Tig Cerbera PDF

CEBORA S.p.A.
TIG SOUND 2540/T AC/DC

POWER SOURCE art. 348
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 power source art. 348...............................................................................................................5
3 - MAINTENANCE.........................................................................................................................................................8
3.1 - Periodic inspection, cleaning............................................................................................................................8
3.2 - Sequence of operations (fig. 3.2.3). .................................................................................................................8
3.2.1 - TIG-AC operation...............................................................................................................................................9
3.2.2 - MMA-AC operation.........................................................................................................................................10
3.2.3 - Power source commands and signals............................................................................................................11
3.3 - Troubleshooting................................................................................................................................................12
3.3.1 - The power source does not start, control panel off.....................................................................................12
3.3.2 - Power source powered, control panel lit, fans (57) stopped.....................................................................14
3.3.3 - Power source powered, display and signals does not indicate the correct values.................................15
3.3.4 - In TIG, the start button produces no effect (temperature check)..............................................................17
3.3.5 - In TIG, no gas flows from the torch..............................................................................................................18
3.3.6 - In TIG, gas flows from the torch, the arc does not start, high frequency missing.................................19
3.3.7 - In TIG, gas flows from the torch, the arc does not light, voltage is missing at the transformer
secondary circuit (64)........................................................................................................................................21
3.3.8 - In open circuit operation, the output voltage is not regular.......................................................................23
3.3.9 - In resistive load operation, the output voltage is not regular.....................................................................25
3.3.10 - TIG-DC, arc unstable, welding irregular. .....................................................................................................27
3.3.11 - TIG-AC, arc unstable, welding irregular. .....................................................................................................27
3.4 - Error codes.........................................................................................................................................................29
3.4.1 - 001 - Hardware lockup.....................................................................................................................................29
3.4.2 - 002 - Hardware lockup.....................................................................................................................................29
3.4.3 - 020 - No interlock signal..................................................................................................................................29
3.4.4 - 025 - Malfunction on the EPLD bus in the control board (23).................................................................29
3.4.5 - 030 -Incorrect setting of the minimum current threshold on the control board (23).............................29
3.4.6 - 048 - Power source stop caused by a brief power outage of the control board (23) (transitory
blackout)..............................................................................................................................................................29
3.4.7 - 052 - Start button pressed during start-up....................................................................................................30
3.4.8 - 053 - Start button pressed during reset from stop due to overtemperature. ............................................30
3.4.9 - 054 - Power source output voltage greater than 48 Vac.............................................................................30
4 - COMPONENTS LIST ..............................................................................................................................................31
4.1 - Power source art. 348 : see file ESP348.pdf enclosed at the end of the manual....................................31
4.2 - Components table: see file ESP348.pdf enclosed at the end of the manual............................................31
4.3 - Spare parts list...................................................................................................................................................31
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5 - ELECTRICAL DIAGRAMS...................................................................................................................................32
5.1 - Power source art. 348 : see file SCHE348.pdf enclosed at the end of the manual. ...............................32
5.2 - Waveforms.........................................................................................................................................................32
5.2.1 - Open-circuit transformer (64) secondary voltage (par. 3.3.6, 3.3.7)........................................................32
5.2.2 - PWM1 and PWM2 signals for igbt board (21) (par. 3.3.7). ......................................................................32
5.2.3 - Power source output voltage, in TIG-AC, with resistive load (par. 3.3.9)..............................................32
5.2.4 - Power source output voltage, in MMA-AC, with resistive load (par. 3.3.9)..........................................33
5.2.5 - Transformer (64) primary circuit current, in TIG-DC, with resistive load (par. 3.3.9). .......................33
5.2.6 - AC power supply board (24) output voltage (par. 3.3.11).........................................................................33
5.3 - Pre-charge board (42) code 5.600.758/B. .....................................................................................................34
5.4 - Flyback board (20) code 5.600.756/B. ..........................................................................................................35
5.5 - Control board (23) code 5.600.771/F.............................................................................................................36
5.6 - Satellite board (22) code 5.600.766/D...........................................................................................................37
5.7 - Igbt driver board code 5.602.040...................................................................................................................38
5.8 - Igbt capacitors board code 5.602.037............................................................................................................38
5.9 - Igbt board (21) code 5.602.069.......................................................................................................................39
5.10 - HF board (25) code 5.602.043........................................................................................................................40
5.11 - Driver board (46) code 5.600.825. .................................................................................................................41
5.12 - Power supply board (24) code 5.602.002.....................................................................................................42
5.13 - Connector board (32) code 5.602.015/C.......................................................................................................43
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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. 348 for TIG and MMA welding systems.
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 Instruction 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 (2 minutes) before accessing the interior of the equipment.
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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2 - SYSTEM DESCRIPTION
2.1 - Introduction.
The TIG SOUND AC/DC 2540/T 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. 348), 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.

To verify the technical specifications, see the machine plate, Instruction Manual, and Sales
Catalogue.
2.3 - Description of power source art. 348.

