Professional Documents
Culture Documents
1) Purpose of Manual
2) Machine description
5) Testing procedure
6) Warranty conditions
7) Technical data
The purpose of this manual is to give useful information on repairing RAINBOW 180E to
authorised Service Centres. This manual must only be used by qualified technicians to
avoid running risks of serious damage to persons or objects.
It is better to read and understand the contents of this manual before repair work.
Repairing a machine means opening it up to gain access to the parts inside after removing
some of the safety guards. For this reason there are certain precautions to be taken, other
than those for just using it for welding, aimed at avoiding being harmed by contact with:
- live parts;
- moving parts;
- parts with elevated temperatures.
WARNING! : Always unplug from the socket before handling parts inside the
machine, as switching on the switch does not prevent danger of being electrocuted.
Always wait for about five minutes before working on the inside parts as some of
the capacitors may still be charged at a high voltage.
Always use original spare parts supplied by CEA
The subject matters in this manual have been organised into a successive logic gradually
leading the operator into gaining a working knowledge of the general characteristics of the
machine (chapter 2) and making it possible to identify the damaged component.
Repairs consist in identifying the damaged part and replacing it only for the parts listed at
chapter 3.
At chapter 4 you’ll find a list with all the necessary instruments for making the correct
diagnosis and repairing.
At chapter 5 you’ll find how to find out the faulty component.
In case you are not able to solve the problem by following the instructions given in this
book, the machine must be sent back to CEA for repairing.
Should you have any doubt or problem when repairing the equipment, you can contact
CEA SpA at any time: we’ll be glad to help you (see chapter 8).
The RAINBOW 180 welder is based on INVERTER technology. By using a high frequency
intermediate section it is possible to use a transformer considerably smaller in size and
weight than standard machines. There are other important factors related to using this
system such as greater efficiency and improved welding quality resulting from the rapid
response from the system.
Figure 2.1 block diagram shows the working principle of the above machine.
The technology used for the RAINBOW 180 greatly adds to these characteristics. In fact, a
totally controlled single-phase inverter is used, which, due to its rapid response, controls
the weld current far more rapidly and effectively: in TIG immediate arc striking (ignition) is
obtained just by lightly touching the work piece (touch and start) and MMA welding
performance is particularly efficient and stable both with basic and steel electrodes. This is
all possible due to the 100 kHz working frequency, IGBT technology and the kind of used
inverter (zero voltage switching inverter). In addition to the above, a microprocessor
control grants an easy but precise machine adjustment.
Figure 2.1 block diagram shows the working principle of the above machine.
°t
+
We are also giving you two side views showing the component position in respect to the
number given on the block diagram (see figure 2.2)
1
7 6
13
10
9
11
14 5
4
8
Figure 2.2
1. Radiodisturbance filter. This is a passive component with the dual task of limiting
machine frequency output as required by EEC norms and making the RAINBOW 180
E immune from problems caused by eventual electronic devices connected to the
same mains supply.
2. Main switch. This has the simple task of switching the machine on and off and is
located on the back panel at the exit of the mains cable.
WARNING! The switch is connected after the radiodisturbance filter so that switching
on power to the mains cable also automatically means supplying the filter, i.e. a part of
the machine is live.
3. Electrolytic capacitors charging circuit. This is a simple circuit required for initially
charging the electrolytic capacitors. In fact, an uncharged capacitor at the initial
moment of the charge transient has the effect of a real short-circuit with very high
currents. Apart from damaging the capacitors themselves, this could also damage the
primary bridge where the entire current is in transit. A resistance has been custom-built
into the feed circuit in order to limit this current to 30A so that the load current will be
kept to tolerated values. This resistance is short-circuited by a relay after a certain time
(about 50 milliseconds) and the machine is then ready to work normally.
4. Primary rectifier. The rectifier is a high voltage diode single-phase bridge, rectifying
the voltage from the mains, achieving a single-direction value.
5. Electrolytic capacitors. The pulsing single-directional output voltage from the primary
bridge is levelled off by the electrolytic capacitors (in this case 4 in parallel) achieving a
practically continuous wave form. Other capacitors also have to be near to the inverter
to eliminate any high frequency harmonics and to reduce interference with the other
components.
