Strictly confidential

C.so E. Filiberto, 27 - 23900 LECCO ITALY

Tel. ++39.0341.22322 - Fax ++39.0341.422646
Cas. Post. (P.O.BOX) 205
e-mail: cea@ceaweld.com - web: www.ceaweld.com
1020h494/A
INDEX:

1) Purpose of Manual

2) Machine description

3) Available spare parts

4) Instruments required for testing and repairing

5) Testing procedure

6) Warranty conditions

7) Technical data

8) Technical assistance procedure request

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1. PURPOSE OF THE MANUAL

The purpose of this manual is to give useful information on repairing RAINBOW 170 HF 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 repairing 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 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 find 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).

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2) Machine description
The RAINBOW 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. The technology used for the RAINBOW 170 HF 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. This is all
possible due to the 100 kHz working frequency, IGBT technology and the kind of used
inverter (zero voltage switching inverter).
Figure 2.1 block diagram shows the working principle of the above machine.

°t

RAINBOW
170 HF
80
90

6
55 0 1 05
0
12

35 130
30 150
5 5 5
15

4 6 1 70 4 6
0
5

3 7 3 7
2 8
A 2 8
1 9 1 9
0 10 0 10

1- Radiodisturbance mains filter 10- Doubler PCB and snubber circuits

2- Line switch 11- Inverter control PCB
3- Electrolytic capacitors charge circuit 12- Interface and panel PCB’s
4- Primary rectifier 13- Torch trigger connector
5- Electrolytic capacitors 14- HF transformer
6- Power inverter 15- Spark gap PCB
7- Main current reading transformer 16- Gas solenoidvalve
8- Main transformer 17- Cooling fan
9- Secondary bridge with thermostat 18- Mains supply circuit

Figure 2.1

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)

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15

16
18 5
6
17

4 8

12
2
3

11 1
7 6
14
10
9

Figure 2.2

The following points give a general description of each item in the block diagram:

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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 170
HF 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. The relay is
fed directly from the main power supply through a capacitive resistance divider, which
not only fixes the voltage but also delays excitation to the relay itself. Problems
eventually caused by this circuit for limiting overcurrents and problems that could arise,
should the relay circuit fail to work, are analysed further on.

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 3 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.

6. Power inverter. Continuous voltage is converted by an inverter into a square wave at

a frequency of 100 kHz. The inverter has the following characteristics:

- complete bridge (H);

- phase shift;
- IGBT switching takes place at zero voltage (ZVS= zero voltage switching);
The inverter controls the crossing current.

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.

8. Power transformer. The transformer supplies a lower voltage to its secondary

terminals necessary for welding. It also provides the electric isolation needed between
the main power supply and the weld circuit.

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 95°C
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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 and HOT START).

12. Interface and panel PCB: it allows you to interface the machine with the
microprocessor digital PCB to control the different functions: (solenoidvalve, switching
on/off of the equipment, etc.)

13. Torch triggers connector. External connector for the connection of the torch
connector and to detect the torch trigger.

14. HF transformer: Increases the welding current up to the values necessary for arc
striking in TIG HF welding.

15. Spark gap PCB. This PCB gives a series of high frequency and voltage pulses which
supply the HF transformer. Such pulses are repeated till the arc strikes and anyway for
no longer than one second.

16. Solenoidvalve. It adjust gas opening and closing when working in TIG according to
the values chosen from the operator.

17. Cooling fan. The fan is directly connected to the auxiliary voltage 24 V.

18. 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.

The components listed at points 1, 3, 4, 5, 6, 7, 18, belong to the inverter assembly or

inverter block.

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3) AVAILABLE SPARE PARTS

Position Electric diagram ref.

Description CODE
(see fig. 3.1) (fig. 3.6)

1 Side panel with sticker (-) 352523

2 Rack panel + sticker (-) 439318
3 Front rack sticker (-) 467027
4 Current adjust.knob (-) 438845
5 Knob+index D. 15 (-) 438853
6 Quick connector ¼’’ + (-) 403635
ringholder5x10.5
7 Female 50 mm2 quick connector (-) 403611
8 6 pole female panel socket CT 419002
9 Threaded nut ¾ -20unef-2A (-) 423134
10 Front panel RAINBOW 170HF + (-) 352457
wings
11 Handle (-) 438205
12 Carrying belt connect.ring (-) 365850
13 Switch knob 0.5x5 (-) 438710
14 Rear panel sticker RAINBOW (-) 467025
170-200
15 Cable ring PG 13.5 (-) 430751
16 Cable holder PG 13.5 (-) 427878
17 Mains cable (-) 235992
18 Rear panel + wings + sticker (-) 352446

Figure 3.1

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 Position Electric diagram ref.
Description CODE
(see fig. 3.2) (fig. 3.7)

19 PCB fixing spacer (-) 424009

20 Spark gap PCB SHF 376917
21 Power and auxil.wiring cable (-) 413758
22 Two pole switch IL 435375
23 Plastic base (-) 352475
24 Metal base (-) 405014
25 Secondary rectifier thermostat TRS 478786
26 Secondary rectifier RS 241116
27 Cylindric ferrite (-) 427405
28 Secondary heat sink (-) 423519
29 Secondary rectifier RS +DB 241123
assembly+doubler
30 Secondary heat sink insulation (-) 353460
31 Front panel wiring cable (-) 413726
32 HF protection filter FR 427555
33 Interface PCB SEI 376949

Figure 3.2

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 Position Electric diagram ref.
Description CODE
(see fig. 3.3) (fig. 3.7)

34 HF circuit zinc coated plate (-) 449547

35 Retex hose 5x10.5 (-) 485040
36 HF transformer THF 299990
37 HF plate fixing (-) 462804
38 Transformer TP 481420
39 Transformer fixing bracket (-) 463220
40 Primary heat sink fixing (-) 427245
41 Primary IGBT’s heat sink (-) 423520
42 Primary IGBT’s (*) Q1 Q2 Q3 Q4 286025
43 Fan motor assembly RAINBOW MVDC 444508
170-200
44 Adjsuted control PCB IC 376992
45 Solenoidvalve 1/8 EVG 425933

(*) Primary IGBT’s are supplied coupled;

Figure 3.3

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 Position Electric diagram ref.
Description CODE
(see fig. 3.4) (fig. 3.7)

46 Front control PCB SPF 376987

47 Two pole switch SW2 423168
48 Potentiometer 1 MΩ POT1, POT3 452998
49 Potentiometer 10 kΩ POT2 452992
50 3 pos. Two pole switch SW1 423167

Figure 3.4

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 Position Electric diagram ref.
Description CODE
(see fig. 3.5) (fig. 3.7)

51 Power inverter group IB 240469

52 Protection varistor (-) 488296
53 Relay 48V – 16A (-) 456764
54 Resistance 10 ohm 15 Watt (-) 457095
55 Electrolytic capacitor 470 µF – (-) 418778
400V

Figure 3.5

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 Position Electric diagram ref.
Description CODE
(see fig. 3.6) (fig. 3.7)
56 IGBT driving components kit (**) (-) …….