Art. 348 is a voltage power source with controlled current, consisting of a three-phase rectifier
bridge, a DC/AC converter (inverter), and an additional rectifier bridge.
Furthermore, an additional DC/AC converter downstream of the second rectifier converts the
welding current back to AC.
Referring to the electrical diagram in par. 5.1, drawing 4.1 and table 4.2, we can identify the
main blocks that make up the power sources.
The main switch (9) directly powers the pre-charging board (42), which generates the 540 V
voltage to power the igbt inverter (21).
The same voltage is also applied to the flyback board (20), which acts as the main power
supply and generates all service voltages for the various power source circuits.
The inverter (21) converts the direct voltage into alternating square wave, suitable for
powering the transformer (64), which provides the secondary circuit with voltage and current
values suitable for welding.
The welding current is regulated in the inverter (21), with the modulation of the output
voltage T.off, while keeping the T.on constant. Consequently, the frequency of the voltage
applied to the transformer is variable, and more specifically ranges between 15 and 43 kHz.
Furthermore, in order to have a broader setting range for the welding current, the T.on may also
be selected from among four fixed, programmed values, automatically selected by the control
based on welding needs.
The secondary circuit of the transformer (64) has a central socket and powers the diode group
(40), which rectifies the alternating current generated by the inverter, making it available to the
next inverting stage.
The diode group (40) is made up of four diodes connected in a single-phase bridge, and
provides a dual output voltage, thus a positive and negative with regard to the central socket of
the transformer acting as a potential 0 . This configuration simplifies insertion of the next
inverting stage, present on the power source art. 348.
The central socket of the transformer, before the terminal of the power source output,
contains the choke (65) to level the welding current, and the HF transformer (26) to start the
welding arc without contact between the electrode and workpiece.
At the output of the diode group (40) is the Hall-effect current transducer (66). This sends the
current feedback signal of the secondary current to the control board (23) to regulate the welding
current.
The inverting stage, by the IGBT module (51), reverses the polarity of the power source
output voltage in AC operating mode.
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The module (51) has two igbt in half-bridge configuration, connected so that the alternating
closure of the two makes the positive and then the negative voltage appear at the output + of
the power source, present on the output terminals of the diode group (40), also marked with +
and . These voltages obviously refer to the potential of the terminal of the power source
output, corresponding to the 0 of the central socket of the secondary circuit of the transformer.
The pre-charge board (42), controlled by the control board (23), acts:
- pre-charges the capacitors-DC on the igbt board (21);
- powers the fans (57) inside the power source.
The control board (23) contains the main power source microprocessor.
It supervises management of the other boards, more specialized in their functions, regulates
the welding current by generating the PWM signal to send to the igbt board (21), and
communicates with the control panel, which in this case is made up of intelligent modules,
equipped with microprocessors, available in two versions (art. 218 and 220, see Sales
Catalogue).
A specialization board, called the satellite board (22), is mounted on the control board (23).
Its primary role is essentially to act as an interface between control board (23), control panel, HF
board (25), and driver board (46).
The igbt board (21) represents the power inverter that powers the transformer (64); it contains
the four igbt connected in H-bridge configuration, the leveling capacitors of the voltage
provided by the pre-charge board, and the TA to detect the primary transformer current. The TA
signal is used by the control board (23) to make sure the inverter is operating correctly, and does
not affect the normal adjustment of the welding current.
The igbt board (21) also has a board mounted on it; this is the driver-igbt board, which carries
out isolated commands to drive the four igbt of the inverter.
The HF board (25), combined with the HF transformer (26), generates the high voltage and
high frequency pulses necessary to start the welding arc. Its operation depends on the presence of
AC voltage on the secondary circuit of the transformer (64), and is controlled by the satellite
board (22).
The driver board (46) drives the two IGBT contained in the module (51), based on the signals
received from the satellite board (22). It also contains a circuit to detect the voltage present on
the capacitors-AC board (49), whose signal is used by the power supply board (24) to check the
maximum voltage reached on the AC-capacitors, in AC power source mode.
The snubber board (43), mounted against the IGBT module (51), contains the RC networks to
protect the two IGBT.
The capacitors-AC board (49) contains the capacitors to recover energy from the choke (65)
while reversing the polarity of the output voltage.
The power supply board (24) is a direct current power source that charges the capacitors on
the capacitors-AC board (49), to ensure sufficient voltage and energy to maintain the stability of
the pilot arc in both half-waves.
Its operation is driven by the control board (23), through the driver board (46), and controlled
via the circuit provided on the driver board (46).
The resistors present in modules (55) and (56) serve to limit peak currents circulating in the
AC capacitors.
The temperature sensor (48) is mounted on the dissipater of the module (51); its signal
reaches the control board (23) for analysis via the driver (46) and satellite (22) boards.
The connector board (32) is located in proximity of the output terminals, and acts as a power
source input/output and output voltage signal conditioning interface. The board also contains the
control circuit of the gas solenoid valve (28), necessary for TIG welding.
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The following signals are available to the power source connector:

Start power source (torch button).
Welding current external adjustment (potentiometer).
Interface signal from cooling unit.
arc lit signal output.
All of these signals are exchanged with the control board (23) via the I2Cbus
communication system.
The signals processed by the electronic boards and present at their connectors are listed in the
table in chapter five of this manual.
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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 open the power source grids and check inside the aeration tunnels.
Remove any dirt or dust to ensure smooth air flow, and thus adequate cooling of the internal
parts of the power source.
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 - Sequence of operations (fig. 3.2.3).

The following sequence represents correct functioning of the machine. It may be used as a
guiding procedure for troubleshooting.
It must be carried out after each repair without any errors.
NOTE
q 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.
q System shut off and disconnected from the mains.

q Connect the gas supply to the fitting (H) on the rear panel.
q Connect the torch to the negative pole of the power source.
q With water-cooled torch, connect the cooling circuit hoses to the torch.
q With water-cooled torch, connect the cooling unit to the power source.
q Connect the cable of the positive pole of the power source to the workpiece.
q Connect the power source or cooling unit to the mains.
q Turn on the switch (E) (also power the cooling unit, if present).
System powered, fans running, pilot lamp (F) lit.
On the control panel, the Process, Mode and Program indicators are lit, per the
settings before the unit was last switched off.
For one second, display (Y) and (Z) indicate the control panel version installed
(ex.: Y = Art; Z = 218 or 220).
Subsequently, display (Y) indicates the current value programmed via the knob
(AC) and display (Z) the output voltage (0 V. in TIG, 57 V. in MMA).
Led (AO) lit. Led (AQ), lit in TIG, off in MMA.
Display (V) reads - - - in TIG or 0 - 99 in MMA.
Correct? NO (see 3.3.1-3.3.2-3.3.3).
YES
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q Press the button (A) several times; the Process selection is repeated in sequence.
q Press the button (B) several times; the Mode selection is repeated in sequence.
q Press the button (C) several times; the Program selection is repeated in sequence.
(Program cannot be selected in MMA).
q Simultaneously press the buttons (AH) and (AI) to enter the preset condition.
q Press the torch trigger several times to check, in sequence, the available preset parameters
(see Instruction Manual).
Display (Z) reads PrE, thus preset.
Each time the start button is pressed, the AG, AP, AH, AQ, AR, AI and AL Leds
light one after another.
Display (Y) reads - - -, or the value corresponding to the function indicated by
the leds AP, AQ and AR.
Display (V) indicates the value corresponding to the function indicated by each
of the Leds AG, AP, AH, AR, AI and AL.
Correct? NO (see 3.3.3).
YES
q Simultaneously press the buttons (AH) and (AI) to exit the preset condition.
3.2.1 - TIG-AC operation.

NOTE
The TIG-AC operating sequence is described below, because it involves all of the internal
power source units, including those for TIG-DC operation.
WARNINGS
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.
DO NOT TRY TO MEASURE THE OUTPUT VOLTAGE DURING THESE STEPS. THE
PRESENCE OF HIGH FREQUENCY MAY DAMAGE THE INSTRUMENT OR THE
POWER SOURCE ITSELF.
q Use the button (A) to select the TIG-AC Process, led (F) lit.
q Use the button (B) to select the TIG-CONTINUOUS Mode with HF, led (L) lit.
q Use the button (C) to select the 2-STAGE-TIG Program, led (Q) lit.
q Briefly press the torch start button.
The pregas phase begins, led (AG) lit, with gas flowing from the torch, for as long
as the button is held down.
Gas continues to flow from the torch for the duration of the post-gas pause time
set, led (AL) lit, even after the start button is released.
Correct? NO (see 3.3.4-3.3.5).
YES
q Press the start button and hold it down for approximately 10 seconds.
The pregas phase begins; the arc frequency is then generated to start the arc, as
well as the power source output voltage.
After approximately three seconds, the output voltage and arc frequency to start
the arc are no longer generated, and the post-gas phase begins (TIG operation
stops if there is no current at the power source output after start-up).
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Correct? NO (see 3.3.6-3.3.7-3.3.8).
YES
q Move the torch near the workpiece and press the torch trigger.
Begin welding. Turn the knob (AC) to obtain the current level suitable for the
type of welding to be done.
Display (Y) indicates the welding current, display (Z) the output voltage.
Correct? NO (see 3.3.11.).
YES
q Release the torch start button.
The arc shuts off immediately (if long ramp times are not set).
Gas continues to flow to protect the welding bath (post-gas).
Correct? NO (see 3.3.5.).
YES
3.2.2 - MMA-AC operation.

