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CEBORA S.p.A.

1





SOUND MIG 5040/T Pulse




POWER SOURCE +
COOLING UNIT +
WIRE FEEDER
art. 288




SERVICE MANUAL



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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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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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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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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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(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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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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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 J 3 on connector board (225) and
J 7 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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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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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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3.3 - Control panel commands and signals.




3.302.122.A 14/04/04
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).

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CEBORA S.p.A. 17
POWER SUPPLY TEST.
Correct?
Flyback board (287), connector J 5, terminals 1 (+) and 4 (-) =+540 Vdc.

YES

NO
Check the wiring between J 5 flyback board (287) and J 1 pre-charge board (303).
After waiting for the DC-capacitors (302) to completely discharge,
temporarily disconnect connector J 5 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 J 5, terminals 3 (+) and 4 (-) =+18 Vdc.

YES

NO
Check the wiring between J 5 flyback board (287) and J 1 pre-charge board (303).
After waiting for the DC-capacitors (302) to completely discharge,
temporarily disconnect connector J 5 on flyback board (287) and check the
resistance between terminals 3 (+) and 4 (-) of J 5 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 J 18, terminals 1 (+) - 6 (-) =+55 Vdc.

YES

NO
Check the wiring between J 18 motor control board (232), connector (206) on wire
feeder, connector (256) on power source and J 3 flyback board (287).
With the power source off, temporarily disconnect the connector J 18 on motor
control board (232) and check the resistance between terminals 1 - 6 of J 18 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 J 6, J 10 and J 1
on flyback board (287) and make sure that on J 18, 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 J 18 (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 J 1, terminals 1 (+) 2 (-) =+8 Vdc.

YES

NO
Check the wiring between J 1 control panel (220) and J 12 motor control board
(232).
With the power source off, temporarily disconnect connector J 1 on control panel
(220) and check the resistance between terminals 1 and 2 of J 1 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 J 15 on motor control
board (232), and make sure the voltage on terminals 1 (+) 2 (-) of J 1 on control
panel (220) =+8 Vdc. If correct, check the wiring between J 1 connector board
(225) and J 15 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 J 2 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 J 3 on connector board (225) to
cause continuous operation of the fan (268).
Correct?
Control board (290), connector J 13, terminals 5 (+) 4 (-) =+24 Vdc.

NO

YES
Check the wiring between fan (268) and connector J 13 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 J 5, terminals 2 (+) 1 (-) =+8 Vdc.
Control board (290), connector J 5, terminals 4 (+) 3 (-) =+15 Vdc.
Control board (290), connector J 14, terminals 8 (+) 5 (-) =+5 Vdc.
Correct?
Control board (290), connector J 14, terminals 1 (+) 5 (-) =-15 Vdc.

YES

NO
Check the wiring between J 5 control board (290), and J 10 flyback board (287).
With the power source off, temporarily disconnect connector J 5 on control board
(290) and check the resistance between terminals 2 and 1 and between terminals 4
and 3 of J 5 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 J 5 control panel (220) and J 3 motor control board
(232), between J 11 motor control board (232), connector (206) of the wire feeder,
connector (256) on the power source and J 4 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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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 J 5, terminals 14 (+) and 15 (-) =+12 Vdc.
Correct?
Connector board (225), connector J 5, terminals 11 (+) and 15 (-) = +5 Vdc, with no
accessories connected to the connector (BB).

YES

NO
Check the wiring between J 1 connector board (225) and J 15 motor control board
(232).
With the power source off, temporarily disconnect connector J 1 on connector
board (225) and check the resistance between terminals 1 and 2 of J 1 on connector
board (225). Correct value =junction of one diode in one direction, >Mohm with
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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 J 4-1 (-) and J 4-2 (+) =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 J 4 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 J 5
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 J 7), 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 J 7 motor control board (232) and connector J 3 connector
board (225).
With power source off, temporarily disconnect the flat cable from connector J 7 on motor
control board (232), and check the resistance between terminals 8 and 10 of J 7 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 J 3 on connector board (225) and
J 7 on motor control board (232).
The start command of the torch (central adapter (BA)), present on J 4 of connector board
(225), is parallel connected to the start command on terminals 1 and 9 of J 5, 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 J 5 (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 J 5 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 J 13 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 J 20, 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 J 20, 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 J 20 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 J 20 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 J 20 of motor
control board (232).

WIRE FEEDER MOTOR ENCODER TEST.
Correct?
Motor control board (232), connector J 19, 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 J 19 motor control board (232) and the
encoder on the wire feeder motor (212).
Make sure that on J 19 of motor control board (232), terminals 1 (+) and 4 (-),
voltage =+5 Vdc. If incorrect, with power source off, disconnect the connector
J 19 from the motor control board, and check the resistance between the terminals
1 and 4 of the patch connector disconnected from J 19. 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 J 19 from the motor control board
(232), and check the resistance between the terminals 2 and 4 of the patch
connector disconnected from J 19. 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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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 J 16 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).
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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 J 14, terminals 6 (+) - 5 (-) =<0.1 Vdc, current at the primary
transformer circuit (319) with open-circuit power source.

