mg022-2 servisní manuál service manual alfin 160
Contents
1. No modification of any type may be made to the welding machine For safety while maintaining the machine please shut off the supply power and wait for 5 minutes until capacity voltage already drops to safe ALFA IN a SERVISN TECHNICK DOKUMENTACE MG022 2 SERVISN MANU L SERVICE MANUAL ALFIN 160 161 page 2 voltage 36V 2 BLOKOV SCH MA ELECTRICAL PRINCIPLE DRAWING ALFA IN a SERVISN TECHNICK DOKUMENTACE page 3 MG022 2 SERVISN MANU L SERVICE MANUAL ALFIN 160 161 MF 161 161 YAOS ZHOG 1082 3504 1 00 2000 080 8 2 1 44 31 1 44 OTIANNYd Jova OJAN MOVIE OAIN NMOJA 3NOJAVA NMOJA INOJIVA HOLIMS SNIVW 34 N338 MONNINA 10 NOUV ji mace 31 1 2 08 lt 1 385 91545 s fi 3 r o lt 0124 9 1000 1100 090 9 JAMOd VZNALOd 624 8600 LO00 0g0 350058 588 er sr pagina 17 di 17 Ultima modifica Last Update 18 03 2008 Rev0 SERVISNI TECHNICKA DOKUMENTACE ALFA IN a 4 MG022 2 SERVISN MANU L SERVICE MANUAL ALF2. The Power Board must be replaced The shunt wires are damaged not Connect the cables or if damaged replace rectly inserted them rent The wire feeding unit Primary fuse of the auxiliary transformer Switch off the machine and disconnect the motor does not work is damaged plug The delayed fuse 5x20 800 mA on the back of the machine must be replaced Controls from the front panel do not Check the connection of the motor feeding reach the motor board wire on the front panel and after that check The motor board is damaged the continuity between the front panel and the amphenol connector picture 9 Check connections between the front panel and the white 4 pin connector if connections are not interrupted replace the front panel The Motor board must be replaced Ultima modifica Last Update 18 03 2008 pagina 13 di 17 161 161 Position of the connector in which they are inserted thermal protection device position 2 5 yellow wires Wire for the output voltage reading position 3 red Shunt wire pin 1 4 6 pin connector Check the continuity of contact of the thermal protection de vice with the diode tester with the heat sink tool temperature less than 40 C Check the continuity between socket and the shunt socket and the output voltage wire Output voltage Thermal protection device Remove the snubber board and check that
3. sva ovac kabel Zemn c kabel nen p ipojen a aT Zkontrolujte zemn c kabel nebo je patn p ipojen patn uta en sva ovac Zkontrolujte uta en kabely sva ovac ch kabel Sva enec je zne i t n olejem 1 6 Obt n se zapaluje oblouk nebo doch z k O ist te sva enec lepen elektrody nebo prachem MMA TIG v b r je patn Vyberte MMA sva ov n 7 Sva ovac proud nelze nastavit Po kozen potenciometr Opravte nebo vym te p edn ho panelu potenciometr 8 Penetrace tavn l zn nedosta uj c d Je nastaven Zvy te sva ovac proud Nep zniv vliv pr vanu Pou ijte z st nu Zm te hle uchycen elektroda Excentrick elektroda Vym te elektrodu Nahn te elektrodu proti sm ru magnetick ho vlivu 9 Nestabiln oblouk Vliv magnetismu Zm te pozici zemn c ho kabelu nebo p idejte zemn c kabel na opa nou stranu sva ence Stroj p li je 5 2 P eh t satel Po kejte az se stroj vychladi 10 LED ALARM sviti Nestandardni Ochrana proud na Otestujte a opravte hlavni prep ti hlavnim obvod PCB po 6 obvodu TROUBLESHOOTING S N Troubles Reasons Solutions The power light damaged or Test and repair the inside 1 Turn on the power source and fan works connection is not good circuit of power light s n 6 but the power light is not on Repair or change power PCB Power PCB failures s n 11 2 on the power source and the power
