CEBORA S.p.A. 1 POWER TIG 1540 DC-HF POWER SOURCE art. 271 SERVICE MANUAL 3.302.
CEBORA S.p.A. 2 CONTENTS 1 - GENERAL INFORMATION...........................................................................................................3 1.1 - Introduction. ...................................................................................................................................3 1.2 - General service policy....................................................................................................................3 1.3 - Safety information............................
CEBORA S.p.A. 3 1 - GENERAL INFORMATION 1.1 - Introduction. The purpose of this manual is to train personnel assigned to carry out maintenance on the power source art. 271 for TIG and MMA welding systems. 1.2 - General service policy.
CEBORA S.p.A. 4 2 - SYSTEM DESCRIPTION 2.1 - Introduction. The POWER TIG 1540 DC-HF is a system for MMA and TIG welding, with arc starting in both contact and high frequency mode. It is made up of an electronic power source (art. 271), and a set of accessories to adapt to various applications (see list in Sales Catalogue). The power source is controlled by a microprocessor circuit, which manages the operative functions of the welding system and operator interface. 2.2 - Technical specifications.
CEBORA S.p.A. 5 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 (2 MINUTES). 3.1 - Periodic inspection, cleaning. Periodically make sure that air is flowing properly within the aeration tunnel. Remove any dirt or dust to ensure adequate cooling of the internal parts of the power source.
CEBORA S.p.A. 6 NOTE Operations preceded by this symbol refer to operator actions. ♦ Operations preceded by this symbol refer to machine responses that must occur following an operator action. 3.2.2 - Starting the power source. System shut off and disconnected from the mains. Connect the power source to the mains. Close the switch (6). ♦ System powered, lamp on the switch (6) lit, fan (16) working, yellow led (G) lit. ♦ After three seconds, all of the leds on panel board (26) lit (lamp-test).
CEBORA S.p.A. 7 Press the start button and hold it down for approximately 5 seconds. ♦ The pre-gas phase begins; the high frequency is then generated to start the arc, as well as the power source output voltage. ♦ After approximately two seconds, the output voltage and high frequency to start the arc are no longer generated, and the post-gas phase begins (TIG operation with HF stops if there is no current at the power source output after start-up).
CEBORA S.p.A. 8 3.3 - 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 (2 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).
CEBORA S.p.A. 9 ♦ Check the wiring between CN2 power board (29) and CN2 panel board (26). ♦ Disconnect temporarily, with power source off, connector CN2 on panel board (26) and verify terminals 1 and 2 of CN2 on panel board (26) are not in short circuit. If the case, replace panel board (26), and verify, powering the power source with connector CN2 disconnected, the presence of 5 Vdc on terminals 1 and 2 of connector CN2 remained free. If lacking replace also power board (29).
CEBORA S.p.A. 10 SIGNALING TEST. Upon start-up, after the lamp-test, pressing button (A) several times the “Process” and “Mode” selection is repeated in sequence, indicated by leds F, E, D, C and B that lit in sequence. YES Correct? NO ♦ Check the wiring between the CN2 power board (29) and CN2 panel board (26). ♦ Replace panel (26) and/or power (29) boards. POTENTIOMETER ADJUSTING TEST.
CEBORA S.p.A. 3.3.4 11 - In TIG, the start button produces no effect. START COMMAND TEST. Power board (29), connector CN1, terminals 4(+) and 8(-) = 0 Vdc (start), with torch button pressed (+5 Vdc with button released). YES Correct? NO ♦ Check the wiring between CN1 power board (29) and CN1 panel board (26). ♦ Make sure the torch connector in correctly inserted in connector (I). ♦ Check cable and start button on the torch. If defective, replace. ♦ Replace panel (26) and/or power (29) boards.
CEBORA S.p.A. 12 3.3.6 - In TIG, gas flows from the torch, the arc does not start, high frequency missing. WARNING DURING THE FOLLOWING TESTS LEAVE FREE FROM CONNECTIONS AND DO NOT TOUCH THE OUTPUT TERMINAL NEGATIVE (P) OF THE POWER SOURCE. THE EVENTUAL PRESENCE OF HIGH VOLTAGE AND HIGH FREQUENCY IS DANGEROUS FOR OPERATOR AND CAN DAMAGE THE INSTRUMENTS OR THE POWER SOURCE. SECONDARY RECTIFIER OUTPUT VOLTAGE TEST. Set the TIG without high frequency operation (led E lit).
CEBORA S.p.A. 13 ♦ Make sure the good insulation of the HF generator circuit devices installed on printed circuit board of power board (29), and remove eventual traces of dirt or powder that can create short circuits between the devices. ♦ Check the distance between the tips of the discharger SC1 (correct = 0.9 mm.). ♦ Replace power board (29). 3.3.7 - In open circuit operation, the output voltage is not regular.
CEBORA S.p.A. 3.3.8 14 - In resistive load operation, the output voltage is not regular. WARNING FOR THE FOLLOWING TESTS SET OPERATION TIG WITH HIGH FREQUENCY, LED (C) LIT, BUT DISCONNECT THE HF TRANSFORMER (27) PRIMARY CIRCUIT TERMINALS FROM “HT” TERMINALS OF POWER BOARD (29) TO AVOID HF GENERATION. 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.
CEBORA S.p.A. 3.3.9 15 - In TIG, arc unstable, welding irregular. NOTE In TIG, the welding quality may not be acceptable due to current instability. In this case we recommend switching to MMA operation, and performing welding tests. MMA WELDING QUALITY TEST. Power source in MMA, welding tests = good welding quality. YES Correct? NO ♦ Perform the “open circuit operation” test (par. 3.3.7) and “operation on resistive load” (par. 3.3.8). ♦ Replace the power board (29).
CEBORA S.p.A. 16 4 - COMPONENTS LIST 4.1 - Power source art. 271: see file ESP271.pdf enclosed at the end of the manual. 4.2 - Components table: see file ESP271.pdf enclosed at the end of the manual. 4.3 - Spare parts list. Essential spare parts. Ref. Code 26 5602183 29 5602182 Description panel board power board Qty. 1 1 Recommended spare parts. Ref. Code Description 6 3190014 switch 16 3165075 fan Qty. 1 1 5 - ELECTRICAL DIAGRAMS 5.1 - Power source art. 271: see file SCHE271.
CEBORA S.p.A. 5.2.2 3.302.212 17 - Topographical drawing.
CEBORA S.p.A. 18 5.3 - Panel board (26) code 5.602.183. 5.3.1 - Topographical drawing. 5.3.2 - Connector table. Connector Terminals CN1 1 CN1 2 CN1 3 CN1 4 CN1 5 CN1 6 CN1 7 CN1 8 CN2 1 CN2 2 CN2 3-4-5-6-7-8 CN2 9 CN2 10 CN2 11 CN2 12 CNP 1 CNP 2 CNP 3 CNP 4 CNP 5 CNP 6 CNP 7 CNP 8 CNP 9 CNP 10 3.302.212 Function “+” input for torch potentiometer. torch potentiometer cursor output. “-“ input for torch potentiometer. “START” signal output. “DOWN” signal output. “UP” signal output. NU.