(**) The IGBT driving components are always supplied coupled

DC1 DC2

DC4 DC3

Figure 3.6

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 Figure 3.7

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4) INSTRUMENTS REQUIRED FOR TESTING AND REPAIRING (AND ELECTRIC
DIAGRAMS)

The following instruments are needed to check the machine:

A test PCB (cod. ???????) (see figure 4.1). This PCB allows you to test the machine
without digital control.

Figure 4.1

A multimeter with following scale:

- Ohm: from 0 to a few Mohm;

- Diode control test (*);
- Continuous voltages (VDC): from mVDC up to 1000 VDC;
- Alternating voltages (VAC): from 10 VAC up to 700 VAC;
(*) References will often be made to diode control in this manual and in this respect you have to remind that:
- Red anode and black cathode (directly polarised connection): the readout varies from multimeter to
multimeter and from diode to diode (0.3-0.6V);
- Black anode and red cathode (inversely polarised connection): the readout varies according to the type
of multimeter and type of diode (2V-5V). In this case it is referred to an open circuit.

NOTE: It is better to use an automatic range instrument because it is not possible to

estimate the extent of electricity to be measured in a damaged machine.
Remember that other settings can be used as well, but with over capacity you lose in
accuracy while, with reduced capacity, measurements have to be taken quickly to prevent
the instrument from overheating.

A hand oscilloscope (model FLUKE 123 or better) with the following characteristics:
- two channels
- at least 20MHz band width

A probe with the following characteristics:

- attenuation 1:1
- insulation voltages to earth of at least 600VRMS .

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It is essential to also have the following instruments:

24 VDC test on control PCB (see 5.2, 5.3, 5.4)

A stabilised DC supplier with voltage up to 30 V and current at least at 2 A.

A link wire needed to connect the DC supplier to the control card;

Low voltage test 48 VAC (see 5.3)

An auxiliary transformer at 220V \ 48V 220 VA (cod. 481432);

A 2 A magnetothermic switch;

A 250V 5A minimum mains switch.

To calibrate the current and for working tests:

A current probe model FLUKE I1010 or another one with similar or better features.

To replace components in contact with heat sink (e.g. thermostats) use thermic 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:

- Fig. 4.2 (a, b, c) inverter PCB;

- Fig. 4.3 (a, b) control PCB;
- Fig. 4.4 doubler PCB;
- Fig. 4.5 spark gap PCB;
- Fig. 4.6 Front control PCB (the layout shows the PCB seen from the side with
weldings and not from the components side)
- Fig. 4.7 interface PCB.

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 ELECTROLYTIC
CAPACITOR
CIRCUIT CHARGE
ELECTROLYTIC
CAPACITOR
RECTIFIER
PRIMARY
FILTER
EMC
SUPPLY CIRCUIT

Figure 4.2.a
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 3 7 4 5
6
12 13 10 11 14 15
9
8
2
1

Figure 4.2.b

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 Figure 4.2.c
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 G1 E1 G2 E2

BLACK
WIRE

RED
WIRE
A

E4 G4 E3 G3

DC1 DC2

DC4 B
DC3

Figure 4.3

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 1
2

3
4

5
6 9 10

7
8

Figure 4.4

Figure 4.5

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 18 19 21 1 22 23 20

2 3 4 5 6

7 8 9

12 13 10 11

14 15 16 17
Figure 4.6

PIN2 PIN3

Figure 4.7
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5. TESTING PROCEDURE

Testing is divided into the following steps:

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 testing card replacing the digital and interface PCB, connected 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 5.2, 5.3, 5.4 and the relative control circuit (if open circuit driving, i.e. without
IGBT’s does not check figure 5.5) Pls follow instructions given at chapter 5.2;

3) Low voltage test using:

• reduced supply(48 VAC 50-60 Hz) connected to the mains cable;
• auxiliary power supply (24 VDC) to the control PCB
• the testing card replacing the digital and interface PCB, connected to the control PCB.

The purpose of this test is to check all the power parts of the equipment without any risk
for the operator and machine safety. Pls follow instructions given at chapter 5.3 and id
the block diagrams figure 5.7;
4) mains supply test as following:
- Rated mains supply (230V±10% 50-60 Hz) connected to the mains cable;
- auxiliary power supply (24 VDC) to the control PCB
- the testing card replacing the digital and interface PCB, connected to the control PCB.
The purpose of this test is to check the mains supply circuit and the machine functions
such as high frequency, solenoidvalve, auxiliary supply. Pls follow instructions given at
chapter 5.4
5) A function test: the purpose of this test is to check the correct working of front control
PCB and interface PCB. Pls follow instructions given at chapter 5.3

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.
N.B. Touching the electronic components with the hands can create irreparable
damages because of electrostatic discharges. Pls be careful above all when
handling IGBT’s. Use in this case anti-static wristbands around your wrists.

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 N.B. Replace any part which is in contact with the heat sinks only after cleaning
the contact surfaces with alcohol and spread a layer of thermal paste.
N.B. After any replacement, tighten carefully the screws on the power contacts
and all the PCB’s connectors to avoid overheating and false contacts.

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5.1 VISUAL EXAMINATION INSIDE AND OUTSIDE THE MACHINE

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 encoder and the keys to see if they are eventually blocked.
c) Open the machine removing the outside screws (see fig. 5.1) following the procedure
given below:
• unscrew the 2 screws holding the handle;
• loosen the 4 screws holding the rear and front panels and remove
the two metallic side panels;
• disconnect the earth wiring to the side panels by the relative
connectors.

