current is in transit. A resistance has been custom-built
into the feed circuit in order to limit this current to 30A so that the load current will be
kept to tolerated values. This resistance is short-circuited by a relay after a certain time
(about 50 milliseconds) and the machine is then ready to work normally.
4. Primary rectifier. The rectifier is a high voltage diode single-phase bridge, rectifying
the voltage from the mains, achieving a single-direction value.
5. Electrolytic capacitors. The pulsing single-directional output voltage from the primary
bridge is levelled off by the electrolytic capacitors (in this case 4 in parallel) achieving a
practically continuous wave form. Other capacitors also have to be near to the inverter
to eliminate any high frequency harmonics and to reduce interference with the other
components.
6. Power inverter. Continuous voltage is converted by an inverter into a square wave at
a frequency of 100 kHz. The inverter has the following characteristics:
- complete bridge (H);
- phase shift;
- IGBT switching takes place at zero voltage (ZVS= zero voltage switching);
The inverter controls the crossing current.
7. Primary current reading transformer. It is installed at the output of the inverter and
on the transformer primary. It is designed to give a current value in proportion to the
current given from the inverter and necessary for its protection.
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8. Power transformer. The transformer supplies a lower voltage to its secondary
terminals necessary for welding. It also provides the electric isolation needed between
the main power supply and the weld circuit, as requested from the norms.
9. Secondary rectifier circuit with thermostatic protection: the square wave voltage
given from the inverter is rectified by a fast diode rectifier. On the secondary diodes
heat sink there is a thermostatic protection being operated at 100°C
10. Doubler and snubber circuits. The doubler is designed for the quality of welding i.e.
to achieve a longer and more stable arc and easier efficient ignition. There is also a
system of snubbers to limit over-voltages on the diodes of the secondary bridge
change-over.
11. Inverter control card. The card includes the IGBT control circuit. This circuit sets the
IGBT conduction time according to the value chosen by the control potentiometer. The
circuit reduces IGBT conduction time if the output value is too high and increases
conduction time if the output value is too low. There are also circuits to control the weld
current during electrode welding (ARC FORCE).
12. Analogic front controls PCB. This PCB allows you to choose the requested welding
parameters (current process) through the adjustment panel.
13. Current reading shunt. It allows to read the welding current and to adjust it according
to the value set from the operator on the analogic panel.
14.Supply circuit: it gives the necessary continuous supply (24 V) necessary for
supplying the control PCB and the relays for the high frequency and the gas solenoid
valve.
The components listed at points 1, 3, 4, 5, 6, 7, 14, belong to the inverter assembly or
inverter block.
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3) AVAILABLE SPARE PARTS
Position
(see fig. 3.1)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Description
Front panel+wing
Female 50 mm2 quick connector
Current adjust.knob
Front rack sticker
Rack panel + sticker
Handle
Side panel
Rear panel+wings + sticker
Mains supply cable
Cableholder ring PG 13.5
Cableholder PG 13.5
Switch knob 0.5x5
Rear panel sticker
Carrying belt connect.ring
Electric diagram ref.
(fig. 3.6)
(-)
(-)
(-)
(-)
(-)
(-)
(-)
(-)
(-)
(-)
(-)
(-)
(-)
(-)
CODE
352441
403611
438845
467023
439311
438205
352523
352446
235992
430751
427878
438710
467025
365850
Figure 3.1
Position
(see fig. 3.2)
Description
Electric diagram ref.
(fig. 3.6)
CODE
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15
16
17
18
19
20
21
22
23
24
25
26
Shunt 200A
Secondary rectifier heat sink
Secondary heat sinks insulation
Front control PCB
Two pole switch 12 x 16A
Inverter group
Fan motor assembly
Primary IGBT’s heat sink
Rear primary IGBT’s heat sink
Secondary rectifier assembly +
double
Secondary rectifier thermostat
Secondary rectifier
SH
(-)
(-)
SF
IL
IB
MVDC
(-)
(-)
RS +DB
376470
423515
353470
376980
435375
240462
444508
423520
423528
241125
TRS
RS
478786
241116
Figure 3.2
7
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Position
(see fig. 3.3)
Description
27
28
29
30
31
32
33
34
35
36
Primary IGBT’s fixing
Primary IGBT’s (*)
Control PCB
Power and auxiliary wiring
Dinse connection cables
Transformer
Transformer fixing bracket
Primary rectifier heat sink
Set primary rectifier
Plastic base
Electric diagram ref.
(fig. 3.6)
(-)
Q1 Q2 Q3 Q4
IC
(-)
(-)
TP
(-)
(-)
RP
(-)
CODE
427250
286025
376990
413757
413715
481420
463220
423530
455510
352475
(*) Primary IGBT’s are always supplied coupled.
Figure 3.3
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Position
(see fig. 3.4)
37
38
39
40
41
Description
RAINBOW supply circuit
Protection Varistor
Resistance 10 ohm 15 Watt
Relay 48V – 16A
Electrolytic capacitor 470 µF –
400V
Electric diagram ref.
(fig. 3.6)
(-)
(-)
(-)
(-)
(-)
CODE
456950
488296
457095
456764
418778
Figure 3.4
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Position
(see fig. 3.5)
42
Electric diagram ref.
(fig. 3.6)
(-)
Description
IGBT’s driving circuit (**)
CODE
……..
(**)The IGBT driving components are always supplied coupled
DC1
DC2
X8
DC4
DC3
Figure 3.5
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Figure 3.6
4) INSTRUMENTS REQUIRED FOR TESTING AND REPAIRING (AND ELECTRIC
DIAGRAMS)
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The following instruments are needed to check the machine:
A multimeter with following scale:
- Ohm: from 0 to a few Mohm;
- Diode control test (*);
- Continuous voltages (VDC): from mVDC up to 1000 VDC;
- Alternating voltages (VAC): from 10 VAC up to 700 VAC;
(*) References will often be made to diode control in this manual and in this respect you have to remind that:
- Red anode and black cathode (directly polarised connection): the readout varies from multimeter to
multimeter and from diode to diode (0.3-0.6V);
- Black anode and red cathode (inversely polarised connection): the readout varies according to the type
of multimeter and type of diode (2V-5V). In this case it is referred to an open circuit.
