Service Manual Digistar 250 EN

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
1020h709/A
INDEX:
1) Purpose of Manual………………………………………..………………… Chapter 1
2) Machine description……………………………………………….…..…… Chapter 2
3) Available spare parts……………………………………...…………..…… Chapter 3
4) Instruments required for testing and repairing………………..……… Chapter 4
5) Testing procedure…………………………………………………………... Chapter 5
6) Components replacement…………………………………………………. Chapter 6
7) Warranty conditions………………………………………...……………… Chapter 7
8) Technical data……………………………………………………………….. Chapter 8
9) Technical assistance request procedure………………………………. Chapter 9
http://www.ceaweld.com/ _______________________ DIGISTAR 250 PULSED 2

1) PURPOSE OF THE MANUAL
The purpose of this manual is to give useful information on repairing DIGISTAR 250
PULSED 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 (as described in chapter 2) and making it possible to identify the damaged
component.
Repairs consist in identifying the damaged part and replacing it only for the parts listed at
chapter 3.
At chapter 4 you’ll find a list with all the necessary instruments for making the correct
diagnosis and repairing.
At chapter 5 you’ll find how to find out the faulty component.
At chapter 6 you’ll find the instruction to replace 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.
The rights of translation, copy and partial or total modification in any way (including copies,
films and microfilms) are not allowed without written authorization from CEA S.p.A.
Should you have any doubt or problem when repairing the equipment, you can contact
CEA S.p.A at any time: we’ll be glad to help you (see chapter 9).

2) MACHINE DESCRIPTION
The DIGISTAR 250 PULSED welders are based on INVERTER technology. By using a
high frequency intermediate section it is possible to use a transformer considerably smaller
in size and weight than standard machines. There are other important factors related to
using this system such as greater efficiency and improved welding quality resulting from
the rapid response from the system.
Figure 2.1 block diagram shows the working principle of the above machine.
.
250 PULSED
A HOLD
SY N
CHECK
CH EC K Fx
M
R UN
ME M
1. Antiradiodisturbance main filter 2. Main switch

3. Contactor 4. Electrylitic capacitors load resistance
5. Primary rectifier 6. Electrolytic capacitors
7. Lower/upper primary IGBT 8. Primary current reading transformer.
9. Mains transformer with thermostat 10.Secondary rectifier and its snubbers
11.Inductance 12.Hall effect transductor for welding current
reading
13.Inverter PCB 14.Auxiliary supply PCB
15.Digital PCB 16.Water cooling connector
17.Cooling fans 18.Gas solenoid valve
19.Torch connector 20.Remote controls connector
21.Wire feeding motor + encoder
Note: The components no. 3, 4, 5, 6, 7, 8 13 belong to the inverter PCB
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)

2 1
14
12
10
5 9
3 8
4
6 7
11
15
19 17
20
16
21
Figure 2.2

1. Antiradiodisturbance mains filter: this is a passive component with the dual task of
limiting machine frequency output as required by EEC standards and making
DIGISTAR 250 PULSED immune from problems caused by eventual electronic devices
connected to the same mains supply.
2. Mains 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.
3. Contactor: this component is needed for short-circuiting the resistances mentioned at

point 4. This operation, occurring after about 2 second from machine switching on, puts
the equipment in normal operation conditions.
4. Electrolytic capacitor load resistance: These are simple components required for
initially loading the electrolytic capacitors. In fact, an unloaded 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. In order to limit this current we
have built in series to the supply circuit one resistance with a such a value in order to
bring to acceptable values the loading current. This resistance is short-circuited by the
the contactor mentioned at point 3.
5. Primary rectifier. The rectifier is a high voltage diode single-phase bridge, rectifying
the voltage from the mains, achieving a single-direction value.
6. Electrolytic capacitors: the pulsing single-direction voltage coming out from the
primary rectifier is levelled by the electrolytic capacitors (in our application we have 6 of
them connected as shown in figure 3.8).
7. Upper/lower primary IGBT: continuous voltage is converted by an inverter into a

square wave at a frequency of about 50 kHz. There are two modules corresponding at
the two inverter’s sides. A thermostat (set at 85°C) is fixed on the heat sink and it turns
off the inverter in case of overheating. Inverter modulation allows welding current
control.
8. Primary current reading transformer: it allows the reading of the transformer primary
current necessary for the protection of the inverter.
9. 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. On the transformer there is a thermostat
adjusted to 110°C.
10. Secondary rectifier and snubbers: the square wave voltage given from the inverter is
rectified by a fast diode rectifier with snubber circuit connected to its clamps.
11. Welding current smoothing inductance: the purpose of this device is to level the
current inside the welding circuit in order to have an as much as possible continuous
value at high frequencies.
12. Current transductor (hall effect): the transductor allows to measure the welding
current necessary for the adjustment.
13. Inverter PCB.
This PCB receives on the input the three mains phases and supplies on the output
the necessary supply voltage for the main transformer. It also controls the following
signals:
- inverter set point signal giving the conduction time of the IGBT according to the
value given from the microprocessor PCB;
- the current signal from the primary current reading transformer for inverter
protection;
- the thermostat signals;
- the inverter switching on signal;
- the voltage signal from the primary bridge output necessary for the machine voltage
protection;
- the voltage signal from one of the mains phases necessary for switching off the
display after that the machine has been switched off;
- the supply (24VDC) given from the auxiliary supply PCB for the internal operation.
The PCB gives the following signals to the digital PCB:

- overvoltage (maximum line voltage alarm);
- undervoltage (minimum line voltage alarm);
- overcurrent (inverter maximum voltage alarm);
- thermostat intervention alarm;
- mains switch switching off signal;
- auxiliary supply (15VDC).
14. Auxiliary supply PCB
This PCB is supplied from the output of the primari rectifier (about 700 V) and gives 3
auxiliary supplies (24 VDC) for the operation of the inverter PCB, of the digital PCB
and for the wire feeder motor. There is also a relay which controls the water cooling
pump according to the signal coming from the inverter PCB.
Note: it is very important that this PCB is correctly supplied according to the
correct polarity. Pls check the polarity when you reconnect the connectors after
any repairing or replacement.
15. Digital PCB.
The PCB implements all the machine functions set from the operator through he front
panel and displays the active alarms. The PCB is supplied by three auxiliary supplies:
- 24VDC for the internal operation given from the auxiliary supply PCB;
- 24VDC for feeding the wire feeder motor given from the auxiliary supply PCB;
- 15VDC for the internal operation given from the inverter PCB.
16.Water cooler connection: for connecting the water cooling equipment. The signals
are:
- 400 V from the mains supply for switching on the water cooling equipment which is
controlled by the function “cooling on demand”; one phase goes directly to the
mains supply, while the other phase is coming from the auxiliary PCB relay;

- pressure switch alarm signal when the water is not circulating inside the water
cooling equipment;
- signal confirming the presence of the water cooling equipment.
17.Cooling fan. The fan is necessary for cooling the internal parts of the machine. It’s
operated directly from the control “fan on demand” coming from the digital PCB.
18.Gas solenoidvalve. It adjusts gas opening and closing when working in MIG according
to the values chosen from the operator.
19.Torch connector. It allows to insert the torch power component. Torch push button
wires are located on the same connector.
20.Remote controls connector. It allows to connect all the remote controls foreseen for
the welding equipment.
21.Wire feeling motor + encoder. It is the wire feeding device. The encoder gives a
signal for the motor speed adjustment.

