CEBORA S.p.A. 1

SOUND MIG 5040/T Pulse

POWER SOURCE + COOLING UNIT +

WIRE FEEDER art. 288

SERVICE MANUAL

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CEBORA S.p.A. 2

CONTENTS

1 - GENERAL INFORMATION.......................................................................................................................... 4 1.1 - Introduction. ................................................................................................................................................. 4 1.2 - General service policy. ................................................................................................................................. 4 1.3 - Safety information. ....................................................................................................................................... 4 1.4 - Electromagnetic compatibility...................................................................................................................... 4

2 - SYSTEM DESCRIPTION .............................................................................................................................. 5 2.1 - Introduction. ................................................................................................................................................. 5 2.2 - Technical specifications................................................................................................................................ 5 2.3 - Description of SOUND MIG 5040/T Pulse system (art. 288). ..................................................................... 5 2.4 - Description of MIG5040/T Pulse power source. .......................................................................................... 6 2.5 - Description of WF4-P Wire Feeder. ............................................................................................................. 8

2.5.1 - Accessories table........................................................................................................................................ 9 2.6 - Description of GR52 Cooling Unit............................................................................................................... 9

3 - MAINTENANCE.......................................................................................................................................... 10 3.1 - Periodic inspection, cleaning. ..................................................................................................................... 10 3.2 - Welding system fittings and connectors. .................................................................................................... 10 3.3 - Control panel commands and signals. ........................................................................................................ 11 3.4 - Operating sequences. .................................................................................................................................. 12

3.4.1 - Welding system operation........................................................................................................................ 12 3.4.2 - MIG mode................................................................................................................................................ 13 3.4.3 - TIG operation........................................................................................................................................... 14 3.4.4 - MMA mode. ............................................................................................................................................ 15

3.5 - Troubleshooting.......................................................................................................................................... 16 3.5.1 - The power source does not start, control panel off. ................................................................................. 16 3.5.2 - Power source powered, control panel on, fan (268) stopped. .................................................................. 19 3.5.3 - System powered, display and signals do not show the correct values. .................................................... 20 3.5.4 - The start button produces no effect.......................................................................................................... 21 3.5.5 - Some connector for accessories (BB) signals do not work. ..................................................................... 23 3.5.6 - System powered, no gas flows from the torch. ........................................................................................ 24 3.5.7 - System powered, the wire feeder motor does not work. .......................................................................... 25 3.5.8 - In open circuit operation, the output voltage is not regular. .................................................................... 26 3.5.9 - In resistive load operation, the output voltage is not regular. .................................................................. 29 3.5.10 - In MIG or TIG mode, arc difficult to strike, the arc shuts off immediately after striking (stuttering start-

up). .......................................................................................................................................................... 31 3.5.11 - In synergic mode, the welding quality is not satisfactory, the wire speed is not suited to the output

current. .................................................................................................................................................... 31 3.5.12 - In MMA, arc difficult to strike and/or unsatisfactory welding quality. ................................................... 31 3.5.13 - In MIG mode, when the start button is released, the wire sticks to the workpiece (ineffective motor

braking). .................................................................................................................................................. 32 3.5.14 - Cooling unit accessibility......................................................................................................................... 33 3.5.15 - Cooling unit GR52 does not work correctly. ........................................................................................... 34

3.6 - Error codes and alarm signals..................................................................................................................... 37 3.6.1 - 1 - Internal RAM error............................................................................................................................. 37 3.6.2 - 2 - EEPROM error. .................................................................................................................................. 37 3.6.3 - 5 - Communication error on the I2C-BUS............................................................................................... 37 3.6.4 - 6 - Communication error on CAN-BUS, detected by control board (290). ............................................. 37 3.6.5 - 7 - Hardware error on the CAN-BUS communication line...................................................................... 37 3.6.6

................................................................................................................................................................. 37- 8 - Communication error on the CAN-BUS between control panel (220) and motor control board (232).

3.6.7 - 9 - Communication error on the CAN-BUS between control panel (220) and control board (290). ....... 37 3.6.8 - 10 - Missing voltage and current at the power source output. ................................................................. 37 3.6.9 - 11 - Overload at the power source output. ............................................................................................... 37 3.6.10 - 13 - Missing communication between control board (290) and pre-charge board (303), upon power

source start-up. ........................................................................................................................................ 38 3.6.11 - 14 - Microprocessor supply voltage error on control board (290). .......................................................... 38

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CEBORA S.p.A. 3 3.6.12 - 15 - Direct current voltage at pre-charge board output (303) below setting. ........................................... 38 3.6.13 - 16 - Direct current voltage at pre-charge board output (303) below minimum permitted value.............. 38 3.6.14 - 17 - Direct current voltage incorrectly divided among the DC-capacitors (302). .................................... 38 3.6.15 - 18 - Direct current voltage incorrectly divided among the DC-capacitors (302). .................................... 38 3.6.16 - 19 - Missing communication between control board (290) and pre-charge board (303). ........................ 39 3.6.17 - 20 - Absence of interlock signal on TA board (313)................................................................................ 39 3.6.18 - 25 - Error on the EPLD bus in the control board (290)............................................................................ 39 3.6.19 - 30 - Incorrect setting of the minimum current threshold on control board (290)..................................... 39 3.6.20 - 41 - Connector board (225) missing or disconnected. ............................................................................. 40 3.6.21 - 42 - Error in the signal of the motor encoder (212). ................................................................................ 40 3.6.22 - 43 - Communication error with connector board (225). .......................................................................... 40 3.6.23 - 44 - CAN-BUS communication error, detected by motor control board (232)........................................ 41 3.6.24 - 52 - trG on display (O). In MIG and TIG mode, start button pressed upon start-up. ........................... 41 3.6.25 - 53 - trG on display (O). Start button pressed while resetting from stop due to temperature outside

limits........................................................................................................................................................ 41 3.6.26 - 56 - Short-circuit at the output lasts too long........................................................................................... 41 3.6.27 - 57 - Mot on display (O). Excessive wire feeder motor (212) current................................................... 42 3.6.28 - 61 - Voltage of input phase L1 below minimum permitted. .................................................................... 42 3.6.29 - 62 - Voltage of input phase L1 above maximum permitted..................................................................... 42 3.6.30 - 63 - Voltage of input phase L2 below minimum permitted. .................................................................... 42 3.6.31 - 64 - Voltage of input phase L2 above maximum permitted..................................................................... 42 3.6.32 - 65 - Voltage of input phase L3 below minimum permitted. .................................................................... 42 3.6.33 - 66 - Voltage of input phase L3 above maximum permitted..................................................................... 42 3.6.34 - 73 - Led (G) on. High diode group (272) temperature............................................................................. 42 3.6.35 - 74 - Led (G) on. High igbt group (293) temperature. .............................................................................. 42 3.6.36 - 75 - H2O on display (O). Low pressure in the cooling circuit. ............................................................ 43 3.6.37 - 76 - H2O on display (O). Cooling unit not connected.......................................................................... 43 3.6.38 - 80 - OPn on display (O). Wire feed unit guard open............................................................................ 43 3.6.39 - 99 - OFF on display (O). Incorrect mains voltage (machine shutdown). ............................................. 43

4 - COMPONENTS LIST................................................................................................................................... 44 4.1 - Power source art. 288 : see file ESP288.pdf enclosed at the end of the manual......................................... 44 4.2 - Table of components: see file ESP288.pdf enclosed at the end of the manual. .......................................... 44 4.3 - List of spare parts. ...................................................................................................................................... 44

5 - ELECTRICAL DIAGRAMS ........................................................................................................................ 45 5.1 - Power source art. 288 : see file SCHE288.pdf enclosed at the end of the manual...................................... 45 5.2 - Waveforms. ................................................................................................................................................ 45

5.2.1 - Speed feedback signal from the wire feeder motor encoder (212)(par. 3.5.7). ........................................ 45 5.2.2 - Open-circuit voltage on the transformer (319) secondary circuit (par. 3.5.8).......................................... 45 5.2.3 - Command signal for driver boards (292) (par. 3.5.8). ............................................................................. 45 5.2.4 - Output current feedback signal on resistive load (par. 3.5.9)................................................................... 46 5.2.5 - Wire feeder motor (212) voltage during correct braking (par. 3.5.13)..................................................... 46 5.2.6 - Wire feeder motor (212) voltage during incorrect braking (par. 3.5.13). ................................................ 46

5.3 - Filter board (288) code 5.602.100/B........................................................................................................... 47 5.4 - Pre-charge board (303) code 5.602.099/A.................................................................................................. 48 5.5 - Flyback board (287) code 5.602.097/D. ..................................................................................................... 49 5.6 - Control board (290) code 5.602.101/D. ...................................................................................................... 50 5.7 - Igbt-driver board (292) code 5.602.096...................................................................................................... 52 5.8 - TA board (289) code 5.602.123.................................................................................................................. 52 5.9 - Thermostat board (307) code 5.602.137. .................................................................................................... 53 5.10 - Cooling board (31) code 5.602.093/A. ....................................................................................................... 53 5.11 - Motor control board (232) code 5.602.103................................................................................................. 54 5.12 - Connector board (225) code 5.602.104/A................................................................................................... 56

6 - UPGRADES.................................................................................................................................................. 57 6.1 - Kit Driver + Igbt, code 5.710.071 replace instructions............................................................................... 57

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CEBORA S.p.A. 4 1 - GENERAL INFORMATION

1.1 - Introduction.

