MG050-2 SERVISNÍ MANUÁL SERVICE MANUAL
Contents
1. Transils on the snubber board are dam aged The inductive value of the Power Tra sformer is null The welding is non opti opattering occurs during MMA welding mal The arc goes out during the AC welding Ultima modifica Last Update 18 03 2008 Rev0 Connect the cable or eventually replace it figura 6 The fan must be replaced owitch off the machine and disconnect the plug Connectthe cables or if they are dam aged replace them picture 7 Connect the inversion board cable to the module board and whether it s dam aged replace it Connect the cable to the inversion board and whether it s damaged replace it Replace the damaged boards If the protection devices is always opened it is defective it must be accordingly replaced f itis closed make sure the two terminals are well inserted in the connector picture 5 Power board feed problems it must be accordingly replaced Switch off the machine and disconnect the plug Remove the snubber board 0065 above the ISOTOP diodes picture 8 check with a diode tester the diodes status If damaged they must be replaced check with a diode tester the inversion module status If it s damaged it must be replaced picture 8 check with a diode tester the status of the transils on the snubber board sostituire il TF POT nel caso sia danneg giato Make sure welding polarity is correct the earth clamp is fixed correctly an2. DC page 14 Neto li se ventil tor zkontrolujte nap jen 24V ze silov desky a veden k ventil tor m co x N n o O ALFA IN a s SERVISN TECHNICK DOKUMENTACE MG050 2 SERVISN MANU L SERVICE MANUAL ALFIN 200 AC DC page 15 Obr zek 7 ALFA IN a s I 3 T a Pro kontrolu v stupn ch usm r ova odmontujte PCB RC filtr a podle n sleduj c tabulky zm te testerem diod erven ern hodnota Pro kontrolu st da e podle n sleduj c tabulky erven ern hodnota Nakonec zkontrolujeme osm transil na PCB RC filtr V obou sm rech mus vyk zat p eru en obvod SERVISN TECHNICK DOKUMENTACE MG050 2 SERVISN MANU L SERVICE MANUAL ALFIN 200 AC DC page 16 Zkontrolujte testerem diod pr chodnost mezi body A B na silov PCB a pin X Y na propojce k PCB d c x n ALFA IN a s SERVISN TECHNICK DOKUMENTACE 200 AC DC 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 Electrical power does not reach the ma Make sure the line switch is closed the switch on chine protection devices fuses have not been enabled and that the power supply cable is intact Switch the machine off and disconnect the Voltage reaches the machine switch but plug Make sure that when the switch is th
3. Input bridge rectifier carry out the following measurements with a diode tester o se o se 2 NEN Should there be a short circuit on one of these measure ments the input bridge rectifier must be replaced PICTURE 3 To check the inverter carry out the following measure ments with a diode tester Red Probe Black Probe Measure PICTURE 4 should there be a short circuit on one of these measure ments or an OL instead of a numeric value the power board must be replaced Make sure the two terminals of the thermal devices are well inserted in the 6 pin blue connector on the power board PICTURE 5 Thermal device Thermal device Ultima modifica Last Update 18 03 2008 RevO pagina 17 di 21 200 AC DC Make sure that the fan cables 24 V are correctly in serted 2 pin connector on the power board 2 pin connector on the fan Lu o gt H Make sure that the output filter board 0031 cables rectly inserted in the front panel connectors LLI o gt H n Ultima modifica Last Update 18 03 2008 RevO pagina 18 di 21 200 AC DC To check diodes remove the snubber board and carry out the following measures with a diode tester a Pel bar bar te At the ends of the two transils see below positioned on the snubber board OL must always be measured Probe bar bar In order to