7. Primary current reading transformer. It is installed at the output of the inverter and
on the transformer primary. It is designed to give a current value in proportion to the
current given from the inverter and necessary for its protection.
9. Secondary rectifier circuit with thermostatic protection: the square wave voltage
given from the inverter is rectified by a fast diode rectifier. On the secondary diodes
heat sink there is a thermostatic protection being operated at 100°C
10. Doubler and snubber circuits. The doubler is designed for the quality of welding i.e.
to achieve a longer and more stable arc and easier efficient ignition. There is also a
system of snubbers to limit over-voltages on the diodes of the secondary bridge
change-over.
11. Inverter control card. The card includes the IGBT control circuit. This circuit sets the
IGBT conduction time according to the value chosen by the control potentiometer. The
circuit reduces IGBT conduction time if the output value is too high and increases
conduction time if the output value is too low. There are also circuits to control the weld
current during electrode welding (ARC FORCE).
12. Analogic front controls PCB. This PCB allows you to choose the requested welding
parameters (current process) through the adjustment panel.
13. Current reading shunt. It allows to read the welding current and to adjust it according
to the value set from the operator on the analogic panel.
14.Supply circuit: it gives the necessary continuous supply (24 V) necessary for
supplying the control PCB and the relays for the high frequency and the gas solenoid
valve.
Figure 3.1
Figure 3.2
Figure 3.3
Figure 3.4
DC1 DC2
X8
DC4 DC3
Figure 3.5
A hand oscilloscope (model FLUKE 123 or better) with the following characteristics:
- two channels
- at least 20MHz band width
A 2 A magnetothermic switch;
To replace components in contact with heat sink (e.g. thermostats) use thermal paste from
RS COMPONENT (Cod. 554-311) or similar with same thermal characteristics.
To replace IGBT:
A solder for electronics fitted with tip with anti-static earthing to weld the IGBT.
Two anti-static wristbands around the wrists are necessary when welding IGBT.
Here below we give you the list of the figures which allow you find out the measurement
points and all the components involved in the testing procedure described in chapter 5:
Figure 4.1.a
Figure 4.1.b
Q1 Q2
Black
wire
Red
wire
Q4 Q3
E3 G3 E4 G4
Figure 4.2
5
6
7
8
Figure4.3
1 10
Figure 4.4
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5. TESTING PROCEDURE
1- a preliminary detailed visual examination to be repeated also after replacing the faulty
parts. Pls follow instructions given at chapter 5.1;
2- inverter and relative control card check using
• auxiliary power supply (24 VDC) to the control PCB
The purpose of this test is to find out if there is any burnt IGBT (if driving does not check
figures 5.3, 5.4, 5.5) and the relative control circuit (if open circuit driving, i.e. without
IGBT’s does not check figure 5.6) Pls follow instructions given at chapter 5.2 and the block
diagram of figure 5.1:
3- a check the primary bridge and of the electrolytics load resistance using a multimeter.
The correct procedure is described at chapters 5.3 and 5.4
N.B. The machine should not be connected to the mains or any auxiliary supply
when carrying out control tests, unless otherwise specified.
N.B. The cards are painted so be sure that there is a good electrical contact
between measuring instrument and the part being tested during working tests.
N.B. Only use original spare parts supplied by CEA, particularly nylon screws (
where existing) holding the IGBT heat sink as these are live primary conductors.
N.B. After replacing any component begin again the testing procedure from the
beginning.
a) Disconnect the machine from the mains and disconnect the welding cables.
b) Inspect the outside of the machine and make sure there are no visible damages.
Particularly control mechanical sealing and integrity of the front control panel. This can
also be done by moving the potentiometer and the switch checking if they are
eventually blocked.
c) Open the machine removing the outside screws (see fig. 5.1) following the procedure
given below:
Figure 5.1
d) First of all check dust deposits especially the metallic ones. Please remind that even a
thin layer could create contacts (particularly in the electronic part), giving problems not
only to the part involved but also to those connected to it.
e) Cooling air grids are particularly important, so make sure they are not obstructed or
damaged, otherwise the duty cycle of the machine could be reduced.
f) Also check all the internal parts of the machine, paying special attention to burn marks,
deformations, breakage, clearly unforeseen contacts, loose contacts. Replace the
damaged part immediately.
g) In any case clean all the components with dry compressed air to remove any dust
deposit. Repeat the visual inspection after this operation.
