Bravo Synergic MIG 4540/T Manual de usuario

CEBORA S.p.A. 1

BRAVO SYNERGIC

POWER SOURCE art. 597

SERVICE MANUAL

3.302.200 29/04/05

CEBORA S.p.A. 2

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 source. .........................................................................................................4

3 - MAINTENANCE.............................................................................................................................6

3.1 - Periodic inspection, cleaning. ........................................................................................................6

3.2 - Operating sequence........................................................................................................................6

3.2.1 - Power source commands and connections. .................................................................................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 (58) does not work.............................................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 - System powered, no gas flows from the torch...........................................................................12

3.3.6 - Power source powered, the wire feeder motor does not work...................................................13

3.3.7 - In open circuit operation, the output voltage is not regular.......................................................14

3.3.8 - In resistive load operation, the output voltage is not regular.....................................................16

3.3.9 - In synergic mode, he welding quality is not satisfactory, the wire speed is not suited to the

output current. ...........................................................................................................................17

3.3.10- Arc difficult to strike, the arc goes out immediately after lighting............................................17

3.3.11- When start button is released, the wire sticks to the workpiece (ineffective motor braking)....18

3.4 - Alarm signals. ..............................................................................................................................19

3.4.1 - Led (F) lit = transformer (5) temperature too high, or wire coil cover open, or cooling liquid

flow low, or fuse on 16 Vac power supply tripped. ..................................................................19

4 - COMPONENTS LIST....................................................................................................................20

4.1 - Power source art. 597 : see file ESP597.pdf enclosed at the end of the manual..........................20

4.2 - Components table : see file ESP597.pdf enclosed at the end of the manual................................20

4.3 - Spare parts list..............................................................................................................................20

4.4 - Fuse table. ....................................................................................................................................20

5 - ELECTRICAL DIAGRAMS..........................................................................................................21

5.1 - Power source art. 597 : see file SCHE597.pdf enclosed at the end of manual. ...........................21

5.2 - Waveforms...................................................................................................................................21

5.2.1 - Wire feeder motor (403) voltage during correct braking (par. 3.3.11)......................................21

5.2.2 - Wire feeder motor (403) voltage during incorrect braking (par. 3.3.11)...................................21

5.3 - Timing board (62) code 5.602.211...............................................................................................22

5.4 - Control board (4) code 5.602.205................................................................................................23

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1- GENERAL INFORMATION

1.1 - Introduction.

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

power source art. 597 for MIG Synergic welding system.

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 MIG 4540/T is a system for welding mild and stainless steel and

aluminium, using a Synergic MIG process.

It is made up of an electrical power source (art. 597) with on board wire feeder unit and a

range of accessories to adapt to various types of use (see list in the Sales Catalogue).

The power source is controlled by a microprocessor circuit, which manages the operative

functions of the welding system and operator interface.

2.2 - Technical specifications.

To verify the technical specifications, see the machine plate, Instruction Manual, and Sales

Catalogue.

2.3 - Description of power source.

Art. 597 is a direct current power source, essentially electromechanical, consisting of a three-

phase transformer and a rectifier bridge.

Referring to the electrical diagram in par. 5, the fig. in par. 4 and fig. 3.2.1 you can see the

main blocks that make up the power source.

The switch (Q)(43) powers the service transformer (55), that supplies power to the fan (58),

timing board (62), socket (15) for the cooling unit, and control board (4).

The switches (R)(44) and (S)(45) act as selectors for the output voltage of the power source.

Depending on their position, the supply voltage is applied to the various intermediate sockets of

the primary winding of the transformer (5), 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.

The mains voltage is applied to the power transformer (5) only after the contactor (51) closes,

which is controlled by the control board (4), based on the welding conditions set by the operator.

The service transformer (55) receives the supply voltage through the voltage change terminal

board (59), which serves to adapt power source operation to the mains voltage (230 or 400 Vac).

As a result of this adaptation, and operation as an autotransformer of the primary winding of

the service transformer (55), fan (58) and cooling unit, if connected to socket (15), they are

always powered at 230 Vac even with the mains at 400 Vac; the secondary voltages of the

service transformer (55) also maintain the same value.

The 28 Vac secondary voltage powers the control board (4).

The 16 Vac secondary voltage powers the timing board (62), which manages the pump and

fan on the cooling unit through the socket (15), the fan (58) of the power source, and the circuit

corresponding to the safety devices of the welding system (microswitch (46) on the guard of the

wire feed unit, thermostat on the windings of power transformer (5) and flow meter on the

cooling unit). If the cooling unit is not present the plug (16), provided, must be connected to the

connector (17).

When one of the these devices is tripped, it in turn trips the alarm of the control board (4) that

stops the power source by opening the contactor (51); the alarm is indicated on the control panel

(led F lit).

The control board (4) 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 (4) receives the positioning information from the switches (44) and (45),

corresponding to the output power source voltage selection, and consequently adjusts the motor

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CEBORA S.p.A. 5

speed based on the most suitable synergic curve selected from among those saved in the memory

of the board.

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 (H)) the wire speed is adjusted manually, thus

regardless of the position of switches (44) and (45), 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 (4),

which is powered with the same supply voltage as the control board (4), supplied by the service

transformer (55).

When the torch button is pressed, the control board (4) sends the closing command to the

contactor (51), which coincides with the start signal for the timing board (62), which controls

operation of the fan (58) and the cooling unit. After welding, thus when the start button on the

torch is released, the contactor (51) is disabled immediately, while the pump and fans on the

cooling unit and fan (58) on the power source remain running for approximately ten minutes

longer, after which time they also stop and await a new start command.

The secondary transformer (5) circuit is connected to the rectifier bridge (56), which keeps the

welding current constant. The choke (53) inserted downstream of the rectifier bridge (56), serves

to level the welding current, and its intermediate sockets allow you to maximize welding quality

as the material to be welded changes.

The shunt (23) inserted between the positive pole of the rectifier bridge (56) and the central

adapter (39) of the torch, provides the control board (4) with the signal to show the welding

current on display (H) during welding.

The power source power outputs are gathered together on the front panel. A central adapter

(G)(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 negative output terminal (V) of the power source is located on the front panel, and is

composed by three terminals of the choke (53) to select the choke portion to use.

The following are present on the rear panel of the power source:

−the socket (15) for the cooling unit power supply;

−the connector (17) to connect the flow meter on the cooling unit;

The gas solenoid valve (12) is activated by the torch start button, and its opening time also

depends on the post-gas time set.

Similarly the line contactor (51) 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 (46) on the wire feed unit guard, and thermostat located on the windings of the power

transformer (5)).

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.

DISCONNECT THE POWER SOURCE FROM THE MAINS BEFORE PERFORMING

MAINTENANCE.

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 shows the correct operation 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 connections.

NOTES

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.

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3.2.2 - Power source operation.

System shut off and disconnected from the mains.

Connect the gas supply to the fitting provided on the rear panel.

Insert the plug (16), provided, into connector (17) of the power source.

Connect the torch to the central adapter (G) of the power source.

Connect the negative pole (V) cable of the power source to the workpiece.

Connect the power source to the mains.

Set the switch (Q) on the power source to position 1.

♦System powered, on control panel all leds and displays are lit (lamp-test).

♦After one second, display (H) shows the version of the work programs saved

(ex:F01).

♦After two seconds, display (H) 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.

Correct?

♦After two seconds, display (H) shows the wire speed programmed for the manual

program, or, for synergic programs, the programmed current based on the position

of switches (44) and (45) and knob (P).

NO (see 3.3.1, 3.3.3).

YES

Press the key (E) several times to select the “Mode” repeatedly in sequence.

Correct?

♦Each time the key (E) is pressed, the leds (B), (C), and (D) light in sequence, and

display (H) 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.

Switch the switches (44) and (45) for an output voltage suited to the welding to be done.

Use the key (E) to select the “program” mode, led (B) lit.

Use the button (O) or (N) to select the manual working program (P00 on display (H)).

Turn knob (P) for a wire speed suitable for the set welding current.

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

♦Gas begins to flow from the torch as long as the button is held down plus the set

post-gas time.

♦Wire begins flowing out of the torch, or in any case the wire feeder motor begins

operating, and open-circuit output voltage is generated for as long as the button is

held down.

Correct?

♦Fan (58) running for as long as the button is held down plus the time set on timing

board (62) (approximately 10 minutes).

NO (see 3.3.2, 3.3.4, 3.3.5.

3.3.6, 3.3.7).

YES

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.

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CEBORA S.p.A. 8

Correct?

♦Display (H) shows the welding current.

NO (see 3.3.8, 3.3.10).

YES

Release the start button, holding the torch in welding position until gas stops flowing out.

Correct?

♦The arc shuts down immediately without the wire sticking to the workpiece, the

wire stops exiting the torch, and gas flow is interrupted after the post-gas time set.

NO (see 3.3.11).

YES

Use the keys (E), (O) or (N) to select a saved synergic program (see Instruction Manual and

table provided in the compartment of the wire feed unit).

♦Display (H) indicates the selected program number (ex.: P01).

♦After 1 second display (H) shows the programmed value of the measurement

indicated by lighting one of the leds (M), (L) or (I). This value may be selected

using the keys (O) and (N).

♦With current selected (led M lit) the value on display (H) may be changed using

knob (P) and switches (44) and (45).

Correct?

♦With voltage (led I lit) or thickness (led L lit) selected, the value on display (H)

may be changed using the switches (44) and (45).

NO (see 3.3.3, 3.3.7).

YES

Use the keys (E), (O) or (N) to select a synergic program suitable for the type of welding to be

done (see Instruction Manual and table provided in the compartment of the wire feed unit).

Turn the knob (P) to the central position (SYNERGIC).

Move the torch near the workpiece and press the start button.

Correct?

♦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 (H) and thus the quality of the welding in

progress.

NO (see 3.3.9, 3.3.10).

YES

Release the start button, holding the torch in welding position until gas stops flowing out.

Correct?

♦The arc shuts down immediately without the wire sticking to the workpiece, the

wire stops exiting the torch, and gas flow is interrupted after the post-gas time set.

NO (see 3.3.11).

YES

REGULAR OPERATION.

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CEBORA S.p.A. 9

3.3 - Troubleshooting. WARNINGS

ANY INTERNAL INSPECTIONS OR REPAIRS MUST BE CARRIED OUT BY QUALIFIED

PERSONNEL.

DISCONNECT THE POWER SOURCE FROM THE MAINS BEFORE PERFORMING

MAINTENANCE.

NOTES

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).

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

MAINS SUITABILITY TEST.

Correct?

Missing voltage at the power source input due to tripped mains protection.

YES

♦Eliminate any short-circuits or isolation leaks between the various conductors and

towards earth in connections between the power cable, terminal board (50),

contactor (51), switches (44) (45), service transformer (55), fan (58) and socket

(15).

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

MAINS CONNECTION TEST.

Correct?

Contactor (51), power terminals = approximately 3 x 400 Vac or 3 x 230 Vac, depending on

mains voltage.

YES

♦Check power cable and plug and connections on terminal board (50), and replace

if necessary.

♦Check the mains voltage conditions.

CONTROL BOARD (4) POWER SUPPLY TEST.

Correct?

Control board (4), connector J7, terminals 1 - 2 = approximately 28 Vac.

YES

♦Check the wiring between service transformer (55), and control board (4).

♦Check the wiring between contactor (51), switch (43), voltage change terminal

board (59), service transformer (55), fan (58) and socket (15).

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CEBORA S.p.A. 10

♦Make sure the setting of the voltage change terminal board (59) matches the

mains voltage.

♦Make sure the fuse on the primary circuit of the service transformer (55) is intact.

If interrupted, replace and check the resistance of the primary winding.

Correct values: terminals 0 – 230V = approximately 7 ohm;

terminals 0 – 440V = approximately 12 ohm.

If incorrect replace the service transformer (55).

♦Make sure the fuse on the 28Vac secondary circuit of the service transformer (55)

is intact. If interrupted, replace it and check the resistance on terminals 1 and 2 of

J7 on control board (4). Correct value = >Mohm in both measurement directions.

If incorrect, replace control board (4).

♦Replace service transformer (55).

♦Replace control board (4).

3.3.2 - Power source powered, control panel on, fan (58) does not work.

NOTE

The fan (58) may be activated using the start command of the torch button, and continues

running after it is released for the time set on the timing board (62)(approximately 10 minutes).

FAN (58) TEST.

Correct?

Terminals of fan (58) = approximately 230 Vac, with mains at either 230 Vac or 400 Vac with

start button pressed.

YES

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

♦Check, with power source off, the resistance on fan (58) terminals. Correct value

= approximately 50 ohm. If >Mohm (winding broken), replace the fan (58).

♦Replace the fan (58).

♦Check the wiring between fan (58), terminal board on service transformer (55) and timing

board (62)(contact of RL1).

♦Make sure the fuse on the power supply for fan (58) is intact, located on the terminal board of

the service transformer (55). If interrupted, before replacing it check the resistance between

the terminals of the fan (58). Correct values = approximately 50 ohm.

If incorrect, replace fan (58).

♦Make sure the contactor (51) remains closed for as long as the start button is held down. If

incorrect carry out the START COMMAND TEST in par. 3.3.4. If correct check on terminals

7 and 8 of J1 timing board (62) voltage = approximately 28 Vac when contactor (51) is

closed. If incorrect check the wiring between timing board (62) and contactor (51).

TIMING BOARD (62) POWER SUPPLY TEST.

Timing board (62), connector J1, terminals 1 and 2 = approximately 16 Vac.

3.302.200 29/04/05

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