YES

NO
Check the wiring between J 14 control board (290) and J 1 TA board (313).
Make sure that there are no short-circuits or isolation leaks towards earth in the
connections between the primary circuit of the transformer (319) and the
terminals 1 of the igbt modules (293).
With the power source off, temporarily disconnect J 1 from the TA board (313)
and check the resistance on terminals 1 and 2 of J 1 on TA board (313). Correct
value =10 ohm. If incorrect replace the TA board (313).
With power source off, temporarily disconnect J 14 from the control board (290)
and check the resistance on terminals 6 and 5 of J 14 on control board (290).
Correct value =8,5 ohm. If incorrect, replace control board (290).
Check the conditions of the transformer (319). If you notice burn signs or
deformities, replace the transformer (319).
Replace the control (290) and/or TA board (313).
Replace the transformer (319).

DRIVER BOARDS (292) COMMAND TEST.
With power source off, temporarily disconnect connectors J 7 and J 9 on control board (290).
Correct?
Power up the power source again, and check the following terminals on control board (290):
connector J 7, terminals 1 and 2 (gnd) =terminals 5 and 4 (gnd) =fig. 5.2.3,
connector J 9, terminals 1 and 2 (gnd) =terminals 5 and 4 (gnd) =fig. 5.2.3,
command signal for the driver boards (292), in MIG or TIG mode, with start button pressed:

NO

YES
Check the wiring between J 7 and J 9 control board (290) and driver boards (292).
With power source off, and connectors J 7 and J 9 disconnected from control board
(290), check the resistance on the following connectors of the driver boards (292):
L+(+) and L- (-) =approx. 400 ohm; L+(-) and L- (+) =approx. 455 ohm.
H+(+) and H- (-) =approx. 400 ohm; H+(-) and H- (+) =approx.455 ohm.
GH (+) and EH (-) =approx. 2200 ohm; GH (-) and EH (+) =approx. 1300 ohm.
GL (+) and EL (-) =approx. 2200 ohm; GL (-) and EL (+) =approx. 1300 ohm.
If incorrect, replace the driver board (292) and the igbt module (293) to which it is
connected.
(Due to the complexity of the circuit, some types of instruments may measure 455
ohm instead of 400 ohm, thus the measurement is independent of the polarity of
the instrument probes).
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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 J 14 control board (290).
With power source off, temporarily disconnect connector J 14 from the control
board (290) and check the resistance between terminals 4 and 1 of the patch
connector disconnected from J 14. Correct value =approximately 1500 ohm. If
incorrect, replace the current transducer (289).
With power source off, reconnect J 14 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 J 14 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 J 14, 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 J 20 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 J 20 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 J 2 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 J 2 of pre-charge board (303).
With power source off, temporarily disconnect connector J 2 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 J 15, on control board (290).
With power source off, temporarily disconnect connector J 15 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 J 15 of control board (290) (cooling unit connected signal).
With power source off, temporarily disconnect J 15 from control board (290), and
make sure that when the power source is turned back on, voltage on terminals 3
(+) and 4 (-) of J 15 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 J 1A and J 1B on cooling board (31).
Check fuse on cooling board (31). If tripped, replace and temporarily disconnect
the terminals J 1A and J 1B 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 J 1A and J 1B 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 impediments jamming the motor-driven pump (36).
Replace if necessary.
Replace motor-driven pump (36).

PRESSURE SWITCH (37) TEST.
Control board (290), connector J 15, terminals 5 (+) and 6 (-) =0 Vdc, with motor-driven
pump (36) running (pressure switch contact closed =suitable pressure); +24 Vdc, with power
source on and motor-driven pump (36) stopped (pressure switch contact open =pressure low).
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Correct?
YES

NO
Check the wiring between terminals 5 (+) and 6 (-) of J 15 control board (290)
with terminals TP4 (+) and TP3 (-) of cooling board (31), and between TP8 and
TP7 with pressure switch (37).
Check the integrity of pressure switch (37), replace if defective.
With power source off, temporarily disconnect J 15 from control board (290).
Power up the power source again and once again check the voltage on the
terminals 5 (+) and 6 (-) of J 15, control board (290) =+24 Vdc. If incorrect,
replace control board (290).
Check the continuity of the printed circuit tracks on the cooling board (31). TP7
must be connected to TP3; TP8 must be connected to TP4. If necessary, restore
the tracks or replace the cooling board (31).
Check rotation direction of the motor-driven pump (36).
Make sure that the lines of the cooling circuit are not clogged, especially in the
part where it is connected the pressure switch (37).
Replace pressure switch (37) and/or motor-driven pump (36).

FAN (33) TEST.
Correct?
Fan (33) terminals =230 Vac, with cooling unit enabled.

YES

NO
Check the wiring between the terminals of the fan (33) and terminals 1 and 2 of J 3
on cooling board (31).
Check the wiring between J 2 of cooling board (31) and transformer (32).
With power source off, temporarily disconnect terminals J 1A, J 1B, J 3-1 and J 3-2
on cooling board (31) and check the resistance between the terminals of J 2
(windings of the transformer (32)). Correct values =terminals 1 and 4 (400 Vac)
=approximately 160 ohm; terminals 3 and 4 (230 Vac) =approximately 100 ohm.
If incorrect, replace transformer (32).
Replace transformer (32) and/or cooling board (31).
Make sure that there are no mechanical impediments blocking the fan (33).
Replace fan (33).
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3.6 - Error codes and alarm signals.

