MATRIX 200 AC/DC

Strictly confidential

CEA COSTRUZIONI ELETTROMECCANICHE ANNETTONI S.p.A.

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
1020h577/A
INDEX:

PURPOSE OF THE MANUAL charter 1

MACHINE DESCRIPTION Charter 2

AVAILABLE SPARE PARTS Chapter 3

INSTRUMENTS REQUIRED FOR TESTING AND REPAIRING Charter 4

TESTIN PROCEDURE Charter 5

WARRANTY CONDITIONS Charter 6

TECHNICAL DATA Charter 7

TECHNICAL ASSISTANCE PROCEDURE REQUEST Charter 8

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1. PURPOSE OF THE MANUAL

The purpose of this manual is to give useful information on repairing MATRIX 200 AC DC
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.
No way CEA Spa will be responsible for damages, direct and/or indirect, suffered by
persons or things due to a careless reading or negligence to putting into practice
what described in this manual.
Always use original spare parts supplied by CEA

The 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, thus greatly helping damaged component identification (see chapter 2).
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 read 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 rights of translation, copy and partial or total modification in any way (including copies,
film and microfilm) are not allowed without written authorization from CEA SpA.

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2) MACHINE DESCRIPTION

The MATRIX 200 AC/DC 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 advantages in using
this system such as greater efficiency and improved welding quality resulting from system
quick response.

Figure 2.1 block diagram shows the working principle of the above machine.

°t
°t

1. Antidisturbance mains filter 2. Mains switch

3. Electrolytic capacitors charging circuit 4. Primary bridge
5. Electrolytic capacitors 6. Primary inverter
7. Primary current reading transformer 8. Main transformer
9. Secondary bridge with thermostat 10. Secondary inverter with thermostat
11. Driver PCB 12. Inductor
13. Welding current reading Shunt 14. HF PCB filter
15. HF transformer 16. Spark-gap PCB
17. Arc welding stabilizer PCB 18. Inverter control circuit
19. Supply voltage circuit 20. Pump, electric fan and solenoid-valves relays
21. Solenoid gas valve 22. Cooling electric fan
23. Water cooling connector 24. External signal filter PCB
25. Digital interface PCB 26. Auxiliary transformer
(i)
(ii) 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 picture 2.2)

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 25 1
3
4
10 22

13 17
11

5
6
9
8
15
16 12
Figura 2.2

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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 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. Two resistors have 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. These resistors are short-circuited by two relays 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
continuous wave form. Other capacitors are also needed near to the inverter to
eliminate any high frequency harmonics and to reduce interferences 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 welding current control is obtained by the inverter modulation.

7. Inverter current reading transformer. It is installed at the output of the inverter and
on the primary side of the transformer. Its purpose is to give a proportional current
value in function to the current given from the inverter and necessary for its protection.

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8. Power transformer. The transformer supplies a lower voltage to its secondary
terminals necessary for welding. It also provides the needed electric insulation between
the main power supply and the welding circuit, as requested by the standards.

9. Secondary rectifier circuit with thermostatic protection: the square wave voltage
given from the inverter is rectified by a fast diode rectifier (D1, D2, D3 and D4 – see fig.
2.3). D1 and D2 rectify the positive wave form, while the D3 and D4 the negative one.
On the secondary heat sink diodes there’s a thermostatic protection.

IS

Fig. 2.3

10. Secondary inverter. Figure 2.3 shows the secondary inverter connection (IS). The
INVERTER is used to turn from positive into negative the output voltage by IGBT pair
which alternatively connects the positive and negative side, of the secondary rectifier,
to the output. In TIG and MMA DC mode G1 IGBT is always on and the output polarity
is as written on front panel. In TIG AC mode the polarity change continuously with
frequency between 50kHz and 150 kHz and the balance between “+10” to “-35”;
frequency and balance can be both adjusted from the operator. On IGBT’s heatsink
there’s a thermostat that turns off the inverter in case of overheating.

11. Driver PCB. It gives the piloting signal to the secondary inverter according to the digital
card output. IGBT’s are ON by means a signal of 17V dc between gate-emitter and are
OFF by a signal of -7V DC.

12. Inductor: the purpose of this device (L) is to level the current inside the welding circuit
in order to have a continuous value.

13. Shunt: this device allows both the control and current measurement, giving an output
value proportional to the welding current needed for the adjustment.

14. HF PCB filter. This circuit is necessary for closing the high voltage produced from the
HF transformer. It also protects the machine components from over-voltages.

15. HF transformer: gives the necessary voltage for the electric arc striking when the
machine is set in TIG mode, both AC and DC.

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16. 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.

17. Arc welding stabilizer PCB. The purpose of it is to give an higher voltage value than
the required one in order to obtain a more stable arc welding during the switching
phase from negative current (positive electrode) to positive one (negative electrode).
Such value is given between L inductor output and E2 point at fig. 2.3

18. Inverter control circuit. The card includes the IGBT control circuit. This circuit sets the
IGBT conduction time according to the value chosen by the control potentiometer.

19. Supply circuit: it gives the necessary continuous supply (24 V) necessary for
supplying the electronic devices of the relays and the fan motor (that one next to the
inverter heat sink).

20. Pump, fun motor and gas solenoid valve relays: these relays controls the gas
solenoid valve, the water cooler and the fan motor too; their activation is shown by the
related LEDs placed on inverter PCB.

21. Gas solenoid valve. It adjusts gas opening and closing in TIG mode according to the
values chosen from the operator.

22. Cooling fan motor. The fans are necessary to cool down the internal parts of the
machine. There’re two fan motors; one is supplied by 24V dc and the other one by
230V ac (directly taken from the mains). They are operated directly from the control
“fan on demand”.

23. Water cooling equipment connection: needed for connecting the water cooling
equipment. The signals are:
- 230 V mains supply;
- signal that the water cooler is switched on, controlled by the “cooling on demand”
facility;
- pressure switch alarm signal when the water is not circulating inside the water
cooling equipment;

24. External control filter PCB. It purposes is to protect the machine against over voltage
which can be induced by HF among external wire devices (i.e. UP/DOWN trigger torch
and all the remote potentiometers).

25. Microprocessor PCB: this card implements all the equipment functions set by the
operator on the front panel.

26. Auxiliary transformer. It gives the auxiliary supply voltage (9 V ac) necessary for
supply external control circuits.