4. the transils are not in short circuit At the ends of the two transils see below positioned on the snubber board OL must always be measured a i Transil PICTURE 2 Ultima modifica Last Update 18 03 2008 pagina 14 di 17 161 161 Input bridge rectifier on power board check the Input bridge rectifier carry out the following measurements with a diode tester PICTURE 3 Should there be short circuit on one of these measurements the input bridge rectifier must be replaced To check the inverter carry out the following measurements with a diode tester Red Probe Black Probe Should there be a short circuit on one of these measurements or an OL instead of a numeric value the power board must be replaced The varistor is a blue discs near the ground wire of the power board This device is necessary to protect the board from input overvoltage When there is overvoltage it explode causing a short circuit most of the times If the extent of the short circuit is very high its becomes an open circuit Lu D 2 1O LU 2 Fr Ultima modifica Last Update 18 03 2008 pagina 15 di 17 161 MF 161 To check the mosfet of the switching power supply unit carry the following measurements with a diode tester PICTURE 6 Should there be a short circuit on one of these measurements
5. v obou sm rech vyk zat p eru en obvod OL o gt G SERVISN TECHNICK DOKUMENTACE MG022 2 SERVISN MANU L SERVICE MANUAL ALFIN 160 161 MF Obr zek 3 Obr zek 4 ALFA IN a s page 10 desce Vstupn usm r ova na silov Pro kontrolu m stku zm te tento podle n sleduj c tabulky testerem diod erven ern Nam e vodi vodi n hodnota F D OL D F gt 0 450 D F OL F D gt 0 450 Pro kontrolu tranzistor zm te tyto podle n sleduj c tabulky testerem diod erven ern hodnota S G 0 28 G S 0 6 Hodnoty jsou orienta n Nam te li zkrat nebo rozpojen obvod OD je nutn PCB vym nit SERVISN TECHNICK DOKUMENTACE MG022 2 SERVISN MANU L SERVICE MANUAL ALFIN 160 161 Obr zek 5 Obr zek 6 _ ALFA IN a page 11 Varistor je bl zko vstupu nap jec ho nap t na silovou PCB Toto za zen slou k ochran PCB p ed vstupn m p ep t m P i p ep t exploduje a zkratuje vstup Je li rozsah zkratu velmi vysok obvod se p eru Pro kontrolu tranzistor zm te podle n sleduj c tabulky testerem diod erven ern hodnota G D 0 5 D S OL G S 0 6 Hodnoty jsou orienta n Nam te
6. IN 160 161 SPARE PARTS N HRADN D LY 3 2509 7 3 WO 2 M Y 29 09 09 59 27 25 04 SERVISN TECHNICK DOKUMENTACE ALFA IN a s MG022 2 SERVISN MANU L SERVICE MANUAL ALFIN 160 161 page 5 Poz CODE N zev DESCRIPTION ks 1 005 0001 0008 Popruh BELT 2 011 0001 0181 Kryt CASE 3 0150001 0001 Chladi 107mm DISSIPATER L 107mm 4 015 0001 0002 Chladi 50mm DISSIPATER L 50mm 5 012 0001 0000 Vnit n r m INTERNAL FRAMEWORKS 6 050 005 0001 PCB silov A160MF POWER BOARD 7 046 0004 0004 Isola n deska POWER BOARD INSULATION 8 012 0001 0001 Nylonov z kladn deska kr tk SHORT BLACK NYLON BASE 9 045 0005 0006 Bo n k SHUNT 10 011 0010 0005 Dr k p edn FRONT SUPPORT 11 050 5052 0001 PCB d c ALFIN 161 FRONT PANEL 12 014 0001 0004 Ovl dac knofl k COVER AND HANDLE WITH POINTER 13 711P001004 Rychlost 10 25 panel FIXED SOCKET 200A 14 021 0004 3360 ts konektor ho ku TORCH CONNECTOR vidlice 15 050 0001 0042 Konektor ho ku z suvka TORCH CONNECTOR BOARD 16 AO 20501 Rychlospo 10 25 kabel MOVABLE PLUG 200A 17 012 0004 0010 P edn plastov r m FRONT 18 017 0002 0806 Hadice plynov GAS PIPE 19 040 0003 1080 Termostat tepeln ochrany THERMAL CUT OUT 20 BG 90625 Konektor EURO EURO
7. MG022 2 SERVISN MANU L SERVICE MANUAL ALFIN 160 161 page 1 SERVISN MANU L ALFIN 160 161 MF SERVICE MANUAL ALFIN 160 161 MF O a own o o 2 ASTM 1 VAROV N WARNING UPOZORN N Pouze osoba spl uj c kvalifikaci danou z konem je opr vn na opravovat stroj P ED OTEV EN M KRYTU STROJE JEJ ODPOJTE VYTA EN M S OV VIDLICE ZE S T Ka d 4 m s ce otev ete stroj a jemn ho vyfoukejte stla en m such m vzduchem POZOR NEPOU VEJTE STLA EN VZDUCH O P LI VYSOK M TLAKU ABY NEDO LO K MECHANICK MU PO KOZEN ELEKTROSOU STEK Ka d 4 m s ce zkontrolujte dn stav sva ovac ch kabel a s ov ch kabel Nen povolena dn modifikace sva ovac ho stroje Pro Va i bezpe nost je nutn pose kat se sund n m krytu ze stroje po odpojen ze s t po dobu minim ln 5 minut kdy klesne nap t na kondenz torech na hodnotu pod 36 V NOTE Only trained personnel are permitted to work inside the machine BEFORE OPENING THE MACHINE CUT OFF ITS ELECTRICAL POWER BY REMOVING THE PLUG FROM THE MAINS SUPPLY SOCKET Every six months open the machine and clean it inside using compressed dehumidified air CAUTION DO NOT USE COMPRESSED AIR AT TOO HIGH A PRESSURE YOU COULD DAMAGE THE ELECTRONIC COMPONENTS With the same frequency check the welding cables and the supply cables