NOTE
The MMA-AC operating sequence is described below, because it involves all of the internal
power source units, including those for MMA-DC operation.
q Connect the electrode clamp to the positive pole of the power source.
q Connect the cable of the negative pole of the power source to the workpiece.
q Use the button (A) to select the MMA-AC Process, led (G) lit.
q Use the button (B) to select the ARC-FORCE Mode, led (I) lit.
q The Program cannot be selected in MMA mode.
Voltage begins to be generated at the power source output.
Display (Y) shows the programmed welding current, display (Z) the output open-
circuit voltage of the power source.
YES
q Use the knob (AC) to set the current based on the electrode you intend to use.
q Move the electrode clip near the workpiece.
Begin welding. Adjust the (AC) knob and the ARC-FORCE function if necessary
(see Instruction Manual) to maximize welding quality.
Display (Y) indicates the welding current, display (Z) the output voltage.
YES
REGULAR OPERATION.
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3.2.3 - Power source commands and signals.
0
I
D A B N C H G E N F
H P
mm
I Q
L R
M S
N T
O U
W V W1 AM AN Y

mm
D
AO
< 48V AC
E
Z
Art. 220
F
5 6
AQ
4 7
G 3 8
AD
2 9
A
A
1
A
10 AI
B Hz 4
5 6
7
5 6 1 1 5 6 5 6
4 7 3 8 4 7 4 7
C 3 8
2 2
2 9 3 8 3 8
3 3
2 9 1 10 2 9 2 9
4 4
X 1 10 5 5
A 1 10 1 10
AC Hz PULSE
AA AG AP AB AH AE AC AF AR AL
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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).
q 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).
3.3.1 - The power source does not start, control panel off.
MAINS SUITABILITY TEST.

q No voltage for mains protection.
NO Correct?
YES
Eliminate any short-circuits on the connections between power cable, switch (9)
and pre-charge board (42).
Make sure that the terminals U, V and W on the pre-charge board (42) are not
short-circuited.
Mains not suitable to power the power source (ex.: insufficient installed power).
MAINS CONNECTION TEST.

q Terminals U, V and W on pre-charge board (42) = 3 x 400 VAC, with switch (9) closed.
YES Correct?
NO
Check power cable and plug and replace if necessary.
Check switch (9), and replace if defective.
Check the mains voltage conditions.
Replace pre-charge board (42).
POWER SUPPLY TEST

q Flyback board (20), terminals TP2 (+) and TP1 (-) = 540 Vdc;
YES Correct?
NO
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Check wiring between TP1 and TP2 flyback board (20) with J1 igbt board (21).
Check the wiring between J2 and J3 igbt board (21) with J5 and J10 pre-charge
board (42).
Temporarily disconnect, with power source off, connector J1 on igbt board (21)
and check the resistance between terminals TP2 and TP1 on flyback board (20). If
short-circuited, replace flyback (20) and pre-charge (42) boards.
Temporarily disconnect, with power source off, terminals J2 and J3 on igbt board
(21), and check the resistance between terminals J2 and J3 on igbt board (21). If
short-circuited, replace igbt (21) and pre-charge (42) boards.
CONTROL BOARD (23) POWER SUPPLY TEST

q Control board (23), connector J14, terminals 1 (+) 2 (-) = 24 VDC; terminals 3 (+) - 4 (-) =
14 Vdc.
YES Correct?
NO
Check the wiring between J14 control board (23) and J2 flyback board (20).
Temporarily disconnect, with power source off, connector J14 on control board
(23) and check the resistance between terminals 1 - 2 of J14 on control board (23).
If short-circuited, replace control board (23).
Replace flyback board (20).
CONTROL PANEL POWER SUPPLY TEST

q Temporarily disconnect J3 from the satellite board (22).
q Control panel, connector J1, terminals 5 6 (gnd) = +5 Vdc.
YES Correct?
NO
Check the wiring between J3 micro board on control panel and J3 flyback board
(20).
Temporarily disconnect, with power source off, connector J3 on flyback board
(20) and check the resistance between terminals 1 - 2 of J3 on micro board of the
control panel. If short-circuited, replace micro board on control panel.
Replace control panel.
Replace control board (23).
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3.3.2 - Power source powered, control panel lit, fans (57) stopped.
CONTROL PANEL TEST.

q Control panel lit with correct indicators.
YES Correct?
NO
See par. 3.3.3.
FANS TEST.
q Pre-charge board (42), connectors J1 and J2, terminals 1 (-) 2 (+) = 24 Vdc.
NO Correct?
YES
Check the wiring between fans (57) and connectors J1 and J2 pre-charge board
(42).
Make sure that there are no mechanical impediments blocking the fans.
Replace the fans (57).
FANS CONTROL TEST.

q Control board (23), connector J16, terminals 1 2 = 24 Vdc.
NO Correct?
YES
Check the wiring between J16 control board (23) and J3 pre-charge board (42).
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3.3.3 - Power source powered, display and signals does not indicate the correct values.
ERROR CODE TEST.

q Upon start-up the display (Y) shows an error code, red led (AN) on control panel = lit.
NO Correct?
YES
See par. 3.4.
CONTROL PANEL RECOGNITION TEST.

q Upon start-up the display (Y) shows Art, displays (Z and V) are off.
NO Correct?
YES
Check the wiring between J3 satellite board (22) and J1 micro board on control
panel (RS485 serial communication).
Make sure the satellite board (22) is correctly mounted on the control board (23).
Replace micro board on control panel (defective or not programmed).
Replace control board (23), (defective or not programmed).
Replace satellite board (22).
CONNECTOR BOARD (32) POWER SUPPLY TEST.

q Connector board (32), connector J10, terminals 3 4 (gnd) = + 24 Vdc.
q Connector board (32), connector J3, terminals 1 8 (gnd) = + 24 Vdc; terminals 2 - 8 (gnd) =
+ 5 Vdc (with connector J3 free, no components connected to J3).
YES Correct?
NO
Check the wiring between J10 connector board (32) and J6 and J1 on flyback
board (20).
Make sure that the terminals 1 2 and 3 4 of J10 are not short-circuited. If
short-circuited, replace connector board (32).
DISPLAY (Y) TEST.