NOTE: It is better to use an automatic range instrument because it is not possible to
estimate the extent of electricity to be measured in a damaged machine.
Remember that other settings can be used as well, but with over capacity you lose in
accuracy while, with reduced capacity, measurements have to be taken quickly to prevent
the instrument from overheating.
A hand oscilloscope (model FLUKE 123 or better) with the following characteristics:
- two channels
- at least 20MHz band width
A probe with the following characteristics:
- attenuation 1:1
- insulation voltages to earth of at least 600VRMS .
It is essential to also have the following instruments:
24 VDC test on control PCB (see 5.2, 5.5, 5.6)
A stabilised DC supplier with voltage up to 30 V and current at least at 2 A.
A link wire needed to connect the DC supplier to the control card;
Low voltage test 48 VAC (see 5.5)
An auxiliary transformer at 220V \ 48V 220 VA (cod. 481432);
A 2 A magnetothermic switch;
A 250V 5A minimum mains switch.
To calibrate the current and for working tests (chapter 5.7)
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A current probe model FLUKE I1010 or another one with similar or better features.
To replace components in contact with heat sink (e.g. thermostats) use thermal paste from
RS COMPONENT (Cod. 554-311) or similar with same thermal characteristics.
To replace IGBT:
A solder for electronics fitted with tip with anti-static earthing to weld the IGBT.
Two anti-static wristbands around the wrists are necessary when welding IGBT.
Here below we give you the list of the figures which allow you find out the measurement
points and all the components involved in the testing procedure described in chapter 5:
-
figure 4.1 (a, b, c) inverter PCB;
figure 4.2 (a, b) control PCB;
figure 4.3 doubler PCB;
figure 4.4 front control PCB.
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ELETTROLYTIC
CAPACITOR
ELETTROLYTIC
CHARGE CIRCUIT
PRIMARY
RECTIFIER
EMC
CIRCUIT
SUPPLY
CIRCUIT
Figure 4.1.a
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7 4 14 15
5 3
6
11
12 13 10
9
8
2
1
Figure 4.1.b
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Figure 4.1.c
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G1
E1
G2
E2
Q1
Q2
Q4
Q3
Black
wire
Red
wire
E3
G3
E4
G4
Figure 4.2
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1
2
R5
3
4
5
6
7
8
Figure4.3
1
10
Figure 4.4
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5. TESTING PROCEDURE
Testing is divided into the following steps:
1- a preliminary detailed visual examination to be repeated also after replacing the faulty
parts. Pls follow instructions given at chapter 5.1;
2- inverter and relative control card check using
•
auxiliary power supply (24 VDC) to the control PCB
The purpose of this test is to find out if there is any burnt IGBT (if driving does not check
figures 5.3, 5.4, 5.5) and the relative control circuit (if open circuit driving, i.e. without
IGBT’s does not check figure 5.6) Pls follow instructions given at chapter 5.2 and the block
diagram of figure 5.1:
3- a check the primary bridge and of the electrolytics load resistance using a multimeter.
The correct procedure is described at chapters 5.3 and 5.4
4- Low voltage test using:
•
reduced supply(48 VAC 50-60 Hz) connected to the mains cable;
•
auxiliary power supply (24 VDC) to the control PCB
The purpose of this test is to check all the power parts of the equipment without any risk
for the operator and machine safety. Pls follow instructions given at chapter 5.5 and id
the block diagrams figure 5.7;
5- mains supply and auxiliary supply test as following:
-
Rated mains supply (230V±10% 50-60 Hz) connected to the mains cable;
-
auxiliary power supply (24 VDC) to the control PCB
The purpose of this test is to check the supply circuit of the machine. Pls follow instructions
given at chapter 5.6.
6- mains supply and working test as following:
-
Rated mains supply (230V±10% 50-60 Hz) connected to the mains cable;
The purpose of this test is to check the machine functions such as arc force, lift current,
minimum/maximum current.. Pls follow instructions given at chapter 5.7 and 5.8.
N.B. The machine should not be connected to the mains or any auxiliary supply
when carrying out control tests, unless otherwise specified.
N.B. The cards are painted so be sure that there is a good electrical contact
between measuring instrument and the part being tested during working tests.
N.B. Only use original spare parts supplied by CEA, particularly nylon screws (
where existing) holding the IGBT heat sink as these are live primary conductors.
N.B. After replacing any component begin again the testing procedure from the
beginning.
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N.B. Touching the electronic components with the hands can create irreparable
damages because of electrostatic discharges. Pls be careful above all when
handling IGBT’s. Use in this case anti-static wristbands around your wrists.
N.B. Replace any part which is in contact with the heat sinks only after cleaning
the contact surfaces with alcohol and spread a layer of thermal paste.
N.B. After any replacement, tighten carefully the screws on the power contacts
and all the PCB’s connectors to avoid overheating and false contacts.
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5.1 VISUAL EXAMINATION INSIDE AND OUTSIDE THE MACHINE
a) Disconnect the machine from the mains and disconnect the welding cables.
b) Inspect the outside of the machine and make sure there are no visible damages.
Particularly control mechanical sealing and integrity of the front control panel. This can
also be done by moving the potentiometer and the switch checking if they are
eventually blocked.
c) Open the machine removing the outside screws (see fig. 5.1) following the procedure
given below:
• unscrew the 2 screws holding the handle;
• loosen the 4 screws fixing the rear and front panel and
remove the two metallic side panels;
• disconnect the conductors connected to the side panels and
their fast-on;
Proceed in the reverse order to re-assemble the machine.
Figure 5.1
d) First of all check dust deposits especially the metallic ones. Please remind that even a
thin layer could create contacts (particularly in the electronic part), giving problems not
only to the part involved but also to those connected to it.
e) Cooling air grids are particularly important, so make sure they are not obstructed or
damaged, otherwise the duty cycle of the machine could be reduced.
f) Also check all the internal parts of the machine, paying special attention to burn marks,
deformations, breakage, clearly unforeseen contacts, loose contacts. Replace the
damaged part immediately.
g) In any case clean all the components with dry compressed air to remove any dust
deposit. Repeat the visual inspection after this operation.
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h) Check all the wirings and connectors. Troubles given from not good electrical
connections are more difficult to find, as you always think that they are properly done.