3.6.1 - 1 - Internal RAM error.
3.6.2 - 2 - EEPROM error.
Block due to software error. Replace the control board (290).

3.6.3 - 5 - Communication error on the I2C-BUS.
Communication error between the microprocessor and the EEPROM memory, in saving the
control panel data, on the control board (290). Replace the control board (290).

3.6.4 - 6 - Communication error on CAN-BUS, detected by control board (290).
Communication error between control board (290) and motor control board (232), or between
control board (290) and control panel (220), detected by MASTER control, on control board
(290). Perform the usual tests in case of failure of the CAN-BUS COMMUNICATION TEST in
par. 3.5.3.

3.6.5 - 7 - Hardware error on the CAN-BUS communication line.
Fault (interruption, short-circuit, isolation leak towards earth, etc.) on the CAN-BUS
communication line, detected by MASTER control on control board (290).
Check the wiring between J 5 control panel (220) and J 3 motor control board (232), between
J 11 motor control board (232), connector (206) of the wire feeder, connector (256) on the power
source and J 4 control board (290).
Replace the control (290) and/or motor control (232) and/or control panel (220) boards.

3.6.6 - 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).
Communication errors on the CAN-BUS line detected by the PANEL control, on control
panel (220). Perform the usual tests in case of failure of the CAN-BUS COMMUNICATION
TEST in par. 3.5.3.

3.6.8 - 10 - Missing voltage and current at the power source output.
When the start command is activated, the circuits to detect the output voltage and output
current on the control board (290), detect voltage =0 and current =0. This situation is possible
only with the inverter broken (thus is does not generate the alternating voltage on the primary
circuit of the transformer (319)), or with one or both voltage and current detection lines
interrupted.
Perform the open circuit operation test in par. 3.5.8 and the operation on resistive load
test in par. 3.5.9.

3.6.9 - 11 - Overload at the power source output.
The control board (290) has detected a power overload at the power source output. This
situation may be due to a fault in the output voltage and current detection circuits on the power
source, thus the control receives incorrect values, and may order power delivery beyond the
maximum allowed.
Check the wiring between J 16 of control board (290) and output terminals (+) (BR) and (-)
(BO) of the power source (voltage feed-back line), and carry out the CURRENT
TRANSDUCER (289) POWER SUPPLY TEST and POWER SOURCE OUTPUT CURRENT
FEEDBACK SIGNAL TEST in par. 3.5.9 (current feedback line).
If the results of these tests are positive, replace control board (290).
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3.6.10 - 13 - Missing communication between control board (290) and pre-charge board
(303), upon power source start-up.
The pre-charge board (303) communicates with the control board (290) through an optically
isolated serial line, using a dedicated protocol. Via this line, the pre-charge board (303) (J 4)
informs the control board (290) (J 2) of the status of the mains voltage, the direct current on the
DC-capacitors (302), and the internal circuits of the pre-charge board (303). Based on these data,
the control board (290) either does or does not order the pre-charge relay closed, and based on
information regarding any alarms, orders the power source blocked and the type of error to be
displayed on the control panel.
Check the wiring between connectors J 4 on pre-charge board (303) and J 2 on control board
(290), and replace the two boards if necessary.

3.6.11 - 14 - Microprocessor supply voltage error on control board (290).
Perform the CONTROL BOARD (290) POWER SUPPLY TEST in par. 3.5.2, paying special
attention to the 8 Vdc and 5 Vdc voltages.

3.6.12 - 15 - Direct current voltage at pre-charge board output (303) below setting.
The direct current voltage at the output of the pre-charge board (303) is found to be below the
value calculated based on the values detected by each individual phase of the mains voltage. This
may be due to a possible distortion of the mains voltage (or of a single phase of the mains
voltage), or a fault in the pre-charge board (303), or of the built-in rectifier bridge.
Check the condition of the three phases of the mains voltage, and replace the pre-charge board
(303) if necessary.
If the alarm appears upon power source start-up, there may be a short-circuit, or strong
absorption, by the DC-capacitors (302) or igbt modules (293), thus we recommend carrying out
the POWER SUPPLY TEST in par. 3.5.1.

3.6.13 - 16 - Direct current voltage at pre-charge board output (303) below minimum
permitted value.
Alarm (similar to error 15) indicating that the direct current voltage on the DC-capacitors is
not sufficient to ensure proper operation of the inverter, and thus of the power source.
In addition to the tests indicated for error 15, carry out the INVERTER POWER SUPPLY
TEST in par. 3.5.9, or better yet, the operation on resistive load tests in par. 3.5.9.