4. Varistor je blizko vstupu napajeciho na PCB vstupni filtr 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 Y vu N i O ALFA IN a s SERVISN TECHNICK DOKUMENTACE MG050 2 SERVISN MANU L SERVICE MANUAL ALFIN 200 AC DC page 12 Pro kontrolu tranzistor zm te podle n sleduj c tabulky testerem Hodnoty jsou orienta n Nam te li zkrat nebo rozpojen obvod OL je nutn PCB vym nit Obr zek 2 Vstupn usm r ova na silov desce Pro kontrolu m stku zm te tento podle n sleduj c tabulky testerem diod erven ern Nam e vodi vodi n hodnota Fr D OL D F 05 _ D F O Obr zek 3 3 TT 1 os Vstupni usme rnovac ALFA IN a s SERVISN TECHNICK DOKUMENTACE MG050 2 SERVISN MANU L SERVICE MANUAL ALFIN 200 AC DC page 13 Pro kontrolu tranzistor zm te tyto podle n sleduj c tabulky testerem diod S G 06 Hodnoty jsou orienta n Nam te li zkrat nebo rozpojen obvod OL je nutn PCB vym nit Obr zek 4 Zkontrolujte obvod dvou teplotn ch idel na 6 pinov m konektoru na silov desce Obr zek 5 ALFA IN a s SERVISN TECHNICK DOKUMENTACE MG050 2 SERVISN MANUAL SERVICE MANUAL ALFIN 200 AC
5. reset the parameters switch the machine on while the S2 and S4 buttons are being pressed e Lu os gt H Ultima modifica Last Update 18 03 2008 Rev0 pagina 19 di 21 200 AC DC Check continuity with a diode tester between points A B of the power board and x y poles of the connector that goes to the front panel PICTURE 10 Ultima modifica Last Update 18 03 2008 Rev0 pagina 20 di 21 MG050 2 SERVISN MANUAL SERVICE MANUAL ALFIN 200 AC DC V pracoval Prezkoumal Schv lil Worked out ZM Inspected PS Approved P
6. 10 No n d lkov ovl d n ped l MAX JEZDEC MIN tla N C POT 2KOhm 10KOhm e REMOTE CONNECTOR ALFA IN a s TORCH WITH POTENTIOMETER MAX 9 A RIF T MIN RE SWITCH N C NC e POT 2KOhm 10KOhm REMOTE CONTROL POT 2KOhm 10KOhm REMOTE FOOT CONTROL MAX A T RIF ap MIN oC SWITCH SD E N C F POT 2KOhm 10KOhm SERVISN TECHNICK DOKUMENTACE MG050 2 SERVISN MANUAL SERVICE MANUAL ALFIN 200 AC DC page 4 MAINS SWITCH YELLOW GREEN 050 0001 0048 JP2 JP3 Lu lt O lt 3 N HRADN D LY SPARE PARTS ALFA IN a s SERVISN TECHNICK DOKUMENTACE MG050 2 SERVISN MANUAL SERVICE MANUAL ALFIN 200 AC DC page 5 0 n gt N i x her T 4 23 15 DESCRIPTION CODE IKs BELT Drz k PCB BOARD 916 0010 0001 PCB silova POWER BOARD 050 0001 0025 6 Termostat s s THERMAL CUT OUT 040 0003 1270 8 Krytkavnit n LATERAL SUPPORT _ 011 0008 0030 1 9 Tlumivka INDUCTOR 04400040004 1 2 COVER amp HANDLE WITHOUT Knoll k POINTER 014 0002 0002 Rychlospojka silova FIXED SOCKET 400A 021 0001 0259 ALFA IN a s SE
7. MG050 2 SERVISN MANU L SERVICE MANUAL ALFIN 200 AC DC page 1 SERVISN MANU L ALFIN 200 AC DC SERVICE MANUAL ALFIN 200 AC DC 1 VAROVANI 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 NEPOUZIVEJTE STLA EN VZDUCH O P LI VYSOK M TLAKU ABY NEDOSLO K MECHANICK MU POSKOZEN 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 ALFA IN a s 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 No modification of any type may be made to the welding machine For safety while maintaining
8. RVISN TECHNICK DOKUMENTACE MG050 2 SERVISN MANUAL SERVICE MANUAL ALFIN 200 AC DC page 6 Trafo TRANSFORMER SUPPORT Seo do p ipojen TIG KIT FOR TIG TORCH 021 0000 0001 ALFA IN a s SERVISN TECHNICK DOKUMENTACE MG050 2 SERVISN MANUAL SERVICE MANUAL ALFIN 200 AC DC page 7 Poz N zev DESCRIPTION CODE 1 2 N dr ka TANK 010 0004 0110 1 3 Lev kryt LEFTSIDE 0110000 0381 1 6 Ventilator FAN 003 00020008 1 8 Prednipanel FRONTPANEL 011 0012 0005 1 9 Rychlospoky QUICK CLUTCH 018 0002 0004 2 Co N ALFA IN a s SERVISN TECHNICK DOKUMENTACE MG050 2 SERVISN MANUAL SERVICE MANUAL ALFIN 200 AC DC page 8 UNION M rouben 1 4 MALE ELBOW 1 4 GAS 017 0003 0009 Uhlov rouben 1 8 MALE ELBOW 1 8 GAS 017 0003 0002 GAS P pojka 1 8 GAS MALE CONNECTOR 1 8 GAS 017 0003 0007 TUBE TO HOSE STEM 017 5001 3010 4 Z VADY E EN Po Z vada P ina e en LED nebo jej p ipojen je Opravte p ipojen nebo vym te Stroj je zapnut ventil tor funguje LED vadn LED po 10 zapnut nesv t Silov PCB je vadn ee nebo vym nte PCB 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 Stroj je zapnut LED zapnut nesv t na