Proceed in the reverse order to re-assemble the machine.

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.

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g) In any case clean all the components with dry compressed air to remove any dust
deposit.

h) Check all the wirings and connectors. Troubles given from not good electrical
connections are more difficult to find, as you always think that they are properly done.

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5.2 TEST WITH 24 V DC TO THE CONTROL PCB

N.B The equipment must be disconnected from the mains supply.

Figure 4.3 gives the layout of the control card showing the positions of the components
and points for measurement. Operate as follows:

• Disconnect connector J1 (fig. 4.7) from the interface PCB and

connect the testing PCB to the female connector you have just
removed;
• Make sure the control module is connected to the inverter pcb
with the connectors X5, X6, X7, X8, X9 (4.3.a);
• Disconnect the X1 connector (see fig. 4.2.c) from the inverter
PCB and connect the stabilised DC supplier to the female
connector you have just removed; supply the PCB paying
attention to the polarity; the negative pole has a black
conductor and the positive pole has a red one
• Adjust the output voltage of the supplier on 24 V ± 1 V to the
control pcb;
• Set the test PCB switch in ON position;
• Adjust the test PCB potentiometer at the maximum value (all in
clock-wise);

a) If the green led on the test PCB is off replace immediately the control card as explained
in 5.2.2 and repeat the control from the beginning.
b) If the yellow led is on check the follow the instructions here below, otherwise go to point
c):

• Disconnect the X3 connector from the inverter PCB (fig. 4.2.c)

Check the electric continuity (0 Ω) between points 9 and 10 on the female connector
(see figure 4.4) you have just removed (the two points correspond to the pins 5 and 6
on the connector).
If the above conditions fails, check the electric continuity on the primary rectifier
thermostat, whose clamps are accessible. If OK, replace the secondary , otherwise the
primary rectifier thermostat.
If you have electric continuity between points 9 and 10 on the female connector X3
replace the control PCB as explained at 5.2.2. and start again the control from the
beginning.

• Reconnect the X3 connector from the inverter PCB (fig. 4.2.c)

c) If the red led is on check the follow the instructions here below, otherwise go to point
d):

• Disconnect the supply from the PCB;

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 • Disconnect the control PCB as explained at 5.2.2;
• Supply again the PCB;

If the led red is still on when the PCB has been disconnected, replace the control card
as explained at 5.2.2., otherwise replace the inverter PCB as explained at 5.2.3.

d) IGBT DC1, DC2, DC3, DC4 driving control

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:
• switch on the oscilloscope;
• set the oscilloscope as follows:
! vertical 5 V/division;
! horizontal 2 ns/division;
• connect the oscilloscope probe between G1 and E1 (earth) as
shown in fig. 4.3.a (DC1 driving)

NOTE: After checking DC1, repeat the same tests explained at points 1, 2, 3, 4, 5, 6:
- 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 to point e)

1. Make sure that the wave form on the oscilloscope is similar to the one in figure 5.2.

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 5.2.2 and repeat the test from the beginning.

• Set the control PCB switch in OFF position

3. Make sure that the wave form on your oscilloscope has a zero value. If not replace the
control card as explained in 5.2.2 and repeat the test from the beginning.
• Set the control PCB switch in ON position
• set the oscilloscope as follows:
! vertical 5 V/division;
! horizontal 500ns/division;
! Down edge trigger;

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4. Make sure that the wave form on your oscilloscope is similar to figure 5.3.

1>

1) CH1: 5 Volt 2 us

Figure 5.2

• set the oscilloscope as follows:

! vertical 5 V/division;
! horizontal 500ns/division;
! Up edge trigger;

5. Make sure that the wave form on your oscilloscope is similar to figure 5.4.

6. Check the pick value 14.4 V ± 0.4 V;

e) After completing the test following these remarks:

If all the driving always have zero output voltage replace first the control card integrated. If
the problem persists replace the complete control card (see 5.2.2) without replacing the
IGBT’s, but in any case repeat the test from the beginning

If at least one of the driving does not have the conditions of points 1,2,4,5,6 following the
instructions given at chapter 5.2.1, otherwise go to 5.3

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 T

1>

1) CH1: 5 Volt 500 ns

Figure 5.3

1>

1) CH1: 5 Volt 500 ns

Figure 5.4

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5.2.1 NO LOAD TEST ON DC1 DC2 DC3 DC4 DRIVING (WITH CONTROL CARD LIFT
UP FROM THE INVERTER CARD)

Check only the driving which in the previous tests didn’t correspond to the requested
conditions.
Follow these instructions:
• switch off the supplier;
• unscrew the metallic screw which you can clearly see in the
middle of the control card through the hole on the panel (see
part no. 34 on the spare parts list);
• lift up the card and remove totally the connectors from the PCB
below. Do not use any tool which could damage the tracks;
• place a paper sheet between the inverter card and the control
card to insulate one from the other;
• Set the oscilloscope as follows:

! Vertical 5 V/division
! Horizontal 2 ms/division

• connect the oscilloscope probe between G and E (earthed to E),

see fig.4.3.a, on each driving which failed in the previous
test;
• switch on supplier and adjust supplier output voltage to 24 V ±
1 V;

Check that the yellow led on the test PCB is on, otherwise replace the control PCB (see
5.2.2) and start again the control from point 5.2

• make a short circuit (important) between pins 4 and 5 on the

X5 connector on the control PCB (fig. 4.2.a). Pin 1 is the one
placed more internally on the PCB.
NOTE: It the yellow led turns off, it means that the circuit is
OK.

• Set the test control PCB switch in ON position;

• Adjust the test PCB potentiometer at the maximum value (all in
clock-wise);

1. Make sure that the oscilloscope wave form is similar to the one in figure 5.5
2. Make sure that oscillation frequency is 100 kHz ÷101.5 kHz.

If you do not have this frequency value replace the control card immediately (see 5.2.2)
and start again the control from point 5.2

If the test is successful, pass on to test the eventually remaining drivings.

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If the no load driving is damaged replace the IGBT (see 5.2.3) and the relative driving
circuit (see 5.2.2). If the driving is correct replace the correspondent IGBT’s (see 5.2.3).