q Upon start-up, after the control panel recognition, display (Y) shows the programmed current
values: in TIG = 5 250; in MMA = 10 200, turning knob (AC) and torch potentiometer if
present.
YES Correct?
NO
Check the wiring between J5 board (32) and J2 control board (23).
Check for 0 - 5 Vdc between the terminals 10 (+) and 7 (-) of J3 connector board
(32), adjustable via the potentiometer on the torch. (5 Vdc without potentiometer
connected to J3). If missing, replace connector board (32).
Replace connector board (32).
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DISPLAYS (Z) AND (V) TEST.

q Upon start-up, after the control panel recognition, displays (Z and V) indicate: display (Z) =
0 V in TIG, 57 V. in MMA; display (V) = - - - in TIG, 0 - 99 in MMA.
YES Correct?
NO
Check the wiring between J5 connector board (32) and J2 control board (23).
Check the wiring between TP6 connector board (32) and output terminal (+) of
the power source, TP5 and between the shared point between choke (65) and HF
transformer (26), checking the integrity of the filter connected between TP6, TP5
and the power source frame.
Replace control board (23), (defective or not programmed).
INDICATOR LED TEST

q Upon start-up, after the control panel recognition, the indicator leds carry out all of the steps
described in the operating sequence (see par. 3.2).
YES Correct?
NO
Check the wiring between J3 satellite board (22) and J1 micro board on control
panel (RS485 serial communication).
Make sure the satellite board (22) is correctly mounted on the control board (23).
Regular operation of the control panel.
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3.3.4 - In TIG, the start button produces no effect (temperature check).
COOLING UNIT TEST (if present).

q Connector board (32), connector J3, terminals 8 - 4 = 20 Vdc, cooling unit working properly
or disconnected; (0 Vdc = cooling unit alarm).
YES Correct?
NO
See CONNECTOR BOARD (32) POWER SUPPLY TEST par. 3.3.3.
See cooling unit Service Manual.
POWER SOURCE TEMPERATURE TEST.

With power source off, remove satellite board (22) from the control board (23), and set up a
jumper on terminals 7 8 of J7 on control board (23). Remount satellite board (22) on the
control board (23) and power the power source.
Display (Y) indicates the temperature of the igbt board (21).
Display (Z) indicates the temperature of the igbt module (51) (ignore the comma).
q Control panel, led (AM) = off (temperature within limits).
q Displays (Y) and (Z) show real temperature values, and within the limits.
YES Correct?
NO
Check the wiring between J1 control board (23) and CT1 on igbt board (21).
Temporarily disconnect CTI from the igbt board (21). Display (Y) must read
144 (full scale value). If incorrect, replace control board (23).
Check the wiring between J1 igbt board (21) and J5 flyback board (20),
(temperature sensor power supply TH1 on igbt board (21)).
Replace igbt board (21).
Check the wiring between temperature sensor (48) and J5 driver board (46).
Check the wiring between J4 driver board (46) and J5 satellite board (22).
Temporarily disconnect J5 from the driver board (46). Display (Z) must read
144 (full scale value). If incorrect, replace control board (23) or satellite board
(22).
Check the presence of 5 Vdc on terminals 3 4 of connector J5, board (46). If
absent, make sure that sensor (48) is not short-circuited. Replace if necessary.
Replace temperature sensor (48).
With power source off, remove satellite board (22) from the control board (23), and remove
the jumper previously made, on terminals 7 8 of J7 on control board (23). Remount satellite
board (22) on the control board (23) and power the power source.
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START COMMAND TEST.

q Connector board (32), connector J3, terminals 9 1 = 0 Vdc (start) with torch button pressed
(20 Vdc with button released).
YES Correct?
NO
Check the wiring between connector J3 connector board (32) and torch button.
Check torch button. If defective, replace.
Check the wiring between connector J5 connector board (32) and J2 control board (23).
3.3.5 - In TIG, no gas flows from the torch.
SOLENOID VALVE (28) TEST.

q Solenoid valve terminals (28) = 24 Vdc with torch button pressed (the duration of the
solenoid valve opening depends on the pregas and post-gas parameters set).
NO Correct?
YES
Check the presence of gas at the gas supply fitting (H), and make sure that the
pressure and air flow, in the intake line, comply with the specifications of the TIG
SOUND AC/DC (see specifications in the Sales Catalogue).
Make sure there are no occlusions in the gas hoses of the power source.
Replace solenoid valve (28).
Check the wiring between connector J9 of connector board (32) and solenoid valve (28).
Check the solenoid valve terminals (28) = 56 ohm. If 0 ohm (short-circuit), replace solenoid
valve (28) and connector board (32). If > Mohm (winding broken), replace solenoid valve
(28).
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3.3.6 - In TIG, gas flows from the torch, the arc does not start, high frequency missing.
HF BOARD (25) POWER SUPPLY TEST.
WARNING
FOR THIS TEST SET THE TIG OPERATION WITHOUT HIGH FREQUENCY
(LED N ON CONTROL PANEL LIT FIG. 3.2.3).
q HF board (25), connector J5, terminals 1 - 4 (gnd) = fig. 5.2.1, (secondary circuit transformer
(64) voltage waveform, open circuit operation, with start button pressed.
YES Correct?
NO
Go to par. 3.3.7.
HF OSCILLATOR TEST.
q Reset TIG operation with high frequency (led L on control panel lit).
q HF board (25), SC1 discharger discharges at regular intervals, with start button pressed.
NO Correct?
YES
Make sure that there is no short-circuit between connectors J1 and J2 on HF board
(25) or in the wiring of the primary HF transformer circuit (26).
Check the connections of the secondary circuit HF transformer (26), choke (65)
output terminal - of the power source. If you find loose connections, tighten and
replace any damaged components.
Check the connections and integrity of the HF filter, made up of 3 capacitors
connected between the terminals TP5 and TP6 of connector board (32), and
between these and earth. If damaged, replace.
Check cable and torch electrode holder; replace if worn or damaged.
Make sure the torch fitting (Gifas) has no isolation leaks, thus is not crossed by
surface high voltage discharges. If necessary, replace with a new one.
Check the distance between the tips of the discharger SC1 (correct = 0.9 mm.).
Replace HF transformer (26).
Replace HF board (25).
HF BOARD (25) CONTROL POWER SUPPLY TEST.

q Flyback board (20), connector J1, terminals 1 2 (gnd) = + 24 Vdc, with connection made
between J3 HF board (25) and J7 flyback board (20).
YES Correct?
NO
Check the wiring between J3 HF board (25) and J7 flyback board (20).
With the power source off, temporarily disconnect the connector J7 on flyback
board (20) and check the resistance between terminals 1 - 2 of J3 on HF board
(25). If short-circuited, replace board HF (25) and flyback board (20).
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HF BOARD (25) COMMAND TEST.