8. SOCKET 21 3494 Posuv CMS100 4 9900006 06 WIRE DRAWING MOTOR 2087 Kladka pr m 40 22 ROLLER 40 0 6 1 0 6 0 8mm dr ka V 0 8mm GROOVE V 2088 Kladka pr m 40 22 ROLLER 40 0 8 1 22 0 8 1 0mm dr ka V 1 0mm GROOVE V 2247 Kladka pr m 40 22 ROLLER 40 0 8 1 0 8 1 0mm dr ka U 1 0mm GROOVE U 2317 Kladka pr m 40 22 1 0 8 1 0mm pro trubi dr t 23 041 0005 0004 Pomocn transform tor AUXILIARY TRANSFORMER 24 016 0009 0001 No ka gumov RUBBER FOOT 25 011 0010 0007 R m BASE 26 011 0010 0008 Dr k silov sti POWER SUPPORT 27 015 0001 0004 Chladi 75mm DISSIPATER L 75mm 28 032 0002 0255 Izotop dioda ISOTOPE DIODE 29 050 0001 0021 PCB regulace ot ek MOTOR BOARD 30 011 0010 0003 Vnit n deska INTERNAL PLATE 31 011 0006 0050 Dr k c vky dr tu K200 K200 SPOOL SUPPORT 32 050 0001 0033 PCB double A150 DOUBLER BOARD ALFA IN a s SERVISN TECHNICK DOKUMENTACE MG022 2 SERVISN MANU L SERVICE MANUAL ALFIN 160 161 page 6 33 011 0010 0006 Zadn postrann panel REAR SIDE PANEL 34 012 0004 0100 Zadn plastov ram BACK 35 017 0001 5542 Plynov ventil SOLENOID VALVE 36 013 0007 0200 Panel zadni REAR PANEL 37 045 0000 0001 Kabelov pr chodka CABLE GRIP 38 045 0002 0001 S ov kabel NEOPRENE CABLE 39 021 0000 0000 Sada pro p ipojen plynu KIT FOR GAS CONNECTORS 40 040 0001 0001 Vyp n
9. There is something in the fan Clear out light is on but fan doesn t work The fan motor damaged Change fan motor No input voltage Check whether there is input voltage 3 Turn on the power source and the power light is not on and fan doesn t work Overvoltage Input voltage is Check input voltage too much or not 4 No no load voltage output There is trouble inside the Check the power switch machine Welding cable is not 5 No current output in the welding connected with the two Connect the welding cable to the welder s output output of the welder ALFA IN a SERVISN TECHNICK DOKUMENTACE MG022 2 SERVISN MANU L SERVICE MANUAL ALFIN 160 161 page 8 Welding cable is broken Wrap repair or change the welding cable Earth cable is not connected or loosen Check the earth clamp Not easy to start arc in the welding or easy The plug loosen or connect not well Check and tighten the plug Oil or dust covered the workpiece Check and clear out 5 to cause sticking MMA TIG welding selection is Selecting the welding wrong The welding current 7 The welding current can not be potentiometer in the front Repair or change the adjusted panel connection not so good potentiometer or damaged 8 The penetration of molten pool is not The welding current adjusted Increase the welding current enough MMA too low Airflow disturbance Use the shelter
10. a dvoup lov TWO POLE SWITCH 41 0500001 0003 PCB snubber SNUBBER BOARD 42 2681 Z mek SLIDE CLOSURE 43 012 0000 0001 Kryt c vky K200 SPOOL COVERS 44 2911 Ventil tor FAN 45 2686 Plastov pant PLASTIC HINGE 46 011 0000 0201 Otev rac kryt posuvu DOOR 47 042 0003 0001 Silov transform tor TRANSFORMER 4 Z VADY E EN Po Z vada P ina e en LED nebo jej p ipojen je Opravte p ipojen nebo vym te 1 Stroj je zapnut ventil tor funguje LED vadn LED 611 zapnut nesv t Silov PCB je vadn hee nebo vym nte PCB 2 Stroj je zapnut LED zapnut sv t P ek ka rotace ventil tor Odstra te ventil tor neb Motor ventil tor po kozen Vym te ventil tor Nen nap t v s ti Zkontrolujte jestli je v s ti 3 Stroj je zapnut LED zapnut nesv t nap t ventil tor neb P ep t nebo podp t v s ti Zkontrolujte s ov nap t 4 dn nap t na pr zdno Z vada gener tor Zkontrolujte hlavn vyp na 5 dn sva ovac proud na svork ch Sva ovac kabely nejsou P ipojte sva ovac kabely do p ipojeny do konektor rychlospojek na stroji ALFA IN a s SERVISN TECHNICK DOKUMENTACE MG022 2 SERVISN MANU L SERVICE MANUAL ALFIN 160 161 page 7 Vym te nebo opravte Po kozen sva ovac kabel 1
