Cebora SOUND MIG 3840/T Pulse User manual

Brand: Cebora

Model: SOUND MIG 3840/T Pulse

Category: Welding System

Type: User manual

CEBORA S.p.A. 1

SOUND MIG 3840/T Pulse

POWER SOURCE +

COOLING UNIT +

WIRE FEEDER

art. 287

SERVICE MANUAL

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CEBORA S.p.A. 2

CONTENTS

1 - GENERAL INFORMATION..........................................................................................................................4

1.1 - Introduction. .................................................................................................................................................4

1.2 - General service policy. .................................................................................................................................4

1.3 - Safety information........................................................................................................................................4

1.4 - Electromagnetic compatibility......................................................................................................................4

2 - SYSTEM DESCRIPTION ..............................................................................................................................5

2.1 - Introduction. .................................................................................................................................................5

2.2 - Technical specifications................................................................................................................................5

2.3 - Description of SOUND MIG 3840/T Pulse system (art. 287)......................................................................5

2.4 - Description of MIG3840/T Pulse power source...........................................................................................6

2.5 - Description of WF4-P Wire Feeder..............................................................................................................8

2.5.1 - Accessories table........................................................................................................................................9

2.6 - Description of GR54 Cooling Unit...............................................................................................................9

3 - MAINTENANCE..........................................................................................................................................10

3.1 - Periodic inspection, cleaning......................................................................................................................10

3.2 - Welding system fittings and connectors.....................................................................................................10

3.3 - Control panel commands and signals. ........................................................................................................11

3.4 - Operating sequences...................................................................................................................................12

3.4.1 - Welding system operation........................................................................................................................12

3.4.2 - MIG mode................................................................................................................................................13

3.4.3 - TIG operation...........................................................................................................................................14

3.4.4 - MMA mode. ............................................................................................................................................15

3.5 - Troubleshooting..........................................................................................................................................16

3.5.1 - The power source does not start, control panel off..................................................................................16

3.5.2 - Power source powered, control panel on, fan (512) stopped. ..................................................................19

3.5.3 - System powered, display and signals do not show the correct values.....................................................20

3.5.4 - The start button produces no effect..........................................................................................................21

3.5.5 - Some signals from connector for accessories (BB) do not work.............................................................23

3.5.6 - System powered, no gas flows from the torch.........................................................................................24

3.5.7 - System powered, the wire feeder motor does not work...........................................................................25

3.5.8 - In open circuit operation, the output voltage is not regular. ....................................................................26

3.5.9 - In resistive load operation, the output voltage is not regular...................................................................29

3.5.10 - In MIG or TIG mode, arc difficult to strike, the arc shuts off immediately after striking (stuttering start-

up).

..........................................................................................................................................................31

3.5.11 - In synergic mode, the welding quality is not satisfactory, the wire speed is not suited to the output

current.

....................................................................................................................................................31

3.5.12 - In MMA, arc difficult to strike and/or unsatisfactory welding quality. ...................................................31

3.5.13 - In MIG mode, when the start button is released, the wire sticks to the workpiece (ineffective motor

braking).

..................................................................................................................................................32

3.5.14 - Cooling unit GR54 does not work correctly............................................................................................33

3.6 - Kit Driver + igbt, code 5.710.511 replace instructions...............................................................................35

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3.7

- Error codes and alarm signals.....................................................................................................................36

3.7.1 - 2 - EEPROM error...................................................................................................................................36

3.7.2 - 6 - Communication error on CAN-BUS, detected by control board (543)..............................................36

3.7.3 - 9 - Communication error on the CAN-BUS between control panel (324) and control board (543)........36

3.7.4 - 10 - Missing voltage and current at the power source output. .................................................................36

3.7.5 - 13 - Missing communication between control board (543) and pre-charge board (562).........................36

3.7.6 - 14 - Microprocessor supply voltage error on control board (543)...........................................................37

3.7.7 - 16 - Direct current voltage at pre-charge board (562) output below minimum permitted value..............37

3.7.8 - 20 - Absence of interlock signal on TA board (558)................................................................................37

3.7.9 - 25 - Error on the EPLD bus in the control board (543)............................................................................37

3.7.10 - 30 - Incorrect setting of the minimum current threshold on control board (543).....................................37

3.7.11 - 41 - Connector board (225) missing or disconnected. .............................................................................38

3.7.12 - 42 - Error in the signal of the motor (404) encoder. ................................................................................38

3.7.13 - 43 - Communication error with connector board (225)...........................................................................38

3.7.14 - 52 - “trG” on display (O). In MIG and TIG mode, start button pressed upon start-up............................39

3.7.15 - 53 - “trG” on display (O). Start button pressed while resetting from stop due to temperature outside

limits........................................................................................................................................................39

3.7.16 - 54 - Short-circuit between torch and workpiece upon start-up................................................................39

3.7.17 - 56 - Short-circuit at the output lasts too long...........................................................................................39

3.7.18 - 57 - “Mot” on display (O). Excessive wire feeder motor (404) current...................................................40

3.7.19 - 61 - Mains voltage below minimum permitted........................................................................................40

3.7.20 - 73 - “TH0” on display (O). Led (G) lit. Diode group (567) high temperature.........................................40

3.7.21 - 74 - “TH1” on display (O). Led (G) lit. Igbt group (548) high temperature............................................40

3.7.22 - 75 - “H2O” on display (O). Low pressure in the cooling circuit. ............................................................41

3.7.23 - 80 - “OPn” on display (O). Wire feed unit guard open............................................................................41

3.7.24 - 99 - “OFF” on display (O). Incorrect mains voltage (machine shutdown)..............................................41