q HF board (25), connector J4, terminals 1 2 = 13 Vdc, green led LED1 on HF board (25)
lit, with start button pressed.
YES Correct?
NO
Check the wiring between connector J4 of HF board (25) and J4 of satellite board
(22).
Make sure that terminals 1 - 2 of J4 on HF board (25) are not short-circuited. If
so, replace HF board (25).
Make sure satellite board (22) is correctly mounted on control board (23).
Make sure that the connection between J1 and J2 of HF board (25) and the primary HF
transformer circuit (26) is not broken.
Replace HF board (25).
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3.3.7 - In TIG, gas flows from the torch, the arc does not light, voltage is missing at the
transformer secondary circuit (64).
HF BOARD (25) POWER SUPPLY TEST.
WARNING
FOR THIS TEST SET THE TIG OPERATION WITHOUT HIGH FREQUENCY
(LED N ON CONTROL PANEL LIT FIG. 3.2.3).
q HF board (25), connector J5, terminals 1 - 4 (gnd) = fig. 5.2.1, (secondary circuit transformer
(64) voltage waveform, open circuit operation, with start button pressed.
NO Correct?
YES
Go to par. 3.3.6.
Check the wiring between J5 driver-igbt board and J5 control board (23).
IGBT BOARD (21) COMMAND TEST.

q Driver-igbt board, connector J5, terminals 1 2 (gnd), and terminals 3 - 4 (gnd) = fig. 5.2.2,
(PWM1 and PWM2 signal waveform for IGBT, open circuit operation with start button
pressed).
NO Correct?
YES
Make sure driver-igbt board is correctly mounted on the igbt board (21).
Make sure that the connection between the terminals TRA1 and TRA2 of board
(21) and the primary circuit of the transformer (64) is not broken.
Check the wiring between secondary circuit transformer (64), diode group (40)
and choke (65). If you find loose connections, tighten and replace any damaged
terminals or modules.
Replace driver-igbt board.
Replace the transformer (64).
Replace diode group (40).
Check the wiring between J5, HF board (25), AC1 terminal diode group (40) and choke (65)
transformer side (64).
TRANSFORMER (64) PRIMARY CIRCUIT CURRENT TEST.

q Control board (23), connector J11, terminals 1 - 2 = 0 ohm, (interlock, = igbt board
connected recognition signal).
q Control board (23), connector J11, terminals 3 - 4 = < 100 mVdc, (current signal to primary
circuit, with open-circuit power source).
YES Correct?
NO
Check the wiring between J11 control board (23) and J10 igbt board (21).
Check diode group (40). If short-circuited, replace.
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Replace the transformer (64).

CURRENT TRANSDUCER(66) POWER SUPPLY TEST.

q Transducer (66), terminals - and + = 13 Vdc.
YES Correct?
NO
Check the wiring between transducer (66) and connector J11 control board (23).
Make sure that the terminals - and + of the transducer are not short-circuited.
If necessary, replace the transducer (66) and the control board (23).
Replace the control board (23).
TRANSFORMER (64) SECONDARY CIRCUIT CURRENT TEST.

q Control board (23), connector J11, terminals 6 8 = < 1 Vdc, (current signal to secondary
circuit with open-circuit power source).
YES Correct?
NO
Check the wiring between transducer (66) and connector J11 control board (23).
Check the wiring between diode group (40), IGBT module (51), snubber board
(43), resistances (55) and (56), and AC-capacitors board (49).
Check the IGBT module (51). If short-circuited, replace.
Replace current transducer (66).
Replace driver-igbt board.
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3.3.8 - In open circuit operation, the output voltage is not regular.
WARNING
FOR THESE TESTS SET THE TIG OPERATION WITHOUT HIGH FREQUENCY (LED N
ON CONTROL PANEL LIT FIG. 3.2.3), OR DISCONNECT THE CONNECTOR J5 FROM
THE HF BOARD (25).
OPEN-CIRCUIT OUTPUT VOLTAGE TEST.

q Output terminal power source (-) and output terminal + power source (+) = voltages per
table:
Process Voltage Condition
TIG DC + 55 VDC Start button pressed
MMA-DC + 55 VDC Power source powered
TIG AC - 55 VDC Start button pressed
MMA-AC + 55 VDC Power source powered
NO Correct?
YES
Correct operation.
DIODE GROUP (40) OUTPUT VOLTAGE TEST.

q Output terminal power source (-) and C1 terminal igbt module (51) (+) = + 57 VDC.
q Output terminal power source (-) and E2 terminal igbt module (51) (+) = - 57 VDC.
(in TIG with start button pressed, in MMA with power source powered).
YES Correct?
NO
See par. 3.3.7 (no voltage at secondary circuit transformer (64).
Check the wiring between diode group (40) and igbt module (51), and
connections between central transformer socket (64), choke (65), HF transformer
(26) and output power source terminal. If you find loose connections, tighten
and replace any damaged terminals or modules.
DRIVER BOARD (46) POWER SUPPLY TEST.

q With the power source off, temporarily disconnect the connector J5 from the driver board
(46). Power the power source, driver board (46), connector J5, terminals 3 - 4 (gnd) = + 5
Vdc.
q Driver board (46), connector J3 terminal 4( - ) and connector J2, terminal 1 ( + ) = + 24 Vdc
with power source powered, in TIG AC.
YES Correct?
NO
Check the wiring between J2 driver board (46) and J4 flyback board (20).
With the power source off, temporarily disconnect the connector J4 on flyback
board (20) and check the resistance between terminals 5 - 6 of J2 on driver board
(46). If short-circuited, replace driver board (46).
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DRIVER BOARD (46) ENABLE TEST.

q Driver board (46), connector J4, terminals 1 2 = 4.5 Vdc, led 2 on board (46) lit
(in TIG-DC and MMA, with power source powered).
q Driver board (46), connector J4, terminals 3 4 = 4.5 Vdc, led 3 on board (46) lit
(in TIG-AC, with power source powered).
YES Correct?
NO
With the power source off, temporarily disconnect the connector J5 on satellite
board (22) and check the resistance between terminals 1 - 2 and 3 - 4 of J4 on
driver board (46). If short-circuited, replace board (46).
Replace driver board (46).
Check the wiring between igbt module (51), driver board (46).
Check the wiring between igbt module (51), output terminal + power source, diode group
(40), and between central transformer socket (64), choke (65), HF transformer (26) and output
terminal power source.
Check the integrity of the igbt module (51). Replace if defective.
Check the wiring and integrity of the snubber board (43) (especially diodes D1 and D2),
capacitors-AC board (49) and resistors (55) and (56). A fault could cause the new igbt module
(51) to break.
Replace igbt module (51).
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3.3.9 - In resistive load operation, the output voltage is not regular.
WARNINGS
THE HF BOARD (25).
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 Resistor Maximum output Power source Condition
resistive load current output voltage
TIG DC 0.08 ohm 250 Adc + 20 Vdc Start button pressed
MMA-DC 0.15 ohm 200 Adc + 30 Vdc Power source powered
TIG AC 0.08 ohm 250 Aac 20 Vac (fig.5.2.3) Start button pressed
MMA-AC 0.15 ohm 200 Aac 30 Vac (fig. 5.2.4) Power source powered
RESISTIVE LOAD OUTPUT VOLTAGE TEST.

