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
1020h633/A
INDEX:

PURPOSE OF THE MANUAL Chapter 1

MACHINE DESCRIPTION Chapter 2

AVAILABLE SPARE PARTS Chapter 3

INSTRUMENTS REQUIRED FOR TESTING AND REPAIRING Chapter 4

TESTIN PROCEDURE Chapter 5

WARRANTY CONDITIONS Chapter 6

TECHNICAL DATA Chapter 7

TECHNICAL ASSISTANCE PROCEDURE REQUEST Chapter 8

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1. PURPOSE OF THE MANUAL

The purpose of this manual is to give useful information on DIGTECH 300 PULSED
repairing to authorised Service Centres. This manual must only be used by qualified
technicians to avoid running risks of serious damages 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 DIGITECH 300 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 2.2 (for the power source) and 2.3 (for the wire feeder) block diagram shows the
working principle of the above machine.

300 PULSED

A
COLLEGAMENTO GRUPPO TRAINAFILO
M
HO LD

SYN

CH
CHECK
ECK Fx
RUN

MEM

1. Antiradisturbance mains filter 2. Mains switch

3. Contactor
5. Primary rectifiers (2 in parallel)
7. Lower primary IGBT driver PCB
electrolytic capacitors and thermostat
9. Main transformer with thermostat
11.Induttanza
13.Resistance for welding voltage reading
15.Digital PCB
17.Cooling fans
19.Auxiliary transformer
21.Fusibile secondario trasformatore ausiliario
23.Remote controls connector
25.Push pull PCB (optional)
27. Motor control PCB
4. Electrolytic capacitor charge resistances
6. Upper primary IGBT driver PCB with
electorlytic capacitors and thermostat
with 8. Primary current reading PCB
10.Secondary rectifier with thermostat
12.Trasduttore a effetto hall per lettura corrente
di saldatura
14.Inverter control PCB
16.Relay PCB
18.Water cooling connector
20.Auxiliary transformer primary fuse
22.Wire feeding motor + encoder
24.Torch connection
26.Gas solenoide valve

Figure 2.1

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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)

2
3
6 9
17
5 8
10
7 11

16
1
4 27
19 14

20
15
21
24

23
18

22

Figure 2.2

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1. Antiradiodisturbance mains filter.This is a passive component with the dual task of
limiting machine frequency output as required by EEC norms and making DIGITECH
300 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.

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

point 4. This operation, occuring after about 2 seconds from machine switching on,
puts the equipment in normal operation condition.

4. Electrolytic capacitor charge resistance. These are simple components 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. Three resistors have been custom-
built into the feed circuit in order to limit this current, so that the load current will be kept
to tolerated values. These resistors are short-circuited by the contactor mentioned at
point 3 after a certain time and the machine is then ready to work

5. Primary rectifier. The rectifier is a high voltage diode three-phase bridge, rectifying the
voltage from the mains, achieving a single-direction value. There are 2 rectifiers in
parallel.

6. Upper primary IGBT driver PCB with thermostat and electrolytic capacitors.
Continuous voltage is converted by an inverter into a square wave at a frequency of
about 50 kHz. There are 2 PCB’s corresponding to the two inverter sides.
A thermostat (adjusted at 80°C) is fixed on the heat sink which turns off the inverter in
case of overheating. Inverter modulation allows welding current control.
There are also two electrolytic capacitors levelling the voltage from the primary rectifier.
Other capacitors are required for eliminating any high frequency harmonics and to
reduce interferences with the other components.

7. Lower inverter side with thermostat and electrolytic capacitors. The same as
already explained at point 6.

8. Primary current reading PCB. The transformer allows to measure and check the
welding current necessary for the adjustment.

9. Trasformatore di potenza. 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. A
thermostat adjusted at 140°C is fixed on the transformer.

10. Secondary rectifier circuit with thermostatic protection and snubber: the square
wave voltage given from the inverter is rectified by a fast diode bridge with snubber
circuit. On the secondary diodes heat sink there’s a thermostatic protection (adjusted at
100°C).

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11. Inductor: : the purpose of this device is to level the current inside the welding circuit in
order to have a continuous value at high frequencies.

12. Current transformer (Hall type): the transducer allows current control and
measurement, giving an output value proportional to the welding current needed for the
adjustment.

13. Resistance for welding voltage reading. A 680 Ohm resistance is fixed in series on
the transducer used for welding voltage measurement.

14. Inverter PCB. This PCB controls the following signals :

• IGBT piloting giving the conduction time of the same in accordance to the value
given from the CPU PCB;
• the current signal from the primary current reading PCB (8) for inverter protection;
• the thermostat signals;
• the supplies (two at 19V) given from the auxiliary transformer for the internal
operation;
• the voltage signal from the primary bridge output necessary for the machine voltage
protection;
• the welding current (from the Hall effect current transformer). The current signal is
also passed to the CPU PCB for the control of the same;
• the welding voltage through properly amplified shunt output. The voltage signal is
passed to the CPU PCB for the control of the same.

15. Digital PCB. The PCB implement all the machine functions set from the operator
through the front panel and display the active alarms. The PCB are feeded from the
auxiliary transformer through 12 VAC alternate voltage.

16. Relay PCB. This allows to handle through some relays the water cooling (cooling on
demand), fans (fan on demand) and contactor operation.

17. Cooling fan motor. The fan is necessary to cool down the machine internal parts.
They are directly operated from the control “fan on demand”

18. Water cooling equipment connection. Needed for connecting the water cooling
equipment. The signals are:
- 400 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.

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19. Auxiliary transformer. It gives the necessary auxiliary supply voltage for machine
circuits supply. The transformer is supplied from the mains at 400V and gives the
following outputs:
a) 230V in autotransformer;
b) 0V-42V-48V;
c) 19V-0V-19V;
d) 19V-0V-19V;
e) 0V-12V;
f) 0V-12V;

20. Auxiliary transformer primary fuse. It is fixed on the rear panel. It protects the
auxiliary transformer primary.

21. Auxiliary transformer secondary fuse. It is fixed on the rear panel. It protects the
12V output of the auxiliary transformer secondary, which suppiles the digital PCB and
the motor control PCB.

22. Wire feeding motor + encoder. It is the wire feeding device. The encoder gives a
signal for the motor speed adjustment.

23. Remote control connector. It allows to connect all the remote controls foreseen for
the welding equipment.

24. Torch connection. It allows to insert the torch power component. Torch push button
wires are located on the same connector.

25. Push pull PCB (optional). This PCB allows to supply the push pull torch motor. 42
Vac supply is given from the power source auxiliary transformer.