The purpose of this manual is to train personnel assigned to carry out maintenance on the SOUND MIG 5040/T Pulse multi-process welding system, art. 288.

1.2 - General service policy.

It is the responsibility of the customer and/or operator to use the equipment appropriately, in accordance with the instructions in the Instructions Manual, as well as to maintain the equipment and related accessories in good working condition, in compliance with the instructions provided in the Service Manual.

Any internal inspection or repairs must be carried out by qualified personnel who are responsible for any intervention on the equipment.

It is forbidden to attempt to repair damaged electronic boards or modules; replace them with original Cebora spare parts.

1.3 - Safety information.

The safety notes provided in this manual are an integral part of those given in the Instruction Manual. Therefore, before working on the machine, please read the paragraph on safety instructions in the aforementioned manual.

Always disconnect the power cord from the mains, and wait for the internal capacitors to discharge before accessing the interior of the equipment.

THE DISCHARGE TIME FOR THE DC-CAPACITORS (302) IS HEAVILY AFFECTED BY

THE OPERATING MODE OF THE FLYBACK BOARD (287). UNDER NORMAL CONDITIONS THE TIME IS APPROXIMATELY 3 MINUTES, WITH THE FLYBACK

BOARD (287) BROKEN OR DISCONNECTED IT MAY BECOME 6 MINUTES. Some internal parts, such as terminals and dissipaters, may be connected to mains or

otherwise hazardous potentials. It is therefore forbidden to work with the safety guards removed from the machine unless strictly necessary. In this case, take special precautions such as wearing insulating gloves and footwear, and working in a perfectly dry environment with dry clothing.

1.4 - Electromagnetic compatibility.

Please read and observe the instructions provided in the paragraph Electromagnetic compatibility of the Instruction Manual.

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CEBORA S.p.A. 5

2 - SYSTEM DESCRIPTION

2.1 - Introduction. The SOUND MIG 5040/T Pulse is a multi-process system suitable for welding different types

of iron, steel and aluminum, with the Pulsed Synergic MIG/MAG, non Pulsed Synergic MIG/MAG, Conventional MIG/MAG, TIG (DC) with strike starting of the arc, and MMA processes. It is made up of the MIG5040/T Pulse electronic power source, the WF4-P Wire feeder, GR52 Cooling Unit, and a series of accessories to adapt to various types of use (see list in the Sales Catalogue).

The operator interface consists of Sound DIGIBOX MIG P1 Control Panels (art. 223), or alternatively Sound DIGIBOX MIG P2 (art. 221) which, in the present manual, are treated simply as welding system management elements. They have a specific, separate Service Manual that deals with their maintenance.

2.2 - Technical specifications.

To check the technical specifications, see the plates affixed to the equipment, the Instruction Manual, and the Sales Catalogue.

2.3 - Description of SOUND MIG 5040/T Pulse system (art. 288).

The welding system is controlled by microprocessor-based circuits, which manage the operative functions of the welding system and the operator interface.

Referring to the electrical diagram in par. 5.1, drawing 4.1 and table 4.2, you may identify the main blocks that make up the system.

Each system component, power source, wire feeder and control panel (not including the cooling unit) contains a microprocessor circuit, which not only manages the functions of the unit to which it belongs, but also communicates with the other microprocessors via CAN-BUS serial line, to actively and continuously assist system operation.

Based on this architecture, the following units may be identified: MASTER microprocessor, in the control board (290) of the power source; MOTOR microprocessor, in the motor control board (232) of the wire feeder; PANEL microprocessor, in the micro board (220) of the control panel.

Each microprocessor is programmed with a different program, which must obviously be compatible with those of the other microprocessors. To make it easier to enter and upgrade these programs, a single-access system is provided (the connector (282) for RS232 serial communication, (BP) on the front panel of the power source), which allows the three microprocessors to be programmed in a single programming session. With this step the three programs are simultaneously entered into the three microprocessors, each automatically in its place.

The version of the programs entered can be seen on the start-up screen of the control panel in the following form (see fig. 3.3): With SOUND DIGIBOX MIG P1 panel (art. 223): display O = Pan, display P = 4 = (PANEL progr., version 4 for control panel); display AN1 = MSt - 6 = (MASTER progr., version 6 for power source control); display AN2 = Mot - 6 = (MOTOR progr., version 6 for motor control). With SOUND DIGIBOX MIG P2 panel (art. 221), the programs are shown only on displays

O and P in the following sequence: display O = Pan, display P = 4 = (PANEL progr., version 4 for control panel); display O = Mot, display P = 6 = (MOTOR progr., version 6 for motor control); display O = MSt, display P = 6 = (MASTER progr., version 6 for power source control).

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CEBORA S.p.A. 6 (beginning with version 5.7.7. on panel P2, (art. 221) the programs are displayed in the same

sequence as panel P1 (art. 223), and thus PANEL, MASTER, MOTOR). The upgraded PANEL, MASTER and MOTOR programs are grouped together, along with

the Cebora Downloader programming software, in a single programming file available (including instructions) from the Cebora Web site www.cebora.it, or better www.cebora.it\prod\28800.htm (for the English version www.cebora.com\ing\prod\28800.htm).

The work programs that meet the synergic curves pre-programmed by Cebora are integrated into the MASTER program.

Customizations of the welding system modes (parameter set-up) and the welding programs created by the operator are saved in the control panel (220), in a different memory area from the one containing the PANEL program. To allow the control panel to be replaced (for example following a breakdown or to change the type of panel (art. 221 or 223)) without losing these data, they may be saved in the memory of the control board (290), and subsequently called up on the new control panel using the CP (copy) function, available in the programming file on the Cebora Web site, beginning with version 4.4.6.6 (see the Instruction Manual for control panels arts. 221and 223).

The memory area of the control panel, which contains the parameter set-up and the welding programs created by the operator, may be cleared (all data they contain may be deleted) by performing the following RESET procedure: With power source off, press the key (E) on the control panel; Power the power source using the switch (254), holding down the key (E) until you hear a

beep lasting approximately ten seconds. Release the key (E) as soon as the beep starts (within no more than 2 seconds), and wait for

the normal start-up procedure to end (if you delay releasing the key (E) too long, the error code 44 may appear on the display (P); clear it by shutting off and correctly restarting the power source). With this procedure, the PANEL program remains saved in its memory area, but the

parameter setting returns to the original factory setting. After a RESET operation, the parameter set-up previously saved in the control board (290)

may be called up using the CP (copy) function in the control panel (220), thus restoring the conditions prior to replacing the control panel, if applicable

2.4 - Description of MIG5040/T Pulse power source.

The MIG5040/T Pulse is a direct current power source with controlled current, consisting of a three-phase rectifier bridge, a DC/AC converter (inverter), and an additional rectifier bridge.

The main switch (254) powers the filter board (288), which contains the filter to reduce conducted interference reflected in the mains, and the three-phase choke (262) to level the current absorbed by the mains (improved mains cosf).

The pre-charge board (303), inserted downstream from the choke (262), contains the power rectifier bridge, the DC-capacitor pre-charge circuit (302) of the inverter, and the circuits to analyze the mains voltage. It communicates with the control board (290) through an optically isolated serial line, using a dedicated protocol.

The rectifier bridge converts the alternating mains voltage (400 Vac) to direct current (540 Vdc) suitable for powering the inverter, the DC-capacitors (302) to level this direct current and the flyback board (287).

The pre-charge circuit of the DC-capacitors (302) is made up of the PTC (PTC1 - PTC8) and relay RL1 on the pre-charge board (303). The latter is controlled by the microprocessor of the pre-charge board (303), which analyzes the mains voltage and the direct current on the DC-capacitors (302). More specifically, check the presence and amplitude of each phase of the mains voltage, the level of the direct current at the rectifier bridge output, thus on the DC-capacitors (302), and the division of this direct current between the 2 DC-capacitors (302).

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CEBORA S.p.A. 7 If the test result is positive, the pre-charge relay RL1 is closed and the power source is

operated; otherwise RL1 remains open and the power source is blocked, while the control panel (220) displays the cause of the block.