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5.2 TEST WITH 24V DC SUPPLY TO THE CONTROL CARD
N.B The equipment must be disconnected from the mains supply.
In figure 4.2.a you’ll find the control PCB layout showing the components position and the
measurement points.
Initial operations to be done before checking the components:
•
•
•
•
•
disconnect the Y3 connector (see fig. 4.2.a) from the control
PCB;
make sure that the control module is correctly connected to the
below inverter PCB with its connectors X5, X6, X7, X8, X9;
using its proper cable, connect the stabilised DC supplier to
the male Y3 connector you have just removed; pay attention to
the polarity ; the negative pole has a black conductor and the
positive pole has a red one
Adjust the output voltage of the supplier on 24 V ± 1 V and
supply the control pcb;
Go now to block diagram in figure 5.2 and follow the
instructions.
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TEST WITH 24 VDC AUXILIARY POWER
(PAR. 5.2)
NO
NO
DOES PANEL PCB
WORK PROPERTLY?
(5.2.3)
YES
YES
REPLACE CONTROL PCB
(5.2.5) AND SUPPLY AGAIN
THE PCB
REPLACE PANEL PCB
(5.2.4)
NO
YES
RECONNECT PREVIOUS
CONTROL PCB
(5.2.5)
YES
NO
CONTROL WIRINGS AND
CONNECTORS BETWEEN
CONTROL PCB AND PANEL PCB
YES
DOES THERMOSTAT WORK
PROPERTLY?
(5.2.6)
NO
REPLACE DEFECTIVE
THERMOSTAT AND
SUPPLY CONTROL PCB
(5.2.7)
NO
REPLACE CONTROL PCB (5.2.5)
AND SUPPLY AGAIN THE PCB
YES
YES
NO
RECONNECT PREVIOUS
CONTROL PCB
(5.2.5)
T
DRIVERS DC1, DC2, DC3, DC4
CONTROL (5.2.1)
CONTROL WIRINGS
1>
T
NO
YES
NO LOAD DRIVERS
DC1, DC2, DC3, DC4 CONTROL
(5.2.2)
YES
NO
REPLACE CONTROL PCB
OR KIT COMPONENT
DRIVER (5.2.5)
RAPLACE INVERTER PCB
OR IGBT (5.2.8)
RAPLACE INVERTER PCB
OR IGBT (5.2.8)
Figure 5.2
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5.2.1 IGBT DC1, DC2, DC3, DC4 DRIVING CONTROL
Check the driving and write down which ones do not have at least one of the conditions
listed here below at points 1, 2, 3, 4, 5, 6. It is sufficient only one of the below conditions is
missing and you can avoid checking all the others.
Proceed as following:
•
!
!
•
•
set the oscilloscope as follows:
vertical 5 V/division;
horizontal 2µs /division;
Check that the output voltage from the supplier is 24 V ± 1 V;
connect the oscilloscope probe between G1 and E1 (earth) as
shown in fig. 4.2.a (DC1 driving)
NOTE: After checking DC1, repeat the same tests explained at points 1, 2, 3, 4, 5 on
the remaining drivings:
- driving DC2 connect the probe between G2 and E2 (earth);
- driving DC3 connect the probe between G3 and E3 (earth);
- driving DC4 connect the probe between G4 and E4 (earth);
After you have checked ALL the drivings go back to the block diagram.
1. Make sure that the wave form on the oscilloscope is similar to the one in figure 5.3.
N.B. If all the drivings have 0 output voltage, replace the complete control PCB
(chapter 5.2.5) without replacing the IGBT’s, but in any case start again all the controls
from the beginning.
2. Make sure that the oscillation frequency has the following value:
- 100 kHz ÷101.5 kHz .
If the frequency value is not correct (even if point 1 is correct) replace immediately the
control card as explained in 5.2.5 and repeat the test from the beginning.
•
!
!
!
set the oscilloscope as follows:
vertical 5 V/division;
horizontal 500ns/division;
Down edge trigger;
3. Make sure that the wave form on the oscilloscope is similar to the one in figure 5.4.
•
!
!
!
set the oscilloscope as follows:
vertical 5 V/division;
horizontal 500ns/division;
Up edge trigger;
4. Make sure that the wave form on the oscilloscope is similar to the one in figure 5.5.
5. Check the pick value 14.4 V ± 0.4 V;
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T
1>
1) CH1:
5 Volt 2 us
Figure 5.3
T
1>
1) CH1:
5 Volt 500 ns
Figure 5.4
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T
1>
1) CH1:
5 Volt 500 ns
Figure 5.5
•
End up this procedure and go back to the block diagram only
after you have checked all the four drivings.
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5.2.2 NO LOAD TEST ON DC1 DC2 DC3 DC4 DRIVING (WITH CONTROL CARD LIFT
UP FROM THE INVERTER CARD
Check only the driving which in the previous tests didn’t correspond to the requested
Follow these instructions:
• switch off the supplier;
• lift
up the control card so till you can take out completely
the connector from the below PCB. Don’t use any tool which
could damage the PCB tracks. Leave the Y1 connector connected
(see figure 4.2.a);
• be careful that the PCB pins do not touch the parts of the
inverter PCB. You can place a paper sheet between the inverter
card and the control card to insulate one from the other;
• switch on the supplier;
Check that the yellow led on the panel PCB is on, otherwise replace the control PCB (see
5.2.5) and start again the control from point 5.2
•
Set the oscilloscope as follows:
! Vertical 5 V/division
! Horizontal 2 µs/division
•
•
connect the oscilloscope probe (channel 1)
between G1 and E1
(earthed to E1);
switch on supplier and adjust supplier output voltage to 24 V ±
1 V, thus supplying the control PCB;
1. Make sure that the wave form on the oscilloscope is similar to the one shown in figure
5.6.
2. Make sure that the oscillation frequency has the following value:
100 kHz ÷101.5 kHz.
If you don’t find this value replace immediately the control PCB (procedure 5.2.5).
If all the above conditions are OK, you can now control the remaining drivings.
If the noload driving is damaged replace the IGBT (see 5.2.8) and the relative driving
circuit (see 5.2.5). If the driving is correct replace the correspondent IGBT’s (see 5.2.8).
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T
1>
T
1) CH1:
5 Volt 2 us
Figure 5.6
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5.2.3 CHECK OF THE FRONT CONTROL PCB
Figure 4.4 shows the front control PCB layout showing the components position and the
measurement points (pls refer to X1 connector).