26. Gas solenoide valve. It adjusts gas opening and closing in MIG and TIG mode as per
the operator’s settings.

27. Motor control PCB. It handles all the wire feeding device functions and in particular:
- Wire feeding motor reading the motor turns through the encoder;
- Displa and remote controls;
- push pull PCB;
- the gas solenoide valve.

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3) Available spare parts

Pos. Electrical diagram reference

Description PART NO.
(Figure 3.1) (Figure 3.8)
1 Front panel RK 352420
2 Keyboard (-) 447834
3 Knob without index for current adjustment (-) 438888
4 Knob without index for voltage adjustment (-) 438849
5 Rear panel cover (-) 352435
6 Lock (-) 412346
7 Mobile part cover (-) 420524
8 Lateral guide (-) 352422
9 Flange for central connection (-) 428110
10 Euro connection (-) 266632
11 Sticker (-) 466973
12 6 pin female panel plug CA 419050
13 50mm2 female quick connection (-) 403611

Figure 3.1

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 Pos Electrical diagram reference
Description PART NO.
(Figure 3.2) (Figure 3.8)
14 Sticker (-) 468713
15 Rear panel (-) 352425
16 PG16 black cable gland cap (-) 430755
17 PG 16 black cable gland (-) 427875
18 6.3 x 32 fuse holder (-) 451740
19 1.6A 500V 6.3 x 32 delayed fuse F1 429049
20 1.6A 500V 6.3 x 32 delayed fuse F2 429049
21 6 x 6 switch knob (-) 438700
22 Front panel cover (-) 352430
23 Fixed part cover (-) 420523
24 9 pin female panel plug CHR 419049
25 48VAC 50/60Hz solenoide valve EVG 425984
26 5x10.5 gas tube (-) 485040
2
27 4 x 2.5mm 4m mains cable (-) 235994

Figure 3.2

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 Pos. Electrical diagram reference
Description PART NO.
(Figure 3.3) (Figure 3.8)
28 Wire feeding device adapter (-) 400000
29 Motoreducer 42V 100W + encoder ME 444470
30 Motor fan cover (-) 454349
31 Metallic base (-) 407978
32 Coil hub (-) 241840
33 4R wire feeding device + vertical motor 42V (-) 260111

Figure 3.3

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 Pos. Electrical diagram reference
Description PART NO.
(Figure 3.4) (Figure 3.8)
34 3 phase rectifier 35A 1600V RP 455501
35 230V 45W Fan motor MV 486380
36 IGBT thermostat 80 °C TH1 478848
37 Primary IGBT driver PCB SPIL, SPIH 376967
38 40A 1200V Primary IGBT module IGBT 286019
39 100°C Secondary rectifier thermostat TH2 478786
680 ohm 25W wirewound resistor aluminium
40 R3 457067
housed
41 Power secondary diode D2 423236
42 Secondary diode varistor group VR 488318
43 Transformer TA2 481946
44 Outlet heating assembly CP 418872
45 Secondary circuit RC group C2 R2 427685
46 Main transformer TP 481416
47 Inductor L 240219
48 Anterior deflector (-) 463561
49 Additional insulation (-) 352411
50 Current reading PCB SLC 376966
51 Rear deflector (-) 463560

Figure 3.4

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 Posizione Riferimento schema elettrico
Descrizione COD. N°
(Figura 3.5) (Figura 3.8)
52 EMC Filter F-EMC 376887
53 Primary snubber resistor R1 457122
54 Auxiliary cable (-) 413674
55 Motor control digital PCB SMC 377003
56 10A 0.5x20 delayed fuse (-) 429011
57 Relay PCB SR 376962
58 PWM PCB SE 376969
59 Auxiliary transformer TAUX 481501
60 Upper flatcar (-) 449561
61 16A 48V 50 / 60Hz contactor CL 419937
62 32A 600V three pole switch IL 435760
63 Front panel digital PCB SD 377001
64 Encoder (-) 454150
65 Front CPU PCB SCPU 377002

Figure 3.5

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 Pos. Electrical diagram reference
Description PART NO.
(Figure 3.6) (Figure 3.8)
1001 Test PCB (-) 377570
1002 PWM control integrated (-) 352508
1003 Voltage reading transformer (-) 481905

Figure 3.6

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 Posizione Riferimento schema elettrico
Descrizione COD. N°
(Figura 3.7) (Figura 3.8)
1004 Electrolytic capacitor (-) 418778
1005 Piloting circuit (-) 456955

+ +

- -
J2B

Figure 3.7

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 Figure 3.8

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4) NECESSARY INSTRUMENTS FOR TESTING AND REPAIRING

For machine testing the following parts are needed:

1) 1 testing PCB part no. 377570 (see figure 4.1). This PCB allows to test the machine
without digital PCB. In particular it is possible:
a) to switch on and adjust all the machine devices:
- cooling pump (PUMP);
- cooling fan motors (FAN);
- inverter (INVERTER);
- contactor (CONTACTOR);
- inverter adjustment (S.P. PWM);
- Voltage measurement selection from wire feeder (MIG) or from power source
(ELE), only on DIGITECH 400 with separate wire feeder
b) Display machine signals:
- Thermostat switch on (led °C);
- Auxiliary supplies (led POWER);
- overvoltage (O.V.), undervoltage (U.V.), overcurrent (O.C.) alarm signals;
- welding voltage (between V-SALD and GND) and welding current (between I-SALD
and GND);

Figure 4.1

2) U One multimeter with the following scales:

- Ohm: from 0 to a few Mohm;
- Diode control test(∗);
- Continuous voltages (VDC): from mVDC up to 1000 VDC;
- Alternate 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 anhode and black cathode (directly polarised connection): the readout varies from multimeter to
multimeter and from diode to diode (0.3-0.6V);
- Black anhode and red cathode (inversely polarised connection): the readout is different depending on
the multimeter and diode type (2V-5V).

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REMARK: 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 loose in
accuracy while, with reduced capacity, measurements have to be taken quickly to prevent
instrument overheating.

3) A hand oscilloscope (model FLUKE 123 or superior) 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 similar or better features or
a shunt of 250A.

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

7) A 4A magnetothermal switch;

8) A 250V 5A min mains switch;

For IGBT’s replacement:

9) An antistatic wristband;

For replacing components in contact with heat sink (for example thermostats) pls use
thermal paste from RS COMPONENT (Ref. 554-311) or a different type but with the same
thermal features.

Pls see here following all the figures showing the test points and all the components
involved in the testing procedure described in chapter 5:

- figure 4.2 inverter PCB layout;

- figure 4.3 driver PCB layout;
- figure 4.4 CPU PCB layout;
- figure 4.5 panel PCB layout;
- figure 4.6 relay PCB layout;
- figure 4.7 motor control PCB layout;
- figure 4.8 push pull PCB layout;
- figure 4.9 test PCB layout;
- figure 4.10 current reading PCB layout.