3.6.14 - 17 - Direct current voltage incorrectly divided among the DC-capacitors (302).
3.6.15 - 18 - Direct current voltage incorrectly divided among the DC-capacitors (302).
The voltage on the capacitor connected to the negative pole is greater (alarm 17) or less
(alarm 18) than the voltage on the capacitor connected to the positive pole.
The imbalance may be due to the need for the DC-capacitors to regenerate, especially after
a lengthy down-time or with a new machine, or to an interruption in one of the discharge
resistors (296), or a fault in the pre-charge board (303).
With these alarms present, leave the power source powered for at least 1 hour, constantly
observing whether the voltage imbalance tends to diminish and split equally between the two
DC-capacitors (regeneration phenomenon), or tends to increase.
WARNING
Perform this test with the power source panels closed. If the imbalance is due to a
capacitor fault rather than the need for regeneration, the voltage imbalance tends to increase
rather than decrease, to the point where the DC-capacitors are likely to explode.
3.302.122.A 14/04/04
CEBORA S.p.A. 39

In a static situation, make sure that the wiring between pre-charge board (303) and DC-
capacitors (302) is not leaking isolation towards earth or other parts of the power source, and
replace the DC-capacitors (302) and/or resistors (296) and/or pre-charge board (303) if
necessary.

3.6.16 - 19 - Missing communication between control board (290) and pre-charge board
(303).
Situation similar to those described for error 13 (par. 3.6.10), with the difference that the
communication is interrupted while the power source is running.
Check the wiring between connectors J 4 on pre-charge board (303) and J 2 on control board
(290), and replace the two boards if necessary.

3.6.17 - 20 - Absence of interlock signal on TA board (313).
The interlock signal is provided by a jumper between terminals 3 and 4 of J 1 on TA board
(313), and is used to make sure that the TA board (313) is connected to the control board (290)
(current feedback signal line to the primary circuit of the transformer (319)).
Check the wiring between terminals 3 and 4 of J 1 on TA board (313) and terminals 8 and 7 of
J 14 on control board (290).
Make sure that there is a short-circuit between terminals 3 and 4 of J 1 on TA board (313).
With power source off, temporarily disconnect connector J 14 from control board (290).
Power up the power source again and check the supply voltage on J 14 of control board (290),
terminals 8 (+) and 7 (-) =+5 Vdc. If incorrect, replace control board (290).
Replace the control (290) and/or TA board (313).

3.6.18 - 25 - Error on the EPLD bus in the control board (290).
This code calls up various problems that may occur in controlling the igbt inverter (293).
Generally they are those defects that cause a high absorbed current in the primary circuit of the
transformer (319), due for example to a short-circuit in the windings of the transformer (319) or
in the diode group (272).
For an analysis of the problem, see open circuit operation par. 3.5.8 and operation on
resistive load par. 3.5.9.

3.6.19 - 30 - Incorrect setting of the minimum current threshold on control board (290).
MINIMUM CONTROL BOARD (290) CURRENT THRESHOLD SETTING.
Correct?
Control board (290), connector J 14, terminal 3 (+) and 5 (-) =+360 mVdc, +/- 10 mVdc with
power source powered but not delivering current.

YES

NO
With power source off, temporarily disconnect J 14 from control board (290) and
check the resistance on terminals 3 and 5 of J 14 on control board (290) =26.6
ohm. If incorrect, replace control board (290).
Adjust trimmer TR1 on control board (290) to have 360 mVdc +/- 10 mV.
Replace control board (290).
Regular operation.

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CEBORA S.p.A. 40

3.6.20 - 41 - Connector board (225) missing or disconnected.
CONNECTOR BOARD (225) CONNECTED TEST.
Correct?
Motor control board (232), terminals 1 (+) and 2 (-) of OP4 =approximately +1.2 Vdc, with
power source powered.

YES

NO
Check flat cable between J 3 connector board (225) and J 7 of motor control board
(232).
With power source off, temporarily disconnect J 7 from motor control board (232)
and check the resistance on terminals 4 and 6 of J 7 on motor control board (232).
Correct value =junction of two diodes in both directions measured. If incorrect,
replace the motor control board (232).
With the power source off, temporarily disconnect J 7 from the motor control
board (232) and power up the power source again. Make sure that on terminals 6
(+) and 4 (-) of the patch connector disconnected from J 7 of motor control board
(232) the voltage =approximately +12 Vdc. If incorrect replace the connector
board (225).
Replace motor control board (232).

3.6.21 - 42 - Error in the signal of the motor encoder (212).
The signal provided by the encoder built into the motor (212) is used as a speed feedback
signal to adjust the motor speed. Error 42 indicates that the signal provided by the encoder is
not suited to the reference signal generated by the motor control board (232), and thus the motor
speed (212) is out of control.
Perform the wire feeder motor operation test in par. 3.5.7.

3.6.22 - 43 - Communication error with connector board (225).
The communication error may be due to incorrect communication line supply voltages, or to
an actual failure to recognize the data exchanged between the boards.
In the latter instance, check flat cable between J 3 connector board (225) and J 7 of motor
control board (232), especially terminals 14 (RX signal) and 13 (TX signal), and proceed by trial
and error, replacing the connector board (225) and/or the motor control board (232).

SERIAL COMMUNICATION LINE POWER SUPPLY TEST.
Motor control board (232), terminals 6 (+) and 5 (-) of OP8 =approximately +5 Vdc, with
power source powered (power supply for TX signal).
Correct?
Motor control board (232), terminal 1 of OP7 (+) and terminal 5 (-) of OP8 =approximately
+12 Vdc, with power source powered, after start-up (power supply for RX signal).