q Turn knobs (X) all the way counter-clockwise (to minimum), knob (AA) to its central
position (ideal balance) and knob (AC) all the way clockwise (to maximum) (fig. 3.2.3.).
q Output terminal power source (gnd) and output terminal + power source (probe) = values
and waveforms as shown in the table.
NO Correct?
YES
Correct operation.
DIODE GROUP (40) OUTPUT VOLTAGE TEST.

q For this test, temporarily disconnect connector J3 on power supply board (24).
q Igbt module (51), terminals E2 (-) and C1 (+) = + 115 Vdc +/- 10%, loaded, in TIG with start
button pressed, in MMA with power source powered.
YES Correct?
NO
See par. 3.3.7 (no voltage at secondary circuit transformer (64)).
Check the wiring between diode group (40) and igbt module (51).
See DRIVER BOARD (46) POWER SUPPLY TEST, par.3.3.8.
DRIVER BOARD (46) ENABLE TEST.

q Driver board (46), led 2 = lit (in TIG-DC and in MMA-DC).
q Driver board (46), led 2 and led 3 = lit simultaneously (in TIG-AC and in MMA-AC).
Actually, the led 2 and 3 light alternately at a frequency of approximately 50 Hz.
YES Correct?
NO
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With the power source off, temporarily disconnect the connector J5 on satellite
board (22) and check the resistance between terminals 1 - 2 and 3 - 4 of J4 on
driver board (46). If short-circuited, replace board (46).
TRANSFORMER (64) SECONDARY CIRCUIT CURRENT TEST.

q Control board (23), connector J11, terminals 6 8 (gnd) = + 6 Vdc in TIG, + 5 Vdc in MMA,
both with knob (AC) at maximum.
YES Correct?
NO
See CURRENT TRANSDUCER (66) POWER SUPPLY TEST, par. 3.3.7.
Check the wiring between transducer (66) and connector J11, control board (23).
Check the wiring between central transformer socket (64), choke (65), HF
transformer (26) and output terminal power source.
Check the wiring between transducer (66), diode group (40), igbt module (51) and
output terminal + of the power source.
Check the integrity of the igbt module (51). If defective, replace and check the
wiring and integrity of snubber board (43) (especially diodes D1 and D2 on it),
capacitors-AC board (49) and resistors (55) and (56). A fault could cause the new
igbt module (51) to break.
Check the wiring between igbt module (51), driver board (46).
Replace current transducer (66).
Replace igbt module (51).
TRANSFORMER (64) PRIMARY CIRCUIT CURRENT TEST.

q Control board (23), connector J11, terminals 3 - 4 (gnd) = fig.5.2.5, current waveform to
primary circuit transformer (64), loaded power source (for ex.: resistors), in TIG DC, with
knob (AC) at maximum (in MMA similar waveform, with slightly different frequency and
amplitude values).
YES Correct?
NO
Check the wiring between J11 control board (23) and J10 igbt board (21).
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3.3.10 - TIG-DC, arc unstable, welding irregular.
NOTE
In TIG-DC the welding quality may not be acceptable due to current instability. In this case we
recommend switching to MMA-DC operation, and performing welding tests.
MMA-DC WELDING QUALITY TEST.

q Power source in MMA-DC, welding tests = good welding quality.
YES Correct?
NO
Perform the open circuit operation test (par. 3.3.8) and operation on resistive
load (par. 3.3.9).
Check the condition of the torch and electrode. If necessary, sharpen the tip of the electrode.
Check the presence and continuity of the gas flow (solenoid valve vibration) at the torch
output (see par. 3.3.5).
3.3.11 - TIG-AC, arc unstable, welding irregular.
WARNINGS
THE HF BOARD (25).
POWER SUPPLY BOARD (24) OUTPUT VOLTAGE TEST.

q Power supply board (24), connector J4, terminals 4 (probe) and 1 (gnd) = fig.5.2.6, power
supply board (24) output voltage waveform, power source loaded (for ex.: resistors) with
knobs (X) at minimum, (AA) central, (AC) at maximum, fig. 3.2.3.
NO Correct?
YES
Check the wiring and integrity of snubber board (43) (especially D1 and D2),
capacitors-AC board (49) and resistors(55) and (56).
Check the efficiency of the balance adjustment, checking the effects of cleaning
and penetration on the weld, attainable by turning the knob (AA) (fig. 3.2.3). If
no effects are noticeable, check the efficiency of the potentiometer (AA), or
replace the control panel.
Check the condition of the torch and electrode. If necessary, sharpen the tip of the
electrode.
Check for the presence of gas in output from the torch (see par. 3.3.5).
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POWER SUPPLY BOARD (24) POWER TEST.

q Power supply board (24), connectors J1 (+), J2 (-) = 540 Vdc, with power source powered.
YES Correct?
NO
Check the wiring between J1 and J2 power supply board (24) and pre-charge
board (42).
POWER SUPPLY BOARD (24) ENABLE TEST.

q Power supply board (24), led 1 = lit, with power source in TIG-AC.
YES Correct?
NO
Check the wiring between J3 power supply board (24) and J2 driver board (46),
and between J1 driver board (46) and terminals 5 6 of J16 control board (23).
With the power source off, temporarily disconnect the connector J2 on driver
board (46) and check the resistance between terminals 1 - 2 of J3 on power supply
board (24). If short-circuited, replace power supply board (24).
Check the fuse F1 on power supply board (24). If broken, replace and check the efficiency of
the pre-charge board (42).
Replace power supply board (24).
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3.4 - Error codes.
3.4.1 - 001 - Hardware lockup.

3.4.2 - 002 - Hardware lockup.
Power source lockup due to software error. Replace control board (23).
3.4.3 - 020 - No interlock signal.

