Cebora SOUND MIG 3840/T Pulse Page 1 Service Manual Download

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CEBORA S.p.A.

SOUND MIG 3840/T Pulse

POWER

COOLING UNIT +

WIRE FEEDER

art. 287

SERVICE MANUAL

3.302.191

15/02/05

Summary of Contents for SOUND MIG 3840/T Pulse

Page 1: ...CEBORA S p A 1 SOUND MIG 3840 T Pulse POWER SOURCE COOLING UNIT WIRE FEEDER art 287 SERVICE MANUAL 3 302 191 15 02 05...

Page 2: ...el 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...

Page 3: ...ed 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...

Page 4: ...se 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...

Page 5: ...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 progr...

Page 6: ...lse 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 f...

Page 7: ...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...

Page 8: ...l 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 co...

Page 9: ...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...

Page 10: ...pection 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...

Page 11: ...CEBORA S p A 11 3 3 Control panel commands and signals 3 302 191 15 02 05...

Page 12: ...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 t...

Page 13: ...ng 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 p...

Page 14: ...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 posit...

Page 15: ...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 g...

Page 16: ...oblems solutions 3 5 1 The power source does not start control panel off MAINS SUITABILITY TEST Correct No voltage for mains protection NO YES Eliminate any short circuits on the connections between p...

Page 17: ...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...

Page 18: ...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 of...

Page 19: ...re 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...

Page 20: ...ng 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 TES...

Page 21: ...ation OPn OFF NO YES See Error codes and alarm signals par 3 7 NOTE The start command may be given to the power source either through the central adapter for the torch BA or via the connector BB on th...

Page 22: ...J5 is properly welded especially pins 1 and 9 on connector board 225 and check the wiring between the patch connector of the torch and the torch start button Replace the entire torch if necessary Rep...

Page 23: ...nector J5 BB signals as shown in the table with power source powered and accessory connector inserted in BB Signal J5 terminals Function active Function not active Start 1 9 0 Vdc 12 Vdc Current down...

Page 24: ...and flow rate in the intake line meet the specifications of the SOUND MIG 3840 T Pulse Make sure the gas lines in the wire feeder are not clogged Replace the solenoid valve 227 Check the wiring betwee...

Page 25: ...Motor control board 232 connector J17 terminals 2 and 4 fig 5 2 1 with button AR on control panel pressed fixed speed wire test speed feed back signal from motor encoder In case of different speed se...

Page 26: ...waveform in fig 5 2 2 will be visible only for 1 second in how much reading power source output voltage 0 terminal BR is disconnected the control board 543 commands the block for error 56 in MMA or e...

Page 27: ...the resistance on terminals 6 and 5 of J1 on micro board 543 Correct value 19 ohm If incorrect replace control board 543 Check the conditions of the transformer 531 If you notice burn signs or deform...

Page 28: ...one diode If incorrect replace the defective igbt module 548 along with the driver board 548 to which it is connected WARNING In case of a fault on an igbt module 548 or driver board 548 it is advisa...

Page 29: ...ith start button pressed in MMA with the only MMA process selected YES NO Carry out the test in par 3 5 8 NOTE For the following tests use a resistive load capable of withstanding the maximum power so...

Page 30: ...0 mVdc with power source powered approximately 3 3 Vdc or fig 5 2 4 output current feedback signal with power source on resistive load in the table conditions NO YES Correct operation Make sure that t...

Page 31: ...t of the welding drop This function may be selected using the key AH and adjusted using the keys AX and AM on control panel 324 see Instruction Manual In all of these situations when there are problem...

Page 32: ...tip wire type and diameter type of gas etc with the type of welding being carried out Check the wear status of the torch and its components replacing if necessary Replace the control board 543 and or...

Page 33: ...onnector J4 on pre charge board 562 and make sure resistance on autotransformer 540 terminals Correct value on 0 400 terminals 15 ohm approximately on 0 230 terminals 8 ohm approximately If not correc...

Page 34: ...dc If correct check the integrity of pressure switch 127 If incorrect make sure on J5 interface board 543 terminals 5 and 2 voltage 24 Vdc If correct replace control board 543 If not correct make sure...

Page 35: ...to the heatsink Take the Therm strate sheet code 3085413 being careful not to crease it gently remove the two protective films to uncover the two layers of thermally conductive grease with your hands...

Page 36: ...ection lines interrupted Perform the open circuit operation test in par 3 5 8 and the operation on resistive load test in par 3 5 9 3 7 5 13 Missing communication between control board 543 and pre cha...

Page 37: ...ke sure that there is a short circuit between terminals 3 and 4 of J1 on TA board 558 With power source off temporarily disconnect connector J1 from micro board 543 Power up the power source again and...

Page 38: ...encoder is not suited to the reference signal generated by the motor control board 232 and thus the motor 404 speed is out of control Perform the wire feeder motor operation test in par 3 5 7 3 7 13 4...

Page 39: ...y 3 7 16 54 Short circuit between torch and workpiece upon start up Upon power source start up this test checks the operating conditions by performing a brief test to generate the open circuit output...

Page 40: ...he wire feeder motor operation tests in par 3 5 7 3 7 19 61 Mains voltage below minimum permitted The control board 543 checks for the MAINS mains voltage presence signal status coming from pre charge...

Page 41: ...feed unit guard open This alarm indicates that the safety cover of the wire feed unit is open Check the wiring between J1 motor control board 232 and switch 211 on the guard of the wire feed unit Che...

Page 42: ...1 electric pump 1 131 3165075 fan 1 232 5605833 motor control circuit 1 404 5750740 gearmotor 1 512 3165091 fan 1 539 5602184 flyback board 1 542 5602196 filter board 1 543 5605134 control circuit 1 R...

Page 43: ...manual 5 2 Waveforms 5 2 1 Speed feedback signal from the wire feeder motor encoder 404 par 3 5 7 in MIG wire test mode thus with button AR pressed fixed speed 5 2 2 Open circuit voltage on the trans...

Page 44: ...feedback signal on resistive load par 3 5 9 5 2 5 Wire feeder motor 404 voltage during correct braking par 3 5 13 5 2 6 Wire feeder motor 404 voltage during incorrect braking par 3 5 13 5 2 7 PRECHARG...

Page 45: ...N L1 phase 1 mains input IN L2 phase 2 mains input IN L3 phase 3 mains input OUT L1 phase 1 mains output OUT L2 phase 2 mains output OUT L3 phase 3 mains output J L1 phase 1 mains output for service s...

Page 46: ...power supply J2 3 2 coolant liquid pressure signal output J2 5 6 cooling unit enable signal input J3 1 2 25 Vdc input for pre charge relay command J3 3 GND J3 4 5 mains voltage presence signal output...

Page 47: ...d 232 power supply J3 3 NU J4 NU J5 1 4 540 Vdc input for flyback board 539 power supply J5 3 flyback board 539 control power supply input J6 1 2 25 Vdc output for pre charge board 562 power supply J7...

Page 48: ...fan 512 J5 1 4 NU J5 3 2 cooling liquid pressure signal input J5 5 6 cooling unit enable signal output J6 1 2 25 Vac input for thermostat board 551 circuits power supply J7 1 2 25 Vdc output for pre c...

Page 49: ...nt transducer 529 power supply J1 5 GND J1 6 transformer 531 primary circuit current signal input J1 7 interlock signal input J1 8 5 Vdc output for interlock signal J2 NU J3 2 1 8 Vdc input for micro...

Page 50: ...L2 5 9 TA board 558 code 5 602 123 5 9 1 Topographical drawing 5 9 2 Connector table Connector Terminals Function J1 2 1 transformer 531 primary circuit current signal output J1 3 4 interlock signal...

Page 51: ...CEBORA S p A 51 5 11 Motor control board 232 code 5 602 103 B 5 11 1 Topographical drawing 3 302 191 15 02 05...

Page 52: ...unication line J8 NU J9 NU J10 NU J11 1 2 8 Vdc output for CAN BUS 0 on interface board 543 power supply J11 3 4 CAN BUS 0 communication line J12 1 2 8 Vdc output for control panel 324 power supply J1...

Page 53: ...1 9 start command input from remote control connector BB J5 2 DOWN VOLT signal input J5 3 DOWN MOTOR signal input J5 4 5 ARC ON signal output relay contact voltage free J5 6 UP MOTOR signal input J5 7...

Page 54: ...tion J1 1 2 8 Vdc input for control panel 324 power supply J2 signals bus between panel board and micro board inside control panel 324 J3 GND J4 NU RS232 serial communication line J5 1 2 CAN BUS commu...

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