YES

NO
With power source off, temporarily disconnect the flat cable from J 7 on motor
control board (232) and check the resistance on terminals 9 and 11 of J 7 on motor
control board (232). If a short-circuit is detected, replace the motor control (232)
and connector (225) boards.
3.302.122.A 14/04/04
CEBORA S.p.A. 41

With power source off, temporarily disconnect the flat cable from J 7 on motor
control board (232) and power up the power source again. Make sure that on
terminals 9 (+) and 11 (-) of the patch connector disconnected from J 7, the voltage
=approximately +5 Vdc, and on terminals 12 (+) and 11 (-) of the patch connector
disconnected from J 7, voltage =approximately +12 Vdc. If incorrect replace the
connector board (225).
Smooth serial line power supply.

3.6.23 - 44 - CAN-BUS communication error, detected by motor control board (232).
Communication error between control board (290) and motor control board (232), or between
motor control board (232) and control panel (220), detected by MOTOR check on motor control
board (232). Perform the usual tests in case of failure of the CAN-BUS COMMUNICATION
TEST in par. 3.5.3.

3.6.24 - 52 - trG on display (O). In MIG and TIG mode, start button pressed upon start-
up.
See START COMMAND TEST and START SIGNAL TEST, par. 3.5.4.

3.6.25 - 53 - trG on display (O). Start button pressed while resetting from stop due to
temperature outside limits.
The high temperature alarm stops the power source, lights the yellow led (G) and signals the
corresponding alarm to the overheated unit (see alarms 73 and 74) on the control panel. These
alarms are automatically reset when the temperature returns 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
power source block, with the message trG on display (O).
To restore proper operation, remove the start command, performing the START COMMAND
TEST and START SIGNAL TEST if necessary, par. 3.5.4.

3.6.26 - 56 - Short-circuit at the output lasts too long.
It is normal to detect short-circuits at the output during welding, as long as they do not last
beyond a given interval. Error 56 indicates that the short-circuit has exceeded this limit.
This situation may be caused by a short-circuit created between the contact tip and gas nozzle
on the MIG torch due to deposits of dirt or metal dust.
In MMA mode it may also derive from an interruption in the output voltage detection line.
In any case, in addition to cleaning the torch, check:
wiring between connector J 16 of control board (290) and output terminals (-) (BO) and output
(+) (BR);
power wiring between end terminals of the transformer (319), diode group (272), and output
terminal (+) (BR);
power wiring between central transformer socket (319), choke (310), and output terminal (-)
(BO) of the power source.
If you find defective connections, fix and replace any damaged components.
If necessary, perform the tests for open circuit operation, par. 3.5.8, and operation on
resistive load, par. 3.5.9.
Replace control board (290) and/or transformer (319).

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CEBORA S.p.A. 42

3.6.27 - 57 - Mot on display (O). Excessive wire feeder motor (212) current.
The motor control board (232) is equipped with a supply current limiting circuit for motor
(212), to protect any overload, and a circuit that detects when the limiter is continuously tripped,
indicating a permanent overload.
This overload is primarily due to mechanical causes, such as dirt in the gears of the
gearmotor, friction from a lack of lubrication, impediments in feeding the wire coil, bottlenecks
in the torch sheath along the torch cable, etc.
Therefore, clean the wire feed unit and check whether the problem continues to occur if
operating without the wire feeder. If so, you may hypothesize that the motor winding or
mechanical reducer built into the motor have deteriorated, and thus replace the motor (212).
If necessary, perform the wire feeder motor operation tests in par. 3.5.7.

3.6.28 - 61 - Voltage of input phase L1 below minimum permitted.
3.6.29 - 62 - Voltage of input phase L1 above maximum permitted.
3.6.30 - 63 - Voltage of input phase L2 below minimum permitted.
3.6.31 - 64 - Voltage of input phase L2 above maximum permitted.
3.6.32 - 65 - Voltage of input phase L3 below minimum permitted.
3.6.33 - 66 - Voltage of input phase L3 above maximum permitted.
The pre-charge board (303) checks for the presence and proper value of the three power
supply phases of the mains voltage, determining when these values fall outside the allowed
limits.
Perform the MAINS CONNECTION TEST in par. 3.5.1, and replace the pre-charge board
(303) if necessary.

3.6.34 - 73 - Led (G) on. High diode group (272) temperature.
3.6.35 - 74 - Led (G) on. High igbt group (293) temperature.
With these alarms we recommend that you not shut off the power source, to keep the fan
running and thus cool the unit more rapidly. Normal operation is restored automatically as soon
as the temperature returns within the allowed limits.
Make sure that the fan (268) is working properly (see par. 3.5.2).
Check for proper air flow and make sure there is no dust or obstacles to cooling in the
aeration tunnel.
Make sure that the operating conditions meet the specification values, especially observe the
duty cycle.
Check the wiring between J 1 control board (290), and thermostat (275) on the diode group
(272).
Make sure that the thermostat (275) mounted on the diode group (272) is properly mounted
and in good working order; its contact must be closed at ambient temperature.
Make sure that the thermostat board (307) is properly mounted on the igbt group (293); the
temperature signal transmitted to the control board (290) is PWM type, with duty cycle
proportionate to the temperature, and thus difficult to check. If necessary replace the
thermostat board (307).
Check the wiring between J 3 control board (290), and thermostat board (307) on igbt group
(293).
Make sure that on J 3 of control board (290), terminals 3 (+) and 4 (-), voltage =+5 Vdc. If
incorrect, with power source off, temporarily disconnect J 3 on control board (290) and check
the resistance between terminals 3 and 4 of the patch connector disconnected from J 3. Correct
value =junction of one diode in one direction and >Mohm with the probes reversed. If
incorrect replace the thermostat board (307), and check the voltage on terminals 3 and 4 of J 3
again without the thermostat board connection. If incorrect, also replace control board (290).
3.302.122.A 14/04/04
CEBORA S.p.A. 43
Replace control board (290).