9. d 0025 is damaged The Front Panel must be replaced The Hall Effect is damaged or the cable The Power Board must be replaced is disconnected Connect the cable in the right way or if damaged the Hall Effect must be re placed Gas comes out but the Pre gas settings are not correct Regulate pre gas settings machine doesn t weld The machine can t stop The slope up and slope down are not cor Regulate in the correct way the slopes welding or the welding set current is not the one set Otherwise reset the parameters and reset the machine picture 9 Ultima modifica Last Update 18 03 2008 RevO pagina 15 di 21 200 AC DC The varistor is a blue discs near the ground wire of the power board This device is for protecting the board from input overvoltage When there is overvoltage they explode causing a short circuit most of the times If the extent of the short circuit is very high they become an open circuit a ad gt H To check the mosfet of the switching power supply unit carry the following measurements with a diode tester Red Probe Black Probe CN Lu jaa gt H should there be a short circuit on of these measure ments or an OL instead of a numeric value the power board must be replaced Mosfet of the switching power Ultima modifica Last Update 18 03 2008 Rev0 pagina 16 di 21 200 AC DC Input bridge rectifier To check the
10. d check the hot start and arc force values that have to be decreased if they are too high The inversion board 0071 or the front panel must be replaced pagina 13 di 21 200 AC DC PROBLEM CASE SOLUTION When welding the pro Make sure the welding current does not re Decrease the welding current taction devices of the quire greater power than the one supplied line set off by the line The remote control is damaged The machine does not strike HF mode Gas does not come out from solenoid valve The torch button does nt work Check that the 2 pin blue connector is correctly inserted on the power board The Front Panel could be damaged The front panel could be damaged The HF board 0027 could be damaged HF board cable could be damaged or disconnected The HF transformer is damaged or not connected to the front panel Excessive gas pressure Damage solenoid valve wiring The solenoid valve control relay on the front panel is damaged No 24 V solenoid valve is damaged Non continuit nel cablaggio della scheda amphenol 0042 Cablaggio pulsante torcia che va da scheda 0042 a scheda 0031 rotto o non collegato Cablaggio che va da scheda 0031 a scheda 0026 rotto o non collegato ll cablaggio 24 V nominato 24 V aux che va da scheda potenza a scheda pannello frontale 0026 danneggiato o sconnesso La scheda del pannello frontale 0026 danneggiata Ult
11. e elektrodu proti sm ru magnetick ho vlivu Vliv magnetismu Zm te pozici zemn c ho kabelu nebo p idejte zemn c kabel na opa nou stranu sva ence Stroj p li Po kejte a se stroj vychlad zat en Nestandardn Ochrana proud na Otestujte a opravte hlavn LED ALARM sv t p ep t hlavn m obvod PCB po 5 obvodu TROUBLESHOOTING Troubles Reasons Solutions The power light damaged or Test and repair the inside Turn on the power source and fan works connection is not good circuit of power light s n 10 but the power light is not on Power PCB failures oe or change power PCB Turn on the power source and the power There is something in