4 - COMPONENTS LIST...................................................................................................................................42

4.1 - Power source art. 287 : see file ESP287.pdf enclosed at the end of the manual.........................................42

4.2 - Table of components: see file ESP287.pdf enclosed at the end of the manual...........................................42

4.3 - List of spare parts. ......................................................................................................................................42

5 - ELECTRICAL DIAGRAMS ........................................................................................................................43

5.1 - Power source art. 287 : see file SCHE287.pdf enclosed at the end of the manual......................................43

5.2 - Waveforms. ................................................................................................................................................43

5.2.1 - Speed feedback signal from the wire feeder motor encoder (404)(par. 3.5.7).........................................43

5.2.2 - Open-circuit voltage on the transformer (531) secondary circuit (par. 3.5.8)..........................................43

5.2.3 - Command signal for driver boards (548) (par. 3.5.8). .............................................................................43

5.2.4 - Output current feedback signal on resistive load (par. 3.5.9)...................................................................44

5.2.5 - Wire feeder motor (404) voltage during correct braking (par. 3.5.13).....................................................44

5.2.6 - Wire feeder motor (404) voltage during incorrect braking (par. 3.5.13). ................................................44

5.2.7 - “PRECHARGE” signal (par. 3.7.5).........................................................................................................44

5.3 - Filter board (542) code 5.602.196/B...........................................................................................................45

5.4 - Pre-charge board (562) code 5.602.187/A..................................................................................................46

5.5 - Flyback board (539) code 5.602.184/E.......................................................................................................47

5.6 - Interface board (543) code 5.602.186.........................................................................................................48

5.7 - Micro board (543) code 5.602.185/C..........................................................................................................49

5.8 - Igbt-driver board (548) code 5.602.188......................................................................................................50

5.9 - TA board (558) code 5.602.123..................................................................................................................50

5.10 - Thermostat board (551) code 5.602.137.....................................................................................................50

5.11 - Motor control board (232) code 5.602.103/B.............................................................................................51

5.12 - Connector board (225) code 5.602.104/B...................................................................................................53

5.13 - Control panel (324) cod. 5.602.110/C. .......................................................................................................54

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1 - GENERAL INFORMATION

1.1 - Introduction.

The purpose of this manual is to train personnel assigned to carry out maintenance on the

SOUND MIG 3840/T Pulse multi-process welding system, art. 287.

1.2 - General service policy.

It is the responsibility of the customer and/or operator to use the equipment appropriately, in

accordance with the instructions in the Instructions Manual, as well as to maintain the equipment

and related accessories in good working condition, in compliance with the instructions provided

in the Service Manual.

Any internal inspection or repairs must be carried out by qualified personnel who are

responsible for any intervention on the equipment.

It is forbidden to attempt to repair damaged electronic boards or modules; replace them with

original Cebora spare parts.

1.3 - Safety information.

The safety notes provided in this manual are an integral part of those given in the Instruction

Manual. Therefore, before working on the machine, please read the paragraph on safety

instructions in the aforementioned manual.

Always disconnect the power cord from the mains, and wait for the internal capacitors to

discharge before accessing the interior of the equipment.

THE DISCHARGE TIME FOR THE DC-CAPACITORS (561) IS HEAVILY AFFECTED BY

THE OPERATING MODE OF THE FLYBACK BOARD (539). UNDER NORMAL

CONDITIONS THE TIME IS APPROXIMATELY 3 MINUTES, WITH THE FLYBACK

BOARD (539) BROKEN OR DISCONNECTED IT MAY BECOME 6 MINUTES.

Some internal parts, such as terminals and dissipaters, may be connected to mains or

otherwise hazardous potentials. It is therefore forbidden to work with the safety guards removed

from the machine unless strictly necessary. In this case, take special precautions such as wearing

insulating gloves and footwear, and working in a perfectly dry environment with dry clothing.

1.4 - Electromagnetic compatibility.

Please read and observe the instructions provided in the paragraph “Electromagnetic

compatibility” of the Instruction Manual.

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2 - SYSTEM DESCRIPTION

2.1 - Introduction.

The SOUND MIG 3840/T Pulse is a multi-process system suitable for welding different types

of iron, steel and aluminum, with the Pulsed Synergic MIG/MAG, non

Pulsed Synergic

MIG/MAG, Conventional MIG/MAG, TIG (DC) with strike starting of the arc, and MMA

processes. It is made up of the MIG3840/T Pulse electronic power source, the WF4-P Wire

feeder, GR54 Cooling Unit, and a series of accessories to adapt to various types of use (see list in

the Sales Catalogue).

The operator interface consists of Sound DIGIBOX MIG P1 Control Panel (art. 223),

included in the welding system.

2.2 - Technical specifications.

To check the technical specifications, see the plates affixed to the equipment, the Instruction

Manual, and the Sales Catalogue.

2.3 - Description of SOUND MIG 3840/T Pulse system (art. 287).

The welding system is controlled by microprocessor-based circuits, which manage the

operative functions of the welding system and the operator interface.

Referring to the electrical diagrams in par. 5.1, drawing 4.1, and table 4.2, you may identify

the main blocks that make up the system.

Each system component, power source, wire feeder and control panel (not including the

cooling unit) contains a microprocessor circuit, which not only manages the functions of the unit

to which it belongs, but also communicates with the other microprocessors via CAN-BUS serial

line, to actively and continuously assist system operation.

Based on this architecture, the following units may be identified:

− MASTER microprocessor, in the micro board (543) of the power source;

− MOTOR microprocessor, in the motor control board (232) of the wire feeder;

− PANEL microprocessor, in the micro board (324) of the control panel.