3.6.36 - 75 - H2O on display (O). Low pressure in the cooling circuit.
The pressure switch (37) measures the coolant pressure in the cooling circuit. For an analysis
of the corresponding circuit, see PRESSURE SWITCH TEST (37), par. 3.5.15.

3.6.37 - 76 - H2O on display (O). Cooling unit not connected.
The cooling unit connected signal is provided by a jumper between terminals 3 and 4 of the
patch connector on J 15 of control board (290). For an analysis of the circuit, see COOLING
UNIT ENABLE TEST, par. 3.5.15.

3.6.38 - 80 - OPn on display (O). Wire feed unit guard open.
This alarm indicates that the safety cover of the wire feed unit is open.
Check the wiring between J 1 motor control board (232), and switch (211) on the guard of the
wire feed unit.
Check the voltage on J 1 of motor control board (232), terminals 1 (+) and 2 (-) =0 Vdc,
correct condition =cover closed; +15 Vdc =alarm =cover open. If incorrect, replace switch
(211) or motor control board (232).
Make sure that the switch (211) and the unit cover are properly mounted. If incorrectly
positioned, correct; replace if defective.
Replace motor control board (232).

3.6.39 - 99 - OFF on display (O). Incorrect mains voltage (machine shutdown).
This signal normally appears whenever the power source is shut off.
When mains voltage is missing, for example after opening the switch (254), all control
circuits remain powered for a few seconds due to the effects of the DC-capacitor (302)
discharge. The pre-charge board (303) detects the missing mains voltage, notifies the control
board (290) (signal on J 1 1-2), which orders the power source to stop, and notifies the control
panel (220) via CAN-BUS to signal OFF on display (O).
Carry out the MAINS CONNECTION TEST and POWER SUPPLY TEST, in par 3.5.1, and
replace the pre-charge board (303) if necessary.
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CEBORA S.p.A. 44

4 - COMPONENTS LIST

4.1 - Power source art. 288 : see file ESP288.pdf enclosed at the end of the manual.

4.2 - Table of components: see file ESP288.pdf enclosed at the end of the manual.

4.3 - List of spare parts.

Essential spare parts.

Ref. Code Description Qty.
33 3165092 fan 1
36 3165090 electric pump 1
212 3165089 gearmotor 1
213 5710061 wire guide group 1
232 5605131 motor control circuit 1
268 3165091 fan 1
287 5602097 flyback board 1
288 5602100 filter board 1
290 5605094 control circuit 1

Recommended spare parts.

Ref. Code Description Qty.
29 3065287 radiator 1
37 5710190 pressure switch 1
204 3060278 coil support 1
227 3160193 solenoid valve 1
274 5710072 diode kit +insulation 1
305 5710073 pre-charge kit 1
319 5610009 power transformer 1
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CEBORA S.p.A. 45

5 - ELECTRICAL DIAGRAMS

5.1 - Power source art. 288 : see file SCHE288.pdf enclosed at the end of the manual.

5.2 - Waveforms.

5.2.1 - Speed feedback signal from the wire feeder motor encoder (212)(par. 3.5.7).
(in MIG wire test mode, thus with button (AR) pressed, fixed speed).


5.2.2 - Open-circuit voltage on the transformer (319) secondary circuit (par. 3.5.8).


5.2.3 - Command signal for driver boards (292) (par. 3.5.8).
3.302.122.A 14/04/04
CEBORA S.p.A. 46


5.2.4 - Output current feedback signal on resistive load (par. 3.5.9).


5.2.5 - Wire feeder motor (212) voltage during correct braking (par. 3.5.13).


5.2.6 - Wire feeder motor (212) voltage during incorrect braking (par. 3.5.13).
3.302.122.A 14/04/04
CEBORA S.p.A. 47

5.3 - Filter board (288) code 5.602.100/B.

5.3.1 - Topographical drawing.




5.3.2 - Connector table.

Connector Terminals Function
- AC_IN_1 phase 1 mains input.
- AC_IN_2 phase 2 mains input.
- AC_IN_3 phase 3 mains input.
- AC_OUT_1 phase 1 mains output.
- AC_OUT_2 phase 2 mains output.
- AC_OUT_3 phase 3 mains output.
J 1 - earth connection.
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CEBORA S.p.A. 48

5.4 - Pre-charge board (303) code 5.602.099/A.

5.4.1 - Topographical drawing.



5.4.2 - Connector table.

