Revised July/24/00

ADVANCED WELDING SYSTEMS

SERVICE MANUAL
Turbo Pulse 350 / 500 DF
CPVDP-350
(P6934) 460V model
(P6972) 230V model
CPDP-500
(P6920) 460V model
(P6973) 230V model

5311 W.T. Harris Blvd. West, Charlotte, N.C. 28269

Telephone: (704) 597-8240 Fax: (704) 333-9790

P. 1
273300709.doc

Setup:
Voltage: Units are singe voltage rated only
*208/230 VAC, Model
460 VAC, Model
CPDP 350 DF
P6972
P6934
CPDP 500 DF
P6973
P6920
*208/230V require a slide switch change located on PCB P6972Q00
Wire Feeders:
CMH 231
CMWH-231
CMH 147
CMWH-147
CMH 145
CMWH-145

Rolls
2
2
4
4
4
4

Metal
Steel
Steel
Aluminum
Aluminum
Aluminum
Aluminum

Cooling
Air
Water
Air
Water
Air
Water

Tachogenerator
No
No
No
No
Yes
Yes

Note: Water-cooled is recommend for use with CPDP 500 DF due to heat with the
higher current.
Welding Guns:
WTCMU-3503
WTCMUA-2501
WTCSW-5002
WTCAW-5002

Metal
Steel
Aluminum
Steel
Aluminum

Cooling
Air
Air
Water
Water

CPDP 350 DF
Recommended
Recommended
Applicable
Applicable

CPDP 500 DF
Applicable
Applicable
Recommended
Recommended

Extension Cables:
Remote Control
Wire Feeder

15 FT
BMCPJ-0605
BMCPJ-0705

33 FT
BMCPJ-0610
BMCPJ-0710

50 FT
BMCPJ-0615
BMCPJ-0715

66 FT
BMCPJ-0620
BMCPJ-0720

Input Protection:
Fuse
F1, F3
F2
F4
F5

Part #
4610-030
4610-004
4612-006
4612-006

Amps
75
10
3
3

Function
Power Supply
Power Supply Bd.
T2 and MS1 (Contactor)
T3, PC Boards. and Fan

P. 2
273300709.doc

Power Capacitors Voltage:

The power capacitors (C2-C4) voltage is approximately 325 VDC per capacitor.

PC Board: (See page 22 for optional EPROMS available)

PC Board
PCB1
PCB2
PCB2
PCB3
PCB4
PCB5
WP-POT
EPROM
EPROM
EPROM
EPROM
EPROM

Part #
P6840P00
P6972Q00
P6848Q00
P6768S00
P6768T00
P6848Y00
K5012C00
K4774
K4775
K4781
K4782
K4773

230 V model
P6972, P6973
P6972, P6973
P6972, P6973
P6972, P6973
P6972, P6973
P6972
P6973

460 V model
Function
P6934, P6920 Main Control Bd. (less EPROM)
Power Supply Board
P6934,
Power Supply Board
P6934, P6920 IGBT Driver Board
P6934, P6920 Filter Board
P6934, P6920 MS Contactor Driver Board
P6934, P6920 Wave Pulse Potentiometer
P6934
Op. Wave Pulse EPROM
P6920
Op. Wave Pulse EPROM
Op. Wave Pulse EPROM
Op. Wave Pulse EPROM
P6920
Op. .035 EPROM

Trouble Shooting Guide (Chart 1)

Error
#

Error Description

Warning
Indicator
(on front panel)

1
2
3
4
5
6
7
8
9
10
11
12
13
14

Torch switch ON
Program Push Switch Error
Emergency Stop
Input Overvoltage
Output Overcurrent
Thermal Overload (2-Tstats)
Inverter drive circuit error
Primary (CT1)/Secondary (CT2)
current error
+ 15V Low or Shorted Voltage
Arc voltage detecting error
Microprocessor error (1)
Waveform control circuit error
Microprocessor error (2)
Water pressure error (8.55 PSI min.)
Indicator is Off,
Indicator is ON,