3) Available spare parts
Position Electrical diagram reference

Description PART NO.
(Figure 3.1) (Figure 3.8)
1 Keyboard RK 447837
2 Knob w/out current adjustment index (-) 438888
3 Knob w/out voltage adjustment index (-) 438849
4 Rear panel cover + hose seat (-) 352427
5 Sliding Lock (-) 414326
6 Movable part cover (-) 420515
7 Side guide (-) 352421
8 Central connector flange (-) 428110
9 Tubetto guidafilo (-) 434249
10 Short euro connector + tube (-) 236631
11 Dinse sticker (-) 466968
12 17 pin female panel plug CA 419051
2
13 50 mm female quick connection (-) 403611
Figure 3.1

14 Handle tube (-) 438116
15 Front cap (-) 466418
16 Front panel cover + hose seat (-) 352424
17 Front panel (-) 352420
18 Cover (-) 420516
19 9 pole female panel plug CHR 419049
20 Solenoidvalve 24VDC EVG 425938
21 Gas hose retex 5x10.5 (-) 485040
22 Rear panel (-) 352432
2
23 Mains cable 4 x 1.5mm 4m (-) 235989
24 Complete cableholder (-) 427895
25 Rear panel sticker (-) 468708
26 Switch knob 0.5 x 5 (-) 438710
Figure 3.2

27 Metallic base (-) 404972
28 Coil hub (-) 241840
29 4R plastic wire feeding device (-) 240611
30 Wire feeling device adaptor (-) 400000
31 Motoreducer 24V 50W + encoder ME 444469
32 Encoder (-) 454151
Figure 3.3

33 3 pole switch 16A 600V IL 435755
34 EMC filter F-EMC 376887
35 Auxiliary wiring (-) 413654
36 Current transformer TA 481946
37 Upper plate (-) 449566
38 Transfoerm thermostat TT 478866
39 Maintransformer TP 481411
40 Output capacitor assembly CP 418872
41 Inductor L2 240222
42 Termosthat 85 °C TH1 478846
43 Fan motor 24V 120x120x38 MV1, MV2 486377
44 Secondary circuit RC group C2 R2 427685
45 Secondary power diode D2 423236
46 Secondary diodes varistor group VR 488318
Figure 3.4

47 CPU fron PCB S-CPU 377007
48 Encoder (-) 454150
49 Control inverter PCB (-) 377008
50 Primary rectifier RP 455504
51 Primary IGB module MIH, MIL 286019
52 Auxiliary supply PCB S-INV 377011
Figure 3.5

1001 Test PCB (-) 377580
Figure 3.6

1002 Relay (-) 456750
1003 Electrolytic capacitors load resistance (-) 457095
1004 Electrolytic capacitor (-) 418778
1005 Driving circuit (-) 456945
1006 PWM integrated control (-) 352508
1007 Fuse (-) ?????
Figure 3.7

W
U
Figure 3.8

4) INSTRUMENTS REQUIRED FOR TESTING AND REPAIRING (AND ELECTRIC
DIAGRAMS)
The following instruments are needed to check the machine:
1) A test PCB part no. 377580 (see figure 4.1). Such PCB allows to test the equipment
without digital PCB. In particular you can:
a) Operate and ad just all the machine devices:
- cooling pump (PUMP);
- cooling fans (FAN);
- inverter (INVERTER);
- contactor (CONTACTOR);
- inverter adjustment (POT1 to be measured between TP3 and TP2);
b) display the signals coming from the equipment:
- thermostat operation (led °C on) ;
- presence of auxiliary supply (led POWER on);
- presence of overvoltage alarms (O.V. on), undervoltage (U.V. on), overcurrent
(O.C. on) power fail (P.F on);
- presence of pressure switch alarm (PRESS on)
- water cooling equipment (IR on);
- active torch trigger (led TORCH), up (led UP on), DOWN (led DOWN on)
- water cooling equipment presence signal (led REMOTE on)
- welding voltage (between TP7 -VOUT and TP6 +VOUT) and welding current
(between TP5 GND-IOUT and TP4 IOUT);
It is also possible to check the wiring between the connector and the point of arrival
Figure 4.1
2) A multimeter with the following scales:

- Ohm: from 0 to a few Mohm;

- Diode control test (∗);
- Continuous voltages (VDC): from mVDC to 1000 VDC;
- Alternated voltages (VAC): from 10 VAC 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.
3) A hand oscilloscope (model FLUKE 123 or better) with the following

characteristics:
- two channels
- at least 20MHz passband
4) A probe with the following characteristics:

- attenuation 1:1
- insulation voltages to earth of at least 600VRMS
5) A current probe model FLUKE I1010 or another one with same or better features or
as alternative a shunt with scale limit current 250 A
6) A stabilised DC supplier with two 24 VDC outputs with at least 5A
7) An insulating auxiliary transformer 220V \ 48V 220 VA (part no. 481432);
8) A magnetothermic switch 4 A;
9) A line switch at least 250V 5A
For the replacement of IGBT:
10) anti-static wristbands around the wrists
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 (the
mark on the connector shows PIN1):
- Fig. 4.2.a - layout inverter PCB seen from the upper side;
- Fig. 4.2.b - layout inverter PCB seen from the lower side;
- Fig. 4.3 - layout capacitors PCB;
- Fig. 4.4 - layout relays PCB;
- Fig. 4.5 - layout digital panel PCB;

E2-H E1C2-H C1-H E1-H dr G1-H dr
E2-H dr
(a) G2-H dr
E1-L dr
G1-L dr
C1-L E1C2-L E2 - L G2-L dr E2-L dr
T S R 5 6 7 8 9
LED2
LED1
CN3
REL1
3
1
CN2
R35 R19
4
2
(b)
CN6 CN5
J2
J1
Figure 4.2 a-b

CN10 CN9 VR4
R57
SC15 SC3 SC6 R58 C49 R65 IC31 IC35
D12
IC13 IC16 J1
R176
FLAT TASTI TR4

RL1
IC6
TR5
C53
(c)
C26 C33 Q2 PZ1
RL2
C91
SC8 SC9 SC10 SC11
R99
C30 R100 C99
R101
R102 C100
VR1
C92
R61
SC1
IC39
C31 C50
IC29
C105
C32 C51 D10
SC14
C88
C25 R128
D9 R121
C93 C97 TP17
C78 R166
C129C138 R154
C14
C98 C94
D11 R71
R74 L2
R90
L3 C126
R70
L1
C15
Figure 4.3
Figure 4.2 c
C62
IC42
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C40 D5
IC23
R51 C41 R62 D6
R44 R52 C59
R45 C42
R53 C106 IC41
R46 C43
R54 C95
C44
R47 R55
C45
R48 R56 C132
IC25 IC30
R175
R49
R112
R157
TP5
R1 R26 C54
R2 R27 C115 C134
R3 R28 C135
R4 R29
C1 C18 IC33
IC19 R141
C2 C19 R142
C3 C20
C69 R143
R5 R30 R35
R6 R17 R25 R36 R77
R7 R12 R18 C21 R37 C71 R144 GND
R8 C9 R31 R38 R145 Iprim
R83 R146
C4 C22 R39 R125
R84
C5 C23 R40 R126
C75 IC34
R9 R41 C66
C24 C72 R88
C6 C36
U4
R32 C27
R10 R33 R42
C7 R13 R19 R34 C28
R11 R14
D1
C10
D2
R15
D3
D4
C39 C55 C80 C101 C120
DIGISTAR 250 PULSED 20

FUSE1
TP2
CN5
CN4
LED4
TP1
LED2
LED3
LED1
Figure 4.4
CN4 CN5 CN6 CN7
CN8
CNXX
CN10
CN2 CN1
Figure 4.5

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 instructions given at
chapter 5.2;
3- an alarm and inverter driving test. Pls follow instructions given at chapter 5.3;
4- a low voltage test (48VAC 50/60 Hz). Pls follow instructions given at chapter 5.4;
5- a mains supply test (400VAC 50/60HZ). Pls follow instructions given at chapter 5.5;
6- a digital panel PCB test Pls follow instructions given at chapter 5.6.
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. After replacing any component (see chapter 6) 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.
N.B. Do not make any repairing or control if not foreseen by this manual.
N.B. Pls refer to the manual instruction book for anything which is not written in this
manual.

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. In this case replace immediately the front panel.
c) Open the machine following the procedure given below:
1. Remove the six screws (two on the front panel and the other
four on the rear panel) as shown in the pictures. Remove the
complete handle from the two covers (front and rear).
2. Remove the six screws (see picture) fixing the machine cover
to the chassis;
3. Remove the metallic covers disconnecting the earth cable from

the fixed side. Don’t forget to connect again the earth cable
to its own clamp after repairing, before closing the machine.
4. Proceed vice-versa 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.
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.