The 540 Vdc voltage present at the output of the rectifier bridge is applied to the flyback board (287), which acts as a main power source and generates the service voltages for the various system circuits (power source, wire feeder, control panel).

The inverter is made up of four igbt (2 for each igbt module (293)) connected in an H-bridge configuration, driven by the driver-igbt (292) boards mounted directly on the terminals of the igbt modules (293), in turn controlled by the control board (290).

Mounted on the power terminals of the igbt modules (293) are two snubber capacitors, electrically connected in parallel to the DC-capacitors (302), whose task is to reduce the overvoltages that develop on the igbt during operation. Their integrity and connection (which must be as short as possible on the igbt terminals) is essential for the inverter to operate; tampering with them may seriously damage the igbt (293).

The task of the igbt inverter is to generate the square-wave alternating voltage for the power transformer (319). The welding current is adjusted by modulating this voltage appropriately.

The TA (313) inserted in the circuit between an igbt module (293) and the transformer (319) provides the control board (290) with the feed-back signal of the current at the primary circuit of the transformer (319), to verify that the inverter is working properly; this signal does not normally affect the welding current adjustment.

The transformer (319) provides the secondary circuit with voltage and current values suitable for welding. Its secondary circuit is made up of 4 windings connected to a shared point on the central socket, to which the choke (310) is connected to level the welding current.

The other ends of the windings are connected to the diode group (272), which rectifies the alternating current generated by the inverter, making it available at the power source output.

The diode group (272) is made up of 4 diodes connected to a shared cathode, and provides a positive output voltage compared to the central socket of the transformer (319). Actually, each diode in the group is in turn made up of two diodes parallel connected together.

The Hall-effect current transducer (289), inserted at the diode group (272) output, sends the feed-back signal of the secondary current to the control board (290), to regulate the welding current.

The output voltage signal of the power source, used by the control board (290) to adapt the behavior of the power source based on the conditions of the welding arc in the various possible types of welding, is taken from the + (BR) and (BO) output terminals of the power source.

The control board (290) contains the main microprocessor of the power source (MASTER). It supervises management of the other boards, more specialized in their respective functions,

regulates the welding current by generating the PWM signal to be sent to the driver-igbt boards (292), and communicates with the microprocessors of the control panel (PANEL) and wire feeder (MOTOR) (see par. 2.3).

The temperature signals from the thermostat board (307), located among the igbt modules (293), to detect the temperature of the inverter, and from the thermostat (275) mounted on the dissipater of the diode group (272), to detect its temperature, both lead to the control board (290).

The fan (268) to cool the power elements of the power source is controlled by the control board (290). Its operation is conditioned by the temperature of the inverter and diode group and the ambient temperature, and is activated in the following conditions in particular: upon machine start-up, and for 10 after the pre-charge stage; with ambient temperature greater than 40C; during welding, in the 3 minutes after welding is finished, and after 3 minutes if the igbt

temperature (293) is greater than 40C; with the machine blocked, signaling an error code; when the machine is shut off.

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CEBORA S.p.A. 8 The connector (256) to connect the wire feeder is located on the rear panel of the power

source. The - power output BO of the power source is located on the front panel, while the +

power output BR is located on the rear panel. They must be connected to the wire feeder differently according to the type of welding to be carried out (see Instruction Manual).

2.5 - Description of WF4-P Wire Feeder.

The wire feeder is powered by the flyback board (287) of the power source, through the connector (206), which is connected to connector (256) of the power source. The supply voltage (55 Vdc) is applied to the motor control board (232), which generates the auxiliary power supplies necessary to operate the wire feeder, including the control panel (220).

Te connector (206) also includes the CAN-BUS communication line, with which the microprocessors of the control panel (PANEL) and wire feeder (MOTOR) communicate with the microprocessor of the power source (MASTER) (see par. 2.3).

The motor control board (232) contains the circuit to adjust the wire feeder motor (212) speed (which in this case is equipped with speed feed-back signal obtained from the encoder built into the motor (212)), the continuation of the CAN-BUS communication line to dialogue with the control panel (220), and the circuit to manage and drive the gas solenoid valve (227).

A microswitch on the door of the wire feed unit provides the motor control board (232) with the signal to stop the power source in case the door is opened. This alarm condition is signaled on the control panel (see error code par. 3.6.35).

The connector board (225), located on the front panel of the wire feeder, receives power from the motor control board (232), and communicates with the latter by means of a dedicated RS232 serial line. A microprocessor handles the input and output signals of the wire feeder, and thus of the welding system, on the connector (BB).

These signals include: Start power source (from the button on MIG or TIG torches or from an automated system). Inputs for external adjustment of the welding current (from UP/DOWN buttons). Inputs for external adjustment of the welding current (from external potentiometer). Inputs for external adjustment of the wire feeder motor speed (from UP/DOWN buttons). Inputs for torch recognition or other connected accessories. Motor power supply output for push-pull torches (not yet available). Arc on signal output (NO contact free from voltage). RS232 serial communication line for dialogue with external system controllers.

Based on the torch recognition signal, an analogic signal whose levels, spaced at intervals of 0,25 Vdc, identify the devices connected to the connector (BB), the microprocessor on the connector board (225) prepares the welding system so that it can be controlled by means of the aforementioned signals. One of the possible positions enables the external RS232 serial line, to control the welding system by means of an external controller. This line is normally kept disabled.

The start and arc-on signals are exchanged with the motor control board (232) in clear, thus directly; all of the other signals are converted into serial information and exchanged via the internal RS232 serial line, inserted in the connections between J3 on connector board (225) and J7 on motor control board (232). All these signals are isolated from the circuits of the motor control board (232), by means of the optic isolators present on the motor control board (232).

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CEBORA S.p.A. 9 The following accessories may currently be connected to the connector (BB):

2.5.1 - Accessories table.

Art. Description art. Active signals Torch recognition signal (pins 16-15 of BB).

1243 1265

MIG torch TIG torch

Start (from central adapter (BA)). 0 Vdc ((BB) free).

193 + 1191

Foot control + adapter extension

(193 no start).

Start (from torch (BA)) + current adjustment (193).

187 + 1191 + 1192

Remote control + adapter extensions.

Start (from torch (BA)) + current adjustment (187).

0.25 Vdc +/- 0.1.

1245 MIG Torch up/down. Start +

up/down speed + up/down current.

1 Vdc +/- 0.1.

The central adapter (BA) (222) for MIG or TIG torches is located on the front panel of the wire feeder; the adapter includes a power socket, two contacts for the start command, and a pneumatic fitting for gas.

2.6 - Description of GR52 Cooling Unit.

The GR52 cooling unit is powered with two phases of the mains voltage, drawn from the pre-charge board (303), practically parallel to the mains input terminals.

This voltage arrives at the cooling board (31), which acts as a connection interface between the components of the unit and the actual control circuit, the control board (290) of the power source, to which it is connected.

More specifically, the enable cooling unit signal of the control board (290) commands the relay on the cooling board which directly powers the coolant pump (36), and the autotransformer (32) which adapts (400/230 Vac) the supply voltage of the fan (33). The pressure switch (37), inserted in the hydraulic circuit on the pump (36) delivery, provides the isolated signal for the fluid pressure to the control board (290), via the cooling board (31).

If the control panel (220) is set to continuous or automatic mode (see Control Panel Instruction Manual), when the unit is switched on, the pump (36) and fan (33) will operate for 30 seconds, to fill the torch tubes and check the pressurization of the hydraulic circuit; if no welding command is received from the operator, they will then stop awaiting a new start command.

If the pressure switch (37) does not detect the appropriate pressure within 30 seconds after start-up, the control board (290) orders the power source blocked, generating the relative alarm signals on the control panel (see error code, par. 3.6.33).

In automatic mode the pump and fan enter start running when MIG or TIG welding begins, and stop 3 minutes after welding has stopped.

In continuous mode the pump and fan are always kept running. Only a lack of pressure can stop them, along with the power source.

In the MMA process, cooling unit operation is disabled. The factory setting of the cooling unit is OFF, thus this setting must be changed the first

time the welding system is used, or after a RESET procedure (see Control Panel Instruction Manual).

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CEBORA S.p.A. 10

3 - MAINTENANCE WARNINGS

ANY INTERNAL INSPECTIONS OR REPAIRS MUST BE CARRIED OUT BY QUALIFIED

PERSONNEL.

BEFORE BEGINNING MAINTENANCE OPERATIONS, UNPLUG THE MACHINE FROM THE MAINS AND WAIT FOR THE INTERNAL CAPACITORS TO DISCHARGE.

THE DISCHARGE TIME FOR THE DC-CAPACITORS (302) IS HEAVILY AFFECTED BY

THE OPERATING MODE OF THE FLYBACK BOARD (287). UNDER NORMAL CONDITIONS THE TIME IS APPROXIMATELY 3 MINUTES, WITH THE FLYBACK

BOARD (287) BROKEN OR DISCONNECTED IT MAY BECOME 6 MINUTES.