Each microprocessor is programmed with a different program, which must obviously be

compatible with those of the other microprocessors. To make it easier to enter and upgrade these

programs, a single-access system is provided (the connector (534) for RS232 serial

communication, (BP) on the front panel of the power source), which allows the three

microprocessors to be programmed in a single programming session. With this step the three

programs are simultaneously entered into the three microprocessors, each automatically in its

place.

The upgraded PANEL, MASTER and MOTOR programs are grouped together in a single

programming file, recognizable from the extension “.ceb”, available from the Cebora Web site

www.cebora.it.

For theirs use is necessary to download and to install in the computer the “Cebora Device

Manager” program, available in Cebora Web site

www.cebora,it. With such program it is

possible to record in the computer the files relative to “firmware Cebora” (programs releasable

from the Cebora site) and to insert them in the machines that have to be programmed or updated.

The version of the inserted programs, is visible during start-up in the control panel, in the

following form (see fig. 3.3):

− display AN1 =“04.04.04”= version 04 of MASTER, PANEL and MOTOR programs.

Working programs related to the synergic curves programmed by Cebora are integrated in the

Master program and their version is visible during start-up in the control panel, in the following

form (see fig. 3.3):

− display AN2 = “SYn 1.0.0” = version 1.0.0 of synergic curves programs created by Cebora.

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Customizations of the welding system modes (parameter set-up) and the welding programs

created by the operator are saved in the EEprom in the micro board (543).

In order to concur the substitution of micro board (543) without to lose these data, the

EEprom is mounted on socket so as to be able to be removed from the board and being inserted

in one new board. In the same way it is also possible to transfer the customizations and the

customer programs from a generator to the other, so that this last one is found to operate with the

same identical parameters of the first generator.

With the Factory set-up function it is possible to cancel EEprom memory and to reshape it as

it was to exited new machine from factory. In order to select the Factory function:

− press push-button (AO) and maintaining pressed it press the push-button (E);

− select with grip knob (N), “FAC” function on display (O);

− select with grip knob (Q) one of the functions that appear on display (P), considering how

much it follows:

noP it means that it comes brought back to the factory set-up the operating parameters set-up

(the operating parameters set-up carried out from the customer comes cancelled) and

remain instead stored customized programs realized from the customer.

ALL it means that the control will come brought back to the factory set-up with cancellation

of all operating parameters set-ups and customer programs realized from the customer.

PrG it means that they come brought back to the factory set-up the job programs

(customized programs realized from the customer will be cancelled) and remain instead

stored the operating parameters set-up.

− in order to activate function to press push-button (AP).

2.4 - Description of MIG3840/T Pulse power source.

The MIG3840/T Pulse is a direct current power source with controlled current, consisting of a

three-phase rectifier bridge, a DC/AC converter (inverter), and an additional rectifier bridge.

The main switch (504) powers the filter board (542), which contains the filter to reduce

conducted interference reflected in the mains, and the chokes (516+522) to level the current

absorbed by the mains.

The pre-charge board (562), inserted downstream from the chokes (516+522), contains the

power rectifier bridge, the DC-capacitor (561) pre-charge circuit of the inverter, and the circuits

to analyze the mains voltage. It communicates with the control board (543) through an optically

isolated signals.

NOTE

The control board (543) is composed from two boards (interface and micro) mounted one on the

other. For greater clarity in the identification of the connectors, in the present manual the two

boards are indicated singularly, and with the same identification number of control board (es.:

control board (543); interface board (543); micro board (543)).

The rectifier bridge converts the alternating mains voltage (400 Vac) to direct current (540

Vdc) suitable for powering the inverter, the DC-capacitors (561) to level this direct current and

the flyback board (539).

The pre-charge circuit of the DC-capacitors (561) is made up of the PTC (PTC1 - PTC8) and

relay RL1 on the pre-charge board (562). The latter is controlled by the micro board (543),

which analyzes the “mains voltage presence” and “DC-capacitors (561) direct current voltage”

signals coming from pre-charge board (562), through interface board (543).

More specifically, check the presence of each phase of the mains voltage and the level of the

direct current voltage at the rectifier bridge output, thus on the DC-capacitors (561).

If the test result is positive, the pre-charge relay RL1 is closed and the power source is

operated; otherwise RL1 remains open and the power source is blocked, while the control panel

(324) displays the cause of the block.

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The 540 Vdc voltage present at the output of the rectifier bridge is applied to the flyback

board (539), which acts as a main power source and generates the service voltages for the

various system circuits (power source, wire feeder, control panel).

The inverter is made up of four igbt (2 for each igbt module (548)) connected in an “H-

bridge” configuration, driven by the driver-igbt boards (548) mounted directly on the terminals

of the igbt modules (548), in turn controlled by the interface board (543).

Mounted on the power terminals of the igbt modules (548) are two “snubber” capacitors,

electrically connected in parallel to the DC-capacitors (561), whose task is to reduce the

overvoltages that develop on the igbt during operation. Their integrity and connection (which

must be as short as possible on the igbt terminals) is essential for the inverter to operate;

tampering with them may seriously damage the igbt (548).

The task of the igbt inverter is to generate the square-wave alternating voltage for the power

transformer (531). The welding current is adjusted by modulating this voltage appropriately.

The TA (558) inserted in the circuit between an igbt module (548) and the transformer (531)

provides the micro board (543) with the feed-back signal of the current at the primary circuit of

the transformer (531), to verify that the inverter is working properly; this signal does not

normally affect the welding current adjustment.

The transformer (531) provides the secondary circuit with voltage and current values suitable

for welding. Its secondary circuit is made up of 4 windings connected to a shared point on the

central socket, to which the choke (530) is connected to level the welding current.

The other ends of the windings are connected to the diode group (567), which rectifies the

alternating current generated by the inverter, making it available at the power source output.

The diode group (567) is made up of 4 diodes connected to a shared cathode, and provides a

positive output voltage compared to the central socket of the transformer (531). Actually, each

diode in the group is in turn made up of two diodes parallel connected together.

The Hall-effect current transducer (529), inserted at the diode group (567) output, sends the

feed-back signal of the secondary current to the micro board (543), to regulate the welding

current.

The output voltage signal of the power source, used by the interface board (543) to adapt the

behavior of the power source based on the conditions of the welding arc in the various possible

types of welding, is taken from the “+”(BR) and “–”(BO) output terminals of the power source.

The micro board (543) contains the main microprocessor of the power source (MASTER).

It supervises management of the other boards, more specialized in their respective functions,

regulates the welding current by generating the PWM signal to be sent to the driver-igbt boards

(548), and communicates with the microprocessors of the control panel (PANEL) and wire

feeder (MOTOR) (see par. 2.3).

The temperature signals from the thermostat board (551), located among the igbt modules

(548), to detect the temperature of the inverter, and from the thermostat (526) mounted on the

dissipater of the diode group (567), to detect its temperature, both lead to the interface board

(543).

The fan (512) to cool the power elements of the power source is controlled by the interface

board (543). Its operation is conditioned by the temperature of the inverter and diode group and

the ambient temperature, and in particular, is activated in the following conditions:

− upon machine start-up, and for 10 seconds after the pre-charge phase;

− with ambient temperature greater than 40°C;

− during welding, in the 3 minutes after welding is finished, and after 3 minutes if the igbt

temperature (548) is greater than 40°C;

− with the machine blocked, signaling an error code;

− when the machine is shut off.

The connector (506) to connect the wire feeder is located on the rear panel of the power

source.

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The “-”(BO) power output of the power source is located on the front panel, while the

“+”(BR) power output is located on the rear panel. They must be connected to the wire feeder

differently according to the type of welding to be carried out (see Instruction Manual).

2.5 - Description of WF4-P Wire Feeder.

The wire feeder is powered by the flyback board (539) of the power source, through the

connector (206), which is connected to connector (506) of the power source. The supply voltage

(55 Vdc) is applied to the motor control board (232), which generates the auxiliary power

supplies necessary to operate the wire feeder, including the control panel (324).

The connector (206) also includes the CAN-BUS communication line, with which the

microprocessors of the control panel (PANEL) and wire feeder (MOTOR) communicate with the

microprocessor of the power source (MASTER) (see par. 2.3).

The motor control board (232) contains the circuit to adjust the wire feeder motor (404) speed

(which in this case is equipped with speed feed-back signal obtained from the encoder built into

the motor (404)), the continuation of the CAN-BUS communication line to dialogue with the

control panel (324), and the circuit to manage and drive the gas solenoid valve (227).

The switch (211) on the door of the wire feed unit provides the motor control board (232)

with the signal to stop the power source in case the door is opened. This alarm condition is

signaled on the control panel (see error code par. 3.7).

The connector board (225), located on the front panel of the wire feeder, receives power from

the motor control board (232), and communicates with the latter by means of a dedicated RS232

serial line. A microprocessor handles the input and output signals of the wire feeder, and thus of

the welding system, on the connector (BB).

These signals include:

− Start power source (from the button on MIG or TIG torches or from an automated system).

− Inputs for external adjustment of the welding current (from UP/DOWN buttons).

− Inputs for external adjustment of the welding current (from external potentiometer).

− Inputs for external adjustment of the wire feeder motor speed (from UP/DOWN buttons).

− Inputs for torch recognition or other connected accessories.

− Motor power supply output for push-pull torches (not yet available).

− Arc on signal output (NO contact free from voltage).

− RS232 serial communication line for dialogue with external system controllers.

Based on the “torch recognition” signal, an analogic signal whose levels, spaced at intervals

of 0,25 Vdc, identify the devices connected to the connector (BB), the microprocessor on the

connector board (225) prepares the welding system so that it can be controlled by means of the

aforementioned signals. One of the possible positions enables the external RS232 serial line, to

control the welding system by means of an external controller. This line is normally kept

disabled.

The “start” and “arc-on” signals are exchanged with the motor control board (232) in clear,

thus directly; all of the other signals are converted into serial information and exchanged via the

internal RS232 serial line, inserted in the connections between J3 on connector board (225) and

J7 on motor control board (232). All these signals are isolated from the circuits of the motor

control board (232), by means of the optocouplers present on the motor control board (232).

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The following accessories may currently be connected to the connector (BB):

2.5.1 - Accessories table.

Art. Description art. Active signals.

Torch recognition signal

(pins 16-15 of BB).

1243

1265

MIG torch

TIG torch

Start (from central adapter

(BA)).

0 Vdc ((BB) free).

193 +

1191

Foot control + adapter

extension

(193 no start).

Start (from torch (BA)) +

current adjustment (193).

187 +

1191 + 1192

Remote control +

adapter extensions.

Start (from torch (BA)) +

current adjustment (187).

0.25 Vdc +/- 0.1.

1245 MIG Torch up/down.

Start +

up/down speed +

up/down current.

1 Vdc +/- 0.1.

The central adapter (BA)(222) for MIG or TIG torches is located on the front panel of the

wire feeder; the adapter includes a power socket, two contacts for the start command, and a

pneumatic fitting for gas.

2.6 - Description of GR54 Cooling Unit.

The GR54 cooling unit is completely dependent from MIG 3840/T Pulse power source from

which receives the supply voltage. Its components are directly connected to the power source

boards.

Due to the autotransformer (540) adapter effect (400/230 Vac) the supply voltage is 230 Vac.

The coolant pump (125), and the fans (131) are managed by control board (543) through relay

RL2 on the pre-charge board (562).

The pressure switch (127), inserted in the hydraulic circuit on the pump (125) delivery,

provides the isolated signal for the fluid pressure to the control board (543) through pre-charge

board (562).

At the power source start up, if the cooling unit is set in continuous or automatic mode (see

Instruction Manual), the pump (125) and fans (131) will operate for 30 seconds, to fill the torch

tubes and check the pressurization of the hydraulic circuit; if no welding command is received

from the operator, they will then stop awaiting a new start command.

If the pressure switch (127) does not detect the appropriate pressure with pump (125) and fans

(131) working on, the control board (543) orders the power source blocked, with relative error

code indication on control panel (see error code, par. 3.7).

In automatic mode the pump (125) and fans (131) enter start running at MIG or TIG welding

beginning, and stop 3 minutes after welding has stopped.

In continuous mode the pump (125) and fans (131) are always kept running. Only the

eventual lack of pressure can stop them together to the generator.

In the MMA process, cooling unit operation is disabled.

The factory set-up of the cooling unit is “OFF”, for which to the first use of the welding

system, or after a procedure of “Factory set-up”, is necessary to modify such set-up (see

Instruction Manual).

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3 - MAINTENANCE

WARNINGS

ANY INTERNAL INSPECTIONS OR REPAIRS MUST BE CARRIED OUT BY QUALIFIED

PERSONNEL.

BEFORE BEGINNING MAINTENANCE OPERATIONS, UNPLUG THE MACHINE FROM

THE MAINS AND WAIT FOR THE INTERNAL CAPACITORS TO DISCHARGE.

THE DISCHARGE TIME FOR THE DC-CAPACITORS (561) IS HEAVILY AFFECTED BY

THE OPERATING MODE OF THE FLYBACK BOARD (539). UNDER NORMAL

CONDITIONS THE TIME IS APPROXIMATELY 3 MINUTES, WITH THE FLYBACK

BOARD (539) BROKEN OR DISCONNECTED IT MAY BECOME 6 MINUTES.

3.1 - Periodic inspection, cleaning.

Periodically open the grids on the power source and check inside the aeration tunnel.

Remove any dirt or dust to ensure smooth air flow, and thus adequate cooling of the internal

parts of the power source.

Remove any dirt or metal dust from the wire feed liner and gear motor unit, also making sure

that they are not worn to the point of needing replacement.

Check the condition of the output terminals, output and power supply cables of the power

source; replace if damaged.

Check the condition of the internal power connections and connectors on the electronic

boards; if you find “loose” connections, tighten or replace the connectors.

3.2 - Welding system fittings and connectors.

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3.3 - Control panel commands and signals.

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3.4 - Operating sequences.

The following sequences reflect proper machine operation. They may be used as guidelines

for troubleshooting. After each repair, they must be carried out without encountering any error or

impediment.

Given the various operating modes available, due to the different possible configurations,

only the main sequence for each welding process is described below.

NOTE

 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.

3.4.1 - Welding system operation.

 System shut off and disconnected from the mains.

 Temporarily connect a rubber hose to the (BQ) fittings of the cooling unit, thus creating a by-

pass for coolant circulation.

 Connect the signal cable provided to the connectors (BD) on the wire feeder and (BS) on the

power source.

 Connect the power source to the mains.

 Close the switch (BU).

♦ System powered; led (H) on control panel flashes rapidly.

♦ After one second, all leds and display light on (lamp test).

♦ After one second, the display (O) reads “Art”, and display (P) reads “287”; the

displays AN1 reads PANEL, MASTER, MOTOR programs version (es.:

“04.04.04”); displays AN2 reads synergic curves programs version (es.: “SYn

1.0.0”). Then the entire control panel returns to the condition it was in before the

last shutdown.

♦ After one second, the switch (BU) is closed, the fan (512) on the power source

runs for 10 seconds, then stops.

Correct?

♦ If the cooling unit mode is set to (see Instruction Manual):

-“automatic”, the pump (125) and fans (131) run for 30 seconds then stop;

-“continuous”, the pump (125) and fans (131) run continuously;

-“OFF”, the pump (125) and fan (131) do not operate.

NO (see 3.5.1, 3.5.2, 3.5.3,

3.5.14).

YES

 Press the button (AI) several times; the “Process” selection is repeated in sequence.

 Press the button (AJ) several times; the “Mode” selection is repeated in sequence.

 Press the button (AK) several times; the “Diameter” selection is repeated in sequence.

 Press the button (AL) several times; the “Material” selection is repeated in sequence.

 Press the button (AH) several times; the “accessory functions” selection is repeated in

sequence.

♦ Each time the button (AI) is pressed, the leds R (1-2-3-4-5) light in sequence.

♦ Each time the button (AJ) is pressed, the leds S, T and U light in sequence.

♦ Each time the button (AK) is pressed, the leds V light in sequence.

♦ Each time the button (AL) is pressed, the leds W and X light in sequence, the

display AN1 shows the existing programs for the type of material selected, and

the display AN2 shows the existing programs for type of gas associated with the

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type of material (existing material and gas types may be selected using the (AM)

and (AX) buttons).

Correct?

♦ Each time the button (AH) is pressed, the leds Y-Z-AA-AB-AC-AD-AE-AF-AG

light in sequence, in observance of the conditions imposed by the selected

“Process” and “Mode”.

NO (see 3.5.3).

YES

3.4.2 - MIG mode.

WARNING

DURING THE FOLLOWING TESTS DO NOT AIM THE TORCH AT PEOPLE OR PARTS

OF THE BODY, BUT ONLY TOWARDS AN OPEN SPACE OR THE WORKPIECE.

 Shut off the power source using the switch (BU).

 Connect the gas supply to the fitting (BE) on the rear panel.

 Connect the power cable provided to the connectors (BF) on the wire feeder and (BR) on the

power source.

 Connect the MIG torch to the central adapter (BA) of the wire feeder (also connect the torch

commands patch connector to the connector (BB) on the wire feeder, if present).

 On a water-cooled torch, connect the torch cooling lines to the fittings (BI).

 On a water-cooled torch, remove the temporary by-pass for coolant circulation from the

fittings (BQ), and connect the hoses provided to the fittings (BT) on the cooling unit and (BH)

on the wire feeder, matching the hose color.

 Connect the negative pole cable (BO) of the power source to the workpiece.

 Restart the power source using the switch (BU).

 After start-up, use the button (AI) to select the conventional MIG “process” (led R-3 on).

 Use the button (AJ) to select two-stage “mode”, led (S) on.

 Use the “diameter” and “material” buttons (AK, and AL) for which a program has already

been inserted, compatible with the torch used (e.g. : leds V-1,2 and W-FE lit).

 Hold down the torch start button for a few seconds.

♦ Gas flows from the torch as long as the button is held down.

♦ The wire feeds from the torch, or the wire feeder motor begins operating, as long

as the button is held down (the wire speed is adjustable using the knob (N) and

displayed on the display (O) with led (C ) on).

Correct?

♦ The unit generates open-circuit output voltage as long as the button is held down,

shown on display (P) with led (J) lit.

NO (see 3.5.3, 3.5.4, 3.5.6,

3.5.7, 3.5.8).

YES

 Move the torch near the workpiece and press the torch trigger.

♦ Begin welding. Turn the knobs (N) and (Q) to obtain the wire speed (shown on

display (O) with led (C ) lit) and output voltage (shown on display (P) with led (J)

lit) suitable for the welding to be performed.

♦ During welding, display (O) shows the welding current (with led (D) lit) and

display (P) indicates the arc voltage (with led (J) lit).

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CEBORA S.p.A. 14

Correct?

NO (see 3.5.9, 3.5.10, 3.5.11).

YES

 Release the torch start button.

Correct?

♦ The arc is immediately shut off and the wire feed stopped, while gas flow stops

after the post-gas stage (the post-gas time is activated only if the power source has

delivered current).

NO (see 3.5.13).

YES

REGULAR OPERATION.

3.4.3 - TIG operation.

WARNING

DURING THE FOLLOWING TESTS DO NOT AIM THE TORCH AT PEOPLE OR PARTS

OF THE BODY, BUT ONLY TOWARDS AN OPEN SPACE OR THE WORKPIECE.

 Shut off the power source using the switch (BU).

 Connect the gas supply to the fitting (BE) on the rear panel.

 Connect the power cable provided to the connectors (BF) on the wire feeder and (BO) on the

power source.

 Connect the TIG torch to the central adapter (BA) of the wire feeder (also connect the patch

connector of the torch to the connector (BB) of the wire feeder, if present).

 On a water-cooled torch, connect the torch cooling lines to the fittings (BI) on the wire feeder.

 On a water-cooled torch, remove the temporary by-pass for coolant circulation from the

fittings (BQ), and connect the hoses provided to the fittings (BT) on the cooling unit and (BH)

on the wire feeder, matching the hose color.

 Connect the cable of the positive pole (BR) of the power source to the workpiece.

 Restart the power source using the switch (BU).

 After start-up, use the button (AI) to select the TIG “process” (led R-4 lit).

 Use the button (AJ) to select two-stage “mode”, led (S) on (it is not possible to select the

“diameter” and “material” in TIG mode).

 Hold down the torch start button for a few seconds.

♦ Gas flows from the torch as long as the button is held down.

♦ Open-circuit output voltage is generated for as long as the button is held down.

Correct?

♦ Display (O) shows the programmed welding current (led (D) lit), adjustable with

knob (N), and display (P) indicates the open-circuit output voltage (led (J) lit).

NO (see 3.5.3, 3.5.4, 3.5.6,

3.5.8).

YES

 Use the knob (N) to set the current based on the type of welding to be carried out.

 Move the torch near the workpiece and press the torch trigger.

♦ Begin welding. Turn the knob (N) to optimize the current level.

♦ Display (O) shows the welding current (led (D) lit) and display (P) shows the arc

voltage (led (J) lit).

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CEBORA S.p.A. 15

Correct?

NO (see 3.5.9, 3.5.10).

YES

 Release the torch start button.

♦ The arc shuts off immediately if a long ramp time is not set (slope-down).

Correct?

♦ The gas flow ends after the post-gas period (the post-gas time is activated only if

the power source has delivered current).

NO (see 3.5.6).

YES

REGULAR OPERATION.

3.4.4 - MMA mode.

 Shut off the power source using the switch (BU).

 Leave the signal cable provided connected to the connectors (BD) on the wire feeder and (BS)

on the power source.

 Connect the cable to the electrode holder and the earth cable to the negative (BO) and positive

(BR) connectors, observing the polarity of the electrodes to be used.

 Restart the power source using the switch (BU).

 After start-up, use the button (AI) to select the “process” MMA (led R5 lit).

♦ Voltage begins to be generated at the power source output, and the fan (512) starts

running.

Correct?

♦ Display (O) shows the programmed welding current (led (D) lit), adjustable via

knob (N), and display (P) shows the open-circuit output voltage (led (J) lit).

NO (see 3.5.2, 3.5.3, 3.5.8).

YES

 Use the knob (N) to set the current based on the electrode you intend to use.

 Move the electrode clip near the workpiece.

♦ Begin welding. Turn the knob (N) to optimize the current level.

Correct?

♦ Display (O) shows the welding current (led (D) lit) and display (P) shows the arc

voltage (led (J) lit).

NO (see 3.5.9, 3.5.12).

YES

REGULAR OPERATION.

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3.5 - Troubleshooting.

WARNINGS

ANY INTERNAL INSPECTIONS OR REPAIRS MUST BE CARRIED OUT BY QUALIFIED

PERSONNEL.

BEFORE REMOVING THE PROTECTIVE GUARDS AND ACCESSING INTERNAL

PARTS, DISCONNECT THE POWER SOURCE FROM THE MAINS AND WAIT FOR THE

INTERNAL CAPACITORS TO DISCHARGE.

THE DISCHARGE TIME FOR THE DC-CAPACITORS (561) IS HEAVILY AFFECTED BY

THE OPERATING MODE OF THE FLYBACK BOARD (539). UNDER NORMAL

CONDITIONS THE TIME IS APPROXIMATELY 3 MINUTES, WITH THE FLYBACK

BOARD (539) BROKEN OR DISCONNECTED IT MAY BECOME 6 MINUTES.

NOTE

Items in boldface describe problems that may occur on the machine (symptoms).

 Operations preceded by this symbol refer to situations the operator must determine (causes).

♦ Operations preceded by this symbol refer to actions the operator must perform in order to

solve the problems (solutions).

3.5.1 - The power source does not start, control panel off.

MAINS SUITABILITY TEST.

Correct?

 No voltage for mains protection.

YES

♦ Eliminate any short-circuits on the connections between power cable, switch

(504), filter board (542), chokes (516+522) and pre-charge board (562).

♦ Make sure that the terminals of the chokes (516+522) on the terminal board (265)

are not short-circuited towards the earth of the power source.

♦ Replace chokes (516+522) and/or filter (542) and/or pre-charge (562) boards.

♦ Mains not suitable to power the power source (ex.: insufficient installed power).

MAINS CONNECTION TEST.

Correct?

 Terminals L1, L2 and L3, on pre-charge board (562) = 3 x 400 Vac, with switch (504) closed.

YES

♦ Check power cable and plug and replace if necessary.

♦ Check switch (504), and replace if defective.

♦ Check connections between switch (504), filter board (542), terminal board (265)

of the chokes (516+522) and pre-charge board (562).

♦ Check the mains voltage conditions.

♦ Replace the chokes (516+522) and/or filter board (542).

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POWER SUPPLY TEST.

Correct?

 Flyback board (539), connector J5, terminals 1 (+) and 4 (-) = +540 Vdc.

YES

♦ Check the wiring between J5 flyback board (539) and J6 pre-charge board (562).

♦ After waiting for the DC-capacitors (561) to completely discharge

temporarily disconnect connector J5 on flyback board (539). Power up the power

source again and check the voltage on the terminals Vdc+1 (+) and Vdc-1 (-) of

pre-charge board (562) = +540 Vdc. If correct, replace the flyback board (539).

♦ After waiting for the DC-capacitors (561) to completely discharge

temporarily disconnect the wires from the + and - terminals of the DC-capacitors

(561) and check the resistance between the + and - terminals of the DC-capacitors

(561). Correct value = >Mohm in one direction, and junction of two diodes with

the probes reversed (NOTE: while measuring, the instrument display reaches the

final value slowly, due to the DC-capacitors (561)). If correct replace the pre-

charge board (562). If incorrect, identify which of the following components is

short-circuited or leaking: DC-capacitors (561), igbt modules (548), discharge

resistors (552), snubber capacitors mounted on the terminals 2 and 3 of the igbt

(548).

FLYBACK BOARD (539) POWER SUPPLY TEST.

Correct?

 Flyback board (539), connector J5, terminals 3 (+) and 4 (-) = +18 Vdc.

YES

♦ Check the wiring between J5 flyback board (539) and J6 pre-charge board (562).

♦ After waiting for the DC-capacitors (561) to completely discharge,

temporarily disconnect connector J5 on flyback board (539) and check the

resistance between terminals 3 (+) and 4 (-) of J5 flyback board (539). Correct

value = >Mohm in one direction, and junction of a diode with the probes reversed.

If correct replace the pre-charge board (562). If incorrect replace the flyback

board (539).

♦ Replace the pre-charge (562) and/or flyback (539) boards.

MOTOR CONTROL BOARD (232) POWER SUPPLY TEST.

Correct?

 Motor control board (232), connector J18, terminals 1 (+) - 6 (-) = +55 Vdc.

YES

♦ Check the wiring between J18 motor control board (232), connector (206) on wire

feeder, connector (506) on power source and J3 flyback board (539).

♦ With the power source off, temporarily disconnect the connector J18 on motor

control board (232) and check the resistance between terminals 1 - 6 of J18 on

motor control board (232). If short-circuited, replace the motor control (232) and

flyback (539) boards.

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CEBORA S.p.A. 18

♦ With the power source off, temporarily disconnect the connectors J6, J8 and J10

on flyback board (539) and make sure that on J18, terminals 1 (+) - 6 (-) on motor

control board (232) voltage = +55 Vdc. If correct, identify which of the three

disconnected connectors is causing the incorrect value of the voltage on J18 (55

Vdc), and eliminate the cause of the probable overload or short-circuit, replacing

the control (543) and/or pre-charge (562) boards if necessary.

♦ Replace the motor control (232) and/or flyback (539) boards.

CONTROL PANEL (324) POWER SUPPLY TEST.

Correct?

 Control panel (324), connector J1, terminals 1 (+) – 2 (-) = +8 Vdc.

YES

♦ Check the wiring between J1 control panel (324) and J12 motor control board

(232).

♦ With the power source off, temporarily disconnect connector J1 on control panel

(324) and check the resistance between terminals 1 and 2 of J1 on control panel

(324). If short-circuited, replace control panel (324) and/or motor control board

(232).

♦ With the power source off, temporarily disconnect connector J15 on motor control

board (232), and make sure the voltage on terminals 1 (+) – 2 (-) of J1 on control

panel (324) = +8 Vdc. If correct, check the wiring between J1 connector board

(225) and J15 motor control board (232) and replace the connector board (225) if

necessary.

♦ Replace control panel (324) and/or motor control board (232).

♦ Make sure the micro board on the panel board in the control panel (324) is properly mounted,

especially that there are no bent pins or short-circuits between the pins of the connector J2 on

the micro board of the control panel (324).

♦ Check the wiring of the CAN-BUS communication line, carrying out the CAN-BUS

COMMUNICATION TEST in par. 3.5.3.

♦ Replace control panel (324) and/or motor control board (232).

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3.5.2 - Power source powered, control panel on, fan (512) stopped.

NOTE

The fan (512) on the power source is controlled by the interface board (543), and its operation

depends on the power source conditions, as shown in the par. 2.4, Description of MIG3840/T

Pulse power source. For this reason, the following tests may be verified only during the first 15

seconds of power supply or during a blocked situation. For this purpose it is possible to

simulate the error 41, by disconnecting the connector J3 on connector board (225).

FAN (512) TEST.

 With the power source off, temporarily disconnect connector J3 on connector board (225) to

cause continuous operation of the fan (512).

Correct?

 Control board (543), connector J4, terminals 1 (+) – 2 (-) = +24 Vdc.

YES

♦ Check the wiring between fan (512) and connector J4 on interface board (543).

♦ Make sure there are no mechanical impediments blocking the fan.

♦ Replace the fan (512).

CONTROL BOARD (543) POWER SUPPLY TEST.

 Micro board (543), connector J3, terminals 2 (+) – 1 (-) = +8 Vdc.

 Micro board (543), connector J3, terminals 4 (+) – 3 (-) = +15 Vdc.

 Micro board (543), connector J12, terminals 1 (+) – 6 (-) = +5 Vdc.

Correct?

 Micro board (543), connector J1, terminals 1 (+) – 5 (-) = -15 Vdc.

YES

♦ Check the wiring between J3 micro board (543), and J10 flyback board (539).

♦ With the power source off, temporarily disconnect connector J3 on control board

(543) and check the resistance between terminals 2 and 1 and between terminals 4

and 3 of J3 on micro board (543). If short-circuited, replace control board (543)

and flyback board (539).

♦ Make sure the micro board (543) and the interface board (543) is properly

mounted, especially that there are no bent pins or short-circuits between the pins

of the connectors J10 and J11 of the interface board with J10 and J11 of micro

board, on the control board (543).

♦ Replace the flyback (539) and/or control board (543).

♦ Replace the control board (543) and/or fan (512).

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CEBORA S.p.A. 20

3.5.3 - System powered, display and signals do not show the correct values.

CAN-BUS COMMUNICATION TEST.

Correct?

 Upon start-up, on control panel (324), led (H) flashes rapidly for approximately one second,

after which the system operating status is displayed (correct operation or error condition).

YES

♦ Check the wiring between J5 control panel (324) and J3 motor control board

(232), between J11 motor control board (232), connector (206) of the wire feeder,

connector (506) on the power source and J9 interface board (543).

♦ Check the supply voltages of the control panel (324), motor control board (232)

and control board (543), performing if necessary the MOTOR CONTROL

BOARD (232) POWER SUPPLY TEST and CONTROL PANEL (324) POWER

SUPPLY TEST in par. 3.5.1, and the CONTROL BOARD (543) POWER

SUPPLY TEST in par. 3.5.2.

♦ Make sure that the correct programs have been entered in the control panel (324),

in the motor control (232) and control (543) boards, performing if necessary the

programming procedure available on the Cebora Web site (see par. 2.3,

Description of SOUND MIG 3840/T Pulse (art. 287)).

♦ Replace control panel (324) and/or motor control board (232) and/or control board

(543).

ERROR CODE TEST.

Correct?

 Upon start-up, after start-up, an error condition displayed, thus display (O) reads “Err” and

display (P) shows a number identifying the type of error.

YES

♦ See Error codes and alarm signals, par. 3.7.

PROGRAMS INSTALLED TEST.

 At start-up, led (H) on control panel flashes rapidly for approximately one second, then

display (O) reads “Art”, while display (P) shows “287”; the displays AN1 reads PANEL,

MASTER, MOTOR programs version (es.: “04.04.04”); displays AN2 reads synergic curves

programs version (es.: “SYn 1.0.0”).

Correct?

 The versions of the programs entered are compatible with one another.

YES

♦ Check the compatibility of the programs on the three boards, comparing the

installed version indexes with the specifications cited on the Cebora Web site.

These programs must be in compatible versions, thus if any one of these 3 boards

is replaced, you must make sure of this compatibility; better yet, reprogram the

entire system with the latest available versions.

3.302.191 15/02/05

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Cebora SOUND MIG 3840/T Pulse User manual

Brand: Cebora

Model: SOUND MIG 3840/T Pulse

Category: Welding System

Type: User manual

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Cebora SOUND MIG 3840/T Pulse User manual

Cebora SOUND MIG 3840/T Pulse User manual

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