5.2) PRELIMINARY CONTROL OF THE POWER PARTS USING A MULTIMETER
N.B The equipment must be disconnected from the mains supply.
Initial operations to be done before checking the components:
• Switch off any supply to the machine;

• Set the mains switch in position O (OFF).
• Disconnect the three connectors from the inverter PCB (points R,
S, T in figure 4.2.b thus removing the connection of the primary
rectifier to the mains supply);
1) EMC MAINS FILTER
• Take out the black caps from the filter clamps so that they
are ready for measurement.
Check the electrical continuity of the filter pointing the multimeter probes between the
inputs and corresponding outputs. The ohmic resistance value must be the same as a
shortcircuit.
Check the phases insulation versus the filter earth conductor. The ohmic resistance value
must be the same as an open circuit.The phases are connected to the earth lead by
capacitors, therefore wait for a few seconds before reading the value displayed on the
multimeter.
If one of the above conditions fails, replace the EMC filter, otherwise go ahead with point
2.
2) MAINS SWITCH
• Fix back the black caps on the EMC filter clamps so that they
are insulated;
Using a multimeter pls check that between the input (R/L1, S/L2, T/L3), and the
corresponding outputs (U/T1, V/T2, W/T3) of the switch there is an open circuit. If OK
you can proceed, if not replace the switch.
• Set the mains switch in position I (ON);
check that between the input (R/L1, S/L2, T/L3), and the corresponding outputs (U/T1,
V/T2, W/T3) of the switch there is an open circuit. If not replace the switch.
3) FUSE
• Remove the fuse (fuse1 in figure 4.4) from its seat.

Check the fuse integrity.
If it is OK reconnect it and go to point 4, otherwise remove the connector CN4 from the
auxiliary supply PCB (figure 4.4), and check with a multimeter that between points TP1

and TP2 (figure 4.4) there is a series of two diodes (TP1 anode TP2 cathode). In direct
polarità you should have a value between 0.75 and 0.95 V. If you don’t have this
value, replace the auxiliary supply PCB, otherwise replace only the fuse and go to
point 4 after reconnecting the CN4 connector.
4) ELECTROLITYC CAPACITORS LOAD RESISTANCE AND RELAY
• Reconnect the fuse (fuse1 in figure 4.4);
a) Check that there is a resistance of 10Ω±1Ω placing the multimeter between points 1
and 2 of figure 4.2.b:
If the condition has been fulfilled go to point b) otherwise replace the electrolytic
capacitors load resistance (R35 and R19 in figure 4.2.b).
b) Check that there is a resistance of 10Ω±1Ω placing the multimeter between points 3
and 4 in figure 4.2.b:
If the condition has been fulfilled go to point c) otherwise replace the electrolytic
capacitors load resistance (R19 and R35 in figure 4.2.b).
c) Check that there is an open circuit placing the multimeter between points T and 6 of
figure 4.2.b;
d) Check that there is a resistance of 20Ω±2Ω placing the multimeter between points
S and 7 in figure 4.2.b.
If the conditions have been fulfilled at the same time go to the following point,
otherwise replace the relay (REL1 in figure 4.2.b).
5) PRIMARY RECTIFIER
Using a multimeter check according to figure 4.2.b the presence of diodes between
the given points :
- point 5 (cathode) and point 9 (anode);

- point 5 (anode) and point 8 (cathode);
- If the above conditions have been fulfilled go to the following point 6, otherwise
replace the primary rectifier and repeat the above operations from the beginning.
6) INVERTER MODULES
Using a multimeter check according to figure 4.2.a the presence of diodes between
the given points :
- point C1-H (cathode) and point E1C2-H (anode);

- point E1C2-H (cathode) and point E2-H (anode);

- point C1-L (cathode) and point E1C2-L (anode);
- point E1C2-L (cathode) and point E2-L (anode);
If at least one of the above conditions has not been fulfilled replace both the IGBT
modules, otherwise go the following point 7. Nb la verifica del circuito di pilotaggio
andrà poi eseguita come descritto al paragrafo 5.3. Nb The check of driver circuit of
the IGBT will be done in as described at paragraph 5.3.
7) SECONDARY BRIDGE AND SECONDARY SNUBBER CIRCUIT
a) Check with the multimeter the secondary diodes (four in parallel) between points 1
(anode) and 2 (cathode) as shown in fig. 5.1.The voltage drop value in direct
polarity is very low (also due to the snubber parallel) and it is about 0.1÷0.2V. If they
are not damaged go to point b. Otherwise disconnect all the connections on the
diode anode. Check again the four diodes which are now separated and replace the
module with at least one damaged diode.
After the replacement of components check with a multimeter the resistance between
points 4 and 5 in figure 5.1. The correct value is 10Ω ± 1 Ω. If you don’t have the
correct value replace at the same time the resistance and the secondary snubber
capacitor.
1 2 3
4 5 6 7
Figure 5.1
b) Check with the multimeter the secondary diodes (four in parallel) between points 3
(anode) and 2 (cathode) as shown in fig. 5.1.The voltage drop value in direct
polarity is very low (also due to the snubber parallel) and it is about 0.1÷0.2V. If they
are not damaged go to point b. Otherwise disconnect all the connections on the
diode anode. Check again the four diodes which are now separated and replace the
module with at least one damaged diode.

After the replacement of components check with a multimeter the resistance between
points 6 and 7 in figure 5.1. The correct value is 10Ω ± 1 Ω. If you don’t have the
correct value replace at the same time the resistance and the secondary snubber
capacitor.
8) FEMALE PANEL PLUG ON THE MACHINE FRONT PANEL
• Remove the keyboard from the front panel by unscrewing the 4

screws fixing it to the panel;
• disconnect all the digital PCB connectors (see figure 4.3)
and connect the test PCB to the connectors you have just
disconnected (see figure 4.5). The only connector which
cannot be branched to the test PCB is the one coming from the
encoder (CN9);
Measure the electric continuity between the points given here below:
pin 1 on the CNxx connector on the test PCB (see test 4.5) and the pin M on the
17 pole female connector on the machine front panel (see figure 5.2.a);
pin 2 on the CNxx connector on the test PCB (see test 4.5) and the pin L on the
pin 3 on the CNxx connector on the test PCB (see test 4.5) and the pin G on the
pin 4 on the CNxx connector on the test PCB (see test 4.5) and the pin H on the
pin 5 on the CNxx connector on the test PCB (see test 4.5) and the pin J on the 17
pole female connector on the machine front panel (see figure 5.2.a);
pin 6 on the CNxx connector on the test PCB (see test 4.5) and the pin K on the
If all the above points have been fulfilled you can proceed, otherwise check the wiring
between the CN10 connector on the test PCB and the 17 pole connector and
eventually replace the connector on the machine front panel .
pin 3 on the CN8 connector on the test PCB (see test 4.5) and the pin E on the 17
pin 4 on the CN8 connector on the test PCB (see test 4.5) and the pin D on the 17
pin 5 on the CN8 connector on the test PCB (see test 4.5) and the pin F on the 17
pin 6 on the CN8 connector on the test PCB (see test 4.5) and the pin C on the 17
between the CN8 connector on the test PCB and the 17 pole connector and eventually
replace the connector on the machine front panel .

M
A L
B
C
N K
D P T
J
R S
E H
F G A)
1
2 8
9
3 7
5
4 6
B)
Figura 5.2
pin 1 on the CN4 connector on the test PCB (see test 4.5) and the pin 1 on the 9
pole female connector on the back of the machine (see figure 5.2.b);
between the CN4 connector on the test PCB and the 9 pole connector and eventually
replace the connector on the back of the machine.
pin 4 on the CN5 connector on the auxiliary supply PCB (see figure 4.4) and the
pin 4 on the 9 pole female connector on the back of the machine (see figure 5.2.b);

orange lead on the mains switch and the pin 6 on the 9 pole female connector
on the back of the machine (see figure 5.2.b);
between the above given points and eventually replace the connector on the back of the
machine.