Connector Terminals Function
- L1-L2-L3 three-phase mains input.
- VC/1 DC-capacitors midpoint.
- Vdc+1 +540 Vdc power output.
- Vdc+2 +540 Vdc power output.
- Vdc-1 0 Vdc power output.
- Vdc-2 0 Vdc power output.
J 1 1(+) - 4(-) +540 Vdc output for flyback board (303) power supply.
J 1 3 flyback board (303) control power supply output.
J 2 A - B 400 Vac output for cooling unit.
J 3 1(+) - 2(-) +25 Vdc input for pre-charge relay power supply.
J 3 3 - 4 pre-charge board (303) control power supply input.
J 4 1 NU.
J 4 2 enable pre-charge signal input.
J 4 4 GND
J 4 5 NU.
J 4 6 mains voltage error output signal.
J 5 - NU.
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CEBORA S.p.A. 49

5.5 - Flyback board (287) code 5.602.097/D.

5.5.1 - Topographical drawing.



5.5.2 - Connector table.

Connector Terminals Function
J 1 1(+) - 2(-) +25 Vdc output for pre-charge relay power supply.
J 1 3 - 4 pre-charge board (303) control power supply output.
J 3 1-2(+) - 4-5(-) +55 Vdc output for motor control board (232) power supply.
J 3 3 NU.
J 4 - NU.
J 5 1(+) - 4(-) +540 Vdc input for flyback board (303) power supply.
J 5 3 flyback board (303) control power supply input.
J 6 1(+) - 2(-) +25 Vdc output for cooling unit interface circuits power supply.
J 8 - NU.
J 9 - NU.
J 10 2(+) - 1(-) +8 Vdc output to control board (290) power supply.
J 10 4(+) - 3(-) +15 Vdc output to control board (290) power supply.
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CEBORA S.p.A. 50

5.6 - Control board (290) code 5.602.101/D.

5.6.1 - Topographical drawing.



3.302.122.A 14/04/04
CEBORA S.p.A. 51

5.6.2 - Connector table.

Connector Terminals Function
J 1 1-2-3-4 NU.
J 1 5 - 6 thermostat on diode group (272) input.
J 2 1 GND.
J 2 2 enable pre-charge output signal.
J 2 3 - 4 NU.
J 2 5 mains voltage error signal input.
J 2 6 power supply output for enable pre-charge and mains voltage error signals.
J 3 3(+) - 4(-) +5 Vdc output for thermostat board (307) power supply.
J 3 1 igbt group (293) temperature signal input.
J 4 1(+) - 2(-) +8 Vdc input to CAN-BUS on control board (290) power supply.
J 4 3 - 4 CAN-BUS communication line.
J 5 2(+) - 1(-) +8 Vdc input for control board (290) power supply.
J 5 4(+) - 3(-) +15 Vdc input for control board (290) power supply.
J 6 - NU.
J 7 1(GH2) - 2(EH2) igbt H2 drive signal output.
J 7 3 NU.
J 7 4(EL2) - 5(GL2) igbt L2 drive signal output.
J 8 - NU.
J 9 1(GH1) - 2(EH1) igbt H1 drive signal output.
J 9 3 NU.
J 9 4(EL1) - 5(GL1) igbt L1 drive signal output.
J 10 - NU.
J 11 - RS232 serial communication for system programming.
J 12 - NU.
J 13 2(+) - 1(-) +25 Vdc input for cooling unit interface circuits power supply.
J 13 3 - 6 NU.
J 13 5(+) - 4(-) +24 Vdc output for fan (268).
J 14 1 -15 Vdc output for current sensor (289) power supply.
J 14 2 NU.
J 14 3 power source output current signal input.
J 14 4 +15 Vdc output for current sensor (289) power supply.
J 14 5 GND.
J 14 6 transformer (319) primary circuit current signal input.
J 14 7 interlock signal input.
J 14 8 +5 Vdc output for interlock signal.
J 15 1(+) - 2(-) +24 Vdc output, signal to enable motor-driven pump (36) on cooling unit.
J 15 3(+) - 4(-) cooling unit connected signal input.
J 15 5(+) - 6(-) cooling liquid pressure signal input.
J 16 1(+) - 2(-) power source output voltage input.
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CEBORA S.p.A. 52

5.7 - Igbt-driver board (292) code 5.602.096.

5.7.1 - Topographical drawing.



5.7.2 - Connector table.

Connector Terminals Function
- H+- H- drive signal input for igbt H (H1 or H2).
- L+- L- drive signal input for igbt L (L1 or L2).
- GH - EH command output for igbt H (H1 or H2).
- GL - EL command output for igbt L (L1 or L2).





5.8 - TA board (289) code 5.602.123.

5.8.1 - Topographical drawing.



5.8.2 - Connector table.

Connector Terminals Function
J 1 2(+) - 1(-) transformer (319) primary circuit current signal output.
J 1 3 - 4 interlock signal output.
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CEBORA S.p.A. 53

5.9 - Thermostat board (307) code 5.602.137.

5.9.1 - Topographical drawing.



5.9.2 - Connector table.

Connector Terminals Function
- TP1 0 Vdc input for thermostat board (307) power supply.
- TP2 +5 Vdc input for thermostat board (307) power supply.
- TP3 igbt group (293) temperature signal output.



5.10 - Cooling board (31) code 5.602.093/A.

5.10.1 - Topographical drawing.



5.10.2 - Connector table.

