Language: English

CITIG 1500 DC Date creation: Mar 2008

Rev.: 00

Service Manual

CITIG 1500 DC

Designed by Mario Jurik

 CITIG 1500 DC

1.0 REPAIR INSTRUCTIONS correct value of the power resistance (fig. 2)

1.1 GENERAL CLEANING

Remove the machine shell and clean care- V1
fully with compressed air.
R4
R3
1.2 MACHINE: VISUAL INSPECTION
R5
1. On the electronic circuit ref. 3 check the vari-
stor (fig. 1), if it presents bursting marks, FIG. 2
replace the electronic circuit
2. Electronic circuit ref. 32: check for the pre-
sence of short circuits on the mosfet of fig. 3
between points G-S, G-D, D-S; in case of
fault replace the electronic circuit.

R1

FIG. 1

2. Check on the electronic circuit ref. 1:

• the state of the levelling capacitors CE1,
FIG. 3
CE2, CE3 and CE4.
If there are swellings or breaks on the contai- 3. Electronic circuit ref. 1: check:
ner, replace the electronic circuit • IGBT of the primary circuit and diodes of
• check for the presence of cracks or breaks recycle: test points G-C, G-E, C-E of compo-
on the welds of the following components: nents 1 and 2; points A-K of components 3
and 4 (fig. 3); if there are short circuits in any
• transformer T2 of these components the board is broken.
• impedance L1
3. Check for the presence of burned tracks or 1
electric discharge marks on the electronic cir- 3
cuit in the generator.
4. Check on all the harnesses the insulation of
the cables and the state at the connection
4
points. Always grease the thermostatic probe
after replacement of the corresponding har- 2
ness (grease with a basis of silicone).
FIG. 4

1.3 CHECK OF THE MAIN COMPONENTS • Diodes of the secondary circuit: check
WITH TESTER (OHMMETER) points A-B of diode 1 and points C-D of
1. Electronic circuit ref. 3: check the presence of diode 2 (fig. 5): if at least one shows short
short circuits on the rectifier bridge and the circuits the board is broken.

1102 Pag. 3
 CITIG 1500 DC

• If the waveform or the voltages differ from

the figure or no waveform or voltage are
A
present, the IGBT are fault.
B 1
C 2
D

FIG. 5 FIG. 9

• Prefeeding resistances R1 and R2: verify
for each resistance the value 3K3 with the
levelling condensers discharged; if there
are other readings the resistances are bro-
ken.
• Disconnect the feeder; set the oscillo-
scope with a range of 1V/DIV and connect
the probe X100 between points XT2-
3(GND) and XT2-1(probe) (fig. 10), con-
nect the machine to the power supply,
switch it on:

1.4 CHECK OF GENERATOR WORKING IN

MMA WITH OSCILLOSCOPE AND VOLT-
METER
1. Set the generator in MMA, short-circuit points
A and XT1-5 (fig. 6), connect a feeder on the 3
points XT1-1 and XT1-5 and supply with 1
approx. 15Vdc, set the oscilloscope on a time
base of 5 uS and a range of 0.5 V/DIV with
probe x10 and verify:

FIG. 10

• after approx. 2 seconds a wave will appear

as in fig. 11

1
5

A
FIG. 6

• The presence between points: XT2-

8(GND) - XT2-7(probe) and XT2-3(GND) -
XT2-4(probe) (fig. 8) of the wave form
shown in fig. 9: FIG. 11

• check with a voltmeter that the output vol-

tage is approx. 55V (see test specification
point 2).
• If the waveform does not appear or the
8 output voltage is not correct, verify, the pre-
7 sence of approx. 300Vdc between points U
4 (GND) and T (POS) of fig. 12; with this rea-
3