5.3) ALARM AND INVERTER DRIVER CIRCUIT CONTROL
Follow these steps:
• Reconnect all the components which were previously disconnected

for replacements or repairing;
• Set the mains switch in position O (off);
• Switch off the stabilised supplier;
• Set all the switches (INVERTER, CONTACTOR, PUMP, FAN, EVG) on
test PCB in position “OFF” and set the potentiometer POT1 to
the minimum (completely aticlockwise);
• Disconnect the CN3 connector (4 poles mod2) from the inverter
PCB (see figure 4.2.b);
• Connect to the male connector you have just removed on the on
inverter PCB the stabilised supplier. NB the positive pole must
be pin 4 (see figure 4.2.b);
• Make a short circuit between the two jumpers J1 and J2 on the
inverter PCB (see figure 4.2.b);
• Switch on the stabilised supplier and ad just the voltage to
24V±1V. Make sure that the PCB is correctly supplied.
1) Check that the green led LED2 on the inverter PCB (see figure 4.2.b) is steadily on,
otherwise replace the inverter assembly.
2) Check that the green led LED1 on the inverter PCB (see figure 4.2.b) is steadily off,
otherwise replace the inverter assembly.
3) Check that the green led POWER on the test PCB (see figure 4.5) is steadily on,
otherwise replace the inverter assembly after having checked also the wiring between
inverter PCB and test PCB (20 pin connector between CN2 inverter PCB and CN3 test
PCB).
PROTECTION CONTROL
4) Check that the led U.V (under voltage) O.V. (over voltage) O.C. (over current) P.F.
(power fail) on the test PCB (see figure 4.5) are steadily off, otherwise replace the
inverter PCB.
• Remove the jumper J1 on the inverter PCB;
5) Check that the led U.V (under voltage) on the test PCB (see figure 4.5) is steadily on,
PCB).
• Remove the jumper J2 on the inverter PCB;
6) Check that the led O.V (over voltage) and P.F. (power fail) on the test PCB (see figure
4.5) are steadily on, otherwise replace the inverter assembly after having checked also

the wiring between inverter PCB and test PCB (20 pin connector between CN2
inverter PCB and CN3 test PCB).
• Reconnect the jumpers J1 and J2 to the inverter PCB;
7) Check that the yellow led on the test PCB (°C) is steadily off. If OK go to the following
point, otherwise follow these steps:
• Disconnect the connectors CN5 and CN6 from the inverter PCB
(see figure 4.2.b);
- Using a multimeter check if there is a closet contact on both female CN5 and CN6
connectors that you have just removed. If it not closed replace the relative
thermostats, otherwise replace the inverter assembly.
• After the replacement, reconnect the CN5 and CN6 connectors

to the inverter PCB;
8) Follow these steps:
• Remove one of the connectors CN4 CN5 CN6 from the inverter
Check that the led on the test PCB (°C) is steadily on, otherwise replace the
inverter assembly.
• reconnect the connectors that you have removed;
IGBT PILOTING CONTROL
9) Follow these steps
• Set the INVERTER switch on the test PCB in position ON;
9a) Check that the led LED1 on the inverter PCB (see figure 4.2.b) is steadily on,
PCB).
• Connect the oscilloscope probe on points G1–h dr and E1– H dr

(round on E1 – Hdr) (piloting 1) of the inverter PCB (see
figure 4.2.a);
• Set the oscilloscope as following:
vertical 5V/div;
horizontal 10μs/div;

Figure 5.3

9b) Check that the oscilloscope displays the wave form of figure 5.3 considered with a
time base of 10 μs and 0.4 μs. You should also get the following values:
- Frequency 48kHZ ÷ 52kHZ;

- positive value 14V ÷ 15V;
- negative value 0V ÷ 0.2V;
- slope up time 1.44 ÷ 1.76 us;
- slope down time 220 ÷ 310 ns;
REMARK The same measures and considerations at point “9ba” will have to be
repeated with the other pilotings, i.e.:
- points G2 – H dr and E2 – H dr g(round on E2 – H dr) of the connector CN2 (piloting
2);
- points G1 – L dr and E1 – L dr (ground on E1 – L dr) of the connector CN2 (piloting
3);
- points G2 – L dr and E2 – L dr (ground on su E2 – L dr) of the connector CN2
(piloting 4);
-
If the displayed wave form is always at 0 for all the pilotings replace the pwm control
integrated and check again the pilotings otherwise go to the next point. If you still have
the problem (after replace the pwm control integrated) replace the inverter assembly.
9c) If the displayed wave form is correct for all the pilotings go to point 10 otherwise
disassemble the inverter group and follow these steps:
• cut the IGBT module feet so that it will be then possible to

remove the feet singularly;
• lay down the PCB you have just removed on an insulating
surface;
• reconnect the stabilised supplier to the CN3 connector on the
inverter PCB. N.B. the positive pole must be pin 4 (see
figure 4.2.b);
• set the oscilloscope as following:
vertical 2V/div;
• connect the oscilloscope probe on the points in order to
check all the pilotings:
- G1–h dr and E1– Hdr (ground on E1 – Hdr) of the inverter
PCB (see figure 4.2.a);
- G2–h dr e E2– Hdr (ground on E2 – Hdr) of the inverter
- G1–L dr e E1– Ldr (ground on u E1 – Ldr) of the inverter
- G2–L dr e E2– Ldr (ground on E2 – Ldr) of the inverter PCB
(see figure 4.2.a);
• switch on the stabilised supplier and ad just the voltage to
- Check that the wave form displayed on the oscilloscope is as per figure 5.6. It also
must have the following values:

- frequency 48kHZ ÷ 52kHZ;
- positive value14V ÷ 15V;
- negative value 0V ÷ 0.5V;
Figure 5.4
If all the PCB pilotings are correct replace only the IGBT modules, otherwise follow
these steps:
• Remove all the piloting circuit components concerning the

piloting which does not suit the wave form 5.4;
vertical 5V/div;
• connect the oscilloscope probe between the following points
– for the upper IGBT module pin 7 of the integrated U2 and
the heat sink of the integrated U4 (ground) (see figure
4.2.c);
• - for the upper IGBT module pin 5 of the integrated U2 and
4.2.c);
- for the lower IGBT module pin 7 of the integrated U3 and
4.2.c);
- for the lower IGBT module pin 5 of the integrated U3 and
4.2.c);

If the wave form displayed on the oscilloscope is corresponding to figure 5.5
replace the piloting circuit and obviously the IGBT module, if not replace the
inverter assembly.
NB If you replace the inverter assembly you have to replace the inverter PCB
complete with IGBT and primary rectifier.
NOTE. If you replace the driver circuit and the IGBT it is necessary to repeat again all
the steps of this chapter so that at the end all the driver pilotings are correct with the
connected IGBT module.
Figure 5.5
10) Follow these steps
• Set the INVERTER switch on the test PCB in position OFF;

• Connect the oscilloscope probe on the points G1–h dr and E1–
H dr (round on E1 – Hdr) (piloting 1) of the inverter PCB
(see figure 4.2.a);
vertical 5V/div;
NOTE: Same measures and same remarks of points “10a and 10b” shall be repeated
for the remaining pilotings, i.e.:
- points G2 – H dr and E2 – H dr (ground on E2 – H dr) of the connector CN2 (piloting
2);
3);
4);

10a) Check that the voltage measured with the oscilloscope is equal to 0V on each
piloting, otherwise replace the inverter assembly.
• Set the INVERTER switch on the test PCB in position ON;

• Disconnect the connector CN4 from the inverter PCB(see
figure 4.2.b).
10b) Check that the voltage measured with the oscilloscope is equal to 0V on each
piloting, otherwise replace the inverter assembly.
• Reconnect the connector CN4 from the inverter PCB (see

figure 4.2.b;
• Disconnect the oscilloscope probe from the PCB.
11) RELAY CONTROL (CONTACTOR), FAN, PUMP AND GAS SOLENOIDVALVE
Do the following:
• switch off the supplier;