3.1 - Periodic inspection, cleaning. Periodically open the grids on the power source and check inside the aeration tunnel. Remove any dirt or dust to ensure smooth air flow, and thus adequate cooling of the internal

parts of the power source. Remove any dirt or metal dust from the wire feed liner and gear motor unit, also making sure

that they are not worn to the point of needing replacement. Check the condition of the output terminals, output and power supply cables of the power

source; replace if damaged. Check the condition of the internal power connections and connectors on the electronic

boards; if you find loose connections, tighten or replace the connectors.

3.2 - Welding system fittings and connectors.

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CEBORA S.p.A. 11

3.3 - Control panel commands and signals.

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CEBORA S.p.A. 12

3.4 - Operating sequences. The following sequences reflect proper machine operation. They may be used as guidelines

for troubleshooting. After each repair, they must be carried out without encountering any error or impediment.

Given the various operating modes available, due to the different possible configurations, only the main sequence for each welding process is described below, and only with the MIG P1 control panel, art. 223 (for references to the MIG P2 panel art. 221 see Control Panel Instruction Manual).

NOTE

Operations preceded by this symbol refer to operation actions. Operations preceded by this symbol refer to machine responses that must occur following an

operator action.

3.4.1 - Welding system operation.

System shut off and disconnected from the mains. Temporarily connect a rubber hose to the (BQ) fittings of the cooling unit, thus creating a by-

pass for coolant circulation. Connect the signal cable provided to the connectors (BD) on the wire feeder and (BS) on the

power source. Connect the power source to the mains. Close the switch (BU).

System powered; led (H) on control panel flashes rapidly. After one second, the display (O) reads Pan, and display (P) shows the version

of the PANEL program in the control panel; the displays AN1 reads MSt and shows the version of the MASTER program in the power source control board; the displays AN2 reads Mot and shows the version of the MOTOR program in the motor control board on the wire feeder. Then the entire control panel returns to the condition it was in before the last shutdown.

One second after the switch (BU) is closed, the fan (268) on the power source runs for 10 seconds, then stops.

Correct?

If the cooling unit mode is set to (see Control Panel Instruction Manual): -automatic, the pump (36) and fan (33) run for 30 seconds then stop; -continuous, the pump (36) and fan (33) run continuously; -OFF, the pump (36) and fan (33) do not operate.

NO (see 3.5.1, 3.5.2, 3.5.3, 3.5.15). YES

Press the button (AI) several times; the Process selection is repeated in sequence. Press the butt (AJ) several times; the Mode selection is repeated in sequence. Press the button (AK) several times; the Diameter selection is repeated in sequence. Press the button (AL) several times; the Material selection is repeated in sequence. Press the button (AH) several times; the accessory functions selection is repeated in

sequence. Each time the button (AI) is pressed, the leds R (1-2-3-4-5) light in sequence. Each time the button (AJ) is pressed, the leds S, T and U light in sequence. Each time the button (AK) is pressed, the leds V light in sequence.

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CEBORA S.p.A. 13 Each time the button (AL) is pressed, the leds W and X light in sequence, the

display AN1 shows the existing programs for the type of material selected, and the display AN2 shows the existing programs for type of gas associated with the type of material (existing material and gas types may be selected using the (AM) and (AX) buttons).

Correct?

Each time the button (AH) is pressed, the leds Y-Z-AA-AB-AC-AD-AE-AF-AG light in sequence, in observance of the conditions imposed by the selected Process and Mode.

NO (see 3.5.3). YES

3.4.2 - MIG mode. WARNING

DURING THE FOLLOWING TESTS DO NOT AIM THE TORCH AT PEOPLE OR PARTS OF THE BODY, BUT ONLY TOWARDS AN OPEN SPACE OR THE WORKPIECE.

Shut off the power source using the switch (BU). Connect the gas supply to the fitting (BE) on the rear panel. Connect the power cable provided to the connectors (BF) on the wire feeder and (BR) on the

power source. Connect the MIG torch to the central adapter (BA) of the wire feeder (also connect the torch

commands patch connector to the connector (BB) on the wire feeder, if present). On a water-cooled torch, connect the torch cooling lines to the fittings (BI). On a water-cooled torch, remove the temporary by-pass for coolant circulation from the

fittings (BQ), and connect the hoses provided to the fittings (BT) on the cooling unit and (BH) on the wire feeder, matching the hose color.

Connect the negative pole cable (BO) of the power source to the workpiece. Restart the power source using the switch (BU). After start-up, use the button (AI) to select the conventional MIG process (led R-3 on). Use the button (AJ) to select two-stage mode, led (S) on. Use the diameter and material buttons (AK, and AL) for which a program has already

been inserted, compatible with the torch used (e.g. : leds V-1,2 and W-FE lit). Hold down the torch start button for a few seconds.

Gas flows from the torch as long as the button is held down. The wire feeds from the torch, or the wire feeder motor begins operating, as long

as the button is held down (the wire speed is adjustable using the knob (N) and displayed on the display (O) with led (C ) on).

Correct?

The unit generates open-circuit output voltage as long as the button is held down, shown on display (P) with led (J) lit.

NO (see 3.5.3, 3.5.4, 3.5.6, 3.5.7, 3.5.8). YES

Move the torch near the workpiece and press the torch trigger. Begin welding. Turn the knobs (N) and (Q) to obtain the wire speed (shown on

display (O) with led (C ) on) and output voltage (shown on display (P) with led (J) lit) suitable for the welding to be performed.

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CEBORA S.p.A. 14

Correct?

During welding, display (O) shows the welding current (with led (D) lit) and display (P) indicates the arc voltage (with led (J) lit).

NO (see 3.5.9, 3.5.10, 3.5.11). YES

Release the torch start button.

Correct?

The arc is immediately shut off and the wire feed stopped, while gas flow stops after the post-gas stage (the post-gas time is activated only if the power source has delivered current).

NO (see 3.5.13). YES

REGULAR OPERATION.

3.4.3 - TIG operation. WARNING

DURING THE FOLLOWING TESTS DO NOT AIM THE TORCH AT PEOPLE OR PARTS OF THE BODY, BUT ONLY TOWARDS AN OPEN SPACE OR THE WORKPIECE.

Shut off the power source using the switch (BU). Connect the gas supply to the fitting (BE) on the rear panel. Connect the power cable provided to the connectors (BF) on the wire feeder and (BO) on the

power source. Connect the TIG torch to the central adapter (BA) of the wire feeder (also connect the patch

connector of the torch to the connector (BB) of the wire feeder, if present). On a water-cooled torch, connect the torch cooling lines to the fittings (BI) on the wire feeder. On a water-cooled torch, remove the temporary by-pass for coolant circulation from the

fittings (BQ), and connect the hoses provided to the fittings (BT) on the cooling unit and (BH) on the wire feeder, matching the hose color.

Connect the cable of the positive pole (BR) of the power source to the workpiece. Restart the power source using the switch (BU). After start-up, use the button (AI) to select the TIG process (led R-4 on). Use the button (AJ) to select two-stage mode, led (S) on (it is not possible to select the

diameter and material in TIG mode). Hold down the torch start button for a few seconds.

Gas flows from the torch as long as the button is held down. Open-circuit output voltage is generated for as long as the button is held down.

Correct?

Display (O) shows the programmed welding current (led (D) lit), adjustable with knob (N), and display (P) indicates the open-circuit output voltage (led (J) lit).

NO (see 3.5.3, 3.5.4, 3.5.6, 3.5.8). YES

Use the knob (N) to set the current based on the type of welding to be carried out. Move the torch near the workpiece and press the torch trigger.

Begin welding. Turn the knob (N) to optimize the current level. Display (O) shows the welding current (led (D) lit) and display (P) shows the arc

voltage (led (J) lit).

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CEBORA S.p.A. 15

Correct? NO (see 3.5.9, 3.5.10). YES

Release the torch start button. The arc shuts off immediately if a long ramp time is not set (slope-down).

Correct?

The gas flow ends after the post-gas period (the post-gas time is activated only if the power source has delivered current).

NO (see 3.5.6). YES

REGULAR OPERATION.

3.4.4 - MMA mode.

Shut off the power source using the switch (BU). Leave the signal cable provided connected to the connectors (BD) on the wire feeder and (BS)

on the power source. Connect the cable to the electrode holder and the earth cable to the negative (BO) and positive

(BR) connectors, observing the polarity of the electrodes to be used. Restart the power source using the switch (BU). After start-up, use the button (AI) to select the process MMA (led R5 lit).

Voltage begins to be generated at the power source output, and the fan (268) starts running.

Correct?

Display (O) shows the programmed welding current (led (D) lit), adjustable via knob (N), and display (P) shows the open-circuit output voltage (led (J) lit).