Connector Terminals Function
- TP1 - TP2 400 Vac input for cooling unit power supply.
- TP3 - TP4 cooling liquid pressure signal output.
- TP5 - TP6 +24 Vdc input to enable motor-driven pump (36) signal.
- TP7 - TP8 pressure switch (37) input.
J 1 A - B output for motor-driven pump (36).
J 2 1 400 Vac connection for autotransformer (32).
J 2 2 NU.
J 2 3 230 Vac connection for autotransformer (32).
J 2 4 0 Vac connection for autotransformer (32).
J 3 A - B output for fan (33).
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CEBORA S.p.A. 54

5.11 - Motor control board (232) code 5.602.103.

5.11.1 - Topographical drawing.



3.302.122.A 14/04/04
CEBORA S.p.A. 55

5.11.2 - Connector table.

Connector Terminals Function
J 1 1 - 2 wire feed unit door open signal input.
J 2 - NU.
J 3 1 - 2 CAN-BUS communication line, with control panel.
J 3 3(+) - 4(-) +5 Vdc for CAN-BUS with control panel power supply.
J 4 - NU.
J 5 - NU.
J 6 - NU.
J 7 1(+) - 3(-) ARC-ON signal output.
J 7 2 NU.
J 7 6(+) - 4(-) torch recognition signal input.
J 7 5 NU.
J 7 7 NU.
J 7 8(+) - 10(-) start signal input.
J 7 9(+) - 11(-) +5 Vdc for serial communication line (TX) power supply.
J 7 12(+) - 14(-) RX signal input, serial communication line.
J 7 13 TX signal output, serial communication line.
J 8 - NU.
J 9 - NU.
J 10 - NU.
J 11 1(+) - 2(-) +8 Vdc output for CAN-BUS on control board (290) power supply.
J 11 3 - 4 CAN-BUS communication line.
J 12 1(+) - 2(-) +8 Vdc output for control panel (220) power supply.
J 13 1(+) - 2(-) +27 Vdc output, solenoid valve (227) command.
J 14 - NU.
J 15 1 - 2 connector board (225) power supply output.
J 16 - NU.
J 17 - NU.
J 18 1-2(+) - 5-6(-) +55 Vdc input for motor control board (232) power supply.
J 18 3 - 4 NU.
J 19 1(+) - 4(-) +5 Vdc output for wire feeder motor (212) encoder power supply.
J 19 2 speed signal input from wire feeder motor (212) encoder.
J 19 3 NU.
J 20 A(+) - B(-) output for wire feeder motor (212).
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CEBORA S.p.A. 56

5.12 - Connector board (225) code 5.602.104/A.

5.12.1 - Topographical drawing.


5.12.2 - Connector table.

Connector Terminals Function
J 1 1 - 2 connector board (225) power supply input.
J 2 - NU.
J 3 1(+) - 3(-) ARC-ON signal input.
J 3 2 NU.
J 3 6(+) - 4(-) torch recognition signal output.
J 3 5 NU.
J 3 7 NU.
J 3 8(+) - 10(-) start signal output.
J 3 9(+) - 11(-) +5 Vdc for (TX) serial communication line power supply.
J 3 12(+) - 14(-) RX signal output, serial communication line.
J 3 13 TX signal input, serial communication line.
J 4 A - B start command input from external button on the torch.
J 5 1(+) - 9(-) start command input from remote control connector (BB).
J 5 2 DOWN-VOLT signal input.
J 5 3 DOWN-MOTOR signal input.
J 5 4 - 5 ARC-ON signal output (relay contact free from voltage).
J 5 6 UP-MOTOR signal input.
J 5 7 current reference signal input from external potentiometer cursor.
J 5 8 NU.
J 5 10 UP-VOLT signal input.
J 5 11 +5 Vdc external current potentiometer power supply.
J 5 12(+) - 16(-) analog recognition torch signal input.
J 5 13 NU.
J 5 14 +12 Vdc external communication line power supply (NU.).
J 5 15 0 Vdc, shared for external potentiometer, UP/DOWN buttons and external
communication line.
J 5 17 NU.
J 5 18 TX signal output for external communication line (NU.).
J 5 19 RX signal input for external communication line (NU.).
J 6 - NU.
J 7 - earth connection.
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CEBORA S.p.A. 57

6 - UPGRADES

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


6.1.1 - Removing igbt modules from heatsink and preparing heatsink.
- Remove the two igbt modules SKM200GB125D.
- Remove the two thin sheets of metal Therm-strate covered with grease and inserted between
the heatsink and the igbt modules.
- Clean the dissipater to remove the residue left by the metal sheet Therm-strate, using a rag
soaked in denatured alcohol. No residue must be left on the heatsink which must be perfectly
clean.

6.1.2 - Apply the igbt to the heatsink.
- Take the Therm-strate sheet (code 3085391), being careful not to crease it, gently remove the
two protective films to uncover the two layers of thermally conductive grease with your
hands; also take care not to contaminate it with dust or dirt.
- Apply the Therm-strate sheet on the dissipater in place of those previously removed.
- Make sure that the bottom part of the igbt modules (metal base) is perfectly clean.
- Apply the igbt module over the Therm-strate sheet.
- Insert the four holding screws (A, B, C, D) and turn the screws without tightening them
completely.
- Continue tightening the screws by degrees, proceeding in the order A, C, D, B.
- Caution! The tightening torque of the screws must be between 3 and 5 Nm.
3.302.122.A 14/04/04