MERKLE PU 520 DW Service Instructions Manual

Service-Instructions PU 520 DW
with pcb RPM-control ME-2QR-24/42-2.1
02.07.2003
1) Clean the machine and watch out for external damages (painting, front panel).
2) Visual check:
Cabels, connectors and screw contacts: check well placed cables and save fixings; Cables for voltage measuring – the minuspole of the choke must be mounted in the direction of the bush mass cable; cover at the main switch; Check if the fixing feet of the pcbs are screwed tight;
Check if the pcb MTC-1.2 is screwed with metal supports M3 and on its top fixed with springs; Check if the 10-pol. flat cable between pcb ME-MTC-1.2 and ME-2QR-24/42-2.1 goes under pcb ME-MTC-1.2; Pcb ME-I-SD-1.1: check bridge at connector X5/1-10 ;
Clean the unit, check the contacts of the pcbs (free of vernis) Check serial number, sticker with date on the pcbs;
Disconnect
all pcb connectors (except flat cables) !
PAL MTC 2 on pcb ME-MTC-1.2 E-Prom: MTC 1.82 / 29.06.1999 // PU 500 1.73 / 26.04.2000
Check the jumpers: Pcb ME-I-SD-1.1:
X4/6-8 placed JP1 placed JP2 MAG JP3 placed JP4 intern JP5 placed Bridges closed and brazed
Pcb: ME-MTC/M-2.0: ME-PPMR-2.1: JP1 PU 500 JP1 placed
P2 opened JP2(<3m) placed
Pcb ME-2QR-24/42-2.1) Jumper (DV25 and DV30) set acc. wiring diagram
At the pcb 2QR-24/42 in connection with the DV30 a capacitor 0,1 uF,1000V between clamps 5 and 6 must be parallely mounted to avoid interferences with the tacho;
Check the polarity of the connection to rectifier, cascade, capacitors. Have a look at the distance of the cable shoes between steel plates and main transformer/cascade;
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Check the direction of the current cable before you introduce it into the current transformer LEM
Check tight connection of the primary at the main transformer; Check capacitors at the plus- and minus-bush: 0,1 uF/1000V plus-bush Ö minus-bush 0,1 uF/1000V plus-bush Ö housing, 0,1 uF/1000V minus-bush Ö housing,
Fan must turn freely;
3) Measurings of the voltages:
Switch ON machine; F1 – F2 (0-400V at control transformer) 400 V AC
Pcb RPM control ME-2QR24/42-2.1: A6 – X1/3, X1/4 42 V AC
Pcb ME-I-SD-1.1: A1 - X6/1, X6/2 18 V AC A1 - X6/5, X6/6 18 V AC A1 - X6/3, X6/4 9 V AC A1 - X5/1, X5/2 9 V AC A1 - X8/11, X8/12 42 V AC A1 - X9/1, X9/2 230 V AC
Pcb ME-I-SD/K-1.1: A2 - X3a/1, X3a/2 18 V AC
Pcb ME-MTC-1.2: A3 - X1/1, X1/2 9 V AC A3 - X1/3, X1/4 18 V AC
Pcb ME-PPMR-2.1: A7 - X2/5, X2/6 42 V AC
Main rectifier: Entrance 3 x 56 V AC Exit app. 78 V DC Entrance cascade app. 78 V DC
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Pcb ME-I-SD-1.1: Measure NTC resistors between A1 - X5/3, X5/4 app. 75...125 kOhm A1 - X5/5, X5/6 app. 30... 75 kOhm
Switch OFF unit
4) Connect the wire feeder and clean it
Have a look at the distance between front plate and plus cable; Connect supply and mass cable; Disconnect coupling of waterflow = deaeration of the water pump; fill the cooling liquid into the cooling system;
Connect the TEDAC-torch;
5) Plug in connectors to the pcbs;
Switch ON unit
Check the direction of the waterflow;
Check fan: Fan is turning with a reduced speed; Bridge on pcb ME-I-SD-1.1 A1-X5/3-4: fan is turning with max. speed Bridge on pcb ME-I-SD-1.1 A1-X5/5-6: fan is turning with max. speed;
The following LEDs are enlighted:
At pcb ME-I-SD-1.1
After main switch on
green +5V – supply voltage
green +15V – supply voltage
green -15V – supply voltage
green +15VP – control voltage (FET-control-transistor cascade)
LED after torch trigger pressed or mode electrode:
red - Start (torch trigger pressed or mode electrode)
green – PWM ON control (20 KHz-pulse modulation)
yellow - relais GAS – gasvalve on
green – relais Lüfter – fan (Inverter) running
green – relais waterpump / fan (torchcooling) running
LED after arc on
red -I>0 (when the arc is on)
red - relais I>0 Rel. potential free contact is switched
Gas Rel. (torch trigger pressed) Fan Rel.(when the arc is on) Waterpump Rel. (when the arc is on Ö cuts after app. 5min.)
LED when failure
red - Stoer. =General failure-LED ON in connection with:
red - Uebert (OVERHEATING) – unit is dirty or the duty cycle has been passed, or
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