Follow these instructions:
• Switch off the auxiliary supplier or any power supply to the
machine;
• Disconnect the front control PCB by removing the Y2 connector
(see fig. 4.2.a);
• Lay down the female connector you have removed before on an
insulated surface with the slits upwards, so that you can
connect the multimeter. Point 1 is the one on the left, i.e.
close to the process selector switch (see fig. 4.4).
Check the following:
1. Check the diode between the clamp 1 (anode) and the clamp 10 (cathode). You should
find about 2V, according to the type of multimeter you are using.
2. Check the diode between the clamp 1 (anode) and the clamp 6 (cathode). You should
find about 2V, according to the type of multimeter you are using.
3. Check between the clamps 10 and 5 and process selector switch set on TIG, if there is
any short circuit. Changing the position of the process selector switch you should find
an open circuit.
4. Check between the clamps 4 and 3 and process selector switch set on TIG, if there is
any short circuit. Changing the position of the process selector switch you should find
an open circuit.
5. Check between the clamps 2 and 3 and process selector switch set on basic electrode
(no Cr Ni, if there is any short circuit. Changing the position of the process selector
switch you should find an open circuit.
6. Check between the clamps 7 and 9 (you can choose any position of the process
selector switch) if you have a resistance value of 1 kΩ.
7. Check between the clamps 9 and 8 (you can choose any position of the process
selector switch):
- With current adjustment potentiometer to the minimum → 1kΩ;
- With current adjustment potentiometer to the minimum → short circuit (0Ω).
If you get a positive result and all the above conditions are OK, it means that the front
control PCB is working correctly.
Go back to the block diagram and follow the instructions.
5.2.4 REPLACEMENT OF THE FRONT CONTROL PCB
To replace the front control PCB follow these instructions:
• Switch off the auxiliary supplier or any power supply to the
machine;
• Unscrew the side screw fixing the potentiometer knob;
• Unscrew the potentiometer fixing nut;
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• Unscrew the process selector switch fixing nut;
• Pull the PCB towards the internal side, in order to remove it
completely from the front cover;
• To fix the new PCB follow the same procedure in reverse order.
Go back to the block diagram and follow the instructions.
5.2.5 DISCONNECTION AND REPLACEMENT OF THE CONTROL
REPLACEMENT OF THE DRIVING CIRCUIT COMPONENTS KIT
PCB
OR
You will find here all the necessary instructions to disconnect the contrl PCB so that you
can:
- Replace the complete control PCB;
- replace the driving circuits if damaged. It’s anyway always better to replace the
complete control card.
Follow these instructions:
• Switch off the auxiliary supplier or any power supply to the
machine;
• Disconnect the Y2 and Y1 connectors from the control PCB (see
fig. 4.2.a);
• lift up the card and remove totally the connectors from the PCB
below. Do not use any tool which could damage the tracks;
If you need to r place the drivings follow these instructions:
- replace the drivers whose test (5.2.1) gave a negative result;
- replace all the components of each driving (see figure 4.2.b) including the ones which
do not seem to be damaged;
- pay attention to the weldings;
- always replace the driver circuits in couple, i.e. DC1 with DC2 and DC3 with DC4;
- If the tracks are particularly damaged and can hardly be repaired, replace the complete
control PCB;
- We remind you that a faulty driving could damage, when supplied, the corresponding
IGBT. Be therefore very careful when making these operations.
If you have replaced the control PCB or after repairing the driver circuits follow these
steps to reinsert correctly the PCB:
•
•
connect the new card and be careful not to bend its pins while
being inserted into the underneath inverter card;
never forget to screw back the metallic screw in the middle of
the control card;
Go back to the block diagram and follow the instructions.
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5.2.6 THERMOSTATIC PROTECTION CONTROL
Check if the thermostats are correctly working, only after that the machine has been
switched for at least 3 minutes in the following way:
• Switch off the auxiliary supplier or any power supply to the
machine;
• Disconnect the thermostat from the doubler PCB by removing the
J2 connector (see fig. 4.3);
• Place the probes on the female connector of the thermostat and
check if there is a short circuit (0Ω). (If not, it means that
the thermostat is damaged).
Go back to the block diagram and follow the instructions.
5.2.7 THERMOSTATS REPLACEMENT
Follow these instructions:
•
•
•
•
Disconnect (if you didn’t it before) the thermostat from the
doubler PCB by removing the J2 connector (see fig. 4.3);
Turn the themostat body,in order to unscrew it from the heat
sink;
Pay attention to the thermic coupling with the heat sink. Clean
carefully the surfaces and spread a layer of thermic paste on
all the surface before fixing the new component;
Reconnect the connector:
Go back to the block diagram and follow the instructions.
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5.2.8 INVERTER PCB ASSEMBLY REPLACEMENT AND IGBT’S REPLACEMENT
INVERTER PCB ASSEMBLY REPLACEMENT
If the IGBT’s are damaged we suggest you to replace the complete inverter power
assembly (and not the IGBT’s only) as following:
•
•
•
•
•
•
•
•
•
•
Remove completely all the screws from the rear panel;
Remove the four conductors from the mains cable;
Remove the mains cable conductors from the inverter PCB;
The rear panel has now been completely removed;
Unscrew the two lower scres on the cooling fan (important);
Unscrew the two upper screws on the cooling fan and disconnect
the X4 connector, then remove the cooling fan;
Unscrew the screw placed near the R14 resistance (see fig.4.1.c)
fixing the inverter PCB to the secondary heat sink;
Lay down the machine on one side;
Remove the two screws fixing the inverter plastic base to its
base;
Disconnect fast-on J3 and J4 (see figure 4.1.c) on the
transformer;
The inverter PCB is now completely disconnected and you can make all the necessary
replacement and measurements operations according to the instructions given in the
chapter you are following in the repairing manual.
•
Connect all the
reverse order.
parts
back
following
the
same
procedure
in
IGBT’S REPLACEMENT
If IGBT’s are damaged and you do not have the proper tooling, we suggest you to replace
the complete inverter power group (and not the single IGBT’s).
For IGBT’s replacement follow the instructions given in the manual. We remind you that
the IGBT’s must always be replaced in couple, regardless to the tests you have made, i.e.