• disconnect the connector CN3 on the inverter PCB and
reconnect to the same connector the connector coming from the
auxiliary supply PCB ;
• connect the stabilised supplier to the CN1 connector on the
test PCB. N.B. the positive pole must be pin 4 (see figure
4.5)and negative pole pin 1;
• Set the FAN switch on the test PCB in position OFF;
11a) Check that the cooling fans are off otherwise check the wiring between the cooling
fan and the connector CN2 on the test PCB (figure 4.5 pin 7 and 8).
• Set the FAN switch on the test PCB in position ON;
11b) If both the cooling fans are on (it takes a few seconds for the fan motor to reach
the maximum speed) go to the following step. If not check the voltage on the
cooling fans connector. If the value is equal to 24V ± 5V replace the cooling fan
and check the wiring between the cooling fan and the connector CN2 on the test
PCB (figure 4.5 pin 7 and 8).
• Set the FAN switch on the test PCB in position OFF;

• Set the CONTACTOR switch on the test PCB in position ON;
11c) Check if there is a closed contact placing the multimeter between points T and 6 in
figure 4.2;

11d) Check if there is a closed contact placing the multimeter between points S and 6
in figure 4.2;
If both conditions failed replace the relay after checking the wiring between the
connector CN2 on the test PCB (pin 1 and 3) and the connector CN1 of the
inverter PCB.
• Set the CONTACTOR switch on the test PCB in position OFF;
11e) Check that between pins 1 and 4 of the connector CN5 on the auxiliary supply
(figure 4.4) there isn’t a closed contact otherwise replace the auxiliary supply PCB
after checking the wiring between the connector CN6 of the auxiliary supply PCB
and the connector CN2 on the test PCB (pin 4 and 9).
• Set the PUMP switch on the test PCB in position ON;
11f) Check if there is a closed contact between pins 1 and 4 of the connector CN5 on
the auxiliary supply PCB (figure 4.4) otherwise replace the auxiliary supply PCB
after checking the wiring between the connector CN6 of the auxiliary supply PCB
and the connector CN2 on the test PCB (pin 4 and 9).
• Set the PUMP switch on the test PCB in position OFF;

• Switch off the supplier;
• Disconnect the connector CN3 on the inverter PCB and
reconnect to the same connector the connector coming from
the auxiliary supply PCB;
• Disconnect the CN7 connector from the test PCB;
• Connect the CN7 connector connector on the test PCB. N.B.
the positive pole must be pin 3 (see figure 4.5)and negative
pole pin 1;
• Connect eventually the compressed air to the gas hose to
check the solenoid valve excitation;
11g) Check that the gas solenoidvalve is not excited otherwise check the wiring
between the solenoidvalve and the connector CN8 on the test PCB (pin 9 and 10).
• Set the EVG switch on the test PCB in position ON;
11h) Check that the gas solenoidvalve is excited otherwise check the wiring between
the solenoidvalve and the connector CN8 on the test PCB (pin 9 and 10).
• Set the EVG switch on the test PCB in position OFF;

• switch off the stabilised supplier;
• Disconnect the connector CN7 on the inverter PCB and
reconnect to the same connector the connector coming from the
auxiliary supply PCB;

5.4) LOW VOLTAGE TESTING
Before carrying out this testing make sure that IGBT driver pilotings are ok, as described in
chapter 5.3.
After each component replacement it is necessary to resume the controls from the chapter
beginning.
The testing consists in suplying the machine with an insulating auxiliary transformer with
output voltage of 48V AC and a magnetothermic of 4A (see figure 5.5) on two alternates of
the mains cable. The inverter PCB must be supplied with 24VDC and a supply from the
test PCB
Proceed as follows:
• Reconnect all the components previously disconnected for

eventual repairings or replacement;
• Reconnect the three connectors to the inverter PCB (points R, S,
T in figure 4.2.b);
• Leave the test PCB connected;
• Keep the short-circuit on the bridges J1 and J2 of the inverter
PCB (see figure 4.2);
• set the switch CONTACTOR on the test PCB in position OFF;
• set the switch INVERTER on the test PCB in position OFF;
• set the mains switch in position O (OFF);
• connect the oscilloscope probe between points +VCC (positive
pole) and 0VCC (negative pole) in figure 4.2.c;
vertical 10V/div;
horizontal 4ms/div;
• disconnect the connector CN3 (4 poles mod2) from the inverter
• connect to the male connector that you have just removed on the
inverter PCB the stabilised supplier. NB the positive pole must
be pin 4 (see figure 4.2.b);
• disconnect the connector CN1 from the test PCB;
• connect to the connector CN1 on the control test the stabilised
supplier. NB the positive pole must be pin 4 (see figure 4.5)
and the negative pole pin 1.
NOTE The supply can be the same used for the inverter PCB;
• switch on the stabilised supplier and adjust the voltage to
24V±1V. Make sure that the PCB are correctly supplied.
• Do not connect to connector CN7 on the test PCB the stabilised
supplier;
• Connect the voltage of 48 VAC to two leads of the mains cable
(see figure 5.6) and supply the equipment;

C
400
48 D
A B 230 48 VAC al c avo
0 di alim entazione
230 VAC
0
A – Mains supply 230 VAC 50 Hz

B – Mains switch 250V 5A
C – Insulating transformer code 481432
D – Load switch 50V 4A
Figure 5.6
1) If it not possible to supply the machine with 48 VAC because of short circuit, replace
the mains cable. If the problem still persists, replace the EMC filter.
2) Measure the voltage on the mains cable input conductors to the EMC filter which have
been supplied. If the value is equal to the supply voltage about 48VAC go to the
following point otherwise replace the mains cable after checking that the equipment is
correctly supplied
3) Measure the voltage on the remaining input conductors to the EMC filter. If the value is
equal to the half of the mains supply about 48VAC go to the following point otherwise
replace the EMC filter.
4) Do the following:

• After a few seconds, set the switch CONTACTOR on the test PCB
in position ON;
• Set the potentiometer of the test PCB on the maximum value;
5) If the magnetothermic of the 48 VAC intervenes for shortcircuit replace the electrolytic
capacitors otherwise go on with the following point.
6) Measure the voltage displayed on the oscilloscope. The correct value is the one of the
supply alternate voltage moltiplied by 1.41. The voltage must be without oscillations.
• Set the switch INVERTER on the test PCB in position ON;
7) Measure the voltage displayed on the oscilloscope. The correct value is slightly lower
than the one measured at point 6 of about 3V÷5V. The voltage must be without
oscillations.
If both the previous conditions are fulfilled go to the next point otherwise replace the
electrolytic capacitors.

8) Measure with a multimeter the voltage between the clamps TP7 VOUT (negative)
and TP6 VOUT of figure 5. The correct value is 0V ÷ 8.0V DC). If the value is right
go to the next point otherwise measure the machine output voltage (positive and
negative dinse)
- If the value is 6.0V ÷ 8.0V DC check the wiring between the output dinse and the
connector CN6 on the test PCB.
- If the value isn’t 6.0V ÷ 8.0V DC follow these steps:
• Set the INVERTER switch on the test PCB in position OFF;

• Set the main switch in position OFF O (OFF);
• Connect the oscilloscope probe between points E1C2-H and
0VCC (ground) of figure 4.2.
vertical 20V/div;
slope up trigger.
• set the mains switch in position I (ON)

• set the swicth INVERTER on test PCB in position ON;
Check that the wave form displayed on the oscilloscope is as per figure 5.7. If not
replace the transformer.
• set the swicth INVERTER on test PCB in position OFF;

• set the mains switch in position O (OFF);
• connect the oscilloscope probe between points +VCC and E1C2-
L (ground) of figure 4.2.
• set the mains switch in position I (ON);
• set the swicth INVERTER on test PCB in position ON;
Check that the wave form displayed on the oscilloscope is as per figure 5.7. If not
replace the transformer.
• Remove the oscilloscope probe;

Figure 5.7
• set the swicth INVERTER on test PCB in position OFF;

• remove the oscilloscope probe;
Measure with a multimeter the voltage between clamps “TP7 –VOUT” (negative) and
“TP6 VOUT” of the test PCB(figure 4.5). The correct value is 0V. If the value is correct
go to the following point, otherwise replace the inverter assembly.
• Shortcircuit the two output welding connectors (+ and -);