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 1 2

CN10

LV1

CN8 CN7
CN6

2 1 2 1 6 1 4 1

Figure 4.2

E2-H E1C2-H C1-H E1-H dr G1-H dr

+ +

E2-H dr

G2-H dr

- -
J2B

+ + J1C

E1-L dr

G1-L dr

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

Figure 4.3

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 DL4

1 6

Figure 4.4

Figure 4.5

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 Figure 4.6

CN3
1

CN2 1

10
CN1

DL1
1

Figure 4.7

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 X1

Figure 4.8

Figure 4.9

Figure 4.10

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5) TESTING PROCEDURE

The testing procedure includes the following steps, to be carried out as following detailed:

1- a preliminary and accurate visual control to be repeated also after damaged parts
replacement. Pls follow the instructions given in chapter 5.1;

2- a preliminary control of the power components by use of a multimeter. Pls follow the
instructions given in chapter 5.2;

3- testing of auxiliary supplies and inverter PCB (IGBT drivers). Pls follow the instructions
given in chapter 5.3;

4- (48VAC 50/60 Hz) low voltage testing. Pls follow the instructions given in chapter 5.4;

5- Panel PCB and wire feeder testing. Pls follow the instructions given in 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. Since the PCB’s are painted pls make sure while testing that there is a proper
electrical contact between the measuring instrument and the component being
tested.

N.B. Pls repeat the testing procedure from the beginning after each component
replacement.

N.B. Hand contact with electronic component clamps may cause serious damages,
due to electrostatic discharges. IGBT’s in particular are to be treated very carefully.
In any case pls wear antistatic wristbands.

N.B. Pls replace parts in contact with heat sinks only after cleaning the contact
surfaces with alcohol and spreading a layer of thermal paste.

N.B. After replacement operations pls tighten carefully the screws on the power
contacts and the connectors on the PCB’s, in order to avoid any overheating or
false contact.

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5.1 MACHINE INTERNAL AND EXTERNAL VISUAL CONTROL

a) Unplug the equipment from the mains supply and disconnect the welding cables.

b) Pls check the machine externally and make sure that there are no visible damages.
Pls control in particular the mechanical seal and the integrity of the front control panel.
You can make this control also moving the encoder, the potentiometers and the push
buttons, to find out if they are eventually blocked. In case of any suspect damage pls
replace immediately the front panel, taking off the screws and disconnecting the
connectors.

c) Open the power source following these instructions:

1.Remove the two screws fixing the cover, the front and rear
handles

2.Remove the two protection decks (point 5 on figure 3.1 and

point 22 on figure 3.2);

3.Remove the metallic bands disconnecting the earth cable;

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

d) Pls check at first dust deposits, in particular the metallic ones. Pls note that even a
small layer could create contacts (especially in the electronic part), causing problem
not only to the involved component but also to those connected to it.

e) Cooling air grids are particularly important. Pls check that they are not obstructed or
damaged. Partial or total obstruction may cause a duty cycle reduction.

f) Pls control also all the internal parts of the equipment paying particular attention to any
burning, deformation, breakage, clearly unforseen contacts, loose contacts. Replace
immediately any damaged part.

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g) In any case pls clean all the components with dry compressed air, removing dust
deposits. Repeat the visual control after that.

h) Check all the wirings and connectors. Troubles given from bad electrical connections
are more difficult to be detected, as you always think that they are properly done.

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5.2) PRELIMINARY CONTROL OF POWER COMPONENTS WITH MULTIMETER

N.B The machine must be disconnected from the mains supply during testing.

Some preliminary operations are necessary before checking the components:

• Switch off any supply to the machine;

• Set the mains switch on position 0 (OFF);

1) EMC MAINS FILTER

Do the following:

• Take off the black caps from the filter clamps so that they are
ready for measuring;

Control the filter electrical continuity putting the multimeter between the correspondent
inputs and outputs. The measured ohmic resistance value must be equal to a short circuit

Check the insulation between the phases and the filter ground cable. The measured ohmic
value should be like open circuit.

If any of the mentioned conditions is not fulfilled replace the EMC filter as here following
indicated and repeat the controls from the beginning, otherwise go ahead with point 2.

EMC filter replacement

The filter replacement is easy following the given instructions:

• Disconnect the connectors which from the mains switch and from
the mains cable are linked to the filter, taking note of their
proper connection;
• Remove the screws fixing the filter to the base.

Pls proceed in reverse order for reconnection and then repeat the controls from the
beginning.

2) MAINS SWITCH

Using a multimeter pls check that between the corresponding inputs and outputs fo the
switch there is an open circuit. If the condition is met proceed with point 3, otherwise
replace the switch as here following indicated.

• Set the mains switch in postion I (ON);

Check with a multimeter that between the inputs and the correspondent outputs of the
switch there is a short circuit. If not replace the switch.

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Switch replacement
Switch replacement is easily made following these instructions:

• Take off the screw fixing the handle to the switch;

• Unscrew the screws fixing the switch to the rear panel;
• Remove the conductors from the mains cable, taking note of their
proper connection.

Pls proceed in inverse order to reconnect and after repeat the controls from the beginning.

3) FUSES AND AUXILIARY TRANSFORMER

Check the fuses F1 and F2 integrity.

If none of the 2 is interrupted then go on to point 4, otherwise:

- if fuse F1 is burnt disconnect connectors CN 1 from relay (figure 4.5) and inverter PCB
(figure 4.2) and check that between 400V and 0V auxiliary transformer clamps you
have 10Ω±2Ω. If the value is not correct replace the auxiliary transformer otherwise
measure the resistance on the cooling fan motor connector. If the value is lower than
50Ω change the cooling fan motors otherwise replace the pump after checking the
cable on the cooling equipment connector.

- if fuse F2 is burnt replace it and test the wiring from 0V 9V auxiliary transformer output
to the digital panel PCB CN2 connector (figure 4.4). In contrary case you will check in
chapter 5.5 if it is necessary to replace digital CPU or panel PCB. Go on to the
following point.

4) ELECTROLITHIC CAPACITOR CHARGE RESISTANCE AND CONTACTOR

a) Check thath there is a resistance of 220Ω±5Ω positioning the multimeter between

points 1 and 2 of figure 5.1:

If the condition is not fulfilled replace the electrolithic capacitor charge resistance.

Pls follow these steps:

• press and keep pressed with a tooling the contactor on point

“A” on figure 5.1, so that its contacts are closed;

b) Check that there is a short circuit (0Ω) positioning the multimeter between the following
points (see figure 5.1):

- 1 and 2;
- 3 and 4;

Provided that all the conditions are met you can proceed with the folloiwng point, otherwise
you have to replace the contactor.