Q1 with Q2 andQ3 with Q4.
•
Connect all the
reverse order.
parts
back
following
the
same
procedure
in
NB repeat the equipment test starting from point 5.2 either if you have replaced the
inverter group or the single IGBT’s.
Go back to the block diagram and follow the instructions.
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5.3 PRIMARY RECTIFIER
Initial operations needed for testing:
• Switch off the auxiliary supplier or any power supply to the
machine;
• Remove the two upper conductors and the two lower conductors
from the mains switch;
• Remove the control PCB as following:
• loosen the metallic screw which you can clearly see in the
middle of the control PCB;
• disconnect the Y2 and X1 connectors (see fig. 4.2.a);
• lift up the card and remove totally the connectors from the PCB
below. Do not use any tool which could damage the tracks;
• once you have made all the above operations, reconnect the
nylon screw.
Figure 4.1.b shows the PCB layout with the position of the primary bridge clamps and the
measurement points.
1.
2.
3.
4.
point 12 anode and point 13 cathode;
point 12 anode and point 10 cathode;
point 11 anode and point 13 cathode;
point 11 anode and point 10 cathode;
If any of the above conditions fail, replaced the bridge as explained at chapter 5.3.1,
otherwise go to point 5.4.
5.3.1 PRIMARY BRIDGE REPLACEMENT
To replace bridge and thermostat follow these instructions:
•
•
•
•
•
•
Remove completely all the screws from the rear panel;
Remove the four conductors from the mains cable;
Remove the mains cable conductors from the inverter PCB;
The rear panel has now been completely removed;
Unscrew the two lower scres on the cooling fan (important);
Unscrew the screw placed near the R14 resistance (see fig.4.1.c)
fixing the inverter PCB to the secondary heat sink;
• Remove the two screws fixing the inverter plastic base to its
base;
• Disconnect fast-on J3 and J4 (see figure 4.1.c) on the
transformer;
• Remove the primary bridges by cutting the 8 pins and unwelding
them one by one, paying attention not to damage the pins on the
inverter PCB;
• Replace the complete primary rectifier with heat sink. Be
careful with the weldings.
• Connect all the parts back following the same procedure in
reverse order.
Go to point 5.4
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5.4 R14 RESISTANCE CONTROL
Initial operations needed for testing:
•
Remove the two upper conductors and the two lower conductors
from the mains switch;
Check the following:
1. Check that between points 5 and 6 in fig. 4.1.b there is a resistance value of about 10
Ω ± 1 Ω.
Should you find a short circuit (0Ω) or an open circuit, replace immediately the relay
8REL1) (sticked contacts) and the R1 resistance. The correct replacement procedure is
explained at chapter 5.5.15. Once you have replaced the component check again this
point.
Be careful not to measure by mistake open circuits, which could be due to a thick
layer of paint on the PCB!
Go to chapter 5.5.
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5.5 LOW VOLTAGE TEST
Before making the low voltage test make sure that all the drivings described at point 5.2
are correct.
Supply the machine by an auxiliary insulation transformer with an output voltage of 48V
AC and a standard 2A magnetothermic switch (see figure 5.7). The control PCB must still
be supplied with the separate 24 V DC.
The logic sequence suggested for this procedure is shown in the block diagram no. 5.8:
INITIAL OPERATIONS
•
•
•
•
•
•
Re-connect anything that has been previously disconnected XY1
connector on the control PCB.
Connect the insulation transformer © and the magnetothermic
switches (B) and (D) according to the electric diagram in fig.
5.8;
Switch the mains switch in position O (OFF);
Set the process selector switch in position Cr Ni;
Supply the machine closing the switches B and D (fig. 5.8);
Supply the control PCB;
If the magnetothermic D is activated within a few seconds check the switch (see chapter
5.5.10) and the EMC filter (see chapter 5.5.12) and replace them if necessary following the
instructions given at chapter 5.5.11 (switch) , 5.513 (EMC filter varistor) and 5.5.3 (for the
remaining components of the EMC filter). If both the components are OK, check if there is
any short circuit on the mains cable, on the wirings or on the tracks.
You can continue only when leaving the mains switch open the thermostat is not activated.
•
Close the mains switch (position I ON);
If the magnetothermic D is activated within a few seconds check the electrolytic capacitors
(chapter 5,.5.16) and replace them if necessary (chapter 5.5.17). Then check if there is
any short circuit on the wirings or on the tracks.
Go to the block diagram in fig. 5.8 and follow the instructions from the point where you can
supply the machine with 48 VAC.
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C
400
A
230 VAC
B
48
230
0
D
48 VAC to the main
l socket
Supply
0
A - Power supply 230 V ac 50 Hz
B - Mains switch 250V - 5 A minimum
C - Insulating transformer cod 481432
D – Magnetothermic load switch 50 V 2A
A–
Figure 5.7
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Figure 5.8
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REPLACE
MAIN SWITCH
(5.5.11)
REPLACE VARISTOR
(5.5.13) OR
INVERTER UNIT
(5.2.8)
NO
REPLACE SUPPLY
CABLE AND CONTROL
WIRINGS
YES
NO
YES
NO
DOES ELECTROLYTIC
CAPACITOR CIRCUIT CHARGE
WORK PROPERTLY?
(5.5.14)
IS MAIN SWITCH
VOLTAGE 48VAC?
(5.5.3)
REPLACE ELECTROLYTIC
CAPACITOR CIRCUIT CHARGE
(5.5.15)
OR INVERTER UNIT (5.2.8)
YES
DOES MAIN SWITCH
WORK PROPERTLY?
(5.5.10)
DOES EMC FILTER
WORK
PROPERTLY?
(5.5.12)
NO
NO
NO
YES
REPLACE
ELECTROLYTIC
CAPACITOR (5.5.17)
NO
DOES ELECTROLYTIC
CAPACITOR WORK
PROPERTLY?
(5.5.16)
IS ELECTROLITIC
CAPACITOR VOLTAGE
60V ± 5V? (5.5.4)
YES
YES
WIRING,TRACK
AND CONNECTOR
CONTROL
YES
REPLACE
SECONDARY
RECTIFIER (5.5.6)
NO
DOES SECONDARY
RECTIFIER WORK
PROPERTLY?
