Service Manual Cpdp-350 500

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

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1

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

2

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

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3

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

4

PC Board: (See page 22 for optional EPROMS available) PC Board PCB1 PCB2 PCB2 PCB3 PCB4 PCB5 WP-POT EPROM EPROM EPROM EPROM EPROM

5

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

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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

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Check for gas to power supply by pushing S4 switch “Gas Check” to check (Gas output)

Gas doesn’t 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

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

Arc blow occurs

6

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

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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

o

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

7

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 ・Relay　circuit ・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)

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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

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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

０

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 μs 37.5 μ 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 μs

3 1 .5 μs 15V 0V

3 1 .5 μs 6 μs 4 3. 5 μs

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 μ 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 μ sec

(S) CH304(-) - CH601(+) Example of non-pulse welding 0.2V is equivalent to 100A. ［ E x a m ple ］

３ Ｖ

CH801 "MULTI" control setting

Only (S) CH304(-) - CH801(+) welding Example of non-pulse welding ( non-pulse ５ Ｖ ) 2 V /div 2 ～ 5 m s/div

０ 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

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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"

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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

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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

高電圧危険

C H5

C H 1

R11

CH 2

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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 μs

3 1 .5 μs 14 V 0V

3 1 .5 μs 6 μs 4 3. 5 μs 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 μ 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

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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

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8

Check the performance of main semiconductors

When checking main power parts, pay attention to electric shock.( Refer to｢1.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.( 1Ω 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. ∞ 19Ω 19Ω 19Ω 19Ω 19Ω 19Ω

(-)

(-)

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. 16Ω 16Ω

( + 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. 13Ω

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.

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Feeding motor

(ＴＧ) 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

ＬＦ１

CH309

P6768T

filter

(P6916S)

(Open phase)

MS1 driver

ＬＦ２ ＭＳ２

CH104 CH201

ＥＰＲＯＭ

CH102

Gas check (terminal)

Ｄ／Ａ

Motor control

P6848Q (2/2)

Ｉ／Ｏ

Timer

RAM

ＣＰＵ

Internal bus

converter

A/D

1/4

CH103

Ｉ／Ｏ

OVP / UVP

P6848Q (1/2)

Capacitor

CH403,404

Extended connector

Extended bus

D/A converter

CH308

controller

ＰＷＭ

(P6848S)

IGBT driver

Inverter circuit

CCset／CPset

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

Primary rectifier

CC/CP/MULTI changeover

(P6848Y)

MS2 driver

ＬＥＤ

ＭＳ１

Magnetic contactor

Ga t e a l l ey

CH801

MLTset

CH402

OCP

CH407

ＣＴ

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

Ｐ６９０６Ｐ

1/2

CH901

Output voltage detect

Direct

－

ＣＴ

Terminal

＋

ＤＣＬ

P6840P

Line filter

10 Block diagram

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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 Ｓ ９ ０ １

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

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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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