PL202

PCB 1, P6840P00
PL203 PL204 PL205

Indicator is Flashing

P. 3
273300709.doc

Problem
No Arc when
Torch
switch is
pressed

Check and Replace if needed

Check Ground cable between
power supply and base metal

Power ON
indicator PL1 is
not lit
Fan Motor

PL1 failure
No power to power supply

Warning indicator
PL2 is lit when
control power
switch is turned
on see chart

Thermostats THP1 or THP2 bad

Check Torch power connections

between power supply and torch
Check Program Switch for proper
settings to front panel setting
Check Warning Lamp
Check Remote Control
Check all control cables
Check Torch switch
Check Power Fuses

Power indicator PL1 is not lit

Power indicator PL1 is lit

Welding power supply is

overloaded or duty cycle to high
Ambient temperature is high
Ventilation is blocked

Improper line voltage (over or

under voltage)
Make sure fan is running
Emergency Stop
No Gas even
when torch switch
is pressed

Check for gas to power supply by

pushing S4 switch Gas Check to
check (No gas output)

Action Required
Attach Ground cable with good
connection from power supply to
base metal
Attach Power cable with good
connection to power supply
Set to proper setting per front
panel
Refer to above chart 1
Connect if not
Plug in or replace if needed
Replace if needed
TR1, TR2 or DR1 may be
damaged if so call factory
authorized service center
Replace PL1
Apply proper 3-Phase line voltage
and ground
See PL1 section
Check F4, F5 (on sub-chassis) T3
and check CN13 on PC Board
P6840P for 200 VAC for Fan
motor replacing if needed
Check and replace if needed
Check connections CN8 and CN9
on PC Board P6840P
Reduce load or cycle and allow to
cool
Operate at and ambient of 104
degrees F or less
Remove exterior items from
around power supply
Turn power OFF use clean dry air
to blow out power supply
Check input power for proper line
voltage and correct if needed
See fan section
Check for jumper on Q Board CN5
terminals 7 and 8 to reset the
power supply
If no gas turn on gas tank and
regulator for proper pressure
make sure gas hose is hooked up
Check (SOL, #4813-001) 24 VDC
Gas solenoid valve in wire feeder
and replace if needed
Check for +24 VDC from Q Board

P. 4
273300709.doc

Check for gas to power supply by

pushing S4 switch Gas Check to
check (Gas output)

Gas doesnt stop

flowing

Check the Gas Check S4 switch

Gas flows when

the torch switch is
pressed but load
voltage is not
generated
No Gas pre-flow
time

Control circuit failure

No Gas post-flow
time
No Wire Feed

Welding current is
to much and out
of control

replace if needed
Check wire feeder control cable
and replace if needed
Gas control circuit failure check Q
Board and replace if needed
Check control cables line # 107,
108 and 109
Check filter (T) Board
Warning indicator lit check
indicating chart 1 and repair as
needed
Set in the Weld Position
Check for 24 VDC at gas valve if
none present replace gas solenoid
#4813-001
Check for 24 VDC at gas valve if
present check Q Board CN5
terminals 11 and 12 for open
contact and replace Q Board
Check P6840P Board and replace
if needed

Gas control circuit failure

Check P and Q Boards replacing

as needed
Check P6840P dip-switch S201
OFF position is .08 and ON 1.0
position #2
seconds set to ON for more time
Gas control circuit failure
Check P and Q Boards replacing
as needed
Check P6840P dip-switch S201
OFF position is .035 and ON 3.0
position #3
seconds set to ON for more time
F2 Fuse on Front panel blown
Check wire feeder, welding torch
and then replace F2 Fuse
Remote control and cables broken Plug-in or replace as needed
or bad contacts
Motor control circuit failure
Check Wire feeder motor, P and Q
board replacing as needed
Filter circuit failure
Check and replace T board if
needed
Control circuit failure
Check and replace PCB P6840P if
needed
Filter circuit failure
Check T Board and replace if
needed
Remote control or cable failure
Repair or replace if needed
Breaking of arc voltage detection
Check S901 on PCB P6840P
line
(standard position is TANSI under
100 ft. and DIRECT over 100 ft. as
P. 5
273300709.doc

Remote control
does not regulate
welding output

Control circuit failure

Filter circuit failure
Remote control or cable failure

No welding during
Crater Fill when
switch is in W/O
PULSE or
W/PULSE
position
WCR contact kept
closed

Crater-filler switch S2 on front

panel
WCR circuit failure

Unstable arc and

welding bead is
not neat

Connection failure

Current transducer CT2 failure

WCR circuit failure

Improper setting of
PULSE ARC CONTROL
Improper welding conditions

Wire feeding not smooth

Wire or base metal

Shielding gas

well as special wiring) and check

arc voltage detection lead
Check PCB P6840P and replace if
needed
Check T Board and replace if
needed
Check remote control variable
resistors R20 and R21 in remote
control and check remote control
cable replacing as needed
Replace if needed
Check PCB P6840P and replace if
needed
Replace CT2
Check PCB P6840P and replace if
needed
Check all power, ground and
control cables repair or replace as
needed
Check for proper tip and replace if
needed
Readjust for proper setting of
PULSE ARC CONTROL
Check settings of program switch,
current, voltage, gas flow, gas
type and welding speed changing
if required
Check pressure adjustment of
wire feed readjusting if needed
Check feed, pressure rolls and
torch for welding wire diameter
used
Check torch liner for metallic dust
inside of liner cleaning or
replacing if necessary
Check whether conduit of torch is
bent severally replacing if needed
Check whether oil or the like
cleaning surface if necessary
Check whether welding wire is
rusted changing to new wire
Gas mixture bad requires
changing to new tank
Air in gas check for bad
connections and gas hose failure

P. 6
273300709.doc

correcting if necessary
Change the direction of welding
Change the place of grounding
point of the base metal

Arc blow occurs

Dip Switch Guide

S201 (Factory Settings)

ON
OFF
Set
1
2
3
4

o
1

o
2

OFF
X
.08
.35
X

o
3
ON
1.0
3.0
CM-231

o
4
S201 Description
ON for Initial current when using crater-filler mode
ON for longer Pre-flow in seconds
ON for longer Post-flow in seconds
Always set to OFF (Only turn ON if using CM-231 wire feeder)

S202 (Factory Settings)

ON
OFF
Set
1
2
3
4
5
6
7
8

o
1
OFF

o
2
ON

o
3

o
4

o
5

o
6

o
7

o
8

S202 Description
ON = 20 Amp change to pulse peak current
ON = 40 Amp change to pulse peak current
ON = 80 Amp change to pulse peak current
OFF = Increases 1, 2, 3 ON = Decreases 1, 2, 3 of pulse peak current
ON = 0.1 ms change to pulse duration
ON = 0.2 ms change to pulse duration
ON = 0.4 ms change to pulse duration
OFF = Increases 5, 6, 7 ON = Decreases 5, 6, 7 of pulse duration

P. 7
273300709.doc

S203 (Factory Settings)

ON
OFF

Set
1
2
3
4
5
6
7
8

o
1

o
2

OFF

ON

o
3

o
4

o
5

o
6

o
7

o
8

S203 Description
ON = Base current to be fixed at 60 Amp
Always set to OFF
ON = Cancels slow down function
ON = Changes current and voltage from 0-15 VDC to 0-10 VDC
Always set to OFF
Always set to OFF
Always set to OFF
ON = Automatic operation (using E-stop terminals for start-stop)
S901 (Factory Settings)

TANS1
DIRECT

Standard under 100 ft

Over 100 ft away requires a lead from voltage detection terminal to work ( -)

Burn-back Time:
R125 potentiometer located on P6840P Board adjustments are Center = Standard (preset),
CCW = -250 ms shorter, CW = +250 ms longer
Burn-back Voltage:
R124 potentiometer located on P6840P Board adjustments are Center = Standard (preset),
CCW = -9 V lower, CW = +10 V higher
CN5 on Q Board (12 Pin Terminal Block)
-

Gas Solenoid Valve

N. C. = Gas Flow
N. O. = No Gas Flow

E-Stop *
N. C. = Run
N. O. = Stopped

Ammeter** Voltmeter***

Weld Current Relay Power Prep Relay

N. C. = Welding
24 VDC
N. O. = Stopped N. C. = Power ON w/No
Faults
Note: * Using the E-Stop terminals requires resetting power to power supply.
** Shunt for: CPDP 350 = 400A/60mV, CPDP 500 = 600A/60mV
*** Recommend a voltmeter with a full scale of 100 V
P. 8
273300709.doc

Printed Circuit Board (PCB)

7.1 Location and functions of P.C.B.

PC Board
Part #
P6840P

Location

Function

Upper chassis Sequence control ( micro-computer )

Output voltage setting
Pulse waveform control
Multi-static characteristic control
Constant penetration control
Voltage feedback
Current feedback
Input over voltage protect circuit
Shortage of input voltage protect circuit
Thermal overload protect circuit
PWM control circuit
Over current protect circuit
DC magnetization protect circuit
WCR circuit
Short-circuit detector

P6848Q
(460Vmodel)
P6972Q
(230Vmodel)

Upper chassis Wire feeding motor control circuit

Relaycircuit
External connection terminal
Power supply for P.C.B.

P6768S
P6768T

Upper chassis IGBT driver

Lower chassis Filter circuit for remote control and wire feeder
(Sub chassis)
Upper chassis Magnetic contactor driver

P6848Y
(460Vmodel
only)

P. 9
273300709.doc

7.2 PC Board P6840P

7.2.1 Measurement ( P6840P )
Check
Function
pin #
CH101 Reset signal for
CPU
CH102 Wire feeding speed
setting

Condition
N.A.
TS (Torch
Switch) is
OFF.

( In test CP mode )

Waveform or Voltage
(T) means Tester,(S) means Oscilloscope
N.A.
(T) CH304(-) - CH102(+) 0-9.5V
(depending on program #)
According to welding current setting knob
in remote pendant.

CH103 Welding current

setting of
remote control

TS is OFF. (T) H304(-) - CH103(+) 0-5V

(depending on program #)
According to welding current setting knob
in remote pendant.

CH104 Welding voltage

setting of
remote control

TS is OFF. (T) CH304(-) - CH104(+) 0-5V

(depending on program #)
According to welding voltage setting knob
in remote pendant

CH201 Feedback of tachogenerator

Wire
inching

CH301
CH302
CH303
CH304
CH406
CH305
CH306
CH307
CH308

+5V line
N.A.
Ground for +5V
N.A.
+15V line
N.A.
Ground for
N.A.
+15V, -15V
-15V line
N.A.
+24V line
N.A.
Ground for +24V
N.A.
Output setting
TS is OFF.
signal
non-pulse
( In test CP mode ) mode

CH309 Torch switch signal

(T) CH304(-) - CH201(+) 0-5V

According to wire feeding speed.
( Only when using wire feeder with tachogenerator(CM(W)H-145) )
(T) CH302(-) - CH301(+) +5V
N.A.
(T) CH304(-) - CH303(+) +15V
N.A.
(T) CH305(-) - CH304(+) +15V
(T) CH307(-) - CH306(+) +24V
N.A.
(T) CH304(-) - CH308(+)approx.0V-10V
According to welding voltage setting knob
in remote pendant

TS is ON. (T) CH304(-) -CH309(+) 0V

TS is OFF.. (T) CH304(-) -CH309(+) +4.2V

P. 10
273300709.doc

CH401 Actual welding

current
waveform

Welding

(S) CH304(-) - CH401(+)

Example of pulsed MAG. 1V is equivalent
to 100A.
E x a m ple
1 V /div
5 m s/div

CH402 Voltage feedback

for "MULTI"
control

TS is ON,
and
no load
output

(T) CH304 - CH402 Approx. 3V

(S) CH304 - CH402
6V
0V

In pulse
mode
CH403 Control pulse for
CH404 IGBT

6 s
37.5 s

TS is OFF. (T) CH304(-) - CH403 (CH404) (+)

+15V
TS is ON
(T) CH304(-) - CH403 (CH404) (+)
and no
Approx. +8V
load output (S) CH304 -CH403(CH404)
15V
0V

4 3. 5 s

3 1 .5 s
15V
0V

3 1 .5 s
6 s
4 3. 5 s

CH403 and CH404 shall not be 0V at

same time.
CH405 Voltage feedback
signal
(In test CP or CC
mode )
CH407 Current feedback
for OCP

TS is ON.

(T) CH304(-) -CH405(+)Approx. 1/10 of

output voltage.

Welding

(S) CH304(-) - CH407(+)

37.5 sec

0V

*Pulse width and pulse peak vary

according to instantaneous value of
welding current and voltage.
P. 11
273300709.doc

CH408 Feedback signal for TS is ON

(S) CH304(-) - CH408(+)
protection of DC
and no
magnetization
load output
In pulse
mode
CH601 Current feedback
signal for A/D
converter

Only
welding
(nonpulse )

30V
0V

-30 V
75 sec

(S) CH304(-) - CH601(+)

Example of non-pulse welding
0.2V is equivalent to 100A.
E x a m ple

CH801 "MULTI" control

setting

Only
(S) CH304(-) - CH801(+)
welding
Example of non-pulse welding
( non-pulse

)
2 V /div
2 5 m s/div

CH901 Output voltage

signal
CH902 Short-circuit detect
signal

CH903 Voltage feedback

signal for A/D
converter

0.2 V/div
5 m s/div

TS is ON
(T) CH901(-) - CH304(+)
and no
Approx. +8V-+9V
load output
TS is OFF. (T) CH304(-) - CH902(+) 0V
( equivalent to short)
TS is ON
(T) CH304(-) - CH902(+) +15V
and no
( equivalent to arc )
load output
TS is OFF. (T) CH304(-) - CH903(+) 0V
TS is ON
(T) CH304(-) - CH903(+) Approx.+4V
and no
load output

P. 12
273300709.doc

7.2.2 Potentiometers ( P6840P )

Refer to owner's manual " 11. 1 Build-in function and adjustment " for details.
Potentiometers on P.C.B. are already adjusted to optimum value. But some of them can be
re-adjusted by the operator. The following is the meaning of each potentiometer.
Do not re-adjust the potentiometer marked .
Symbol No.
R124
R125
R126
R251
R301
R418
R421
R938
R946

Meaning of potentiometer
Antistick voltage adjustment
Antistick time adjustment
No use
Gain adjustment of tacho-generator feedback ( Only when using wire
feeder with tacho-generator)
Input over voltage threshold adjustment
Voltage feedback adjustment (for CP)
Voltage feedback adjustment (for "MULTI" control )
Output voltage detector compensation for Hall current sensor
Output voltage feedback adjustment for A/D converter

7.2.3 Jumper sockets( P6840P )

Do not changeover the jumper sockets.
Symbol Meaning of jumper socket
No.
J101 EPROM/ extended bus
changeover
J303 Input for thermostat changeover
J401 PWM setting signal changeover
J402 "MULTI" control changeover

"a" side

"b" side

EPROM

Extended
bus
2
External
signal
Software

1
Internal signal
Hardware

Standard
position
"a"
"b"
"a"
"a"

P. 13
273300709.doc

CH407

CH402

CH408

CH403

CH304

CH801

CH405

CH307

CH601

J303

CH404

J402

CH902

CH305

CH303

CH301

R938

CH903

R418

CH406

CH401

R421

J401

CH901

R946

S901
CH306

R301

PART NO. P6840P

R126

CH201

CH104
CH308

R124

CH302

CH103

J101

R125

CH101

CH102

CH309

7.2.4 Location of check pins and potentiometers on P6840P

P. 14

273300709.doc

7.3 PC Board P6848Q

7.3.1 Measurement ( P6848Q )
Check
pin #
CH1
CH2
CH3
CH4
CH5
CH6
CH7

Function
Power supply for
wire feeding motor
Power supply -15V
Power supply +24V
Ground for +24V
Power supply +15V
Ground for +5V,
+15V,-15V
Power supply +5V

Condition

Waveform or Voltage
(T) means Tester,(S) means Oscilloscope
TS is OFF. (T) CH1(-) - CH6(+) Approx. +30V
TS is OFF. (T) CH2(+) - CH6(-) +15V
TS is OFF. (T) CH4(-) - CH3(+) Approx.+24V-+26V
N.A.
N.A.
TS is OFF. (T) CH6(-) - CH5(+) +15V
N.A.
N.A.
TS is OFF. (T) CH6(-) - CH7(+) +5V

7.3.2 Potentiometers ( P6848Q)

Refer to owner's manual " 11. 1 Build-in function and adjustment " for details.
Potentiometers on P.C.B. are already adjusted to optimum value. But some of them can be
re-adjusted by the operator. The following is the meaning of each potentiometer.
Do not re-adjust the potentiometer marked .
Symbol No.
R11

Meaning of potentiometer
Wire feeding speed adjustment

PART No .P 6848Q

CH 3

C H 4

CH 7

CH6

7.3.3 Location of check pins and potentiometers on P6848Q/P6972Q

C H5

C H 1

R11

CH 2

P. 15
273300709.doc

7.4 PC Board P6848S

7.4.1 Measurement ( P6848S )
Check
pin #
CH1
CH2
CH3
CH4
CH5

Function
+15V line
Ground for +15V
Power supply for
IGBT driver
Control pulse for
IGBT (1)

Condition

Waveform or Voltage
(T) means Tester,(S) means Oscilloscope
TS is OFF. (T) CH2(-) - CH1(+) +15V
N.A.
N.A.
TS is OFF. (T) CH2(-) - CH3(+) +15V
TS is OFF. (T) CH2(-) - CH4(CH5) (+) Approx.
+14V
TS is ON
(T) CH2(-) - CH4(CH5) (+) Approx.+8V
andno load (S) CH2(-) - CH4(CH5) (+)
output
14 V
0V

4 3. 5 s

3 1 .5 s
14 V
0V

3 1 .5 s
6 s
4 3. 5 s
CH6

IGBT driver error

signal (1)

TS is OFF. (T) CH2(-) - CH6(+) 0V

(When error occurs, +14V appears.)

CH7

IGBT driver error

signal (2)

TS is OFF. (T) CH8(-) - CH7(+) Approx. 0V

(When error occurs, +15V appears.)

CH8
CH10
CH11

Ground for CH7

Voltage between
gate and emitter of
IGBT(VGE)

N.A.
N.A.
TS is OFF. (T) CH11(-) - CH10(+) Approx. +6V
TS is ON, (T) CH10(-) CH11(+) Approx. +2.5V
and no
(S) CH10(-) CH11(+)
load output

a p pro x.+ 1 5 V
0V
a p p r o x .- 6 V

75 sec

CH20
CH21

Voltage between
gate and emitter of
IGBT (VGE)

TS is OFF. (T) CH21(-) CH20(+) Approx. +6V

TS is ON, (T) CH20(-) CH21(+) Approx. +2.5V
and no
(S) CH20(-) CH21(+)
load output
Same as CH10-CH11 waveform

P. 16
273300709.doc

CH30
CH31

Voltage between
gate and emitter of
IGBT (VGE)

TS is OFF. (T) CH31(-) - CH30(+) Approx. +6V

CH40
CH41

Voltage between
gate and emitter of
IGBT (VGE)

TS is OFF. (T) CH41(-) - CH40(+) Approx. +6V

TS is ON, (T) CH30(-) CH31(+) Approx. +2.5V

and no
(S) CH30(-) CH31(+)
load output
Same as CH10-CH11 waveform

TS is ON, (T) CH40(-) CH41(+) Approx. +2.5V

and no
(S) CH40(-) CH41(+)
load output
Same as CH10-CH11 waveform

7.4.2 Location of check pins and potentiometers on P6848S

C H 241
C H 40

C H 3
C H 1

C H 5
C H 2
CH 11

C H 20

CH 21
CH 10

C H 32

CH 30
CH 41

C H 31

CH4

PART No .P6768S

C H 22

C H 1 2C H 6
C H 7 C H 8

P. 17
273300709.doc

Check the performance of main semiconductors

When checking main power parts, pay attention to electric shock.( Refer to1.Precautions at
maintenance.)
8.1. Primary rectifier module ( Diode module ) DR1
Turn off the control power switch and wait for more than 3 minutes to discharge the
capacitors.
And then disconnect the wirings ( No.18 or 19 and 20 ).
Measure the resistance between terminals of DR1 with analogue tester.( 1 range)
Resistance shall be the value as follows.
Probe RED AC1 AC2 AC3 AC1
Probe
BLACK
Resistance

(-)

AC2

AC3

(+)

(+)

(-)

(-)

AC1

AC2

(+)

(-)

(+)

(+)

(+)

Approx. Approx. Approx. Approx. Approx. Approx.

19 19 19 19 19 19

(-)

(-)

AC3 AC1 AC2 AC3

8.2 IGBT module TR1,2

AC 1 AC 2 AC 3
AC 1 AC2 AC3
Turn off the control power switch and wait for more than 3 minutes to discharge the
capacitors.
G 2
And then disconnect the wirings ( No.49 and 50 ).
E2
Measure the resistance same as DR1.
Resistance shall be the value as follows.

(+)

(-)

Probe RED C1
C2E1 C2E1
Probe
C2E1
E2
C1
BLACK

Resistance Approx. Approx.

16
16

( + C) 2 E 1 E 2

C (1- )

E1
G 1

E2
C2E1

G2
E2
E2

C2E1

C1

8.3 Secondary rectifier module ( Diode module )

E1

Turn off the control power switch and wait for more than 3 minutes to discharge the
capacitors.
And then disconnect the wirings ( No.31 ).
Measure the resistance same as DR1.
Resistance shall be the value as follows.
Probe RED
Probe BLACK
Resistance

K
A
Approx.
13

A
K

A
A

K
K

A
A

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9 General procedure for checking the troubles

In case of checking only sequence circuit without applying input power to main
circuit, remove the wirings
( No.18 or 19, 20 ) from terminals of rectifier module DR1, and insulate them.
9.1 When main fuse F1 and / or F3 blows. (460V model only)
1) Check the main semiconductors according to 4. Check the performance of main
semiconductors, and replace them if necessary.
2) Replace fuses blown.
3) Disconnect the wirings from DR1 as mentioned above.
4) Turn on control power switch.
5) Check the pin CH1-CH5 ,CH10-CH42 on P.C.B. P6848S according to 1.4.1.
6) If P.C.B. P6768S is abnormal, check the pin CH403, CH404 on P.C.B. P6840P.
(Disconnect CN13 of P6840P and short-circuit 7pin and 8pin of CN13 on P.C.B..)
7) If P.C.B. P6840P is abnormal, replace it. If not, replace P.C.B. P6768S.
8) Check resistor R28, R29 on sub chassis replace them if necessary.
9) If any abnormality is not found, connect the wirings to DR1. And turn on control
power switch. Turn on torch switch and observe the no load output voltage. ( Refer to
owner's manual for rated no load voltage. ) If no load voltage is less than 50V, check
CH308, CH309,CH402-CH408 of P.C.B. P6840P.
9.2 When welding power source does not work ( Main fuse F1 and / or F3 does not blow.).
1) Check cartridge fuses F4, F5 on sub chassis ( lower chassis ).
2) Check whether magnetic contactor MS1 is ON when turning on the control power
switch. If not P.C.B. P6768S may be damaged.
3) Check warning indicators. (Refer to 3. Warning indicators )
4) Check control power supply ( CH301, CH303, CH305, CH306 ) according to 1.2.1.
5) When PL201 is not flickering even if CH301 is normal, P.C.B. P6906P may be
damaged.
6) Check 5)(7 of 5.1.Details of troubleshooting are printed in owner's manual.

P. 19
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Feeding motor

() Gas valve

Torch switch

Remote control

Voltage setting

Current setting

Inching

Front panel

Crater filler
setting

Penetration

Crater ON/OFF

Welding mode

Synergic/separate

Gas check/weld

Control power

CH309

P6768T

filter

(P6916S)

(Open phase)

MS1 driver

CH104
CH201

CH102

Gas check (terminal)

Motor control

P6848Q (2/2)

Timer

RAM

Internal bus

converter

A/D

1/4

CH103

OVP / UVP

P6848Q (1/2)

Capacitor

CH403,404

Extended connector

Extended bus

D/A converter

CH308

controller

(P6848S)

IGBT driver

Inverter circuit

CCsetCPset

+5V,15V,24V
Power supply for control circuit

Primary rectifier

CC/CP/MULTI changeover

(P6848Y)

MS2 driver

Magnetic contactor

Ga t e a l l ey

CH801

MLTset

CH402

OCP

CH407

CH401

Voltage
feedback

Secondary rectifier

Level
shift

CH903

Multi-characteristic control

A/D converter

Calculation

CH601

Integral circuit
D/A converter

CH405

DC magnetization protect

CH408

Inverter transformer

Short-circuit
detect

1/2

1/2

CH901

Output voltage
detect

Direct

Terminal

P6840P

Line filter

10 Block diagram

P. 20

273300709.doc

11 Others
11.1 Arc voltage direct feedback
When output side cables is longer than 30m,welding problems may occur as follows.
Too much spatter is generated.
Arc is unstable.
Wire feeds, however it does not melt.
In that case, directly detecting the work side of arc voltage may solve the problems.
(Torch side is already connected
to detecting circuit. )
Procedure of directly detecting work side of arc voltage.
Prepare optional detecting wire K2809B.
Connect the wire to the terminal on output terminal plate and work piece.
Set switch S901 on P.C.B. P6906P to "DIRECT" side.

P.C.B.P6848Q
Rear

Front

A r c v o lt a g e d ir e c t
d e t e c ti n g t e r m i n a l

P.C.B.P6840P

A r c v o lt a g e d ir e c t
d e t e c ti n g w ir e ( K 2 8 0 9 B )

W ork pie c e

C o n n e ct K 2 8 0 9 B to w ork
p i e c e w it h w o r k s i d e c a b l e .

W o rk sid e c a ble

P. 21
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11.2 Optional EPROM

Optional EPROMS for Turbo Pulse DF Series

EPROM #
K4773
500DF, 460V

Program
14
26
27
35
36
43

Mild Steel
Stainless Steel
Cored Wires

Welding Method
CO2
MAG
Pulsed MAG
MIG
Pulsed MIG
MAG

.035

NOTE: Wave Pulse requires Part # K5012C00 Wave Pulse Potentiometer

K4774
350DF, 460V

K4775
500DF, 460V

K4781
350DF,
230/208V

K4782
500DF,
230/208V

55
56
65
66
71
72
81
82
55
56
65
66
71
72
55
56
65
66
71
72
81
82
55
56
65
66
71
72

Soft Aluminum
Hard Aluminum

Wave Pulsed
MIG

Inconel

Pulsed MIG

Silicon Bronze

MIG Brazing

Soft Aluminum
Hard Aluminum

Wave Pulsed
MIG

Inconel

Pulsed MIG

Soft Aluminum
Hard Aluminum

Wave Pulsed
MIG

Inconel

Pulsed MIG

Silicon Bronze

MIG Brazing

Soft Aluminum
Hard Aluminum

Wave Pulsed
MIG

Inconel

Pulsed MIG

3/64
1/16
3/64
1/16
.035
.045
.030
.035
3/64
1/16
3/64
1/16
.035
.045
3/64
1/16
3/64
1/16
.035
.045
.030
.035
3/64
1/16
3/64
1/16
.035
.045

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