NO YES
NO YES
RECONNECT PREVIOUS
CONTROL PCB
(5.2.5) NO YES
REPLACE DEFECTIVE
THERMOSTAT AND
SUPPLY CONTROL PCB
(5.2.7)
NO
REPLACE CONTROL PCB (5.2.5)
AND SUPPLY AGAIN THE PCB
YES
YES NO
RECONNECT PREVIOUS
CONTROL PCB
(5.2.5)
CONTROL (5.2.1)
NO YES
NO LOAD DRIVERS
DC1, DC2, DC3, DC4 CONTROL
(5.2.2)
YES NO
Figure 5.2
Check the driving and write down which ones do not have at least one of the conditions
listed here below at points 1, 2, 3, 4, 5, 6. It is sufficient only one of the below conditions is
missing and you can avoid checking all the others.
Proceed as following:
NOTE: After checking DC1, repeat the same tests explained at points 1, 2, 3, 4, 5 on
the remaining drivings:
- driving DC2 connect the probe between G2 and E2 (earth);
- driving DC3 connect the probe between G3 and E3 (earth);
- driving DC4 connect the probe between G4 and E4 (earth);
After you have checked ALL the drivings go back to the block diagram.
1. Make sure that the wave form on the oscilloscope is similar to the one in figure 5.3.
N.B. If all the drivings have 0 output voltage, replace the complete control PCB
(chapter 5.2.5) without replacing the IGBT’s, but in any case start again all the controls
from the beginning.
2. Make sure that the oscillation frequency has the following value:
- 100 kHz ÷101.5 kHz .
If the frequency value is not correct (even if point 1 is correct) replace immediately the
control card as explained in 5.2.5 and repeat the test from the beginning.
3. Make sure that the wave form on the oscilloscope is similar to the one in figure 5.4.
4. Make sure that the wave form on the oscilloscope is similar to the one in figure 5.5.
1>
1) CH1: 5 Volt 2 us
Figure 5.3
1>
Figure 5.4
1>
Figure 5.5
Check only the driving which in the previous tests didn’t correspond to the requested
Check that the yellow led on the panel PCB is on, otherwise replace the control PCB (see
5.2.5) and start again the control from point 5.2
! Vertical 5 V/division
! Horizontal 2 µs/division
1. Make sure that the wave form on the oscilloscope is similar to the one shown in figure
5.6.
2. Make sure that the oscillation frequency has the following value:
100 kHz ÷101.5 kHz.
If you don’t find this value replace immediately the control PCB (procedure 5.2.5).
If all the above conditions are OK, you can now control the remaining drivings.
If the noload driving is damaged replace the IGBT (see 5.2.8) and the relative driving
circuit (see 5.2.5). If the driving is correct replace the correspondent IGBT’s (see 5.2.8).
1>
1) CH1: 5 Volt 2 us
Figure 5.6
Figure 4.4 shows the front control PCB layout showing the components position and the
measurement points (pls refer to X1 connector).
1. Check the diode between the clamp 1 (anode) and the clamp 10 (cathode). You should
find about 2V, according to the type of multimeter you are using.
2. Check the diode between the clamp 1 (anode) and the clamp 6 (cathode). You should
find about 2V, according to the type of multimeter you are using.
3. Check between the clamps 10 and 5 and process selector switch set on TIG, if there is
any short circuit. Changing the position of the process selector switch you should find
an open circuit.
4. Check between the clamps 4 and 3 and process selector switch set on TIG, if there is
any short circuit. Changing the position of the process selector switch you should find
an open circuit.
5. Check between the clamps 2 and 3 and process selector switch set on basic electrode
(no Cr Ni, if there is any short circuit. Changing the position of the process selector
switch you should find an open circuit.
6. Check between the clamps 7 and 9 (you can choose any position of the process
selector switch) if you have a resistance value of 1 kΩ.
7. Check between the clamps 9 and 8 (you can choose any position of the process
selector switch):
- With current adjustment potentiometer to the minimum → 1kΩ;
- With current adjustment potentiometer to the minimum → short circuit (0Ω).