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 1 3 A

2 4
Figure 5.1

5) PRIMARY RECTIFIER

Do the following:

• Release the tooling closing the contactor on point “A” shown on

figure 5.1;
• Disconnect the four fastons (points 6 and 7 of figure 5.2) thus
removing the connection between the primary rectifier and the
two inverter sides.

Referring to figure 5.2 check with the multimeter the diodes between the listed points:
- point 1 (cathode) and point 4 (anode);
- point 2 (cathode) and point 4 (anode);
- point 3 (cathode) and point 4 (anode);
- point 1 (anode) and point 5 (cathode);
- point 2 (anode) and point 5 (cathode);
- point 3 (anode) and point 5 (cathode);

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 4 3 6

1
2 5

7
Figure 5.2

If the previous conditions are satisfied go ahead with the following control (point 6)
otherwise replace both the primary rectifiers following the below given instructions and
resume then from the beginning.

Primary bridge replacement

• disconnect all the connectors from the bridges, taking note of

their proper connection;
• remove the screws fixing the 2 bridges to the heat sink;
• replace the new components spreading thermal paste only after
cleaning carefully the contact surfaces with alcohol;

Pls proceed in reverse order for reconnection and then resume the controls from chapter
beginning.

6) INVERTER MODULES

Follow these steps:

• Reconnect the four fastons (points 6 and 7 of figure 5.2)

previously disconnected;

Referring to figure 4.3 check with multimeter the diodes between the given points:

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- 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 any of the above conditions is not satisfied replace both IGBT modules as following
indicated otherwise go on to the next transformer test (point 7).

IGBT modules replacement

• wear antistatic wristbands after proper earth connection;

• disconnect all the connectors from the upper and lower primary
IGBT driver PCB, noting their proper connection;
• remove the screws fixing the modules to the heat sink;
• cut the IGBT module pins, so that it will be then possible to
remove each pin singularly;
• replace the new component taking all the necessary precautions
as follows:
- antistatic elements like bands, footboards and soldering guns
earth connected;
- careful thermal coupling with the heat sink using thermal paste
and cleaning contact surfaces;

Proceed in reverse order for reconnection and then resume the controls from the chapter
beginning.

7) SECONDARY BRIDGE AND SECONDARY SNUBBER CIRCUIT

Carry out the following:

• Disconnect the connector CN6 from the inverter PCB (figure

4.2);

a) Check with the multimeter the secondary diodes (four in parallel) between points 1
(anode) and 2 (cathode) referring to figure 5.3. The voltage drop value in direct polarity
is very low and is around 0.1÷0.2V. If they are not damaged go to point b. Otherwise
disconnect all the connections on diode anode. Verify again the four diodes now
separated and replace the module with at least one damaged diode.

Snubber diode modules replacement

It is recommended to replace both the snubber diode modules as following detailed:

• Remove all the wires from secondary snubber diodes;

• Take off the screws fixing the modules to the heat sink;

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• Replace the new component taking care of the thermal coupling
with the heat sink using thermal conductive paste after
cleaning the contact surfaces.

Pls repeat the steps in reverse order for reconnection.

After component replacement check with the multimeter the resistance between points 4
and 5 of figure 5.3. The correct value is 10Ω ± 1 Ω. If the value is not correct replace at the
same time the resistance and the secondary snubber capacitor. After replacing the parts
repeat the control from the beginning.

b) Verify with the multimeter the secondary diodes (four in parallel) between points 3
(anode) and 4 (cathode) making reference to figure 5.3. The voltage drop value in
direct polarity is very low and is about 0.1÷0.2V. If they are not damaged proceed with
point 8. Otherwise disconnect all the connections on diode anode. Verify again the four
diodes which are now separated and replace the module with at least one damaged
diode.

Snubber diode modules replacement

It is recommended to replace both the snubber diode modules as here following described:

• Remove all the wires from secondary snubber diodes;

• Take away the screws fixing the modules to the heat sink;
• Replace the new component taking care of the thermal coupling
with the heat sink using thermal conductive paste after
cleaning the contact surfaces.

Pls repeat the steps in reverse order for reconnection.

After component replacement control with the multimeter the resistance between points 6
and 7 on figure 5.3. The correct value is 10Ω ± 1 Ω. If the value is not correct replace at
the same time the resistance and the secondary snubber capacitor. After replacing the
parts repeat the control from the beginning.

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 4
1
5

6
3
7

Figure 5.3

8) RESISTANCE AND WELDING VOLTAGE READING TRANSFORMER

• Reconnect connector CN6 to inverter PCB (figure 4.2);

Follow this step:

Verify with a multimeter the resistance value between the positive and negative quick
connection. If the value is 530Ω±30Ω go to paragraph 5.3 otherwise measure the
resistance value between the negative dinse connection and pin 1 of connector CN6 of
the inverter PCB (figure 4.2). If the value is about 590Ω±30Ω replace the transformer on
the inverter PCB (LV1 of figure 4.2) otherwise the voltage reading resistance in the
following way:

• Disconnect the front panel removing the lower screws;

• Disconnect the connectors linking the resistance to the
connector CN6/1 (of the inverter PCB)and the negative dinse
connection;
• Unscrew the two screws fixing the resistance to the upper
base.

Proceed vice versa for reconnection.

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5.3) ALARM AUXILIARY SUPPLY VOLTAGES AND INVERTER DRIVER PILOTING
CONTROL

Note During this testing it is necessary to take measures with a part of 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 paragraph beginning.

Follow these steps:

Initial operations to be done before checking the components:

• Reconnect all the components which were previously disconnected

for replacements or repairing;
• Disconnect connectors CN2, CN3 from CPU PCB (see figure 4.4)
and connect the test PCB to the just disconnected connectors
(see figure 4.9);
• Disconnect all the remaining connectors from CPU and front PCB;
• Disconnect the connectors CN2 and CN3 from motor control PCB
(see figure 4.7);
• Disconnect the connector CN10 from inverter PCB (figure 4.2);
• Disconnect the connector from push pull PCB (if there is) (see
figure 4.8);
• Set all the switches (INVERTER, CONTACTOR, PUMP, FAN) on test
PCB in position “OFF” and set switch “MIG ELE” in position
“ELE” ;
• NOTE: disconnect connector (CBT on figure 3.8) and connect a
supply cable with a connector of type:
- Contacts type MOLEX 42023 or equivalent;
- Contact holder type MOLEX 42021 or equivalent.
• Link to the previous connector the single phase voltage of 400V
± 10% and frequency 50Hz/60Hz;
• Set the mains switch in position I (ON).