(5.5.5)
RAPLACE
DOUBLER
(5.5.8)
NO
DOES DOUBLER
WORK PROPERTLY?
(5.5.7)
YES
REPLACE
TRANSFORMER
(5.5.9)
YES
REPLACE
FEED CIRCUIT
(5.5.18)
NO
RETURN TO
PARAGRAPH 5.6
YES
5.5.1 OUTPUT VOLTAGE CONTROL
Measure the following:
•
measure the voltage on the machine clamps (dinse) using
multimeter and paying attention to the correct polarity;
a
The correct value is 17V ± 2V.
Go back to the block diagram and follow the instructions.
5.5.2 VOLTAGE CHECK ON THE SUPPLY CIRCUIT
Measure the following:
1. place the red probe of your tester (see fig. 4.1.b) on point 9 (integrated IC1 case) and
the black probe on point 8 ( DZ6 anode).
The correct value is 60 V ± 5 V.
Go back to the block diagram and follow the instructions.
5.5.3 MAINS SWITCH VOLTAGE MEASUREMENT
Follow these instructions:
•
Disconnect the
two main transformer fast-on from clamps
and J4 (see figure 4.1.c);
• Disconnect the two upper conductors from the mains switch.
J3
Measure the voltage on the mains switch output conductors (connected to clamps J1 and
J2 in fig. 4.1.c).
The correct value corresponds to the supply voltage, i.e. 48 VAC.
•
Reconnect the
two main transformer fast-on from clamps
and J4 (see figure 4.2.c);
• Reconnect the two upper conductors from the mains switch.
J3
Go back to the block diagram and follow the instructions.
5.5.4 ELECTROLYTIC CAPACITORS VOLTAGE MEASUREMENT
Follow these instructions:
• Switch off the machine;
•
Disconnect the
two main transformer fast-on from clamps
and J4 (see figure 4.1.c);
• Reconnect the machine to the supply.
J3
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Make the following test (the correct measurement is done with the probes placed near the
R15 resistance body and not on the printed circuit) placing the red probe of your tester
(see fig. 4.1.b) on point 14 and the black probe on point 15.
The correct value is 60 V ± 5 V.
• Reconnect the
two
disconnected before.
main
transformer
fast-on
which
you
have
Go back to the block diagram and follow the instructions.
5.5.5 SECONDARY RECTIFIER CONTROL
Initial operations needed for testing:
•
switch off the supply from the machine
Check the following:
1. Using a multimeter check the diode between one clamp of the rectifier (anode) and the
secondary heat sink (cathode) → 0.1-0.3 V (with direct polarity)
2. Using a multimeter check the diode between the remaining clamp of the rectifier
(anode) and the secondary heat sink (cathode) → 0.1-0.3 V (with direct polarity)
If any of the two above conditions fail, the secondary rectifier is correctly working.
Go back to the block diagram and follow the instructions.
5.5.6 SECONDARY RECTIFIER REPLACEMENT
To replace this part you have to loosen the two screws fixing it to the heat sink and to the
conductors.
When fixing the new rectifier pay attention to the thermic coupling with the heat sink. Clean
carefully the surfaces and spread a layer of thermic paste on all the surface before fixing
the rectifier to the heat sink.
Go back to the block diagram and follow the instructions.
5.5.7 DOUBLER CONTROL
Follow these instructions:
• Switch off any power supply to the machine;
Figure 4.3 shows the doubler PCB layout with the components position and the
measurement points. Check the following:
1.
2.
3.
4.
Check the diode between point 1 anode and point 2 cathode;
Check the diode between point 3 anode and point 4 cathode;
Check the diode between point 5 anode and point 6 cathode;
Check the diode between point 7 anode and point 8 cathode;
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If any of the above conditions fail, you have to replace the doubler.
The remaining troubles on the doubler components are not easy to find out, but luckily
they are seldom. The components function is necessary for a good welding quality and
particularly for the electric arc l length. We therefore suggest you to replace them if the
electric arc is very short.
Return to the block diagram and follow the instructions.
5.5.8 DOUBLER ASSEMBLY REPLACEMENT
In the spare parts list the doubler is supplied complete with heat sink and secondary
rectifier.
Follow these instructions:
•
•
•
•
•
•
Switch off the auxiliary supplier or any power supply to the
machine;
Loosen the metallic screw placed near the R14 resistance
(see fig. 4.1.c) fixing the inverter PCB to the secondary
heat sink;
disconnect Y1 connector from the control pcb (see 4.3.a);
loosen the two screws fixing the heat sink to the base;
loosen completely the two front panel screws;
disconnect the power conductors from the secondary rectifier.
Now the secondary rectifier assembly and doubler is completely disconnected and it can
be removed.
• Connect all the parts back following the same procedure in
reverse order.
Return to the block diagram and follow the instructions.
5.5.9 TRANSFORMER REPLACEMENT
To replace the transformer follow these instructions:
• Switch off any voltage from the machine;
•
•
•
•
•
•
Disconnect the fast-on J3 and J4 from the primary winding on
the transformer;
Lay down the machine on its right side;
Disconnect the power cables from the secondary winding of the
transformer;
Loosen the screws holding the fixing bracket of the main
transformer;
Remove the transformer from its seat;
Connect the
new transformer following the same procedure in
reverse order.
Return to the block diagram and follow the instructions.
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5.5.10 MAINS SWITCH CONTROL
Initial operations needed for testing:
• Switch off any voltage from the machine;
•
Disconnect the upper conductors and the two lower conductors
from the mains switch;
Check the following:
1. Check the electrical working placing the two probes of your multimeter on the two side
clamps. Setting the switch in position O (open) and then in position I (closed) you
should find respectively a value showing an open circuit and a short circuit (0Ω).
2. Repeat the same operation on the remaining side clamps.
3. Set the mains switch in position 1 and check if you have an open circuit between the
two upper terminals.
If any of the above conditions fail, replace the component (chapter 5.5.11).
Return to the block diagram and follow the instructions or go back to the point of the
manual where you come from.
5.5.11 MAINS SWITCH REPLACEMENT
To replace the mains switch follow these instructions:
• Loosen the screw fixing the knob and then the internal screws
fixing the switch to the front panel; push the switch from the
opposite side;
• disconnect the conductors unscrewing their fixing screws;
• Connect the
new component following the same procedure in
reverse order.
