Pegasus 200 ACDC PULSE Service Manual

MG125-4 PEGAS 200 AC-DC PULSE SERVICE MANUAL page 1

ALFA IN a. s. © 2012 SERVISNÍ TECHNICKÁ DOKUMENTACE

SERVISNÍ MANUÁL PEGAS 200 AC­DC PULSE

SERVICE MANUAL PEGAS 200 AC­DC PULSE

1. VAROVÁNÍ WARNING
UPOZORNĚNÍ – Pouze osoba splňující

kvalifikaci danou zákonem je oprávněna
opravovat stroj.

PŘED OTEVŘENÍM KRYTU STROJE JEJ
ODPOJTE VYTAŽENÍM SÍŤOVÉ VIDLICE ZE
SÍTĚ.

Každé 4 měsíce otevřete stroj a jemně ho
vyfoukejte stlačeným suchým vzduchem
POZOR, NEPOUŽÍVEJTE STLAČENÝ
VZDUCH O PŘÍLIŠ VYSOKÉM TLAKU, ABY
NEDOŠLO K MECHANICKÉMU POŠKOZENÍ
ELEKTROSOUČÁSTEK.

Každé 4 měsíce zkontrolujte řádný stav
svařovacích kabelů a síťových kabelů.

Není povolena žádná modifikace
svařovacího stroje.

Pro Vaši bezpečnost je nutné posečkat se
sundáním krytu ze stroje po odpojení ze sítě
po dobu minimálně 5 minut, kdy klesne
napětí na kondenzátorech na hodnotu pod
36 V.

NOTE Only trained personnel are
permitted to work inside the machine.

BEFORE OPENING THE MACHINE, CUT
OFF ITS ELECTRICAL POWER BY
REMOVING THE PLUG FROM THE MAINS
SUPPLY SOCKET.

Every six months, open the machine and
clean it inside, using compressed
dehumidified air.
CAUTION. DO NOT USE COMPRESSED
AIR AT TOO HIGH A PRESSURE. YOU
COULD DAMAGE THE ELECTRONIC
COMPONENTS.

With the same frequency, check the
welding cables and the supply cables.

No modification, of any type, may be
made to the welding machine.

For safety while maintaining the machine,
please shut off the supply power and wait
for 5 minutes, until capacity voltage
already drops to safe voltage 36V.

2. BLOKOVÉ SCHÉMA ELECTRICAL PRINCIPLE DRAWING

MG125-4 PEGAS 200 AC-DC PULSE SERVICE MANUAL page 2

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MG125-4 PEGAS 200 AC-DC PULSE SERVICE MANUAL page 3

ALFA IN a. s. © 2012 SERVISNÍ TECHNICKÁ DOKUMENTACE

3. NÁHRADNÍ DÍLY SPARE PARTS

Pos
.

Item No Popis Description

Quantit

y

1

8.253.020

Držák - madlo P250 Handle P250

1

2

8.301.099

Kryt horní P250

Upper Cover P250

1

3

8.062.543

PCB Installation Panel P200AC­DC

PCB Installation Panel
P200AC-DC

1

4

7.202.123

Pojistka 3A

Fuse 3A

1

5

7.202.029

Držák pojistek P200AC-DC Fuse Holder P200AC-DC

1

6

5.496.931

PCB EMC P200AC-DC

PCB EMC P200AC-DC

1

7

5.496.526-B

Spínaný zdroj PCB P200AC-DC

SWITCH POWER PCB P200AC­DC

1

8

5.496.875-E

PCB měření napětí

Voltage test PCB P200AC-DC

1

9

5.496.415-E

PCB řídící P200P AC-DC

Control PCB P200P AC-DC

1

10

5.496.373-C

PCB HF P200AC-DC PCB HF P200AC-DC

1

11

6.185.515

Hlavní transformátor P200AC­DC

Main transformer P200AC-DC

1

12

6.271.515

Tlumivka P200AC-DC Choke P200AC-DC

1

MG125-4 PEGAS 200 AC-DC PULSE SERVICE MANUAL page 4

ALFA IN a. s. © 2012 SERVISNÍ TECHNICKÁ DOKUMENTACE

13

5.496.204-B

HF filtr PCB P200P AC-DC

HF filter PCB P200P AC-DC

1

14

6.174.515

Trafo HF P200AC-DC

Transformer HF P200AC-DC

1

15

7.321.002

Sonda Hall 200A Pegas Hall sensor 200A Pegas

1

16

8.055.543

Kryt spodní P200AC-DC

Bottom Plate P200AC-DC

1

17

8.050.099

Kryt boční P250 Side Cover P250

2

18

5.496.416-B

PCB přední P200P AC-DC Front PCB P200P AC-DC

1

19

8.068.099

Panel přední/zadní plast P250

Plastic Front/Rear Panel P250

1

20

8.306.441

Panel přední kov P200P AC­DC+fólie

Metal Front Panel P200P AC­DC+folie

1

21

7.458.053

Knoflík Pegas černý P200P Knob Pegas black P200P

1

22

8.065.570

Panel přední kov spodní
P200AC-DC

Metal Front Panel For Output
P200AC-DC

1

23

7.152.312

Rychlosp. 35-70mm P250 35-70mm Socket P250

2

24

7.132.114

Konektor zásuvka P250

14-Pin Socket P250

1

25

8.462.104

Konektor plyn Pegas P200AC­DC

Gas Connector Pegas P200AC­DC

1

26

8.307.634

Panel zadní kov P200AC-DC

Metal Rear Panel For Output
P200AC-DC

1

27

7.232.022

Vypínač Pegas P200AC-DC Switch On/OFF Pegas P200AC-

DC

1

28+

29

7.155.001

Průchodka P250

Cable Connector P250

1

30

8.122.366

Panel pro ventilátor P200AC­DC

Metal Panel For Fan P200AC­DC

1

31

7.253.013

Ventil Pegas Solenoid Valve Pegas

1

32

7.720.030

Ventilátor P250 Fan P250

1

A-1

8.425.502

Chladič 3 P200AC-DC Heat Sink 3 P200AC-DC

1

A-2

8.746.030

Box chladiče 2 P200AC-DC Heat Sink Box 2 P200AC-DC

1

A-3

8.425.503

Chladič 4 P200AC-DC Heat Sink 4 P200AC-DC

1

A-4

7.445.311

Rezistor 6ohm P200AC-DC

Rezistor 6ohm P200AC-DC

2

A-5

7.231.275

Termostat PEGAS Thermo switch

2

A-6

7.425.631

Tranzistor IGBT Discrete1 P40 Discrete1 IGBT P40

8

A-6

7.425.631

Tranzistor IGBT Discrete1 P40 Discrete1 IGBT P40

4

A-7

7.421.681

Dioda P200AC-DC

Diode P200AC-DC

2

A-8

5.496.674-C

PCB silová P200AC-DC

PCB Power P200AC-DC

1

A-9

8.306.301

Krycí deska 1 P200AC-DC

Blanking plate 1 P200AC-DC

1

B-1

8.425.500

Chladič 2 P200AC-DC Heat Sink 2 P200AC-DC

1

B-2

8.425.501

Chladič 1 P200AC-DC Heat Sink 1 P200AC-DC

1

B-3

8.746.029-D

Box chladiče 1 P200AC-DC Heat Sink Box 1 P200AC-DC

1

B-4

7.411.010

Usměrňovač PEGAS 160 E Rectifier Bridge

2

B-5

5.496.527-B

Vstupní usměrňovač PCB
P200AC-DC

Input rectifier PCB P200AC-DC

1

MG125-4 PEGAS 200 AC-DC PULSE SERVICE MANUAL page 5

ALFA IN a. s. © 2012 SERVISNÍ TECHNICKÁ DOKUMENTACE

B-6

7.460.801

Kondenzátor kapacitní P200P
AC-DC

Capacitor P200P AC-DC

6

B-7

8.052.500

Krycí deska 2 P200AC-DC

Blanking plate 2 P200AC-DC

1

4.

TROUBLESHOOTING

S/N

Troubles Reasons Solutions

The power light
damaged or connection
is not good

Check and repair Pr7

The transformer of
power is broken

Repair or change the transformer

1

Turn on the power source, and fan works,

but the power pilot lamp is not on.

Control PCB failures Repair or change the control Pr4
There is something in

the fan

Clear out

The start capacitor of
fan damaged

Change capacitor

2

Turn on the power source, and the power
pilot lamp is on, but fan doesn’t work

The fan motor
damaged

Change fan

No power supply input

Check whether there is power
supply

3

Turn on the power source, the power pilot
lamp is not on, and fan doesn’t work

The fuse inside the
machine damaged

Change it (3A)

4 The number on the display is not intact.

The LED in the display
is broken

Change the LED

The max value is not
accordant (refer to

§3.1)

Adjust potentiometer Imin on the
power board.

5

The max and min value displayed doesn’t

accord with the set value.

The min value is not
accordant (refer to

§3.1)

Adjust potentiometer Imaxin the
current meter.

6 No no-load voltage output (MMA)

The machine is

damaged

Check the main circuit and the Pr4.

The welding cable is

not connected with the
two output of the
welder.

Connect the welding cable to the
welder’s output.

The welding cable

damaged.

Repair or change it.

The earth cable

connected unstably.

Check the earth cable.

The welding cable is

too long.

Use an appropriate welding cable.

There is oil or dust on

the workpiece.

Check and remove it.

There is spark on the HF
igniting board.

The distance between

tungsten electrode
and workpiece is too
long.

Reduce the distance (about 3mm).

The HF igniting board

does not work.

Repair or change Pr8

The distance between

the discharger is too
short.

Adjust this distance (about 0.7mm).

7

Arc can
not be
ignited
(TIG)

There is not spark on the HF
igniting board.

The malfunction of the
welding gun switch.

Check the welding gun switch,
control cable and aero socket.

MG125-4 PEGAS 200 AC-DC PULSE SERVICE MANUAL page 6

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Gas cylinder is close or
gas pressure is low

Open or change the gas cylinder

Something in the valve Remove it

8 No gas flow (TIG)

Electromagnetic valve
is damaged

Change it

The gas-test on the
front panel is on

The gas-test on the front panel is off

Something in the valve Remove it
Electromagnetic valve
is damaged

Change it 9

Gas always flows

The adjustment knob of
pre-gas time on the
front panel is damaged

Repair or change it

10 The welding current can not be adjusted

The welding current
potentiometer on the
front panel connection
is not good or damaged

Repair or change the potentiometer

The power PCB is in
trouble.

Repair or change it.

The AC drive PCB
damaged.

Change it.

11 No AC output while selecting “AC”

The AC IGBT module
damaged.

Change it.

The min value
displayed isn’t
accordant with the
actual value. (Please

refer to §3.1)

Adjust potentiometer Imin on the
power board.

12

The welding current displayed isn’t
accordant with the actual value.

The max value
displayed isn’t
accordant with the
actual value. (Please

refer to §3.1)

Adjust potentiometer Imax on the
power board.

The welding current is
adjusted too low

Increase the welding current

13

The penetration of molten pool is not
enough.

The arc is too long in
the welding process

Use 2T operation

Two much
welding
current

Reduce the welding current output

Over
heat
protecti
on

Working time
too long

Reduce the duty cycle (work

intermittently)
Over­voltage
protecti
on

Power
supply
fluctuates

Using the stable power supply

Power
supply
fluctuates

Using the stable power supply
Low­voltage
protecti
on

Too many
machines
using power
supply in the
same time

Reduce the machines using power

supply in the same time

14 The alarm light on the front panel is on

Over­current
protecti
on

Unusual
current in the
main circuit

Check and repair the main circuit

and drive Pr6

MG125-4 PEGAS 200 AC-DC PULSE SERVICE MANUAL page 7

ALFA IN a. s. © 2012 SERVISNÍ TECHNICKÁ DOKUMENTACE

5. Konektor Connector

5.0189 Sada konektorů pro PEGAS AC/DC AERO

5.0189 Set of Connectors for PEGAS AC/DC AERO

Image

Kód

CZ

EN Quantity

5.0181 PIN pro konektor PEGAS DOV Male AERO plug Male PIN 2

5.0179 Konektor PEGAS AERO čelo AERO Plug PEGAS part#1 1

5.0180 Konektor PEGAS AERO kryt AERO plug PEGAS part 2 1

5.0182 Připojení plynu PEGAS AC/DC
matice převlečná

Gas fitting part 1 PEGAS AC/DC 1

5.0183 Připojení plynu PEGAS AC/DC
koncovka

Gas fitting part 2 PEGAS AC/DC 1

5.0184 Připojení plynu#PEGAS AC/DC
matice zajišťovací

Gas fitting part 3 PEGAS AC/DC 1

Sada 5.0198 obsahuje pouze dva piny. Pro
zapojení různých druhů dálkového ovládání
budete potřebovat více pinů. Viz schémata
níže.

The set 5.0198 content two pieces of PINs. In
order to connect different kinds of remote
controls you will need order more PINs. See
the schemas below.

6. Hořák Torch

7. Hořák s potenciometrem ­nepodporováno

Torch with potentiometer – not supported

MG125-4 PEGAS 200 AC-DC PULSE SERVICE MANUAL page 8

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8. Dálkové ovládání + hořák Remote Control + torch

9. Nožní dálkové ovládání-pedál Remote foot control

10. Hořák s UD & DOWN Torch with UD & DOWN

11. Zapojení plynového konektoru Gas connector

MG125-4 PEGAS 200 AC-DC PULSE SERVICE MANUAL page 9

ALFA IN a. s. © 2012 SERVISNÍ TECHNICKÁ DOKUMENTACE

1. Na plynovou hadici nasaďte dílec C

2. Sešroubujte dílec A a B

3. Nasaďte trn z dílce A do hadice

4. Pevně utáhněte dílec B, tak, že vznikne
mezera mezi osazením dílce A a dílcem
B. Tím se zajistí hadice (viz obr. Níže).

1. Fit C onto the hose

2. Screw A and B together

3. Fit the nipple of A into the hose

4. Firmly tighten B in the way that between
A and B appears a gap. That way you
fix the hose (see the image below)

Worked out: DJ 4/11/2011 Revision: Vh 4/7/2012 Approved: vh 4/7/2012