If you get a positive result and all the above conditions are OK, it means that the front
control PCB is working correctly.
You will find here all the necessary instructions to disconnect the contrl PCB so that you
can:
- Replace the complete control PCB;
- replace the driving circuits if damaged. It’s anyway always better to replace the
complete control card.
If you have replaced the control PCB or after repairing the driver circuits follow these
steps to reinsert correctly the PCB:
• connect the new card and be careful not to bend its pins while
being inserted into the underneath inverter card;
• never forget to screw back the metallic screw in the middle of
the control card;
Check if the thermostats are correctly working, only after that the machine has been
switched for at least 3 minutes in the following way:
The inverter PCB is now completely disconnected and you can make all the necessary
replacement and measurements operations according to the instructions given in the
chapter you are following in the repairing manual.
IGBT’S REPLACEMENT
If IGBT’s are damaged and you do not have the proper tooling, we suggest you to replace
the complete inverter power group (and not the single IGBT’s).
For IGBT’s replacement follow the instructions given in the manual. We remind you that
the IGBT’s must always be replaced in couple, regardless to the tests you have made, i.e.
Q1 with Q2 andQ3 with Q4.
NB repeat the equipment test starting from point 5.2 either if you have replaced the
inverter group or the single IGBT’s.
Figure 4.1.b shows the PCB layout with the position of the primary bridge clamps and the
measurement points.
If any of the above conditions fail, replaced the bridge as explained at chapter 5.3.1,
otherwise go to point 5.4.
• Remove the two upper conductors and the two lower conductors
from the mains switch;
1. Check that between points 5 and 6 in fig. 4.1.b there is a resistance value of about 10
Ω ± 1 Ω.
Should you find a short circuit (0Ω) or an open circuit, replace immediately the relay
8REL1) (sticked contacts) and the R1 resistance. The correct replacement procedure is
explained at chapter 5.5.15. Once you have replaced the component check again this
point.
Be careful not to measure by mistake open circuits, which could be due to a thick
layer of paint on the PCB!
Go to chapter 5.5.
Before making the low voltage test make sure that all the drivings described at point 5.2
are correct.
Supply the machine by an auxiliary insulation transformer with an output voltage of 48V
AC and a standard 2A magnetothermic switch (see figure 5.7). The control PCB must still
be supplied with the separate 24 V DC.
The logic sequence suggested for this procedure is shown in the block diagram no. 5.8:
INITIAL OPERATIONS
If the magnetothermic D is activated within a few seconds check the switch (see chapter
5.5.10) and the EMC filter (see chapter 5.5.12) and replace them if necessary following the
instructions given at chapter 5.5.11 (switch) , 5.513 (EMC filter varistor) and 5.5.3 (for the
remaining components of the EMC filter). If both the components are OK, check if there is
any short circuit on the mains cable, on the wirings or on the tracks.
You can continue only when leaving the mains switch open the thermostat is not activated.
If the magnetothermic D is activated within a few seconds check the electrolytic capacitors
(chapter 5,.5.16) and replace them if necessary (chapter 5.5.17). Then check if there is
any short circuit on the wirings or on the tracks.
Go to the block diagram in fig. 5.8 and follow the instructions from the point where you can
supply the machine with 48 VAC.
Figure 5.7
NO IS ELECTROLITIC YES NO
NO DOES MAIN SWITCH CAPACITOR VOLTAGE
WORK PROPERTLY? 60V ± 5V? (5.5.4)
(5.5.10)
Figure 5.8
DOES DOUBLER
YES
NO
YES DOES ELECTROLYTIC YES WORK PROPERTLY?
CAPACITOR WORK (5.5.7)
PROPERTLY?
(5.5.16)
NO
NO
1. place the red probe of your tester (see fig. 4.1.b) on point 9 (integrated IC1 case) and
the black probe on point 8 ( DZ6 anode).
The correct value is 60 V ± 5 V.
Measure the voltage on the mains switch output conductors (connected to clamps J1 and
J2 in fig. 4.1.c).
The correct value corresponds to the supply voltage, i.e. 48 VAC.