• Set the test PCB potentiometer on the minimum value;
Check that turning the potentiometer the machine current value varies from 0 to a
maximum of about 75A.
REMARK: If for the low voltage testing you do not use the mentioned transformer (part
no. 481432) the maximum current value, which depends on the transformer features,
can be different.
If it is not possible to change the current replace the inverter assembly (after checking
the connector CN3 on the test PCB and the connector CN2 on the inverter assembly)
otherwise go the next point.
• Switch off the stabilised supply;

• Switch off the auxiliary supply 48VAC

5.5) MAINS SUPPLY TEST
Note During this testing it is necessary to take measures with the equipment connected to
the mains supply. It is very important to take particular care to the safety of all the
measures effected and avoid doing any step in case of hesitation. After each component
replacement it is necessary to resume the controls from the beginning.
Follow these steps:
• Reconnect all the components which were previously

disconnected, after replacements or measures;
• Leave only the test PCB connected;
• Disconnect the connector CN1 on the test PCB and reconnect to
the same connector the one coming from the auxiliary supply
PCB;
• Disconnect the connector CN3 on the INVERTER PCB and reconnect
to the same connector the one coming from the auxiliary supply
PCB;
• Eliminate the connected short circuit on the machine output;
• NOTE: set the switch CONTACTOR on the test PCB in position OFF.
This operation is very important to avoid the solicitation of
the primary rectifier by its insertion;
• Set the switch INVERTER on the test PCB in position OFF;
• Take off the bridges J1 and J2 (see figure 4.2b);
• Set the mains switch in position 0 (OFF);
• Connect the mains cable to the mains supply with a voltage of
400V ± 10% and frequency 50Hz/60Hz and feed the machine;
• Set the switch FAN on the test PCB in position ON.
NOTE: Values close to the maximum (460V) and minimum (320V) could activate
overvoltage or undervoltage protection;
1) If it is not possible to supply the machine for short circuits replace the mains cable. If
you still have the problem replace the EMC filter.
2) Measure the voltage on the 3 mains switch input conductors. If the value is equal to the
supply voltage go to the following point otherwise replace the mains cable after making
sure that the equipment is properly supplied.

• After about 3 seconds set the switch CONTACTOR in position ON;
3) Check that the led’s LED1, LED2, LED3, LED4 on the auxiliary supply PCB (figure
4.4) are all steadily on. If it is OK go to the following point, otherwise replace the
auxiliary supply PCB after checking the wiring between auxiliary supply PCB and test
PCB and start again the operation from the beginning of this chapter.
4) Measure the voltaqe between pin 5 and 6 (positive) on the connector CN1 of the
auxiliary supply PCB. If the value is 25V±0.5V go to the following point, otherwise

adjust with the trimmer RT1 the value to 25V. If it is not possible to make this
adjustment replace the auxiliary supply PCB and start again the operation from the
beginning of this chapter.
• Set the switch INVERTER on the test PCB in position ON and set
the potentiometer to max;
5) Measure the voltage on the machine output:
If the value is 64V ÷ 66V (with 400V mains supply and anyway with a proportional
value to the mains supply) go to the following point;
If the above condition fails replace the inverter assembly and start again the low
voltage test.

• connect the oscilloscope probe between points TP1 GND (ground)
and TP2 Iprim of the inverter PCB (see figure 4.2.c);
vertical 100V/div;
slope up trigger.
Check that the wave form displayed on the oscilloscope is as per figure 5.8 go to the
following point. If not replace the inverter PCB start again the low voltage test.

• Remove the oscilloscope probe;
Measure with a multimeter the voltage between clamps TP1 – GND (ground) and TP5
of the test PCB (figure 4.2.C). If the value is 2.48÷2.50V go to the following point,
otherwise adjust it to this value acting on trimmer RT7. If it is not possible to make this
adjustment replace the inverter assembly and start again the low voltage test.

Figure 5.8
• Shortcircuit the two output welding connectors (+ and -) and

insert a clamp meter or a shunt to measure the secondary
current;
• Set the test PCB potentiometer on the maximum value;
• Connect the oscilloscope probe between points TP5 GND IOUT
(ground) and TP4 IOUT of the test PCB (see figure 4.5);
vertical 2V/div;
slope up trigger.
• Set the INVERTER switch on the test PCB in position ON and take
it back in OFF position after maximum 1÷2 seconds;
Check that the wave form displayed on the oscilloscope is as per figure 5.9. In particular
the pick value must be 7.0V÷7.5V.
If the above condition is OK go to the following point, otherwise replace the current
transductor and start again from the beginning.

Figure 5.9
• Remove the short circuit on the machine output;

• Remove the oscilloscopi probe;
• Set the switch FAN on the test PCB in position OFF.
• Connect a torch which is correctly working to the torch
connector;
• Push and hold the torch trigger;
If the led 7 TORCH on the test PCB is steadily on go to the following point, otherwise
follow these steps :
• Release the torch trigger;

• Set the mains switch in position O (OFF);
• Set the switch CONTACTOR on the test PCB in position OFF;
• Disconnect the torch from the connector;
Check the wiring between the torch trigger and the test PCB by placing the tester
between the torch trigger pins on the torch connector and pins 1 and 2 of connector
CN8 on the test PCB (figure 4.5). After these operations check again this point after
switching on correctly the equipment (first switch and then relay).

10) Follow these steps (only for UP/DOWN torches, otherwise go to the next point)
• Connect a torch with UP/DOWN remote control you must be sure

that this torch is properly working;
• Push and hold the button UP;
If the led 10 UP on the test PCB is on go to the following point, otherwise follow these
instructions:
• Release the button UP;

Check the wiring between the pins D and F on the remote control connector (figure
5.2.a) and the test PCB (connector CN8 pin 5 and 4). After these operations check
again this point after switching on correctly the equipment (first switch and then relay).
11) Follow these steps (only for UP/DOWN torches, otherwise go to the next point):

• Push and hold the button DOWN;
If the led 8 DOWN on the test PCB is on go to the following point, otherwise follow these
instructions:
• Release the button DOWN;

Check the wiring between the pins E and D on the remote control connector (figure
5.2.a) and the test PCB (connector CN8 pin 3 and 4). After these operations check
again this point after switching on correctly the equipment (first switch and then relay).
12) Only for UP/DOWN torches, otherwise go to the next point):
If the led 9 REMOTE on the test PCB is steadily on go to the following charter,
otherwise do the following:


Check the wiring between the pins C and D on the remote control connector (figure 5.2.a)
and the test PCB (connector CN8 pin 6 and 4). After these operations check again this
point after switching on correctly the equipment (first switch and then relay).

5.6) DIGITAL PCB TEST
Note During this testing it is necessary to take measures with the equipment connected to
the mains supply. It is very important to take particular care to the safety of all the
measures effected and avoid doing any step in case of hesitation. After each component
replacement it is necessary to resume the controls from the beginning.
The eventual PCB replacement is easy by screw and connector removing.
Figure 5.10 shows the description of the push buttons and leds on the machine front
panel.
Figura 5.10
Do the following:
• Disconnect ay supply from the machine;

• reconnect all the components which were previously disconnected
after repairings and replacement and connect the digital PCB in
replacement of the test PCB;

• connect the mains cable to the mains supply with a voltage of
400V ± 10% and frequency 50Hz/60Hz and feed the machine.
• set the mains switch in position I (ON);
1) Check that the led’s LED1, LED2, LED3, LED4 on the auxiliary supply PCB are all
steadily on (figure 4.4). If this is OK go to the following point, otherwise replace the
digital PCB.
2) Check the following led’s (figure 5.11). If the condition fail, replace the digital PCB
LED CONDITION
DL1 On and flinking
DL2 On
DL3 Off
DL4 On
DL5 On
DL6 NOT USED
DL7 Off
DL8 Off
DL9 On and blinking with a time of about one
sec.
3) Check that the display is on and shows the following wordings:
- display current a number between 10 and 250;

- display voltage a numeric value;
- display programmes with the wordings Pxxx in mode mig, mig pulsed, mig double
pulsed and off for tig and electrode mode.
If the above is OK on go to the following point, otherwise replace the digital PCB :
Do the following:
• Select welding process electrode with the welding process
push button (if electrode mode is already selected then
switch to TIG LIFT, MIG PULSED, MIG DUAL PULSED, MIG and then
back to the electrode mode).
4) If the welding process push button is working go to the next point otherwise check Fx
led. If the led is on unblock the machine in the following way:
• Press and keep pressed the push button Fx;

• Press and keep pressed the push button WIRE AND GAS TEST
until the lower display shows “uNbL”;
The operation is necessary to unblock the machine. Now you
can select the electrode mode
If the led is off but it is anyway not possible to adjust the welding process replace the
keyboard and if you still have the problem replace the digital PCB.