the fan light is on but fan doesn t work The fan motor damaged Change fan motor No input voltage Check whether there is input voltage 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 No no load voltage output There is trouble inside the Check the power switch ALFA IN a s SERVISN TECHNICK DOKUMENTACE MG050 2 SERVISN MANUAL SERVICE MANUAL ALFIN 200 AC DC page 10 po ee Welding cable Sne Connect the welding cable to connected with the two the welder s output output of the welder Wrap repair or change the Welding cable is broken 5 No current output in the welding welding cable Earth cable is not conn
12. ected Check the earth clamp or loosen The plug loosen or connect Check and tighten the plug not well Oil or dust covered the Check and clear out Not easy to start arc in the welding or easy workpiece to cause sticking MMA TIG welding selection is wrong The welding current The welding current can not be potentiometer in the front Repair or change the adjusted panel connection not so good potentiometer or damaged The welding current adjusted i ecco the welding current too low The arc force adjusted too Selecting the MMA welding The penetration of molten pool is not enough MMA Increase the arc force small Airflow disturbance Use the shelter from airflow Adjust the electrode angle The electrode eccentricity Change the electrode Incline the electrode to the opposite way of the magnetic 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 Over Induce the current welding Over heat current protection Working time too long Unusual current in Induce the duty cycle interval 11 The alarm light is on work Over current protection Test and repair the main circuit and drive PCB s n 5 the main circuit 5 KONTROLA SILOVE PCB CHECKING THE POWER PCB ALFA IN a s SERVISN TECHNICK DOKUMENTACE MG050 2 SERVISN MANUAL SERVICE MANUAL ALFIN 200 AC DC page 11
13. ere is no voltage after the contacts closed there is continuity between the contact input and output and the varistor is not broken picture 1 There is voltage after the disconnecting Switch the machine off and disconnect the switch but the machine does not go on plug Check the mosfet of the switching power supply unit on the power board picture 2 The protection devices Damaged power supply cable with short Switch off the machine and disconnect the of the line set off when circuited wires plug Make sure that there are no short cir the switch is activated cuits between the poles of the plug caused by a damaged power supply cable and the machine does Inverter is damaged Switch off the machine disconnect the not go on plug and check varistor picture 1 inverter picture 4 Input bridge rectifier picture 3 switching power supply unit picture 2 The front panel does The fan works but the front panel does Switch off the machine and disconnect the not switch on not go on 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 Both the fan and the front panel do not Switch off the machine disconnect the Work plug and check the mosfet of the switching power supply
14. ima modifica Last Update 18 03 2008 Rev0 Insert the wires into the connectors correctly and insert the connectors into their housings Should this not be sufficient replace the front panel board The front panel must be replaced The HF board must be replaced Connect the cables or if damaged replace them Connect the HF transformer or replace it Remove the gas connection Carry out a gas test on the front panel in the TIG pro cedure and check opening of the solenoid valve Reduce gas pressure Restore con nections and carry out a gas test 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 Front Panel must be replaced Check continuity between points A B of the