NO (see 3.5.2, 3.5.3, 3.5.8). YES

Use the knob (N) to set the current based on the electrode you intend to use. Move the electrode clip near the workpiece.

Begin welding. Turn the knob (N) to optimize the current level.

Correct?

Display (O) shows the welding current (led (D) lit) and display (P) shows the arc voltage (led (J) lit).

NO (see 3.5.9, 3.5.12). YES

REGULAR OPERATION.

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CEBORA S.p.A. 16

3.5 - Troubleshooting. WARNINGS

ANY INTERNAL INSPECTIONS OR REPAIRS MUST BE CARRIED OUT BY QUALIFIED

PERSONNEL.

BEFORE REMOVING THE PROTECTIVE GUARDS AND ACCESSING INTERNAL PARTS, DISCONNECT THE POWER SOURCE FROM THE MAINS AND WAIT FOR THE

INTERNAL CAPACITORS TO DISCHARGE.

THE DISCHARGE TIME FOR THE DC-CAPACITORS (302) IS HEAVILY AFFECTED BY THE OPERATING MODE OF THE FLYBACK BOARD (287). UNDER NORMAL

CONDITIONS THE TIME IS APPROXIMATELY 3 MINUTES, WITH THE FLYBACK BOARD (287) BROKEN OR DISCONNECTED IT MAY BECOME 6 MINUTES.

NOTE

Items in boldface describe problems that may occur on the machine (symptoms). Operations preceded by this symbol refer to situations the operator must determine (causes). Operations preceded by this symbol refer to actions the operator must perform in order to

solve the problems (solutions).

3.5.1 - The power source does not start, control panel off.

MAINS SUITABILITY TEST.

Correct?

No voltage for mains protection. NO YES

Eliminate any short-circuits on the connections between power cable, switch (254), filter board (288), choke (262) and pre-charge board (303).

Make sure that the terminals of the choke (262) on the terminal board (265) are not short-circuited towards the earth of the power source.

Replace choke (262) and/or filter (288) and/or pre-charge (303) boards. Mains not suitable to power the power source (ex.: insufficient installed power).

MAINS CONNECTION TEST.

Correct?

Terminals L1, L2 and L3, on pre-charge board (303) = 3 x 400 Vac, with switch (254) closed. YES NO

Check power cable and plug and replace if necessary. Check switch (254), and replace if defective. Check connections between switch (254), filter board (288), terminal board (265)

of the choke (262) and pre-charge board (303). Check the mains voltage conditions. Replace the choke (262) and/or filter board (288).

3.302.122.A 14/04/04

CEBORA S.p.A. 17 POWER SUPPLY TEST.

Correct?

Flyback board (287), connector J5, terminals 1 (+) and 4 (-) = +540 Vdc. YES NO

Check the wiring between J5 flyback board (287) and J1 pre-charge board (303). After waiting for the DC-capacitors (302) to completely discharge,

temporarily disconnect connector J5 on flyback board (287). Power up the power source again and check the voltage on the terminals Vdc+1 (+) and Vdc-1 (-) of pre-charge board (303) = +540 Vdc. If correct, replace the flyback board (287).

After waiting for the DC-capacitors (302) to completely discharge, temporarily disconnect the wires from the + and - terminals of the DC-capacitors (302) and check the resistance between the + and - terminals of the DC-capacitors (302). Correct value = >Mohm in one direction, and junction of two diodes with the probes reversed (NOTE: while measuring, the instrument display reaches the final value slowly, due to the DC-capacitors (302)). If correct replace the pre-charge board (303). If incorrect, identify which of the following components is short-circuited or leaking: DC-capacitors (302), igbt modules (292), discharge resistors (296), snubber capacitors mounted on the terminals 2 and 3 of the igbt (292).

FLYBACK BOARD POWER SUPPLY TEST (287).

Correct?

Flyback board (287), connector J5, terminals 3 (+) and 4 (-) = +18 Vdc. YES NO

Check the wiring between J5 flyback board (287) and J1 pre-charge board (303). After waiting for the DC-capacitors (302) to completely discharge,

temporarily disconnect connector J5 on flyback board (287) and check the resistance between terminals 3 (+) and 4 (-) of J5 flyback board (287). Correct value = >Mohm in one direction, and junction of a diode with the probes reversed. If correct replace the pre-charge board (303). If incorrect replace the flyback board (287).

Replace the pre-charge (303) and/or flyback board (287).

MOTOR CONTROL BOARD (232) POWER SUPPLY TEST.

Correct?

Motor control board (232), connector J18, terminals 1 (+) - 6 (-) = +55 Vdc. YES NO

Check the wiring between J18 motor control board (232), connector (206) on wire feeder, connector (256) on power source and J3 flyback board (287).

With the power source off, temporarily disconnect the connector J18 on motor control board (232) and check the resistance between terminals 1 - 6 of J18 on motor control board (232). If short-circuited, replace the motor control (232) and flyback boards (287).

With the power source off, temporarily disconnect the connectors J6, J10 and J1 on flyback board (287) and make sure that on J18, terminals 1 (+) - 6 (-) on motor

3.302.122.A 14/04/04

CEBORA S.p.A. 18 control board (232) voltage = +55 Vdc. If correct, identify which of the three disconnected connectors is causing the incorrect value of the voltage on J18 (55 Vdc), and eliminate the cause of the probable overload or short-circuit, replacing the control (290) and/or pre-charge (303) boards if necessary.

Replace the motor control (232) and/or flyback board (287).

CONTROL PANEL (220) POWER SUPPLY TEST.

Correct?

Control panel (220), connector J1, terminals 1 (+) 2 (-) = +8 Vdc. YES NO

Check the wiring between J1 control panel (220) and J12 motor control board (232).

With the power source off, temporarily disconnect connector J1 on control panel (220) and check the resistance between terminals 1 and 2 of J1 on control panel (220). If short-circuited, replace control panel (220) and/or motor control board (232).

With the power source off, temporarily disconnect connector J15 on motor control board (232), and make sure the voltage on terminals 1 (+) 2 (-) of J1 on control panel (220) = +8 Vdc. If correct, check the wiring between J1 connector board (225) and J15 motor control board (232) and replace the connector board (225) if necessary.

Replace control panel (220) and/or motor control board (232). Make sure the micro board on the panel board in the control panel (220) is properly mounted,

especially that there are no bent pins or short-circuits between the pins of the connector J2 on the micro board of the control panel (220).

Check the wiring of the CAN-BUS communication line, carrying out the CAN-BUS COMMUNICATION TEST in par. 3.5.3 if necessary.

Replace control panel (220) and/or motor control board (232).

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CEBORA S.p.A. 19

3.5.2 - Power source powered, control panel on, fan (268) stopped.

NOTE The fan (268) on the power source is controlled by the control board (290), and its operation

depends on the power source conditions, as shown in the figure in par. 2.4, Description of MIG5040/T Pulse power source. For this reason, the following tests may be verified only during the first 15 seconds of power supply or during a blocked situation. For this purpose it is possible to simulate the error 41, by disconnecting the connector J3 on connector board (225).

FAN (268) TEST. With the power source off, temporarily disconnect connector J3 on connector board (225) to

cause continuous operation of the fan (268).

Correct?

Control board (290), connector J13, terminals 5 (+) 4 (-) = +24 Vdc. NO YES

Check the wiring between fan (268) and connector J13 on control board (290). Make sure there are no mechanical impediments blocking the fan. Replace the fan (268).

CONTROL BOARD (290) POWER SUPPLY TEST. Control board (290), connector J5, terminals 2 (+) 1 (-) = +8 Vdc. Control board (290), connector J5, terminals 4 (+) 3 (-) = +15 Vdc. Control board (290), connector J14, terminals 8 (+) 5 (-) = +5 Vdc.

Correct?

Control board (290), connector J14, terminals 1 (+) 5 (-) = -15 Vdc. YES NO

Check the wiring between J5 control board (290), and J10 flyback board (287). With the power source off, temporarily disconnect connector J5 on control board

(290) and check the resistance between terminals 2 and 1 and between terminals 4 and 3 of J5 on control board (290). If short-circuited, replace control board (290) and flyback board (287).

Replace the flyback (287) and/or control board (290). Replace the control board (290) and/or fan (268).

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CEBORA S.p.A. 20

3.5.3 - System powered, display and signals do not show the correct values.

CAN-BUS COMMUNICATION TEST.

Correct?

Upon start-up, on control panel (220), led (H) flashes rapidly for approximately one second, after which the system operating status is displayed (correct operation or error condition). YES NO

Check the wiring between J5 control panel (220) and J3 motor control board (232), between J11 motor control board (232), connector (206) of the wire feeder, connector (256) on the power source and J4 control board (290).