1. Using a multimeter check the diode between one clamp of the rectifier (anode) and the
secondary heat sink (cathode) → 0.1-0.3 V (with direct polarity)
2. Using a multimeter check the diode between the remaining clamp of the rectifier
(anode) and the secondary heat sink (cathode) → 0.1-0.3 V (with direct polarity)
If any of the two above conditions fail, the secondary rectifier is correctly working.
To replace this part you have to loosen the two screws fixing it to the heat sink and to the
conductors.
When fixing the new rectifier pay attention to the thermic coupling with the heat sink. Clean
carefully the surfaces and spread a layer of thermic paste on all the surface before fixing
the rectifier to the heat sink.
Figure 4.3 shows the doubler PCB layout with the components position and the
measurement points. Check the following:
The remaining troubles on the doubler components are not easy to find out, but luckily
they are seldom. The components function is necessary for a good welding quality and
particularly for the electric arc l length. We therefore suggest you to replace them if the
electric arc is very short.
In the spare parts list the doubler is supplied complete with heat sink and secondary
rectifier.
Follow these instructions:
Now the secondary rectifier assembly and doubler is completely disconnected and it can
be removed.
• Connect all the parts back following the same procedure in
reverse order.
Return to the block diagram and follow the instructions.
1. Check the electrical working placing the two probes of your multimeter on the two side
clamps. Setting the switch in position O (open) and then in position I (closed) you
should find respectively a value showing an open circuit and a short circuit (0Ω).
2. Repeat the same operation on the remaining side clamps.
3. Set the mains switch in position 1 and check if you have an open circuit between the
two upper terminals.
If any of the above conditions fail, replace the component (chapter 5.5.11).
Return to the block diagram and follow the instructions or go back to the point of the
manual where you come from.
• Loosen the screw fixing the knob and then the internal screws
fixing the switch to the front panel; push the switch from the
opposite side;
• disconnect the conductors unscrewing their fixing screws;
• Connect the new component following the same procedure in
reverse order.
Return to the block diagram and follow the instructions or go back to the point of the
manual where you come from.
Figure 4.1.a shows the position of mains radiodisturbance filter. Initial operations needed
for testing:
• Switch off the supply from the machine and disconnect the
transformer supply cable;
• Set the mains switch in position 0 (OFF);
• Disconnect the upper conductors and the two lower conductors
from the mains switch;
Figure 4.1.b shows the PCB layout with the filter components position and the
measurement points. Check the following:
If any of the 1,2,3 conditions has failed replace the inverter PCB (see 5.2.8). If the varistor
is damaged replace it as explained at 5.3.13.
Return to the block diagram and follow the instructions or go back to the instruction book
to the point you were before.
Return to the block diagram and follow the instructions or go back to the instruction book
to the point you were before.
Figure 4.1.a shows the components position of electrolytic capacitors charge circuit.
Initial operations needed for testing:
1. Repeat a careful visual inspection of the circuit components. Immediately replace any
components with traces of burning, especially on the relay (REL 1 and REL2) (see point
5.5.15);
2. Check for a resistance value of about 6.8 Kohm (R17) between points 3 and 4.
3. Check the diode D11 with the measurement points 7 anode and 4 cathode.
4. Check for a resistance value of about 10 ohm ± 0.5 ohm between points 5 and 6.
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5. Check the relay coil measuring the resistance value between point 3 and one phase of
the mains switch.
If any of above conditions has failed replace the components as explained at 5.5.15.
Be careful not to detect an open circuit due to a thick layer of paint on the card!
N.B. if parts R17, D11, C17, C3 are faulty replace the complete inverter PCB as
explained at chapter 5.2.8.
The remaining parts (R14, REL 1 and REL2 can be replaced).
Figure 4.1.a shows the inverter pcb layout with the position of the electrolytic capacitors.
N.B. Electrolytic capacitors are generally deformed when faulty, so it is easy to detect their
damage. Visual inspection is fundamental in this case. If the block diagrams leads you to
an electrolytics control you have to make this test.
Proceed as explained at 5.2.8 for replacing the complete inverter assembly, so that you
can reach the components and then replace them as following:
N.B! Insert the electrolytic capacitor with correct polarity comparing the instructions
written outside each component with the card assembly layout.
Figure 4.1.A shows the inverter pcb layout with the position of the supply circuit
components.
Proceed as explained at 5.2.8 for replacing the complete inverter assembly. Also remove
the control card as following:
• loosen the metallic screw which you can clearly see in the
middle of the control PCB;
• lift up the PCB without using any tool which could damage the
tracks and check the drivers writing down the ones where at
least one of the above conditions fails;
The supply circuit is completely accessible and can be replaced. Replace all the circuit
components. After removing the components, check the tracks conditions leading the
supply at the two points 8 and 9 in figure 4.1.b. If they are broken repair them or replace
the complete inverter card if repairing is too difficult.
We remind you that the two tracks have 325 V, therefore pay attention to their insulation.
Return to the block diagram and follow the instructions or go back to the instructions book
to the page you were before.
1. Check the closing of both electrolytic capacitors charge relays (REL1 and REL2 figure
4.1.c) immediately after switching on the machine. If this condition fail, check the
electrolytic capacitors charge circuit (5.5.14) and if necessary replace the damaged
components(5.5.15).
2. Measure the output voltage. The value should be about 90 V ± 5 V. If not check wiring
cables, tracks and connectors on the machine and if necessary check again all the
components.
3. Check that the cooling fan is turning. If not remove its connector from the inverter PCB
(X4 figure 4.1.c). Measure the voltage on X4. If the value is 29V ± 2V replace the
cooling fan as explained at chapter 5.6.1, otherwise replace the supply circuit as
explained at 5.5.18. After replacing the fan check again if it’s working.
NOTE: Before making any short circuit check that the machine is off.
1. If the measured value is different from 5A ± 1A 25A ± 1A, adjust the current acting on
the RT4 (should be RT6) trimmer on the control PCB (figure 4.2.a).
If the current goes to the maximum value and you cannot adjust it, check the wiring
cable between the Y1 connector on the control PCB (fig. 4.2.a) and the shunt. If the
connection are good replace the control PCB (procedure 5.2.5) and start again the
mains supply control from the beginning.
2. Measure the current value supplied from the machine. The correct value is 180A ± 5A. If
you don’t have this value adjust the current acting on the RT2 trimmer on the control PCB
(fig. 4.2.a)
Check that the current goes to 165A ± 5A. If not, switch off supply from the machine and
check the R5 resistance on the doubler PCB (fig. 4.2). The correct value is 220 Ω ± 20. Ω
If you don’t have this value replace the secondary rectifier assembly. If the value is correct
replace the control PCB and start again the control from the beginning.
Thermostats intervention
Wait for the thermostat intervention, which must be activated within 10 minutes maximum.
If not, switch off the machine immediately and replace the thermostat.
After the thermostat has been activated, the machine must stay off for at least 5 minutes,
otherwise replace the thermostat and repeat the test.
Now weld using different current adjustments. Any welding quality problem can be caused
from the control PCB. We remind you that if you replace the PCB, you have to repeat all
the controls from the beginning.
We remind you that CEA Spa does not repair under warranty damages:
• caused by repairing attempts carried out by personnel not authorised by CEA to repair
and service its products;
• caused by improper use;
• caused by connection to incompatible devices;
• caused by additional modifications to the machine itself;
• caused by instruments used for repairs non-conforming to those indicated in chapter 4;
• caused by repair procedures differing from the ones given in the manual.
8) TECHNICAL DATA
TIG MMA
Input voltage 1ph 230 V single phase ± 15%
Installed power 3.1 kVA 4.6 kVA
Max. input current 26 A rms 36 A rms
Absorbed input current at
14.0
14.0 A rms 19.0 A rms
(X=100%)
Power factor 0.65
Efficiency (X=100%) 0.8
Cosϕ
Cosϕ 0.99
Adjustment range 0-180A 0-180A
Welding current 180 A X=20% 180 A X=20%
Welding current X=60% 130 A 130 A
Welding current X=100% 110 A 110 A
Open circuit voltage 88 V
Protection
Protection class IP 23
Standard EN60974 EN50199
Dimensions (lxpxh) 390 * 300 * 135 (mm)
Weight 6 kg
Operators with difficulties in identifying faulty parts to be replaced should contact CEA
Technical Assistance Service.
Information may be given by telephone or fax at the following numbers:
Tel. : +39(0)34122322
Fax : +39(0)341422646
Or else by e-mail: