Cebora 583 Bravo synergic punto MIG 3035/T User manual
- Category
- Welding System
- Type
- User manual
CEBORA S.p.A. 1
3.302.152 09/01/04
BRAVO SYNERGIC
POWER SOURCES
arts. 572 – 573 – 576 – 577 – 579 – 581 – 583
SERVICE MANUAL
CEBORA S.p.A. 2
3.302.152 09/01/04
CONTENTS
1 - GENERAL INFORMATION...................................................................................................... 3
1.1 - Introduction..............................................................................................................................3
1.2 - General service policy. .............................................................................................................3
1.3 - Safety information.................................................................................................................... 3
1.4 - Electromagnetic compatibility. .................................................................................................3
2 - SYSTEM DESCRIPTION ..........................................................................................................4
2.1 - Introduction..............................................................................................................................4
2.2 - Technical specifications............................................................................................................4
2.3 - Description of power sources....................................................................................................4
3 - MAINTENANCE .......................................................................................................................6
3.1 - Periodic inspection, cleaning. ................................................................................................... 6
3.2 - Operating sequence. .................................................................................................................6
3.2.1 - Power source commands and signals......................................................................................6
3.2.2 - Power source operation. ......................................................................................................... 7
3.3 - Troubleshooting. ......................................................................................................................9
3.3.1 - The power source does not start, control panel off. ................................................................. 9
3.3.2 - Power source powered, control panel on, fan (26) stopped.................................................... 10
3.3.3 - Control panel on, display and signals do not show correct values.......................................... 11
3.3.4 - The start button produces no effect....................................................................................... 12
3.3.5 - Power source powered, no gas flows from the torch. ............................................................ 13
3.3.6 - Power source powered, the wire feeder motor does not work................................................ 14
3.3.7 - In open circuit operation, the output voltage is not regular.................................................... 17
3.3.8 - In resistive load operation, the output voltage is not regular.................................................. 19
3.3.9 - In synergic mode, the welding quality is not satisfactory, the wire speed is not suited to the
output current. .....................................................................................................................20
3.3.10 - Arc difficult to strike, the arc goes out immediately after lighting. ........................................ 20
3.3.11 - When the start button is released, the wire sticks to the workpiece (ineffective motor braking).
............................................................................................................................................ 21
3.4 - Alarm signals. ........................................................................................................................ 22
3.4.1 - Led (F) lit = high temperature signal, or open wire coil cover............................................... 22
4 - COMPONENTS LIST.............................................................................................................. 23
4.1 - Power sources arts. 572-573-576-577-579-581-583 : see file ESP5**.pdf enclosed at the end of
the manual.............................................................................................................................. 23
4.2 - Components table : see file ESP5**.pdf enclosed at the end of the manual..............................23
4.3 - Spare parts list........................................................................................................................ 23
5 - ELECTRICAL DIAGRAMS ....................................................................................................24
5.1 - Power sources arts. 572-573-576-577-579-581-583: see file SCHE5**.pdf enclosed at the end
of the manual.......................................................................................................................... 24
5.2 - Waveforms.............................................................................................................................24
5.2.1 - Correct wire feeder motor (5) voltage during braking (par. 3.3.11)........................................ 24
5.2.2 - Incorrect wire feeder motor (5) voltage during braking (par. 3.3.11). .................................... 24
5.3 - Control board (42) code 5.602.153.......................................................................................... 25
5.4 - Push-pull board (54) code 5.602.154/B................................................................................... 26
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1 - GENERAL INFORMATION
1.1 - Introduction.
The purpose of this manual is to train personnel assigned to carry out maintenance on the
power sources art. 572, 573, 576, 577, 579, 581 and 583 for welding systems with Synergic MIG
process.
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 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 before accessing the interior of the
equipment.
Some internal parts, such as terminals and dissipaters, may be connected to mains or
otherwise hazardous potentials. It is therefore forbidden to work with the safety guards removed
from the machine unless strictly necessary. In this case, take special precautions such as wearing
insulating gloves and footwear, and working in a perfectly dry environment with dry clothing.
1.4 - Electromagnetic compatibility.
Please read and observe the instructions provided in the paragraph “Electromagnetic
compatibility” of the Instruction Manual.
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2 - SYSTEM DESCRIPTION
2.1 - Introduction.
The BRAVO SYNERGIC system is made up of equipment for welding mild steel, stainless
steel and aluminum using the synergic MIG process. Each piece of equipment essentially
consists of an electric power source with built-in wire feed unit.
The power sources that make up the series include arts. 572, 573, 576, 577, 579, 581 and 583.
2.2 - Technical specifications.
To verify the technical specifications, see the machine plate, Instruction Manual, and Sales
Catalogue.
2.3 - Description of power sources.
The articles in the BRAVO SYNERGIC serie described in the present manual are direct
current power sources, essentially electromechanical, made up of a single-phase (arts. 572 and
576) or three-phase transformer (arts. 573, 577, 579, 581 and 583) and a rectifier bridge.
Referring to the electrical diagrams in par. 5, the figs. in par. 4 and fig. 3.2.1 you can see the
main blocks that make up the power sources.
In power sources arts. 572 and 573, the switch (N) (50) acts as both the main switch and
output voltage selector for the power source. Depending on its position, the supply voltage is
applied to the various intermediate sockets of the primary winding of the transformer (30), for
the purpose of altering the voltage on the secondary winding and thus at the power source output.
This adapts the output current of the power source to specific welding needs (see Instruction
Manual).
In power sources arts. 576, 577, 579, 581 and 583 the switch (N) (51) acts as a main switch,
while the output voltage is selected via the combined action of the two switches (50) and (51).
The switches (50) and (51) directly affect the service transformer (44), which powers the
electronic boards and the internal services of the power source. The mains voltage is applied to
the power transformer (30) only after the contactor (47) is closed as controlled by the control
board (42) based on the operating conditions of the power source.
The control board (42) contains a microprocessor circuit that manages all of the power source
functions, the operator interface and the wire feeder motor speed control, in compliance with the
synergic programs saved on the board.
The control board (42) receives the positioning information from the switches (50) and (51),
corresponding to the output power source voltage selection, and consequently adjusts the motor
speed based on the most suitable synergic curve selected from among those saved in the memory
of the microprocessor.
Within the speed range associated with the selected synergic curve, it is possible to fine-tune
the wire speed using the potentiometer provided (knob P).
If the manual program is set (P00 on display (S)) the wire speed is adjusted manually, thus
regardless of the position of switches (50) and (51), and may be adjusted from 0 to
approximately 20 m/min. using knob (P).
The motor speed is adjusted by the electronic regulator present on the control board (42),
which is powered with the same supply voltage as the control board (42), supplied by the service
transformer (44).
A second service voltage provided by the transformer (44) is used to power the isolated circuit
of the start button on the torch and the safety devices of the power source (safety switch (59) on
the wire feed unit guard, and thermostat (63) located on the windings of the power transformer
(30)).
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When these are tripped it interrupts the power supply to the start command circuit of the
control board (42) and stops the power source, opening the contact (47) and lighting the led (F)
on the control panel.
The secondary transformer circuit (30) is connected to the rectifier bridge (24), which keeps
the welding current constant.
In art. 576, the capacitor (58) levels the output voltage of the rectifier bridge (24) to improve
the welding start and overall welding quality.
The choke (49) inserted downstream from the rectifier bridge (24) in arts. 572, 576, 577 and
583 serves to level the welding current. The intermediate sockets in arts. 577 and 583 maximize
the welding quality for the various materials to be welded.
The resistor (18) installed parallel with the choke (49) in power sources arts. 576 and 577,
improves the welding start.
The shunt (53) inserted between the positive pole of the rectifier bridge (24) and the central
adapter (39) of the torch, provides the control board (42) with the signal to show the welding
current on display (S) during welding.
The polarity selector switch (61) provided on arts. 572 and 573 makes it possible to use these
power sources with flux-cored wire.
On the front panel of the power source, next to the control board (42), is the push-pull board
(54), which contains the motor speed control circuit on the push-pull torch, and the interface
connector of the signals for the spool-gun and push-pull torches.
These signals include:
− Start power source, from spool-gun or push-pull torch button.
− External adjustment of the welding current, by potentiometer on spool-gun torch or
UP/DOWN buttons on push-pull torch.
− Inputs for spool-gun or push-pull torch recognition.
− Power supply output for motors of spool-gun or push-pull torches.
The power source power outputs are gathered together on the front panel. A central adapter
(H) (39) is set up for the torch with a built-in power socket, two contacts for the start command,
and a pneumatic socket for gas.
The start signal of the central adapter (H) (39) is similar to those present in the connector (I)
of the power source (connector (J1) push-pull board (54)); these are alternately enabled based on
the type of torch connected to the power source.
With the standard torch the connector (I) of the power source remains free, and the start
command must be applied to the start terminals of the central adapter (39).
With spool-gun or push-pull torches the start input on central adapter (39) is deactivated, and
the start command must be applied to the start terminals of the connector (I) of the power source.
The gas solenoid (14) is activated by the torch start button, and its opening time also depends
on the post-gas time set.
Similarly the line contactor (47) is activated by the torch start button, and its closing time also
depends on the Burn-Back time set and the status of the safety parts in the power source (safety
switch (59) on the wire feed unit guard, and thermostat (63) located on the windings of the
power transformer (30)).
The signals processed by the electronic boards and present at their connectors are listed in the
table in chapter five of this manual.
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3 - MAINTENANCE
WARNINGS
ANY INTERNAL INSPECTIONS OR REPAIRS MUST BE CARRIED OUT BY QUALIFIED
PERSONNEL.
BEFORE CARRYING OUT ROUTINE MAINTENANCE, DISCONNECT THE POWER
SOURCE FROM THE MAINS AND WAIT FOR THE INTERNAL CAPACITORS (ART.
576) TO DISCHARGE.
3.1 - Periodic inspection, cleaning.
Periodically remove dirt and dust from the internal parts of the power source, using a jet of
low-pressure dry compressed air or a brush.
Check the condition of the output terminals and power cables of the power source and torch;
replace if aged or 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 - Operating sequence.
The following sequence represents correct functioning of the machine. It may be used as a
guiding procedure for troubleshooting.
It must be carried out after each repair without any errors.
3.2.1 - Power source commands and signals.
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Correct?
Correct?
NOTES
q Operations preceded by this symbol refer to operator actions.
♦ Operations preceded by this symbol refer to machine responses that must occur following an
operator action.
3.2.2 - Power source operation.
q System shut off and disconnected from the mains.
q Connect the gas supply to the fitting provided on the rear panel.
q Connect the torch to the central adapter (H) of the power source (with spool-gun or push-pull
torches, also connect the patch connector of the torch to the connector (I) of the power
source).
q Connect the negative pole cable (L) or (M) of the power source to the workpiece.
q Connect the power source to the mains.
q Set the selector switch (N) to position 1.
♦ System powered, fan running, all indicators and displays lit on the control panel
(lamp-test).
♦ After one second, display (S) shows the version of the work programs saved
(Cebora Firmware).
♦ After one second, display (S) shows the selected working program, and some
indicator leds remain lit; all as they were set before the last time the unit was shut
off.
♦ After two seconds, display (S) shows the wire speed programmed for the manual
program, or, for synergic programs, the programmed current based on the position
of switches (50) and (51).
NO (see 3.3.1, 3.3.2, 3.3.3).
YES
q Press the key (A) several times to select the “Mode” repeatedly in sequence.
♦ Each time the key (A) is pressed, the leds (B), (C), (D) and (E) light in sequence,
and display (S) shows the value of the function indicated by the corresponding lit
led.
NO (see 3.3.3).
YES
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.
q Turn the switches (50) and/or (51) for an output voltage suitable for the kind of welding to be
done (see Instruction Manual and the table provided with the power source, in the
compartment of the wire feed unit).
q Use the key (A) to select the “program” mode, led (B) lit.
q Use the buttons (Q) or (R) to select the manual working program (P00 on display (S)).
q Turn knob (P) for a wire speed suitable for the set welding current.
q Hold down the torch start button for a few seconds.
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Correct?
Correct?
Correct?
Correct?
Correct?
♦ Gas begins to flow from the torch as long as the button is held down plus the set
post-gas time.
♦ Wire begins to feed from the torch, or at least the wire feeder motors begin
running, for as long as the button is held down.
♦ Open-circuit output voltage is generated for as long as the button is held down.
NO (see 3.3.4, 3.3.5,
3.3.6, 3.3.7).
YES
q Move the torch near the workpiece and press the torch trigger.
♦ Begin welding. Turn knob (P) to the current level and wire speed suitable for the
kind of welding to be performed.
♦ Display (S) shows the welding current.
NO (see 3.3.8, 3.3.10).
YES
q Release the start button, holding the torch in welding position until gas stops flowing out.
♦ The arc shuts down immediately without the wire sticking to the workpiece
(Burn-Back function), the wire stops exiting the torch, and gas flow is interrupted
after the post-gas time set.
NO (see 3.3.5, 3.3.11).
YES
q Use the keys (A), (Q) or (R) to set a synergic program suitable for the type of welding to be
done (see Instruction Manual and the table provided with the power source, in the
compartment of the wire feed unit).
q Turn the knob (P) to the central position (SYNERGIC).
q Move the torch near the workpiece and press the start button.
♦ Begin welding. Turn the knob (P) for fine-tune the wire speed within the field
permitted by the synergic curve being used. Changing the speed also affects the
welding current shown on display (S) and thus the quality of the welding in
progress.
NO (see 3.3.9, 3.3.10).
YES
q Release the start button, holding the torch in welding position until gas stops flowing out.
♦ The arc shuts down immediately without the wire sticking to the workpiece
(Burn-Back function), the wire stops exiting the torch, and gas flow is interrupted
after the post-gas time set.
NO (see 3.3.5, 3.3.11).
YES
REGULAR OPERATION.
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Correct?
Correct?
3.3 - Troubleshooting.
WARNINGS
ANY INTERNAL INSPECTIONS OR REPAIRS MUST BE CARRIED OUT BY QUALIFIED
PERSONNEL.
BEFORE CARRYING OUT ROUTINE MAINTENANCE, DISCONNECT THE POWER
SOURCE FROM THE MAINS AND WAIT FOR THE INTERNAL CAPACITORS (ART.
576) TO DISCHARGE.
NOTES
Items in boldface describe problems that may occur on the machine (symptoms).
q Operations preceded by this symbol refer to situations the operator must determine (causes).
♦ Operations preceded by this symbol refer to actions the operator must perform in order to
solve the problems (solutions).
In the following chapters the tests and descriptions preceded by a parenthetical indication, e.g.
(art. 572) refer only to the power sources listed in parentheses. If there is no such indication, the
test and description refer to all power sources.
3.3.1 - The power source does not start, control panel off.
MAINS SUITABILITY TEST.
q Missing voltage at the power source input due to tripped mains protection.
NO
YES
♦ Eliminate any short-circuits or isolation leaks between the various conductors and
towards earth in connections between the power cable, terminal board (46),
contactor (47), switches (50) and (51), service transformer (44) and fan (26).
♦ Mains not suitable to power the power source (ex.: insufficient installed power).
MAINS CONNECTION TEST.
q (arts. 572, 576) Contactor (47), power terminals = approximately 230 Vac.
q (arts. 573, 577, 579, 581, 583) Contactor (47), power terminals = approximately 3 X 400 Vac
or 3 X 230 Vac, depending on mains voltage.
YES
NO
♦ Check power cable and plug and connections on terminal board (46), and replace
if necessary.
♦ Check the mains voltage conditions.
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Correct?
Correct?
CONTROL BOARD (42) POWER SUPPLY TEST.
q Control board (42), connector J7, terminals 1 - 2 = approximately 28 Vac.
YES
NO
♦ Check the wiring between service transformer (44) and control board (42).
♦ Check the wiring between contactor (47), switches (50) or (51), voltage change
terminal board (29) (where present) and service transformer (44).
♦ (arts. 573, 577, 579, 581, 583) Make sure the setting of the voltage change
terminal board (29) matches the mains voltage.
♦ Make sure the fuse is intact at the secondary service transformer circuit (44). If
interrupted, replace and check the resistance between terminals 1 and 2 of J7 on
control board (42). Correct value = >Mohm in both measurement directions. If
incorrect, also replace control board (42).
♦ Make sure the fuse is intact on the primary circuit of the service transformer (44).
If interrupted, replace and check the resistance of the primary winding.
Correct values:
terminals 0 – 230V = approximately 10 ohm, (arts. 572, 573);
approximately 6 ohm, (arts. 576, 577, 579, 581, 583);
terminals 0 – 440V = approximately 18 ohm, (arts. 572, 573);
approximately 11 ohm, (arts. 576, 577, 579, 581, 583).
♦ Check the efficiency of the switches (50) and (51) (see contact table in the
electrical diagram of par. 5).
♦ Replace the service transformer (44).
♦ Replace the control board (42).
3.3.2 - Power source powered, control panel on, fan (26) stopped.
FAN (26) TEST.
q Terminals of fan (26) = approximately 230 Vac, with mains at either 230 Vac or 400 Vac.
NO
YES
♦ Check the wiring between fan (26) and terminal board on service transformer
(44).
♦ Make sure that there are no mechanical impediments blocking the fan.
♦ Replace the fan (26).
♦ Make sure the fuse on the power supply for fan (26) is intact, located on the terminal board of
the service transformer (44). If interrupted, replace and check the resistance between the
terminals of the fan (26).
Correct values = approximately 500 ohm, (arts 572, 573);
approximately 60 ohm, (arts. 576, 577, 579, 581, 583).
If incorrect, also replace fan (26).
♦ Replace service transformer (44).
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Correct?
3.3.3 - Control panel on, display and signals do not show correct values.
DISPLAY AND INDICATOR LED TEST.
q Upon start-up the display and leds are all lit for 1 second (lamp-test).
q After one second, display (S) shows the version of the work programs saved (Cebora
Firmware).
q After one second, display (S) shows the selected working program, and some indicator leds
remain lit, all as set before the last time the unit was shut off.
q After two seconds, display (S) shows the wire speed programmed for the manual program, or,
for synergic programs, the programmed current based on the position of switches (50) and
(51).
q All passages relating to “Mode” and “Program” selections are also possible using the buttons
(A) (Q) and (R) described in par. 3.2.2.
YES
NO
♦ Check the wiring between J7 control board (42) and service transformer (44).
♦ Perform the CONTROL BOARD (42) POWER SUPPLY TEST, par. 3.3.1.
♦ Replace the control board (42).
♦ Regular operation of the control panel.
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Correct?
Correct?
Correct?
Correct?
3.3.4 - The start button produces no effect.
POWER SOURCE SAFETY TEST.
q Control panel, led (F) = lit (temperature outside limits or wire feed unit guard open).
NO
YES
♦ See “Alarm signals”, par. 3.4.
TORCH TYPE RECOGNITION TEST.
q Control board (42), connector J9, terminals 10 (+) and 16 (-) = 0 Vdc with spool-gun torch
inserted (+5 Vdc with other torches).
q Control board (42), connector J9, terminals 13 (+) and 16 (-) = 0 Vdc with push-pull torch
inserted (+5 Vdc with other torches).
YES
NO
♦ Check the wiring between J9 control board (42) and J2 push-pull board (54).
♦ Make sure the spool-gun or push-pull torch is correctly inserted on the connector
(I) of the power source (J1 on push-pull board (54)).
♦ Check the presence of recognition jumper in the patch connector of the torches:
(push-pull torch = terminals 7 and 3; spool-gun torch = terminals 6 and 3).
♦ See CONTROL BOARD (42) POWER SUPPLY TEST par. 3.3.1.
♦ Replace the push-pull (54) and/or control boards (42).
START COMMAND TEST WITH TRADITIONAL TORCH.
q Control board (42), connector J1, terminals 1 – 2 = 0 Vac with button on traditional torch
pressed (16 Vdc with button released).
YES
NO
♦ Check the wiring between connector J1 control board (42), central adapter (39)
and the torch trigger.
♦ Check torch button. Replace if defective.
♦ See CONTROL BOARD (42) POWER SUPPLY TEST, par. 3.3.1.
♦ Replace the control board (42).
START COMMAND TEST WITH SPOOL-GUN OR PUSH-PULL TORCH.
q Control board (42), connector J3, terminals 1 and 2 = 0 Vac, with button on spool-gun or
push-pull torch pressed (approximately 16 Vac with button released).
YES
NO
♦ Check the wiring between J3 control board (42) and J3 push-pull board (54).
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Correct?
♦ Check the wiring between terminals 4 and 5, connector J1, push-pull board (54),
and the button on spool-gun or push-pull torch.
♦ Check torch button. Replace if defective.
♦ See CONTROL BOARD (42) POWER SUPPLY TEST, par. 3.3.1.
♦ Replace the push-pull (54) and/or control boards (42).
♦ Replace the control board (42).
3.3.5 - Power source powered, no gas flows from the torch.
SOLENOID VALVE (14) TEST.
q Solenoid valve (14) terminals = 27 Vac with torch button pressed and as long as the button is
held down.
NO
YES
♦ Check the presence of gas at the fitting provided on the rear panel, and make sure
that the pressure and air flow in the intake line comply with the values specified
for the BRAVO SYNERGIC power sources.
♦ Make sure there are no occlusions in the gas hoses of the power source.
♦ Check the resistance on the solenoid valve terminals (14) = approximately 25
ohm. If >Mohm (winding broken), replace the solenoid valve (14).
♦ Replace the solenoid valve (14).
♦ Check the wiring between terminals 4 and 6 of the connector J7 on control board (42) and
solenoid valve (14).
♦ Check the resistance on the solenoid valve terminals (14) = approximately 25 ohm. If 0 ohm
(short-circuit), replace solenoid valve (14) and control board (42).
♦ See CONTROL BOARD (42) POWER SUPPLY TEST, par. 3.3.1.
♦ Replace the control board (42).
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Correct?
3.3.6 - Power source powered, the wire feeder motor does not work.
WITH TRADITIONAL TORCH
WIRE FEEDER MOTOR TEST.
q Use the buttons (A), (Q) or (R) to select the manual working program (P00 on display (S)),
and the Soft Start function to “99”.
q Control board (42), connector J8, terminals 1 (+) and 2 (-) =
+2 / +23 Vdc approximately (arts. 572, 573);
+2 / +28 Vdc approximately (arts. 576, 577, 579, 581, 583),
adjustable using the knob (P), with start button pressed.
NO
YES
♦ Check the wiring between J8 control board (42) wire feeder motor (5).
♦ Make sure there are no mechanical impediments blocking the motor.
♦ Check the motor rotation direction; if incorrect, reverse the wires on the terminals
of J8 on control board (42).
♦ With the power source off, temporarily disconnect the terminals of the wire feeder
motor (5) from the connector J8 control board (42), and check the resistance
between the motor terminals left free. Correct value = approximately 1 ohm
(resistance of the motor winding). If >Mohm (winding broken), replace wire
feeder motor (5).
♦ Replace the wire feeder motor (5).
♦ Make sure the machine is set for the traditional torch by carrying out the TORCH TYPE
RECOGNITION TEST, par. 3.3.4.
♦ Make sure the wire feeder motor start command is present by carrying out the START
COMMAND TEST WITH TRADITIONAL TORCH, par. 3.3.4.
♦ With the power source off, temporarily disconnect the terminals of the wire feeder motor (5)
from the connector J8 control board (42), and check the resistance between the motor
terminals left free. Correct value = approximately 1 ohm (resistance of the motor winding). If
0 ohm (short-circuited), replace the wire feeder motor (5) and control board (42).
♦ See CONTROL BOARD (42) POWER SUPPLY TEST, par. 3.3.1.
♦ Replace the control board (42).
WITH PUSH-PULL TORCH
WIRE FEEDER MOTORS TEST WITH PUSH-PULL TORCH.
q Use the buttons (A), (Q) or (R) to select the manual working program (P00 on display (S)),
and the Soft Start function to “99”.
q Control board (42), connector J8, terminals 1 (+) and 2 (-) =
+2 / +23 Vdc approximately (arts. 572, 573);
+2 / +28 Vdc approximately (arts. 576, 577, 579, 581, 583),
adjustable by means of UP/DOWN buttons on the torch, with start button pressed.
q Push-pull board (54), connector J1, terminals 1 (+) and 8 (-) (or wire feeder motor terminals
on push-pull torch) =
+13 / +28 approximately (arts. 572, 573);
+13 / +28 approximately (arts. 576, 577, 579, 581 and 583),
adjustable via UP/DOWN buttons on the torch, with start button pressed.
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Correct?
Correct?
NO
YES
♦ Check the wiring between J8 control board (42) and wire feeder motor (5), and
between J1 push-pull board (54) and torch motor.
♦ Make sure that there are no mechanical impediments blocking the motors.
♦ Check the motor rotation direction; if incorrect, reverse the wires on the terminals
of J8 on control board (42) and/or on the torch motor.
♦ With the power source off, temporarily disconnect the terminals of the wire feeder
motor (5) from the connector J8 control board (42), and check the resistance
between the motor terminals left free. Correct value = approximately 1 ohm
(resistance of the motor winding). If >Mohm (winding broken), replace wire
feeder motor (5).
♦ With the power source off, temporarily disconnect the torch from the power
source and check the resistance between terminals 1 and 8 of the patch connector
on the torch. Correct value = approximately 4 - 40 ohm (motor winding
resistance, depends on the rotor stopping point). If >Mohm (winding broken),
check the wiring between connector and torch motor, or replace the torch motor.
♦ Replace the wire feeder motor on the torch, or the entire torch.
♦ Replace the wire feeder motor (5).
MOTOR SPEED REFERENCE SIGNAL TEST WITH PUSH-PULL TORCH.
q Control board (42), connector J9 terminal 4 (+) and 9 (-) = approximately 0 Vdc, with UP
button on torch pressed; approximately +2.5 Vdc, with DOWN button on torch pressed; +4
Vdc approximately with UP and DOWN buttons released.
YES
NO
♦ Check the wiring between J9 control board (42) and J2 push-pull board (54).
♦ Check wiring between J1 push-pull board (54) and UP/DOWN torch buttons.
♦ Make sure that the buttons on the torch are working properly, and replace if
defective, or replace the entire torch.
♦ Replace the control (42) and/or push-pull (54) boards.
♦ Make sure the unit is set for push-pull torch, by carrying out the TORCH TYPE
RECOGNITION TEST, par. 3.3.4.
♦ Make sure the wire feeder motor command is present by carrying out the START
COMMAND TEST WITH SPOOL-GUN OR PUSH-PULL TORCH, par. 3.3.4.
♦ With the power source off, temporarily disconnect the terminals of the wire feeder motor (5)
from the connector J8 control board (42), and check the resistance between the motor
terminals left free. Correct value = approximately 1 ohm (resistance of the motor winding). If
0 ohm (short-circuited), replace the wire feeder motor (5) and control board (42).
♦ With the power source off, temporarily disconnect the torch from the power source and check
the resistance between terminals 1 and 8 of the patch connector on the torch. Correct value =
approximately 4 - 40 ohm (motor winding resistance, depends on the rotor stopping point). If
0 ohm (short-circuit), check the wiring between connector and torch motor, and replace the
torch motor, or the entire torch, and push-pull board (54) if necessary.
♦ See CONTROL BOARD (42) POWER SUPPLY TEST, par. 3.3.1.
♦ Replace the control (42) and/or push-pull board (54).
CEBORA S.p.A. 16
3.302.152 09/01/04
Correct?
Correct?
WITH SPOOL-GUN TORCH
WIRE FEEDER MOTOR TEST ON SPOOL-GUN TORCH.
q Use the buttons (A), (Q) or (R) to select the manual working program (P00 on display (S)),
and the Soft Start function to “99”.
q Push-pull board (54), connector J1, terminals 1 (+) and 9 (-) (or wire feeder motor terminals
on spool-gun torch) = approximately +1 / +19 Vdc, adjustable by means of the potentiometer
on the torch, with start button pressed.
NO
YES
♦ Check the wiring between J1 push-pull board (54) and torch motor.
♦ Make sure that there are no mechanical impediments blocking the motor.
♦ Check the motor rotation direction; if incorrect, reverse the wires on the torch
motor.
♦ With the power source off, temporarily disconnect the torch from the power
source and check the resistance between terminals 1 and 9 of the patch connector
on the torch. Correct value = approximately 4 - 10 ohm (motor winding
resistance, depends on the rotor stopping point). If >Mohm (winding broken),
check the wiring between connector and torch motor, or replace the torch motor.
♦ Replace the wire feeder motor on the torch, or the entire torch.
MOTOR SPEED REFERENCE SIGNAL TEST WITH SPOOL-GUN TORCH.
q Control board (42), connector J9 terminal 4 (+) 9 (-) = 0 / +5 Vdc, adjustable by means of the
potentiometer on the torch.
YES
NO
♦ Check the wiring between J9 control board (42) and J2 push-pull board (54).
♦ Check the wiring between J1 push-pull board (54) and potentiometer on the torch.
♦ Make sure that the potentiometer on the torch is working properly, and replace if
defective, or replace the entire torch.
♦ Replace the control (42) and/or push-pull board (54).
♦ Make sure the unit is set for spool-gun torch, by carrying out the TORCH TYPE
RECOGNITION TEST, par. 3.3.4.
♦ Make sure the wire feeder motor command is present by carrying out the START
COMMAND TEST WITH SPOOL-GUN OR PUSH-PULL TORCH, par. 3.3.4.
♦ With the power source off, temporarily disconnect the torch from the power source and check
the resistance between terminals 1 and 9 of the patch connector on the torch. Correct value =
approximately 4 - 10 ohm (motor winding resistance, depends on the rotor stopping point). If
0 ohm (short-circuit), check the wiring between connector and torch motor, and replace the
torch motor, or the entire torch, and push-pull board (42) if necessary.
♦ See CONTROL BOARD (42) POWER SUPPLY TEST, par. 3.3.1.
♦ Replace the control (42) and/or push-pull (54) boards.
CEBORA S.p.A. 17
3.302.152 09/01/04
Correct?
Correct?
3.3.7 - In open circuit operation, the output voltage is not regular.
NOTE
In power sources with three-phase power supply, when the switches (50) and (51) are set to
certain positions, the secondary voltage values between phases are different due to the particular
connections between switches (50) and (51) and the primary circuit of the transformer (30). This
situation is deliberate in order to offer more voltage levels, with minor differences among them,
using a lower number of intermediate sockets on the windings of transformer (30).
OPEN-CIRCUIT OUTPUT VOLTAGE TEST.
q Output terminal (L) power source (-) and output terminal (H) power source (+) = values direct
current (Vdc) according to the table, with start button pressed and rated mains voltage.
NOTE
The table give the THEORETICAL mean value of the rectified secondary circuit voltages.
When the power source has no load at all, the values that may actually be measured may in
some cases be much higher than those given, due to incorrect operation by the rectifier bridge
(24) without any load at its output.
With a small load (ex. 100 ohm) applied at the power source output, the operation of the
rectifier (24) may improve, and the measurable values may become closer to those given (+/-
10%). Therefore, for measuring we recommend using the latter method, and consider not so
important the precision of the absolute value measured, but rather the difference in value as the
position of switches (50) and (51) changes.
Switch 51 position = 1 Switch 51 position = 2
Switch 50 positions Switch 50 positions
Art
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
572
+17
+18.5
+20 +21.5
+24.5
+27.5
+31 - - - - - - - - -
573
+17.5
+20 +22 +24.5
+27.5
+30.5
+33.5
- - - - - - - - -
576
+18.5
+19.5
+21 +22.5
+23.5
+24.5
- - +25.5
+28.5
+31.5
+34 +37 +40 - -
577
+16.5
+18 +19 +20 +21 +22 - - +23 +25.5
+27.5
+30 +31.5
+34.5
- -
579
+18.5
+20 +21 +22 +23
+25.5
- - +27.5
+30 +33 +35.5
+38.5
+44.5
- -
581
+19.5
+20.5
+21.5
+22.5
+23
+24.5
+25.5
+27 +28.5
+31 +33 +35.5
+37.5
+41 +44 +49.5
583
+16.5
+17.5
+18 +19 +19.5
+20.5
+21 +22 +24 +25.5
+27.5
+29 +30
+32.5
+34 +37.5
NO
YES
♦ Regular operation.
INPUT CONTACTOR (47) TEST.
q Contactor (47) coil terminals = 27 Vac, contacts closed, with start button pressed.
YES
NO
♦ Check the wiring between contactor (47) coil and J7 control board (42).
♦ Check the wiring between switches (50) and (51) and J2 control board (42).
♦ With the power source off and unplugged, check the resistance between the
terminals of the contactor (47) coil. Correct value = approximately 4.7 ohm. If 0
ohm (short-circuit), replace contactor (47) and control board (42).
CEBORA S.p.A. 18
3.302.152 09/01/04
Correct?
♦ Check efficiency of start command, performing if necessary the tests in par. 3.3.4.
♦ With the power source off and unplugged, check the resistance between terminals of contactor
(47) coil. Correct value = approximately 4.7 ohm. If incorrect, replace contactor (47).
VOLTAGE TO SECONDARY CIRCUIT OF THE TRANSFORMER (30) TEST.
q Disconnect the terminals of transformer (30) secondary circuit from the rectifier bridge (24).
q Terminals of transformer (30) secondary circuit = alternating voltage (Vac) values as shown
in the table, with start button pressed, open-circuit power source and rated mains voltage.
NOTE
The table shows the value of the three alternating voltages measured at the secondary circuit;
if these are different (marked by an asterisk (*)) the table gives their average.
This average is thus slightly different from the value of each individual phase measured.
Switch 51 position = 1 Switch 51 position = 2
Switch 50 positions Switch 50 positions
Art
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
572
18.5 21 22.5
24 27.5
30.5
34.5
- - - - - - - - -
573
13 15* 16.5*
18
20.5*
22.5*
25 - - - - - - - - -
576
13.5
14.5
15.5
16.5
17.5
18.5 - - 19 21 23.5
25.5
27.5
29.5
- -
577
12.5
13*
14* 15 15.5*
16.5 - - 17
18.5*
20.5*
22 23.5*
25.5
- -
579
14
14.5*
15.5*
16.5
17.5*
19 - - 20.5
22.5*
24.5*
26.5
28.5*
33 - -
581
14.5
15*
16* 16.5
17*
18 19* 20 21 23*
24.5*
26.5
28*
30.5
32.5*
37
583
12.5
13*
13.5*
14 14.5*
15 15.5*
16.5
17.5
19*
20* 21.5
22.5*
24 25.5*
28
NO
YES
♦ Check the wiring between transformer (30) secondary circuit and rectifier (24).
♦ Check the efficiency of the rectifier bridge (24).
♦ (576) Check the efficiency of the capacitor (58) and resistor (57).
♦ Check the wiring between the negative terminal of rectifier bridge (24), choke
(49) (where present), polarity inverter (61) (where present), and output terminal
(-) (L) of the power source, and between the positive terminal of rectifier bridge
(24), shunt (53), polarity inverter (61) (where present), and central torch adapter
(+) (H). If you find loose connections, tighten them and replace any components
with damaged terminals.
♦ Check the wiring between power cord, contactor (47), switches (50) and (51) and primary
winding of the transformer (30).
♦ (573, 577, 579, 581, 583) Make sure the primary circuit of the transformer (30) is properly
connected on the voltage change terminal board (29), and that the position of the voltage
change (29) matches the mains voltage.
♦ (573, 577, 579, 581, 583) Check the delta connection of the windings that make up the
secondary transformer circuit (30).
♦ Check the efficiency of the switches (50) and (51).
♦ With the power source off and unplugged, check the efficiency of the contacts of contactor
(47), tripping it manually and checking whether the resistance on each contact is
approximately 0 ohm. If you find burnt contacts or have difficulty moving the mobile
equipment, replace the contactor (47).
♦ Replace the transformer (30).
CEBORA S.p.A. 19
3.302.152 09/01/04
Correct?
3.3.8 - In resistive load operation, the output voltage is not regular.
NOTE
Only the tests loaded at the maximum output voltage are described below, and thus at the
maximum current of the power source, since it is assumed that the OPEN CIRCUIT
OPERATION TEST in par. 3.3.7. has been successfully completed, and thus the connections,
pin ratio and operation of the transformer (30) are all assumed correct.
OUTPUT VOLTAGE TEST ON RESISTIVE LOAD.
q Set the manual program (P00 on display (S)), the switches (50) and (51) in the positions
shown in the table, and use a resistive load capable of withstanding the maximum current of
the power source. The appropriate values are shown in the table.
q Output terminal (L) power source (-) and output terminal (H) power source (+) = direct
current values as shown in the table, with start button pressed.
Power
Source
Art.
Position
switch 50
Position
switch 51
Resistive load
resistance
Power source
output current
(Adc)
Power source
output voltage
(Vdc)
572 7 - 0.143 ohm 150 +21.5
573 7 - 0.132 ohm 170 +22.5
576 6 2 0.12 ohm 200 +24
577 6 2 0.12 ohm 200 +24
579 6 2 0.106 ohm 250 +26.5
581 8 2 0.092 ohm 330 +30.5
583 8 2 0.106 ohm 250 +26.5
NO
YES
♦ Regular operation.
♦ Make sure the connections of the primary circuit of the transformer (30) to the switches (50)
and (51) and the voltage change terminal board (29) (where present) are intact. If you find
loose connections, tighten them and replace any components with damaged terminals.
♦ Check the efficiency of switches (50) and (51), especially make sure there are no signs of
burned or misshapen contacts. If necessary replace the defective switch.
♦ With the power source off and unplugged, check the efficiency of the contacts of contactor
(47), tripping it manually and checking whether the resistance on each contact is
approximately 0 ohm. If you find burnt contacts or have difficulty moving the mobile
equipment, replace the contactor (47).
♦ Check the wiring between the secondary circuit winding of transformer (30) and rectifier
bridge (24). If you find loose connections, tighten them and replace any components with
damaged terminals.
♦ Check the efficiency of the rectifier bridge (24).
♦ Make sure the connections between the negative terminal of rectifier bridge (24), choke (49)
(where present), polarity inverter (61) (where present), and output terminal (-) (L) of the
power source are intact, as well as between the positive terminal of rectifier bridge (24), shunt
(53), polarity inverter (61) (where present), and central torch adapter (H) (+). If you find loose
connections, tighten them and replace any components with damaged terminals.
♦ (art. 576) Check the efficiency of the capacitor (58) and resistor (57). Replace if defective.
♦ Replace the transformer (30).
CEBORA S.p.A. 20
3.302.152 09/01/04
Correct?
3.3.9 - In synergic mode, the welding quality is not satisfactory, the wire speed is not
suited to the output current.
NOTE
The parameters entered into the synergic programs are drawn from experience, and thus some
operators may find themselves working in ideal conditions, while others may need to make slight
changes.
For this reason the possibility remains to alter, to a small degree, the ratio between wire speed
and welding current within the synergic programs. These changes may be made using the knob
(P) if using a traditional torch, or with the equivalent commands on the spool-gun or push-pull
torches connected.
SYNERGIC PROGRAM PARAMETERS TEST.
q In synergic mode, the parameters saved in the selected program reflect the actual welding
conditions.
YES
NO
♦ Select the program that best meets your needs and set the correct parameters (see
Instruction Manual and the table provided with the power source, in the
compartment of the wire feed unit).
♦ Make sure the wire feeder motors are working properly, performing if necessary the tests in
par. 3.3.6.
♦ Make sure the control panel is working properly (see par. 3.3.3).
♦ Replace the control board (42).
3.3.10 - Arc difficult to strike, the arc goes out immediately after lighting.
NOTE
In the power sources covered by this manual, the “Soft Start” function is included in the work
programs and is adjustable via the control panel (see Instruction Manual).
In power sources art. 577 and 583, the choke (49) has one (art. 577) or two (art. 583)
intermediate sockets for optimal welding that adapts to the various materials used. These outputs
may also be used for easier welding starts.
Therefore, when dealing with start-up problems and difficulty in maintaining the arc, we
recommend:
− Make sure the “Soft Start” function adjustment is working properly, performing welding
tests with various setting values.
− Carrying out welding tests, changing the working program (with one similar to the one
being used, if available), and adjusting the knob (P) to improve the welding conditions.
− Check the compatibility of the torch with the type of welding being carried out, and
especially matching the torch nozzle with the wire being used.
− Check the wear status of the torch and its components, replacing them if necessary.
− Replace the control board (42).
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Cebora 583 Bravo synergic punto MIG 3035/T User manual
- Category
- Welding System
- Type
- User manual
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