11. ck opening of the sole noid valve Reduce gas pressure Restore connections and carry out a gas test Damage solenoid valve wiring Switch off the machine and disconnect the plug Should there be no continuity single out the disconnection and repair it _ Make sure that the wiring contacts are correctly inserted in the connectors The solenoid valve control relay on the The front panel must be replaced front panel is damaged Solenoid valve is damaged Should the operations carried out not have a positive outcome replace the solenoid valve Should the operations carried out not have a positive outcome try to replace the Toroidal Transformer Ultima modifica Last Update 18 03 2008 pagina 12 di 17 161 161 PROBLEM CASE SOLUTION The torch button does There s no continuity in the amphenol The amphenol cable must be replace 1 work board 0042 cable There is no continuity between the euro Check the connection between the Euro connector and the connector on front connector and pin 1 2 of the Amphenol panel connector Afterwards check the connec tion between the Amphenol connector and the Motor board and between Motor Board and Front Panel The Front Panel is damaged Front Panel must be replace The machine always Switch off the machine and disconnect the welds at maximum cur plug The front panel is damaged The Front Panel must be replaced The Power Board is damaged
12. ck with a diode tester the status of the transil on the snubber board picture 2 check with a diode tester the status of the diodes check the status of the power board picture 4 The Power Transformer must be replace pagina 11 di 17 161 161 PROBLEM CASE SOLUTION When welding the pro Make sure the welding current does not re Decrease the welding current tection devices of the quire greater power than the one supplied line set off by the line The welding is non opti Spattering occurs during welding Make sure welding polarity is correct the mal earth clamp is fixed correctly Porosity in the deposit Decrease the set voltage value and check the gas emission from the torch Too narrow welding seam dry arc Increase the electronic inductance pa rameter and or voltage Too wide welding seam too hot weld Decrease the electronic inductance pa pool rameter and or voltage The machine stops The maximum current that be supplied Decrease the value of the welding parame welding and emits an _ by the machine has been exceeded ters acoustic signal Non optimal MIG weld Spattering occurs on starting and crackling Increase post gas to decrease the oxidation ing start status of the welding wire Gas does not come out Excessive gas pressure Remove the gas connection Carry out a from solenoid valve gas test on the front panel in the MIG TIG procedure and che
13. from airflow Adjust the electrode angle The electrode eccentricity Change the electrode Incline the electrode to the opposite way of the magnetic 9 Arc blow blow Magnetic effect Change the position of earth clamp or add earth cable in the two side of workpiece Use the short arc operation Over Induce the welding current welding Over heat current p protecion Working Induce the duty cycle interval 10 The alarm light is on 00 work long Unusual Over current current in Test and repair the main circuit protection the main and drive PCB s n 6 circuit 5 KONTROLA SILOV PCB CHECKING THE POWER PCB ALFA IN a s SERVISN TECHNICK DOKUMENTACE MG022 2 SERVISN MANU L SERVICE MANUAL ALFIN 160 161 page 9 Obr zek 1 Output voltage Obr zek 2 ALFA IN a s 6 pin connector Thermal protection device Pozice kontakt v konektoru e teplotn idlo lut dr ty pozice 2 5 dr t pro sn m n v stupn ho nap t erven pozice 3 dr ty bo n ku pozice 1 4 Zkontrolujte spojen kontakt tepeln ochrany pomoc testeru diod teplota chladi e nesm b t vy ne 40 Zkontrolujte spojen mezi obj mkou a erven m dr tem Zkontrolujte pr chodnost mezi obj mkou a vodi i bo n ku Na PCB RC filtr um st n nad v stupn m usm r ova em jsou um st ny dva transily Pro kontrolu mus
14. isconnect the plug Check for a short circuit at the DINSE plug with a diode tester A short circuit may be caused by damaged transil on the snubber board damaged diodes damaged inverter The inductive value of the Power Trans former is null Ultima modifica Last Update 18 03 2008 Rev0 Switch off the machine and disconnect the plug Make sure the flat cable that con nects the front panel to the power board is inserted correctly If correctly inserted re place the front panel If the front panel does not go on one of the switching power supply unit outputs is broken Therefore the power board must be replaced Switch off the machine disconnect the plug and check the mosfet of the switching power supply unit on the power board IF it s damaged it must be replaced picture 6 Switch off the machine and disconnect the plug _ Make sure that the wiring contact is cor rectly inserted in the connector Check for continuity between the out put outlets and that the 2 path connector is connected to the front panel picture 1 The power board must be replaced If one of the protection devices is always opened it is defective it must be accordingly replaced If itis closed make sure the two terminals are well inserted in the connector picture 1 Power board feed problems it must be accordingly replaced Switch off the machine and disconnect the plug Remove the snubber board che
15. li zkrat nebo rozpojen obvod OL je nutn PCB vym nit SERVISN TECHNICK DOKUMENTACE MG022 2 SERVISN MANU L SERVICE MANUAL ALFIN 160 161 MF page 12 Digit ln multimetr OL ozna uje p eru en obvod Obr zek 7 ALFA IN a s SERVISN TECHNICK DOKUMENTACE 161 161 CAUTION Before carrying out any work on the machine make sure it is off and the plug has been dis connected PROBLEM CASE SOLUTION The machine does not switch on The protection devices of the line set off when the switch is activated and the machine does not go on Electrical power does not reach the ma chine Voltage reaches the machine switch but there is no voltage after the contacts There is voltage after the disconnecting switch but the machine does not go on Damaged power supply cable with short circuited wires Inverter is damaged Ultima modifica Last Update 18 03 2008 Make sure the line switches are closed the protection devices fuses have not been enabled and that the power supply cable is intact Switch the machine off and disconnect the plug Make sure that when the switch is closed there is continuity between the contact input and output and that the varis tor is not broken In case the Poewer Board must be replaced picture 5 Switch the machine off and disconnect the plug Check the mosfet of the switching power supp
16. ly unit on the power board picture 6 Switch off the machine and disconnect the plug Make sure that there are no short cir cuits between the poles of the plug caused by a damaged power supply cable Switch off the machine disconnect the plug and check varistors picture 5 inverter picture 4 _ Input bridge rectifier picture 3 switching power supply unit picture 6 If one of these components is damaged replace the power board 050 0011 0001 pagina 10 di 17 161 161 PROBLEM CASE SOLUTION The front panel does not switch on The MMA MIG TIG out put voltage is about 11V and the machine does not weld The output voltage in each procedure is about 11V and enabling of the thermal protection de vice The output voltage is zero The fan works but the front panel does not go on Both the fan and the front panel do not Work The output voltage wiring of the front panel is interrupted picture 1 _ The primary current alarm on the power board is activated Wait a few minutes keeping the machine on to favour cooling of the inverter If the ma chine continues running with the protection devices on switch the machine off and dis connect the plug Remove the hood and make sure temperature of the heat sink tool is less than 40 C If itis less than 40 C check whether the thermal protective device contacts are normally closed Switch the machine off and d
17. or an OL instead of a numeric value the power board must be replaced Tester or digital millimetre OL means Open Loop Lu Ultima modifica Last Update 18 03 2008 pagina 16 di 17 MG022 2 SERVISN MANU L SERVICE MANUAL ALFIN 160 161 Vypracoval Worked out DJ 15 4 2010 Prezkoumal Inspected DJ 15 4 2010 Schv lil Approved VS 15 4 2010
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