Return to the block diagram and follow the instructions or go back to the point of the
manual where you come from.
5.5.12 MAINS RADIODISTURBANCE FILTER CONTROL
Figure 4.1.a shows the position of mains radiodisturbance filter. Initial operations needed
for testing:
• Switch off the supply from the machine and disconnect the
•
•
transformer supply cable;
Set the mains switch in position 0 (OFF);
Disconnect the upper conductors and the two lower conductors
from the mains switch;
Figure 4.1.b shows the PCB layout with the filter components position and the
measurement points. Check the following:
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1. Make sure there is an ohmic resistance between the input terminals (points 1 and 2) of
about 330 Kohm.
2. Check the electrical continuity (0 Ohm) of the filter pointing the multimeter probes
between the inputs (points 1 and 2) and corresponding outputs (lower clamps on the
mains switch).
3. Check the phases insulation versus earth using a multimeter (point 1 with earth clamp
on a zinc coated plate and then point 2 with the same clamp. There should be a
capacity value of 5.0 nF ± 1 nF.
4. Repeat a careful visual inspection of the filter parts especially the RV1 varistor. In case
of visible burning or explosion, replace the part immediately.
If any of the 1,2,3 conditions has failed replace the inverter PCB (see 5.2.8). If the varistor
is damaged replace it as explained at 5.3.13.
Return to the block diagram and follow the instructions or go back to the instruction book
to the point you were before.
5.5.13 VARISTOR REPLACEMENT (MAINS RADIODISTURBANCE FILTER)
To replace RV1 varistor proceed as follows :
•
•
•
•
•
•
completely remove the rear panel screws
disconnect mains cable from inverter card;
disconnect the X4 connector from the cooling fan;
unscrew the four fixing screws to remove the fan from the
plastic base;
You can now reach the filter components pins and you can easily
replace the varistor;
Once you have replaced the component follow the same procedure
in reverse order for reassembling the equipment.
Return to the block diagram and follow the instructions or go back to the instruction book
to the point you were before.
5.5.14 ELECTROLYTIC CAPACITORS CHARGE CIRCUIT CONTROL
Figure 4.1.a shows the components
Initial operations needed for testing:
position of electrolytic capacitors charge circuit.
• Switch off any voltage from the machine;
Figure 4.1.b shows the PCB layout with the charge circuit components position and the
measurement points. Check the following:
1. Repeat a careful visual inspection of the circuit components. Immediately replace any
components with traces of burning, especially on the relay (REL 1 and REL2) (see point
5.5.15);
2. Check for a resistance value of about 6.8 Kohm (R17) between points 3 and 4.
3. Check the diode D11 with the measurement points 7 anode and 4 cathode.
4. Check for a resistance value of about 10 ohm ± 0.5 ohm between points 5 and 6.
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5. Check the relay coil measuring the resistance value between point 3 and one phase of
the mains switch.
If any of above conditions has failed replace the components as explained at 5.5.15.
Be careful not to detect an open circuit due to a thick layer of paint on the card!
Return to the block diagram and follow the instructions
5.5.15CHARGE CIRCUIT PARTS REPLACEMENT
To replace charge circuit components, proceed as follows
• Follow
the instructions given at chapter 5.2.8 if not already
done until when disconnecting completely the inverter block you
can easily reach all the charge circuit components.
N.B. if parts R17, D11, C17, C3 are faulty replace the complete inverter PCB as
explained at chapter 5.2.8.
The remaining parts (R14, REL 1 and REL2 can be replaced).
•
Connect all the
reverse order.
parts
back
following
the
same
procedure
in
Return to the block diagram and follow the instructions.
5.5.16ELECTROLYTIC CAPACITORS CONTROL
Figure 4.1.a shows the inverter pcb layout with the position of the electrolytic capacitors.
N.B. Electrolytic capacitors are generally deformed when faulty, so it is easy to detect their
damage. Visual inspection is fundamental in this case. If the block diagrams leads you to
an electrolytics control you have to make this test.
Initial operations needed for testing:
•
•
•
cut off any voltage from the machine;
connect the supplier to the R15 resistance (4.1.c). Polarity is
important, i.e. positive pole is no. 14 and negative pole is no.
15;(4.1.b)
switch on the supplier and supply 30 V DC;
Check the following:
1.The supplier voltage must remain on 30 V.
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If the above conditions fail, replace the four electrolytic capacitors as explained at point
5.5.17.
•
Repeat the same procedure connecting the components
order.
Return to the block diagram and follow the instructions.
in reverse
5.5.17ELECTROLYTIC CAPACITORS REPLACEMENT
Proceed as explained at 5.2.8 for replacing the complete inverter assembly, so that you
can reach the components and then replace them as following:
Completely replace the four capacitors at the same time.
N.B! Insert the electrolytic capacitor with correct polarity comparing the instructions
written outside each component with the card assembly layout.
•
Repeat the same procedure connecting the components
order.
in reverse
Return to the block diagram and follow the instructions.
5.5.18MAINS SUPPLY CIRCUIT CONTROL REPLACEMENT
Figure 4.1.A shows the inverter pcb layout with the position of the supply circuit
components.
Proceed as explained at 5.2.8 for replacing the complete inverter assembly. Also remove
the control card as following:
•
•
loosen the metallic screw which you can clearly see in the
middle of the control PCB;
lift up the PCB without using any tool which could damage the
tracks and check the drivers writing down the ones where at
least one of the above conditions fails;
The supply circuit is completely accessible and can be replaced. Replace all the circuit
components. After removing the components, check the tracks conditions leading the
supply at the two points 8 and 9 in figure 4.1.b. If they are broken repair them or replace
the complete inverter card if repairing is too difficult.
We remind you that the two tracks have 325 V, therefore pay attention to their insulation.
•
Repeat the same procedure connecting the components
order.
in reverse
Return to the block diagram and follow the instructions or go back to the instructions book
to the page you were before.
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5.6 AUXILIARY SUPPLY TEST
Initial operations needed for testing:
•
•
•
•
•
•
reconnect all the components which had been disconnected before
to the machine, leaving the auxiliary supply connected to the
control PCB;
Switch off the mains switch (pos.0)
Set the process selector on the auxiliary PCB in electrode
position;
Turn the current adjustment potentiometer to mid scale;
Supply the machine correctly (230V 50/60 Hz).
Switch on the mains switch (pos.1);
1. Check the closing of both electrolytic capacitors charge relays (REL1 and REL2 figure
4.1.c) immediately after switching on the machine. If this condition fail, check the
electrolytic capacitors charge circuit (5.5.14) and if necessary replace the damaged
components(5.5.15).
2. Measure the output voltage. The value should be about 90 V ± 5 V. If not check wiring
cables, tracks and connectors on the machine and if necessary check again all the
components.
3. Check that the cooling fan is turning. If not remove its connector from the inverter PCB
(X4 figure 4.1.c). Measure the voltage on X4. If the value is 29V ± 2V replace the
cooling fan as explained at chapter 5.6.1, otherwise replace the supply circuit as
explained at 5.5.18. After replacing the fan check again if it’s working.
5.6.1 COOLING FAN REPLACEMENT
To replace the fan follow these instructions:
•
•
•
•
•
cut off any voltage from the machine;
Completely remove the screws from the rear panel;
Loosen the fan screws;
Remove the cooling fan and replace it;
Repeat the same procedure connecting the components
order.
in reverse
Start again the components control from chapter 5.6.
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5.7 MAINS SUPPLY TEST
Initial operations needed for testing:
•
•
•
•
•
reconnect all the components which had been disconnected before,
so that the machine is ready for working;
Set the process selector switch in electrode Cr Ni position;
Switch off the mains switch (pos.0);
Make a short circuit between the two dinse with a cable of at
least 25 mm2 section and insert the current pincer;
Supply the machine correctly (230V 50/60 Hz).
NOTE: Before making any short circuit check that the machine is off.
Minimum current check
•
Set the front control card
potentiometer to the minimum value;
1. If the measured value is different from 5A ± 1A 25A ± 1A, adjust the current acting on
the RT4 (should be RT6) trimmer on the control PCB (figure 4.2.a).
If the current goes to the maximum value and you cannot adjust it, check the wiring
cable between the Y1 connector on the control PCB (fig. 4.2.a) and the shunt. If the
connection are good replace the control PCB (procedure 5.2.5) and start again the
mains supply control from the beginning.
Maximum current check
Follow these instructions:
•
Go up slowly with the potentiometer to the maximum value.
2. Measure the current value supplied from the machine. The correct value is 180A ± 5A. If
you don’t have this value adjust the current acting on the RT2 trimmer on the control PCB
(fig. 4.2.a)
Arc force control.
•
•
Turn the welding current adjustment potentiometer in order to
have 100 A;
Set the process selector switch in position electrode;
Check that the current goes to 165A ± 5A. If not, switch off supply from the machine and
check the R5 resistance on the doubler PCB (fig. 4.2). The correct value is 220 Ω ± 20. Ω
If you don’t have this value replace the secondary rectifier assembly. If the value is correct
replace the control PCB and start again the control from the beginning.
Lift current control
•
Set the process selector switch
in position TIG;
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Check that the current goes to 50A ± 5A. If not, replace the control PCB and start again
the control from the beginning.
Thermostats intervention
Follow these instructions:
• Switch off any supply from the machine
• Connect the side panels connectors to their fast-on on the
inverter PCB;
• Tighten the four screws fixing the rear and front panel, thus
fixing the two side metallic panels;
• Tighten the two screws fixing the handle;
• Set the process selector switch in position ELECTRODE Cr Ni;
• Adjust the front panel potentiometer to the maximum value (150
A);
• Make a shortcircuit between the two dinse with the machine off;
• Switch on and supply the machine.
Wait for the thermostat intervention, which must be activated within 10 minutes maximum.
If not, switch off the machine immediately and replace the thermostat.
After the thermostat has been activated, the machine must stay off for at least 5 minutes,
otherwise replace the thermostat and repeat the test.
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5.8 WORKING TESTS
Follow these instructions:
• Remove the shortcircuit from the output clamps of the machine;
• Connect a ground cable to the negative dinse and to the
workpiece;
• Connect an electrodeholder pincer to the positive dinse;
Now weld using different types of electrode and different current adjustments. Any welding
quality problem can be caused from the control PCB. We remind you that if you replace
the PCB, you have to repeat all the controls from the beginning.
• Connect
a ground cable to the positive dinse and to the
workpiece;
• Connect the TIG torch to the negative pole. Don’t forget to
connect the gas.
Now weld using different current adjustments. Any welding quality problem can be caused
from the control PCB. We remind you that if you replace the PCB, you have to repeat all
the controls from the beginning.
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7) WARRANTY CONDITIONS
We remind you that CEA Spa does not repair under warranty damages:
• caused by repairing attempts carried out by personnel not authorised by CEA to repair
and service its products;
• caused by improper use;
• caused by connection to incompatible devices;
• caused by additional modifications to the machine itself;
• caused by instruments used for repairs non-conforming to those indicated in chapter 4;
• caused by repair procedures differing from the ones given in the manual.
8) TECHNICAL DATA
Input voltage 1ph
Installed power
Max. input current
Absorbed
input
current
(X=100%)
Power factor
Efficiency (X=100%)
Cosϕ
Cosϕ
Adjustment range
Welding current
Welding current X=60%
Welding current X=100%
Open circuit voltage
Protection
Protection class
Standard
Dimensions (lxpxh)
Weight
TIG
MMA
230 V single phase ± 15%
3.1 kVA
4.6 kVA
26 A rms
36 A rms
at
14.0
14.0 A rms
19.0 A rms
0.65
0.8
0.99
0-180A
0-180A
180 A X=20%
180 A X=20%
130 A
130 A
110 A
110 A
88 V
IP 23
EN60974 EN50199
390 * 300 * 135 (mm)
6 kg
9) REQUEST FOR TECHNICAL ASSISTANCE PROCEDURE
Operators with difficulties in identifying faulty parts to be replaced should contact CEA
Technical Assistance Service.
Information may be given by telephone or fax at the following numbers:
Tel. : +39(0)34122322
Fax : +39(0)341422646
Or else by e-mail:
E_Mail cea@ceaweld.com –web www.ceaweld.com
Fax : +39(0)341422646
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REMARKS
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REMARKS
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