1>

1) CH1: 5 Volt 2 us

Figure 5.5 – No load driving voltage wave form

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5.2.2 DISCONNECTION AND REPLACEMENT OF THE CONTROL PCB AND DRIVING
CIRCUIT

You can find here below the instructions for disconnecting the control PCB in order to:
- replace the complete control card;
- replace the simple driving circuit if damaged. It’s anyway always better to replace the
complete control card.
You don’t need to remove the panel to disconnect the PCB.
Follow these instructions:
• Switch off the auxiliary supplier or any power supply to the
machine;
• unscrew theY2 connector from the control PCB (see figure 4.2.b)
• unscrew (if necessary) the metallic screw which you can clearly
see in the middle of the control card through the hole on the
panel (see part no. 34 on the spare parts list);
• lift up the card and remove totally the connectors from the PCB
below. Do not use any tool which could damage the tracks;
• take out the PCB from the right side moving during this
operation the gas hoses which could obstacle your operation.

If you need to replace the drivings follow these instructions:

- replace the drivers whose test (5.2.1) gave a negative result;
- replace all the components of each driving (see figure 4.3.b) including the ones which
do not seem to be damaged;
- pay attention to the weldings;
- always replace the driver circuits in couple, i.e. DC1 with DC2 and DC3 with DC4;
- If the tracks are particularly damaged and can hardly be repaired, replace the complete
control PCB;
- We remind you that a faulty driving could damage, when supplied, the corresponding
IGBT. Be therefore very careful when making these operation.
- Replace now the faulty IGBT’s as explained in chapter 5.2.3

If you have replaced the control PCB or after repairing the driver circuits, before replacing
the IGBT’s if necessary (see 5.2.3) follow these steps to reinsert correctly the PCB:

• Insert the PCB from the right side moving during this operation
the gas hoses which could bother you.
• connect the spare card and be careful not to bend the pins while
being inserted into the underneath inverter card;
• never forget to screw back the metallic screw in the middle of
the control card;

NB In any case repeat the equipment test starting from point 5.2.

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5.2.3 INVERTER PCB ASSEMBLY REPLACEMENT AND IGBT’S REPLACEMENT
To remote the inverter block follows these instructions:

• Remove all the connectors from the interface and spark gap
PCB’s. Remove all the wiring cables from the panel ring part
no. 34 on the spare parts list)
• Lift up the interface PCB and remove it:
• Disconnect all the fast-on from the panel and loosen the 2
screws fixing the panel on the inverter;
• Remove the panel from its seat;
• Completely remove the screws from the rear panel;
• Disconnect the solenoid valve wires;
• Disconnect the fast-on from the positive dinse connection and
from the HF transformer;
• Disconnect the four main switch wires;
• Disconnect the mains cable wirings from the inverter PCB;
• The rear panel is now completely removed;
• Loosen the two screws underneath the cooling fan (very
important);
• Remove the two screws fixing the inverter plastic base to its
base;
• Disconnect fast-on J3 and J4 (see figure 4.2.c) on the
transformer;
• Loosen the switch knob screw and then the screws inside,
fixing the switch to the front panel;
• Remove the little plastic column from the secondary heat sink;
• Loosen the metallic screw near the relay REL1 (see figure
4.2.c) and fixing the inverter PCB on the secondary heat sink;

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.

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.

• Connect all the parts back following the same procedure in

reverse order.

NB repeat the equipment test starting from point 5.2 either if you have replaced the
inverter group or the single IGBT’s.

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5.3 LOW VOLTAGE TESTING

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 5.6). The control PCB must still
be supplied with the separate 24 V DC and must remain connected to the test card.

The logic sequence suggested for this procedure is shown in the block diagram no. 5.7:

a) INITIAL OPERATIONS

• Re-connect anything that has been previously disconnected or

replaced. Leave the auxiliary supply connected to the Y1
connector on the control PCB. Leave the test PCB connected as in
the previous test;
• remove the Z1 and Z2 connectors (see figure 4.5) from the spark
gap PCB, in order to exclude HF;
• connect the insulation transformer (c) and magnetothermic
switches (b) and (d) as shown in the electric diagram 5.6 to the
mains supply 230 V 50/60 Hz;
• switch the test PCB switch on OFF position;
• adjust the test PCB potentiometer at the maximum value (all in
clock-wise);
• switch the mains switch on position 0 (off);
• supply the machine closing the switches B and D (figure 5.6)

If the magnetothermic switch D is activated within a few seconds, check the switch (see
5.3.10) and the EMC filter (see 5.3.12) and replace them if necessary as explained at
chapters 5.3.11 (switch), 5.3.13 (EMC filter varistor) and 5.2.3 (for the remaining EMC filter
components).
If both components comply with the requested tests, check if there is any short circuit on
the mains cable, the wirings or the tracks.
Go ahead only when the magnetothermic switch D is not activated with open mains switch.

• Switch on the equipment (switch on I position);

If the magnetothermic switch D is activated within a few seconds, check the primary
rectifier (see 5.3.16) and replace it if necessary as explained at chapters 5.3.17.
If the component complies with the requested tests, check the electrolytic capacitors (see
5.3.18) and replace them if necessary (see 5.3.19). Then check if there is any short circuit
on the wirings or the tracks.

Now go to the block diagram of figure 5.7 and follow the instructions from the point where
you can supply the machine with 48 V AC.

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 C
400
D
48
A B 48 VAC t o t he
230
0 Mains
i llsupplyi
230 VAC
0

A - Power supply 230 V ac 50 Hz

B - Mains switch 250V - 5 A minimum
C - Insulating transformer cod 481432
D - Magnetothermic load switch 50 V 2A

Figure 5.6

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 NO YES

NO IS MAIN SWITCH YES YES

VOLTAGE 48VAC?
(5.3.3)

NO IS ELECTROLITIC YES NO
NO DOES MAIN SWITCH CAPACITOR VOLTAGE
WORK PROPERTLY? 60V ± 5V? (5.3.4)
(5.3.10)

YES NO DOES ELECTROLYTIC YES

CAPACITOR CHARGE CIRCUIT
WORK PROPERTLY?
(5.3.14)

DOES SECONDARY YES

NO DOES EMC FILTER NO RECTIFIER WORK
WORK DOES PRIMARY RECTIFIER
WORK PROPERTLY? PROPERTLY?
PROPERTLY? (5.3.5)
(5.3.12) (5.3.16)