Figure 5.11
5) Measure the machine output voltage. The correct value is 62V ÷ 67V (with a supply
voltage of 400V). If not replace the digital PCB.
• Weld both in ELECTRODE and TIG/LIFT mode checking all the

machines functions (arc force, hot start, lift striking…..)
6) If any of the machine function is not properly working replace the digital PCB.
• Press push button Fx;

Verify that the corresponding led is on.
• Press push button RUN/MEM;
Check that programmes display shows a wording beginning with dH300-.
• Press push button CHECK GAS;
Control that the programmes display shows a wording beginning with FP-.
• Press push button CHECK WIRE;
Verify that the programmes display shows a wording beginning with AF-.
• Press push button Fx;
• Press repeatedly the push button WELDING PROCESS.
Verify that related leds are on.
• Activate the welding process MIG;
• Press repeatedly the push button MODE TYPE.

• Turn on welding mode 2 TIMES;
• Press repeatedly the push button WELDING MODE.
• Activate the synergic welding mode
• Press repeatedly push button PROGRAMMES SHIFT-;
Verify that the indication on the display decreases.
• Press repeatedly the push button PROGRAMMES SHFT +;
Verify that the indication shown on the display increases.
• Press repeatedly push button PARAMETER SELECTION – V;
• Switch on led Electronic Inductance;
• Press repeatedly push button PARAMETER SELECTION – A;
• Switch on led A;
If any of the operations is not possible or is not fulfilled replace the keyboard and
eventually the digital PCB, otherwise go ahead with the next point.
• Turn the two encoders clockwise and check that the related
display signal increases;
• Turn the two encoders anticlockwise and verify that relevant display
signal decreases.
If both the conditions are fulfilled go to the next point otherwise replace the encoders on
the digital PCB.
If any display segment is not lit up replace the digital PCB.
• Connect a gas tube to the machine and insert compressed gas;
Verify that there is no gas leak nor from torch connector neither inside the equipment. If
there is replace the difital PCB.
• Press and keep pressed the gas test push button on the wire
feeder;
In case of gas leak from torch connection go to the following point, otherwise replace
the digital PCB.
• Release gas test push button on the wire feeder;

• open the wire feeding rolls;

• Press and keep pressed wire test push button on the wire
feeder;
- If the motor rotates at a constant speed (wire speed of about 8 m/min after a lower
start correspondent to a voltage of about 8V±1V between pins pin 8 and 6 on the
connector CN7) go to the following step;
- If the motor rotates at the maximum speed (voltage between pins pin 8 and 6 on the
connector CN7 of the digital PCB 24V÷2V) and also the LED DL3 is on and blinking
checkthe wiring and the connectors between the encoder and the digital PCB and
eventually replace the encoder. If the problem persists replace the digital PCB;
- If the motor rotates at a different speed from the above (voltage between pins 8 and
6 on the connector CN7 of the digital PCB different from 24V÷2V or 8V±1V) or if it
doesn’t rotate at alland also the LED DL3 is on and blinking check that the wire
feeding device is not blocked or braked. If the problem persists replace the digital
PCB;
• Release the motor test push button on the wire feeder;

• Connect a properly working torch to the torch connector;
• Press and keep pressed the torch push button;
Verify the wire feeder motor rotation or gas solenoide valve closing for some seconds
after push button pressing. If it is ok go ahead with the next step, otherwise replace the
digital PCB.
Follow these steps (only for UP/DOWN torches, otherwise go to the next point):
• Connect a torch with UP/DOWN remote control you must be sure
that this torch is properly working;
• Press and hold the button UP;
Check on the display that the “current” increases. If it is ok go ahead with the next
step, otherwise replace the digital PCB.
13) Follow these steps (only for UP/DOWN torches, otherwise go to the next point):

• Press and hold the button DOWN;
Check on the display that the “current” decreases. If it is ok go ahead with the next
step, otherwise replace the digital PCB.
14) Follow these steps (only for UP/DOWN torches, otherwise end up the test):

• Connect a DIGITORCH which you are sure is properly working;
Check that during the rotation of led’s on the front panel, you can see on the torch
display the writing CEA.
After this check that on the torch display shows a number equal to the value displayed
on the display 1 of the front panel (note: the equipment must not be in mode electrode
or tig).
If these two conditions fail replace the digital PCB.

6) COMPONENTS REPLACEMENT
N.B. Any replacement operation shall be done with the equipment disconnected
from the mains supply or from any other auxiliary supply or transformer.
For components replacement proceed as following:
6.1 EMC FILTER
It is very simple to replace the filter following these instructions.
• Disconnect the connectors coming from the mains switch and

mains cable to the filter;
• Remove the screws fixing the filter to the base;
• After the replacement fix again the black caps to the filter
clamps, so that they are insulated;
• don’t forget to reconnect the two earth connectors to the
filter.
NOTE: It is not important to respect the phase order when connecting the filter, but it is
absolutely necessary to connect the filter with the writing line to the mains supply and
with the writing load to the switch.
6.2 SWITCH
It is simple to replace the switch following these instructions:
• Remove the screw fixing the handle to the switch;

• Remove the screws fixing the switch to the back panel;
• Remove the conductors coming from the filter and from the
inverter PCB.
NOTE: It is not important to respect the phase order when connecting the mains
switch to the switch. It is important that the conductors coming from the filter are
connected to the clamps R/L1 S/L2 T/L3 and the output to U/T1 V/T2 W/T3 as shown
in the electrical diagram in figure 3.8.
6.3 INVERTER ASSEMBLY
NB It is not possible to replace the inverter assembly using the components (IGBT and
rectifier) of an old PCB. For this reason in case of replace of inverter assembly you can
replace the inverter you must replace the three single components (PCB, IGBT modules
and rectifier module) and then you must test them according to write in this manual.
Follow these steps:
• Remove all the connectors from the inverter PCB, taking note
of their right connection. NB Be careful to keep the polarity
of the connectors +VCC and OVCC when you will reconnect them.

The electrical diagram in figure 3.8 shows how to do the
connection.
• Lay down the machine on one side so that the contact surface
of the heat sink is horizontal;
• Remove the 4 screws fixing the IGBT modules to the heat sink
below;
• Remove the 2 screws fixing the rectifier to the heat sink
below;
• Remove the 4 screws fixing the PCB to the heat sink below;
• Cut the connections of the component/s to be replaced so that
you will be then able to remove all the feet one by one;
• Wear and use all the antistatic means as bracelets, carpets
and welders connected to earth;
• Clean carefully the aluminium heat sink with alcohol in order
to remove all the oxyde;
• Clean carefully the primary rectifier and IGBT’s heat sink;
• Spread some thermoconductive paste on the contact surface o
the IGBT and on the components heat sink;
• Place the components on the heat sink moving them slightly in
order to spread the paste equally on all the surface;
• Tighten the 4 screws fixing the IGBT modules to the heat sink
below with a torque of 3±10% Nm;
• Tighten the 2 screws fixing the rectifier to the heat sink
• Mount the PCB on the components taking care not to force the
feet. The maximum force allowed is about 5 N;
• Tighten the 4 screws fixing the PCB to the heat sink below;
• Weld all the replaced components (nb: only after that the PCB
has been fixed;
• At the end reconnect the connectors following the proper
connection that you have noted before.
6.4 INVERTER MODULE AND PRIMARY RECTIFIER
In this case it is necessary to check the PCB and all its components as described at
points 5.2 and 5.3 and following.
connection.
below;

below;
• Cut the connections of the component/s to be replaced so that
you will be then able to remove all the feet one by one;
• Wear and use all the antistatic means as bracelets, carpets
and welders connected to earth (only for IGBT replacement);
• Place the components on the heat sink moving them slightly in
• Mount the PCB on the components taking care not to force the
feet. The maximum force allowed is about 5 N;
• Weld all the replaced components (nb: only after that the PCB
has been fixed;
connection that you have noted before as per figure 3.8.
In this case it is necessary to check the PCB and all its components as described at points
5.2 and 5.3 and following.
6.5 PILOTING CIRCUIT
Replace all the piloting circuit components as described in figures 5.12 and 5.13
which show the component position and their features.

Figure 5.12

RIFERIMENTO SCHEMA
Q.TA' DESCRIZIONE ELETTRICO
Figure 5.13
6.6 AUXILIARY SUPPLY PCB
To replace the auxiliary supply PCB disconnect all the connectors and lift the PCB
from the fixing pins. To reconnect proceed in the same way, but contrarily.
6.7 RELAY AND ELECTROLYTIC CAPACITORS
We suggest to replace all the capacitors on the inverter PCB
connection.
below;
below;
• Cut the connections of the relay to be replaced so that you
will be then able to remove all the feet one by one;
You have now access to the PCB and you can replace and weld the relay or the
electrolytic capacitors.
To reconnect everything proceed as following:


• Place the group on the heat sink moving them slightly in
connection that you have noted before as per figure 3.8.
6.8 ELECTROLYTIC CAPACITORS LOAD RESISTANCE (R19 e R35)
It is possible to replace the resistance without removing the inverter PCB from the heat
sink.
We suggest to replace both the load resistances as following:
• Cut the resistance connections

• Remove the feet one by one;
• Clean the pins so that you can then insert the resistance
feet;
• Insert the new components and check that once that you have
inserted the feet they come only a few millimeters from the
heat sink, so that they are not too close to the heat sink
below;
• Weld the components and make sure that tin goes through the
pin;
After this operation measure the resistance between points S and 7 in figure 4.2.b. If
the value is 20Ω±2Ω end the replacement, otherwise check again the resistance
welding.
6.9 SECONDARY DIODES
We suggest to replace both the secondary diodes as following:
• Remove all the conductors from the secondary diodes;

• Remove the screws fixing the modules to the heat sink;
• Clean carefully the secondary rectifier heat sink;
• Spread some thermoconductive paste on the contact surface of
the heat sink and on the components heat sink;
• Place the component on the heat sink moving them slightly in

below with a torque of 1.5±10% Nm;
• Connect the conductors to the modules with a torque of 1.5±10%
Nm;
6.10 SECONDARY SNUBBER DIODE AND RESISTANCE
• Remove all the conductors connecting the snubber to the

secondary diodes;
• remove the screws fixing the resistance to the heat sink;
• Spread some thermoconductive paste on the contact surface of
the new resistance;
• Place the resistance on the heat sink moving them slightly in
• Tighten the screws fixing the resistance to the rectifier;
• Reconnect all the conductors connecting the snubbers to the
secondary diodes;
6.11 SOLENOIDVALVE, WATER COOLER CONNECTOR (9 POLES PANEL SOCKET)

AND FANS
• Remove the 6 screws fixing the backpanel to the base and the
the separator;

Figure 5.11
• Remove the back panel so that you can reach the solenoidvalve
and the water cooler connector;
• To remove the cooling fans unscrew the 4 screws fixing the
fan support to the backpanel and then the screws fixing the
fan to their support.
Replace the components and remount everything proceeding contrarily.
6.12 THERMOSTATS
You can replace the inverter thermostat as following:

• cut the conductors;
• Introduce a pipe key (number 10) which allows to unscrew it
from the heat sink;
Before fixing again the thermostat spread a little bit of thermoconductive paste on the
contact surface. Be sure that one you have tightened the component it is in contact on
the heat sink.

You can replace the transformer thermostat as following:
• Pull energically the thermostat till it comes out from its

seat;
Insert the new thermostat applying some conductive paste on the contact surface with
the winding. Once you have inserted it, lock it with some acetic silicone so that the air
flow does not reach it directly.
6.13 CURRENT TRANSDUCTOR
• Disconnect the 4 pole connector which is on the component;

• Unscrew the 3 screws fixing the rod to the secondary
rectifier and to the output dinse.
Figure 5.12
• Remove the rod from the current transductor;

• Remote the current transductor screws;
Replace the component and remount contrarily.
6.14 17 POLE PANEL PLUG
You can replace the panel plug as following:
• Remove the front panel unscrewing the 2 lower screws;

• Remove the 2 screws fixing to panel plug to the metallic
base.
By replacing the new component pay attention to the conductors connection, which
must be made as per electric diagram of figure 3.8.
6.15 KEYBOARD AND DIGITALPCB
You can replace the keyboard and the digital PCB as following:

• Remove the screws fixing the keyboard to the front panel;
• Remove all the connectors from the digital PCB;
• Remove the protection caps from the two encoders and unscrew
the nut which is inside it;
• Remove the flat band connector from the PCB;
• Remove the nuts fixing the keyboard to the digital PCB.
Now the two components have been separated and you can replace them. Reconnect
everything and pay attention to connect properly the flat band connection on the digital
PCB.

7) 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”;
8) TECHNICAL DATA
Input voltage 400 V TRIFASE 50/60 Hz

Installed power 7 kVA
Max input current 20 A efficaci
Absorbed input current (X=100%) 10 A efficaci
Power factor 0.7
Efficiency (X=100%) 0.8
Cosϕ 0.99
Adjustment range 10-250 A
Welding current X=40% 250 A
Opent circuit voltage 56 V
Protection class IP 23
Standards EN60974
Dimensions (lxpxh) 615 * 290 * 525 (mm)
Weight 28 kg
9) 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
E-Mail: cea@ceaweld.it – web: www.ceaweld.com

NOTE


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

1) Purpose of Manual………………………………………..………………… Chapter 1

2) Machine description……………………………………………….…..…… Chapter 2

3) Available spare parts……………………………………...…………..…… Chapter 3

4) Instruments required for testing and repairing………………..……… Chapter 4

5) Testing procedure…………………………………………………………... Chapter 5

6) Components replacement…………………………………………………. Chapter 6

7) Warranty conditions………………………………………...……………… Chapter 7

8) Technical data……………………………………………………………….. Chapter 8

9) Technical assistance request procedure………………………………. Chapter 9

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1. Antiradiodisturbance main filter 2. Main switch

Note: The components no. 3, 4, 5, 6, 7, 8 13 belong to the inverter PCB

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3. Contactor: this component is needed for short-circuiting the resistances mentioned at

7. Upper/lower primary IGBT: continuous voltage is converted by an inverter into a

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

The PCB gives the following signals to the digital PCB:

14. Auxiliary supply PCB

15. Digital PCB.

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Position Electrical diagram reference

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The following instruments are needed to check the machine:

2) A multimeter with the following scales:

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

3) A hand oscilloscope (model FLUKE 123 or better) with the following

4) A probe with the following characteristics:

6) A stabilised DC supplier with two 24 VDC outputs with at least 5A

7) An insulating auxiliary transformer 220V \ 48V 220 VA (part no. 481432);

9) A line switch at least 250V 5A

For the replacement of IGBT:

10) anti-static wristbands around the wrists

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C1-L E1C2-L E2 - L G2-L dr E2-L dr

Figure 4.2 a-b

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FLAT TASTI TR4

C32 C51 D10

C93 C97 TP17

C39 C55 C80 C101 C120

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CN4 CN5 CN6 CN7

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Testing is divided into the following steps:

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c) Open the machine following the procedure given below:

3. Remove the metallic covers disconnecting the earth cable from

4. Proceed vice-versa to re-assemble the machine.

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f) Also check all the internal parts of the machine, paying