Power source blocked due to missing interlock signal, caused by connector J11 control board
(23) or J10 igbt board (21) disconnected (the same connectors as the current feedback signal at
the primary circuit of the transformer (64).
See : TRANSFORMER (64) PRIMARY CIRCUIT CURRENT TEST, par. 3.3.7.
3.4.4 - 025 - Malfunction on the EPLD bus in the control board (23).
This code calls up various problems that may occur in controlling the igbt inverter (21). These
are generally those defects that cause excessive current at the primary circuit of the transformer
(64), due for example to a short-circuit at the output of the igbt board (21) or in the diode group
(40).
For an analysis of the problem, see open circuit operation par. 3.3.8 and operation on
resistive load par. 3.3.9.
In case of Error 25 in MMA mode, the Process selection may be blocked in MMA. To
exit this situation, you must shut off the power source, press the Process button (A) (fig. 3.2.3),
restart the power source while holding down the button (A), and release the button as soon as the
process selection switches to TIG.
3.4.5 - 030 -Incorrect setting of the minimum current threshold on the control board (23).
CONTROL BOARD (23) MINIMUM CURRENT THRESHOLD SETTING.
q Control board (23), terminal 8 (-) of connector J11 and test-point TS50 (+) = + 360 mVdc,
with power source powered.
YES Correct?
NO
Adjust trimmer TR1 on control board (23) to have 360 mVdc +/- 10 mV.
Correct operation.
3.4.6 - 048 - Power source stop caused by a brief power outage of the control board (23)
(transitory blackout).
CONTROL BOARD (23) POWER SUPPLY TEST.
q Control board (23), connector J14, terminals 1 (+) 2 (-) = 24 Vdc; terminals 3 (+) - 4 (-) =
14 Vdc.
YES Correct?
NO
Check the wiring between J14 control board (23) and J2 flyback board (20).
Temporarily disconnect, with power source off, connector J14 on control board
(23) and check the resistance between terminals 1 - 2 of J14 on control board (23).
If short-circuited, replace control board (23).
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Make sure that the connectors J2 are intact and correctly inserted on flyback board (20) and
J14 on control board (23).
Check the conditions of the power source power supply mains (see par. 3.3.1).
3.4.7 - 052 - Start button pressed during start-up.

See : START COMMAND TEST par. 3.3.4.
3.4.8 - 053 - Start button pressed during reset from stop due to overtemperature.
The high temperature alarm stops the power source, and the led (AM) on control panel (fig.
3.2.3) lights, but it does not remain in memory. It is automatically reset when the temperature
falls within the allowed limits.
It may occur that the unit resets when the start command is present; therefore, to prevent the
power source from starting suddenly due to a random reset, this situation is detected and causes a
memory block in the power source, with Error 53 indicated.
To reset this situation, shut off the power source, remove the start command and restart the
power source. See par. 3.3.4.
3.4.9 - 054 - Power source output voltage greater than 48 Vac.

For safety reasons, the power source is blocked if the output voltage exceeds 48 Vac during
welding.
In AC open circuit operation, in both TIG and MMA, the power source has an output voltage
of approximately 57 Vdc.
Alternating voltage, as well as operation of the power supply board (24), depend on the
presence of current at the power source output; the hazardous AC voltage control at the power
source output is activated when welding current ceases, to make sure that any breakdown in the
control circuits continues generating alternating voltage with the power source in open-circuit.
This block is indicated when the code 054 appears on the display (Y) and the LED (AO) shuts
off (fig. 3.2.3) on control panel.
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4 - COMPONENTS LIST
4.1 - Power source art. 348 : see file ESP348.pdf enclosed at the end of the manual.
4.2 - Components table: see file ESP348.pdf enclosed at the end of the manual.
4.3 - Spare parts list.
Essential spare parts.
Ref. Code Description Qty.

20 5605803 flyback circuit 1
21 5605583 igbt group 1
22 5605806 satellite circuit 1
25 5602043 HF board 1
40 5605550 diode group 1
42 5605533 pre-charge group 1
Recommended spare parts.
Ref. Code Description Qty.

23 5605084 control circuit 1
32 5605808 connector circuit 1
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5 - ELECTRICAL DIAGRAMS
5.1 - Power source art. 348 : see file SCHE348.pdf enclosed at the end of the manual.
5.2 - Waveforms.
5.2.1 - Open-circuit transformer (64) secondary voltage (par. 3.3.6, 3.3.7).
5.2.2 - PWM1 and PWM2 signals for igbt board (21) (par. 3.3.7).
5.2.3 - Power source output voltage, in TIG-AC, with resistive load (par. 3.3.9).
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5.2.4 - Power source output voltage, in MMA-AC, with resistive load (par. 3.3.9).
5.2.5 - Transformer (64) primary circuit current, in TIG-DC, with resistive load (par.
3.3.9).
5.2.6 - AC power supply board (24) output voltage (par. 3.3.11).
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5.3 - Pre-charge board (42) code 5.600.758/B.
5.3.1 - Topographical drawing.
5.3.2 - Connector table.

Connector Terminals Function
J1 - 24 Vdc output for fan (57).
J2 - 24 Vdc output for fan (57).
J3 12 fan command input.
J3 34 pre-charge relay command input.
J4 J6 - phase V, 400 Vac mains power supply input.
J7 J8 - phase U, 400 Vac mains power supply input.
J9 J11 - phase W, 400 Vac mains power supply input.
J5 J12 - output + 500 Vdc flyback and inverter power supply
J10 J13 - output 0 Vdc flyback and inverter power supply.
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5.4 - Flyback board (20) code 5.600.756/B.

TP1 input 0 Vdc flyback power supply.
TP2 input + 500 Vdc flyback power supply.
J1 12 24 Vdc output.
J3 12 24 Vac output.
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5.5 - Control board (23) code 5.600.771/F.

Conn. Terminals Function
J1 12 igbt inverter temperature input.
J2 1 signal input short at output.
J2 24 isolated power supply for I2CBus.
J2 3 I2CBus SDA communication signal.
J2 5 I2CBus SCL communication signal.
J3 - board programming (microprocessor).
J4 14 RS232 power supply.
J4 2 RS232 Rx signal.
J4 3 RS232 Tx signal.
J5 12 PWM1 output.
J5 34 PWM2 output.
J6 - board pre-selection.
J7 7 - 8- board pre-selection, (jumper for power source temperature diagnostics).
J8 - board pre-selection.
J9 - board programming (EPLD).
J10 - NU
J11 12 interlock signal input.
J11 34 primary circuit current feedback input.
J11 6 secondary circuit current feedback input.
J11 7 NU
J11 58 current transducer power supply output (66).
J12 - I/O bus with satellite board (22).
J13 1 power supply output + 14 Vdc for HF command, on satellite (22).
J13 2 power supply output + 5 Vdc for HF command, on satellite (22).
J13 4 power supply output 0 Vdc for HF command, on satellite (22).
J13 3 HF command output, on satellite (22).
J14 12 24 Vdc power supply input.
J15 - NU
J16 12 fan command output.
J16 34 pre-charge relay command output.
J16 56 enable power supply board.
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5.6 - Satellite board (22) code 5.600.766/D.
Conn. Terminals Function.

J1 2 RS232 Rx signal.
J1 3 RS232 Tx signal.
J2 - NU
J3 1-2-3-4 RS485 signals for control panel.
J4 12 HF command output.
J5 12 gate command output for igbt1 (51).
J5 34 gate command output for igbt2 (51).
J5 9 10 module (51) temperature input.
J6 - I/O bus with control board.
J7 1 power supply input + 14 Vdc for HF.
J7 2 power supply input + 5 Vdc for HF.
J7 4 power supply input 0 Vdc for HF.
J7 3 HF command input.
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5.7 - Igbt driver board code 5.602.040.