power board and x y poles of the connec tor that goes to the front panel picture 10 After that the solenoid valve or the front panel must be replaced Should the operations carried out not have a positive outcome replace the solenoid valve Sostituire la scheda amphenol 0042 Collegare o sostituire il cablaggio che col lega le due schede Sostituire la schede che risultano danneg giate pagina 14 di 21 200 AC DC PROBLEM CASE SOLUTION The machine always The Front Panel 0026 is damaged Switch off the machine and disconnect the welds at maximum cur plug rent The Power Boar
15. p t ventil tor neb _ P ep t podp t v siti Zkontrolujte s ov nap t 1 2 4 Z 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 MG050 2 SERVISN MANUAL SERVICE MANUAL ALFIN 200 AC DC page 9 Vym te nebo opravte Po kozen sva ovac kabel sva ovac kabel Zemn c kabel nen p ipojen m NP A 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 n _ O ist te svarenec Obtizn se zapaluje oblouk nebo dochazi k nebo prachem MMA TIG v b r je patn Vyberte MMA sva ov n lepen elektrody Nestabiln sva ovac oblouk OP Zvy te ARC FORCE Sva ovac proud nelze nastavit Po kozen potenciometr Opravte nebo vym te p edn ho panelu potenciometr Sva ovac proud je nastaven p li n zko ARC FORCE nastaveno p li n zk Nep zniv vliv pr vanu Zvy te sva ovac proud Penetrace tavn l zn nedosta uj c Nestabiln oblouk Zvy te ARC FORCE Pou ijte z st nu Zm te hle uchycen elektroda Excentrick elektroda Vym te elektrodu Nahn t
16. the machine please shut off the supply power and wait for 5 minutes until SERVISN TECHNICK DOKUMENTACE page 2 MG050 2 SERVISN MANUAL SERVICE MANUAL ALFIN 200 AC DC capacity voltage already drops to safe voltage 36V ELECTRICAL PRINCIPLE DRAWING 36 V BLOKOVE SCHEMA 2 050 0001 0065 J4 J8 J6 J5 J733 J1 23456 c lt lt cop 050 0001 0031 JP2 JP1 C 050 0001 0025 FAN 12345678 910 JP1 050 0001 0042 S oa 050 0001 0027 JP4 FLAT 050 0001 0030 J56 J4 p J2 J J3D MAINS SWITCH BROWN O OL BLUE O ON YELLOW GREEN F z SERVISNI TECHNICKA DOKUMENTACE ALFA IN a s MG050 2 SERVISN MANUAL SERVICE MANUAL ALFIN 200 AC DC page 3 Schema zapojeni DOV ALFIN 200 AC DC ELECTRICAL PRINCIPLE DOV ALFIN 200 AC DC tla tko ho ku Konektor ho ku Konektor DOV TORCH CONNECTOR Horak s potenciometrem MAX JEZDEC MIN tla NC o POT 2KOhm 10KOhm TORCH GND o PT j PT 5 N C AS D lkov ovl d n _MAX JEZDEC MIN x N C O N C POT 2KOhm
17. unit picture 2 Ultima modifica Last Update 18 03 2008 RevO pagina 12 di 21 200 AC DC PROBLEM CASE SOLUTION The Machine works and weld but the fan doesn t work too short thermal cycle The cable that connects the Power Board to the Fan is not correctly in serted The fan is damaged The output voltage in MMA TIG is about 11V and the Machine does n t weld The wires that connect the output filter board 0031 to the front panel 0026 are not correctly connected or damaged The cable that connects the inversion board 0071 to the module board 0017 is not correctly connected or is damaged The cable that connects the front panel to the inversion board is not correctly inserted or is damaged The front panel is damaged The power board and or the inversion board are damaged The output voltage in Wait a few minutes keeping the machine on each procedure is about to favour cooling of the inverter If the ma 11V and enabling of the chine continues running with the protection devices on switch the machine off and dis thermal protection de connect the plug Remove the hood and VICE make sure the 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 The output voltage in MMAJ TIG is zero and the welding procedure is blocked in MMA ISOTOP diodes are in short circuit The Inversion Module is damaged
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