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3) Available spare parts
(iii)

Position Electrical diagram reference

Description Code No.
(Figure 3.1) (Figura 3.8)
2) 43
1 Handle 1) (-) 46
96
2 Keyboard RF 447823
3 Knob (-) 438889
4 Front panel MKB 352415
5 Sticker (-) 467050
6 6 poles female socket CT 419050
7 Gas quick connection (-) 403635
8 Welding quick connection 50 mm2 (-) 403614
9 MATRIX cover (-) 420536
10 Cover (-) 352419
11 Switch knob (-) 438710
12 Rear panel (-) 352416
13 9 poles female connector (-) 419049
14 5x10.5 gas tube (-) 485040
15 Mains cable (-) 235992
16 PG 13.5 cable gland (-) 427878
17 PG 13.5 5 cable gland locknut (-) 430751
18 Lateral guide (-) 352412

Figure 3.1

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 Position Electrical drawing reference
Description Code No.
(Figure 3.2-3.3) (Figure 3.8)
19 HF filter FR 427670
20 Gas solenoid valve EVG 425933
21 Inverter assembly support plate (-) 449548
22 150A 60 mV Shunt SH 376476
23 Secondary IGBT module - 300A 600V MS 286023
24 Secondary IGBT thermostat - 80°C TH2 478848
25 Voltage discharger group - BZW50-180 DS 418915
26 Packaged primary rectifier (-) 455510
27 Primary heat sink clamp (-) 427250
28 IGBT dust protection s ticker (-) 467059
29 Fan motor + 24 VDC MV2 444508
30 Primary IGBT heat sink (-) 423520
31 Primary IGBT rear heat sink (-) 423528
32 Support plate inverter block (-) 449549
33 Galvanized base (-) 404985
34 Primary inverter base (-) 352478
35 Secondary IGBT heat sink (-) 423524

Figure 3.2

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 (iv)

Position Electrical drawing reference

Description Code No.
(Figure 3.3) (Figura 3.8)
36 Transformer insulation sticker (-) 468699
37 Transformer fixing bracket (-) 463220
38 Transformer TP 481427
39 Inverter assembly IB 432140
40 Mains switch IL 435755
41 Wiring (-) 413688
42 Fan motor - 230V 50Hz MV1 486374
43 Fan conveyor (-) 466128
44 Front fan motor support (-) 466126
45 Secondary diode heat sink (-) 423522
46 Secondary diodes D1, D2, D3, D4 423236
47 100 °C thermostat diodes TH1 478862
48 Connector insulation support (-) 436050
49 HF transformer THF 239992
50 Inductor L 240220
51 EMC filter FI 427655

Figure 3.3

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 Position Electrical drawing reference
Description Code No.
(Figure 3.4) (Figure 3.8)
52 Digital PCB SDF 376931
53 Encoder ED 454155
54 Trigger torch filter PCB+ remote controls FCTA 376930
55 Driver PCB SDRV 376775
56 Spark gap PCB SHF 376917
57 Arc welding stabilizer PCB SSA 376773

Figure 3.4

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 Position Electrical drawing reference
Description Code No.
(Figure 3.5) (Figura 3.8)
1001 MATRIX AC/DC “test PCB” (-) 377550
1002 Package of No. 4 pre-selected IGBT (-) 286025
1003 Relay - 48V 16A (-) 456764
1004 Resistore - MC T5C/15 10Ω 15W (-) 457095
1005 Resistor - 6k8 8W RWM8X266k85% (-) 457098
1006 Capacitor - 470µF 400V (-) 418778
1007 Current sensor - 25A (-) 439520

1001

1002 1003 1003 1004 1004 1005 1005

1002 1007 1006 1006 1006 1006

Figure 3.5

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 Position Electrical drawing reference
Description Code No.
(Figure 3.6) (Figure 3.8)
1008 UCC3895 I.C. (-) 352508
1009 Pulse transformer (-) 481915
1010 Relay - 24V 5A JZC-32FA -024-HSL1 (-) 456780
1011 Relay - 24V 8A JQX-115F-024-2ZS4 (-) 456785
1012 Transformer - 230V 12V 0.5VA VN20.10.5/2St (-) 481953

1008 1009 1010 1010 1011

1009 1012

1011

Figure 3.6

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 Position Electrical drawing reference
Description Code No.
(Figure 3.7) (Figure 3.8)
1013 IGBT driving circuit KIT (-) 456955
1014 Auxiliary supply circuit KIT (-) 456950

1013

1013 1014

Figure 3.7

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 Figure 3.8

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4) INSTRUMENTS REQUIRED FOR TESTING AND REPAIRING

The following instruments are needed to check the machine:

1) A testing PCB cod. 377550 (vedi figura 4.1). This PCB allows you to test the machine
without the digital PCB. Is possible to:
a) Switch ON and adjust all the available devices on the machine:
- HF (HF);
- Cooling pump (PUMP);
- Cooling fun motors (FAN 230V e FAN 24V);
- Gas solenoid valve (EVG);
- Welding arc stabilizer circuit (BOOST);
- inverter (INVERTER);
- output polarity (OUT+ e OUT-);
- inverter adjustment (S.P. PWM);
b) machine signals displaying:
- thermostat switch ON (led °C);
- Auxiliary supplies (POWER LED and 12Vac between TP4 and TP5);
- Welding voltage (between V-SALD and GND) and welding current (between I-
SALD and GND);

(v) Figure 4.1

2) 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);

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- 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.

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

4) Probe with the following characteristics:

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

5) Current probe model FLUKE I1010 or another one with similar or better features or a
shunt of 250A.

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

7) 2 A magneto -thermal switch;

8) 250V - 5A minimum mains switch.

To replace IGBT:

9) A solder for electronics fitted with anti-static tip earthed to the ground for welding the
IGBT.

10) Two anti-static wristbands around the wrists are necessary when welding IGBT.

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

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.

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, 4.2.b, 4.2.c, 4.2.d - layout inverter PCB seen from the upper side;
- Fig. 4.3 - secondary inverter driver PCB layout;
- Fig. 4.4 - ARC stabilizer PCB layout;
- Fig. 4.5 - Digital panel PCB layout;
- Fig. 4.6 - Spark-gap PCB layout;
- Fig. 4.7 - Torch button trigger and external control filter PCB layout.
- Fig. 4.8 - measure points of the “test card”.

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 11 10 9 8 7 6 5 4 3 2 1

13 12

Figure 4.2.a

Figure 4.2.b

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 PIN1

PIN8
PIN8

PIN1

Figure 4.2.c

1 2 3 G1 E1 G2 E2

Trimmer Rt1
E4 G4 E3 G3
OverVoltage

Figure 4.2.d

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 Figure 4.3

PIN 6

PIN 1

PIN 6 PIN 1

Figure 4.4

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 Figure 4.5

1 2
(vi) Figure 4.6

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 (vii) Figure 4.7

PIN10

Figure 4.8

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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- a preliminary power parts test using a multimeter. Pls. follow the instructions given at
chapter 5.2;
3- auxiliary supplies control and PWM PCB control (IGBT drivers). Follow the instructions
given at chapter 5.3.

4- low voltage test (48VAC 50/60 Hz). 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 5.4.

5- Panel PCB test. Follow the instructions given at chapter 5.5.

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.

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 MACHINE INTERNAL AND EXTERNAL VISUAL EXAMINATION

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.
If you are afraid something is damaged, replace the front panel immediately removing
the screws and disconnecting the connectors.

c) Open the machine following the procedure given below:

1.unscrew the 2 screws holding the handle;

2.remove the handle pulling it back;

3.remove the protection deck and loosen the 3 screws fixing

the cover;

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 4. Push the cover by your hands towards the front panel, to
get free the back area;

5.Remove the cover, lifting it up by your hands;

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

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. Repeat the visual inspection after this operation.

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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PRELIMINARY CONTROL OF THE POWER PARTS USING A MULTIMETER

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

We remind you that after replacing any components it’s necessary to make again all
the controls from the beginning.

Initial operations to be done before checking the components:

• Switch off any supply to the machine;

• Disconnect the three wires removing their fast-on from the
primary rectifier (see points 1,2,3 in figure 4.2.a;

SWITCH
• Set the mains switch in pos. I (ON).
Check with a multimeter that between the inlet and the correspondent outlets of the switch
there is a short-circuit. If not, replace the switch.

• Set the mains switch in position O (OFF).

Check with a multimeter that between the inlet and the correspondent outlets of the switch
there is an open circuit. If not, replace the switch.

You can easily replace the switch loosening the handle fixing screw and then all the switch
fixing screws to the rear panel and to the mains cable.
P.S.: pay attention the mains switch connection which is shown at fig. 3.8. The short-
circuited wires of the mains cable (black and brown) must be connected to J1 and J3
points.

EMC MAINS FILTER

Check the electrical continuity of the filter pointing the multimeter probes between the
inputs (mains cable phases) and corresponding outputs (main switch lower terminal). The
ohmic resistance value must be the same as a shortcircuit.
Check the phases insulation (main switch lower terminal) versus the filter earth conductor
(see fig. 5.1). The ohmic resistance value measured must be the same as an open circuit.

(viii) Figure 5.1

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If one of the above conditions fails, replace the EMC filter (after the mains cable has been
checked too) otherwise go to primary rectifier control chapter.
To replace the EMC, remove the arc stabilizer PCB and the related support fixing screws
which hold the same to the lower base.
Proceed in the reverse order to re-assembly the machine.

PRIMARY RECTIFIER

Using a multimeter check the eight diodes among the test points shown in figure 4.2.a:

a) D24 rectifier
• 4(cathode)and 5 (anode)
• 4(cathode)and 6 (anode)
• 7(anode) and 5 (cathode)
• 7(anode)and 6 (cathode)

b) D25 rectifier
• 8(cathode)and 9 (anode)
• 8(cathode)and 10 (anode)
• 11(anode) and 9 (cathode)
• 7(anode)and 10 (cathode)
In direct polarity you should find about 0,4 - 0,5 V. By reversed
polarity you should find an open circuit. If all the above
conditions succeed, then go to electrolytic capacitors charging
circuit; otherwise replace the primary rectifier following these
instructions:
• Remove both the front and rear panel;
• Disconnect all the wires that from the transformer and
secondary rectifier are connected to the lower side of the
machine;
• Disconnect the thermostats from the inverter PCB;
• Disconnect the transformer from inverter PCB;
• Disconnect the Y1 connector from the driver PCB (see fig. 4.3);
• Disconnect the shunt from the secondary module;
• By using the anti-static wristbands, disconnect the driving
connectors from the secondary module; afterwards make a short-
circuit between gate and emitter of each IGBT’s;
• Unscrew the two screws which fix the inverter PCB to the
secondary heat sinks;
• Unscrew the two screws which fix the inverter PCB to the
inverter support plate;

You can now reach the primary rectifiers and replace both at the same time. Check the
electrolytic capacitors charging circuit before re-connecting the inverter PCB. Proceed in
the reverse order to re-assemble the machine.

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ELECTROLYTIC CAPACITORS CHARGING CIRCUIT

Do the following controls (see fig. 4.2.b):

1) Check the R26 value on the inverter PCB; if it’s about 10Ω±0.5Ω go to point 2. In case
of short circuit, then the relay REL1 must be replaced (see fig. 4.2.a), while if a open
circuit has been found, then both REL1 relay and R26 resistor must be replaced;
2) Check the R33 value on the inverter PCB; if it’s about 10Ω±0.5Ω go to point 3. In case
of short circuit, then the relay REL2 must be replaced (see fig. 4.2.a), while if a open
circuit has been found, then both REL2 relay and R33 resistor must be replaced;
3) Check the R35 value on the inverter PCB; if it’s about 6.8kΩ±0.2kΩ go to point 4,
otherwise replace it.
4) Check the R36 value on the inverter PCB; if it’s about 6.8kΩ±0.2kΩ go to point 5,
otherwise replace it.
5) Check D14 diode on the inverter PCB; if it hasn’t been damaged go to point 6,
otherwise replaced it by a new one (1N4007) and C29 capacitor (22uF 100V
electrolytic type). These parts can be easily found by any electrical shop as are very
common.
6) Check D23 diode on the inverter PCB; if it hasn’t been damaged go to next point,
otherwise replaced it by a new one (1N4007) and C31 capacitor (22uF 100V
electrolytic type). These parts can be easily found by any electrical shop as are very
common.

AUXILIARY TRANSFORME R, DRIVER PCB AND RELAY SUPPLY VOLTAGE

1) Measure the ohmic resistance between 1 (J1) and 2 (J2) points shown at fig. 4.2.a.;
the right value is about 1.2kΩ÷1.3kΩ.

If the above test has successfully carried out go to point 2; otherwise disconnect the
X6 connector from the inverter PCB (see fig. 4.2.c).
a) Measure again the ohmic resistance between 1 (J1) and 2 (J2) points; if you got
about 9kΩ÷10kΩ go to point “b”, otherwise replace the TR5 auxiliary transformer
(see fig. 4.2.c). To replace it do as explained for replacing inverter PCB before,
then replace the TR5.
b) Measure the ohmic resistance between 3 and 5 pins of X6 female connector
previously disconnected. If the measured value is about 1.2kΩ÷1.5kΩ go to point
“c”, otherwise replace the inverter PCB.
c) Measure the ohmic resistance between 2 and 6 pins of X6 female connector
previously disconnected; if you got about 2.2kΩ÷2.5kΩ go to point “d”, otherwise
replace the gas solenoid valve, afterwards measure the same pins (2, 6) ,but this
time, on the male connector of the inverter PCB. The right value must be as an
open circuit, otherwise the REL5 (see fig. 4.2.c) must be replaced. For the
replacing of the component, the inverter PCB must be removed before as
described for the primary rectifier.
d) Measure the ohmic resistance between 1 and 7 pins of X6 female connector
previously disconnected; if you got about 0.6kΩ÷0.7kΩ go to point “2”, otherwise
replace the fun motor cooling, afterwards measure the same pins (1, 7), but this

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 time, on the male connector of the inverter PCB. The right value must be as an
open circuit, otherwise the REL4 (see fig. 4.2.4) must be replaced. For the
replacing of the component, the inverter PCB must be removed before as
described for the primary rectifier.

2) Between 1 and 2 pins of X5 connector (see fig. 4.2.c) should be about 100Ω÷105Ω; if
such value is found, then go to “secondary rectifier control”, otherwise the auxiliary
transformer must be replaced. Se il valore è corretto passare al controllo del
raddrizzatore secondario in caso contrario sostituire il trasformatore ausiliario.

SECONDARY RECTIFIER

D1 and D2 diodes
1) Check by a multimeter the secondary diodes between 1 (cathode) and 2 (anode)
points according to the fig. 5.2. If they are damaged then replace them, otherwise go
to point “2”.
2) Check by a multimeter the secondary diodes between 1 (cathode) and 3 (anode)
points according to the fig. 5.2. If they are damaged then replace them, otherwise go
to point “3”.
P.S.: The measured value on direct polarity is very low: about 0.1V and 0.2V.
The components replacement is quite easy by removing the related screws; never forget
to apply the proper thermal conductive paste (i.e. RHODOSIL COMPOUND 340 - our code
457053), after the contact surface has been carefully cleaned, between the new
component and its heat sink.

Diodi D3 e D4
3) Check by a multimeter the secondary diodes between 4 (anode) and 2 (cathode)
points according to the fig. 5.2. If they are damaged then replace them, otherwise go
to point “4”.
4) Check by a multimeter the secondary diodes between 4 (anode) and 3 (cathode)
points according to the fig. 5.2. If they are damaged then replace them, otherwise go
to point “5”.

P.S.: The measured value on direct polarity is very low: about 0.1V and 0.2V.
The components replacement is quite easy by removing the related screws; never forget
to apply the proper thermal conductive paste (i.e. RHODOSIL COMPOUND 340 - our code
457053), after the contact surface has been carefully cleaned, between the new
component and its heat sink.

Over voltage protection

5) Check by a multimeter the secondary diodes between 4 (anode) and 1 (cathode)
points according to the fig. 5.2. If they aren’t damaged go to “secondary inverter”
control, otherwise the discharger must be replaced both from rectifier and the inverter
side.

SECONDARY INVERTER

1) Check by a multimeter the diode between 1 (anode) and 2 (cathode) according to fig.
5.3. If no short-circuit has found go to point 2, otherwise replace the secondary invert
module.

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2) Check by a multimeter the diode between 3 (cathode) and 2 (anode) according to fig.
5.3. If no short-circuit has found go to 5.3 chapter, otherwise replace the secondary
invert module.

Before replacing the IGBT modules, pls. ensure that DZ13, DZ14, DZ23, DZ24 Zener
diodes (driver PCB fig. 4.3) aren’t short-circuited; all the connectors of IGBT modules
must be disconnected before diode testing. Even if just one Zener diode gives a short
circuit all of them must be replaced. It deals with standard Zener diodes of 20V /12 W.

For components disassembly, it’s enough to remove the related screws and the
connectors of the module as well; during the replacement some precautions must be
taken, that’s:

- Antistatic devices as wrist-band and soldering-guns earth connected;

- Care on thermal coupling with any heat sink;

1 4
D1 D3
2

D2 D4
3

Figure 5.2

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 7
6
5
1 4
2
3

Figure 5.3

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5.3) INVERTER DRIVER PILOTING AND AUXILIARY SUPPLY VOLTAGES CONTROL

P.S.: The equipment must be disconnected from the mains supply.

Initial operations to be done before checking the components:

• reconnect all the components which had been disconnected before

to the machine, with the only exception of the three fast-on
which bring the three phases to the primary bridge (points
1,2,3 in fig. 4.2.a);
• disconnect the CN1, CN2, CN3, CN4 and CN6 connectors from the
digital interface PCB (see fig. 4.5) and connect the “test PCB”
to the related connectors (see fig. 4.8);
• disconnect the Y1 connector from the arc welding stabilizer PCB
(see fig.4.4).
• set OUT+ OUT- switch, on “test PCB”, on OUT+ position;
• set all the other switches in OFF position;
• set to the max the S.P.PWM potentiometer (see fig.4.8)(turning
it in clockwise);
• disconnect X2 and X3 connectors from inverter PCB (see fig.
4.2.d);
• disconnect Y2 (see fig. 4.2.d) connector from inverter PCB and
then connect it (the male one) to the stabilized DC supplier by
using the proper cable.
P.S.: 3 and 2 pins must be short-circuited and connected to the
positive pole, while the 1 pin must be connected to the
negative pole;
• connect the oscilloscope probe to points G1 and E1 (round) of
the inverter PCB (see fig. 4.2.d);
• Set the oscilloscope as follows:
ü vertical 10V/div;
ü horizontal 10µs/div;
ü up slope Trigger;
• set at 24 V ± 1 V the output voltage of the stabilized supplier
and then supply the inverter PCB;

1) Check the LED’s status according the below table:

INVERTER PCB (fig. 4.2.d) TEST PCB (fig. 4.8)

LED1 +24 (green) OFF LED1 (green) ON
LED2 +15 (green) ON LED2 (yellow) ON
LED3 FAN 24V (green) OFF
LED4 WATER PUMP (green) OFF
LED5 FAN (green) OFF
LED6 GAS (green) OFF
LED7 INV ON (green) ON
LED8 TERM (red) ON
If all the LED’s are OFF/ON as above shown go to point 2, otherwise follow the next
instruction.
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Inverter PCB
• LED2: if it’s OFF then disconnect I.C. U1 and check if the LED become ON, if so
replace the I.C. (I.C. stands for Integrated Circuit); otherwise the LED still OFF replace
the INVERTER PCB and repeat the tests from the beginning;
• LED3: if it’s ON replace the INVERTER PCB after that the wiring between “test” and
inverter PCB has been checked;
• LED4: if it’s ON replace the INVERTER PCB after that the wiring between “test” and
inverter PCB has been checked;
• LED5: if it’s ON replace the INVERTER PCB after that the wiring between “test” and
inverter PCB has been checked;
• LED6: if it’s ON replace the INVERTER PCB after that the wiring between “test” and
inverter PCB has been checked;
• LED7: if it’s OFF replace the INVERTER PCB after that the wiring between “test” and
inverter PCB has been checked;
• LED8: if it’s OFF replace the INVERTER PCB

TEST PCB
• LED1 POWER: if it’s OFF check the wiring between “test” and inverter PCB and in case
replace the inverter PCB;
• LED2 °C: if it’s OFF check the wiring between “test” and inverter PCB and in case
replace the inverter PCB;

2) Check that the shown voltage from the oscilloscope is equal to 0V, otherwise replace
the inverter PCB.

• Set the INVERTER ON switch, on “test PCB”, in position ON(see

fig. 4.8);
• Set the PUMP, FAN 230V, EVG, FAN 24V switches in position ON
(see fig. 4.8);

3) Check the LED’s status according the below table:

INVERTER PCB (fig. 4.2.d) TEST PCB (fig. 4.8)

LED1 +24 (green) OFF LED1 (green) ON
LED2 +15 (green) ON LED2 (yellow) ON
LED3 FAN 24V (green) ON
LED4 WATER PUMP (green) ON
LED5 FAN (green) ON
LED6 GAS (green) ON
LED7 INV ON (green) OFF
LED8 TERM (red) ON

If all the LED’s are OFF/ON as above shown go to point 4, otherwise follow the next
instruction.

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Inverter PCB
• LED2: if OFF replace the inverter PCB and repeat the control from the beginning;
• LED3: if OFF replace the inverter PCB;
• LED4, LED 5, LED 6 if at least one of them is OFF check the wiring on X5 connector of
the inverter PCB and in case replaced itself;
• LED7 if OFF replace the inverter PCB;
• LED8 if OFF replace the inverter PCB;

Test PCB
• LED1 if OFF check the wiring between inverter PCB and “test PCB”;
• LED2 if OFF replace the inverter PCB;

4) If the 24V fun motor doesn’t work check its wiring ad in case replace the fun motor;

5) Check that the shown voltage from the oscilloscope is equal to 0V, otherwise replace
the inverter PCB.

• Re-connect X2 and X3 connectors to the inverter PCB (see fig.

4.2.d);

6) LED8 TERM on inverter PCB must be OFF.

If it’s OFF go to point 7 otherwise, switch OFF the auxiliary supply voltage, check the
electrical continuity (0Ω) between points 1 (DZ1 cathode) and 2 (R4 resistor) shown at
fig. 4.2.d.
The two thermostats are serial connected one to the other between these two points
(DZ1 cathode and R4 resistor) and following the electrical path of the internal legs is
easy to find out the thermostat or the electrical track (very unusual) damaged. If all the
thermostats are short-circuited, the inverter PCB must be replaced.

7) LED2 °C on inverter PCB must be OFF, otherwise switch OFF any auxiliary supply
voltage and check the electrical continuity (should be 0 ohm) as below:
- between point 2 of fig. 4.2.d (R4) and TP1 on “test PCB” (fig. 4.8);
- between point 3 of fig. 4.2.d (anode of D1) and pin 10 of CN1 connector of “test
PCB” (fig. 4.8). If both tests are verify then replace the inverter PCB otherwise
check the wiring between inverter PCB and “test PCB”.

8) Verify that on the oscilloscope is displayed the wave form shown at fig. 5.4 (2V - 4µs).
The frequency must be 100 kHz ÷101.5 kHz ; otherwise the inverter PCB must be
replaced by a new one and then repeat the test from the beginning

• Set the oscilloscope as follows:

ü vertical 2V/div;
ü horizontal 200ns/div;
ü slope up Trigger;
9) Make sure that the waveform on your oscilloscope is similar to the one shown at fig.
5.5.

• Set the oscilloscope as follows:

ü vertical 2V/div;
ü horizontal 200ns/div;

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 ü slope down Trigger;

10) Make sure that the waveform on your oscilloscope is similar to the one shown at fig.
5.6

If the waveform at the two previous point is right go to point 11, otherwise cut pins of Q1
IGBT, after you’ve removed the silicone from them, which has been applied to protect
themselves from the dust. Check again the waveform shown on the oscilloscope and
compare it with that one at fig. 5.7. If the waveform is correct, then all the IGBT’s must be
replaced, otherwise replaced at the same time both IGBT’s and the related driving circuits.
In any case, after the replacement, repeats the controls from the beginning of this chapter.

11) The controls at point 8 and the following must be repeated with the remaining piloting;
that’s: G2 E2 (IGBT Q2), G3 E3 (IGBT Q3) and G4 E4 (IGBT Q4) (see fig. 4.2.d).

P.S.: even if just one IGBT is damaged all the IGBT’s must be replaced and all the related
driving circuit.

Whenever IGBT’s must replaced, keep in mind what follows:

- Use anti-static devices as wristbands, footboard and solder earth connected;

- Careful thermal coupling with heatsink;

When the controls are over and when the all the piloting are correct go to next point only.

1 >

1) Ch1: 2 V 4 us

(ix) Fig. 5.4

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 1 >

1) Ch1: 2 V 200 ns

(x) Fig. 5.5

1 >

1) CH1: 5 Volt 500 ns

(xi) Fig. 5.6

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 T

1>

1) CH1: 5 Volt 2 us

(xii) Fig. 5.7

12) Between TP1 (GND) and TP2 (ISALD) points of the “test PCB” you must get less than
1Ω, if so go to next point, otherwise if you get a higher value check the wiring between
CN2 connector of the “test PCB” and SHUNT, since there might be a bad electrical
contact on the shunt terminals.

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5.3 LOW VOLTAGE TESTING

Before making the LOW VOLTAGE TESTING make sure that all the piloting described at
point charter 5.2 are right.
The test consists of supplying the machine by an auxiliary insulation transformer with an
output voltage of 48V AC and a standard 2° magnetothermic switch (see fig. 5.6). The
inverter PCB must be still supplied by the external 24 V DC.

Do the following initial operations:

• re-connect the three connectors which bring the main supply to

the inverter PCB (points 1, 2 and 3 of fig. 4.2.a). Pls. Note
that the wires connected at the same terminal of the mains
switch must be connected to point 1 and 3 of fig. 4.2.a;
• leave the auxiliary supply still connected to Y2 connector (see
fig. 4.2.d) of the inverter PCB;
• leave the “test PCB” still connected to the machine;
• set the mains switch OFF;
• connect the insulation transformer (C) and the magnetothermic
switches (B) and (D),as shown in the electric diagram at fig.
5.6, to the mains supply 230v 50/60 Hz;
• set all the switches of the “test PCB” OFF;
• set the INVERTER switch ON of the “test PCB”;
• supply the machine by closing the B and D switches (fig. 5.8);

C
400
D
48
A B 48 VAC to the
230
0 Mains supply
230 VAC
0

A – Power supply 230V ac 50/60 Hz

B – Mains switch 250 V - 5 A minimum
C – Insulating transformer code 481432
D – Magnetothermic load switch 50 v - 2 A
Fig. 5.8

If the magnetothermic switch D is activated within a few seconds, replace the mains cable
and the wiring between EMC filter and main switch. Go on only if the magnetothermic D is
not activated.

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• Set the mains switch ON;

If the magnetothermic switch D is activated within a few seconds, check the electrolytic
capacitors state (charter 5.3.1) and if necessary replace them; then check if there’s any
short circuit on the wiring or the electrical tracks.

As soon as it’s possible to supply the machine by 48V ac, then follow the below
instructions.

1) Measure the voltage value between point 1 (positive pole) and 4 (negative pole) of fig.
5.2. If the measured value is 20V±1V go to next point, otherwise measure the voltage
value on R34 resistor of fig. 4.2.a (point 12 is the positive pole and 13 the negative
one). If the measured value is 68V±5V replace the main transformer, otherwise replace
the electrolytic capacitors.

Carry out the following operations:

• Connect the oscilloscope probe to the out put terminals of the

main transformer (pin J4 and J5 of fig. 4.2.d);
• Set the oscilloscope as follows:
ü vertical 10V/div;
ü horizontal 5 µs/div;
ü Slope up Trigger;
• Set the adjustment potentiometer of the “test PCB” to the
maximum position;

2) If the displayed wave form on your oscilloscope is similar to the one shown in fig. 5.9
go to next point, otherwise replace the inverter PCB only after checking the wiring (
CN1 connector) between inverter PCB and “test PCB”.

• Set the adjustment potentiometer on the “test PCB” in order to

get 1V between point T1(see fig. 4.8) and the central pin of the
potentiometer itself;

3) If the displayed wave form on your oscilloscope is similar to the one shown in fig. 5.10
go to next point, otherwise replace the inverter PCB only after checking the wiring (
CN1 connector) between inverter and “test PCB” ’s.

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 T

1>

1) CH2: 10 Volt 5 us
Fig. 5.9

1>

1) CH2: 10 Volt 5 us

Fig. 5.10

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5.3.1 ELECTROLYTIC CAPACITORS CONTROL

Fig. 4.2.a shows the inverter PCB layout with highlighted the electrolytic capacitors
position.
P.S.: if the electrolytic capacitors are faulty usually are deformed, so that the damage is
very clear. In such case a visual inspection is of primary importance.
Should the block diagram lead you to check the electrolytic capacitors, then is right to do
the follo w test.

Needed initial operations:

• cut off any voltage from the machine;

• connect the DC supplier to R34 resistor (see fig. 4.2.a). The
right polarity is very important: point 12 is the positive pole
and point 13 is the negative one;
• turn ON the DC supplier and set it at 30V DC;

Make sure the voltage value still about 30V; otherwise replace all the four electrolytic
capacitors as described at chapter 5.3.2.

• Repeat the same procedure connecting the components in reverse

order;

5.3.2 ELECTROLYTIC CAPACITORS REPLACEMENT

For electrolytic capacitors replacement, the inverter PCB must be removed as described
for primary rectifier, to gain access of the components for their replacement. We’d like to
remind you that all four capacitors must be replaced even if just o ne is damaged.

P.S.: pay attention to electrolytic capacitors polarity that must be the same to the one
written on PCB layout.

• Repeat the same procedure connecting the components in reverse

order;

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5.3 MAINS SUPPLY TEST

The test consist of supplying the power source by the mains: 230V 50/60Hz. The inverter
PCB have to be still supplied by the separate 24 VDC and leave still connected the “test
PCB”. Follow the below instructions:

• Disconnect the insulation transformer;

• Leave still connected the auxiliary supply voltage to Y2
connector (see fig. 4.2.d) of the inverter PCB;
• Leave still connected the “test PCB” to the machine;
• Set the mains switch OFF;
• Disconnect the Y1 connector from the related PCB(see fig. 4.4);
• Disconnect the Z2 connector from the related spark-gap PCB(see
fig. 4.6);
• Set all the switches, of the “test PCB”, in position OFF;
• Set OUT+ OUT- switch, of the “test PCB”, in position OUT+;
• Set “test PCB” potentiometer to the maximum;
• Supply the machine by 24VDC auxiliary voltage (warning: always
supply the machine first with the auxiliary voltage and then
with the mains one)
• Connect the machine to the mains voltage (230V ±10% 50/60Hz);
• Set the mains switch ON;

1) Make sure that the following value voltages are available between the shown points at
fig. 5.3:

- between point 4 (positive) and 5 you must get 17V±1V if “OUT+ OUT-“ switch on
“test PCB” set on “OUT+” position, while you get -7V±1V if set “OUT-” position.
- between point 6 and 7 (positive) you must get -7V±1V if “OUT+ OUT-“ switch is set
on “OUT+” position, while you get 17V±1V if set “OUT-” position.

If all the previous conditions are satisfied go to point 2, otherwise do the following
instructions:

• set the mains switch OFF;

• disconnect the connectors from the secondary module;
• in order to protect the module is needed to make a short-
circuit between the pins of all the connectors just
disconnected;

Repeat the same measurement on the female connector just disconnected. If this
time the values are right, replace the related IGBT module, otherwise replace the
driver PCB too.

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 Before replacing the driver PCB, make sure that there isn’t any short-circuits
between the Zener diodes (DZ13, DZ14, DZ23, DZ24) of the PCB itself (see fig.
4.3).
Replace all the Zener even if just one ZENER is damaged. They are standards
Zener diodes of 20V 1/2W.

P.S.: For component replacement it’s sufficient to unscrew the screws and remove
all the connectors from the modules. Keep straight in your mind the following
advice:

- Antistatic items, i.e.: wristbands, footboard and soldering both grounded to the earth.
- Be careful with the thermic coupling with the heat sink;

Proceed in reverse order to re-assemble the machine.

Make again all the control from the beginning of this chapter.

2) Measure the output voltage value from the output terminal of the machine. If you got
0V, got to next point, otherwise replace the inverter PCB and repeat the controls from
the beginning of the chapter.

3) Do the next instruction and then measure again the output voltage:

• Set INVERTER switch ON (on “test PCB”);

If the measured value 63V±3V go to next point, otherwise check the internal wiring
between the output of the secondary rectifier and the welding connectors;

Fig. 5.9

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4) Measure the voltage between the positive welding connector and the point shown at
fig. 5.9 (inductor output).

If the measured value is 63V±3V go to next point, otherwise check the wiring between
negative welding connector and the inductor output and in case replace the HF
transformer.

5) Measure the voltage value between positive welding connector and pin 1 of female
connector (Y1 connector of Fig. 4.4) which has been previously disconnected at the
beginning of this chapter.

If the measured value is 63V±3V go to next point, otherwise check the wiring between
the output inductor and the pin 1 of Yi connector.

6) Do the following instruction:

• Re-connect the Y1 connector to its PCB (see fig. 4.4);

Measure the voltage value between positive welding connector and point TP3 of the
“test PCB” (fig. 4.8).

If the measured value is 28V±3V go to next point, otherwise do the following

instruction:

• Switch OFF the machine;

• Disconnect the Y1 and Y2 connectors from the PCB (see fig.
4.4);

By multimeter you should get 100kΩ±1kΩ as ohm value between pin 1 of Y1

connector (see fig. 4.4) and pin 4 of Y2 connector (see fig. 4.4); if you obtain a
different value then the R2 resistor (100kΩ 5%) must be replaced, afterwards repeat
the control from the beginning of the chapter;

7) Measure the voltage value between positive welding connector and TP3 point on “test
PCB” after you’ve done the following instruction only:

• Set the OUT+ OUT- switch on the “test PCB” on OUT-;

If the measured value is -28V±3V go to next point, otherwise replace the secondary
IGBT module.

8) Measure the voltage value between positive welding connector and TP3 point on “test
PCB” after you’ve done the following instruction only:

• Set the BOOST switch ON of the “test PCB”;

If the value is equal to -150V±10V go to next point, otherwise measure the voltage on
D1 diode (see fig. 4.4). The positive pole is obviously the cathode of the diode. If the

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 value is not equal to 25V±3V, check the wiring between “test PCB” and BOOSTER
PCB, otherwise follow the below instruction:

• Switch OFF any supply from the machine;

• Disconnect the Y1 connector from BOOSTER PCB;
• Switch ON the machine again (first the auxiliary one);

There must be a short circuit (0Ω) between pin 5 and 6 of Y1 connector of

BOOSTER PCB. If not, replace the relay REL1 (see fig. 4.4) of Arc welding
Stabilizer PCB after checked the connection of Y1 connector (fig. 4.4). Once the
replacements are over, repeat the control from the beginning of the charter.

9) Follow these instructions:

• Set the BOOST switch OFF of the “test PCB”;

• Set the INVERTER switch OFF of the “test PCB”;
• Connect the gas by the solenoid gas valve placed on the rear
panel;
• Put in a tube on the quick connector (placed on the front panel
of the machine) to check that the gas is not coming out from
the tube itself;

Check that there’s no leak from the gas circuit, otherwise replace the solenoid gas
valve.

• Set EVG switch ON of the “test PCB”;

Check that the solenoid gas valve has activated and the gas is coming out from the
tube just connected. If that happens go to next point, otherwise check between point 3
and 6 of X6 connector (fig. 4.2.c) the related supply voltage is available; if any voltage
is found, then the relay REL5 (fig. 4.2.c) must be replaced, otherwise replace the
solenoid gas valve.

10) Follow these instructions:

• set EVG switch OFF of the “test PCB”;

• set the FAN 230V switch OFF of the “test PCB”;

Check that the 230V cooling fan is OFF, otherwise the REL4 relay must be replaced
(fig. 4.2.c),.

• set the FAN 230V switch ON of the “test PCB”;

Check that the 230V cooling fan is ON; if so, go to next point, otherwise check
between point 2 and 7 of X6 connector (fig. 4.2.d) that the related supply voltage is
available. If no voltage is found the REL4 (fig. 4.2.c) must be replaced, otherwise
replace the 230V cooling fan.

11) Follow these instruction:

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• set the FAN 230V switch OFF of the “test PCB”;
• set the FAN 24V switch OFF of the “test PCB”;

Make sure that the 24V cooling fan is OFF, otherwise the inverter PCB must be
replaced.

• set the FAN 24V switch ON;

Make sure that the fan is ON. If that is satisfied go to next point, otherwise the 24VDC
cooling fan must be replaced after the wiring between the fun itself and inverter PCB
has been checked (X4 connector of fig. 4.2.d)

12) Follow these instruction:

• Set FAN 24V switch OFF of the “test PCB”;

• Set PUMP switch OFF of the “test PCB”;
• Connect the HR26 water-cooling equipment to rear connector;
• Switch ON the HR26;

Make sure that the water-cooling equipment is OFF, otherwise the REL3 on inverter
PCB must be replaced.

• Set PUMP switch ON of the “test PCB”;

Make sure that the water-cooling equipment is ON; if so go to next point, otherwise
check that supply voltage is available between 1 and 8 points of X6 connector (fig.
4.2.d).
If not, the REL3 (fig. 4.2.c) must be replaced, otherwise check the wiring between X6
connector and water cooling equipment.

13) Follow these instructions:

• Disconnect the HR26 230V water cooling from the rear connector;
• Set PUMP switch OFF of the “test PCB”;
• Set INVERTER switch ON of the “test PCB”;
• Set the HF switch OFF of the “test PCB”;
• Reconnect the Z2 connector (fig. 4.6) of the spark gap PCB;

Make sure no sparks are in the sparks gap PCB, otherwise check the wiring between
sparks gap PCB and “test PCB” (CN4 connector) and in case replace the REL1 on
sparks gap PCB (fig. 4.6).

• Set the HF switch ON of the “test PCB”;

If sparks are in the spark gap PCB go to next point, otherwise follow these instructions:

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 • Set the mains switch OFF;
• Remove the spark gap PCB from its seat without disconnecting
the connectors;
• Disconnect the Z2 connector (fig. 4.6) from spark gap PCB;
• Set the mains switch ON;

If between point 1 and 2 a short-circuit is found, then the spark gap PCB must be
replaced; otherwise replace the REL1 (fig. 4.6) and repeat the controls from the
beginning of the chapter.

14) Follow these instructions:

• Set the HF switch OFF;

Make sure LED1 (+24V), on the inverter PCB, is ON. If it’s OFF go to next point, otherwise
replace the supply circuit.

15) Measure the voltage value between points TP4 and TP5 of the “test PCB”. If the
measured value is equal to 15÷17V ac go to next point, otherwise replace the TR5
transformer (fig. 4.2.a) on the inverter PCB.

16) Follow these instructions:

• Set the mains switch OFF;

• Disconnect the auxiliary supply voltage from Y2 connector (see
fig. 4.2.d) of the inverter PCB;
• Reconnect the Y2 connector to the inverter PCB;
• Leave still connected the “test PCB2vto the machine;
• Set the mains switch ON;

Make sure green leds LED1 +24V and LED2 +15V on inverter PCB are both ON. If the first
one is OFF then the inverter PCB must be replaced; while the second one is OFF, check
the wiring of the Y2 connector.

• Set INVERTER switch OFF of the “test PCB”;

• Set the mains switch OFF;

Go to next chapter.

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5.5) DIGITAL PANEL PCB CONTROL

Follow these instructions:

• Reconnect anything has been previously disconnected;

• Reconnect all the connectors to the digital PCB, removing so
the test PCB;
• Connect the machine to 230V ±10% 50/60Hz mains;
• Set the mains switch ON;

If the digital interface PCB doesn’t ON, replace it. Once it is ON, follow these instructions:

• Set the machine in MMA mode and HOT START and ARC FORCE to zero;

Measure the output voltage of the machine. The right value is 56V ± 5V; otherwise replace
the digital panel PCB.

• Set the mains switch OFF;

• Make short-circuit on the female welding connectors and insert a
shunt for measuring the secondary current;
• Set the mains switch ON;
• Set the machine on HF TIG DC mode;
• Plug in the welding torch on the remote control connector (make
sure the used torch is troubles free and works perfectly);
• Connect the W2 connector on digital PCB (fig. 4.5);
• Using the encoder, set the welding current value to 30A. In case
of troubles with the parameter adjustment, set the mains switch
OFF and short-circuit W3 connector (fig. 4.5) on the digital
PCB. That’s is needed to reset the machine at the factory
settings; consequently, all the user’s stored programmes will be
cancelled. Set the mains switch ON, wait a few seconds and
disconnect the W3 connector “parking” it only one pin;
• Press the trigger torch;

Adjust eventually the current value at 30A±1A by acting PT2 trimmer. If the adjustment is
not possible, replace the digital panel PCB.

• Release the trigger torch;

• Using the encoder set the welding current value to 5A;
• Press the trigger torch;

Adjust eventually the current value at 5A÷6A by acting PT2 trimmer. If the adjustment is
not possible, replace the digital panel PCB.

• Release the trigger torch;

• Using the encoder set the welding current value to 200A;

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• Press the trigger torch;

Adjust eventually the current value at 200A±2A by acting PT1 trimmer. If the adjustment is
not possible, replace the digital panel PCB.

Repeat the maximum (200A) and minimum (5A) adjustments till both values are reached.

• Release the trigger torch;

• Set the machine on TIG lift;
• press the trigger torch.

Make sure the welding current is equal to 25A±5°, otherwise replace the digital panel PCB.

• Set the main switch OFF;

• Remove the short-circuit previously done between the two female
welding connectors;
• Disconnect the W2 pin and leave it on just one pin;
• Set the mains switch ON;
• Check all the machine functions while the welding process (arc
force, hot start, lift striking…..)

In any of the above is not OK, replace the digital panel PCB.

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6) WARRANTY CONDITIONS

We remind you that CEA Spa does not repair under warranty damages caused by:
- Repairing attempts carried out by unauthorized personnel by CEA to repair and
service its products;
- Improper use;
- Connection to incompatible devices;
- Unauthorized additional modifications of the machine;
- Use of any instruments not complying with the ones indicated at chapter 4;
- Repairing procedure different from those given in this “Service Manual”;

7) TECHNICAL DATA

TIG MMA
Input voltage 1 phase (b) 230 V - 50/60 Hz
Installed power 3.8 kVA 4.8 kVA
Max input current 16.5 A RMS 21 A RMS
Absorbed input current (X=100%) 31 A RMS 36 A RMS
Power factor 0.7
Efficiency X=100%) 0.8
Cosϕ 0.99
Adjustment range 5-200A 5-160A
Welding current X=30% 200 A (i) 160A
Welding current X=60% (ii) 130 A (iii) 125A
Welding current X=100% 110A 105A
Open circuit voltage (c) 54 V
Protection class IP 23
Standards (i) EN60974 EN50199
Dimensions (lxpxh) 500 * 425 * 220 (mm)
Weight 18 kg

8) REQUEST FOR TECHNICAL ASSISTANCE PROCEDURE

Operators with difficulties in identifying faulty parts to be replaced should contact CEA
Technical Assistance Service.
Information can be given by telephone or fax at the following numbers:

Tel. : +39(0)34122322
Fax : +39(0)341422646

Or by e-mail:

cea@ceaweld.com

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NOTE

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