J1 12 command output for igbt1 gate.
J5 12 PWM1 input.
J5 34 PWM2 input.
5.8 - Igbt capacitors board code 5.602.037.

FIS1 FIS4 positive capacitor terminals fastening.
FIS2 FIS3 negative capacitor terminals fastening.
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5.9 - Igbt board (21) code 5.602.069.

J1 14 500 Vdc flyback power supply output.
J2 - + 500 Vdc inverter power supply input.
J3 - 0 Vdc inverter power supply input.
J4 12 command input for gate igbt1.
J8 NU.
J9 12 24 Vac temperature sensor power supply input.
J10 12 interlock jumper on igbt board.
J10 34 primary circuit current feedback output.
CT1 12 igbt inverter temperature signal output.
FIS1 FIS4 positive capacitor terminals fastening.
FIS2 FIS3 negative capacitor terminals fastening.
TRA1 TRA2 Vac output for power transformer (64).
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5.10 - HF board (25) code 5.602.043.

J1 J2 - output for HF transformer (26).
J3 12 24 Vac power supply input for HF board (25) control.
J4 12 HF command input.
J5 12 Vac power supply input for HF board (25) power.
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5.11 - Driver board (46) code 5.600.825.

J1 12 power supply board (24) enable input.
J2 12 AC capacitors (49) voltage feedback output.
J2 56 24 Vac power supply input
J2 78 power supply board (24) enable output.
J3 1 input + Vdc voltage feedback from AC capacitors (49).
J3 4 input Vdc voltage feedback from AC capacitors (49).
J4 12 gate command input for igbt1 (51).
J4 34 gate command input for igbt2 (51).
J4 9 10 temperature signal output of the igbt module (51).
J5 1 temperature signal input from sensor (48).
J5 34 5 Vdc power supply output for temperature sensor (48).
G1 E1 gate command output for igbt1 on module (51).
G2 E2 gate command output for igbt2 on module (51).
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5.12 - Power supply board (24) code 5.602.002.
5.12.2 - Connectors and fuses table.

J1 - + 500 Vdc power supply board (24) power supply input.
J2 - 0 Vdc power supply board (24) power supply input.
J3 12 power supply board (24) enable input.
J3 56 voltage feedback input of the AC capacitors (49).
J4 1 0 Vdc AC capacitors (49) pre-charge output.
J4 4 + Vdc AC capacitors (49) pre-charge output.
Fuse Value Function

F1 1.6 A power supply 0 Vdc power supply board (24).
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CEBORA S.p.A. 43
5.13 - Connector board (32) code 5.602.015/C.

J1 - connection with J6.
J3 1 start input from torch button.
J3 2 power supply output + for current potentiometer.
J3 3 input 1 input.
J3 4 enable input from cooling unit.
J3 6 out 1 output (in TIG : arc lit signal = 0 Vdc; arc off = 5Vdc).
J3 7 power supply output for current potentiometer.
J3 8 shared output for input 1 and out 1 signals.
J3 9 start input from torch button.
J3 10 central input from current potentiometer.
J5 1 short at output output signal.
J5 24 isolated power supply output for I2CBus.
J5 3 I2CBus SDA communication signal.
J5 5 I2CBus SCL communication signal.
J9 A-B solenoid valve (28) output.
J10 12 24 Vac power supply input
TP6 input + output voltage.
TP5 input output voltage.
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CEBORA S.p.A.

TIG SOUND 2540/T AC/DC

1.2 - General service policy.

1.3 - Safety information.

1.4 - Electromagnetic compatibility.

2.2 - Technical specifications.

2.3 - Description of power source art. 348.

The following signals are available to the power source connector:

ANY INTERNAL INSPECTIONS OR REPAIRS MUST BE CARRIED OUT BY QUALIFIED

BEFORE BEGINNING MAINTENANCE OPERATIONS, UNPLUG THE MACHINE FROM

3.1 - Periodic inspection, cleaning.

3.2 - Sequence of operations (fig. 3.2.3).

q System shut off and disconnected from the mains.

Correct? NO (see 3.3.1-3.3.2-3.3.3).

Correct? NO (see 3.3.3).

3.2.1 - TIG-AC operation.

Correct? NO (see 3.3.4-3.3.5).

Correct? NO (see 3.3.6-3.3.7-3.3.8).

Correct? NO (see 3.3.11.).

Correct? NO (see 3.3.5.).

3.2.2 - MMA-AC operation.

Correct? NO (see 3.3.8).

Correct? NO (see 3.3.9).

3.2.3 - Power source commands and signals.

ANY INTERNAL INSPECTIONS OR REPAIRS MUST BE CARRIED OUT BY QUALIFIED

BEFORE REMOVING THE PROTECTIVE GUARDS AND ACCESSING INTERNAL

MAINS SUITABILITY TEST.

MAINS CONNECTION TEST.

POWER SUPPLY TEST

CONTROL BOARD (23) POWER SUPPLY TEST

CONTROL PANEL POWER SUPPLY TEST

CONTROL PANEL TEST.

FANS CONTROL TEST.

ERROR CODE TEST.

CONTROL PANEL RECOGNITION TEST.

CONNECTOR BOARD (32) POWER SUPPLY TEST.

DISPLAY (Y) TEST.

Replace control board (23).

DISPLAYS (Z) AND (V) TEST.

INDICATOR LED TEST

3.3.4 - In TIG, the start button produces no effect (temperature check).

COOLING UNIT TEST (if present).

POWER SOURCE TEMPERATURE TEST.

START COMMAND TEST.

3.3.5 - In TIG, no gas flows from the torch.

SOLENOID VALVE (28) TEST.

HF BOARD (25) POWER SUPPLY TEST.

HF BOARD (25) CONTROL POWER SUPPLY TEST.

HF BOARD (25) COMMAND TEST.

HF BOARD (25) POWER SUPPLY TEST.

IGBT BOARD (21) COMMAND TEST.

TRANSFORMER (64) PRIMARY CIRCUIT CURRENT TEST.

Replace the transformer (64).

CURRENT TRANSDUCER(66) POWER SUPPLY TEST.

TRANSFORMER (64) SECONDARY CIRCUIT CURRENT TEST.

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

OPEN-CIRCUIT OUTPUT VOLTAGE TEST.

DIODE GROUP (40) OUTPUT VOLTAGE TEST.

DRIVER BOARD (46) POWER SUPPLY TEST.

DRIVER BOARD (46) ENABLE TEST.

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

RESISTIVE LOAD OUTPUT VOLTAGE TEST.

DIODE GROUP (40) OUTPUT VOLTAGE TEST.