FIG. 8

1102 Pag. 5
 CITIG 1500 DCCITIG 1500 DC

ding, the electronic circuit ref. 1 is correctly • if the voltages are not regular replace the
fed but it does not work. electronic circuit ref. 48; if the fault is still
P there replace the electronic circuit fig. 20
M
2. Short-circuit points G - F of the remote outlet
ref. 51 and check for:
• the presence of a high frequency hum for
approx. 2 seconds; if there is no hum, there
is no command from the board ref. 32
• the presence of 24Vdc on the solenoid
valve ref. 46; if this is not present, replace
the electronic circuit ref. 20; if the fault is still
FIG. 12
there replace the electronic circuit ref. 32
3. In case of malfunction of the tig functions
1.5 CHECK OF GENERATOR WORKING IN TIG (slope down spot, pre-and post gas) replace
the electronic circuit ref. 48
1. Set the generator to tig mode, switch it on and
verify: Carry out the final test after the repair.
• on the electronic circuit ref. 20 check the
voltage on the following points:
2.0 FINAL TEST
• between XF3 and X F2 a voltage of 230
Vac (fig. 13) 1. Carry out the safety test according to our ope-
rative instruction N. SLL12, before procee-
ding, act as follows:

XF2 • disconnect the fan faston, the ground cable

and the clamp screw of the electronic board
XF3 turret ref. 3
• insert an insulating thickness to avoid
discharges or short circuits between the
electronic board (ref. 3) and her supporting
turrets
• on the electronic board (ref. 1) short-circuit
FIG. 13 points U, T and a rheophore of the primary
circuit of the transformer (fig. 15)
• on the connector x4 between points 1
(POS) and 2 (GND) (fig. 14) measure a U
voltage of approx. + 15Vdc T

3
2 RHEOPHORE
THE PRIMARY
1 CIRCUIT

FIG. 15
FIG. 14
• switch on
• on the connector X4 between points 2
(GND) and 3 (POS.) (fig. 14) measure a • short-circuit the feeder plug
voltage of approx. - 1,2Vdc • short-circuit the output dinse.

1102 Pag. 7
 CITIG 1500 DC

• After the test remove all the short circuits
and restore the connections.
2. Connect the generator to the power supply
(230 Vac), set it in MMA and check if the vol-
tage of the outputs is 55 Vdc (+/- 5%): switch
off the generator.
3. Connect the generator to the resistive load:
the load must be regulated so that the voltage
o n th e l o a d , w it h ma x i mu m c u r r e n t , is
between 20V and 25V. Apply oscilloscope
probe as in fig. 8
4. Set the regulation knob to the centre of the
dial, switch on the generator, turn the knob to
the maximum welding current and read with
the amperometer the maximum current indi-
cated on the technical table with +/- 5% tole-
rance. See on the oscilloscope a waveform as
in fig. 16
8. Disconnect the probe, switch off the genera-
tor and with the load to the maximum current,
let the machine work at the greatest capacity
till the thermostatic protection intervenes (the
thermostatic protection led turns on).
9. Wait until the machine starts working again
(the thermostatic protection led turns off) and
disconnect the machine from the resistive
load.
10.Carry out MMA welding tests at the maximum
current (one electrode).
11. Carry out welding tests in tig either in 2 stro-
kes or in 4 strokes and check the following
functions:
• SLOPE DOWN
• SPOT
• PRE-GAS
• POST-GAS

FIG. 16

5. If the current readings differ, adjust the trim-

mer T (fig. 17) till the correct current value is
obtained

T
FIG. 17

6. Short-circuit the load and check that after 1,5

sec. the current descends to approx. 34A
(model 90A) or to approx. 40A (model 150A).
7. Regulate the resistive load to measure the
minimum current (8A - 20A), set the minimum
current on the frontal panel and check that the
amperometer shows a value lower than the
one indicated on the technical table.Discon-
nect the probe, switch off the generator and
with the load to the maximum current, let the

1102 Pag. 9
 SPARE PARTS LIST - PIÈCES DÉTACHÉES - LISTA DE LAS PIEZAS DE RECAMBIO - ERSATZTEILLISTE
EÇAS SOBRESSELENTES - RESERVDELAR - WISSELSTUKKEN - LISTA PIESE COMPONENTE
LISTA CZĘŚCI ZAMIENNYCH - ∫∞∆∞§√°√™ ∞¡∆∞§§∞∫∆π∫ø¡ - ПЕРЕЧЕНЬ ЗАПАСНЫХ ЧАСТЕЙ

38 42

13.1
13

11
56

12 51

52
57

36

48
10

15
20

01
25

03
32

14 46

33 09

08

I
 SPARE PARTS LIST - PIÈCES DÉTACHÉES - LISTA DE LAS PIEZAS DE RECAMBIO - ERSATZTEILLISTE
EÇAS SOBRESSELENTES - RESERVDELAR - WISSELSTUKKEN - LISTA PIESE COMPONENTE
LISTA CZĘŚCI ZAMIENNYCH - ∫∞∆∞§√°√™ ∞¡∆∞§§∞∫∆π∫ø¡ - ПЕРЕЧЕНЬ ЗАПАСНЫХ ЧАСТЕЙ

R. CODE DESCRIPTION DESCRIPTION DESCRIPCIÓN BESCHREIBUNG

01 W000050170 CIRCUIT BOARD HF 344/TH CIRCUIT ÉLECTRONIQUE HF 344/TH CIRCUITO ELECTRÓNICO HF 344/TH ELEKTRONISCHE SCHALTUNG HF 344/TH
03 W000232541 CIRCUIT BOARD HF 343C CIRCUIT ÉLECTRONIQUE HF 343C CIRCUITO ELECTRÓNICO HF 343C ELEKTRONISCHE SCHALTUNG HF 343C
08 W000236149 POWER CABLE CÂBLE ALIMENTATION CABLE DE ALIMENTACIÓN SPEISEKABEL
09 W000227612 CABLE CLAMP SERRE-FIL PRENSACABLE KABLEKLEMME
09.1 W000227620 KNOB D.49 ECRU SERRE-CÂBLE D.49 PERILLA D.49 DREHKNOPF
10 W000233525 SECURING BLOCK BLOC DE FIXATION BLOQUEO DE FIJACIÓN BEFESTIGUNGSBLOCK
11 W000070027 SWITCH INTERRUPTEUR INTERRUPTOR SCHALTER
12 W000231163 OUTLET CONNECTOR RACCORD SORTIE RACOR DE SALIDA AUSGANGSANSCHLUSS
13 W000070032 KNOB BOUTON PERILLA DREHKNOPF
13.1 W000228005 HOOD CAPUCHON CAPUCHÓN KAPPE
14 W000050067 FAN UNIT MOTOVENTILATEUR MOTOR DEL VENTILADOR MOTORVENTILATOR
15 W000050193 BRACKET FOR DINSE ÉQUERRE ESCUADRA WINKEL
20 W000050187 CIRCUIT BOARD TV 316 CIRCUIT ÉLECTRONIQUE TV 316 CIRCUITO ELECTRÓNICO TV 316 ELEKTRONISCHE SCHALTUNG TV 316
32 W000070040 CIRCUIT BOARD HF 317 CIRCUIT ÉLECTRONIQUE HF 317 CIRCUITO ELECTRÓNICO HF 317 ELEKTRONISCHE SCHALTUNG HF 317
33 W000070016 COUPLER COUPLEUR ACOPLADOR KUPPLUNGSSCHLAUCH
36 W000050188 CIRCUIT BOARD CE 22660 CIRCUIT ÉLECTRO-NIQUE CE 22660 CIRCUITO ELECTRÓNICO CE 22660 ELEKTRONISCHE SCHALTUNG CE 22660
38 W000262754 PLASTIC TRIM PROFIL ARÊTE PROFIL ARÊTE RAHMENPROFIL
46 W000050181 SOLENOID VALVE ÉLECTROVANNE ELECTROVALVULA MAGNETVENTIL
48 W000050179 LONG TRIMMER PIN ARBRE LONG POUR TRIMMER EJE LARGO DEL TRIMMER WELLE FÜR TRIMMER
51 W000070019 CLAMP BORNE BORNE KLEMME
52 W000070047 GAS CONNECTION RACCORD GAZ RACOR GAS GASANSCHLUSS
56 W000070049 KNOB BOUTON PERILLA DREHKNOPF
56.1 W000228008 HOOD CAPUCHON CAPUCHÓN KAPPE
57 W000227589 SOCKET PRISE TOMA STECKDOSE

R. CODE DESCRIÇÃO BESKRIVNING BESCHRIJVING DESCRIERE

CIRCUIT ELECTRONIC
01 W000050170 CIRCUITO ELECTRÓNICO HF 344/TH ELEKTRONISK KRETS HF 344/TH ELEKTRONISCH CIRCUIT HF 344/TH
HF 344/TH
CIRCUIT ELECTRONIC
03 W000232541 CIRCUITO ELECTRÓNICO HF 343C ELEKTRONISK KRETS HF 343C ELEKTRONISCH CIRCUIT HF 343C
HF 343C
08 W000236149 CABO DE ALIMENTAÇÃO NÄTKABEL VOEDINGSKABEL CABLU DE ALIMENTARE
09 W000227612 GRAMPO DO CABO KABELKLÄMMA KABELKLEM MAN≤ON CABLURI
09.1 W000227620 PORCA EM NYLON RATT KNOP PIULI∂® NYLON
10 W000233525 BLOCO DE FIXAÇÃO FÄSTBLOCK BEVESTIGINGSBLOKJE BLOC DE FIXARE
11 W000070027 INTERRUPTOR STRÖMBRYTARE SCHAKELAAR •NTRERUP®TOR
12 W000231163 UNIÃO DE SAÍDA KOPPLING AANSLUITSTUK RACORD IE≤IRE
13 W000070032 BOTÃO RATT KNOP BUTON
13.1 W000228005 TAMPA NIPPEL DOPJE CAPAC
14 W000050067 VENTILADOR ELÉCTRICO FLÄKT MOTORVENTILATOR VENTILATOR
15 W000050193 ESQUADRO VINKELHAKE HOEK CADRU CUPRU
CIRCUIT ELECTRONIC
20 W000050187 CIRCUITO ELECTRÓNICO TV 316 ELEKTRONISK KRETS TV 316 ELEKTRONISCH CIRCUIT TV 316
TV 316
CIRCUIT ELECTRONIC
32 W000070040 CIRCUITO ELECTRÓNICO HF 317 ELEKTRONISK KRETS HF 317 ELEKTRONISCH CIRCUIT HF 317
HF 317
33 W000070016 ACOPLADOR KOPPLAR KOPPELSTUK CUPLAJ COMPLET
CIRCUIT ELECTRONIC
36 W000050188 CIRCUITO ELECTRÓNICO CE 22660 ELEKTRONISK KRETS CE 22660 ELEKTRONISCH CIRCUIT CE 22660
CE 22660
38 W000262754 MOLDURA RAMPROFIL LIJSTPROFIEL PROFIL CADRU
46 W000050181 SOLENÓIDE ELEKTROVENTIL ELEKTROMAGNETISCHE KLEP ELECTROVALV®
48 W000050179 EIXO DO TEMPORIZADOR AXEL FÖR TRIMMER AS VOOR TRIMMER AX PENTRU TRIMMER
51 W000070019 TERMINAL KONTAKTDON CONNECTOR CONECTOR
52 W000070047 UNIÃO DO GÁS GASKOPPLING GASAANSLUITING RACORD GAZ
56 W000070049 BOTÃO RATT KNOP BUTON
56.1 W000228008 TAMPA NIPPEL DOPJE CAPAC
57 W000227589 TOMADA UTTAG STOPCONTACT PRIZ®

II
 SPARE PARTS LIST - PIÈCES DÉTACHÉES - LISTA DE LAS PIEZAS DE RECAMBIO - ERSATZTEILLISTE
EÇAS SOBRESSELENTES - RESERVDELAR - WISSELSTUKKEN - LISTA PIESE COMPONENTE
LISTA CZĘŚCI ZAMIENNYCH - ∫∞∆∞§√°√™ ∞¡∆∞§§∞∫∆π∫ø¡ - ПЕРЕЧЕНЬ ЗАПАСНЫХ ЧАСТЕЙ

R. CODE OPIS ¶∂ƒπ°ƒ∞º∏ ОПИСАНИЕ

01 W000050170 OBWÓD ELEKTRONICZNY HF 344/TH ∏§∂∫∆ƒ√¡π∫√ ∫À∫§øª∞ HF 344/TH ЭЛЕКТРOННAЯ CХЕМA HF 344/TH
03 W000232541 OBWÓD ELEKTRONICZNY HF 343C ∏§∂∫∆ƒ√¡π∫√ ∫À∫§øª∞ HF 343C ЭЛЕКТРOННAЯ CХЕМA HF 343C
08 W000236149 KABEL ZASILAJĄCY ∏§∂∫∆ƒπ∫√ ∫∞§ø¢π√ КАБЕЛЬ ПИТАНИЯ
09 W000227612 OPASKA KABLOWA ™∆À¶∂π√£§π¶∆∏™ ∫∞§ø¢π√À ПРИЖИМНОЕ УСТРОЙСТВО КАБЕЛЯ
09.1 W000227620 NAKRĘTKA Z NYLONU ¶∞•πª∞¢π ¡∞´§√¡ ГAЙКA ИЗ НЕЙЛOНA
10 W000233525 PŁYTKA MOCUJĄCA ™∆√πÃ∂π√ ™∆∂ƒ∂ø™∏™ БЛOК КРЕПЕЖНЫЙ
11 W000070027 WYŁĄCZNIK ¢π∞∫√¶∆∏™ РУЧКA
12 W000231163 ZŁĄCZKA WYJŚCIOWA ƒ∞∫√ƒ ∂•√¢√À COЕДИНИТЕЛЬ ВЫХOДНOЙ
13 W000070032 POKRĘTŁO ∫∞§Àªª∞ ГAЙКA ИЗ НЕЙЛOНA
13.1 W000228005 NASADKA ¢π∞∫√¶∆∏™ КOЛПAК
14 W000050067 WIRNIK ª√∆∂ƒ ∞¡∂ªπ™∆∏ƒ∞ ЭЛЕКТРOВЕНТИЛЯТOР
15 W000050193 JARZMO MIEDZIANE ¶§∞∫∞ DINSE CКOБA
20 W000050187 OBWÓD ELEKTRONICZNY HF TV 316 ∏§∂∫∆ƒ√¡π∫√ ∫À∫§øª∞ TV 316 ЭЛЕКТРOННAЯ CХЕМA TV 316
32 W000070040 OBWÓD ELEKTRONICZNY HF HF 317 ∏§∂∫∆ƒ√¡π∫√ ∫À∫§øª∞ HF 317 ЭЛЕКТРOННAЯ CХЕМA HF 317
33 W000070016 KOMPLETNY UKŁAD ŁĄCZĄCY ¶∏¡π√ ∑∂À∫∆∏ МУФТA
36 W000050188 OBWÓD ELEKTRONICZNY CE 22660 ∏§∂∫∆ƒ√¡π∫√ ∫À∫§øª∞ CE 22660 ЭЛЕКТРOННAЯ CХЕМA CE 22660
38 W000262754 PROFIL RAMKI ∂ª¶ƒ√™ ∫√ƒ¡π∑∞ ПРOФИЛЬ ДЛЯ РAМКИ
46 W000050181 ELEKTROZAWÓR ∏§∂∫∆ƒ√µ∞§µπ¢∞ ЭЛЕКТРOКЛAПAН
48 W000050179 TRZPIEŃ TRYMERA ª∞∫ƒÀ ∞o√¡∞∫π °π∞ TRIMMER ВAЛИК ДЛИННЫЙ ДЛЯ ТРИММЕРA
51 W000070019 ŁĄCZNIK ∞∫ƒ√¢∂∫∆∏™ ª¶∞¡∞¡∞ ЗAЖИМ OДНOПOЛЮCНЫЙ
52 W000070047 ZŁĄCZE GAZOWE ƒ∞∫√ƒ ∞∂ƒπ√À COЕДИНИТЕЛЬ ГAЗOВЫЙ
56 W000070049 POKRĘTŁO ∫∞§Àªª∞ ГAЙКA ИЗ НЕЙЛOНA
56.1 W000228008 NASADKA ¢π∞∫√¶∆∏™ КOЛПAК
57 W000227589 PRZYCISKU ™À¡¢∂∆∏ƒ∞™ Рaзъeм

III
DUTY CYCLE - FACTEUR DE MARCHE - CICLO DE TRABALHO - BEDRIJFSCYCLUS - CICLO DE TRABAJO
INTERMITTENSFAKTOR - BEDRIJFSCYCLUS - CICLUCL DE LUCRU
∫À∫§√™ ∂ƒ°∞™π∞™ - РАБОЧИЙ ЦИКЛSE
SCHWEISSSTROMBEREICH - CORRENTE DE SOLDADURA - SVETSSTRÖM - SNIJSTROOM
CORENT DE TAIERE - PRĄD SPAWANIA - ƒ∂Àª∞ ™À°∫√§§∏™∏™ - Сила тока
WELDING CURRENT - COURANT DE SOUDAGE - CORRIENTE DE SOLDADURA

DUTY CYCLE - FACTEUR DE MARCHE - CICLO DE TRABAJO - EINSCHALTDAUER - CICLO DE TRABALHO - INTERMITTENSFAKTOR
BEDRIJFSCYCLUS - CICLUCL DE LUCRU - ∫À∫§√™ ∂ƒ°∞™π∞™ - РАБОЧИЙ ЦИКЛ

VOLT/AMPERE CURVES - COURBES VOLT /AMPERE - CURVA VOLTIOS/AMPERIOS - KURVEN VOLT/AMPERE

CURVAS VOLTAMPÉRICA - VOLT/AMPERE CURVES - KURVOR VOLT/AMPERE - CURBE VOLT-AMPERE
KRZYWE VOLT-AMPER - ∫∞ª¶À§∂™ VOLT/AMPERE - ВОЛЬТАМПЕРНЫЕ ХАРАКТЕРИСТИКИ
V OUT

I OUT

IV
 WIRING DIAGRAM - SCHÉMA ÉLECTRIQUE - ESQUEMA ELÉCTRICO - STROMLAUFPLAN
ESQUEMAS ELÈCTRICOS - ELSCHEMOR - ELEKTRISCHE SCHEMA'S - SCHEMA ELECTRICA
SCHEMAT ELEKTRYCZNY - ∏§∂∫∆ƒπ∫√ ¢π∞°ƒ∞ªª∞ - ЭЛЕКТРИЧЕСКАЯ СХЕМА

V
CIRCUIT BOARD HF 344/TH CE 22519 (W000050170)
ELECTRONIC CIRCUIT BOARD HF 344/TH CE 22519 (W000050170) page 1of2
ELECTRONIC CIRCUIT BOARD HF 344/TH CE 22519 (W000050170) page 2of2
CIRCUIT BOARD HF 344/TH CE 22538 (W000232541)
ELECTRONIC CIRCUIT BOARD HF 344/TH CE 22538 (W000232541)
CIRCUIT BOARD TV 316 CE 22438 (W000050187)
ELECTRONIC CIRCUIT BOARD TV 316 CE 22438 (W000050187)
CIRCUIT BOARD HF 317 CE 22437 (W000070040)
ELECTRONIC CIRCUIT BOARD HF 317 CE 22437 (W000070040)
CIRCUIT BOARD CE 22692
ELECTRONIC CIRCUIT BOARD CE 22692