Cebora SOUND MIG 3840/T Pulse Service Manual

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CEBORA S.p.A. 1

SOUND MIG 3840/T Pulse

POWER SOURCE +

COOLING UNIT +

WIRE FEEDER

art. 287

SERVICE MANUAL

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CEBORA S.p.A. 2

CONTENTS

1 - GENERAL INFORMATION..........................................................................................................................4

1.1 - Introduction. ................................................................................................................................................. 4

1.2 - General service policy. .................................................................................................................................4

1.3 - Safety information........................................................................................................................................4

1.4 - Electromagnetic compatibility......................................................................................................................4

2 - SYSTEM DESCRIPTION..............................................................................................................................5

2.1 - Introduction. ................................................................................................................................................. 5

2.2 - Technical specifications................................................................................................................................5

2.3 - Description of SOUND MIG 3840/T Pulse system (art. 287)......................................................................5

2.4 - Description of MIG3840/T Pulse power source. ..........................................................................................6

2.5 - Description of WF4-P Wire Feeder..............................................................................................................8

2.5.1 - Accessories table........................................................................................................................................9

2.6 - Description of GR54 Cooling Unit...............................................................................................................9

3 - MAINTENANCE..........................................................................................................................................10

3.1 - Periodic inspection, cleaning...................................................................................................................... 10

3.2 - Welding system fittings and connectors.....................................................................................................10

3.3 - Control panel commands and signals. ........................................................................................................11

3.4 - Operating sequences...................................................................................................................................12

3.4.1 - Welding system operation........................................................................................................................12

3.4.2 - MIG mode................................................................................................................................................13

3.4.3 - TIG operation...........................................................................................................................................14

3.4.4 - MMA mode. ............................................................................................................................................ 15

3.5 - Troubleshooting..........................................................................................................................................16

3.5.1 - The power source does not start, control panel off..................................................................................16

3.5.2 - Power source powered, control panel on, fan (512) stopped...................................................................19

3.5.3 - System powered, display and signals do not show the correct values..................................................... 20

3.5.4 - The start button produces no effect.......................................................................................................... 21

3.5.5 - Some signals from connector for accessories (BB) do not work............................................................. 23

3.5.6 - System powered, no gas flows from the torch.........................................................................................24

3.5.7 - System powered, the wire feeder motor does not work........................................................................... 25

3.5.8 - In open circuit operation, the output voltage is not regular. ....................................................................26

3.5.9 - In resistive load operation, the output voltage is n ot regul ar...................................................................29

3.5.10 - In MIG or TIG mode, arc difficult to strike, the arc shuts off immediately after stri king (stuttering start-

up).

..........................................................................................................................................................31

3.5.11 - In synergic mode, the welding quality is not satisfactory, the wire speed is not suited to the output

current.

....................................................................................................................................................31

3.5.12 - In MMA, arc difficult to strike and/or unsatisfactory welding quality. ...................................................31

3.5.13 - In MIG mode, when the start button is released, the wire sticks to the workpiece (ineffective motor

braking).

..................................................................................................................................................32

3.5.14 - Cooling unit GR54 does not work correctly............................................................................................33

3.6 - Kit Driver + igbt, code 5.710.511 replace instructions............................................................................... 35

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3.7

- Error codes and alarm signals..................................................................................................................... 36

3.7.1 - 2 - EEPROM error...................................................................................................................................36

3.7.2 - 6 - Communication error on CAN-BUS, detected by control board (543).............................................. 36

3.7.3 - 9 - Communication error on the CAN-BUS between control panel (324) and control board (543)........36

3.7.4 - 10 - Missing voltage and current at the power source output. .................................................................36

3.7.5 - 13 - Missing communication between control board (543) and pre-charge board (562).........................36

3.7.6 - 14 - Microprocessor supply voltage error on control board (543)...........................................................37

3.7.7 - 16 - Direct current voltage at pre-charge board (562) output below minimum permitted value..............37

3.7.8 - 20 - Absence of interlock signal on TA board (558)................................................................................37

3.7.9 - 25 - Error on the EPLD bus in the control board (543)............................................................................37

3.7.10 - 30 - Incorrect setting of the minimum current threshold on control board (543).....................................37

3.7.11 - 41 - Connector board (225) missing or disconnected..............................................................................38

3.7.12 - 42 - Error in the signal of the motor (404) encoder................................................................................. 38

3.7.13 - 43 - Communication error with connector boar d (225) ...........................................................................38

3.7.14 - 52 - “trG” on display (O). In MIG and TIG mode, start button pressed upon start-up............................39

3.7.15 - 53 - “trG” on display (O). Start button pressed while resetti ng from stop due to temperature outside

limits........................................................................................................................................................39

3.7.16 - 54 - Short-circuit between torch and workpiece upon start-up................................................................ 39

3.7.17 - 56 - Short-circuit at the output lasts too long........................................................................................... 39

3.7.18 - 57 - “Mot” on display (O). Excessive wire feeder motor (404) current...................................................40

3.7.19 - 61 - Mains voltage below minimum permitted........................................................................................40

3.7.20 - 73 - “TH0” on display (O). Led (G) lit. Diode group (567) high temperature......................................... 40

3.7.21 - 74 - “TH1” on display (O). Led (G) lit. Igbt group (548) high temperature............................................ 40

3.7.22 - 75 - “H2O” on display (O). Low pressure in the cooling circuit. ............................................................41

3.7.23 - 80 - “OPn” on display (O). Wire feed unit guard open............................................................................ 41

3.7.24 - 99 - “OFF” on display (O). Incorrect mains voltage (machine shutdown).............................................. 41

4 - COMPONENTS LIST...................................................................................................................................42

4.1 - Power source art. 287 : see file ESP287.pdf enclosed at the end of the manual......................................... 42

4.2 - Table of components: see file ESP287.pdf enclosed at the end of the manual........................................... 42

4.3 - List of spare parts. ...................................................................................................................................... 42

5 - ELECTRICAL DIAGRAMS ........................................................................................................................43

5.1 - Power source art. 287 : see file SCHE287.pdf enclosed at the end of the manual......................................43

5.2 - Waveforms. ................................................................................................................................................ 43

5.2.1 - Speed feedback signal from the wire feeder motor encoder (404)(par. 3.5.7).........................................43

5.2.2 - Open-circuit voltage on the transformer (531) secondary circuit (par. 3.5.8)..........................................43

5.2.3 - Command signal for driver boards (548) (par. 3.5.8).............................................................................. 43

5.2.4 - Output current feedback signal on resistive load (par. 3.5.9)...................................................................44

5.2.5 - Wire feeder motor (404) voltage during correct braking (par. 3.5.13).....................................................44

5.2.6 - Wire feeder motor (404) voltage during incorrect braking (par. 3.5.13). ................................................44

5.2.7 - “PRECHARGE” signal (par. 3.7.5)......................................................................................................... 44

5.3 - Filter board (542) code 5.602.196/B...........................................................................................................45

5.4 - Pre-charge board (562) code 5.602.187/A..................................................................................................46

5.5 - Flyback board (539) code 5.602.184/E.......................................................................................................47

5.6 - Interface board (543) code 5.602.186.........................................................................................................48

5.7 - Micro board (543) code 5.602.185/C..........................................................................................................49

5.8 - Igbt-driver board (548) code 5.602.188...................................................................................................... 50

5.9 - TA board (558) code 5.602.123..................................................................................................................50

5.10 - Thermostat board (551) code 5.602.137..................................................................................................... 50

5.11 - Motor control board (232) code 5.602.103/B............................................................................................. 51

5.12 - Connector board (225) code 5.602.104/B...................................................................................................53

5.13 - Control panel (324) cod. 5.602.110/C. .......................................................................................................54

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1 - GENERAL INFORMATION

1.1 - Introduction.

The purpose of this manual is to train personnel assigned to carry out maintenance on the

SOUND MIG 3840/T Pulse multi-process welding system, art. 287.

1.2 - General service policy.

It is the responsibility of the customer and/or operator to use the equipment appropriately, in accordance with the instructions in the Instructions Manual, as well as to maintain the equipment and related accessories in good working condition, in compliance with the instructions provided in the Service Manual.

Any internal inspection or repairs must be carried out by qualified personnel who are responsible for any intervention on the equipment.

It is forbidden to attempt to repair damaged electronic boards or modules; replace them with original Cebora spare parts.

1.3 - Safety information.

The safety notes provided in this manual are an integral part of those given in the Instruction Manual. Therefore, before working on the machine, please read the paragraph on safety instructions in the aforementioned manual.

Always disconnect the power cord from the mains, and wait for the internal capacitors to discharge before accessing the interior of the equipment.

THE DISCHARGE TIME FOR THE DC-CAPACITORS (561) IS HEAVILY AFFECTED BY

THE OPERATING MODE OF THE FLYBACK BOARD (539). UNDER NORMAL

CONDITIONS THE TIME IS APPROXIMATELY 3 MINUTES, WITH THE FLYBACK

BOARD (539) BROKEN OR DISCONNECTED IT MAY BECOME 6 MINUTES.

Some internal parts, such as terminals and dissipaters, may be connected to mains or otherwise hazardous potentials. It is therefore forbidden to work with the safety guards removed from the machine unless strictly necessary. In this case, take special precautions such as wearing insulating gloves and footwear, and working in a perfectly dry environment with dry clothing.

1.4 - Electromagnetic compatibility.

Please read and observe the instructions provided in the paragraph “Electromagnetic compatibility” of the Instruction Manual.

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2 - SYSTEM DESCRIPTION

2.1 - Introduction.

The SOUND MIG 3840/T Pulse is a multi-process system suitable for welding different types of iron, steel and aluminum, with the Pulsed Synergic MIG/MAG, non

Pulsed Synergic MIG/MAG, Conventional MIG/MAG, TIG (DC) with strike starting of the arc, and MMA processes. It is made up of the MIG3840/T Pulse electronic power source, the WF4-P Wire feeder, GR54 Cooling Unit, and a series of accessories to adapt to various types of use (see list in the Sales Catalogue).

The operator interface consists of Sound DIGIBOX MIG P1 Control Panel (art. 223),

included in the welding system.

2.2 - Technical specifications.

To check the technical specifications, see the plates affixed to the equipment, the Instruction

Manual, and the Sales Catalogue.

2.3 - Description of SOUND MIG 3840/T Pulse system (art. 287).

The welding system is controlled by microprocessor-based circuits, which manage the

operative functions of the welding system and the operator interface.

Referring to the electrical diagrams in par. 5.1, drawing 4.1, and table 4.2, you may identify

the main blocks that make up the system.

Each system component, power source, wire feeder and control panel (not including the cooling unit) contains a microprocessor circuit, which not only manages the functions of the unit to which it belongs, but also communicates with the other microprocessors via CAN-BUS serial line, to actively and continuously assist system operation.

Based on this architecture, the following units may be identified:

− MASTER microprocessor, in the micro board (543) of the power source;

− MOTOR microprocessor, in the motor control board (232) of the wire feeder;

− PANEL microprocessor, in the micro board (324) of the control panel.

Each microprocessor is programmed with a different program, which must obviously be compatible with those of the other microprocessors. To make it easier to enter and upgrade these programs, a single-access system is provided (the connector (534) for RS232 serial communication, (BP) on the front panel of the power source), which allows the three microprocessors to be programmed in a single programming session. With this step the three programs are simultaneously entered into the three microprocessors, each automatically in its place.

The upgraded PANEL, MASTER and MOTOR programs are grouped together in a single programming file, recognizable from the extension “.ceb”, available from the Cebora Web site

www.cebora.it.

For theirs use is necessary to download and to install in the computer the “Cebora Device Manager” program, available in Cebora Web site

www.cebora,it. With such program it is

possible to record in the computer the files relative to “firmware Cebora” (programs releasable from the Cebora site) and to insert them in the machines that have to be programmed or updated.

The version of the inserted programs, is visible during start-up in the control panel, in the

following form (see fig. 3.3):

− display AN1 =“04.04.04”= version 04 of MASTER, PANEL and MOTOR programs.

Working programs related to the synergic curves programmed by Cebora are integrated in the Master program and their version is visible during start-up in the control panel, in the following form (see fig. 3.3):

− display AN2 = “SYn 1.0.0” = version 1.0.0 of synergic curves programs created by Cebora.

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Customizations of the welding system modes (parameter set-up) and the welding programs created by the operator are saved in the EEprom in the micro board (543).

In order to concur the substitution of micro board (543) without to lose these data, the EEprom is mounted on socket so as to be able to be removed from the board and being inserted in one new board. In the same way it is also possible to transfer the customizations and the customer programs from a generator to the other, so that this last one is found to operate with the same identical parameters of the first generator.