Check the supply voltages of the control panel (220), motor control board (232) and control board (290), performing if necessary the MOTOR CONTROL BOARD (232) POWER SUPPLY TEST and CONTROL PANEL (220) POWER SUPPLY TEST in par. 3.5.1, and the CONTROL BOARD (290) POWER SUPPLY TEST in par. 3.5.2.

Make sure that the correct programs have been entered in the control panel (220) and the motor control (232) and control (290) boards, performing if necessary the programming procedure available on the Cebora Web site (see par. 2.3, Description of SOUND MIG 5040/T Pulse system (art. 288)).

Replace control panel (220) and/or motor control board (232) and/or control board (290).

ERROR CODE TEST.

Correct?

Upon start-up, after start-up, and error condition displayed, thus display (O) reads Err and display (P) shows a number identifying the type of error. NO YES

See Error codes and alarm signals, par. 3.6.

PROGRAMS INSTALLED TEST. At start-up, led (H) on control panel flashes rapidly for approximately one second, then

display (O) reads Pan, while display (P) shows the version of the control panel (220) program; the AN1 displays read MSt, with the version of the Master control program of the control board (290); the AN2 displays read Mot, with the version of the Motor control program of the motor control board (232).

Correct?

The versions of the programs entered are compatible with one another. YES NO

Check the compatibility of the programs on the three boards, comparing the installed version indexes with the specifications cited on the Cebora Web site. These programs must be in compatible versions, thus if any one of these 3 boards is replaced, you must make sure of this compatibility; better yet, reprogram the entire system with the latest available versions.

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CEBORA S.p.A. 21

COMMANDS AND SIGNALS TEST.

Correct?

The keys on control panel (220) allow all of the steps regarding the selection of Process, Mode and Programs, as described in par. 3.4 Operating sequences, and in the Instruction Manuals for the SOUND MIG MIG5040/T Pulse system and the Control panels SOUND DIGIBOX MIG P1 (art. 223) or MIG P2 (art. 221). YES NO

Check the supply voltages of the control panel (220), motor control board (232) and control board (290), performing if necessary the MOTOR CONTROL BOARD (232) POWER SUPPLY TEST and CONTROL PANEL (220) POWER SUPPLY TEST in par. 3.5.1, and the CONTROL BOARD (290) POWER SUPPLY TEST in par. 3.5.2.

Replace control panel (220) and/or motor control board (232) and/or control board (290).

Regular operation.

3.5.4 - The start button produces no effect.

POWER SOURCE SAFETY TEST.

Correct?

After the start-up procedure, display (O) shows an alarm situation (OPn, OFF). NO YES

See Error codes and alarm signals, par. 3.6.

NOTE The start command may be given to the power source either through the central adapter for

the torch (BA), or via the connector (BB) on the wire feeder. The two circuits are parallel connected, thus only one of the two signals is enough to start the power source.

CONNECTOR BOARD (225) POWER SUPPLY TEST. Connector board (225), connector J5, terminals 14 (+) and 15 (-) = +12 Vdc.

Correct?

Connector board (225), connector J5, terminals 11 (+) and 15 (-) = +5 Vdc, with no accessories connected to the connector (BB). YES NO

Check the wiring between J1 connector board (225) and J15 motor control board (232).

With the power source off, temporarily disconnect connector J1 on connector board (225) and check the resistance between terminals 1 and 2 of J1 on connector board (225). Correct value = junction of one diode in one direction, >Mohm with

3.302.122.A 14/04/04

CEBORA S.p.A. 22 the probes reversed. If short-circuited, replace the connector board (225) and motor control board (232). If >Mohm in both directions, (circuit broken) replace the connector board (225).

Replace the connector board (225) and/or motor control board (232).

START COMMAND TEST.

Correct?

Connector board (225), terminal J4-1 (-) and J4-2 (+) = 0 Vdc with start button pressed, +12 Vdc with button released (either with button connected to the central adapter (BA), or with button connected to the connector (BB)). YES NO

If the start command comes from the central adapter (BA), check the wiring between J4 connector board (225), central adapter (BA), torch central adapter, and torch button. Replace the entire torch if necessary.

If the start command comes from the connector (BB), make sure the connector J5 is properly welded (especially pins 1 and 9) on connector board (225), and check the wiring between the patch connector of the torch and the torch start button. Replace the entire torch if necessary.

Replace connector board (225).

START SIGNAL TEST.

Correct?

Motor control board (232), OP6 optocoupler (near J7), pins 1 (+) 2 (-) = +1 Vdc with start button pressed (0 Vdc with button released). NO YES

Replace motor control board (232). Check the wiring between connector J7 motor control board (232) and connector J3 connector

board (225). With power source off, temporarily disconnect the flat cable from connector J7 on motor

control board (232), and check the resistance between terminals 8 and 10 of J7 on motor control board (232). Correct value = junction of one diode in one direction and junction of two diodes with the probes reversed. If a short-circuit or broken circuit is detected, replace the motor control board (232).

Replace connector board (225).

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CEBORA S.p.A. 23

3.5.5 - Some connector for accessories (BB) signals do not work.

NOTES The start and arc-on signals are exchanged with the motor control board (232) in clear,

thus directly; all of the other signals are converted into serial information and exchanged via the internal RS232 serial line, inserted in the connections between J3 on connector board (225) and J7 on motor control board (232).

The start command of the torch (central adapter (BA)), present on J4 of connector board (225), is parallel connected to the start command on terminals 1 and 9 of J5, connector board (225) (connector for accessories (BB)), and the torch recognition signal does not distinguish between the two commands. Either one alone is enough to activate the start function.

EXTERNAL TEST SIGNALS. Connector board (225), connector J5 (BB), signals as shown in the table, with power source

powered and accessory connector inserted in (BB).

Signal J5 terminals Function active Function not active Start 1(+) 9(-) Current down 2(+) 15(-) Current up 10(+) 15(-) Speed down 3(+) 15(-) Speed up 6(+) 15(-)

0 Vdc +12 Vdc

Arc-on 4 5 0 ohm >Mohm Current potentiometer 7(+) 15(-) Adjustable from 0 to +5 Vdc. Torch recognition 16(+) 15(-) See accessories table par. 2.5.1.

NOTE For better access to the measuring points of the table, we recommend removing the connector

board (225) from the wire feeder, leaving it connected, so that you can measure the signals on connector J5 on the welding side of the printed circuit of the connector board (225).

Correct? YES

NO

Check the power supply of the connector board (225) by carrying out the CONNECTOR BOARD POWER SUPPLY TEST (225), par. 3.5.4.

Check the wiring and operation of the devices of the accessory connected. Replace the connector board (225).

Replace the connector (225) and/or motor control (232) boards.

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CEBORA S.p.A. 24

3.5.6 - System powered, no gas flows from the torch.

SOLENOID VALVE (227) TEST.

Correct?

Solenoid valve (227) terminals = 24 Vdc with start button pressed, in MIG or TIG mode, or with button (AQ) on control panel pressed (test gas). NO YES

Check for the presence of gas at the intake fitting (BE) and make sure that the pressure and flow rate in the intake line meet the specifications of the SOUND MIG 5040/T Pulse.

Make sure the gas lines in the wire feeder are not clogged. Replace the solenoid valve (227).

Check the wiring between terminals 1 and 2 of connector J13 on motor control board (232) and solenoid valve (227).

Make sure that solenoid valve terminals (227) = 56 ohm. If 0 ohm (short-circuit), replace solenoid valve (227) and motor control board (232). If > Mohm (winding broken), replace the solenoid valve (227).

Replace the motor control board (232).

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CEBORA S.p.A. 25

3.5.7 - System powered, the wire feeder motor does not work.

WIRE FEEDER MOTOR (212) TEST. Motor control board (232), connector J20, terminals 1 (-) and 2 (+) = +17 Vdc, in MIG mode,

with button (AR) on control panel pressed (fixed speed wire test).

Correct?

Motor control board (232), connector J20, terminals 1 (-) and 2 (+) = between approximately +2 and +38 Vdc, in MIG mode, with start button pressed, adjustable using the knob (N) based on the set program and wire diameter. NO YES

Correct operation. Check the wiring between J20 motor control board (232) and wire feeder motor (212). Make sure there are no mechanical impediments blocking the motor (212). With the power source off, temporarily disconnect the wire feeder motor (212) terminals from

connector J20 on motor control board (232), and make sure the resistance between the motor terminals left free = approximately 1,5 ohm (motor winding resistance). If 0 ohm (short-circuit), replace wire feeder motor (212) and motor control board (232). If > Mohm (winding broken), replace wire feeder motor (212).

Check the motor rotation direction. If incorrect, reverse the wires on terminals J20 of motor control board (232).

WIRE FEEDER MOTOR ENCODER TEST.

Correct?

Motor control board (232), connector J19, terminals 2 (+) and 4 (-) = fig. 5.2.1, with button (AR) on control panel pressed (fixed speed wire test) (speed feed-back signal from motor encoder). (In case of different speed set via the torch potentiometer or knob (N), the waveform in fig. 5.2.1 changes only in frequency, maintaining the same form, amplitude and duty-cycle). YES NO

Check the wiring between connector J19 motor control board (232) and the encoder on the wire feeder motor (212).

Make sure that on J19 of motor control board (232), terminals 1 (+) and 4 (-), voltage = +5 Vdc. If incorrect, with power source off, disconnect the connector J19 from the motor control board, and check the resistance between the terminals 1 and 4 of the patch connector disconnected from J19. Correct value = approximately 20 Kohm. If short-circuited, replace motor (212) and motor control board (232). If the circuit is interrupted replace the motor (212).

With power source off, disconnect the connector J19 from the motor control board (232), and check the resistance between the terminals 2 and 4 of the patch connector disconnected from J19. Correct value = approximately 20 Kohm. If short-circuited or if the circuit is broken, replace motor (212).

Replace the wire feeder motor (212). Replace motor control board (232).

Replace motor control (232) and/or control panel board (220). Replace the wire feeder motor (212).

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CEBORA S.p.A. 26

3.5.8 - In open circuit operation, the output voltage is not regular.

OPEN-CIRCUIT OUTPUT VOLTAGE TEST.

Correct?

Output terminal (-) (BO), and output terminal (+) (BR) on power source = approximately +78 Vdc, (in MIG and TIG modes with start button pressed, in MMA with the only the MMA process selected). NO YES

Regular operation. Make sure that the settings on control panel (220) are coherent and match a program present

in the system memory (in MIG mode, see examples in par. 3.4.2 Operating sequences, or Control Panel Instruction Manual (220)).

Check the conditions of the inductor (310) inserted in the aeration tunnel, and of the corresponding connections (remove the ventilation grid on the front panel to inspect). If you find loose connections, tighten and replace any damaged components.

Check the connection between the midpoint of the diode group (272) (connection of the diode cathodes) and (+) output terminal (BR) of the power source. If you find loose connections, tighten and replace any damaged components.

Check the wiring between J16 of control board (290) and output terminals (+) (BR) and (-) (BO) of the power source.

SECONDARY CIRCUIT TRANSFORMER (319) VOLTAGE TEST. With the power source off, temporarily disconnect the 4 end terminals of the secondary

transformer circuit (319) from the diode group (272) terminals.

Correct?

Power the power source. Output terminal (-) (BO) (gnd) (corresponding to the central socket of the transformer (319), and end terminals of the transformer (319), disconnected from the diode group (272) = fig. 5.2.2, on each terminal, (open-circuit voltage on the secondary transformer circuit (319)), in MIG and TIG modes with start button pressed. This test is not possible in MMA mode because the control board (290) does not detect voltage at the power source output (the terminal (+) (BR) appears disconnected), and thus orders a block due to error 56. NO YES

Make sure the diode modules that make up the diode group (272) are properly mounted. The diode group (272) is made up of the four diode modules connected to a shared cathode on the output terminal (+) (BR) of the power source, and each diode module is made up of the two diodes parallel connected together.

Check the wiring between diode group (272) and output terminal (+) (BR) of the power source. If you find loose connections, tighten and replace any damaged components.

With the end terminals of the secondary transformer circuit (319) disconnected from the diode group (272), check the resistance between the terminals left free on the diode group (272) and the central terminal connected to the output terminal (+) (BR) of the power source. Correct value = junction of one diode in one direction, >Mohm with the probes reversed. If you find short-circuits or breaks, replace the diode group (272).

3.302.122.A 14/04/04

CEBORA S.p.A. 27 Replace the diode group (272).

CURRENT TO PRIMARY TRANSFORMER (319) CIRCUIT TEST. With the power source off, connect the 4 end terminals of the secondary transformer circuit

(319) to the terminals of the diode group (272).

Correct?

Control board (290), connector J14, terminals 6 (+) - 5 (-) =

CEBORA S.p.A. 28

With power source off, check the resistance on the following power terminals of the igbt modules (293) (the final values in the measuring instrument are reached slowly due to the effect of the DC-capacitors): 1 (+) and 2 (-) = >Mohm; 1 (-) and 2 (+) = junction of one diode. 1 (-) and 3 (+) = >Mohm; 1 (+) and 3 (-) = junction of one diode. If incorrect, replace the defective igbt module (293), along with the driver board (292) to which it is connected.

WARNING

In case of a fault on an igbt module (293) or driver board (292), it is advisable to replace both the igbt module (293) and the driver board (292) at the same time. A defective igbt frequently damages the driver board to which it is connected. Similarly, a defective driver board frequently damages the igbt to which it is connected.

To replace igbt modules (293) follows instructions listed in par. 6.1.

Make sure that 540 Vdc is present on the terminals of the DC-capacitors (302). If incorrect, check the connections between the DC-capacitors (302) and pre-charge board (303) terminals A2-A3 (VDC+1 and VDC+2) and A4-A5 (VDC-1 and VDC-2), and replace the pre-charge board (303) and/or DC-capacitors (302) if necessary.

Make sure that the primary circuit of the transformer (319) and corresponding connections are not interrupted, short-circuited, or in isolation leak towards earth.

Replace the driver (292) and/or igbt (293) and/or transformer boards (319). Check the supply voltages of the control board (290), performing if necessary the CONTROL

BOARD (290) POWER SUPPLY TEST in par. 3.5.2. Replace the control board (290).

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3.5.9 - In resistive load operation, the output voltage is not regular.

NOTE In TIG and MMA processes, the circuits to detect the short-circuit at the output prevent the

power source from delivering current if the load is already applied at the output. Under normal operating conditions, the load is applied when the power source already delivers a voltage greater than the minimum set in the control. However, given the complexity and danger of this operation, it is specifically not recommended and thus non documented.

The sole purpose of the tests below is to verify the ability of the power source to deliver current, thus for the sake of simplicity and operator safety, only the conventional MIG process (led R3 on) will be considered below.

OPEN-CIRCUIT OPERATING TEST.

Correct?

Output terminal (-) (BO), and output terminal (+) (BR) on power source = approximately +78 Vdc, (in MIG and TIG modes with start button pressed, in MMA with the only MMA process selected). YES NO

Carry out the test in par. 3.5.8.

NOTE For the following tests use a resistive load capable of withstanding the maximum power source

current. The appropriate values are shown in the table.

Process Resistive load resistance Power source output

current Power source output voltage

Conventional MIG 0,078 ohm 500 Adc +39 Vdc

OUTPUT VOLTAGE TEST ON RESISTIVE LOAD. On the control panel, set: process = conventional MIG (led R3 on), mode = 2-stage (led S on),

diameter = 1,2 and material = FE. Use knob (Q) to set the output voltage = 39,0 on display (P) (with led J on).

Correct?

Output terminal (-) (BO), and output terminal (+) (BR) on power source = values as shown in the table, with start button pressed. NO YES

Regular operation.

INVERTER POWER SUPPLY TEST.

Correct?

DC-capacitors (302), terminals (+) and (-) = approximately +540 Vdc, with power source loaded in table conditions, and rated mains voltage. YES NO

Check the voltage on terminals L1, L2 and L3, on pre-charge board (303). If the voltage appears to drop too far compared to the mains voltage, or if you detect an

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CEBORA S.p.A. 30 unbalance in one of the three phases, check the wiring between pre-charge board (303), choke (262), filter board (288) and switch (254). Restore any deteriorated connections and replace any damaged components.

Replace the pre-charge (303) and/or filter (288) and/or choke (262) boards.

CURRENT TRANSDUCER (289) POWER SUPPLY TEST.

Correct?

Current transducer (289), terminals + (+) and (-) = +30 Vdc. YES NO

Check the wiring between current transducer (289) and J14 control board (290). With power source off, temporarily disconnect connector J14 from the control

board (290) and check the resistance between terminals 4 and 1 of the patch connector disconnected from J14. Correct value = approximately 1500 ohm. If incorrect, replace the current transducer (289).

With power source off, reconnect J14 to the control board (290) and temporarily disconnect the connector from the current transducer (28). Power up the power source again and check the voltage on J14 of control board (290), terminals 4 (+) and 5 (-) = +15 Vdc; terminals 1 (+) and 5 (-) = -15 Vdc. If incorrect, replace control board (290).

Replace current transducer (289) and/or control board (290).

POWER SOURCE OUTPUT CURRENT FEEDBACK SIGNAL TEST.

Correct?

Control board (290), connector J14, terminals 3 (+) 5 (-) = +360 mVdc, +/- 10 mVdc with power source powered; approximately +3,6 Vdc, or fig. 5.2.4, (output current feedback signal) with power source on resistive load, in the table conditions. NO YES

Correct operation. Make sure that the control board (290) is correctly set by carrying out the MINIMUM

CURRENT THRESHOLD SETTING TEST in par. 3.6.12. Check the wiring between the terminals of the secondary transformer circuit (319), diode

group (272), and output terminal (+) (BR) of the power source, and between the central transformer socket (319), choke (310), and output terminal (-) (BO) of the power source. If you find short-circuits or loose connections, restore the original connections and replace any damaged components.

Make sure the current transducer (289) is properly mounted on the output cable of the diode group (272), more specifically that the cable is centered in the transducer hole, and that it passes through perpendicularly.

Make sure that the CAN-BUS communication line is working properly between control board (290), motor control board (232) and control panel (220), performing tests with different set-ups or, if necessary, the test in par. 3.5.3 and the instructions described in par. 3.4. Operating sequences.

Replace transformer (319) and/or diode group (272) and/or choke (310). Replace the control board (290) and/or current transducer (40).

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3.5.10 - In MIG or TIG mode, arc difficult to strike, the arc shuts off immediately after striking (stuttering start-up).

3.5.11 - In synergic mode, the welding quality is not satisfactory, the wire speed is not

suited to the output current.

3.5.12 - In MMA, arc difficult to strike and/or unsatisfactory welding quality. To assist welding starts, the work programs include the Hot-Start, Soft Start and

Impedance functions, available depending on the process selected and adjustable using the keys on the control panel (220) (see Control Panel Instruction Manual arts. 221 or 223).

In particular: - the Hot-Start function is available in pulsed MIG, synergic MIG, TIG and MMA. - the Soft Start and Impedance functions are available in MIG processes. The factory setting for Soft Start = auto, on display AN1, with led AA on. In MIG mode, the parameters entered in the pulsed and synergic MIG programs are

determined based on experience, thus some operators may find conditions to be optimal while others may need to make slight changes. This is why it is possible to change the characteristics of the pulses in pulsed MIG programs, and the ratio between wire speed and welding current in synergic MIG programs (see Control Panel Instruction Manual arts. 221 or 223).

In MMA, should you find it difficult to determine the proper balance between welding with too much splattering or an electrode that tends to stick to the workpiece, despite carefully adjusting the welding current, the Arc-force function is available to work based on the arc voltage, and automatically modulates the welding current for faster detachment of the welding drop. This function may be selected using the key (AH) and adjusted using the keys (AX) and (AM) on control panel (220) (see Control Panel Instruction Manual arts. 221 or 223).

In all of these situations, when there are problems striking the arc or welding difficulties despite careful management of the parameters available on the control panel, we recommend that you: Make sure that the parameters selected reflect the actual current welding conditions. Make sure that the adjustments are working properly, by carrying out welding tests with

different parameter settings or switching the working program with a similar one, if available, to determine the practical welding differences in the different settings. If changes to the parameters do not correspond to welding differences, or if you encounter problems in selecting the parameters, make sure the software versions installed in the welding system are compatible. Upgrade if necessary by connecting to the Cebora Web site (see par. 2.3- Description of SOUND MIG 5040/T Pulse system (art. 288) and instructions on the Web site).

Make sure that the power source is working properly, performing if necessary the open circuit operation test in par. 3.5.8 and operation on resistive load test in par. 3.5.9.

Check the compatibility of the components being used (electrode clamp, torch, type of contact tip, wire type and diameter, type of gas, etc.) with the type of welding being carried out.

Check the wear status of the torch and its components, replacing if necessary. Replace the control board (290) and/or motor control board (232) and/or control panel (220).

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3.5.13 - In MIG mode, when the start button is released, the wire sticks to the workpiece (ineffective motor braking).

To maximize the end of MIG welding, the work programs include the Burn-Back function,

adjustable using the keys on the control panel (220) (see Control Panel Instruction Manual arts. 221 or 223).

In case of difficulty at the end of MIG welding: Make sure that the wire feeder motor brakes properly, if necessary performing the WIRE

FEEDER MOTOR (212) BRAKING TEST described below. Make sure that the Burn-Back function adjustment is working, by carrying out welding tests

with different parameter settings or switching the working program with a similar one, if available. If you encounter problems, make sure the software versions installed in the welding system are compatible. Upgrade if necessary by connecting to the Cebora Web site (see par. 2.3- Description of SOUND MIG 5040/T Pulse system (art. 288) and instructions on the Web site).

Check the compatibility of the components being used (torch, type of contact tip, wire type and diameter, type of gas, etc.) with the type of welding being carried out.

Check the wear status of the torch and its components, replacing if necessary. Replace the control board (290) and/or motor control board (232) and/or control panel (220).

WIRE FEEDER MOTOR (212) BRAKING TEST.

Correct?

Motor control board (232), connector J20 terminals 2 and 1 (gnd) = fig. 5.2.5, upon releasing the start button and with open-circuit power source. (voltage on the wire feeder motor (212) during correct braking, beginning with the maximum speed of 22 m/min.). The wire feeder motor stops immediately (braking time approximately 200 msec.). YES NO

Check the wiring between connector J20 of motor control board (232) and motor (212).

If the motor slows down with its own inertia (fig. 5.2.6 or similar), the braking circuit on motor control board (232) may not be working, in which case replace the motor control board (232).

Make sure that there are no mechanical impediments preventing the wire coil from stopping despite the braking action of the motor (ex.: slipping of the wire feeder rollers, improperly adjusted roller spring, etc.).

Replace the motor control (232) and/or motor board (212).

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3.5.14 - Cooling unit accessibility. The internal parts of the cooling unit may be reached by setting the power source and wire

feeder next to the cooling unit (see figures below). In this way the system may be operated by applying a temporary extension to the only connection between connector J2 of pre-charge board (303) and TP1 and TP2 on cooling board (31) (400 Vac power supply of the cooling unit).

The other connections are long enough.

Separate the power source from the cooling unit.

Restore connections using the temporary extension for the cooling unit power cord.

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Final condition, system operative with access to the internal parts of the cooling unit.

3.5.15 - Cooling unit GR52 does not work correctly.

NOTE Operation of the GR52 cooling unit depends on the welding process selected, and it may be

enabled or disabled via a setting on the control panel (220) (see Instruction Manual for control panels arts. 221and 223).

COOLING UNIT POWER SUPPLY TEST.

Correct?

Cooling board (31), terminals TP1 and TP2 = 400 Vac, with power source powered. YES NO

Check the wiring between terminals TP1 and TP2 of cooling board (31) and connector J2 of pre-charge board (303).

With power source off, temporarily disconnect connector J2 on pre-charge board (303) and check the resistance on terminals TP1 and TP2 of cooling board (31). Correct value = >Mohm. If you detect a short-circuit, replace the cooling (31) and pre-charge (303) boards. If you detect a different resistance value, replace the cooling board (31).

Replace the pre-charge board (303).

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COOLING UNIT ENABLE TEST.

Correct?

Cooling board (31), terminals TP6 (+) and TP5 (-) = +24 Vdc, with cooling unit enabled via the control panel. YES NO

Check the wiring between terminals TP6 (+) and TP5 (-) of cooling board (31) and terminals 1 (+) and 2 (-) of connector J15, on control board (290).

With power source off, temporarily disconnect connector J15 on control board (290) and check the resistance between terminals TP6 and TP5 of cooling board (31). Correct value = approximately 1400 ohm. If short-circuited, replace the cooling (31) and control (290) boards. If the circuit is open replace the cooling board (31).

Check for the presence of a jumper between terminals 3 and 4 of the patch connector on J15 of control board (290) (cooling unit connected signal).

With power source off, temporarily disconnect J15 from control board (290), and make sure that when the power source is turned back on, voltage on terminals 3 (+) and 4 (-) of J15 on control board (290) = +24 Vdc. If incorrect, replace control board (290) (power supply for cooling unit connected signal).

Replace the control (290) and/or cooling (31) boards.

MOTOR-DRIVEN PUMP (36) TEST.

Correct?

Motor-driven pump (36) terminals = 400 Vac, with cooling unit enabled. YES NO

Check the wiring between the terminals of the motor-driven pump (36) and terminals J1A and J1B on cooling board (31).

Check fuse on cooling board (31). If tripped, replace and temporarily disconnect the terminals J1A and J1B from cooling board (31), and check the resistance on the terminals of the motor-driven pump (36). Correct value = approximately 60 ohm. If incorrect replace motor-driven pump (36). If correct check the resistance on terminals J1A and J1B of cooling board (31). Correct value = approximately 150 ohm. If incorrect replace transformer (32), or eliminate any short-circuit on the cooling board (31).

Replace the cooling board (31). Check the integrity and connection of the starting capacitor of the motor-driven pump (36).

Replace if necessary. Make sure that there are no mechanical impe