1. Check that the cooling fan motors are off otherwise replace the relay PCB and resume
the controls from the beginning.

2. AUXILIARY SUPPLIES

Measure the auxiliary transformer output voltages (referred to a supply voltage of 400V)
following this table showing the clamps sequence:

Clamp 1 2 3 4 5 6 7 8 9 10
19V 0V 19V 19V 0V 19V 0V 12V 0V 12V

Clamp 11 12 13 14 15 16
0V 230V 400V 0V 42V 48V
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a) clamps 1 and 2 : 19V± 2V;
b) clamps 2 and 3 : 19V ± 2V;
c) clamps 4 and 5 : 19V ± 2V;
d) clamps 5 and 6 : 19V ± 2V;
e) clamps 7 and 8 : 12V ± 1V;
f) clamps 9 and 10 : 12V ± 1V;
g) clamps 11 and 12 : 230V ± 5V;
h) clamps 14 and 15 : 42V ± 3V;
i) clamps 14 and 17 : 48V ± 3V.

2a) If all the points (a), (b), (c), (d), (e), (f), (g), (h), (i) are not fulfilled replace the auxiliary
transformer. The component cab be easily replaced removing the fixing screws and
the connectors;

• Reconnect the connetor CN10 to the inverter PCB (figure 4.2);

2b) If points (a), (b), (c), (d) are not fulfilled replace the inverter PCB. The component can
be easily replaced removing the connectors;

2c) If led power on test PCB (see figure 4.9) is not permanently switched on replace the
inverter PCB after checking the cable between the auxiliary transformer and the
inverter PCB (connector CN10 see figure 4.2) and between the inverter PCB and the
test PCB.

• Reconnect the connectors CN2 and CN3 to the motor control PCB
(see figure 4.6);

2d) If points (e), (f), (i) are not fulfilled replace the motor control PCB. The component can
be easily replaced removing the connectors and the fixing screws.

2e) If led DL1 of the motor PCB (see figure 4.7) is not permanently on replace the motor
PCB;

• Reconnect the connector X1 to the push pull PCB (if there is)
(figure 4.7);

2f) If point (h) is not fulfilled replace the push pull PCB.

2g) Measure the voltage on pins 1 and 3 of the female CN2 connector previously
disconnected from CPU PCB. The value must be 12V ± 1V. If not check the cable
between the auxiliary transformer and the connector.

3) PROTECTION CONTROL

3a) Verify that the two red leds on the test PCB (U.V., O.V. of figure 4.9) are permanently
on. If not replace inverter PCB.

3b) Verify that the red led on the test PCB (OI of figure 4.9) is permanently off. If not
replace the inverter PCB.

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3c) Check that the yellow led on the test PCB (°C) is permanently OFF. If so go on with
IGBT driver piloting control (point 4) otherwise follow these steps:

• Disconnect the machine from the mains supply;

• Disconnect connectors CN3 CN4 and CN5 from inverter PCB (see
figure 4.2);

- Verify with a multimeter if there is a shortcircuit on the female connector CN3 just
disconnected. If it is not shortcircuited replace the corresponding thermostat
otherwise replace the inverter PCB;
- Verify with a multimeter if there is a shortcircuit on the female connector CN4 just
disconnected. If it is not shortcircuited replace the corresponding thermostat
otherwise replace inverter PCB;
- Check with a multimeter if there is a shortcircuit on the female connector CN5 just
disconnected. If it is not shortcircuited replace the corresponding thermostat
otherwise replace the inverter PCB.

4) IGBT DRIVER PILOTING CONTROL

Follow these steps:

• Shortcircuit the bridges J1 adn J2 on the inverter PCB figure

4.2.
• Set the test PCB INVERTER switch in position ON;

4a) Verify that LED 1 on the test PCB is on otherwise replace the inverter PCB after
checking the connector between the test PCB and the inverter PCB.

• Connect the oscilloscope probe with points G1–h dr and E1– H dr

(ground on E1 – Hdr) (driver piloting 1) of the inverter PCB
(see figure 4.3);
• Set the oscilloscope in the following way:
vertical 5V/div;
horizontal 10µs/div;

4b) Check that the wave form displayed on the oscilloscope is as per figure 5.4 with a time
base of 10 µs and 0.4 µs. It also must have the following values:

- frequency 48kHZ ÷ 52kHZ;

- positive value 14V ÷ 15V;
- negative value 0V ÷ 0.2V;
- upslope time 1.44 ÷ 1.76 us;
- downslope time 220 ÷ 310 ns;

REMARK The same measures and considerations at point “a” will have to be repeated
with the other pilotings, i.e.:

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 - points G2 – H dr and E2 – H dr (ground 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 E2 – L dr) of the connector CN2 (piloting
4);

Figure 5.4

4c) If the displayed wave form is always at 0 for all the pilotings replace the pwm control
integrated and check again the pilotings. If you still have the problem replace the
inverter PCB.

4d) If the displayed wave form is correct for all the pilotings go to point 5 otherwise follow
these steps:

• Disconnect connectors CN 7 and CN8 from the inverter PCB (see

figure 4.2).
• Set the oscilloscope in the following way:

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 vertical 5V/div;
horizontal 4µs/div;
• connect the oscilloscope probe between the following points:
- point 1 of hte connector CN7 and the integrated heat sink U4
(ground) (see figure 4.2);
- point 2 of the connector CN7 and the U4 integrated heat sink
(ground) (see figure 4.2);
- point 1 of the connector CN8 and U4 integrated heat sink
(ground) (see figure 4.2);
- point 2 of hte connector CN8 adn the U4 integrated heat sink
(ground) (see figure 4.2);
If in all the cases the displayed wave form is as per figure 5.5 go ahead otherwise
replace the inverter PCB before proceeding.

Figure 5.5

• Reconnect the connectors CN7 and CN8 of the inverter PCB (see
figura 4.2).
• Disconnect supply from the connector;
• wear antistatic wristbands after proper earth connection;
• disconnect all the connectors from the primary driver IGBT
PCB (taking note of their proper connection)for which at
least one piloting has not fulfilled conditions at point 4d;
• remove the screws fixing the PCB to the heat sink;
• cut the IGBT module feet so that it will be then possible to
remove the feet singularly;
• reconnect connector Y1 to the PCB;
• Set the oscilloscope in the following way:
vertical 2V/div;
horizontal 10µs/div;
• connect the oscilloscope probe to the points:

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 - G1–h dr and E1– Hdr (ground
PCB if you are disconnecting
4.3);
- G2–h dr and E2– Hdr (ground
PCB if you are disconnecting
4.3);
- G1–L dr and E1– Ldr (ground
PCB if you are disconnecting
4.3);
- G2–L dr and E2– Ldr (ground
PCB if you are disconnecting
4.3);
• supply the connector again;
on E1 – Hdr) of the upper driver
the upper driver PCB (see figure
on E2 – Hdr) of the upper driver
the upper driver PCB (see figure
on E1 – Ldr) of the upper driver
the lower driver PCB (see figure
on E2 – Ldr) of the upper driver
the lower driver PCB (see figure

- 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;

If both the pilotings of each PCB are correct replace only the IGBT module, otherwise
replace both the IGBT module and the corresponding driver PCB.

NOTE. For inverter PCB and modules replacement it is necessary to repeat again all
the steps of this chapter.

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 Figure 5.5

5) Do the following:

• Set the switch INVERTER on the test PCB in position OFF;

5a) Verify that the voltage measured with the oscilloscope is 0V on each of the pilotings,
otherwise replace the inverter PCB.

• Set switch INVERTER on the test PCB in position ON;

• Disconnect the connector CN3 from the inverter PCB (see figure
4.2)

5b) Verify that the voltage measured with the oscilloscope is 0V on each of the pilotings
otehrwise replace the inverter PCB.

• Reconnect the connector CN3 to the inverter PCB (see figure 4.2)
• Eliminate the shortcircuit on the bridge J1 of the inverter PCB
figure 4.2.

5c) Verify that the voltage measured with the oscilloscope is 0V on each of the piloting
otherwise replace the inverter PCB.

• Unplug the machine;

• Reconnect the bridge J1 previously disconnected on the inverter
PCB;
• Eliminate the shortcircuit on the bridge J2 of the inverter PCB
figure 4.2.
• Reconnect the machine to the mains supply;

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5d) Check that the voltage measured with the oscilloscope is 0V on each of the pilotings
otherwise replace the inverter PCB.

6) CONTACTOR, COOLING FAN MOTOR AND PUMP CONTROLS

Do the following:

• set FAN switch on the test PCB in position ON;

6a) Check that the cooling fan motor is ON (it takes a while for the fan motor to rotate
regularly). If not measure the voltage on the cooling fan motor connector. If the value
is 230V ± 5V replace the cooling fan motor otherwise replace the relay PCB.

• Set the switch FAN on the test PCB in position OFF;

• Set the switch CONTACTOR on the test PCB in position ON;

6b) Verify that the contactor is on. If not measure the voltage between points 7 and 8 of
figure 5.1. If the value is 48V ± 5V replace the contactor otherwise replace the relay
PCB.

• Set the switch CONTACTOR on the test PCB in position OFF;

• Connect and switch on the water cooling equipment;
• Set the switch PUMP (only if the machine is equipped with a
water cooler) on the test PCB in position ON;

6c) Check that the water cooling equipment pump is working. Otherwise replace the relay
PCB after checking the wiring between the relay PCB and the water cooling equipment
connector.

• Set switch PUMP on the test PCB in position OFF;

• Disconnect the machine from any supply voltage.

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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 5.6) on two alternates of
the mains cable.
Proceed as follows:

• Reconnect all the components previously disconnected for

eventual repairings or replacement;
• Leave the test PCB connected and teh auxiliary supply cable
cable to the CBT connector of figure 3.8;
• Create again shortcircuit 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 mains switch in position O (OFF);
• Connect the oscilloscope probe between points J1C (postive
pole) and J2B (negative pole) of figure 4.3.
• Set the oscilloscope in the following way:
vertical 10V/div;
horizontal 4ms/div;
• set the swithc INVERTER on the test PCB in position OFF;
• connect the 48 VAC voltage to the 2 main cable conductors (see
figure 5.6) and supply the machine;

C
400
48 D
A B 230 48 VAC al cavo
0 di alimentazione
230 VAC
0

A – Mains supply 230 VAC 50 Hz

B – Mains switch 250V 5A
C – Insulating trasnformer part no. 481432
D – Switch 50V 4A
Figure 5.6

a) If it is not possible to supply the machine with 48 VAC for short circuit replace the
mains cable. If you still have the problem replacethe EMC filter.

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b) Measure the voltage on the mains cable input conductors which are supplied. If the
value is equal to the supply voltage go to the following point otherwise replace the
mains cable.

c) Proceed as follows:

• Set the mains switch in position I (ON);

• Set the switch CONTACTOR on the test PCB in position ON;
• Set the potentiometer of the test PCB on the maximum value;

d) If the magnetothermic of the 48 VAC intervenes for shortcircuit replace the electrolytic
capacitors otherwise go on with the following point.
It is advisable to replace all the capacitors of both the driver PCB’s. The electrolytic
capacitors’ replacement is easy removing the corresponding driver PCB. In this way
the capacitors’ pins can be easily reached and the relevant components cab be
replaced.

e) 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;

f) Measure the voltage displayed on the oscilloscope. The correct value is slightly lower
than the one measured at point (a) of about 3V÷5V. The voltage must be without
oscillations (figure 5.9 shows an example of voltage with oscillations).

If both the previous conditions are fulfilled go to the next point otherwise replace the
electrolytic capacitors.

g) Measure with a multimeter the voltage between the clamps TP1 GND (negative) and
TP3 V-SALD of figure 4.9. The correct value is 1.0V ÷ 1.3V DC (the value is the one of
the machine voltage divided by 7). If the value is right go to the next point otherwise
measure the machine output voltage.

- If the value is 7V ÷ 9V DC replace the inverter PCB.

- If the value is not 7V ÷ 9V DC follow these instructions:

• Set the main switch on the test PCB in position OFF;

• Set the mains switch in position O (OFF);
• Connect the oscilloscope probe between points E1C2-H and J2B
(ground) of figure 4.2.
• Set the oscilloscope as follows:
vertical 20V/div;
horizontal 4µs/div;
slope up trigger 19.6V.
• set the mains switch in position I (ON);
• set the swicth INVERTER on test PCB in position ON;

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 Verificare che sull’oscilloscopio appaia la forma d’onda di figura 5.7. In caso
contrario sostituire il trasformatore.

• portare il commutatore INVERTER sulla scheda di collaudo in

posizione OFF;
• portare l’interruttore linea in posizione O (OFF);
• collegare la sonda dell’oscilloscopio tra i punti J1B e
E1C2-L (massa) di figura 4.2.
• portare l’interruttore linea in posizione I (ON);
• portare il commutatore INVERTER sulla scheda di collaudo in
posizione ON;

Check that the wave form displayed on the oscilloscope is as per figure 5.7. If not
replace the transformer.

Figure 5.7

h) Do the following:

• Set the main switch on the test PCB in position OFF;

• 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;
• Set the switch INVERTER on the test PCB in position ON;

Check that turning the potentiometer the machine current value varies from 0 to a
maximum of about 75A.

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 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 vary the current value replace the inverter PCB otherwise go to the
next paragraph.

i) Measure the voltage between the points TP1 GND (ground) and TP2 I-SALD (see
figure 4.9). Turning the potentiometer on the test PCB you have to find a voltage value
related to the machine current which is to be 75A for each measured volt.

If the value is right go to the next point, otherwise measure the voltage between pin 1
and 2 of the connector CN2. If the value is 30V±2V replace the current transformer
otherwise replace the inverter PCB;

j) Do the following:

• Disconnect the machine from the auxiliary supply;

• Set the mains switch in position O (OFF);
• Remove the machine output cto;
• Cut off the supply on the mains cable.

Go to the next chapter.

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5.4 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;
• 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 for not non sollecitare in
inserzione il raddrizzatore primario;
• Set the switch INVERTER on the test PCB in position OFF;
• Take off the bridges J1 and J2 (see figure 4.2);
• Disconnect the auxiliary supply to the CBT connector (figure
4.8) and reconnect the same connector;
• Connect the mains cable to the mains supply with a voltage of
400V ± 10% and frequency 50Hz/60Hz and feed the machine.
NOTE: Values close to the maximum (460V) and minimum (320V) could activate
overvoltage or undervoltage protection;

a) 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.

b) 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.

• Set the mains switch in position I (ON);

• After about 3 seconds se the switch CONTACTOR in position OFF;
• Set the switch INVERTER on the test PCB in position ON;

c) Measure the machine output voltage:

If the value is 69V ÷ 71V (with 400V supply voltage and in any case a value
proportional to the supply voltage) go to the following point;

If the previous condition is not met replace the inverter PCB and repeat the controls
from chapter 5.3.

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• Connect the oscilloscope probe between points 1 (ground) and 2
of the inverter PCB (see figure 4.2);

d) If the displayed wave form on the oscilloscope is as per figure 5.8 go to the next
paragraph otherwise follows these steps:

• Disconnect connector Cn1 from the current reading PCB;

• Connect the oscilloscope probe between points 1 (ground) and
2 of the current reading PCB (see figure 4.10);

If the displayed wave form on the oscilloscope is as per figure 5.8 replace the
inverter PCB otherwise replace the current reading PCB.

Figure 5.8

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5.5) PANEL AND MOTOR 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 5.12 shows the description of the push buttons and leds on the machine front
panel.

300 PULSED

A HOLD
V

SYN

CHECK
CHECK Fx
RUN

MEM

Figure 5.11

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;

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• disconnect the connector CN5 from the motor controlo PCB (see
figure 4.7);
• 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 the led DL4 on CPU PCB (figure 4.4). If it is on and blinking go to the following
point otherwise verify if there is a voltage of 9V±1V on connector CN1 of CPU PCB
(figure 4.3). If the value is right replace the CPU PCB, otherwise replace both the fuse
F2 on the rear of the machine and the CPU PCB (figure 4.3).

2. Verify that the display is on and shows the following wordings:

- display current a number between 10 and 300;

- display voltage the value 50 or 70;

If the conditions are met go to the following point otherwise check led DL2 on the CPU
PCB (figure 4.4). If it is permanently on replace the CPU PCB otherwise replace the
panel PCB after checking the wiring between the connector CN4 of the panel PCB
(figure 4.5) and CN4 of the CPU PCB (figure 4.4).

3. Follow these steps:

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

• Reconnect the connector CN5 of the motor control PCB (see
figure 4.7);
• Set the mains switch in position I (ON);
• After the led DL1 starts blinking disconnect the connector
CN5 from the motor control PCB (see figure 4.7);

4. Verify the led DL1 on the CPU PCB (figure 4.4). If it is permanently on go to the next
point otherwise follow these instructions.

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

Measure the electric continuity between the below listed points:

pin 1 of the connector CN3 of the panel PCB (see figure 4.5) and the pin 1 of the
connector CN5 of the motor control PCB (see figure 4.7);
pin 2 of the connector CN3 of the panel PCB (see figure 4.5) and the pin 2 of the
connector CN5 of the motor control PCB (see figure 4.7);
pin 3 of the connector CN3 of the panel PCB (see figure 4.5) and the pin 3 of the
connector CN5 of the motor control PCB (see figure 4.7);
pin 4 of the connector CN3 of the panel PCB (see figure 4.5) and the 4 of the
connector CN5 of the motor control PCB (see figure 4.7);
pin 6 of the connector CN3 of the panel PCB (see figure 4.5) and the pin 6 of the
connector CN5 of the motor control PCB (see figur 4.7);

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 If any of the above conditions is not fulfilled replace the wiring between CPU PCB
and motor control PCB otherwise replace the motor PCB.

5. Verify that led DL2 on the CPU PCB (figure 4.3) is permanently off otherwise replace
the panel PCB and if the problem is not yet solved replace also the CPU PCB.

• Set the switch in position O (OFF);

• Set the mains switch in position I (ON);

6. Verify that led DL1 on the CPU PCB (figure 4.3) is permanently off otherwise replace
the CPU PCB.

• Reconnect connector CN of the motor controla PCB (see figure

4.7);
• Select welding process electrode with the welding process
push button (if electrode mode is already selected then
switch to TIG LIFT and then back to the electrode mode).

7. 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.

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 panel PCB.

8. Measure the machine output voltage. The correct value is 68V ÷ 70V (with a supply
voltage of 400V). If not replacew the CPU PCB.

• Weld both in ELECTRODE adn TIG/LIFT mode checking all the

machines functions (arc force, hot start, innesco in lift…..)

9. If any of the machine function is not properly working replace the CPU PCB.

10. Do the followingi:

• Press push button Fx;

Verify that the corresponding led is blinking.
• 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.

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Verify that related leds are on.
• Turn on the welding process MIG;
• Press repeatedly push button WELDING MODE.
Verify that related leds are on.
• Turn on the welding mode 2 Times;
• Press repeatedly the push button JOB TYPE.
Verify that related leds are on.
• Turn on welding mode synergic;
• 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;
Verify that related leds are on.
• Switch on led Electronic Inuductance;
• Press repeatedly push button PARAMETER SELECTION – A;
Verify that related leds are on.
• Switch on led A;

If any of the operations is not possible or is not fulfilled replace the keyboard otherwise go
ahead with the next point.

11. Do the following:

• 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 panel PCB.

If any display segment is not lit up replace the panel PCB.

12. Proceed as follows:

• 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 so
you can go to the following point, otherwise measure the voltage between PIN 1 and 2 of
connector CN3 on the motor control PCB (figure 4.7). If the value is 48V ± 3V alternate
replace the motor control PCB, otherwise replace gas solenoide valve after checking gas
connections inside the machine.

13. Proceed as follows:

• Press and keep pressed the gas test push button on the wire
feeder;
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 In case of gas leak from torch connection go to the following point, otherwise measure
the voltage on PINS 3 and 4 of connector CN3 of the motor control PCB (see figure
4.7). If the value is not 48V ± 3V alternate replace the motor control PCB, otherwise
replace gas solenoide valve after checking the wiring between the motor control PCB
and gas solenoide valve.

14. Follow these steps:

• Release gas test push button on the wire feeder;

• 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 corrisponding to
about 16V supply) go to the next point;
- If the motor rotates at the maximum speed (wire speed higher than 10 m/min) or by
steps check the wiring and the connectors between the encoder and motor control PCB
and eventually replace the encoder. If you still have the problem replace the motor
control PCB.
- If the motor does not move check the fuse (F3) integrity on the motor control PCB
(figure 4.7). If the fuse is not ok replace it, but before check that the wire feeding device
is not mechanically blocked. If the fuse was ok carry out the following test:

Measure the voltage (always keeping the wire test push button pressed) on PIN 3
and 4 of connector CN3 of the motor PCB (see figure 4.7). If the value is not 48V
± 3V check the wiring inside the machine, otherwise measure the voltage at the
motor edges. If the value is 16V ± 3V continous (always keeping the wire test
push button pressed) replace the wire feeder motor otherwise replace the motor
control PCB.

15. Proceed as follows:

• Release the motor test push button on the wire feeder;

• Connect a 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:

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

Measure if there is a short circuit between pointsi 4 and 5 of connector CN1 (figure
4.7) pressing torch push button. If so replace replace the motor control PCB, otherwise
check the wiring between torch connector and motor PCB.

16. Go ahead like this (only for torch with UP/DOWN facility otherwise go to the next point):

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

• Insert the torch with UP/DOWN remote control;

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• Set the mains switch in position I (ON);
• Press and keep pressed push button UP;

Verify that on display current value increases. If so go ahead, otherwise:

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

Measure if there is a short circuit between points 7 and 8 of connector CN1 (figure
4.7). If there is no short circuit check the wiring between the remote control connector
and the motor control PCB.

Measure if there is a short circuit between points 10 and 8 of connector CN1 (figure
4.7) pressing trigger UP. If there is short circuit replace the motor control PCB,
otherwise check the wiring between the remote control connector and the motor
control PCB.

17. Proceed as follows (only for torch with UP/DOWN facility, otherwise go ahead) :

• Release push button UP;

• Press and keep pressed push button DOWN;

Verify that current value on the display decreases. If so go to the next step, otherwise:

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

Measure if there is a short circuit between points 7 and 8 of connector CN1 (figure
4.7). If there is not check the wiring between the remote control connector and the
motor control PCB.

Measure if there is short circuit between points 9 and 8 of connector CN1 (figure 4.7)
pressing push button DOWN. If so replace the motor control PCB otherwise check the
wiring between the remote control connector and the motor control PCB.

18. Follow these steps (only for remote control RC26 otherwise go to the next step) :

• Set mains switch in position O (OFF);

• Connect remote control RC26;
• Set the two potentiometers on the minimum value (SYNERGIC
turn anticlockwise completely FINE VOLTAGE turn clockwise
completely)
• Set the mains switch in position I (ON);

Verify that turning the potentiometer FINE VOLTAGE on the remote control
anitclockwise the value shown on “voltage” display increases.
Verify that turning the potentiometer FINE VOLTAGE on the remote control clockwise
the value shown on the related display “voltage” decreases.

If so go ahaed, otherwise:

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

Measure if there is a short circuit between points 7 and 8 of connector CN1 (figure
4.7). If not control the wiring between the remote control connector and the motor
control PCB.

Measure if there is a variable reistance (between 0Ω±10Ω and 10kΩ±1kΩ) between

points 10 and 8 of connector CN1 (figure 4.7) turning fine voltage potentiometer. If so
replace the motor control PCB otherwise check the wiring between the remote control
connector and the motor control PCB.

19. Follow these steps (only for remote control RC26 otherwise go to the next point) :

• Set the mains switch in position I (ON);

Verify that turning the potentiometer SYNERGIC on the remote control the value on
display “current” increases.
Check that turning the potentiometer SYNERGIC anticlockwise on the remote control
the value on display “current” decreases.

If so go ahead otherwise:

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

Measure if there is a short circuit between points 7 and 8 of connector CN1 (figure
4.6). If not check the wiring between the remote control connector and the motor
control PCB.

Measure if there is a variable resistance (between 0Ω±10Ω and 10kΩ±1kΩ)

between points 9 and 8 of connector CN1 (figure 4.6) turning the potentiometer
synergic. If so replace the motoro control PCB otherwise open the wire feeder
following the instructions given in chapter 5.1 and check the wiring between the
remote control connector and the motor control PCB.

20. Follow these steps (only for remote control PUSH PULL otherwise go to the next point):

• Set the mains switch in position I (ON);

• Set the push pull torch potentiometer on the minimum value
(clockwise completely).

Verify that turning the potentiometer on the torch clockwise the value on display “current”
increases.
Check that turning the potentiometer on the torch anticlockwise the value on display
“current” decreases.

If so go to the next point otherwise:

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 • set the mains switch in position O (OFF);

Measure if there is a short circuit between points 7 and 8 of connector CN1 (figure
4.7). If not check the wiring between the remote control connector and the motor
control PCB.

Measure if there is a variable resistance (between 0Ω±10Ω and 10kΩ±1kΩ)

between points 9 and 8 of connector CN1 (figure 4.6) turning the synergic
potentiometer. If so replae the motor control PCB otherwise check the wiring
between the remote control connector and the motor control PCB.

21. Carry out the following (only for remote control PUSH PULL otherwise the test is
completed) :

• Press the torch push button;

Check the motor rotation on the torch. If it is ok the test is completed otherwise replace the
motor control PCB after checking wiring inside the machine.

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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

Input voltage 400 V 3 phase 50/60 Hz

Installed power 11 kVA
Max input current 25 A RMS
Absorbed input current (X=100%) 16 A RMS
Power factor 0.7
Efficiency (X=100%) 0.8
Cosϕ 0.99
Adjustment range 10-300 A
Welding current X=40% 300 A
Welding current X=60% 230 A
Welding current X=100% 180 A
Opent circuit voltage 70 V
Protection class IP 23
Standards EN60974 EN50199
Dimensions (lxpxh) 665 * 290 * 525 (mm)
Weight 39 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

E-Mail: cea@ceaweld.it – web: www.ceaweld.com

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NOTE

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