Figure 5.7
YES DOES DOUBLER
YES
NO
YES WORK PROPERTLY?
(5.3.7)

NO
DOES ELECTROLYTIC YES
CAPACITOR WORK
PROPERTLY?
(5.3.18)

NO

REPLACE VARISTOR REPLACE ELECTROLYTIC

REPLACE REPLACE SUPPLY REPLACE WIRING,TRACK
(5.3.13) OR CAPACITOR CHARGE CIRCUIT REPLACE PRIMARY REPLACE SECONDARY RAPLACE REPLACE REPLACE
MAIN SWITCH CABLE AND CONTROL ELECTROLYTIC AND CONNECTOR RETURN TO
INVERTER UNIT (5.3.15) RECTIFIER (5.3.17) RECTIFIER (5.3.6) DOUBLER TRANSFORMER SUPPLY CIRCUIT
(5.3.11) WIRINGS CAPACITOR (5.3.19) CONTROL PARAGRAPH 5.4
(5.2.3) OR INVERTER UNIT (5.2.3) (5.3.8) (5.3.9) (5.3.20)

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37
5.3.1 OUTPUT VOLTAGE MEASUREMENT

Follow these instructions:

• Set the test PCB in position ON;

• Measure the voltage to the machine clamps (dinse) with a
multimeter, respecting the polarity

The correct value is 17V ± 2V.

Return to the block diagram and follow the instructions.

5.3.2 VOLTAGE CHECKING ON THE SUPPLY CIRCUIT

Make the following measurement:

1. Place the tester red probe (see 4.2.b) on point 9 (integrated case C1) and the black
probe on point 8 (DZ1 anode). The correct value is 60 V ± 5 V. Pay attention to this
measurement because the PCB is covered with a thick layer of paint.

Return to the block diagram and follow the instructions.

5.3.3 LINE SWITCH VOLTAGE MEASUREMENT

Make the following measurement:

• disconnect the two upper conductors from the mains switch

• disconnect the two main transformer fast-on from the J3 and J4
clamps (see figure 4.2.c);

Measure the voltage on the output conductors of the mains switch (connected to the
clamps J1 and J2 in figure 4.2.c)
The correct value is the same of the supply voltage, i.e. 48 V AC

• reconnect the two main transformer fast-ons on clamps J3 and J4

in figure 4.2.c;
• reconnect the two upper conductors from the mains switch.
Return to the block diagram and follow the instructions.

5.3.4 ELECTROLYTIC CAPACITORS VOLTAGE MEASUREMENT

Follow these instructions:

• cut off any voltage from the machine;

• disconnect the two main transformer fast-on from clamps J3 and
J4 in figure 4.2.c;
• Switch on the machine.

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Make the following test (you can measure correctly placing the probes near the R15
resistance body and not on the printed circuit) pointing the red probe of the tester (see
4.2.b) on point 14 and the black probe on point 15.
The correct value is 60 V ± 5 V.
• reconnect the two main transformer fast-on on clamps J3 and J4
in figure 4.2.c;

Return to the block diagram and follow the instructions.

5.3.5 SECONDARY RECTIFIER TESTING

Initial operations needed for testing:

• switch off the machine;

Tests are as follows:

1. Check with a multimeter the diode between a rectifier clamp (anode) and the
secondary heat sink (cathode) → 0.1-0.3 V (direct polarity).
2. Check with a multimeter the diode between the remaining rectifier clamp (anode) and
the secondary heat sink (cathode) → 0.1-0.3 V (direct polarity).

If any of the above conditions failed, the secondary rectifier is OK.

Return to the block diagram and follow the instructions.

5.3.6 SECONDARY RECTIFIER REPLACEMENT

To replace it you have to remove the screws fixing it to the heat sink and to the
conductors.
When mounting the new rectifier, pay attention to the thermic coupling with the heat sink.
Clean carefully the surfaces and spread the thermic paste on all the surface before fixing
the rectifier to the heat sink.

Return to the block diagram and follow the instructions.

5.3.7 DOUBLER TESING

Follow these instructions:

• cut off any voltage from the machine;

In figure 4.4 you can find the doubler PCB layout showing the components position and
the measurement points. Check the following:

1. Check the diode between point 1 anode and point 2 cathode

2. Check the diode between point 3 anode and point 4 cathode
3. Check the diode between point 5 anode and point 6 cathode

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4. Check the diode between point 7 anode and point 8 cathode

If any of the above conditions failed replace the doubler.

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 length. We therefore suggest you to replace them if the
electric arc is very short.

Return to the block diagram and follow the instructions.

5.3.8 DOUBLER ASSEMBLY REPLACEMENT

In the spare parts list the doubler is supplied complete with heat sink and secondary
rectifier.
Follow these instructions:
• Switch off the auxiliary supplier or any power supply to the
machine;
• Follow the instructions of chapter 5.2.3 to remove the upper
panel
• Loosen the metallic screw placed near the relay REL 1 (see
4.2.c) and the plastic spacer fixing the inverter PCB to the
secondary heat sink
• disconnect Y1 connector from the control pcb (see 4.3.a)
• loosen the two screws fixing the heat sink to the base
• loosen completely the two front panel screws
• disconnect the power conductors from the secondary rectifier.

Now the secondary rectifier assembly 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.

5.3.9 TRANSFORMER REPLACEMENT

Follow these instructions:

• Switch off the auxiliary supplier or any power supply to the
machine;
• Disconnect the fast-on J3 and J4 from the transformer primary
winding;
• Lay down the machine on the right side;
• Disconnect the power cables from the transformer secondary
winding;
• Loosen the screws holding the fixing plate of the main
transformer;
• Remove the transformer from its seat;
• Connect again the transformer following the same procedure in
reverse order.

Return to the block diagram and follow the instructions.

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5.3.10 MAINS SWITCH CONTROL

Initial operations needed for testing:

• cut off voltage from the machine;

• disconnect the two upper conductors and the two lower conductors
from the mains switch;

Tests are as follows:

1. Check electrical working by pointing the two multimeter probes to the two side
terminals. With the switch set to “O” (open) and then to “l” (close), there should be a
value indicating open circuit and short-circuit (0 ohm) respectively.
2. Repeat the operation for the remaining side terminals.
3. Turn the mains switch to position “l” in order to verify if there is an open circuit
between the two upper terminals.

If any of the above conditions failed replace the component as explained in chapter 5.3.11.

Return to the block diagram and follow the instructions or go back to the instruction book
to the point you were before.

5.3.11 MAINS SWITCH REPLACEMENT

For replacing the mains switch follow these instructions:

• loosen the knob fixing screw and the inside screws fixing the
switch to the front panel:
• push the switch from he opposite side;
• disconnect the conductors loosening completely the fixing
screws;
• Connect again the new switch following the same procedure in
reverse order.

Return to the block diagram and follow the instructions or go back to the instruction book
to the point you were before.

5.3.12 MAINS RADIODISTURBANCE FILTER CONTROL

Figure 4.2.a shows the position of mains radiodisturbance filter. Initial operations needed
for testing:

• Switch off the machine and disconnect the mains cable from the
transformer;
• Set the mains switch in pos.O (OFF)
• disconnect the two upper conductors and the two lower conductors
from the mains switch;

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Figure 4.2 gives the PCB layout showing the position of the filter parts and measurement
points. Tests are as follows:

1. Make sure there is an ohmic resistance between the input terminals (points 1 and 2) of
about 330 Kohm.

2. Check the electrical continuity (0 Ohm) of the filter pointing the multimeter probes
between the inputs (points 1 and 2) and corresponding outputs (lower clamps on the
mains switch).

3. Check the phases insulation versus earth using a multimeter (point 1 with earth clamp
on a zinc coated plate and then point 2 with the same clamp. There should be a
capacity value of 5.0 nF ± 1 nF.

4. Repeat a careful visual inspection of the filter parts especially the RV1 varistor. In case
of visible burning or explosion, replace the part immediately.

If any of the 1,2,3 conditions has failed replace the inverter PCB (see 5.2.3). 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.

5.3.13 VARISTOR REPLACEMENT (MAINS RADIODISTURBANCE FILTER)

To replace RV1 varistor proceed as follows :

• completely remove the rear panel screws

• disconnect mains cable from inverter card;
• remove the solenoidvalve fast-ons;
• remove the mains switch conductors.

You can now reach the filter components pins and you can easily replace the varistor.

• Repeat the same procedure in reverse order.

Return to the block diagram and follow the instructions or go back to the instruction book
to the point you were before.

5.3.14 ELECTROLYTIC CAPACITORS CHARGE CIRCUIT

Figure 4.2.a shows the position of the components of the electrolytic capacitors charge
circuit.
Initial operations needed for testing:

- cut off voltage from the machine;

- remove the upper panel as explained at 5.2.3

Figure 4.2.a gives the card layout showing the charge circuit parts positions and
measurement points. Tests are as follows:

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Repeat a careful visual inspection of the circuit components. Immediately replace any
components with traces of burning, especially on the relay (REL 1) (see point 18);
Check for a resistance value of about 6.8 Kohm (R17) between points 3 and 4.
Check the diode D11 with the measurement points 7 anode and 4 cathode.
Check for a resistance value of about 10 ohm ± 0.5 ohm between points 5 and 6.
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 5.3.15.

Be careful not to detect an open circuit due to a thick layer of paint on the card!

Return to the block diagram and follow the instructions.

5.3.15 CHARGE CIRCUIT PARTS REPLACEMENT

To replace charge circuit components, proceed as follows:

• Follow the instructions given at chapter 5.2.3 if not already

done until when disconnecting completely the inverter block you
can easily reach all the charge circuit components.

N.B. if parts R17, D11, C11 are faulty replace the complete inverter PCB.
Parts R14 and REL1 can be replaced.

• Repeat the same procedure connecting the components in reverse

order

Return to the block diagram and follow the instructions

5.3.16 PRIMARY RECTIFIER

Figure 4.2.a gives the components position of the electrolytic capacitors charge circuit.

Initial operations needed for testing:

- cut off voltage from the machine;

- remove the upper panel as explained at 5.2.3
- loosen the metallic screw which you can clearly see in the
middle of the control PCB;
- lift up the control card without using any tool which could
damage the tracks;

In figure 4.2.a you can find the PCB layout showing the clamps position on the primary
rectifier and the measurement points. Check the diodes placed between the points:

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1. Check the diode between point 12 anode and point 13 cathode
2. Check the diode between point 12 anode and point 10 cathode
3. Check the diode between point 11 anode and point 13 cathode
4. Check the diode between point 11 anode and point 10 cathode

If any of the above conditions failed replace the primary rectifier as explained at point 20

Return to the block diagram and follow the instructions or go back to the instructions book
to the point you were before.

5.3.17 PRIMARY RECTIFIER REPLACEMENT

To replace the primary rectifier follow the instructions given at chapter 5.2.3 removing
completely the inverter PCB and then follow these instructions:

• Remove the primary bridge cutting the 4 pins and removing the
welding one by one. Be careful not to damage the pin on the
inverter PCB;
• Check the track conditions on the inverter PCB;
• Carefully clean the pin and insert the new component;

Replace anyway the complete primary rectifier with heat sink.

• Repeat the same procedure connecting the components in reverse

order. Pay attention to the weldings on the primary rectifier.

Return to the block diagram and follow the instructions or go back to the instructions book
to the point you were before.

5.3.18 ELECTROLYTIC CAPACITORS CONTROL

Figure 4.2 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 electrolytic control you have to make this test.

Initial operations needed for testing:

• cut off any voltage from the machine;
• connect the supplier to the R15 resistance (4.2.c). Polarity is
important, i.e. positive pole is no. 14 and negative pole is no.
15;
• switch on the supplier and supply 30 V DC;

Check the following:

1.The supplier voltage must remain on 30 V.

If the above conditions fail, replace the three electrolytic capacitors as explained at point
22.
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• Repeat the same procedure connecting the components in reverse
order.
Return to the block diagram and follow the instructions.

5.3.19 ELECTROLYTIC CAPACITORS REPLACEMENT

Proceed as explained at 5.2.3 for replacing the complete inverter assembly, so that you
can reach the components and then replace them as following:

Completely replace the four capacitors.

N.B! Insert the electrolytic capacitor with correct polarity comparing the instructions
written outside each component with the card assembly layout.

• Repeat the same procedure connecting the components in reverse

order.

Return to the block diagram and follow the instructions.

5.3.20 MAINS SUPPLY CIRCUIT CONTROL REPLACEMENT

Figure 4.2.A shows the inverter pcb layout with the position of the supply circuit
components.
Proceed as explained at 5.2.3 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 4.2.b. If they are broken repair them or replace
the complete inverter card as explained at 5.2.3.
We remind you that the two tracks have 325 V, therefore pay attention to their insulation.

• Repeat the same procedure connecting the components in reverse

order.

Return to the block diagram and follow the instructions or go back to the instructions book
to the page you were before.

5.4 AUXILIARY SUPPLY TEST

Initial operations needed for testing:

• reconnect all the components which had been disconnected before
to the machine, leaving the 24 VDC auxiliary supply connected
to the control PCB and to the test PCB. Leave the Z1 and Z2

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 spark gap PCB connectors disconnected (see fig. 4.5), as in
the previous test;
• Switch off the mains switch (pos.0)
• Set the process selector on the auxiliary PCB in electrode
position;
• Turn the current adjustment potentiometer to mid scale;
• Supply the machine correctly (230V 50/60 Hz).
• Switch on the mains switch (pos.1);
• Set the switch on the test card in position on.

1. Check the closing of electrolytic capacitors charge relays (REL1 figure 4.2.c)
immediately after switching on the machine. You can do this without opening the
machine, but laying it down on the left side so that you can see the relay contacts. If
this condition fail, check the electrolytic capacitors charge circuit (5.3.18) and if
necessary replace the damaged components(5.3.19).
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 also all the
components.

• Set the selector switch on the auxiliary PCB in position LIFT;

3. Measure the output voltage. The value should be about 53 V ± 5 V. If not check the
diodes D3, D4, D5, D6 on the inverter PCB (see fig. 4.2.c). If the diodes are damaged
replace them or, better, replace the inverter group. If the diodes are not damaged
check the wiring cables, tracks and connectors on the machine and if necessary also
all the components.
4. Check that the red led on the test PCB is on. If not replace the control PCB.
5. Check that the cooling fan is turning. If not remove its connector from the inverter PCB
(X4 figure 4.2.c). Measure the voltage on X4. If the value is 29V ± 2V replace the
cooling fan as explained here below (5.4.1) , otherwise replace the supply circuit as
explained at 5.3.201 After replacing the fan check again if it’s working.

5.4.1 COOLING FAN REPLACEMENT

To replace the fan follow these instructions:

• cut off any voltage from the machine;

• Loosen the solenoidvalve fixing screw;
• Completely remove the screws from the rear panel;
• Loosen the fan screws;
• Remove the cooling fan and replace it;
• Repeat the same procedure connecting the components in reverse
order.

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5.5 MAINS SUPPLY TEST

Initial operations needed for testing:

• reconnect all the components which had been disconnected before

to the machine, leaving the test PCB connected. Leave the Z1 and
Z2 spark gap PCB connectors disconnected (see fig. 4.5), as in
the previous test;
• Switch off the mains switch (pos.0)
• Make a short circuit between the two dinse with a cable of at
least 25 mm2 section and insert the current pincer;
• Set the process selector on TIG HF position and the on/off
switch in ON position;
• Supply the machine correctly (230V 50/60 Hz).

NOTE: Before making any short circuit check that the machine is off.

• Set the minimum value using the potentiometer on the test PCB
• Switch ON the mains switch (pos. 1)

Measure the current value supplied from the machine. The correct value is 0A. If you don’t
have this value, replace the control PCB.

• Set the process selector switch in TIG LIFT position.

Measure the current value supplied from the machine. The correct value is 50A ± 3A. If
you don’t have this value, replace the control PCB.

• Set the process selector switch in TIG HF position.

Measure the current value supplied from the machine. The correct value is 0A ± 3A. If you
don’t have this value, replace the control PCB.

• Go up slowly with the potentiometer to the maximum value.

Measure the current value supplied from the machine. The correct value is 175A ± 10A. If
you don’t have these values replace the control PCB.

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5.6 WORKING TESTS

• Turn OFF the mains switch;

• Connect the front PCB to the interface PCB so that the machine
is ready for working without the test PCB;Leave the short
circuit connected to the output clamps for measuring the welding
current;
• Leave the Z1 and Z2 connectors on the spark gap PCB disconnected
(see fig. 4.5);
• Supply the machine with the correct mains voltage (230V 50/60Hz)
and turn ON the mains switch;
• Set the process selector switch in TIG HF position;
• Connect a welding torch to the 6 pole panel socket (no. 8 on the
spare parts list) in order to have the torch trigger contact.

a) Check that the green led is on. If Ok go to point b, otherwise measure the voltage
between points 1 (positive) and 20 on the front control PCB (see fig. 4.6). If the value is
15V ± 1V DC replace the front control PCB, otherwise replace the interface PCB.
Before making the replacement check the wiring cable between the front control and
the interface PCB.
b) Check that the thermostat yellow led is off. If not, check the wiring cable between the
front control and the interface PCB.

Minimum current control

• Set the potentiometer on the minimum value;

• Press the torch trigger and keep it pressed

1. If you measure a value different from 20A ± 2A, adjust the current value acting on the
RT3 trimmer on the interface PCB (figure 4.7) If this adjustment is not possible check
the front control PCB as explained at 5.6.1. If the front control PCB is OK replace the
interface PCB, then repeat all the operations of this chapter.

Maximum current check in TIG

• Set the maximum value on the potentiometer;

1. If you measure a value different from 170A ± 5A adjust the current value acting on the
RT4 trimmer on the interface PCB (figure 4.7) If this adjustment is not possible check
the front control PCB as explained at 5.6.1. If the front control PCB is OK replace the
interface PCB, then repeat all the operations of this chapter.

• Release the torch trigger.

Maximum current check in ELECTRODE

• Set the process selector switch in ELECTRODE position.

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1. If you measure a value different from 165A ± 5A, adjust the current value acting on the
RT2 trimmer on the interface PCB (figure 4.7) If this adjustment is not possible check
the front control PCB as explained at 5.6.1. If the front control PCB is OK replace the
interface PCB, then repeat all the operations of this chapter.

Solenoidvalve control

• Remove the short circuit from the output clamps;

• Set the process selector switch in TIG HF position.
• Press the torch trigger and keep itp pressed.

Check that the gas solenoidvalve is activated. For this control you can also connect the
gas and check that when pressing the torch trigger you have mains voltage between
clamps 2 and 3 on the J3 connector of the interface PCB (see figure 4.7). If you have th is
voltage replace the solenoidvalve, otherwise check the front control PCB (see 5.6.1) and if
this is also OK replace the interface PCB.

To replace the solenoidvalve follow these instructions:

• Loosen the solenoidvalve fixing screw;

• Remove completely the screws from the back panel;
• Disconnect the mains cable conductors;
• Disconnect the gas hose;
• Loosen the switch knob screw and then the screws fixing inside
the switch to the front panel;

The panel is now completely disconnected and you can easily replace the solenoidvalve.

• Repeat the same procedure connecting the components in reverse

order.

Spark gap PCB control

Follow these instructions:

• Turn OFF the machine;

• Remove any measure instrument from the machine;
• Reconnect the Z1 and Z2 connectors to the spark gap PCB;
• Turn ON the machine;

Press the torch trigger and check that the spark gap (SPGAP figure 4.5) is sparkling for
about one second, if yes then go to weld tests. If not follow these instructions:
• Remove any measure instrument from the machine;
• Connect with the stabilised supplier 24 VDC ± 2V to the two
pins on Z1 connector (see figure 4.5)
• Supply again the machine;
• Press the torch trigger and keep it pressed;
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Check that the spark gap is sparkling. If not, check all the wires connection and if all them
are OK, replace the spark gap PCB, otherwise replace either the front control PCB or the
interface PCB according to the check of the front control PCB made at point 5.6.1

WELDING TESTS

Make some welding tests both in electrode and in TIG.

Should you have any working problem on the equipment both in TIG or electrode welding,
replace the interface PCB or front control PCB according to the result of the front control
PCB test made at point 5.6.1.

For any problem concerning welding quality try to replace the doubler or the control PCB.

5.6.1 FRONT CONTROL PCB TEST

Follow these instructions:

• Switch off the machine;

• Disconnect the J5 connector from the interface PCB (see fig.
4.7);
• Remove the front control PCB and the panel loosening the four
screws fixing it to the chassis.

In figure 4.6 you can find the front control PCB layout with the measurement points.
Make the following tests:

PROCESS SWITCH (TIG HF, TIG LIFT, ELECTRODE)

1) Measure the resistance value between points 4 and 5 with the process switch on TIG
HF. The correct value is a short circuit. With the switch on TIG LIFT and ELECTRODE
you have to find an open circuit.
2) Measure the resistance value between points 7 and 8 with the process switch on TIG
HF. The correct value is a short circuit. With the switch on TIG LIFT and ELECTRODE
you have to find an open circuit.
3) Measure the resistance value between points 5 and 6 with the process switch on
ELECTRODE. The correct value is a short circuit. With the switch on TIG LIFT and TIG
HF you have to find an open circuit.
4) Measure the resistance value between points 8 and 9 with the process switch on
ELECTRODE. The correct value is a short circuit. With the switch on TIG LIFT and TIG
HF you have to find an open circuit.

If any of the above conditions fail, replace the switch or, better, the complete front control
PCB.

2 STROKE, 4 STROKE SWITCH (2T, 4T)

5) Measure the resistance value between points 2 and 3 with the mode switch on 4T. The
correct value is a short circuit. With the switch on 2T you have to find an open circuit.

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If the above condition fails, replace the switch or, better, the complete front control PCB.

SLOPE DOWN POTENTIOMETER

6) Measure the resistance value between points 10 and 11 with the potentiometer set at
the maximum value. The correct value is 1MΩ ± 0.1MΩ. With the potentiometer at the
minimum value you have to measure a short circuit.

If the above condition fails, replace the switch or, better, the complete front control PCB.

POST GAS POTENTIOMETER

7) Measure the resistance value between points 12 and 13 with the potentiometer set at
the maximum value. The correct value is 1MΩ ± 0.1MΩ. With the potentiometer at the
minimum value you have to measure a short circuit.

If the above condition fails, replace the switch or, better, the complete front control PCB.

THERMOSTAT LED

8) Measure with a multimeter set on diodes check position the led placed between points
14 and 15.

If the above condition fails, replace the led or, better, the complete front control PCB.

MAINS SUPPLY LED

9) Measure with a multimeter set on diodes check position the led placed between points
16 and 17.

If the above condition fails, replace the led or, better, the complete front control PCB.

WELDING CURRENT POTENTIOMETER

10) Measure the resistance value between points 18 and 19 with the potentiometer set at
the maximum value. The correct value is 1MΩ ± 0.1MΩ. With the potentiometer at the
minimum value you have to measure a short circuit

If the above condition fails, replace the led or, better, the complete front control PCB.

TRANSISTOR

11) Measure with a multimeter set on diodes check position the transistor (npn) placed
between points 21 (collector), 22 (base) and 23 (emitter).

If the above condition fails, replace the transistor or, better, the complete front control
PCB.

The remaining components and the tracks are seldom damaged and anyway you can
check them using a multimeter.

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If all the above conditions are OK, the front control PCB is working correctly and go back
from the beginning.

6. WARRANTY CONDITIONS

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.

7. TECHNICAL DATA

TIG MMA
Input voltage 1ph 230 V ± 15%
Installed power 3.2 kVA 3.9 kVA
Max. input current
current 24.5 A rms 26.5 A rms
Absorbed input current at
14.0 A rms 17.0 A rms
(X=100%)
Power factor 0.65
Efficiency (X=100%) 0.8
Cosϕ
Cosϕ 0.99
Current range 5-170A 5-150A
Welding current x= % 170 A X=20% 150 A X=25%
Welding current X=60% 115 A 115 A
Welding
Welding current X=100% 95 A 95 A
Open circuit voltage 88 V
Protection class IP 23
Standards EN60974 - EN50199
Dimensions (lxpxh) 390 * 300 * 135 (mm)
Weight 7 kg

8. REQUEST FOR TECHNICAL ASSISTANCE PROCEDURE

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:

E_Mail cea@ceaweld.com –web www.ceaweld.com

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REMARKS

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REMARKS

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