With the Factory set-up function it is possible to cancel EEprom memory and to reshape it as it was to exited new machine from factory. In order to select the Factory function:

− press push-button (AO) and maintaining pressed it press the push-button (E);

− select with grip knob (N), “FAC” function on display (O);

− select with grip knob (Q) one of the functions that appear on display (P), considering how

much it follows:

noP it means that it comes brought back to the factory set-up the operating parameters set-up

(the operating parameters set-up carried out from the customer comes cancelled) and remain instead stored customized programs realized from the customer.

ALL it means that the control will come brought back to the factory set-up with cancellation

of all operating parameters set-ups and customer programs realized from the customer.

PrG it means that they come brought back to the factory set-up the job programs

(customized programs realized from the customer will be cancelled) and remain instead stored the operating parameters set-up.

− in order to activate function to press push-button (AP).

2.4 - Description of MIG3840/T Pulse power source.

The MIG3840/T Pulse is a direct current power source with controlled current, consisting of a three-phase rectifier bridge, a DC/AC converter (inverter), and an additional rectifier bridge.

The main switch (504) powers the filter board (542), which contains the filter to reduce conducted interference reflected in the mains, and the chokes (516+522) to level the current absorbed by the mains.

The pre-charge board (562), inserted downstream from the chokes (516+522), contains the power rectifier bridge, the DC-capacitor (561) pre-charge circuit of the inverter, and the circuits to analyze the mains voltage. It communicates with the control board (543) through an optically isolated signals.

NOTE

The control board (543) is composed from two boards (interface and micro) mounted one on the

other. For greater clarity in the identification of the connectors, in the present manual the two

boards are indicated singularly, and with the same identification number of control board (es.:

control board (543); interface board (543); micro board (543)).

The rectifier bridge converts the alternating mains voltage (400 Vac) to direct current (540 Vdc) suitable for powering the inverter, the DC-capacitors (561) to level this direct current and the flyback board (539).

The pre-charge circuit of the DC-capacitors (561) is made up of the PTC (PTC1 - PTC8) and relay RL1 on the pre-charge board (562). The latter is controlled by the micro board (543), which analyzes the “mains voltage presence” and “DC-capacitors (561) direct current voltage” signals coming from pre-charge board (562), through interface board (543).

More specifically, check the presence of each phase of the mains voltage and the level of the direct current voltage at the rectifier bridge output, thus on the DC-capacitors (561).

If the test result is positive, the pre-charge relay RL1 is closed and the power source is operated; otherwise RL1 remains open and the power source is blocked, while the control panel (324) displays the cause of the block.

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The 540 Vdc voltage present at the output of the rectifier bridge is applied to the flyback board (539), which acts as a main power source and generates the service voltages for the various system circuits (power source, wire feeder, control panel).

The inverter is made up of four igbt (2 for each igbt module (548)) connected in an “Hbridge” configuration, driven by the driver-igbt boards (548) mounted directly on the terminals of the igbt modules (548), in turn controlled by the interface board (543).

Mounted on the power terminals of the igbt modules (548) are two “snubber” capacitors, electrically connected in parallel to the DC-capacitors (561), whose task is to reduce the overvoltages that develop on the igbt during operation. Their integrity and connection (which must be as short as possible on the igbt terminals) is essential for the inverter to operate; tampering with them may seriously damage the igbt (548).

The task of the igbt inverter is to generate the square-wave alternating voltage for the power transformer (531). The welding current is adjusted by modulating this voltage appropriately.

The TA (558) inserted in the circuit between an igbt module (548) and the transformer (531) provides the micro board (543) with the feed-back signal of the current at the primary circuit of the transformer (531), to verify that the inverter is working properly; this signal does not normally affect the welding current adjustment.

The transformer (531) provides the secondary circuit with voltage and current values suitable for welding. Its secondary circuit is made up of 4 windings connected to a shared point on the central socket, to which the choke (530) is connected to level the welding current.

The other ends of the windings are connected to the diode group (567), which rectifies the alternating current generated by the inverter, making it available at the power source output.

The diode group (567) is made up of 4 diodes connected to a shared cathode, and provides a positive output voltage compared to the central socket of the transformer (531). Actually, each diode in the group is in turn made up of two diodes parallel connected together.

The Hall-effect current transducer (529), inserted at the diode group (567) output, sends the feed-back signal of the secondary current to the micro board (543), to regulate the welding current.

The output voltage signal of the power source, used by the interface board (543) to adapt the behavior of the power source based on the conditions of the welding arc in the various possible types of welding, is taken from the “+”(BR) and “–”(BO) output terminals of the power source.

The micro board (543) contains the main microprocessor of the power source (MASTER).

It supervises management of the other boards, more specialized in their respective functions, regulates the welding current by generating the PWM signal to be sent to the driver-igbt boards (548), and communicates with the microprocessors of the control panel (PANEL) and wire feeder (MOTOR) (see par. 2.3).

The temperature signals from the thermostat board (551), located among the igbt modules (548), to detect the temperature of the inverter, and from the thermostat (526) mounted on the dissipater of the diode group (567), to detect its temperature, both lead to the interface board (543).

The fan (512) to cool the power elements of the power source is controlled by the interface board (543). Its operation is conditioned by the temperature of the inverter and diode group and the ambient temperature, and in particular, is activated in the following conditions:

− upon machine start-up, and for 10 seconds after the pre-charge phase;

− with ambient temperature greater than 40°C;

− during welding, in the 3 minutes after welding is finished, and after 3 minutes if the igbt

temperature (548) is greater than 40°C;

− with the machine blocked, signaling an error code;

− when the machine is shut off.

The connector (506) to connect the wire feeder is located on the rear panel of the power source.

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The “-”(BO) power output of the power source is located on the front panel, while the “+”(BR) power output is located on the rear panel. They must be connected to the wire feeder differently according to the type of welding to be carried out (see Instruction Manual).

2.5 - Description of WF4-P Wire Feeder.

The wire feeder is powered by the flyback board (539) of the power source, through the connector (206), which is connected to connector (506) of the power source. The supply voltage (55 Vdc) is applied to the motor control board (232), which generates the auxiliary power supplies necessary to operate the wire feeder, including the control panel (324).

The connector (206) also includes the CAN-BUS communication line, with which the microprocessors of the control panel (PANEL) and wire feeder (MOTOR) communicate with the microprocessor of the power source (MASTER) (see par. 2.3).

The motor control board (232) contains the circuit to adjust the wire feeder motor (404) speed (which in this case is equipped with speed feed-back signal obtained from the encoder built into the motor (404)), the continuation of the CAN-BUS communication line to dialogue with the control panel (324), and the circuit to manage and drive the gas solenoid valve (227).

The switch (211) on the door of the wire feed unit provides the motor control board (232) with the signal to stop the power source in case the door is opened. This alarm condition is signaled on the control panel (see error code par. 3.7).

The connector board (225), located on the front panel of the wire feeder, receives power from the motor control board (232), and communicates with the latter by means of a dedicated RS232 serial line. A microprocessor handles the input and output signals of the wire feeder, and thus of the welding system, on the connector (BB).

These signals include:

− Start power source (from the button on MIG or TIG torches or from an automated system).

− Inputs for external adjustment of the welding current (from UP/DOWN buttons).

− Inputs for external adjustment of the welding current (from external potentiometer).

− Inputs for external adjustment of the wire feeder motor speed (from UP/DOWN buttons).

− Inputs for torch recognition or other connected accessories.

− Motor power supply output for push-pull torches (not yet available).

− Arc on signal output (NO contact free from voltage).

− RS232 serial communication line for dialogue with external system controllers.

Based on the “torch recognition” signal, an analogic signal whose levels, spaced at intervals of 0,25 Vdc, identify the devices connected to the connector (BB), the microprocessor on the connector board (225) prepares the welding system so that it can be controlled by means of the aforementioned signals. One of the possible positions enables the external RS232 serial line, to control the welding system by means of an external controller. This line is normally kept disabled.

The “start” and “arc-on” signals are exchanged with the motor control board (232) in clear, thus directly; all of the other signals are converted into serial information and exchanged via the internal RS232 serial line, inserted in the connections between J3 on connector board (225) and J7 on motor control board (232). All these signals are isolated from the circuits of the motor control board (232), by means of the optocouplers present on the motor control board (232).

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The following accessories may currently be connected to the connector (BB):

2.5.1 - Accessories table.

Art. Description art. Active signals.

Torch recognition signal

(pins 16-15 of BB).

1243 1265

MIG torch

TIG torch

Start (from central adapter

(BA)).

0 Vdc ((BB) free).

193 +

1191

Foot control + adapter

extension

(193 no start).

Start (from torch (BA)) + current adjustment (193).

187 +

1191 + 1192

Remote control +

adapter extensions.

Start (from torch (BA)) + current adjustment (187).

0.25 Vdc +/- 0.1.

1245 MIG Torch up/down.

Start + up/down speed + up/down current.

1 Vdc +/- 0.1.

The central adapter (BA)(222) for MIG or TIG torches is located on the front panel of the wire feeder; the adapter includes a power socket, two contacts for the start command, and a pneumatic fitting for gas.

2.6 - Description of GR54 Cooling Unit.

The GR54 cooling unit is completely dependent from MIG 3840/T Pulse power source from which receives the supply voltage. Its components are directly connected to the power source boards.

Due to the autotransformer (540) adapter effect (400/230 Vac) the supply voltage is 230 Vac.

The coolant pump (125), and the fans (131) are managed by control board (543) through relay RL2 on the pre-charge board (562).

The pressure switch (127), inserted in the hydraulic circuit on the pump (125) delivery, provides the isolated signal for the fluid pressure to the control board (543) through pre-charge board (562).

At the power source start up, if the cooling unit is set in continuous or automatic mode (see Instruction Manual), the pump (125) and fans (131) will operate for 30 seconds, to fill the torch tubes and check the pressurization of the hydraulic circuit; if no welding command is received from the operator, they will then stop awaiting a new start command.

If the pressure switch (127) does not detect the appropriate pressure with pump (125) and fans (131) working on, the control board (543) orders the power source blocked, with relative error code indication on control panel (see error code, par. 3.7).

In automatic mode the pump (125) and fans (131) enter start running at MIG or TIG welding beginning, and stop 3 minutes after welding has stopped.

In continuous mode the pump (125) and fans (131) are always kept running. Only the eventual lack of pressure can stop them together to the generator.

In the MMA process, cooling unit operation is disabled.

The factory set-up of the cooling unit is “OFF”, for which to the first use of the welding system, or after a procedure of “Factory set-up”, is necessary to modify such set-up (see Instruction Manual).

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3 - MAINTENANCE

WARNINGS

ANY INTERNAL INSPECTIONS OR REPAIRS MUST BE CARRIED OUT BY QUALIFIED

PERSONNEL.

BEFORE BEGINNING MAINTENANCE OPERATIONS, UNPLUG THE MACHINE FROM

THE MAINS AND WAIT FOR THE INTERNAL CAPACITORS TO DISCHARGE.

THE DISCHARGE TIME FOR THE DC-CAPACITORS (561) IS HEAVILY AFFECTED BY

THE OPERATING MODE OF THE FLYBACK BOARD (539). UNDER NORMAL

CONDITIONS THE TIME IS APPROXIMATELY 3 MINUTES, WITH THE FLYBACK

BOARD (539) BROKEN OR DISCONNECTED IT MAY BECOME 6 MINUTES.

3.1 - Periodic inspection, cleaning.

Periodically open the grids on the power source and check inside the aeration tunnel.

Remove any dirt or dust to ensure smooth air flow, and thus adequate cooling of the internal parts of the power source.

Remove any dirt or metal dust from the wire feed liner and gear motor unit, also making sure that they are not worn to the point of needing replacement.

Check the condition of the output terminals, output and power supply cables of the power source; replace if damaged.

Check the condition of the internal power connections and connectors on the electronic boards; if you find “loose” connections, tighten or replace the connectors.

3.2 - Welding system fittings and connectors.

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3.3 - Control panel commands and signals.

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3.4 - Operating sequences.

The following sequences reflect proper machine operation. They may be used as guidelines for troubleshooting. After each repair, they must be carried out without encountering any error or impediment.

Given the various operating modes available, due to the different possible configurations, only the main sequence for each welding process is described below.

NOTE

 Operations preceded by this symbol refer to operator actions.

♦ Operations preceded by this symbol refer to machine responses that must occur following an

operator action.

3.4.1 - Welding system operation.

 System shut off and disconnected from the mains.  Temporarily connect a rubber hose to the (BQ) fittings of the cooling unit, thus creating a by-

pass for coolant circulation.

 Connect the signal cable provided to the connectors (BD) on the wire feeder and (BS) on the

power source.

 Connect the power source to the mains.  Close the switch (BU).

♦ System powered; led (H) on control panel flashes rapidly. ♦ After one second, all leds and display light on (lamp test). ♦ After one second, the display (O) reads “Art”, and display (P) reads “287”; the

displays AN1 reads PANEL, MASTER, MOTOR programs version (es.: “04.04.04”); displays AN2 reads synergic curves programs version (es.: “SYn

1.0.0”). Then the entire control panel returns to the condition it was in before the last shutdown.

♦ After one second, the switch (BU) is closed, the fan (512) on the power source

runs for 10 seconds, then stops.

Correct?

♦ If the cooling unit mode is set to (see Instruction Manual):

-“automatic”, the pump (125) and fans (131) run for 30 seconds then stop;

-“continuous”, the pump (125) and fans (131) run continuously;

-“OFF”, the pump (125) and fan (131) do not operate.

NO (see 3.5.1, 3.5.2, 3.5.3,

3.5.14).

YES

 Press the button (AI) several times; the “Process” selection is repeated in sequence.  Press the button (AJ) several times; the “Mode” selection is repeated in sequence.  Press the button (AK) several times; the “Diameter” selection is repeated in sequence.  Press the button (AL) several times; the “Material” selection is repeated in sequence.  Press the button (AH) several times; the “accessory functions” selection is repeated in

sequence.

♦ Each time the button (AI) is pressed, the leds R (1-2-3-4-5) light in sequence. ♦ Each time the button (AJ) is pressed, the leds S, T and U light in sequence. ♦ Each time the button (AK) is pressed, the leds V light in sequence. ♦ Each time the button (AL) is pressed, the leds W and X light in sequence, the

display AN1 shows the existing programs for the type of material selected, and the display AN2 shows the existing programs for type of gas associated with the

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type of material (existing material and gas types may be selected using the (AM) and (AX) buttons).

Correct?

♦ Each time the button (AH) is pressed, the leds Y-Z-AA-AB-AC-AD-AE-AF-AG

light in sequence, in observance of the conditions imposed by the selected “Process” and “Mode”.

NO (see 3.5.3).

YES

3.4.2 - MIG mode.

WARNING

DURING THE FOLLOWING TESTS DO NOT AIM THE TORCH AT PEOPLE OR PARTS

OF THE BODY, BUT ONLY TOWARDS AN OPEN SPACE OR THE WORKPIECE.

 Shut off the power source using the switch (BU).  Connect the gas supply to the fitting (BE) on the rear panel.  Connect the power cable provided to the connectors (BF) on the wire feeder and (BR) on the

power source.

 Connect the MIG torch to the central adapter (BA) of the wire feeder (also connect the torch

commands patch connector to the connector (BB) on the wire feeder, if present).

 On a water-cooled torch, connect the torch cooling lines to the fittings (BI).  On a water-cooled torch, remove the temporary by-pass for coolant circulation from the

fittings (BQ), and connect the hoses provided to the fittings (BT) on the cooling unit and (BH)

on the wire feeder, matching the hose color.

 Connect the negative pole cable (BO) of the power source to the workpiece.  Restart the power source using the switch (BU).  After start-up, use the button (AI) to select the conventional MIG “process” (led R-3 on).  Use the button (AJ) to select two-stage “mode”, led (S) on.  Use the “diameter” and “material” buttons (AK, and AL) for which a program has already

been inserted, compatible with the torch used (e.g. : leds V-1,2 and W-FE lit).

 Hold down the torch start button for a few seconds.

♦ Gas flows from the torch as long as the button is held down. ♦ The wire feeds from the torch, or the wire feeder motor begins operating, as long

as the button is held down (the wire speed is adjustable using the knob (N) and displayed on the display (O) with led (C ) on).

Correct?

♦ The unit generates open-circuit output voltage as long as the button is held down,

shown on display (P) with led (J) lit.

NO (see 3.5.3, 3.5.4, 3.5.6,

3.5.7, 3.5.8).

YES

 Move the torch near the workpiece and press the torch trigger.

♦ Begin welding. Turn the knobs (N) and (Q) to obtain the wire speed (shown on

display (O) with led (C ) lit) and output voltage (shown on display (P) with led (J) lit) suitable for the welding to be performed.

♦ During welding, display (O) shows the welding current (with led (D) lit) and

display (P) indicates the arc voltage (with led (J) lit).

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Correct?

NO (see 3.5.9, 3.5.10, 3.5.11).

YES

 Release the torch start button.

Correct?

♦ The arc is immediately shut off and the wire feed stopped, while gas flow stops

after the post-gas stage (the post-gas time is activated only if the power source has delivered current).

NO (see 3.5.13).

YES

REGULAR OPERATION.

3.4.3 - TIG operation.

WARNING

DURING THE FOLLOWING TESTS DO NOT AIM THE TORCH AT PEOPLE OR PARTS

OF THE BODY, BUT ONLY TOWARDS AN OPEN SPACE OR THE WORKPIECE.

power source.

 Connect the TIG torch to the central adapter (BA) of the wire feeder (also connect the patch

connector of the torch to the connector (BB) of the wire feeder, if present).

 On a water-cooled torch, connect the torch cooling lines to the fittings (BI) on the wire feeder.  On a water-cooled torch, remove the temporary by-pass for coolant circulation from the

fittings (BQ), and connect the hoses provided to the fittings (BT) on the cooling unit and (BH)

on the wire feeder, matching the hose color.

 Connect the cable of the positive pole (BR) of the power source to the workpiece.  Restart the power source using the switch (BU).  After start-up, use the button (AI) to select the TIG “process” (led R-4 lit).  Use the button (AJ) to select two-stage “mode”, led (S) on (it is not possible to select the

“diameter” and “material” in TIG mode).

 Hold down the torch start button for a few seconds.

♦ Gas flows from the torch as long as the button is held down. ♦ Open-circuit output voltage is generated for as long as the button is held down.

Correct?

♦ Display (O) shows the programmed welding current (led (D) lit), adjustable with

knob (N), and display (P) indicates the open-circuit output voltage (led (J) lit).

NO (see 3.5.3, 3.5.4, 3.5.6,

3.5.8).

YES

 Use the knob (N) to set the current based on the type of welding to be carried out.  Move the torch near the workpiece and press the torch trigger.

♦ Begin welding. Turn the knob (N) to optimize the current level. ♦ Display (O) shows the welding current (led (D) lit) and display (P) shows the arc

voltage (led (J) lit).

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Correct?

NO (see 3.5.9, 3.5.10).

YES

 Release the torch start button.

♦ The arc shuts off immediately if a long ramp time is not set (slope-down).

Correct?

♦ The gas flow ends after the post-gas period (the post-gas time is activated only if

the power source has delivered current).

NO (see 3.5.6).

YES

REGULAR OPERATION.

3.4.4 - MMA mode.

 Shut off the power source using the switch (BU).  Leave the signal cable provided connected to the connectors (BD) on the wire feeder and (BS)

on the power source.

 Connect the cable to the electrode holder and the earth cable to the negative (BO) and positive

(BR) connectors, observing the polarity of the electrodes to be used.

 Restart the power source using the switch (BU).  After start-up, use the button (AI) to select the “process” MMA (led R5 lit).

♦ Voltage begins to be generated at the power source output, and the fan (512) starts

running.

Correct?

♦ Display (O) shows the programmed welding current (led (D) lit), adjustable via

knob (N), and display (P) shows the open-circuit output voltage (led (J) lit).

NO (see 3.5.2, 3.5.3, 3.5.8).

YES

 Use the knob (N) to set the current based on the electrode you intend to use.  Move the electrode clip near the workpiece.

♦ Begin welding. Turn the knob (N) to optimize the current level.

Correct?

♦ Display (O) shows the welding current (led (D) lit) and display (P) shows the arc

voltage (led (J) lit).

NO (see 3.5.9, 3.5.12).

YES

REGULAR OPERATION.

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3.5 - Troubleshooting.

WARNINGS

ANY INTERNAL INSPECTIONS OR REPAIRS MUST BE CARRIED OUT BY QUALIFIED

PERSONNEL.

BEFORE REMOVING THE PROTECTIVE GUARDS AND ACCESSING INTERNAL

PARTS, DISCONNECT THE POWER SOURCE FROM THE MAINS AND WAIT FOR THE

INTERNAL CAPACITORS TO DISCHARGE.

THE DISCHARGE TIME FOR THE DC-CAPACITORS (561) IS HEAVILY AFFECTED BY

THE OPERATING MODE OF THE FLYBACK BOARD (539). UNDER NORMAL

CONDITIONS THE TIME IS APPROXIMATELY 3 MINUTES, WITH THE FLYBACK

BOARD (539) BROKEN OR DISCONNECTED IT MAY BECOME 6 MINUTES.

NOTE

Items in boldface describe problems that may occur on the machine (symptoms).

 Operations preceded by this symbol refer to situations the operator must determine (causes).

♦ Operations preceded by this symbol refer to actions the operator must perform in order to

solve the problems (solutions).

3.5.1 - The power source does not start, control panel off.

MAINS SUITABILITY TEST.

Correct?

 No voltage for mains protection.

YES

♦ Eliminate any short-circuits on the connections between power cable, switch

(504), filter board (542), chokes (516+522) and pre-charge board (562).

♦ Make sure that the terminals of the chokes (516+522) on the terminal board (265)

are not short-circuited towards the earth of the power source.

♦ Replace chokes (516+522) and/or filter (542) and/or pre-charge (562) boards. ♦ Mains not suitable to power the power source (ex.: insufficient installed power).

MAINS CONNECTION TEST.

Correct?

 Terminals L1, L2 and L3, on pre-charge board (562) = 3 x 400 Vac, with switch (504) closed.

YES

♦ Check power cable and plug and replace if necessary. ♦ Check switch (504), and replace if defective. ♦ Check connections between switch (504), filter board (542), terminal board (265)

of the chokes (516+522) and pre-charge board (562).

♦ Check the mains voltage conditions. ♦ Replace the chokes (516+522) and/or filter board (542).

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POWER SUPPLY TEST.

Correct?

 Flyback board (539), connector J5, terminals 1 (+) and 4 (-) = +540 Vdc.

YES

♦ Check the wiring between J5 flyback board (539) and J6 pre-charge board (562). ♦ After waiting for the DC-capacitors (561) to completely discharge

, temporarily disconnect connector J5 on flyback board (539). Power up the power source again and check the voltage on the terminals Vdc+1 (+) and Vdc-1 (-) of pre-charge board (562) = +540 Vdc. If correct, replace the flyback board (539).

♦ After waiting for the DC-capacitors (561) to completely discharge

, temporarily disconnect the wires from the + and - terminals of the DC-capacitors (561) and check the resistance between the + and - terminals of the DC-capacitors (561). Correct value = >Mohm in one direction, and junction of two diodes with the probes reversed (NOTE: while measuring, the instrument display reaches the final value slowly, due to the DC-capacitors (561)). If correct replace the precharge board (562). If incorrect, identify which of the following components is short-circuited or leaking: DC-capacitors (561), igbt modules (548), discharge resistors (552), snubber capacitors mounted on the terminals 2 and 3 of the igbt (548).

FLYBACK BOARD (539) POWER SUPPLY TEST.

Correct?

 Flyback board (539), connector J5, terminals 3 (+) and 4 (-) = +18 Vdc.

YES

♦ Check the wiring between J5 flyback board (539) and J6 pre-charge board (562). ♦ After waiting for the DC-capacitors (561) to completely discharge,

temporarily disconnect connector J5 on flyback board (539) and check the resistance between terminals 3 (+) and 4 (-) of J5 flyback board (539). Correct value = >Mohm in one direction, and junction of a diode with the probes reversed. If correct replace the pre-charge board (562). If incorrect replace the flyback board (539).

♦ Replace the pre-charge (562) and/or flyback (539) boards.

MOTOR CONTROL BOARD (232) POWER SUPPLY TEST.

Correct?

 Motor control board (232), connector J18, terminals 1 (+) - 6 (-) = +55 Vdc.

YES

♦ Check the wiring between J18 motor control board (232), connector (206) on wire

feeder, connector (506) on power source and J3 flyback board (539).

♦ With the power source off, temporarily disconnect the connector J18 on motor

control board (232) and check the resistance between terminals 1 - 6 of J18 on motor control board (232). If short-circuited, replace the motor control (232) and flyback (539) boards.

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♦ With the power source off, temporarily disconnect the connectors J6, J8 and J10

on flyback board (539) and make sure that on J18, terminals 1 (+) - 6 (-) on motor control board (232) voltage = +55 Vdc. If correct, identify which of the three disconnected connectors is causing the incorrect value of the voltage on J18 (55 Vdc), and eliminate the cause of the probable overload or short-circuit, replacing the control (543) and/or pre-charge (562) boards if necessary.

♦ Replace the motor control (232) and/or flyback (539) boards.

CONTROL PANEL (324) POWER SUPPLY TEST.

Correct?

 Control panel (324), connector J1, terminals 1 (+) – 2 (-) = +8 Vdc.

YES

♦ Check the wiring between J1 control panel (324) and J12 motor control board

(232).

♦ With the power source off, temporarily disconnect connector J1 on control panel

(324) and check the resistance between terminals 1 and 2 of J1 on control panel (324). If short-circuited, replace control panel (324) and/or motor control board (232).

♦ With the power source off, temporarily disconnect connector J15 on motor control

board (232), and make sure the voltage on terminals 1 (+) – 2 (-) of J1 on control panel (324) = +8 Vdc. If correct, check the wiring between J1 connector board (225) and J15 motor control board (232) and replace the connector board (225) if necessary.

♦ Replace control panel (324) and/or motor control board (232).

♦ Make sure the micro board on the panel board in the control panel (324) is properly mounted,

especially that there are no bent pins or short-circuits between the pins of the connector J2 on the micro board of the control panel (324).

♦ Check the wiring of the CAN-BUS communication line, carrying out the CAN-BUS

COMMUNICATION TEST in par. 3.5.3.

♦ Replace control panel (324) and/or motor control board (232).

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3.5.2 - Power source powered, control panel on, fan (512) stopped.

NOTE

The fan (512) on the power source is controlled by the interface board (543), and its operation depends on the power source conditions, as shown in the par. 2.4, Description of MIG3840/T Pulse power source. For this reason, the following tests may be verified only during the first 15 seconds of power supply or during a blocked situation. For this purpose it is possible to

simulate the error 41, by disconnecting the connector J3 on connector board (225).

FAN (512) TEST.

 With the power source off, temporarily disconnect connector J3 on connector board (225) to

cause continuous operation of the fan (512).

Correct?

 Control board (543), connector J4, terminals 1 (+) – 2 (-) = +24 Vdc.

YES

♦ Check the wiring between fan (512) and connector J4 on interface board (543). ♦ Make sure there are no mechanical impediments blocking the fan. ♦ Replace the fan (512).

CONTROL BOARD (543) POWER SUPPLY TEST.

 Micro board (543), connector J3, terminals 2 (+) – 1 (-) = +8 Vdc.  Micro board (543), connector J3, terminals 4 (+) – 3 (-) = +15 Vdc.  Micro board (543), connector J12, terminals 1 (+) – 6 (-) = +5 Vdc.

Correct?

 Micro board (543), connector J1, terminals 1 (+) – 5 (-) = -15 Vdc.

YES

♦ Check the wiring between J3 micro board (543), and J10 flyback board (539). ♦ With the power source off, temporarily disconnect connector J3 on control board

(543) and check the resistance between terminals 2 and 1 and between terminals 4 and 3 of J3 on micro board (543). If short-circuited, replace control board (543) and flyback board (539).

♦ Make sure the micro board (543) and the interface board (543) is properly

mounted, especially that there are no bent pins or short-circuits between the pins of the connectors J10 and J11 of the interface board with J10 and J11 of micro board, on the control board (543).

♦ Replace the flyback (539) and/or control board (543).

♦ Replace the control board (543) and/or fan (512).

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3.5.3 - System powered, display and signals do not show the correct values.

CAN-BUS COMMUNICATION TEST.

Correct?

 Upon start-up, on control panel (324), led (H) flashes rapidly for approximately one second,

after which the system operating status is displayed (correct operation or error condition).

YES

♦ Check the wiring between J5 control panel (324) and J3 motor control board

(232), between J11 motor control board (232), connector (206) of the wire feeder, connector (506) on the power source and J9 interface board (543).

♦ Check the supply voltages of the control panel (324), motor control board (232)

and control board (543), performing if necessary the MOTOR CONTROL BOARD (232) POWER SUPPLY TEST and CONTROL PANEL (324) POWER SUPPLY TEST in par. 3.5.1, and the CONTROL BOARD (543) POWER SUPPLY TEST in par. 3.5.2.

♦ Make sure that the correct programs have been entered in the control panel (324),

in the motor control (232) and control (543) boards, performing if necessary the programming procedure available on the Cebora Web site (see par. 2.3, Description of SOUND MIG 3840/T Pulse (art. 287)).

♦ Replace control panel (324) and/or motor control board (232) and/or control board

(543).

ERROR CODE TEST.

Correct?

 Upon start-up, after start-up, an error condition displayed, thus display (O) reads “Err” and

display (P) shows a number identifying the type of error.

YES

♦ See Error codes and alarm signals, par. 3.7.

PROGRAMS INSTALLED TEST.

 At start-up, led (H) on control panel flashes rapidly for approximately one second, then

display (O) reads “Art”, while display (P) shows “287”; the displays AN1 reads PANEL,

MASTER, MOTOR programs version (es.: “04.04.04”); displays AN2 reads synergic curves

programs version (es.: “SYn 1.0.0”).

Correct?

 The versions of the programs entered are compatible with one another.

YES

♦ Check the compatibility of the programs on the three boards, comparing the

installed version indexes with the specifications cited on the Cebora Web site. These programs must be in compatible versions, thus if any one of these 3 boards is replaced, you must make sure of this compatibility; better yet, reprogram the entire system with the latest available versions.

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COMMANDS AND SIGNALS TEST.

Correct?

 The keys on control panel (324) allow all of the steps regarding the selection of “Process”,

“Mode” and “Programs”, as described in par. 3.4 Operating sequences, and in the Instruction

Manual.

YES

♦ Check the supply voltages of the control panel (324), motor control board (232)

♦ Replace control panel (324) and/or motor control board (232) and/or control board

(543).

♦ Regular operation.

3.5.4 - The start button produces no effect.

POWER SOURCE SAFETY TEST.

Correct?

 After the start-up procedure, display (O) shows an alarm situation (“OPn”, “OFF”).

YES

♦ See Error codes and alarm signals, par. 3.7.

NOTE

The start command may be given to the power source either through the central adapter for the torch (BA), or via the connector (BB) on the wire feeder. The two circuits are parallel connected, thus only one of the two signals is enough to start the power source.

CONNECTOR BOARD (225) POWER SUPPLY TEST.

 Connector board (225), connector J5, terminals 14 (+) and 15 (-) = +12 Vdc.

Correct?

 Connector board (225), connector J5, terminals 11 (+) and 15 (-) = +5 Vdc, with no

accessories connected to the connector (BB).

YES

♦ Check the wiring between J1 connector board (225) and J15 motor control board

(232).

♦ With the power source off, temporarily disconnect connector J1 on connector

board (225) and check the resistance between terminals 1 and 2 of J1 on connector board (225). Correct value = junction of one diode in one direction, >Mohm with the probes reversed. If short-circuited, replace the connector board (225) and

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motor control board (232). If >Mohm in both directions, (circuit broken) replace the connector board (225).

♦ Replace the connector board (225) and/or motor control board (232).

START COMMAND TEST.

Correct?

 Connector board (225), terminal J4-1 (-) and J4-2 (+) = 0 Vdc with start button pressed, +12

Vdc with button released (either with button connected to the central adapter (BA), or with

button connected to the connector (BB)).

YES

♦ If the start command comes from the central adapter (BA), check the wiring

between J4 connector board (225), central adapter (BA), torch central adapter, and torch button. Replace the entire torch if necessary.

♦ If the start command comes from the connector (BB), make sure the connector J5

is properly welded (especially pins 1 and 9) on connector board (225), and check the wiring between the patch connector of the torch and the torch start button. Replace the entire torch if necessary.

♦ Replace connector board (225).

START SIGNAL TEST.

Correct?

 Motor control board (232), OP6 optocoupler (near J7), pins 1 (+) – 2 (-) = +1 Vdc with start

button pressed (0 Vdc with button released).

YES

♦ Replace motor control board (232).

♦ Check the wiring between connector J7 motor control board (232) and connector J3 connector

board (225). ♦ With power source off, temporarily disconnect the flat cable from connector J7 on motor

control board (232), and check the resistance between terminals 8 and 10 of J7 on motor

control board (232). Correct value = junction of two diodes in both probes senses. If a short-

circuit or broken circuit is detected, replace the motor control board (232). ♦ Replace connector board (225).

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3.5.5 - Some signals from connector for accessories (BB) do not work.

NOTES

The start command of the torch (central adapter (BA)), present on J4 of connector board (225), is parallel connected to the start command on terminals 1 and 9 of J5, connector board (225) (connector for accessories (BB)), and the torch recognition signal does not distinguish between the two commands. Either one alone is enough to activate the start function.

EXTERNAL SIGNALS TEST.

 Connector board (225), connector J5 (BB), signals as shown in the table, with power source

powered and accessory connector inserted in (BB).

Signal J5 terminals Function active Function not active

Start 1(+) – 9(-) 0 Vdc +12 Vdc Current down 2(+) – 15(-) Current up 10(+) – 15(-) Speed down 3(+) – 15(-) Speed up 6(+) – 15(-)

0 Vdc +10 Vdc

Arc-on 4 – 5 0 ohm >Mohm Current potentiometer 7(+) – 15(-) Adjustable from 0 to +5 Vdc. Torch recognition 16(+) – 15(-) See accessories table par. 2.5.1.

NOTE

For better access to the measuring points of the table, we recommend removing the connector board (225) from the wire feeder, leaving it connected, so that you can measure the signals on connector J5 on the welding side of the printed circuit of the connector board (225).

Correct?

YES

♦ Check the power supply of the connector board (225) by carrying out the

CONNECTOR BOARD POWER SUPPLY TEST (225), par. 3.5.4.

♦ Check the wiring and operation of the devices of the accessory connected. ♦ Replace the connector board (225).

♦ Replace the connector (225) and/or motor control (232) boards.

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3.5.6 - System powered, no gas flows from the torch.

SOLENOID VALVE (227) TEST.

Correct?

 Solenoid valve (227) terminals = 24 Vdc with start button pressed, in MIG or TIG mode, or

with button (AQ) on control panel pressed (test gas).

YES

♦ Check for the presence of gas at the intake fitting (BE) and make sure that the

pressure and flow rate in the intake line meet the specifications of the SOUND MIG 3840/T Pulse.

♦ Make sure the gas lines in the wire feeder are not clogged. ♦ Replace the solenoid valve (227).

♦ Check the wiring between terminals 1 and 2 of connector J13 on motor control board (232)

and solenoid valve (227). ♦ Make sure that solenoid valve terminals (227) = 56 ohm. If 0 ohm (short-circuit), replace

solenoid valve (227) and motor control board (232). If >Mohm (winding broken), replace the

solenoid valve (227). ♦ Replace the motor control board (232).

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3.5.7 - System powered, the wire feeder motor does not work.

WIRE FEEDER MOTOR (404) TEST.

 Motor control board (232), connector J19, terminals 1 (-) and 2 (+) = +17 Vdc, in MIG mode,

with button (AR) on control panel pressed (fixed speed wire test).

Correct?

 Motor control board (232), connector J19, terminals 1 (-) and 2 (+) = between approximately

+2 and +46 Vdc, in MIG mode, with start button pressed, adjustable using the knob (N) based

on the set program and wire diameter.

YES

♦ Correct operation. ♦ Check the wiring between J19 motor control board (232) and wire feeder motor (404). ♦ Make sure there are no mechanical impediments blocking the motor (404). ♦ With the power source off, temporarily disconnect the wire feeder motor (404) terminals from

connector J19 on motor control board (232), and make sure the resistance between the motor terminals left free = approximately 1,5 ohm (motor winding resistance). If 0 ohm (shortcircuit), replace wire feeder motor (404) and motor control board (232). If >Mohm (winding broken), replace wire feeder motor (404).

♦ Check the motor rotation direction. If incorrect, reverse the wires on terminals J19 of motor

control board (232).

WIRE FEEDER MOTOR ENCODER TEST.

Correct?

 Motor control board (232), connector J17, terminals 2 (+) and 4 (-) = fig. 5.2.1, with button

(AR) on control panel pressed (fixed speed wire test) (speed feed-back signal from motor encoder). (In case of different speed set via the torch potentiometer or knob (N), the waveform in fig. 5.2.1 changes only in frequency, maintaining the same form, amplitude and duty-cycle).

YES

♦ Check the wiring between connector J17 motor control board (232) and the

encoder on the wire feeder motor (404).

♦ Make sure that on J17 of motor control board (232), terminals 1(+) and 4(-),

voltage = +5 Vdc. If incorrect, with power source off, disconnect the connector J17 from the motor control board, and check the resistance between the terminals 1 and 4 of the patch connector disconnected from J17. Correct value = approximately 20 Kohm. If short-circuited, replace motor (404) and motor control board (232). If the circuit is interrupted replace the motor (404).

♦ With power source off, disconnect the connector J17 from the motor control board

(232), and check the resistance between the terminals 2 and 4 of the patch connector disconnected from J17. Correct value = approximately 20 Kohm. If short-circuited or if the circuit is broken, replace motor (404).

♦ Replace the wire feeder motor (404).

♦ Replace motor control board (232). ♦ Replace motor control (232) and/or control panel board (324). ♦ Replace the wire feeder motor (404).

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3.5.8 - In open circuit operation, the output voltage is not regular.

OPEN-CIRCUIT OUTPUT VOLTAGE TEST.

Correct?

 Output terminal (-) (BO), and output terminal (+) (BR) on power source = approximately +68

Vdc, (in MIG and TIG modes with start button pressed, in MMA with the only the MMA process selected).

YES

♦ Regular operation. ♦ Make sure that the settings on control panel (324) are coherent and match a program present

in the system memory (see examples in par. 3.4 Operating sequences or Instruction Manual).

♦ Check the conditions of the inductor (530) inserted in the aeration tunnel, and of the

corresponding connections (remove the ventilation grid on the front panel to inspect). If you find loose connections, tighten and replace any damaged components.

♦ Check the connection between the midpoint of the diode group (567) (connection of the diode

cathodes) and (+) (BR) output terminal of the power source. If you find loose connections, tighten and replace any damaged components.

♦ Check the wiring between J13 of control board (543) and output terminals (+)(BR) and (-)

(BO) of the power source.

TRANSFORMER (531) SECONDARY CIRCUIT VOLTAGE TEST.

NOTE

For the following test, with the power source off, temporarily disconnect the 4 end terminals of the transformer (531) secondary circuit from the diode group (567) terminals. In this way, the waveform in fig. 5.2.2 will be visible only for 1 second, in how much reading power source output voltage = 0 (terminal (+)(BR) is disconnected), the control board (543) commands the block for “error 56” in MMA or “error 10” in MIG and TIG.

In order to avoid the block, it is possible to apply one voltage of approximately 55 - 60 Vdc with a external power supplier, to the terminals 1(+) and 2(-) of the connector J13 of interface board (543) or to (-)(BO) and (+)(BR) output terminals (valid for MIG and TIG; in MMA it is not possible to exclude the block).

Correct?

 Power the power source. Output terminal (-)(BO) (gnd) (corresponding to the central socket

of the transformer (531), and end terminals of the transformer (531), disconnected from the

diode group (567) = fig. 5.2.2, on each terminal, (open-circuit voltage on the secondary

transformer circuit (531)), in MMA or in MIG and TIG modes with start button pressed.

YES

♦ Make sure the diode modules that make up the diode group (567) are properly

mounted. The diode group (567) is made up of the four diode modules connected to a shared cathode on the output terminal (+)(BR) of the power source, and each diode module is made up of the two diodes parallel connected together.

♦ Check the wiring between diode group (567) and output terminal (+)(BR) of the

power source. If you find loose connections, tighten and replace any damaged components.

♦ With the end terminals of the transformer (531) secondary circuit disconnected

from the diode group (567), check the resistance between the terminals left free on

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the diode group (567) and the central terminal connected to the output terminal (+)(BR) of the power source. Correct value = junction of one diode in one direction, >Mohm with the probes reversed. If you find short-circuits or breaks, replace the diode group (567).

♦ Replace the diode group (567).

TRANSFORMER (531) PRIMARY CIRCUIT CURRENT TEST.

 With the power source off, connect the 4 end terminals of the secondary transformer circuit

(531) to the terminals of the diode group (567).

Correct?

 Micro board (543), connector J1, terminals 6(+) - 5(-) = <0.1 Vdc, current at the transformer

(531) primary circuit with open-circuit power source.

YES

♦ Check the wiring between J1 control board (543) and J1 TA board (558). ♦ Make sure that there are no short-circuits or isolation leaks towards earth in the

connections between the primary circuit of the transformer (531) and the terminals 1 of the igbt modules (548).

♦ With the power source off, temporarily disconnect J1 from the TA board (558)

and check the resistance on terminals 1 and 2 of J1 on TA board (558). Correct value = 10 ohm. If incorrect replace the TA board (558).

♦ With power source off, temporarily disconnect J1 from micro board (543) and

check the resistance on terminals 6 and 5 of J1 on micro board (543). Correct value = 19 ohm. If incorrect, replace control board (543).

♦ Check the conditions of the transformer (531). If you notice burn signs or

deformities, replace the transformer (531).

♦ Replace the control (543) and/or TA (558) board. ♦ Replace the transformer (531).

DRIVER BOARDS (548) COMMAND TEST.

NOTE

For the following test, with the power source off, temporarily disconnect the connectors J2 and J3 on interface board (543). In this way, the waveform in fig. 5.2.3 will be visible only for 1 second, in how much reading power source output voltage = 0 (driver boards (548) are disconnected), the control board (543) commands the block for “error 56” in MMA or “error 10” in MIG and TIG.

Correct?

 Power up the power source again, and check the following terminals on interface board (543):

connector J2, terminals 1 and 2 (gnd) = terminals 5 and 4 (gnd) = fig. 5.2.3,

connector J3, terminals 1 and 2 (gnd) = terminals 5 and 4 (gnd) = fig. 5.2.3,

(command signal for the driver boards (548)), in MMA or in MIG or TIG mode, with start

button pressed:

YES

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♦ Check the wiring between J2 and J3 of interface board (543) and driver boards

(548).

♦ With power source off, and connectors J2 and J3 disconnected from interface

board (543), check the resistance on the following connectors of the driver boards (548): L+ (+) and L- (-) = approx. 380 ohm; L+ (-) and L- (+) = approx. 455 ohm. H+ (+) and H- (-) = approx. 380 ohm; H+ (-) and H- (+) = approx.455 ohm. GH (+) and EH (-) = approx. 2200 ohm; GH (-) and EH (+) = approx. 1200 ohm. GL (+) and EL (-) = approx. 2200 ohm; GL (-) and EL (+) = approx. 1200 ohm. If incorrect, replace the driver board (548) and the igbt module (548) to which it is connected. (Due to the complexity of the circuit, some types of instruments may measure 455 ohm instead of 380 ohm, thus the measurement is independent of the polarity of the instrument probes).

♦ With power source off, check the resistance on the following power terminals of

the igbt modules (548) (the final values in the measuring instrument are reached slowly due to the effect of the DC-capacitors): 1 (+) and 2 (-) = >Mohm; 1 (-) and 2 (+) = junction of one diode. 1 (-) and 3 (+) = >Mohm; 1 (+) and 3 (-) = junction of one diode. If incorrect, replace the defective igbt module (548), along with the driver board (548) to which it is connected.

WARNING

In case of a fault on an igbt module (548) or driver board (548), it is advisable to replace both the igbt module (548) and the driver board (548) at the same time. A defective igbt

frequently damages the driver board to which it is connected. Similarly, a defective driver board frequently damages the igbt to which it is connected.

To replace igbt modules (548) follows instructions listed in par. 3.6.

♦ Make sure that 540 Vdc is present on the terminals of the DC-capacitors (561). If

incorrect, check the connections between the DC-capacitors (561) and pre-charge board (562) terminals VDC+1, VDC+2, VDC-1 and VDC-2, and replace the precharge board (562) and/or DC-capacitors (561) if necessary.

♦ Make sure that the primary circuit of the transformer (531) and corresponding

connections are not interrupted, short-circuited, or in isolation leak towards earth.

♦ Replace the driver (548) and/or igbt (548) and/or transformer boards (531).

♦ Check the supply voltages of the control board (543), performing if necessary the CONTROL

BOARD (543) POWER SUPPLY TEST in par. 3.5.2. ♦ Replace the control board (543).

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3.5.9 - In resistive load operation, the output voltage is not regular.

NOTE

In TIG and MMA processes, the circuits to detect the short-circuit at the output prevent the power source from delivering current if the load is already applied at the output. Under normal operating conditions, the load is applied when the power source already delivers a voltage greater than the minimum set in the control. However, given the complexity and danger of

such operating simulation, this is specifically not recommended and thus non documented.

The sole purpose of the tests below is to verify the ability of the power source to deliver current, thus for the sake of simplicity and operator safety, only the “conventional MIG” process (led R3 lit) will be considered below.

OPEN-CIRCUIT OPERATING TEST.

Correct?

 Output terminal (-)(BO), and output terminal (+)(BR) on power source = approximately +68

Vdc, (in MIG and TIG modes with start button pressed, in MMA with the only MMA process

selected).

YES

♦ Carry out the test in par. 3.5.8.

NOTE

For the following tests use a resistive load capable of withstanding the maximum power source

current. The appropriate values are shown in the table.

Process

Resistive load

resistance

Power source

output current

Power source

output voltage

Conventional MIG 0,087 ohm 380 Adc +33 Vdc

OUTPUT VOLTAGE TEST ON RESISTIVE LOAD.

 On the control panel, set: process = conventional MIG (led R3 lit), mode = 2-stage (led S lit),

diameter = 1,2 and material = FE. Use knob (Q) to set the output voltage = 33,0 on display (P)

(with led J lit).

Correct?

 Output terminal (-)(BO), and output terminal (+)(BR) on power source = values as shown in

the table, with start button pressed.

YES

♦ Regular operation.

INVERTER POWER SUPPLY TEST.

Correct?

 DC-capacitors (561), terminals (+) and (-) = approximately +540 Vdc, with power source

loaded in table conditions, and rated mains voltage.

YES

♦ Check the voltage on terminals L1, L2 and L3, on pre-charge board (562). If the

voltage appears to drop too far compared to the mains voltage, or if you detect an

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unbalance in one of the three phases, check the wiring between pre-charge board (562), chokes (516+522), filter board (542) and switch (504). Restore any deteriorated connections and replace any damaged components.

♦ Replace the pre-charge (562) and/or filter (542) boards and/or chokes (516+522).

CURRENT TRANSDUCER (529) POWER SUPPLY TEST.

Correct?

 Micro board (543), connector J1, terminals 4(+) and 5(-) = +15 Vdc; terminals 1(+) and 5(-) =

-15 Vdc.

YES

♦ Check the wiring between current transducer (529) and J1 micro board (543). ♦ With power source off, temporarily disconnect connector J1 from micro board

(543) and check the resistance between terminals 4 and 1 of the patch connector disconnected from J1. Correct value = approximately 2 Kohm. If incorrect, replace the current transducer (529).

♦ With J1 disconnected from micro board (543), powers up the power source and

check the voltage on J1 of micro board (543), terminals 4(+) and 5(-) = +15 Vdc; terminals 1(+) and 5(-) = -15 Vdc. If incorrect, replace control board (543).

♦ Replace current transducer (529) and/or control board (543).

POWER SOURCE OUTPUT CURRENT FEEDBACK SIGNAL TEST.

Correct?

 Micro board (543), connector J1, terminals 3(+) – 5(-) = +360 mVdc, +/- 10 mVdc with

power source powered; approximately +3,3 Vdc, or fig. 5.2.4, (output current feedback

signal) with power source on resistive load, in the table conditions.

YES

♦ Correct operation.

♦ Make sure that the micro board (543) is correctly set by carrying out the MINIMUM

CURRENT THRESHOLD SETTING TEST in par. 3.7.10. ♦ Check the wiring between the terminals of the transformer (531) secondary circuit, diode

group (567), and output terminal (+)(BR) of the power source, and between the transformer

(531) central socket, choke (530), and output terminal (-)(BO) of the power source. If you

find short-circuits or loose connections, restore the original connections and replace any

damaged components. ♦ Make sure the current transducer (529) is properly mounted on the output cable between

choke (530) and power source (-)(BO) output terminal, more specifically that the cable is

centered in the transducer hole, and that it passes through perpendicularly. ♦ Make sure that the CAN-BUS communication line is working properly between control board

(543), motor control board (232) and control panel (324), performing tests with different set-

ups or, if necessary, the test in par. 3.5.3 and the instructions described in par. 3.4. “Operating

sequences”.

♦ Replace transformer (531) and/or diode group (567) and/or choke (530). ♦ Replace the control board (543) and/or current transducer (529).

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3.5.10 - In MIG or TIG mode, arc difficult to strike, the arc shuts off immediately after

striking (stuttering start-up).

3.5.11 - In synergic mode, the welding quality is not satisfactory, the wire speed is not

suited to the output current.

3.5.12 - In MMA, arc difficult to strike and/or unsatisfactory welding quality.

To assist welding starts, the work programs include the “Hot-Start”, “Soft Start” and “Impedance” functions, available depending on the process selected and adjustable using the keys on the control panel (324) (see Instruction Manual).

In particular:

- the “Hot-Start” function is available in synergic MIG, TIG and MMA.

- the “Soft Start” and “Impedance” functions are available in MIG processes.

In MIG mode, the parameters entered in the “synergic” MIG programs are determined based on experience, thus some operators may find conditions to be optimal while others may need to make slight changes. This is why it is possible to change the ratio between wire speed and welding current in synergic MIG programs (see Instruction Manual).

In MMA, should you find it difficult to determine the proper balance between welding with too much splattering or an electrode that tends to stick to the workpiece, despite carefully adjusting the welding current, the “Arc-force” function is available to work based on the arc voltage, and automatically modulates the welding current for faster detachment of the welding drop. This function may be selected using the key (AH) and adjusted using the keys (AX) and (AM) on control panel (324) (see Instruction Manual).

In all of these situations, when there are problems striking the arc or welding difficulties despite careful management of the parameters available on the control panel, we recommend that you:

− Make sure that the parameters selected reflect the actual current welding conditions.

− Make sure that the adjustments are working properly, by carrying out welding tests with

different parameter settings or switching the working program with a similar one, if available,

to determine the practical welding differences in the different settings. If changes to the

parameters do not correspond to welding differences, or if you encounter problems in

selecting the parameters, make sure the software versions installed in the welding system are

compatible. Upgrade if necessary by connecting to the Cebora Web site (see par. 2.3 -

Description of SOUND MIG 3840/T Pulse system (art. 287) and instructions on the Web

site).

− Make sure that the power source is working properly, performing if necessary the “open

circuit operation” test in par. 3.5.8 and “operation on resistive load” test in par. 3.5.9.

− Check the compatibility of the components being used (electrode clamp, torch, type of contact

tip, wire type and diameter, type of gas, etc.) with the type of welding being carried out.

− Check the wear status of the torch and its components, replacing if necessary.

− Replace the control board (543) and/or motor control board (232) and/or control panel (324).

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3.5.13 - In MIG mode, when the start button is released, the wire sticks to the workpiece

(ineffective motor braking).

To maximize the end of MIG welding, the work programs include the “Burn-Back” function, adjustable using the keys on the control panel (324) (see Instruction Manual).

In case of difficulty at the end of MIG welding:

− Make sure that the wire feeder motor brakes properly, if necessary performing the WIRE

FEEDER MOTOR (404) BRAKING TEST described below.

− Make sure that the “Burn-Back” function adjustment is working, by carrying out welding tests

with different parameter settings or switching the working program with a similar one, if

available. If you encounter problems, make sure the software versions installed in the welding

system are compatible. Upgrade if necessary by connecting to the Cebora Web site (see par.

2.3 - Description of SOUND MIG 3840/T Pulse system (art. 287)).

− Check the compatibility of the components being used (torch, type of contact tip, wire type

and diameter, type of gas, etc.) with the type of welding being carried out.

− Check the wear status of the torch and its components, replacing if necessary.

− Replace the control board (543) and/or motor control board (232) and/or control panel (324).

WIRE FEEDER MOTOR (404) BRAKING TEST.

Correct?

 Motor control board (232), connector J19, terminals 2 and 1 (gnd) = fig. 5.2.5, upon releasing

the start button and with open-circuit power source (voltage on the wire feeder motor (404)

during correct braking, beginning with the maximum speed of 22 m/min.). The wire feeder

motor stops immediately (braking time approximately 200 msec.).

YES

♦ Check the wiring between connector J19 of motor control board (232) and motor

(404).

♦ If the motor slows down with its own inertia (fig. 5.2.6 or similar), the braking

circuit on motor control board (232) may not be working, in which case replace the motor control board (232).

♦ Make sure that there are no mechanical impediments preventing the wire coil from stopping

despite the braking action of the motor (ex.: slipping of the wire feeder rollers, improperly

adjusted roller spring, etc.). ♦ Replace the motor control (232) and/or motor (404) board.

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3.5.14 - Cooling unit GR54 does not work correctly.

NOTE

Operation of the GR54 cooling unit depends on the welding process selected, and it may be enabled or disabled via a setting on the control panel (324) (see Instruction Manual).

COOLING UNIT POWER SUPPLY TEST.

Correct?

 Pre-charge board (562), connector J4, terminals 1 and 6 = 400 Vac, terminals 1 and 3 = 230

Vac, with power source powered.

YES

♦ Check the wiring between connector J4 of pre-charge board (562) and

autotransformer (540).

♦ Make sure on pre-charge board (562), terminals A and B of J5,voltage = 400 Vac

approximately. If not correct, check wiring between J5 pre-charge board (562) and terminals J-L1 and J-L2 on filter board (542), make sure conditions of the mains voltage, performing if necessary the MAINS CONNECTION TEST of par. 3.5.1, replace filter board (542).

♦ Check the fuse on autotransformer (540). If interrupted replace it and disconnect

temporarily, with power source off, connector J4 on pre-charge board (562) and make sure resistance on autotransformer (540) terminals. Correct value on 0-400 terminals = 15 ohm, approximately; on 0-230 terminals = 8 ohm approximately. If not correct replace autotransformer (540).

♦ Replace the pre-charge board (562).

COOLING UNIT ENABLE TEST.

Correct?

 Pre-charge board (562), connector J2, terminals 5(+) and 6(-) = +24 Vdc, with cooling unit

enabled via the control panel.

YES

♦ Check the wiring between J2 pre-charge board (562) and J5 on interface board

(543).

♦ With power source off, temporarily disconnect connector J5 on interface board

(543) and check the resistance between terminals 5 and 6 of J2 on pre-charge board (562). Correct value = approximately 2300 ohm. If short-circuited, replace the pre-charge (562) and control (543) boards. If the circuit is open replace the pre-charge board (562).

♦ Make sure control panel is working correctly, performing, if necessary, tests of

par. 3.5.3.

♦ Replace the control (543) and/or pre-charge (562) boards.

PUMP (125) AND FAN (131) TEST.

 Terminals of fast-on connector (inserted in the wiring between cooling unit and power source)

= 230 Vac, with cooling unit enabled.

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Correct?

YES

♦ Check the wiring between the terminals 2 and 4 on pre-charge board (562), fuse

(BN) on rear panel and fast-on connector (inserted in the wiring between cooling unit and power source).

♦ Check fuse (BN) on power source rear panel. If tripped, replace and make sure

resistance on fast-on connector terminals (inserted in the wiring between cooling unit and power source). Correct value = approximately 19 ohm. If incorrect open cooling unit and make sure resistance of pump (125) = 21 ohm, approximately, and fan (131) = 500 ohm approximately, each fan. If incorrect replace the defective device.

PRESSURE SWITCH (127) TEST.

Correct?

 Interface board (543), connector J5, terminals 3(+) and 2(-) = 0 Vdc, with pump (125) and

fans (131) running (pressure switch contact closed = suitable pressure); +24 Vdc, with pump

(125) and fans (131) stopped (pressure switch contact open = pressure low).

YES

♦ Check the wiring between pressure switch (127) and connector J1 pre-charge

board (562), and between J2 pre-charge board (562) and J5 interface board (543).

♦ With power source off, temporarily disconnect J1 from pre-charge board (562).

Power up the power source and check the voltage on terminals 1(+) and 2(-) of J1, pre-charge board (562) = +24 Vdc. If correct, check the integrity of pressure switch (127). If incorrect, make sure on J5 interface board (543), terminals 5(+) and 2(-) voltage = +24 Vdc. If correct replace control board (543). If not correct make sure on J2 pre-charge board (562), terminals 1(+) and 4(-) voltage = +24 Vdc. If correct replace pre-charge board (562). If not correct check wiring between J2 pre-charge board (562) and J6 flyback board (539), and if necessary replace flyback board (539).

♦ Make sure that the lines of the cooling circuit are not clogged, especially in the

part where it is connected the pressure switch (127).

♦ Check rotation direction of the pump (125). ♦ Replace pressure switch (127) and/or pump (125).

♦ Open cooling unit and check wiring between fast-on connector (inserted in the wiring

between cooling unit and power source), pump (125) and fans (131). ♦ With power source off, temporarily disconnect connections between cooling unit devices

(pump (125) and fans (131)) and make sure resistance on each single device terminals.

Correct values: pump (125) = 21 ohm, approximately, and fan (131) = 500 ohm

approximately, each fan. ♦ Check the integrity and connection of the starting capacitor of the pump (125). Replace if

necessary.

♦ Check rotation direction of the pump (125). ♦ Make sure that there are no mechanical impediments jamming the pump (125) and/or fans

(131).

♦ Make sure coolant liquid level. ♦ Replace pump (125) and/or fans (131) and/or control board (543).

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3.6 - Kit Driver + igbt, code 5.710.511 replace instructions.

3.6.1 - Removing igbt modules from heatsink and preparing heatsink.

- Remove the two igbt modules.

- Remove the two thin sheets of metal Therm-strate covered with grease and inserted between

the heatsink and the igbt modules.

- Clean the dissipater to remove the residue left by the metal sheet Therm-strate, using a rag

soaked in denatured alcohol. No residue must be left on the heatsink which must be perfectly

clean.

3.6.2 - Apply the igbt to the heatsink.

- Take the Therm-strate sheet (code 3085413), being careful not to crease it, gently remove the

two protective films to uncover the two layers of thermally conductive grease with your

hands; also take care not to contaminate it with dust or dirt.

- Apply the Therm-strate sheet on the dissipater in place of those previously removed.

- Make sure that the bottom part of the igbt modules (metal base) is perfectly clean.

- Apply the igbt module over the Therm-strate sheet.

- Insert the two holding screws (A and B) and turn them without tightening completely.

- Continue tightening the screws by degrees, alternatively.

- Caution! The tightening torque of the screws must be between 3 and 5 Nm.

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3.7 - Error codes and alarm signals.

3.7.1 - 2 - EEPROM error.

Block due to software error. Replace the control board (543).

3.7.2 - 6 - Communication error on CAN-BUS, detected by control board (543).

Communication error between control board (543) and motor control board (232), or between control board (543) and control panel (324), detected by MASTER control, on control board (543). Perform the usual tests in case of failure of the CAN-BUS COMMUNICATION TEST in par. 3.5.3.

3.7.3 - 9 - Communication error on the CAN-BUS between control panel (324) and

control board (543).

Communication errors on the CAN-BUS line detected by the PANEL control, on control panel (324). Perform the usual tests in case of failure of the CAN-BUS COMMUNICATION TEST in par. 3.5.3.

3.7.4 - 10 - Missing voltage and current at the power source output.

When the start command is activated, the circuits to detect the output voltage and output current on the control board (543), detect voltage = 0 and current = 0. This situation is possible only with the inverter broken (thus it does not generate the alternating voltage on the primary circuit of the transformer (531)), or with one or both voltage and current detection lines interrupted.

Perform the “open circuit operation” test in par. 3.5.8 and the “operation on resistive load” test in par. 3.5.9.

3.7.5 - 13 - Missing communication between control board (543) and pre-charge board

(562).

This alarm is operative only at the power source start-up. The control board (543) check the “MAINS” (mains voltage presence) and “PRECHARGE” (DC-capacitors (561) direct current voltage) signals, coming from pre-charge board (562).

These signals can be checked on J7 of interface board (543):

− “MAINS” :mains voltage present = 0,1 Vdc, approx. on terminals 4(+) and 5(-).

− “PRECHARGE” : DC-capacitors (561) voltage present = fig. 5.2.7 on terminals 7 and 8(gnd)

(in this waveform is more important the pulses regular presence than their

period and frequency). Based on these signals, the control board (543) perform the following conditions: “MAINS” “PRECHARGE” absent absent = error 13 alarm. present absent = error 16 alarm. absent present = error 61 alarm. present present = regular operation. At the power source start-up, once detected the both signal presence, control board (543)

order the pre-charge relay closed, on pre-charge board (562) and set the power source for regular operation. Starting from this moment error 13 alarm is no more operative.

Check the wiring between connectors J3 on pre-charge board (562) and J7 on interface board

(543), and replace the two boards if necessary.

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3.7.6 - 14 - Microprocessor supply voltage error on control board (543).

Perform the CONTROL BOARD (543) POWER SUPPLY TEST in par. 3.5.2, paying special

attention to the 8 Vdc and 5 Vdc voltages.

3.7.7 - 16 - Direct current voltage at pre-charge board (562) output below minimum

permitted value.

This alarm is operative only at the power source start-up. The direct current voltage on the DC-capacitors (561) is not sufficient to ensure proper

operation of the inverter, and thus of the power source. This may be due to a possible distortion of the mains voltage (or of a single phase of the mains voltage), a short-circuit, or strong absorption from DC-capacitors (561) or igbt (548) modules, or a fault in the pre-charge board (562), or in the built-in rectifier bridge.

Perform the test of par. 3.5.1.

3.7.8 - 20 - Absence of interlock signal on TA board (558).

The “interlock” signal is provided by a jumper between terminals 3 and 4 of J1 on TA board

(558), and is used to make sure that the TA board (558) is connected to the control board (543) (current feedback signal line to the primary circuit of the transformer (531)).

Check the wiring between terminals 3 and 4 of J1 on TA board (558) and terminals 8 and 7 of

J1 on micro board (543).

Make sure that there is a short-circuit between terminals 3 and 4 of J1 on TA board (558). With power source off, temporarily disconnect connector J1 from micro board (543). Power up the power source again and check the supply voltage on J1 of micro board (543),

terminals 8(+) and 7(-) = +5 Vdc. If incorrect, replace control board (543).

Replace the control (543) and/or TA (558) boards.

3.7.9 - 25 - Error on the EPLD bus in the control board (543).

This code calls up various problems that may occur in controlling the igbt inverter (548).

Generally they are those defects that cause a high absorbed current in the primary circuit of the transformer (531), due for example to a short-circuit in the windings of the transformer (531) or in the diode group (567).

For an analysis of the problem, see “open circuit operation” par. 3.5.8 and “operation on

resistive load” par. 3.5.9.

3.7.10 - 30 - Incorrect setting of the minimum current threshold on control board (543).

CONTROL BOARD (543) MINIMUM CURRENT THRESHOLD SETTING.

Correct?

 Micro board (543), connector J1, terminal 3(+) and 5(-) = +360 mVdc, +/- 10 mVdc with

power source powered but not delivering current.

YES

♦ With power source off, temporarily disconnect J1 from micro board (543) and

check the resistance on terminals 3 and 5 of J1 on micro board (543) = 17 ohm. If incorrect, replace control board (543).

♦ Adjust trimmer TR1 on micro board (543) to have 360 mVdc +/- 10 mV. ♦ Replace control board (543).

♦ Regular operation.

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3.7.11 - 41 - Connector board (225) missing or disconnected.

CONNECTOR BOARD (225) CONNECTED TEST.

Correct?

 Motor control board (232), terminals 1(+) and 2(-) of OP4 = approximately +1.2 Vdc, with

power source powered.

YES

♦ Check flat cable between J3 connector board (225) and J7 of motor control board

(232).

♦ With power source off, temporarily disconnect J7 from motor control board (232)

and check the resistance on terminals 4 and 6 of J7 on motor control board (232). Correct value = junction of two diodes in both directions measured. If incorrect, replace the motor control board (232).

♦ With the power source off, temporarily disconnect J7 from the motor control

board (232) and power up the power source again. Make sure that on terminals 6(+) and 4(-) of the patch connector disconnected from J7 of motor control board (232) the voltage = approximately +12 Vdc. If incorrect replace the connector board (225).

♦ Replace motor control board (232).

3.7.12 - 42 - Error in the signal of the motor (404) encoder.

The signal provided by the encoder built into the motor (404) is used as a speed feedback

signal to adjust the motor speed. “Error 42” indicates that the signal provided by the encoder is not suited to the reference signal generated by the motor control board (232), and thus the motor (404) speed is out of control.

Perform the “wire feeder motor operation” test in par. 3.5.7.

3.7.13 - 43 - Communication error with connector board (225).

The communication error may be due to incorrect communication line supply voltages, or to

an actual failure to recognize the data exchanged between the boards.

In the latter instance, check flat cable between J3 connector board (225) and J7 of motor

control board (232), especially terminals 14 (RX signal) and 13 (TX signal), and proceed by trial and error, replacing the connector board (225) and/or the motor control board (232).

SERIAL COMMUNICATION LINE POWER SUPPLY TEST.

Correct?

 Motor control board (232), terminals 6(+) and 5(-) of OP8 = approximately +5 Vdc, with

power source powered.

YES

♦ Check flat cable between J3 connector board (225) and J7 of motor control board

(232).

♦ With power source off, temporarily disconnect the flat cable from J7 on motor

control board (232) and check the resistance on terminals 9 and 11 of J7 on motor control board (232). If a short-circuit is detected, replace the motor control (232) and connector (225) boards.

♦ With power source off, temporarily disconnect flat cable from J7 on motor control

board (232) and check resistance on terminals 12 and 14 of J7 on motor control

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board (232). Correct value = junction of one diode in one sense and 1 Kohm with the probe terminals reversed. If incorrect, replace the motor control board (232).

♦ With power source off, temporarily disconnect the flat cable from J7 on motor

control board (232) and power up the power source again. Make sure that on terminals 9(+) and 11(-) of the patch connector disconnected from J7, the voltage = approximately +5 Vdc, and on terminals 12(+) and 11(-) of the patch connector disconnected from J7, voltage = approximately +5 Vdc. If incorrect replace the connector board (225).

♦ Regular serial line power supply.

3.7.14 - 52 - “trG” on display (O). In MIG and TIG mode, start button pressed upon start-

up.

See START COMMAND TEST and START SIGNAL TEST, par. 3.5.4.

3.7.15 - 53 - “trG” on display (O). Start button pressed while resetting from stop due to

temperature outside limits.

The high temperature alarm stops the power source, lights the yellow led (G) and signals the

corresponding alarm to the overheated unit (see alarms 73 and 74) on the control panel (parr.

3.7.20 and 3.7.21). These alarms are automatically reset when the temperature returns within the allowed limits.

It may occur that the unit resets when the start command is present; therefore, to prevent the

power source from starting suddenly due to a random reset, this situation is detected and causes a power source block, with the message “trG” on display (O).

To restore proper operation, remove the start command, performing the START COMMAND

TEST and START SIGNAL TEST par. 3.5.4, if necessary.

3.7.16 - 54 - Short-circuit between torch and workpiece upon start-up.

Upon power source start-up this test checks the operating conditions by performing a brief

test to generate the open-circuit output voltage. While this is taking place it is important that the torch not touch the workpiece or welding bench.

The following conditions may be detected during this test:

− Output voltage present and output current present = error 54;

− Output voltage present and output current absent = correct operation;

− Output voltage absent and output current present = error 54;

− Output voltage absent and output current absent = error 10.

Error 54 indicates a possible short-circuit or isolation leak in the power circuit downstream of

the diode group (567) and choke (530).

Check the wiring between connector J1 of micro board (543) and current transducer (529),

and the power wiring between the “cathode” terminals of diode group (567) and the output terminal (+)(BR) of the power source, and between the transformer (531) central socket, choke (530) and output terminal (-)(BO) of the power source.

If you find defective connections, fix and replace any damaged components. Carry out the CURRENT TRANSDUCER (529) POWER SUPPLY TEST and POWER

SOURCE OUTPUT CURRENT FEEDBACK SIGNAL TEST in par. 3.5.9.

Replace the control board (543) and/or current transducer (529).

3.7.17 - 56 - Short-circuit at the output lasts too long.

It is normal to detect short-circuits at the output during welding, as long as they do not last

beyond a given interval. “Error 56” indicates that the short-circuit has exceeded this limit.

This situation may be caused by a short-circuit created between the contact tip and gas nozzle

on the MIG torch due to deposits of dirt or metal dust.

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In MMA mode it may also derive from an interruption in the output voltage detection line. In any case, in addition to cleaning the torch, check:

– wiring between connector J13 of interface board (543) and output terminals (-)(BO) and

output (+)(BR);

– power wiring between end terminals of the transformer (531), diode group (567), and output

terminal (+)(BR);

– power wiring between transformer (531) central socket, choke (530), and output terminal (-)

(BO) of the power source. If you find defective connections, fix and replace any damaged components. If necessary, perform the tests for “open circuit operation”, par. 3.5.8, and “operation on

resistive load”, par. 3.5.9.

Replace control board (543) and/or transformer (531).

3.7.18 - 57 - “Mot” on display (O). Excessive wire feeder motor (404) current.

The motor control board (232) is equipped with a supply current limiting circuit for motor

(404), to protect any overload, and a circuit that detects when the limiter is continuously tripped, indicating a permanent overload.

This overload is primarily due to mechanical causes, such as dirt in the gears of the

gearmotor, friction from a lack of lubrication, impediments in feeding the wire coil, bottlenecks in the torch sheath along the torch cable, etc.

Therefore, clean the wire feed unit and check whether the problem continues to occur if

operating without the wire feeder. If so, you may hypothesize that the motor winding or mechanical reducer built into the motor have deteriorated, and thus replace the motor (404).

If necessary, perform the “wire feeder motor operation” tests in par. 3.5.7.

3.7.19 - 61 - Mains voltage below minimum permitted.

The control board (543) checks for the “MAINS” (mains voltage presence) signal status,

coming from pre-charge board (562); if incorrect blocks the power source for error 61.

The signal can be checked on J7 of interface board (543):

− mains voltage present (MAINS) = 0,1 Vdc, approx. on terminals 4(+) and 5(-).

Check the wiring between connectors J3 on pre-charge board (562) and J7 on interface board

(543), and if necessary, perform the MAINS CONNECTION TEST in par. 3.5.1, or replace the pre-charge (562) and/or control (543) boards.

3.7.20 - 73 - “TH0” on display (O). Led (G) lit. Diode group (567) high temperature.

3.7.21 - 74 - “TH1” on display (O). Led (G) lit. Igbt group (548) high temperature.

With these alarms we recommend that you not shut off the power source, to keep the fan

running and thus cool the unit more rapidly. Normal operation is restored automatically as soon as the temperature returns within the allowed limits.

− Make sure that the fan (512) is working properly (see par. 3.5.2).

− Check for proper air flow and make sure there is no dust or obstacles to cooling in the

aeration tunnel.

− Make sure that the operating conditions meet the specification values, especially observe the

“duty cycle”.

− Check the wiring between J12 interface board (543), and thermostat (526) on the diode group

(567).

− Make sure that the thermostat (526) mounted on the diode group (567) is properly mounted

and in good working order; its contact must be closed at ambient temperature.

− Make sure that the thermostat board (551) is properly mounted on the igbt group (548); the

temperature signal transmitted to the control board (543) is PWM type, with duty cycle

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proportional to the temperature, and thus difficult to check. If necessary replace the thermostat board (551).

− Check the wiring between J1 interface board (543), and thermostat board (551) on igbt group

(548).

− Make sure that on J1 of control board (543), terminals 3(+) and 4(-) voltage = +5 Vdc. If

incorrect, with power source off, temporarily disconnect J1 on control board (543) and check the resistance between terminals 3 and 4 of the patch connector disconnected from J1. Correct value = junction of one diode in one direction and >Mohm with the probes reversed. If incorrect replace the thermostat board (551), and check the voltage on terminals 3 and 4 of J1 again without the thermostat board connection. If incorrect, also replace control board (543).

− Replace control board (543).

3.7.22 - 75 - “H2O” on display (O). Low pressure in the cooling circuit.

The pressure switch (37) measures the coolant pressure in the cooling circuit. For an analysis

of the corresponding circuit, see PRESSURE SWITCH TEST (127), par. 3.5.14.

3.7.23 - 80 - “OPn” on display (O). Wire feed unit guard open.

This alarm indicates that the safety cover of the wire feed unit is open.

− Check the wiring between J1 motor control board (232), and switch (211) on the guard of the

wire feed unit.

− Check the voltage on J1 of motor control board (232), terminals 1(+) and 2(-) = 0 Vdc, correct

condition = cover closed; +15 Vdc = alarm = cover open. If incorrect, replace switch (211) or motor control board (232).

− Make sure that the switch (211) and the unit cover are properly mounted. If incorrectly

positioned, correct; replace if defective.

− Replace motor control board (232).

3.7.24 - 99 - “OFF” on display (O). Incorrect mains voltage (machine shutdown).

This signal normally appears whenever the power source is shut off. When mains voltage is missing, for example after opening the switch (504), all control

circuits remain powered for a few seconds due to the effects of the DC-capacitor (561) discharge. The pre-charge board (562) detects the missing mains voltage, notifies the interface board (543) (signal on J7 4-5), which orders the power source to stop, and notifies the control panel (324) via CAN-BUS to signal “OFF” on display (O).

Carry out the MAINS CONNECTION TEST and POWER SUPPLY TEST, in par 3.5.1, and

replace the pre-charge board (562) if necessary.

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4 - COMPONENTS LIST

4.1 - Power source art. 287 : see file ESP287.pdf enclosed at the end of the manual.

4.2 - Table of components: see file ESP287.pdf enclosed at the end of the manual.

4.3 - List of spare parts.

Essential spare parts.

Ref. Code Description Qty.

125 3165031 electric pump 1 131 3165075 fan 1 232 5605833 motor control circuit 1 404 5750740 gearmotor 1 512 3165091 fan 1 539 5602184 flyback board 1 542 5602196 filter board 1 543 5605134 control circuit 1

Recommended spare parts.

Ref. Code Description Qty.

127 5710190 pressure switch 1 133 3065263 radiator 1 204 3060278 coil support 1 227 3160193 solenoid valve 1 525 5710514 diode kit + insulation 1 531 5610065 power transformer 1 564 5710512 pre-charge kit 1

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5 - ELECTRICAL DIAGRAMS

5.1 - Power source art. 287 : see file SCHE287.pdf enclosed at the end of the manual.

5.2 - Waveforms.

5.2.1 - Speed feedback signal from the wire feeder motor encoder (404)(par. 3.5.7).

(in MIG wire test mode, thus with button (AR) pressed, fixed speed).

5.2.2 - Open-circuit voltage on the transformer (531) secondary circuit (par. 3.5.8).

5.2.3 - Command signal for driver boards (548) (par. 3.5.8).

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5.2.4 - Output current feedback signal on resistive load (par. 3.5.9).

5.2.5 - Wire feeder motor (404) voltage during correct braking (par. 3.5.13).

5.2.6 - Wire feeder motor (404) voltage during incorrect

braking (par. 3.5.13).

5.2.7 - “PRECHARGE” signal (par. 3.7.5).

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5.3 - Filter board (542) code 5.602.196/B.

5.3.1 - Topographical drawing.

5.3.2 - Connector table.

Connector Terminals Function

- IN-L1 phase 1 mains input.

- IN-L2 phase 2 mains input.

- IN-L3 phase 3 mains input.

- OUT-L1 phase 1 mains output.

- OUT-L2 phase 2 mains output.

- OUT-L3 phase 3 mains output.

- J-L1 phase 1 mains output for service supply.

- J-L2 phase 2 mains output for service supply.

- J-L3 phase 3 mains output for service supply. J1 - earth connection.

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5.4 - Pre-charge board (562) code 5.602.187/A.

5.4.1 - Topographical drawing.

5.4.2 - Connector table.

Connector Terminals Function

- L1-L2-L3 three-phase mains input.

- VDC+1 +540 Vdc power output.

- VDC+2 +540 Vdc power output.

- VDC-1 0 Vdc power output.

- VDC-2 0 Vdc power output. J1 1(+) - 2(-) coolant liquid pressure signal input. J2 1(+) - 4(-) +25 Vdc input for pre-charge board (562) power sup pl y . J2 3(+) - 2(-) coolant liquid pressure signal output. J2 5(+) - 6(-) cooling unit enable signal input. J3 1(+) - 2(-) +25 Vdc input for pre-charge relay command. J3 3 GND. J3 4 - 5 “mains voltage presence” signal output. J3 6 GND. J3 7 - 8 “pre-charge enable” signal output. J4 1 - 6 400 Vac output for autotransformer (540) supply. J4 3 230 Vac input from autotransformer (540). J4 2 - 4 230 Vac output for cooling unit power supply. J5 A - B 400 Vac input for service supply. J6 1(+) - 4(-) +540 Vdc output for flyback board (539) power sup ply . J6 3 flyback board (539) control power supply output.

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5.5 - Flyback board (539) code 5.602.184/E.

5.5.1 - Topographical drawing.

5.5.2 - Connector table.

Connector Terminals Function

J1 - NU. J2 - NU. J3 1-2(+) - 4-5(-) +55 Vdc output for motor control board (232) power supply. J3 3 NU. J4 - NU. J5 1(+) - 4(-) +540 Vdc input for flyback board (539) power supply. J5 3 flyback board (539) control power supply input. J6 1(+) - 2(-) +25 Vdc output for pre-charge board (562) power supply. J7 - NU. J8 1 - 2 25 Vac output for interface board (543) power supply. J9 - NU. J10 2(+) - 1(-) +8 Vdc output to micro board (543) power supply. J10 4(+) - 3(-) +15 Vdc output to micro board (543) power supply.

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5.6 - Interface board (543) code 5.602.186.

5.6.1 - Topographical drawing.

5.6.2 - Connector table.

Connector Terminals Function

J1 3(+) - 4(-) +5 Vdc output for thermostat board (551) po wer sup ply . J1 1 igbt group (548) temperature signal input. J2 1(GL1) - 2(EL1) igbt L1 drive signal output. J2 3 NU. J2 4(EH1) - 5(GH1) igbt H1 drive signal output. J3 1(GL2) - 2(EL2) igbt L2 drive signal output. J3 3 NU. J3 4(EH2) - 5(GH2) igbt H2 drive signal output. J4 1(+) - 2(-) +24 Vdc output for fan (512). J5 1 - 4 NU. J5 3(+) - 2(-) cooling liquid pressure signal input. J5 5(+) - 6(-) cooling unit enable signal output. J6 1 - 2 25 Vac inp ut for thermostat board (551) circuits power supply. J7 1(+) - 2(-) +25 Vdc output for pre-charge relay command. J7 3 GND. J7 4 - 5 “mains voltage presen ce” signal input. J7 6 GND. J7 7 - 8 “pre-charge enable” signal input. J8 - NU. J9 1(+) - 2(-) +8 Vdc input for CAN-BUS-0 on interface board (543) power supply. J9 3 - 4 CAN-BUS-0 communication line. J10 - signals bus with micro board (543). J11 - signals bus with micro board (543). J12 2(+) - 1(-) NU. (hardware key) . J12 3 - 4 NU. J12 6(+) - 5(-) thermostat on dio de gr o up (5 67 ) i nput . J13 1(+) - 2(-) power source output voltage input. J14 - NU.

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5.7 - Micro board (543) code 5.602.185/C.

5.7.1 - Topographical drawing.

5.7.2 - Connector table.

Connector Terminals Function

J1 1 -15 Vdc output for current transducer (529) power supply. J1 2 NU. J1 3 power source output current input. J1 4 +15 Vd c output for current transducer (529) power supply. J1 5 GND. J1 6 transformer (531) primary circuit current signal input. J1 7 “interlock” signal input. J1 8 +5 Vdc output for “interlock” signal. J2 - NU. J3 2(+) - 1(-) +8 Vdc input for micro board (543) power supply. J3 4(+) - 3(-) +15 Vdc input for micro board (543) power supply. J4 - NU. J5 - NU. J6 - NU. J7 - NU. J8 - NU. J9 - RS232 serial communication for system programming. J10 - signals bus with interface board (543). J11 - signals bus with interface board (543). J12 - NU.

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5.8 - Igbt-driver board (548) code 5.602.188.

5.8.1 - Topographical drawing.

5.8.2 - Connector table.

Connector Terminals Function

- H+ - H- drive signal input for igbt H (H1 or H2).

- L+ - L- drive signal input for igbt L (L1 or L2).

- GH - EH command output for igbt H (H1 or H2).

- GL - EL command output for igbt L (L1 or L2).

5.9 - TA board (558) code 5.602.123.

5.9.1 - Topographical drawing.

5.9.2 - Connector table.

Connector Terminals Function

J1 2(+) - 1(-) transformer (531) primary circuit current signal output. J1 3 - 4 “interlock” signal output.

5.10 - Thermostat board (551) code 5.602.137.

5.10.1 - Topographical drawing.

5.10.2 - Connector table.

Connector Terminals Function

- TP1 0 Vd c input for thermostat board (551) power supply.

- TP2 +5 Vd c input for thermostat board (551) power supply.

- TP3 igbt group (548) temperature signal output.

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5.11 - Motor control board (232) code 5.602.103/B.

5.11.1 - Topographical drawing.

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5.11.2 - Connector table.

Connector Terminals Function

J1 1 - 2 wire feed unit door open signal input. J2 - NU. J3 1 - 2 CAN-BUS communication line, with control panel. J3 3(+) - 4(-) +5 Vdc for CAN-BUS with control panel power sup pl y . J4 - NU. J5 - NU. J6 - NU. J7 1(+) - 3(-) ARC-ON signal output. J7 2 NU. J7 6(+) - 4(-) torch recognition signal input. J7 5 NU. J7 7 NU. J7 8(+) - 10(-) start signal input. J7 9(+) - 11(-) +5 Vdc for serial communication line (TX) power supply. J7 12(+) - 14(-) RX signal input, serial communication line. J7 13 TX signal output, serial communication line. J8 - NU. J9 - NU. J10 - NU. J11 1(+) - 2(-) +8 Vdc output for CAN-BUS-0 on interface board (543) power supply. J11 3 - 4 CAN-BUS-0 communication line. J12 1(+) - 2(-) +8 Vdc output for control pa n el (32 4) power supply. J13 1(+) - 2(-) +27 Vdc output, for sole noid valve (227) command. J14 - NU. J15 1 - 2 connector board (225) power supply output. J16 - NU. J17 1(+) - 4(-) +5 Vdc output for wire feeder m otor (404 ) encoder power supply. J17 2 A signal input from wire feeder motor (404) encoder. J17 3 NU. (B signal input from wire feeder motor (404) encoder). J18 1(+) - 6(-) +55 Vdc input for motor control board (232) power supply. J18 2 - 5 NU. J18 3 - 4 NU. J19 A - B output for wire feeder motor (404). J20 1 - 2 NU. (+55 Vdc output, motor control board (232) power s u p ply ). J22 - NU.

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5.12 - Connector board (225) code 5.602.104/B.

5.12.1 - Topographical drawing.

5.12.2 - Connector table.

Connector Terminals Function

J1 1 - 2 connector board (225) power supply input. J2 - NU. J3 1(+) - 3(-) ARC-ON signal input. J3 2 NU. J3 6(+) - 4(-) torch recognition signal output. J3 5 NU. J3 7 NU. J3 8(+) - 10(-) start signal output. J3 9(+) - 11(-) +5 Vdc for (TX) serial communication line power supply. J3 12(+) - 14(-) RX signal output, serial communication line. J3 13 TX signal input, serial communication line. J4 A - B start command input from external button on the torch. J5 1(+) - 9(-) start command input from remote control connector (BB). J5 2 “DOWN-VOLT” signal input. J5 3 “DOWN-MOTOR” signal input. J5 4 - 5 “ARC-ON” signal output (relay contact voltage free). J5 6 “UP-MOTOR” signal input. J5 7 current reference signal input from external potentiometer cursor. J5 8 NU. J5 10 “UP-VOLT” signal input. J5 11 +5 Vdc external current poten tiometer power supply. J5 12(+) - 16(-) analog recognition torch signal input. J5 13 NU. J5 14 NU. (+12 Vdc external communication line power supply). J5 15 0 Vdc, shared for external potentiometer, UP/DOWN buttons and external

communication line. J5 17 NU. J5 18 NU. (TX signal output for external communication line). J5 19 NU. (RX signal input for external communicatio n line). J6 - NU. J7 - earth connection.

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5.13 - Control panel (324) cod. 5.602.110/C.

5.13.1 - Disegno topografico.

5.13.2 - Connector table.

Connector Terminals Function

J1 1(+) - 2(-) +8 Vdc input for control panel (324) powe r s up pl y . J2 - signals bus between panel board and micro board inside control panel (324). J3 - GND. J4 - NU. (RS232 serial communication line). J5 1 - 2 CAN-BUS communication line, with motor control board (232). J5 3(+) - 4(-) +5 Vdc power supply for CAN-BUS with motor control (232) board.

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Cebora SOUND MIG 3840/T Pulse Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual