Riland Welder REPAIR MANUAL MIG SERIES SHENZHEN RILAND ELECTRIC MFG. CO., LTD.
Riland Welder
REPAIR MANUAL
MIG SERIES
SHENZHEN RILAND ELECTRIC MFG. CO., LTD.
CONTENTS -FOREWORD…………………………………………………………………………………………. 2
-SAFETY………………………………………………………………………………………………. 3
1. AC/DC200P………...……….…..……...……..……….…………………….…..……....……….. 4
1.1 The structure drawing of AC/DC200P………………………………………………………. 4
1.2 The general connection diagram of AC/DC200P………………………………………….. 4
1.3 The PCB diagram of AC/DC200P…………………………………………………………… 5
1.4 Troubleshooting of AC/DC200P……………………………………………………………... 10
2. AC/DC200Ⅱ……………...…….....………..……………….…….………...…………....………. 17
2.1 The structure drawing of AC/DC200Ⅱ……………………………………………………… 17
2.2 The general connection diagram of AC/DC200Ⅱ…………………………………………. 17
2.3 The PCB diagram of AC/DC200Ⅱ………………………………………………………….. 18
2.4 Troubleshooting of AC/DC200Ⅱ…………………………………………………………….. 18
3. WSE200……….…………...…...........…….....………………………………….…..……….….. 25
3.1 The structure drawing of WSE200…………………………………………………………... 25
3.2 The general connection diagram of WSE200………………………………………………. 26
3.3 The PCB diagram of WSE200……………………………………………………………….. 26
3.4 Troubleshooting of WSE200…………………………………………………………………. 30
4. AC/DC315P/250P…...…..…….............……………………………………..…..………………. 35
4.1 The structure drawing of AC/DC315P/250P………………………………………………... 35
4.2 The general connection diagram of AC/DC315P/250P…………………………………… 36
4.3 The PCB diagram of AC/DC315P/250P…………………………………………………….. 36
4.4 Troubleshooting of AC/DC315P/250P………………………………………………………. 41
5. WSE250/315...……………….…….……..…………...…..……….…………………….…….…. 48
5.1 The structure drawing of WSE250/315……………………………………………………… 48
5.2 The general connection diagram of WSE250/315…………………………………………. 49
5.3 The PCB diagram of WSE250/315………………………………………………………….. 50
5.4 Troubleshooting of WSE250/315……………………………………………………………. 51
6. AC/DC160…….……..…..............…....................……………………….………..………….…. 56
6.1 The structure drawing of AC/DC160………………………………………………………… 56
6.2 The general connection diagram of AC/DC160……………………………………………. 57
6.3 The PCB diagram of AC/DC160……………………………………………………………... 58
6.4 Troubleshooting of AC/DC160……………………………………………………………….. 61
REPAIR MANUAL·AC/DC SERIES
1
FOREWORD This manual is only fit for the repairer, who has only digital or pointer multi-meter but special instrument or equipment, to analyze the cause of malfunction, judge which parts of the machine are damaged, and find the right solution through malfunction phenomenon and measure data. When malfunction occurs, uncover the case of machines and check if there is some part burned out or not. Mainly check the following parts:
A. Top PCB: MOSFET, control module, drive module, auxiliary power supply B. Center PCB: rectifying diode, transformer C. Bottom PCB: electrolytic capacitor, thermal resistor, voltage-sensitive resistor
If there is, replace the PCB directly. ◆How to use this manual? This manual is provided to help you locate and repair possible machine malfunctions. Simply
follow the three-step procedure listed below. Step 1. Trouble (symptom) Look under the column labeled “Trouble” (symptom). This column describes possible
symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.
Step 2. Analysis (possible cause) The second column labeled “Analysis”(possible cause) lists the possibilities that may
contribute to the machine symptom. Step 3. Solution This column provides a course of action for the possible cause. If you do not understand or are unable to perform the recommended solution, contact your local
dealer or supplier for further advice. ◆Note: ● Please read and understand the instruction manual carefully before the operation of this
equipment to ensure safety. ● Please read and understand this repair manual carefully before the maintenance of this
equipment to ensure safety. ● Have a qualified electrician to do the maintenance and troubleshooting work. ● Save this manual and keep it handy for quick reference. ● The contents of this manual may be revised without prior notice. ● This repair manual is issued on 1st August 2006.
REPAIR MANUAL·AC/DC SERIES
2
SAFETY Welding and cutting is dangerous to the operator, people in or near the working area, and the surrounding, if the equipment is not correctly operated. Therefore, the performance of welding/cutting must only be under the strict and comprehensive observance of all relevant safety regulations. Please read and understand the instruction manual carefully before the installation and operation.
REPAIR MANUAL·AC/DC SERIES
·The switching of function modes is possibly damaging to theequipment, while the welding operation is performed. ·Do disconnect the electrode-holder cable with the equipment,
before the performance of welding. ·A safety switch is necessary to prevent the equipment fromelectric leakage. ·Welding tools should be of high quality. ·Operators should be qualified. Electric shock: It can kill. ·Connect the earth cable according to standard regulation. ·Avoid all contact with live electrical parts of the welding circuit,electrodes and wires with bare hands. It is necessary for theoperator to wear dry welding gloves while he/she performs thewelding task. ·The operator should keep the work piece insulating fromhimself/herself. Smoke and gas generated while welding or cutting: harmfulto people’s health. ·Avoid breathing the smoke and gas generated while welding orcutting. ·Keep the working area in good ventilation. Arc rays: harmful to people’s eyes and skin. ·Wear welding helmet, anti-radiation glasses and work clothes
while the welding operation is performed. ·Measures also should be taken to protect people in or near theworking area. . Fire hazard ·The welding splash may cause fire, thus remove flammable
material away from the working place. ·Have a fire extinguisher nearby, and have a trained person
ready to use it. Noise: possibly harmful to people’s hearing. ·Noise is generated while welding/cutting, wear approved ear
protection if noise level is high. Machine fault: ·Consult the instruction manual and this repair manual. ·Contact your local dealer or supplier for further advice.
3
1. AC/DC200P 1.1 The structure drawing of AC/DC200P: The structure of AC/DC200P is similar to that of AC/DC315P. (See the structure drawing of AC/DC315P on page 35.) 1.2 The general connection diagram of AC/DC200P:
CONTROL MODULE
ELECTRIC DIAGRAM
Top Board
DRIVE MODULE
PK-03-A1
DC24V
AC/DC200P
VH
-03
VH-02
VH-02
THERMAL SWITCH
PK-05-A4Control Board
VH-03
14V
14V
0 0
AC380V
AC220V
(VH-04)*2
DRIVE LINE
XH
-02
XH
-03
VH-02XH-03
DC12V
VH-02
XH-04 XH-03VH-03 XH-04
CON11
CON6CON1
CON3 CON5CON8CON7CON10
CON2
CON4
CON9CON14
CON15 CON12 CON13
METER CONTROL SIGNALREMOTE RESISTANCE
PK-08-A1
PM-03-A2
CON
4
CON
1
Port
Port
CP3
CP4
INPUT AC220V
CON
6
CO
N11 CO
N1
DC308V
CON7 CON8
CON2
AC220V
CO
N5PH-20-A1
CO
N4
CO
N6A
C22
0V
FA
N *
2
PZ-06-B4
BOTTOM BOARD
CON3
CON2
CON
10
CON2
CO
N9
CENTER BOARD
PD-08-B0VH
-07(
6)
CON1
+
-
+-
OU
T1
OU
T2
INVERTER BOARD
PN-0
7-A
1PN
-08-
B0
CO
N11
CON1
ARC FORCE
CON
12
PRO
TE
CT L
ED
CU
RR
EN
T
CON13CON14
THERMAL SWITCH
CONTROL BOARD
PK-31-A0
CON
1V
H-0
5V
H-0
4
50W
450R
*2
CON1 CON5
PK-09-A3
DRIVE BOARD
CON
15
CON
3AC2
0V*4
0
AC
380V
AC
220V
T
T
CO
N2
O
R
C
ON
4
XH-03(2)
PH-10-A2Gun Switch Board
Gun switch
CON
9
CON10
2T/4T
CON5
AC/DC
CON
TRO
L G
AS
CONTROL HF
CON6 CON7
ARC/TIG CONTROL GAS
CON8
CONTROL HF
CON2 CON3
CONTROL PULSE
CON4
PH-10-A01
CON15 DC12VPK-05-A4
PK-31-A0CONTROL BOARD
REPAIR MANUAL·AC/DC SERIES
4
1.3 The diagram of AC/DC200P’s top PCB PM-03-A2, center PCB PD-08-B0, bottom PCB PZ-06-B4, control panel PK-31-A0, low-voltage control PCB PK-05-A4, control module PK-03-A1, secondary drive PCB PK-09-A3, secondary inverter PCB PN-07-A1, PN-08-B0, power supply conversion PCB PH-20-A1, meter display preset PCB PH-10-A01:
C12.4
C12.3
C12.2
C12.1
CON1
CON4
CON5
1
CON3
C5
C6
R10.1 R10.2
R9.2R9.1
R12.5R12.4R12.3R12.2R12.1R10.5R10.4R10.3
C8 C10
C11C9 R13
R14R7
R8
R9.3 R9.4 R9.5 R11.1 R11.2 R11.3 R11.4 R11.5
C7.2
C7.1
C7.3
VT4.3 VT4.4 VT4.5VT4..2VT4.1VT2.5VT2.4VT2.3VT2.2VT2.1
VT3.3 VT3.4 VT3.5VT3.2VT3.1VT1.5VT1.4VT1.3VT1.2VT1.1
T1
CON2
2006.02.08
PM-03-A2
VH-03(2)
CON2
R18 R17 R18 R17 R18 R17 R18 R17
R17R18R17R18R17R18R17R18
C16C15
CON1
T2.2 T2.3 T2.4
C14C13 C13 C14 C14C13
C14C13C13 C14C14C13C13 C14
C13 C14
T2.1
D2D1D2D1 D2D1
D1 D2 D1 D2 D1 D2D1 D2
D1 D2
CON3
R23
L2.5X31.0
RT4
R02
R01
AC/DC.ARC.MIG.TIG(T) 2005.09PD-08-B0
+
REPAIR MANUAL·AC/DC SERIES
5
P1 P2
Q1
+
+
+ +
+
+ +RELAY1
D10
D7
C17
CON5
RELAY4
CON9
CON1
C12C13
C6
R11
C18VT2
C8C7
RV2 RV3
RV5RT1
D5
CP3
CP4
RELAY3VT3
U1
CON4
C11
C5
C10
C4
RELAY2
CP1
CP2
R9
CON11
CON6
RV4
CON8
C19
R1
R4
C20
CON3
D4
D2
D1
D9
D11
R7
R5
D6
C15
T1
CON10
Z2
Z1
Z3
CON7
C14
RV1
C9
C16
R8
R6
CON2
R2
R3
C3
D3
C2
C1
VT1
R10 D8
PZ-06-B4
2005.11.30
- +
-++-
+ -
- +
D18
D22
D1
D2
Z1
D24
D26
D25
D23Z5
D6
D11
D8
D16
D14D12
Z4
D9
Z3 D7
D5
D13
D10
D15
D20
D17
D21
D27
D4
D3
Z2
D19
D28
D30
D29
C18
R32
R45
R72
Q1
R15
C1
C17
C8
R1
C9
R4
CON5
Q3 Q4
R35
R37
R41
C29
R70 C26
C27
R6
R13
R18
R59
R62
R64
R65
R68
R58
R61
VR4
U7U6U5 U8
U3
CON6
CON10
CON9
CON7
CON11 CON12 LED1LED2
VR7
VR1
VR6VR8 VR9
VR2 VR3
VR5
U4
R12R9 R10
R2
R5
R19
R21 R22 R23 R24
R27 R29 R30
R33
R34
R38R39
R42
R25
R43 R44
R46 R47 R48
R50
R54
R51 R52
R56 R55
R57
R60
R69
R71
R73
R74
R76
CON13 CON15
D32D31 D34D33
C23
C22
U9
U2
R7
R11
CON8
L2L1
U1
C3
C5
L6L5
C2
R53
C15
C16
R63
R66
C21
C28
R67
C25
CON4
R8
CON3CON2CON1 R3
Q2
C10R17
R40
R36
R31
C4
L4
L3
C12
R20
R26
Q5 Q6
C24
C19
R14
R16
C6
C20
R75
L7
R28
C13
R49
C7
CON14
C14
C11
PK-31-A02006.02.08
REPAIR MANUAL·AC/DC SERIES
6
+ +
+ +
+
CON12
CON3CON6
R2
R3
C9
R11
R12
R5
C1
C19R30
z1
R29
D7Z2
D1
D3
D4
D11 D12U6 Q2
CON1
C21
C14
CON10
C11
C5
CON15CON14
CON5
C3
CON13
R27R31
R23R26
C15
C22
R33
R22
R25
R4
U3 U5U4
U2
Q1
C28
C29
C24
R17
CON11
C2
CON2
C4
C6
R6R7
R9
CON4
LED1 R8
R32
U1U9
D6D5
CON9
C8
C18
L1
U7 C34C33
C26
C13
C27
C16
C25
C12
C20
U8
R19D8
D10
R10
R13
C31
CON7 CON8
R14
R20
R18R16
R15
R24R28
R35
R1
C32
C23
C17
R34
C10
C30
R21
PK-05-A4 2006.02.08
C13
D1
C12
C7
LED2
LED1
R4
P1
R14
R17
R29
R16
R31
R25
R21
R19 D5
R28
C8
R15
C15
Z2 Z3
R7R6
C4
R23
R32
D4
D3D2
Z1R12
R13
R9
R1
R2
R8
C6
C9
C5
C18 C1 C2
R30
U2
Q5
Q8Q7
Q4
C16
Q9
Q1
Q3
C14U3
C17
C10
C11
Q2
R24R22
R18
R3
R27
R5
R11R10
Q6
R26
C3
R20
U1
PK-03-A1 2006.02.08
REPAIR MANUAL·AC/DC SERIES
7
+
+
+
C13
C12
C5
C17
C2
C8
CON3
CON2
R5
U1
C7
D1
C6
Q3
Q4
U4U5
C1
C4
R1
U3
U2Q2
Q1C3
C10 Q5
Q6
U8
U6
R10
U7
D5
C11
C9
C16
CON1
U10
U9
Q8
Q7 C14
D7
C15
U11
R13
CON5
CON4
R3
R7
R11
R15
D2
Z1Z2
Z3
Z4
D6
D3
D4
R14
R6
R2R4
R8
R12
R16
R9
2006.02.08PK-09-A3
VT10
R10
VT9
R9
VT8
R8
VT7
R7
VT6
R6
VT5
R5
VT4
R4
VT3
R3
VT2
R2
VT22
R23
VT21
R22
VT20
R21
VT19
R20
VT18
R19
VT17
R18
VT16
R17
VT15
R16
VT14
R15
VT1
R1
Z2
Z1
VT13
13
4
9
C4
D1
5
2
1
C3
3
7
12
C1
C2
C5
Z5
Z4
R14
VT11
VT12
CON1
R12
R11
C6Z3R13
11
14
15
6
8
10
AC/DC200/200II/200P(T)
2.5X191.8
2.5X191.8
2.5X191.8
2.5X81.2
2.5X81.2
2.5X81.2
2.5X127.8
2.5X127.8
2.5X127.8
PN-07-A1
2005.09
REPAIR MANUAL·AC/DC SERIES
8
VT11
12
14
16
R11
R1
VT1
CON1
6
5
2
11
1
Z1
Z2
Z4
Z3
9
VT12
R12
VT13
R13
VT14
R14
VT15
R15
VT16
R16
VT17
R17
VT18
R18
VT19
R19
VT20
R20
R2
VT2
R3
VT3
R4
VT4
R5
VT5
R6
VT6
R7 R8
VT8VT7
R9
VT9
R10
VT10
AC/DC200/200II/200P(T)
PN-08-B0
2005.09
2.5X81.2
2.5X127.8
2.5X191.8
2.5X81.22.5X127.8
2.5X191.8
2.5X81.2
2.5X127.8
2.5X191.8
CON1
CON3
CON6CON5CON4
CON2
2005.09
PH-20-A1
REPAIR MANUAL·AC/DC SERIES
9
+12V
CON2
CON1
VR1
R1
D1 U1
PH-10-A01
1.4 Troubleshooting of AC/DC200P:
Trouble Analysis Solution 1. Turn on the machine, no display of the meter, the fan doesn’t work, no no-load voltage output in TIG/ARC mode.
a. The input voltage is abnormal. b. The power supply cable matching
CP3/CP4 on bottom PCB PZ-06-B4 is disconnected, or the tie-in is damaged.
c. The power supply switch may be damaged.
d. The connecting cable matching socket CON1 — CON6 on power supply conversion PCB is in loose connection.
a. Check if the input voltage is AC 220V.
b. Check. c. Replace the power supply switch
if it’s damaged. d. Check.
REPAIR MANUAL·AC/DC SERIES
10
2. Turn on the machine, the meter displays, press the welding torch switch in TIG mode, there is gas out and no HF, no no-load voltage output in ARC mode.
a. The connecting cable matching socket CON1 on bottom PCB PZ-06-A3 is in loose connection.
b. The prime relay RELAY3 on bottom PCB PZ-06-A3 doesn’t close well; the value of thermal resistor RT1 increases.
c. The connecting cable matching rectifying bridge with socket CON11/CON6 is in loose connection.
d. Some part on control module PK-03-A1 is damaged.
e. Some part on control PCB PK-05-A4 is
damaged.
a. Check if the voltage of socket CON1 is DC308V.
b. Check and replace if necessary. c. Check. d. Check with a multi-meter if chip
U1 is damaged. Check if the 16th pin of U1 is 5V. If it’s not, replace the chip because U1 is damaged. Check if resistor R32, diode D2/D3/D4, zener diode Z1/Z2/Z3, audion Q2/Q3/Q4/Q5/Q6/Q7/Q9, thyristor Q1 or capacitor C17 is damaged.
e. Check if MOSFET U2/U3/U4/U5 or resistor R32 is damaged.
3. Turn on the machine, the meter displays, but the thermal resistor RT1/RT2/RT3/RT5 on bottom PCB PZ-06-B4 heats and smokes after a while.
a. The connecting cable (+24V) matching socket CON10 on bottom PCB PZ-06-A4 with socket CON14 on control PCB PK-05-A4 is in loose connection.
b. The relay RELAY3 on bottom PCB PZ-06-A4 is damaged.
c. The auxiliary power supply part on control PCB PK-05-A4 is damaged.
a. Check. b. Check. c. Check with a multi-meter if chip
U6, audion Q2, MOSFET U1, capacitor C23 or resistor R35 on control PCB PK-05-A4 is damaged.
REPAIR MANUAL·AC/DC SERIES
11
4. Turn on the machine and it appears normal, there is no-load voltage output in ARC mode, press the welding torch in TIG mode and there is gas out, the malfunction LED is not on, no HF.
a.
b.
c.
d.
e.
f.
The connecting cable matching socket CON3 on top PCB PM-03-A2 with socket CON3 on bottom PCB PZ-06-B4 is in loose connection. High voltage silicon granule D1/D2/D4/D5 or high voltage output capacitor C12/C13 on bottom PCB PZ-06-B4 is damaged. The connecting cable is in loose connection with CP1/CP2 on bottom PCB. The discharge nozzle P1/P2 on bottom PCB has conglutination, excessive clearance or serious oxidation problem. The ARC/TIG conversion switch on the panel or chip U7 on control panel PK-31-A0 is damaged. The connecting cable matching socket CON8 on control PCB PK-31-A0 with socket CON2 on bottom PCB PZ-06-B4 is in loose connection, or HF relay RELAY1, audion Q1, MOSFET VT1 or diode D3 on bottom PCB is damaged.
a. Check. b. Check. c. Check. d. Adjust or replace it if necessary. e. Check and replace it if necessary. f. Check. Short-circuit socket CON2
on bottom PCB PZ-06-B4, then turn on the machine and press the manual switch. If there is no HF, there is something wrong with the HF circuit on bottom PCB. If there is, the inductor L1/L2, chip U1/U3 or resistor R6 on control PCB PK-31-A0 is damaged.
REPAIR MANUAL·AC/DC SERIES
12
5. Turn on the machine and it appears normal, press the welding torch switch and there is gas out, the malfunction LED is on, turn to ARC mode, the malfunction LED turns on.
a. Over-current protection occurs when welding is carried out.
b. Over-heating protection occurs when welding is carried out.
c. Some parts on top PCB, center PCB, or
bottom PCB are damaged.
a. Turn off the machine for 5mins and restart.
b. Stop the welding operation for 5mins, or the secondary inverter thermal switch is damaged.
c. Check. Turn off the machine, pull out the connecting cable matching the socket CON3 on top PCB PM-03-A2 with the socket CON3 on bottom PCB PZ-06-B4, turn on the machine. If the malfunction LED is off, the transformer T1 is short-circuited or damaged. If it’s on, turn off the machine, pull out the connecting cable matching socket CON1 on top PCB PM-03-A2, turn on the machine. If the malfunction LED is on, MOSFET VT1.1—/VT4.5 on top PCB or some parts on drive module PK-08-A1 are damaged; if it’s off, transformer T2.1/T2.2/ T2.3/T2.4 or rectifying diode D1/D2 on PCB PD-08-B0 is damaged.
6. Turn on the machine and it appears normal, it can start arc in TIG mode, but the welding point appears black.
a. The magnet valve or the gas tube is blocked.
b. The magnet valve is damaged. c. The connecting cable matching socket
CON10 on bottom PCB PZ-06-A4 with socket CON7 on control panel PK-31-A0 is in loose connection.
d. Some parts in magnet valve control circuit on bottom PCB PZ-06-B4 or some parts in magnet valve control circuit on control panel PK-31-A0 are damaged.
e. The welding torch is damaged. f. The tungsten is of bad quality or the
argon is impure.
a. Clear. b. Replace. c. Check. d. Check with a multi-meter if the
MOSFET VT1, resistor R3/R2, diode D3 or audion Q1 on bottom PCB or audion Q1 on control PCB PK-31-A0 is damaged or if the magnet valve control cable matching the socket CON4 is disconnected.
e. Remove the welding torch and the gas-electricity tie-in, and press the welding torch switch. If there is gas out, the welding torch is damaged. Replace it.
f. Check and replace it if necessary.
REPAIR MANUAL·AC/DC SERIES
13
7. The cutting current is unstable and out of control.
a. The connecting cable matching socket CON2 on control PCB PK-05-A4 with socket CON11 on control panel PK-31-A0 is in loose connection.
b. The capacitor C14/C15/C16/C9/C7/C8 on bottom PCB PZ-06-B4 leaks or is damaged.
c. The input cable or output cable is too slim and too long.
d. Loose connection exists inside the machine, e.g. the remote control connecting cable matching socket CON4 on control panel.
a. Check and replace it if necessary. b. Check and replace it if necessary. c. Enlarge the cross section area of
the cable. d. Check.
8. Turn on the machine but it strips.
a. The rectifying bridge matching the socket CON6/CON11 on bottom PCB PZ-06-B4 is damaged.
b. The power supply cable is disconnected or short-circuited.
a. Replace. b. Check.
9. Adjust the decay potentiometer to the max value and release the welding torch switch, the gas shuts off and then no current output.
a. The diode D1/D2 or chip U3 on control panel PK-10-A1 is damaged.
a. Check and replace it if necessary.
10. Press the welding torch switch, there is HF discharge buzz, but no welding voltage output.
a. The earth cable of welding torch is in loose connection.
b. The output terminal of the earth cable is in loose connection with gas-electricity tie-in or with center PCB PD-01-A2.
a. Check and replace it if necessary. b. Check and replace it if necessary.
11. The arc starting is bad in TIG mode.
a. The space between discharge nozzles P1 and P2 on bottom PCB PZ-06-B4 is too big or small, or their surface is badly oxidized.
b. The high-voltage capacitor C12/C13 on bottom PCB is damaged, or the capacitance becomes smaller.
c. The tungsten is of bad quality or the argon is impure.
d. The welding torch is in loose connection.e. Incorrect turn rate or turn-to-turn
electricity leakage problem exists in arc-starting coil matching CP1/CP2 on bottom PCB.
a. Adjust the space between them, or clear their surface.
b. Check and replace it if necessary. c. Check and replace it if necessary. d. Check. e. Check.
REPAIR MANUAL·AC/DC SERIES
14
12. Turn on the machine, and it appears normal, but the malfunction LED turns on once welding is carried out.
a. The connecting cable matching socket CON11 on control PCB PK-05-A4 with the output bypass is in loose connection.
b. Loose contact exists in MOSFET VT1.1— VT4.5 on top PCB PM-03-A2 or rectifying diode D1/D2 on center PCB PD-08-B1.
c. Some parts on control module PK-03-A1 are damaged.
a. Check. b. Check with a multi-meter. c. Check if the chip U2 or audion Q9
on PK-03-A1 is damaged. 13. Turn on the machine, and there is HF.
a. Some parts in manual switch control circuit are damaged.
b. The connecting cable matching socket
CON8 on control panel PK-31-A0 with socket CON2 on bottom PCB PZ-06-B4 is in loose connection, or chip U1 on control panel PK-31-A0 is damaged.
a. Check with a multi-meter if chip U8 or diode D14/D18 on control panel PK-31-A0 is damaged. Disconnect the connecting cable matching socket CON9, and short-circuit both terminal of CON9, then check if the manual switch board PH-10-A1 is short-circuited.
b. Check.
14. Incessant HF exists when welding is carried out.
a. The relay RELY1, audion Q1, diode D3, MOSFET VT1 on bottom PCB PZ-06-B4 or chip U1 on control panel PK-31-A0 is damaged.
b. The connecting cable matching socket CON13 on control panel PK-31-A0 with socket CON5 on control PCB PK-05-A4.
a. Check and replace it if necessary. b. Check.
15. There is deviation between the preset value and real value of the show value of the meter.
a. The value of the variable resistor R9 on control PCB PK-05-A4 or VR1 on preset PCB PH-10-A01 changes.
a. Adjust. Methods: 1. Turn to ARC mode, adjust the value of variable resistor R9 on control PCB PK-05-A4 to make the show value of the meter is 200. 2. Turn to TIG mode, do not press the manual switch, adjust the value of variable resistor VR1 on preset PCB to make the show value of the meter is 200.
16. No pulse in the pulse mode.
a. The pulse conversion switch on the panel is damaged.
b. The connecting cable matching socket CON2/CON3 on control panel PK-31-A0 with the pulse conversion switch is short-circuited, or chip U4, capacitor C4/C11, potentiometer VR2/VR3 or diode D24 is damaged.
a. Check and replace it if necessary. b. Check.
REPAIR MANUAL·AC/DC SERIES
15
17. When no-load in ARC mode, it appears normal in DC mode, but there is abnormal sound in AC mode.
a. Some of the MOSFET on the secondary inverter PCB PN-07-A1/PN-08-B0 is damaged.
a. Check. Method: Turn to ARC mode, then AC mode, turn off the machine after 3mins of no-load, touch the MOSFET on the secondary inverter PCB with your hand one by one. The extra hot ones are damaged.
18. No 4T state or 4T is inaccurate.
a. The 2T/4T conversion switch on the panel is damaged, or the connecting cable matching it with socket CON10 on control panel PK-31-A0 is in loose connection.
b. Some part on control panel PK-31-A0 is damaged.
a. Check. b. Check if chip U8/U2, diode D6 or
capacitor C2 on control panel is damaged.
19. No AC output in AC mode. a. The AC/DC conversion switch on the panel is damaged.
b. Some part on the control panel PK-31-A0 is damaged.
c. Some part on the secondary drive PCB PK-09-A3 is damaged.
a. Check. b. Check if the diode D9/D2/D1,
audion Q2, chip U6 or potentiometer VR4 on control panel is damaged.
c. Check with a multi-meter if chip U2/U4/U8/U9/U3, audion Q1—Q8 or zener diode Z1/Z2/Z3/Z4 on drive PCB is damaged.
20. No AC sound when welding in AC mode.
a. The value of the resistor matching socket CON1 on inverter PCB PN-07-A1 varies.
b. The MOSFET VT1, rectifying diode VT11, diode D1 or zener diode Z3 on inverter PCB PN-07-A1 is damaged.
a. Check and replace it if necessary. b. Check and replace it if necessary.
21. Press the welding torch switch, there is gas out, the show value of the meter is invariable, there is only small current, and the pre-flow time is variable.
a. The connecting cable matching socket CON11 on control panel PK-31-A0 with socket CON2 on control PCB PK-05-A4 is in loose connection.
b. Some part on control panel PK-31-A0 is damaged.
a. Check. b. Check if chip U5, audion Q3/Q4 or
potentiometer VR7 on control panel PK-31-A0 is damaged.
22. When the pulse conversion switch is in no-pulse mode, in ARC or TIG mode, the welding current is invariable, and there is only maximum current.
a. The diode D24 on control panel PK-31-A0 is damaged.
a. Check.
REPAIR MANUAL·AC/DC SERIES
16
23. Turn on the machine, the indicator of protection status is on because the voltage is too low.
a. The input voltage is too low or is unstable.
b. The thermal switch matching socket CON14 on control panel PK-31-A0 is damaged.
c. The connecting cable matching socket CON15 on control panel PK-31-A0 is in loose connection.
d. The resistor R51/R44 or chip U6 on control panel PK-31-A0 is damaged.
a. Check. b. Check. c. Check. d. Check. Method: properly reduce
the value of resistor R44.
2. AC/DC200Ⅱ 2.1 The structure drawing of AC/DC200Ⅱ: (Lack for the moment) 2.2 The general connection diagram of AC/DC200Ⅱ:
CONTROL MODULE
ELECTRIC DIAGRAM
Top Board
DRIVE MODULE
PK-03-A1
DC24V
AC/DC200
VH
-03
VH-02
VH-02
THERMAL SWITCH
PK-05-A4Control Board
VH-03
14V
14V
0 0
AC380V
AC220V
(VH-04)*2
DRIVE LINE
XH
-02
XH
-03
VH-02XH-03
DC12V
VH-02
XH-04 XH-03VH-03 XH-04
CON11
CON6CON1
CON3 CON5CON8CON7CON10
CON2
CON4
CON9CON14
CON15 CON12 CON13
METER CONTROL SIGNALREMOTE RESISTANCE
PK-08-A1
PM-03-A2
CON
4
CON
1
Port
Port
CP3
CP4
INPUT AC220V
CON
6
CO
N11 CO
N1
DC308V
CON7 CON8
CON2
AC220V
CO
N5PH-20-A1
CON
4C
ON
6AC2
20V
F
AN
*2
PZ-06-B4
BOTTOM BOARD
CON3
CON2
CON
10
CON2
CO
N9
CENTER BOARD
PD-08-B0VH
-07(
6)
CON1
+
-
+-
OU
T1
OU
T2
INVERTER BOARDPN
-07-
A1
PN-0
8-B0
CON
8
CON1
ARC FORCE
CON
9
PRO
TEC
T L
EDCU
RREN
T
CON10CON11
THERMAL SWITCH
CONTROL BOARD
PK-30-A0
CON
1V
H-0
5V
H-0
4
50W
450R
*2
CON1 CON5
PK-09-A3
DRIVE BOARD
CON
12
CON
3AC2
0V*4
0
AC
380V
AC
220V
T
T
CO
N2
O
R
CO
N4
XH-03(2)
PH-10-A2Gun Switch Board
Gun switch
CON
5
CON6
2T/4T
CON7
AC/DC
CON
TRO
L G
AS
CONTROL HF
CON2 CON3
ARC/TIG CONTROL GAS
CON4
CONTROL HF
CON1
PH-10-A01
CON15 DC12VPK-05-A4
PK-31-A0CONTROL BOARD
REPAIR MANUAL·AC/DC SERIES
17
2.3 The diagram of AC/DC200Ⅱ’s control panel PK-30-A0:
-+
+-
D13
D3
D25
D12
D14
D33
D31
Z2
D32
D1
D2
D4
D5
D6
Z3
D18
D21
D23
D19 D17
D20
D22
D24
D26
D16
D15
D7 D11D10D8 D9
Z1
L6
L5
R4
R7
L7
R56
R66
C15
R30
C4
R23 R24
C19
R33C20
C3
D28D27 D30D29
L4L3
R67
C26
C23
C25
C21
Q6
C16
U3
R41
C2
R13
R11
C11
U5
C12CON5
U1 U2
VR1
VR4
VR5
VR2 VR3
LED2LED1
R12
R1
R58R49
R46
R29
R27
R25
R21
R57
R48
R45
R38
R32
R28
R8
R6
R65
R9
R55
R42
R40
R60
R51
U7
CON4
CON12
CON8 CON9 CON11
CON1
0
CON7
CON6
U6
C13
C17
U8
R47
R44
R43
R37
R34
U4
CON3
R39
Q2
Q3
R36
C10C8 C9
Q1
C6
C1
C22
Q4 Q5
R54
R64
R59
R52 R53
R63R62R61
R50
C14
R19R18R17R15 R16 R20
C7
R22
R35
CON1
R5
R3
R2
C5
L2L1CON2
R26
R10
R14
C24
R31C18
PK-30-A02006.02.08
2.4 Troubleshooting of AC/DC200Ⅱ:
Trouble Analysis Solution 1. Turn on the machine, there is no display of the meter, the fan doesn’t work, no no-load voltage output in ARC/TIG mode.
a.
b.
c.
d.
The input voltage is abnormal.
The power supply cable matching CP3/CP4 on bottom PCB PZ-06-B4 is disconnected, or the tie-in is damaged. The power supply switch may be damaged, or it’s not closed. The connecting cable matching socket CON1-CON6 on power supply conversion PCB PH-20-A1 is in loose connection.
a. Check if the input voltage is AC 220V.
b. Check. c. Check. d. Check.
REPAIR MANUAL·AC/DC SERIES
18
2. Turn on the machine, the meter displays, press the welding torch switch in TIG mode, there is gas out and no HF, no no-load voltage output in ARC mode.
a. The connecting cable matching socket CON1 on bottom PCB PZ-06-B4 is in loose connection.
b. The prime relay RELY3 on bottom PCB PZ-06-B4 doesn’t close well; the value of thermal resistor RT1 increases.
c. The connecting cable matching socket CON11/CON6 on bottom PCB PZ-06-B4 with the rectifying bridge is in loose connection.
d. Some part on control module PK-03-A1 is damaged.
e. Some part on control PCB PK-05-A4 is
damaged.
a. Check. Make sure the voltage of socket CON1 is DC308V.
b. Check and replace if necessary. c. Check. d. Check with a multi-meter if chip
U1 on PK-03-A1 is damaged. Method: Check if the output voltage of the 16th pin of U1 is 5V. If it’s not, U1 is damaged. Check if audion Q2/Q3/Q4/Q5/Q6/Q7/Q9, thyristor Q1, diode D2/D3/D4, zener diode Z1/Z2/Z3, capacitor C17 or resistor R32 is damaged.
e. Check if MOSFET U2/U3/U4/U5 or resistor R32 is damaged.
3. Turn on the machine, the meter displays, but the thermal resistor RT1/RV2/RV3/RV5 on bottom PCB PZ-06-B4 heats and smokes after a while.
a.
b.
c.
The connecting cable (+24V) matching socket CON10 on bottom PCB PZ-06-A4 with socket CON14 on control PCB PK-05-A4 is in loose connection. The relay RELAY3 on bottom PCB PZ-06-A4 is damaged. The auxiliary power supply part on control PCB PK-05-A4 is damaged.
a. Check. b. Check. c. Check with a multi-meter if chip
U6, audion Q2, MOSFET U1, capacitor C23 or resistor R35 on control PCB PK-05-A4 is damaged.
REPAIR MANUAL·AC/DC SERIES
19
4. Turn on the machine and it appears normal, there is no-load voltage output in ARC mode, press the welding torch in TIG mode and there is gas out, the malfunction LED is not on, no HF.
a.
b.
c.
d.
e.
f.
The connecting cable matching socket CON3 on top PCB PM-03-A2 with socket CON3 on bottom PCB PZ-06-B4 is in loose connection. High voltage silicon granule D1/D2/D5/D4 or high voltage output capacitor C12/C13 on bottom PCB PZ-06-B4 is damaged. CP1/CP2 is disconnected with the bottom PCB. The discharge nozzles P1/P2 on bottom PCB have conglutination, excessive clearance or serious oxidation problem. The ARC/TIG conversion switch on the panel or the chip U4 on control panel PK-30-A0 is damaged. The connecting cable matching socket CON4 on control PCB PK-30-A0 with socket CON2 on bottom PCB PZ-06-B4 is in loose connection, or HF relay RELAY1, audion Q1, MOSFET VT1 or diode D3 on bottom PCB is damaged.
a. Check. b. Check. c. Check. d. Adjust or replace it if necessary. e. Check and replace it if necessary. f. Check. Method: short-circuit the
socket CON2 on bottom PCB PZ-06-B4, turn on the machine, and press the manual switch. If there isn’t HF, the HF circuit on bottom PCB goes wrong. If there is, the inductor L3/L4, chip U5/U3 or resistor R9 on control PCB PK-30-A0 is damaged.
REPAIR MANUAL·AC/DC SERIES
20
5. Turn on the machine and it appears normal, press the welding torch switch and there is gas out, the malfunction LED is on, the malfunction LED turns on when turning to ARC mode.
a. Over-current protection occurs when welding is carried out.
b. Over-heating protection occurs when welding is carried out.
c. Some parts on top PCB, center PCB, or
bottom PCB are damaged.
a. Turn off the machine for 5mins and restart.
b. Stop the welding operation for 5mins, or the secondary inverter thermal switch is damaged.
c. Check. Method: turn to TIG mode, turn off the machine, and pull out the connecting cable matching the socket CON3 on top PCB PM-03-A2 with the socket CON3 on bottom PCB PZ-06-B4, then turn on the machine. If the malfunction LED is off, the transformer T1 is short-circuited or damaged. If it’s on, turn off the machine, pull out the connecting cable matching socket CON1 on top PCB PM-03-A2, turn on the machine. If malfunction LED is on, MOSFET VT1.1—/VT4.5 on top PCB or some part on drive module PK-08-A1 is damaged; if off, transformer T2.1/T2.2/T2.3/T2.4 or rectifying diode D1/D2 on PCB PD-08-B0 is damaged.
6. Turn on the machine and it appears normal, it can start arc in TIG mode, but the welding point appears black.
a. The magnet valve or the gas tube is blocked.
b. The magnet valve is damaged. c. The connecting cable matching socket
CON10 on bottom PCB PZ-06-B4 with socket CON3 on control panel PK-30-A0 is in loose connection.
d. Some part in magnet valve control circuit on bottom PCB PZ-06-B4 or some part in magnet valve control valve circuit on control panel PK-30-A0 is damaged.
e. The welding torch is damaged. f. The tungsten is of bad quality or the
argon is impure.
a. Clear. b. Replace. c. Check. d. Check with a multi-meter if the
MOSFET VT1, resistor R3/R2, diode D3 or audion Q1 on bottom PCB or audion Q1 on control PCB PK-30-A0 is damaged or if the magnet valve control cable matching the socket CON4 is disconnected.
e. Remove the welding torch and the gas-electricity tie-in, and press the welding torch switch. If there is gas out, the welding torch is damaged. Replace it.
f. Check and replace it if necessary.
REPAIR MANUAL·AC/DC SERIES
21
7. The welding current is unstable and out of control.
a. The connecting cable matching the socket CON2 on the control PCB PK-05-A4 with socket CON8 on control panel PK-30-A0 is in loose connection.
b. The capacitor C14/C15/C16/C9/C7/C8 on bottom PCB PZ-06-B4 leaks or is damaged.
c. The input cable or output cable is too slim and too long.
d. Loose connection exists inside the machine, e.g. the connecting cable matching socket CON1 with the remote control.
a. Check and replace it if necessary. b. Check and replace it if necessary. c. Enlarge the cross section area of
the cable. d. Check.
8. Turn on the machine but it strips.
a. The rectifying bridge matching the socket CON6/CON11 on bottom PCB PZ-06-B4 is damaged.
b. The power supply cable is disconnected or short-circuited.
a. Replace. b. Check.
9. In TIG mode, adjust the decay potentiometer to the max value and release the welding torch switch, the gas shuts off and then no current output.
a. The audion Q4, resistor R54/R59/R63 or chip U8 on control PCB PK-30-A0 is damaged.
a. Check and replace it if necessary.
10. Press the welding torch switch, there is HF discharge buzz, but no welding voltage output.
a. The earth cable of welding torch is in loose connection.
b. The output terminal of the earth cable is in loose connection with gas-electricity tie-in.
a. Check and replace it if necessary. b. Check and replace it if necessary.
11. The arc starting is bad in TIG mode.
a. The space between discharge nozzles P1 and P2 on bottom PCB PZ-06-B4 is too big or small, or their surface is badly oxidized.
b. The high-voltage capacitor C12/C13 on bottom PCB is damaged, or the capacitance becomes smaller.
c. The tungsten is of bad quality or the argon is impure.
d. The welding torch is in loose connection.e. Incorrect turn rate or turn-to-turn
electricity leakage problem exists in arc-starting coil matching CP1/CP2 on bottom PCB.
a. Adjust the space between them, or clear their surface.
b. Check and replace it if necessary. c. Check and replace it if necessary. d. Check. e. Check.
REPAIR MANUAL·AC/DC SERIES
22
12. Turn on the machine, and it appears normal, but the malfunction LED turns on once welding is carried out.
a. The connecting cable matching socket CON11 on control PCB PK-05-A4 with the output bypass is in loose connection.
b. Loose contact exists in MOSFET VT1.1-VT4.5 on top PCB PM-03-A2 or rectifying diode D1/D2 on center PCB PD-08-B0.
c. Some part on control module PK-03-A1 is damaged.
a. Check. b. Check with a multi-meter. c. Check if the chip U2 or audion Q9
on PK-03-A1 is damaged. 13. Turn on the machine, and there is HF.
a. Some parts in manual switch control circuit on bottom PCB are damaged.
b. The connecting cable matching socket
CON4 on control panel PK-30-A0 with socket CON2 on bottom PCB PZ-06-B4 is short-circuited or in loose connection, or chip U3 on control panel PK-30-A0 is damaged.
a. Check with a multi-meter if chip U1 or diode D1/D2 on control panel PK-30-A0 is damaged. Disconnect the connecting cable matching socket CON5, short-circuit both terminal of socket CON5 and check if the manual switch board PH-10-A1 is short-circuited.
b. Check.
14. Incessant HF exists when welding is carried out.
a. The relay RELAY1, audion Q1, diode D3, MOSFET VT1 on bottom PCB PZ-06-B4 or chip U3 on control panel PK-30-A0 is damaged.
b. The connecting cable matching socket CON10 on control panel PK-30-A0 with socket CON5 on control PCB PK-05-A4 is in loose connection.
a. Check and replace it if necessary. b. Check.
15. There is deviation between the preset value and real value of the show value of the meter.
a. The value of the variable resistor R9 on control PCB PK-05-A4 or VR1 on preset PCB PH-10-A01 changes.
a. Adjust. Methods: 1. Turn to ARC mode, adjust the value of variable resistor R9 on control PCB PK-05-A4 to make the show value of the meter is 200. 2. Turn to TIG mode, do not press the manual switch, adjust the value of variable resistor VR1 on preset PCB to make the show value of the meter is 200.
16. No welding voltage output in ARC mode, but it’s normal in TIG mode.
a. The ARC/TIG conversion switch on the panel is damaged.
b. The connecting cable matching socket CON2/CON3 on control panel PK-30-A0 with ARC/TIG conversion switch is in loose connection, or chip U4, resistor R7 or diode D3 is damaged.
a. Check and replace it if necessary. b. Check.
REPAIR MANUAL·AC/DC SERIES
23
17. When no-load in ARC mode, it appears normal in DC mode, but there is abnormal sound in AC mode.
a. Some of the MOSFET on the secondary inverter PCB PN-07-A1/PN-08-B0 is damaged.
a. Check. Method: Turn to ARC mode, then AC mode, turn off the machine after 3mins of no-load, touch the MOSFET on the secondary inverter PCB with your hand one by one. The extra hot ones are damaged.
18. No 4T state or 4T is inaccurate.
a. The 2T/4T conversion switch on the panel is damaged, or the connecting cable matching it with socket CON6 on control panel PK-30-A0 is in loose connection.
b. Some part on control panel PK-30-A0 is damaged.
c. Interfered by the manual switch PCB.
a. Check. b. Check if chip U1/U2, diode D4 or
capacitor C2 on control panel is damaged.
c. The porcelain capacitor 102/2KV on the manual switch PCB is damaged.
19. No AC output in AC mode. a. The AC/DC conversion switch on the panel is damaged.
b. Some part on the control panel PK-30-A0 is damaged.
c. Some part on the secondary drive PCB
PK-09-A3 is damaged.
a. Check. b. Check if the diode D18/D11/D10,
audion Q6, chip U8 or potentiometer VR2 on control panel PK-30-A0 is damaged.
c. Check with a multi-meter if chip U2/U4/U8/U9/U3, audion Q1-Q8 or zener diode Z1/Z2/Z3/Z4 on drive PCB is damaged.
20. No AC sound when welding in AC mode.
a. The value of the resistor matching socket CON1 on inverter PCB PN-07-A1 varies.
b. The MOSFET VT1, rectifying diode VT11, diode D1 or zener diode Z3 on inverter PCB PN-07-A1 is damaged.
a. Check and replace it if necessary. b. Check and replace it if necessary.
21. Press the welding torch switch, there is gas out, the show value of the meter is invariable, there is only small current, and the pre-flow time is variable.
a. The connecting cable matching socket CON8 on control panel PK-30-A0 with socket CON2 on control PCB PK-05-A4 is in loose connection.
b. Some part on control panel PK-30-A0 is damaged.
a. Check. b. Check if chip U7, audion Q3/Q2 or
potentiometer VR5 on control panel PK-30-A0 is damaged.
REPAIR MANUAL·AC/DC SERIES
24
22. Turn on the machine, the indicator of protection status is on because the voltage is too low.
a. The input voltage is too low or is unstable.
b. The thermal switch matching socket CON11 on control panel PK-30-A0 is damaged.
c. The connecting cable matching socket CON12 on control panel PK-30-A0 is in loose connection.
d. The resistor R47/R44 or chip U8 on control panel PK-30-A0 is damaged.
a. Check. b. Check. c. Check. d. Check. Method: properly reduce
the value of resistor R47.
3. WSE200 3.1 The structure drawing of WSE200:
The structure of WSE200 is similar to that of RILTIG315AC/DC. (See the above structure drawing.)
No. Description No. Description No. Description 1 Cover 9 Pilot-socket (2 pins) 17 Center PCB 2 Handle 10 Pilot-socket (3 pins) 18 Inverter PCB 2 3 Button 11 Rubber foot 19 Fan 4 Function switch 12 Coupling socket 20 HF PCB 5 Function switch 13 Panel PCB 21 Heat sink 6 Main switch 14 Control PCB 22 Input cable 7 Front panel 15 Top PCB (left) 23 Digital meter 8 Fast-socket 16 Inverter PCB 1
Note: WSE200 is without No.20 HF PCB.
REPAIR MANUAL·AC/DC SERIES
25
3.2 The general connection diagram of WSE200:
ELECTRIC DIAGRAM
Top Board
DRIVE MODULE
WSE200
REMOTE RESISTANCE
PK-07-B0
PM-01-A3
CON
4---
CO
N3
CON
8
Port
Port
CP3
CP4
INPUT AC220V
CON
5 C
ON
9
CON
1
DC308V
CON2 CON8
CON2
AC220V
CO
N5PH-20-A1
CO
N4
CO
N6A
C22
0V
FA
N *
2
PZ-27-A0
BOTTOM BOARD
CON3
CON
2
CO
N10
CON7
CO
N3
CENTER BOARD
PD-06-A2VH
-07(
6)
CON2
+
-
+-
OU
T1
OU
T2
INVERTER BOARD
PN-0
2-A
2PN
-01-
A1
CON10CON8 OR CON9
CON
12
PROTECT LEDCURRENT R
CON6
CON11
THERMAL SWITCH
CONTROL BOARD
PK-10-A1
CON
1V
H-0
5V
H-0
4
50W
160R
CON1 CON5
PK-09-A3
DRIVE BOARD
CON
3
CON
3AC2
0V*4
0
AC
380V
AC
220V
T
CO
N2
O
R
C
ON
4
XH-03(2)
PH-10-A2Gun Switch Board
Gun switch
CON
4
CON7
CON
5
AC/DC
CON
TRO
L H
F
CON1
CON6
CO
N8HF
CONTROL MODULE
PK-02-A1
+24V
CON
6
FEED BACK
CON
1
CONTROL GAS TIME
CON2
REMOTE SWITCH
CO
NT
RO
L M
ETE
R
CON5 CON2CON2
THERMAL SWITCH
CON9
3.3 The diagram of WSE200’s top PCB PM-01-A3, control module PK-02-A1, center PCB PD-06-A2, bottom PCB PZ-27-A0 and secondary inverter PCB PN-01-A1 and PN-02-A2:
+
+
+
+
C4
VT7
VT9
VT8
VT10
PK-07-B0 PK-02-A1(C)
P1
VR4
T2
VT4.1
VT6.1
VT2
R35
C10.3
C10.2
C10.1
CON8
C19
Q1
C1
C20
D6
R25
R26
R27R32
R23
R22
R24
C27
R33
C21.2
LED2C18
CON6
CON5
C24
CON2
R34
R37
CON3---CON4
R10
C16
R30
R15
R13
R11
C3
U2
R38
R29
R5
R14
C8
C7
R31
C29
R20.1
R19.1
U3
C32
C28
D5.2
D5.1
R36
Q2
C33
C31
CON10
CON9
103C21
CON1
C21.1
C17
C23
C5.1 C5.2
R28
LED1
R12
Z6Z5
BR2.1
Z3
BR2.2
BR2.3
BR2.4
D9D10
Z4
D7
D8
C25
C22
P1
R39
L1
300:1:1
T3
C14
VT4.2 VT4.3
R20.3R20.2
VT3.1
R17.1
VT3.2 VT3.3
R17.3R17.2
VT6.2
R19.2
VT6.3
R19.3
VT5.1
R18.1
VT5.2
R18.2
VT5.3
R18.3
R16
C9
R4
C6
CON7
2006.02.08
PM-01-A3
X4
REPAIR MANUAL·AC/DC SERIES
26
++
R19 R20
R25
C10
R22
R27
C15
Q2
U2
C9
C7
D4
R29
Q4
Q1
R16
R18
C3
R24
Q3
Q8
Q9
Q6U1
C13
LED1
LED2
D1 D2
R8
Z4
R28
C5
C6
C2
C8
C14
Z2
R23
C1
C11
D3
Z1
C16
R9
R17
R3
R10
R13
R2R12
R14
R11
R4R5 R6
R15
R26
R30
Q7
Q5
R7
Z3
C4
C12
R1
R21
2006.02.08PK-02-A1
CON1
L2.5X31.0
T1-1
D3.1 D2.2 D3.2 D2.3 D3.3
D3.6D2.6D3.5D2.5D3.4D2.4
C14
C13
L3.0X99.8
D12
D13
Z01
hz
R21
R7.5 R6.5 R7.6 R6.6
R6.3R7.3R6.2R7.2R6.1R7.1
R6.4R7.4
C11.1C12.1
C11.4C12.4 C12.5 C11.5 C12.6 C11.6
C12.3 C11.3C12.2 C11.2
T1-2 T1-3
CON2
R8
L1-1
L1-2
RV5
RV4
RV3 C01
D2.1
2005.09PD-06-A2AC/DC200.ARC160/200 (T)
REPAIR MANUAL·AC/DC SERIES
27
P1 P2 + +
+
+ +
R8
C10
C11
T1
Z4
Z3
R1
R5
R6
CON6
RV1
R9
C17 VT1
CON1
C5C4
RT2 RT3
RT4RT1
CP3
CP4RELAY3
VT2
U1
CON4
R7
CON9
CON5
RV2
CON8
C19C18
D7
D8
D6
C13
D1
CON10
CON
7
C12
C14 C15
D5
CON2
C8
C6
C7
C2
CP1
CP2
R2
R4
D4
D3
D2
C16
C1
C9
CON3
C3
Z1Z2
R3
Z5
RELAY1
RELAY2
AC/DC200(D)
L1
R101K 5W
2005.09
PZ-27-A0
+-- +
-++ -
-+-+
-+
-+
+ --+
CON12
R11
D25
C23
C24
R23C18
C1
C5
C16
D18
R10
U4
D13
D10
D8
R14
D23D22
D12
D11
CON2CON1
D14
R19
R17
C6
C8
C15
C10
C13
R22
C4
Q1 Q2
C22
R5
R1
R3
R25
R7
R4
R13
R12
C9
C2
D9
D1
C14
C20
C11
R31
R2
R32
R35
R28
R6
R16
Q4
Q3
R18
R15
R20
C3
C19
C21
C7
R29
D15
D3
D19
U3
R24
R34
R26
CON7 CON8CON5CON4 CON6 CON11
VR4
VR5
VR2VR1 VR3
LED2LED1
CON3 CON9 CON10
D20
D16
D21
D17
C12
D5
D4
R8
D2
R27R30
R33
R21
D24
R9
C17
D6
U1
U2
D7
PK-10-A1 2006.02.09
REPAIR MANUAL·AC/DC SERIES
28
C1
Z4
Z3
Z2
Z1 R3 R4
R12R11R10R9
R5 R6
R7 R8
R2R1
VT1 VT2 VT3 VT6
VT7 VT9 VT10 VT11
35
32
34
37
VT5
VT12
VT4
VT8
AC/DC200(D)
2005.09
PN-01-A1
R8
R7
Z5
Z4
Z2
Z1
R3 R4
R15R14R13R12
R5 R6
R10 R11
R2R1
VT1 VT2 VT3 VT6
VT8 VT9 VT10 VT12
VT5
VT13
VT4
VT11
C5
CON1
C6
Z3R9
D1
VT7
D1
C3
C1
C4
C2
AC/DC200(D)
PN-02-A2
2005.09
REPAIR MANUAL·AC/DC SERIES
29
3.4 Troubleshooting of WSE200: Trouble Analysis Solution
1. Turn on the machine, the power indicator is not on, the fan doesn’t work, no no-load voltage output.
a. The input voltage is abnormal. b. The power supply cable is not in good
connection with CP3/CP4 on bottom PCB PZ-27-A0, or the tie-in is damaged.
c. The power supply switch may be damaged or unclosed.
d. The connecting cable matching socket CON1-CON6 on power supply conversion PCB PH-20-A1 is in loose connection.
a. Check if the input voltage is AC 220V.
b. Check. c. Check and replace it if necessary. d. Check.
2. Turn on the machine, the power indicator is on, press the welding torch switch in TIG mode, there is gas out, no HF, and no no-load voltage output.
a. The connecting cable matching socket CON1 on bottom PCB PZ-27-A0 is in loose connection.
b. The prime relay RELAY3 on bottom PCB PZ-27-A0 doesn’t close well; the value of resistor RT1-RT4 increases.
c. The connecting cable matching socket CON5/CON9 on bottom PCB PZ-27-A0 with rectifying bridge is in loose connection.
d. Some part on control module PK-02-A1 is damaged.
e. Some part on top PCB PM-01-A3 is
damaged.
a. Check and make sure the voltage of socket CON1 is DC308V.
b. Check and replace if necessary. c. Check. d. Check with a multi-meter if chip
U1 on PK-02-A1 is damaged. Check if the 16th pin of U1 is 5V. If it’s not, replace the chip because U1 is damaged. Check if diode D1/D2/D3, audion Q1/Q2/Q3/Q4/ Q5/Q6/Q7/Q8/Q9 or zener diode Z1/Z2/Z3/Z4 is damaged.
e. Check if MOSFET VT7-VT10, resistor R15 or manostat U3 is damaged.
3. Turn on the machine, the power indicator turns on, but the thermal resistor RT1-RT4 on bottom PCB PZ-27-A0 heats and smokes after a while.
a. The connecting cable (+24V) matching socket CON10 on bottom PCB PZ-27-A0 with socket CON10 on top PCB PM-01-A3 is in loose connection.
b. The relay RELAY3 on bottom PCB PZ-27-A0 is damaged.
c. The auxiliary power supply part on top PCB PM-01-A3 is damaged.
a. Check. b. Check. c. Check with a multi-meter if
resistor R22/R24, MOSFET VT2, diode D6/D8/D7/D9/D10, zener diode Z3/Z4, OC U2 or audion Q1 on top PCB PM-01-A3 is damaged.
REPAIR MANUAL·AC/DC SERIES
30
4. Turn on the machine and it appears normal, press the welding torch and there is gas out, the malfunction LED is not on, no HF, and there is no-load voltage output.
a. The connecting cable matching socket CON7 on top PCB PM-01-A3 with socket CON3 on bottom PCB PZ-27-A0 is in loose connection.
b. High voltage silicon granule D3/D2/D5/D4 or high voltage output capacitor C14/C15/C16 on bottom PCB PZ-27-A0 is damaged.
c. CP1/CP2 is disconnected with the bottom PCB.
d. The discharge nozzles P1/P2 on bottom PCB have conglutination, excessive clearance or serious oxidation problem.
e. The connecting cable matching socket CON2 on bottom PCB PZ-27-A0 with both output terminal is in loose connection, or HF relay RELAY1, zener diode Z1/Z2, bridge D1 or resistor R1/R3 on bottom PCB is damaged.
a. Check. b. Check. c. Check. d. Adjust or replace it if necessary. e. Check.
5. Turn on the machine, and it appears normal, press the welding torch switch and there is gas out, the malfunction LED is on.
a. Over-current protection occurs when welding is carried out.
b. Over-heating protection occurs when welding is carried out.
c. Some parts on top PCB, center PCB, or
bottom PCB are damaged.
a. Turn off the machine for 5mins and restart.
b. Stop the welding operation for 5mins, or the secondary inverter thermal switch is damaged.
c. Check. Turn off the machine, pull out the connecting cable matching the socket CON7 on top PCB PM-01-A3 with the socket CON3 on bottom PCB PZ-27-A0, turn on the machine. If the malfunction LED is off, the transformer T1 is short-circuited or damaged. If it’s on, turn off the machine, pull out the connecting cable matching socket CON8 on top PCB PM-01-A3, turn on the machine. If the malfunction LED is on, MOSFET VT3.123/VT4./VT5./ VT6. on top PCB or some part on drive module PK-07-B0 is damaged; if it’s off, transformer T1-1/T1-2/T1-3 or rectifying diode D2.1/D3.5/D3.6 on center PCB PD-05-A2 is damaged.
REPAIR MANUAL·AC/DC SERIES
31
6. Turn on the machine and it appears normal, it can start arc, but the welding point appears black.
a. The magnet valve or the gas tube is blocked.
b. The magnet valve is damaged. c. The connecting cable matching socket
CON4 on bottom PCB PZ-27-A0 with socket CON8/CON9 on control panel PK-10-A1 is in loose connection.
d. Some part in the magnet valve control circuit on bottom PCB PZ-27-A0 or on control panel PK-10-A1 is damaged.
e. The welding torch is damaged. f. The tungsten is of bad quality or the
argon is impure.
a. Clear. b. Replace. c. Check. d. Check with a multi-meter if the
relay RELAY4, MOSFET VT1, resistor R8, diode D7 or zener diode Z3 on bottom PCB or audion Q3 on control PCB PK-10-A1 is damaged or if the magnet valve control cable matching the socket CON4 is disconnected.
e. Remove the welding torch and the gas-electricity tie-in, and press the welding torch switch. If there is gas out, the welding torch is damaged. Replace it.
f. Replace them if necessary.
7. The welding current is unstable and out of control.
a. The connecting cable matching socket CON10 on control panel PK-10-A1 with socket CON5 on top PCB PM-01-A3 is in loose connection.
b. The capacitor C4/C5/C12/C13 on bottom PCB PZ-27-A0 leaks or is damaged.
c. The input cable or output cable is too slim and too long.
d. Loose connection exists inside the machine.
a. Check and replace it if necessary. b. Check and replace it if necessary. c. Enlarge the cross section area of
the cable. d. Check.
8. Turn on the machine but it strips.
a. The rectifying bridge matching the socket CON5/CON9 on bottom PCB PZ-27-A0 is damaged.
b. The power supply cable is disconnected or short-circuited.
a. Replace. b. Check.
9. Adjust the value of the decay potentiometer to the maximum and release the welding torch switch, the gas valve shuts off, and no current output.
a. The diode D1/D2 or chip U3 on control panel PK-10-A1 is damaged.
a. Check and replace it if necessary.
10. Press the welding torch switch, there is HF discharge buzz, but no welding voltage output.
a. The earth cable of welding torch is in loose connection.
b. The output terminal of the earth cable is in loose connection with gas-electricity tie-in.
a. Check and replace it if necessary. b. Check and replace it if necessary.
REPAIR MANUAL·AC/DC SERIES
32
11. The arc starting is bad. a. The space between discharge nozzles P1 and P2 on bottom PCB PZ-27-A0 is too big or small, or their surface is badly oxidized.
b. The high-voltage capacitor C14/C15/C16 on bottom PCB is damaged, or the capacitance becomes smaller.
c. The tungsten is of bad quality or argon is impure.
d. The welding torch is loose or broken. e. Incorrect turn rate or turn-to-turn
electricity leakage problem exists in arc-starting coil matching CP1/CP2 on bottom PCB.
a. Adjust the space between them, or clear their surface.
b. Check and replace it if necessary. c. Check and replace it if necessary. d. Check. e. Check.
12. Turn on the machine, and it appears normal, but the malfunction LED turns on once welding is carried out.
a. The connecting cable matching socket CON6 on top PCB PM-01-A3 with socket CON2 on center PCB PD-06-A2 is in loose connection.
b. Loose contact exists in MOSFET VT1.1-VT4.5 on top PCB PM-01-A3 or rectifying diode D1/D2 on center PCB PD-06-A2.
c. Some part on control module PK-02-A1 is damaged.
a. Check. b. Check with a multi-meter. c. Check if the chip U2 or audion Q9
on PK-02-A1 is damaged. 13. Turn on the machine, and there is HF.
a. Some parts in manual switch control circuit on bottom PCB are damaged.
b. The connecting cable matching socket
CON3 on control panel PK-10-A0 with socket CON3 on AC drive PCB PK-09-A3 is in loose connection, or chip U3/U4 or diode D11/D12/D14/D15 on control panel PK-10-A1 is damaged.
c. Some MOSFET on inverter PCB PN-01-A1/PN-02-A2 is damaged.
a. Check with a multi-meter if chip U3, diode D18/D22 or audion Q4 on control panel PK-10-A1 is damaged. Disconnect the connecting cable matching socket CON5/4, and check if the manual switch board PH-10-A1 is short-circuited.
b. Check. c. Check with a multi-meter one by
one. 14. Incessant HF exists when welding is carried out.
a. The relay RELAY1or zener diode Z1/Z2 on bottom PCB PZ-27-A0 is damaged.
b. Some part on inverter PCB PN-02-A2 is damaged.
a. Check and replace it if necessary. b. Check if rectifying diode D1,
MOSFET VT7, zener diode Z3 or resistor matching socket CON1 on PN-02-A2 is damaged.
REPAIR MANUAL·AC/DC SERIES
33
15. Press the manual switch, when no-load, it appears normal in DC mode, but there is abnormal sound in AC mode.
a. Some MOSFET on the secondary inverter PCB PN-01-A1/PN-02-A2 is damaged.
a. Check. Method: Press the manual switch, turn to AC mode, turn off the machine after 3mins of no-load, touch the MOSFET on the secondary inverter PCB with your hand one by one. The extra hot ones are damaged.
16. No AC output in AC mode. a. The AC/DC conversion switch on the panel is damaged.
b. Some part on the control panel PK-10-A1 is damaged.
c. Some part on the secondary drive PCB
PK-09-A3 is damaged.
a. Check. b. Check if the diode D23/D24, chip
U4 or potentiometer VR2 on control panel PK-10-A1 is damaged.
c. Check with a multi-meter if chip U2/U4/U8/U9/U3, audion Q1-Q8 or zener diode Z1/Z2/Z3/Z4 on drive PCB is damaged.
17. No AC sound when welding in AC mode.
a. The value of the resistor matching socket CON1 on inverter PCB PN-02-A2 varies.
b. The MOSFET VT7, rectifying diode D1 or zener diode Z3 on inverter PCB PN-02-A2 is damaged.
a. Check and replace it if necessary. b. Check and replace it if necessary.
18. Press the welding torch switch, there is gas out, there is only small current, and the pre-flow time is variable.
a. The connecting cable matching socket CON10 on control panel PK-10-A1 with socket CON5 on top PCB PM-01-A3 is in loose connection.
b. Some part on control panel PK-10-A1 is damaged.
c. The remote control conversion switch on
the panel is damaged.
a. Check. b. Check if audion Q1/Q2 or
potentiometer VR5 on control panel PK-10-A1 is damaged.
c. Check.
19. Turn on the machine, the indicator of protection status is on because the voltage is too low.
a. The input voltage is too low or is unstable.
b. The thermal switch matching socket CON11 on control panel PK-10-A1 is damaged.
c. The connecting cable matching socket CON3 on control panel PK-10-A1 is in loose connection.
d. The resistor R17/R19 or chip U4 on control panel PK-10-A1 is damaged.
a. Check. b. Check. c. Check. d. Check. Method: properly reduce
the value of resistor R17. 20. The tungsten is badly burned out in ARC mode.
a. The value of clean width potentiometer VR2 on control panel PK-10-A1 is adjusted too big.
a. Adjust the clean width smaller, or parallel connect a resistor of 200K or so with resistor R3 on control panel PK-10-A1.
REPAIR MANUAL·AC/DC SERIES
34
21. The manual control is normal, but the pedal control goes wrong.
a. The panel conversion switch is damaged.b. The inching switch inside the pedal
control is damaged. c. The potentiometer inside the pedal
control is damaged. d. The connecting cable matching socket
CON1/CON2 on control panel PK-10-A1 is in loose connection.
a. Check and replace it if necessary.b. Check and replace it if necessary. c. Check and replace it if necessary. d. Check.
22. The welding current is variable, but the maximum current is too big.
a. The audion Q1/12 on control panel PK-10-A1 is damaged.
a. Check and replace it if necessary.
4. AC/DC315P/250P 4.1 The structure drawing of AC/DC315P/250P 4.1.1 The structure drawing of AC/DC315P:
No. Description No. Description No. Description 1 Cover 9 Pilot-socket (2 pins) 17 Inverter PCB 2 2 Handle 10 Pilot-socket (3 pins) 18 AC Driver PCB 3 Button 11 Rubber foot 19 Fan 4 Function switch 12 Coupling socket 20 Inductance 5 Function switch 13 Panel PCB 21 Heat sink 6 Main switch 14 Control PCB 22 Input cable 7 Front panel 15 Top PCB (left) 23 Digital meter 8 Fast-socket 16 Inverter PCB 1
4.1.2 The structure drawing of AC/DC250P: The structure of AC/DC250P is similar to that of AC/DC315P. (See the structure drawing of AC/DC315P on page ) REPAIR MANUAL·AC/DC SERIES
35
4.2 The general connection diagram of AC/DC315P/250P:
CONTROL MODULE
ELECTRIC DIAGRAM
Top Board
DRIVE MODULE
PK-03-A1
DC24V
AC/DC315P
VH
-03
VH-02
VH-02
THERMAL SWITCH
PK-05-A4Control Board
VH-03
14V
14V
0 0
AC380V
AC220V
(VH-04)*2
DRIVE LINE
XH
-02
XH
-03
VH-02XH-03
DC12V
VH-02
XH-04 XH-03VH-03 XH-04
CON11
CON6CON1
CON3 CON5CON8CON7CON10
CON2
CON4
CON9CON14
CON15 CON12 CON13
METER CONTROL SIGNALREMOTE RESISTANCE
PK-08-A1
PM-04-A3
CON
3
CON
1Port
Port
CP3
CP2
INPUT AC380V
CON
6 2
CO
N4
CO
N5
CON
8/C
ON
7
DC532V
CON6CON3
CON2
AC220V
CO
N5PH-20-A1
CO
N4
CO
N6A
C22
0V
FA
N *
2
PZ-03-B0
BOTTOM BOARD
CON3
VH-04
CON
1
CENTER BOARD
PD-13-B0
VH
-09(
8)
CON3
+
-
+-
OU
T1
OU
T2
INVERTER BOARD
PN-0
5-A
2PN
-06-
A1
CO
N11
CON1
ARC FORCE
CON
12
PRO
TE
CT L
ED
CU
RR
EN
T
CON13CON14
THERMAL SWITCH
CONTROL BOARD
PK-31-A0
CON
1V
H-0
5V
H-0
4
50W
450R
*4
CON1 CON5
PK-09-A3
DRIVE BOARD
CON
15
CON
3AC2
0V*4
0
AC
380V
AC
220V
T
T
CO
N2
O
R
C
ON
4
XH-03(2)
PH-10-A2Gun Switch Board
Gun switch
CON
9
CON10
2T/4T
CON5
AC/DC
CON6 CON7
ARC/TIG CONTROL GAS
CON8
CONTROL HF
CON2 CON3
CONTROL PULSE
CON4
PH-10-A01
CON15 DC12VPK-05-A4
PK-31-A0CONTROL BOARD
CP1
Port
DC+24V
HF BOARD
PZ-35-A0C
ON
2
HF
CON1
CO
N4
CON2
GAS
+24V
CON3
+24V CONTROL GAS(PK-31-A0 CON7)
4.3 The diagram of AC/DC315P/250P’s top PCB PM-04-A3, center PCB PD-13-B0, bottom PCB PZ-03-B0, HF PCB PZ-35-A0, control panel PK-31-A0, control PCB PK-05-A4, control module PK-03-A1, AC drive PCB PK-09-A3 and inverter PCB PN-05-A2 and PN-06-A1:
R1 R4 R6 R10 R14 R17 R19 R21 R23 R27 R30 R33
R32R31R26R22R20R18R16R15R9R5R3R2
R12
R13 R25
CON3 C14C13
C2 C8
C9C1R29
R28
R8
R7 R24
C10
C11
C12
C7
C6
C5
C4
R11RT1
CON1
CON2
U2 U4 U6 U8 U10 U12 U14 U16 U18 U20 U22 U24
U23U21U19U17U15U13U11U9U7U5U3U1
2006.02.08
PM-04-A3
REPAIR MANUAL·AC/DC SERIES
36
1 111
R11
R9
R10
L1
CON3D8D7
CON1
D1R3
C2C1
R2
U9 U10 U11 U12 U1 U2 U3 U4 U5 U6 U7
U20U16 U24U17 U19U18U13 U23U22U21
U8
T3 T1
T2
T4
U14 U15
R4
C4C3
R1 R6
C6C5
R5 R8
C8C7
R7
R13
C12
R12 R17
C14C13
R16 R15
C10
C15
R14
R19
C17C16
R18
C11
D2
RV1
C9
AC/DC315/315P/TIG315 (T) 2005.09PD-13-B0
++
++
++
RT1
CON7
R1
R2 R5
R6
R4R3
C5
C6
C3
C4
C2
C1
CON8
CON1
RELY1
CON2
CON4
CON5
CP1
CP2
CP3
CON6
CON3
RT2
X4X3
X2
2005.09PZ-03-B0AC/DC.TIG(T)
REPAIR MANUAL·AC/DC SERIES
37
D6
C8
C10
Q1
R5
R4
D5 VT1
R3
R6
CON4
D1
D2
D3
R2
R1
CP2
CP1
C1
C3
C2
C5
D4
C6
T1
CON1
C4
RELAY1
Z1
CON3
VT2
C9
CON2
C7
PZ-35-A0
2006.03.06
P1 P2
- +
-++-
+ -
- +
D18
D22
D1
D2
Z1
D24
D26
D25
D23Z5
D6
D11
D8
D16
D14D12
Z4
D9
Z3 D7
D5
D13
D10
D15
D20
D17
D21
D27
D4
D3
Z2
D19
D28
D30
D29
C18
R32
R45
R72
Q1
R15
C1
C17
C8
R1
C9
R4
CON5
Q3 Q4
R35
R37
R41
C29
R70 C26
C27
R6
R13
R18
R59
R62
R64
R65
R68
R58
R61
VR4
U7U6U5 U8
U3
CON6
CON10
CON9
CON7
CON11 CON12 LED1LED2
VR7
VR1
VR6VR8 VR9
VR2 VR3
VR5
U4
R12R9 R10
R2
R5
R19
R21 R22 R23 R24
R27 R29 R30
R33
R34
R38R39
R42
R25
R43 R44
R46 R47 R48
R50
R54
R51 R52
R56 R55
R57
R60
R69
R71
R73
R74
R76
CON13 CON15
D32D31 D34D33
C23
C22
U9
U2
R7
R11
CON8
L2L1
U1
C3
C5
L6L5
C2
R53
C15
C16
R63
R66
C21
C28
R67
C25
CON4
R8
CON3CON2CON1 R3
Q2
C10R17
R40
R36
R31
C4
L4
L3
C12
R20
R26
Q5 Q6
C24
C19
R14
R16
C6
C20
R75
L7
R28
C13
R49
C7
CON14
C14
C11
PK-31-A02006.02.08
REPAIR MANUAL·AC/DC SERIES
38
+ +
+ +
+
CON12
CON3CON6
R2
R3
C9
R11
R12
R5
C1
C19R30
z1
R29
D7Z2
D1
D3
D4
D11 D12U6 Q2
CON1
C21
C14
CON10
C11
C5
CON15CON14
CON5
C3
CON13
R27R31
R23R26
C15
C22
R33
R22
R25
R4
U3 U5U4
U2
Q1
C28
C29
C24
R17
CON11
C2
CON2
C4
C6
R6R7
R9
CON4
LED1 R8
R32
U1U9
D6D5
CON9
C8
C18
L1
U7 C34C33
C26
C13
C27
C16
C25
C12
C20
U8
R19D8
D10
R10
R13
C31
CON7 CON8
R14
R20
R18R16
R15
R24R28
R35
R1
C32
C23
C17
R34
C10
C30
R21
PK-05-A4 2006.02.08
C13
D1
C12
C7
LED2
LED1
R4
P1
R14
R17
R29
R16
R31
R25
R21
R19 D5
R28
C8
R15
C15
Z2 Z3
R7R6
C4
R23
R32
D4
D3D2
Z1R12
R13
R9
R1
R2
R8
C6
C9
C5
C18 C1 C2
R30
U2
Q5
Q8Q7
Q4
C16
Q9
Q1
Q3
C14U3
C17
C10
C11
Q2
R24R22
R18
R3
R27
R5
R11R10
Q6
R26
C3
R20
U1
PK-03-A1 2006.02.08
REPAIR MANUAL·AC/DC SERIES
39
+
+
+
C13
C12
C5
C17
C2
C8
CON3
CON2
R5
U1
C7
D1
C6
Q3
Q4
U4U5
C1
C4
R1
U3
U2Q2
Q1C3
C10 Q5
Q6
U8
U6
R10
U7
D5
C11
C9
C16
CON1
U10
U9
Q8
Q7 C14
D7
C15
U11
R13
CON5
CON4
R3
R7
R11
R15
D2
Z1
Z2Z3
Z4
D6
D3
D4
R14
R6
R2R4
R8
R12
R16
R9
2006.02.08PK-09-A3
C1
1
17
VT13 VT14 VT15 VT16 VT17 VT18 VT19 VT20 VT21 VT22 VT23 VT24
Z1
Z2
A2
A3
A1
Z4
Z3
12
7
VT1 VT2 VT3 VT4 VT5 VT6 VT7 VT8 VT9 VT10 VT11 VT12
R1 R12R11R10R9R8R7R6R5R4R3R2
16
2
5
4
3
_1
_2
_3
9
13
11
10
14
R24R13 R14 R15 R16 R17 R18 R19 R20 R21 R22 R23
8
15
6
PN-06-A1
2005.09
AC/DC250B.315(T)
REPAIR MANUAL·AC/DC SERIES
40
CON1 R13
3
6
C2
1
8
VT14 VT15 VT16 VT17 VT18 VT19 VT20 VT21 VT22 VT23 VT24 VT25
C1
Z3R14
D1
R15
Z1
Z2
A2
A3
A1
Z5
Z4
_8
_3
D2
C6
C3
VT13
C8
C7
C4
VT1 VT2 VT3 VT4 VT5 VT6 VT7 VT8 VT9 VT10 VT11 VT12
R1 R12R11R10R9R8R7R6R5R4R3R2
_12
_1
4
2
5
7
_5
_9
_7
_6
_4
_10
_11
_2
D3
R27R16 R17 R18 R19 R20 R21 R22 R23 R24 R25 R26
C5
X2
PN-05-A2
AC/DC250B.315(T)
2005.09
4.4 Troubleshooting of AC/DC315P/250P:
Trouble Analysis Solution 1. Turn on the machine, no display of the meter, the fan doesn’t work, no no-load voltage output in TIG/ARC mode.
a. The input voltage is abnormal. b. The power supply cable is not in good
connection with CP1/CP3 on bottom PCB PZ-03-B0, or the tie-in is damaged.
c. The power supply switch may be damaged or unclosed.
d. The connecting cable matching socket CON1-CON6 on power supply conversion PCB PH-20-A1 is in loose connection.
a. Check if the input voltage is AC 380V.
b. Check. c. Check and replace it if necessary. d. Check.
REPAIR MANUAL·AC/DC SERIES
41
2. Turn on the machine, the meter displays, press the welding torch switch in TIG mode, there is gas out, no HF, turn to ARC mode, no no-load voltage output.
a. The connecting cable matching socket CON7/CON8 on bottom PCB PZ-03-B0 is in loose connection.
b. The prime relay RELAY1 on bottom PCB PZ-03-B0 doesn’t close well; the value of resistor RT1/RT2 increases.
c. The connecting cable matching socket CON2/CON4/CON5 on bottom PCB PZ-03-B0 with rectifying bridge is in loose connection.
d. Some part on control module PK-03-A1 is damaged.
e. Some part on control PCB PK-05-A4 is
damaged.
a. Check and make sure the voltage of socket CON1 is DC532V.
b. Check and replace if necessary. c. Check. d. Check with a multi-meter if chip
U1 on PK-03-A1 is damaged. Check if the 16th pin of U1 is 5V. If it’s not, replace the chip because U1 is damaged. Check if diode D2/D3/D4, audion Q2/Q3/Q4/Q5/ Q6/Q7/Q9, thyristor Q1, zener diode Z1/Z2/Z3, capacitor C17 or resistor R32 is damaged.
e. Check if MOSFET U2/U3/U4/U5 or resistor R32 is damaged.
3. Turn on the machine, the meter displays, but the thermal resistor RT1/RT2 on bottom PCB PZ-03-B0 heats and smokes after a while.
a. The connecting cable (+24V) matching socket CON1 on bottom PCB PZ-03-B0 with socket CON14 on control PCB PK-05-A4 is in loose connection.
b. The relay RELAY1 on bottom PCB PZ-03-B0 is damaged.
c. The auxiliary power supply part on control PCB PK-05-A4 is damaged.
a. Check. b. Check. c. Check with a multi-meter if
resistor R35, MOSFET U1, audion Q2, chip U6 or capacitor C32 on control PCB PK-05-A4 is damaged.
REPAIR MANUAL·AC/DC SERIES
42
4. Turn on the machine and it appears normal, there is no-load voltage output in ARC mode, press the welding torch in TIG mode and there is gas out, the malfunction LED is not on, no HF.
a. The connecting cable matching socket CON2 on top PCB PM-04-A3 with socket CON1 on HF PCB PZ-35-A0 is in loose connection.
b. High voltage silicon granule D1/D2/D3/D4 or high voltage output capacitor C6/C7 on bottom PCB PZ-27-A0 is damaged.
c. CP1/CP2 is disconnected with the HF PCB.
d. The discharge nozzles P1/P2 on HF PCB have conglutination, excessive clearance or serious oxidation problem.
e. The ARC/TIG conversion switch on the panel or chip U7 on control panel PK-31-A0 is damaged.
f. The connecting cable matching socket CON8 on control PCB PK-31-A0 with socket CON4 on HF PCB PZ-35-A0 is in loose connection, or HF relay RELAY1, audion Q1, MOSFET VT1 or diode D5 on HF PCB is damaged.
a. Check. b. Check. c. Check. d. Adjust or replace it if necessary. e. Check and replace it if necessary. f. Check. Method: short-circuit the
socket CON4 on HF PCB PZ-35-A0, and turn on the machine, if no HF, the HF circuit on HF PCB goes wrong; if there is, the inductor L1/L2, chip U1/U3 or resistor R6 on control PCB PK-31-A0 is damaged.
5. Turn on the machine, and it appears normal, press the welding torch switch and there is gas out, the malfunction LED is on. Turn to ARC mode, the malfunction LED turns on.
a. Over-current protection occurs when welding is carried out.
b. Over-heating protection occurs when welding is carried out.
c. Some parts on top PCB, center PCB, or
bottom PCB are damaged.
a. Turn off the machine for 5mins and restart.
b. Stop the welding operation for 5mins, or the secondary inverter thermal switch is damaged.
c. Check. Turn off the machine, pull out the connecting cable matching the socket CON2 on top PCB PM-04-A3 with the socket CON1 on HF PCB PZ-35-B0, turn on the machine. If the malfunction LED is off, the transformer T1 on HF PCB is short-circuited or damaged. If it’s on, turn off the machine, pull out the connecting cable matching socket CON1 on top PCB PM-04-A3, turn on the machine. If the malfunction LED is on, MOSFET U1-U24 on top PCB or some part on drive module PK-08-A1 is damaged; if it’s off, transformer T1/T2/T3/T4 or rectifying diode U1/U24 on center PCB PD-13-B0 is damaged.
REPAIR MANUAL·AC/DC SERIES
43
6. Turn on the machine and it appears normal, it can start arc in TIG mode, but the welding point appears black.
a. The magnet valve or the gas tube is blocked.
b. The magnet valve is damaged. c. The connecting cable matching socket
CON3 on HF PCB PZ-35-A0 with socket CON7 on control panel PK-31-A0 is in loose connection.
d. Some part in the magnet valve control circuit on HF PCB PZ-35-A0 or on control panel PK-31-A0 is damaged.
e. The welding torch is damaged. f. The tungsten is of bad quality or the
argon is impure.
a. Clear. b. Replace. c. Check. d. Check with a multi-meter if
MOSFET VT2, diode D6, zener diode Z1 on HF PCB or audion Q1 on control PCB PK-31-A0 is damaged or if the magnet valve control cable matching the socket CON2 is disconnected.
e. Remove the welding torch and the gas-electricity tie-in, and press the welding torch switch. If there is gas out, the welding torch is damaged. Replace it.
f. Replace them if necessary.
7. The welding current is unstable and out of control.
a. The connecting cable matching socket CON2 on control PCB PK-05-A4 with socket CON11 on control panel PK-31-A0 is in loose connection.
b. The capacitor C1/C2/C3/C4/C5/C6 on bottom PCB PZ-03-B0 leaks or is damaged.
c. The input cable or output cable is too slim and too long.
d. Loose connection exists inside the machine, e.g. the connecting cable matching socket CON4 on control panel with the remote control.
a. Check and replace it if necessary. b. Check and replace it if necessary. c. Enlarge the cross section area of
the cable. d. Check.
8. Turn on the machine but it strips.
a. The rectifying bridge matching the socket CON2/CON4/CON5 on bottom PCB PZ-03-B0 is damaged.
b. The power supply cable is disconnected or short-circuited.
a. Replace. b. Check.
9. When in TIG mode, adjust the value of the decay potentiometer to the maximum and release the welding torch switch, the gas valve shuts off, and no current output.
a. The diode D1/D2 or chip U3 on control panel PK-10-A1 is damaged.
a. Check and replace it if necessary.
REPAIR MANUAL·AC/DC SERIES
44
10. Press the welding torch switch, there is HF discharge buzz, but no welding voltage output.
a. The earth cable of welding torch is in loose connection.
b. The output terminal of the earth cable is in loose connection with gas-electricity tie-in.
a. Check and replace it if necessary. b. Check and replace it if necessary.
11. The arc starting is bad in TIG mode.
a. The space between discharge nozzles P1 and P2 on HF PCB PZ-34-A0 is too big or small, or their surface is badly oxidized.
b. The high-voltage capacitor C3/C4 on HF PCB is damaged, or the capacitance becomes smaller.
c. The tungsten is of bad quality or argon is impure.
d. The welding torch is loose or broken. e. Incorrect turn rate or turn-to-turn
electricity leakage problem exists in arc-starting coil matching CP1/CP2 on HF PCB.
a. Adjust the space between them, or clear their surface.
b. Check and replace it if necessary. c. Check and replace it if necessary. d. Check. e. Check.
12. Turn on the machine, and it appears normal, but the malfunction LED turns on once welding is carried out.
a. The connecting cable matching socket CON11 on control PCB PK-05-A4 with the output bypass is in loose connection.
b. Loose contact exists in MOSFET VT1-VT24 on top PCB PM-04-A3 or rectifying diode U1/U24 on center PCB PD-13-B0.
c. Some part on control module PK-03-A1 is damaged.
a. Check. b. Check with a multi-meter. c. Check if the chip U2 or audion Q9
on PK-03-A1 is damaged. 13. Turn on the machine, and there is HF.
a. Some parts in manual switch control circuit are damaged.
b. The connecting cable matching socket
CON8 on control panel PK-31-A0 with socket CON4 on bottom PCB PZ-35-A0 is in loose connection, or chip U1 on control panel PK-31-A0 is damaged.
a. Check with a multi-meter if chip U8 or diode D14/D18 on control panel PK-31-A0 is damaged. Disconnect the connecting cable matching the socket CON9, short-circuit both terminal of socket CON9 and check if the manual switch board PH-10-A1 is short-circuited.
b. Check.
REPAIR MANUAL·AC/DC SERIES
45
14. Incessant HF exists when welding is carried out.
a. The relay RELAY1, audion Q1, diode D5, MOSFET VT1 on HF PCB PZ-35-A0 or chip U1 on control panel PK-31-A0 is damaged.
b. The connecting cable matching socket CON13 on control panel PK-31-A0 with socket CON5 on control PCB PK-05-A4 is in loose connection.
a. Check and replace it if necessary. b. Check.
15. There is deviation between the preset value and real value of the show value of the meter.
a. The value of the variable resistor R9 on control PCB PK-05-A4 or VR1 on preset PCB PH-10-A01 changes.
a. Adjust. Methods: 1. Turn to ARC mode, adjust the value of variable resistor R9 on control PCB PK-05-A4 to make the show value of the meter be the value of the corresponding machine type. 2. Turn to TIG mode, do not press the manual switch, adjust the value of variable resistor VR1 on preset PCB PH-10-A0 to make the show value of the meter be the value of the corresponding machine type.
16. No pulse when in pulse mode.
a. The panel pulse conversion switch is damaged.
b. The connecting cable matching socket CON2/CON3 on control panel PK-31-A0 with the pulse conversion switch is short-circuited, or chip U4, capacitor C4/C11, potentiometer VR2/VR3 or diode D24 is damaged.
a. Check and replace it if necessary. b. Check.
17. When no-load in ARC mode, it appears normal in DC mode, but there is abnormal sound in AC mode.
a. Some MOSFET on the secondary inverter PCB PN-05-A2/PN-06-A1 is damaged.
a. Check. Method: Turn to ARC mode, then AC mode, turn off the machine after 3mins of no-load, touch the MOSFET on the secondary inverter PCB with your hand one by one. The extra hot ones are damaged.
18. No 4T state or 4T is inaccurate.
a. The 2T/4T conversion switch on the panel is damaged, or the connecting cable matching it with socket CON10 on control panel PK-31-A0 is in loose connection.
b. Some part on control panel PK-31-A0 is damaged.
a. Check. b. Check if chip U8/U2, diode D6 or
capacitor C2 on control panel is damaged.
REPAIR MANUAL·AC/DC SERIES
46
19. No AC output in AC mode. a. The AC/DC conversion switch on the panel is damaged.
b. Some part on the control panel PK-31-A0 is damaged.
c. Some part on the secondary drive PCB
PK-09-A3 is damaged.
a. Check. b. Check if the diode D9/D2/D1, chip
U6, audion Q2 or potentiometer VR4 on control panel PK-31-A0 is damaged.
c. Check with a multi-meter if chip U2/U4/U8/U9/U3, audion Q1-Q8 or zener diode Z1/Z2/Z3/Z4 on drive PCB is damaged.
20. No AC sound when welding in AC mode.
a. The value of the resistor matching socket CON1 on inverter PCB PN-05-A2 varies.
b. The MOSFET VT13, rectifying diode D1/D3, resistor R14/R13 or zener diode Z3 on inverter PCB PN-05-A2 is damaged.
a. Check and replace it if necessary. b. Check and replace it if necessary.
21. Press the welding torch switch, there is gas out, the show value of the meter is invariable, there is only small current, and the pre-flow time is variable.
a. The connecting cable matching socket CON11 on control panel PK-31-A0 with socket CON2 on control PCB PK-05-A4 is in loose connection.
b. Some part on control panel PK-31-A0 is damaged.
a. Check. b. Check if chip U5, audion Q3/Q4 or
potentiometer VR7 on control panel PK-31-A0 is damaged.
22. When the pulse conversion switch is at no-pulse state, in ARC/TIG mode, the welding current is invariable, and there is only maximum current.
a. The diode D24 on control panel PK-31-A0 is damaged.
a. Check and replace it if necessary.
23. Turn on the machine, the indicator of protection status is on because the voltage is too low.
a. The input voltage is too low or is unstable.
b. The thermal switch matching socket CON14 on control panel PK-31-A0 is damaged.
c. The connecting cable matching socket CON15 on control panel PK-31-A0 is in loose connection.
d. The resistor R51/R44 or chip U6 on control panel PK-31-A0 is damaged.
a. Check. b. Check. c. Check. d. Check. Method: properly reduce
the value of resistor R44. 24. The tungsten is badly burned out in AC mode.
a. The value of AC clean width on the panel is adjusted too big.
a. Adjust the clean width smaller.
25. The manual control is normal, but the pedal control goes wrong.
a. The connecting cable matching socket CON4 on control panel PK-31-A0 is in loose connection.
b. Some part on control panel PK-31-A0 is damaged.
a. Check. b. Check if diode D23, zener diode
Z5, resistor R32/R35/R46 or inductor L3/L4 on control panel PK-31-A0 is damaged.
REPAIR MANUAL·AC/DC SERIES
47
5. WSE250/315 5.1 The structure drawing of WSE250/315 5.1.1 The structure drawing of WSE250
The structure of WSE250 is similar to that of RILTIG315AC/DC. (See the above structure drawing.)
No. Description No. Description No. Description 1 Cover 9 Pilot-socket (2 pins) 17 Center PCB 2 Handle 10 Pilot-socket (3 pins) 18 Inverter PCB 2 3 Button 11 Rubber foot 19 Fan 4 Function switch 12 Coupling socket 20 HF PCB 5 Function switch 13 Panel PCB 21 Heat sink 6 Main switch 14 Control PCB 22 Input cable 7 Front panel 15 Top PCB (left) 23 Digital meter 8 Fast-socket 16 Inverter PCB 1
REPAIR MANUAL·AC/DC SERIES
48
5.1.2 The structure drawing of WSE315
The structure of WSE315 is similar to that of RILTIG315AC/DC. (See the above structure drawing.)
No. Description No. Description No. Description 1 Cover 9 Pilot-socket (2 pins) 17 Center PCB 2 Handle 10 Pilot-socket (3 pins) 18 Inverter PCB 2 3 Button 11 Rubber foot 19 Fan 4 Function switch 12 Coupling socket 20 HF PCB 5 Function switch 13 Panel PCB 21 Heat sink 6 Main switch 14 Control PCB 22 Input cable 7 Front panel 15 Top PCB (left) 23 Digital meter 8 Fast-socket 16 Inverter PCB 1
5.2 The general connection diagram of WSE250/315:
CONTROL MODULE
ELECTRIC DIAGRAM
Top Board
DRIVE MODULE
PK-03-A1
DC24V
WSE250/315
VH
-03
VH-02
VH-02
THERMAL SWITCH
PK-05-A4Control Board
VH-03
14V
14V
0 0
AC380V
AC220V
(VH-04)*2
DRIVE LINE
XH
-02
XH
-03
VH-02XH-03
DC12V
VH-02
XH-04 XH-03VH-03 XH-04
CON11
CON6CON1
CON3 CON5CON8CON7CON10
CON2
CON4
CON9CON14
CON15 CON12 CON13
METER
PK-08-A1
PM-04-A3
CON
3
CON
1Port
Port
CP3
CP2
INPUT AC380V
CON
6 2
CO
N4
CO
N5
CON
8/C
ON
7
DC532V
CON6CON3
CON2
AC220V
CON
5PH-20-A1
CON
4CO
N6A
C22
0V
FA
N *
2
PZ-03-B0
BOTTOM BOARD
CON3
VH-04
CON
1
CENTER BOARD
PD-13-B0
VH
-09(
8)
CON3
+
-
+-
OU
T1
OU
T2
INVERTER BOARD
PN-0
5-A
2PN
-06-
A1
CON
1V
H-0
5V
H-0
4
50W
450R
*4
CON1 CON5
PK-09-A3
DRIVE BOARD
CON
3AC2
0V*4
0
AC380V
AC220V
T
T
CON
2
OR
C
ON
4
XH-03(2)
PH-10-A2Gun Switch Board
Gun switch
CONTROL HF
PH-10-A01
CON15 DC12VPK-05-A4
PK-10-A1CON12
CP1
Port
DC+24V
HF BOARD
PZ-34-A0
CON
2
HF
CON3
CO
N4
CON1
+24V
CON2
+24V CONTROL GAS
REMOTE RESISTANCE
CON
10
CON8 OR CON9CON12
PROTECT LED
CON
6
CON11
THERMAL SWITCH
CONTROL BOARD
PK-10-A1
CON
3
CON
4
CON7
CON
5
AC/DC
CON1
CONTROL GAS
CON2
REMOTE SWITCH
CONTROL METER
ARC FORCE
PK-10-A1 CON8/9
GAS
REPAIR MANUAL·AC/DC SERIES
49
5.3 The diagram of WSE250/315’s HF PCB PZ-34-A0 and control panel PK-10-A1:
+
VT1
R2
VT2
Z2Z3
C11
R3
C5
RELAY1
CON3
C6
T1
BR1
CON1
Z1
C10
C8
C7
C9
C1
CON2
C2
R4
CON4
D2
D1
D3D4
R5
C4
C3
R1
CP1CP2
2006.03.06
PZ-
34-A0
5W1K
1mH
R6C12
L1
R7
P2P1P1
- CON12
R11
D25
C23
C24
R23C18
C1
C5
C16
D18
R10
U4
D13
D10
D8
R14
D23D22
D12
D11
CON2CON1
D14
R19
R17
C6
C8
C15
C10
C13
R22
C4
Q1 Q2
C22
R5
R1
R3
R25
R7
R4
R13
R12
C9
C2
D9
D1
C14
C20
C11
R31
R2
R32
R35
R28
R6
R16
Q4
Q3
R18
R15
R20
C3
C19
C21
C7
R29
D15
D3
D19
U3
R24
R34
R26
CON7 CON8CON5CON4 CON6 CON11
VR4
VR5
VR2VR1 VR3
LED2LED1
CON3 CON9 CON10
D20
D16
D21
D17
C12
D5
D4
R8
D2
R27R30
R33
R21
D24
R9
C17
D6
U1
U2
D7
PK-10-A1 2006.02.09
REPAIR MANUAL·AC/DC SERIES
50
5.4 Troubleshooting of WSE250/315: Trouble Analysis Solution
1. Turn on the machine, no display of the meter, the fan doesn’t work, no no-load voltage output in ARC/TIG mode.
a. The input voltage is abnormal. b. The input cable is not in good connection
with CP3/CP2/CP1 on bottom PCB PZ-03-B0, or the tie-in is damaged.
c. The power supply switch may be damaged or not closed.
d. The connecting cable matching socket CON1-CON6 on power supply conversion PCB PH-20-A1 is in loose connection.
a. Check if the input voltage is AC 380V.
b. Check. c. Check and replace the power
supply switch if it’s damaged. d. Check.
2. Turn on the machine, the meter displays, press the welding torch switch in TIG mode, there is gas out, no HF, turn to ARC mode, no no-load voltage output.
a. The connecting cable matching socket CON7/CON8 on bottom PCB PZ-03-B0 is in loose connection.
b. The prime relay RELAY1 on bottom PCB PZ-03-B0 doesn’t close well; the value of resistor RT1/RT2 increases.
c. The connecting cable matching socket CON2/CON4/CON5 on bottom PCB PZ-03-B0 with rectifying bridge is in loose connection.
d. Some part on control module PK-03-A1 is damaged.
e. Some part on control PCB PK-05-A4 is
damaged.
a. Check and make sure the voltage of socket CON1 is DC532V.
b. Check and replace if necessary. c. Check. d. Check with a multi-meter if chip
U1 on PK-03-A1 is damaged. Check if the 16th pin of U1 is 5V. If it’s not, replace the chip because U1 is damaged. Check if diode D2/D3/D4, audion Q2/Q3/Q4/Q5/ Q6/Q7/Q9, thyristor Q1, zener diode Z1/Z2/Z3, capacitor C17 or resistor R32 is damaged.
e. Check if MOSFET U2/U3/U4/U5 or resistor R32 is damaged.
3. Turn on the machine, the meter displays, but the thermal resistor RT1/RT2 on bottom PCB PZ-03-B0 heats and smokes after a while.
a. The connecting cable (+24V) matching socket CON1 on bottom PCB PZ-03-B0 with socket CON14 on control PCB PK-05-A4 is in loose connection.
b. The relay RELAY1 on bottom PCB PZ-03-B0 is damaged.
c. The auxiliary power supply part on control PCB PK-05-A4 is damaged.
a. Check. b. Check. c. Check with a multi-meter if
resistor R35, MOSFET U1, audion Q2, chip U6 or capacitor C32 on control PCB PK-05-A4 is damaged.
REPAIR MANUAL·AC/DC SERIES
51
4. Turn on the machine and it appears normal, there is no-load voltage output in ARC mode, press the welding torch in TIG mode and there is gas out, the malfunction LED is not on, no HF.
a. The connecting cable matching socket CON2 on top PCB PM-04-A3 with socket CON3 on HF PCB PZ-34-A0 is in loose connection.
b. High voltage silicon granule D1/D2/D3/D4 or high voltage output capacitor C6/C7 on HF PCB PZ-34-A0 is damaged.
c. CP1/CP2 is disconnected with the HF PCB.
d. The discharge nozzles P1/P2 on HF PCB have conglutination, excessive clearance or serious oxidation problem.
e. The ARC/TIG conversion switch on the panel is damaged.
f. The connecting cable matching both output terminal with socket CON4 on HF PCB PZ-34-A0 is in loose connection, or HF relay RELAY1, zener diode Z2/Z3, MOSFET VT1 or resistor R4/R6 on HF PCB is damaged.
a. Check. b. Check. c. Check. d. Adjust or replace it if necessary. e. Check and replace it if necessary. f. Check.
5. Turn on the machine, and it appears normal, press the welding torch switch and there is gas out, the malfunction LED is on. Turn to ARC mode, the malfunction LED turns on.
a. Over-current protection occurs when welding is carried out.
b. Over-heating protection occurs when welding is carried out.
c. Some parts on top PCB, center PCB, or
bottom PCB are damaged.
a. Turn off the machine for 5mins and restart.
b. Stop the welding operation for 5mins, or the secondary inverter thermal switch is damaged.
c. Check. Turn to TIG mode, turn off the machine, pull out the connecting cable matching the socket CON2 on top PCB PM-04-A3 with the socket CON3 on HF PCB PZ-34-A0, turn on the machine. If the malfunction LED is off, the transformer T1 on HF PCB is short-circuited or damaged. If it’s on, turn off the machine, pull out the connecting cable matching socket CON1 on top PCB PM-04-A3, turn on the machine. If the malfunction LED is on, MOSFET U1-U24 on top PCB or some part on drive module PK-08-A1 is damaged; if it’s off, transformer T1/T2/T3/T4 or rectifying diode U1/U24 on center PCB PD-13-B0 is damaged.
REPAIR MANUAL·AC/DC SERIES
52
6. Turn on the machine and it appears normal, it can start arc in TIG mode, but the welding point appears black.
a. The magnet valve or the gas tube is blocked.
b. The magnet valve is damaged. c. The connecting cable matching socket
CON2 on HF PCB PZ-34-A0 with socket CON8/CON9 on control panel PK-10-A1 is in loose connection.
d. Some part in the magnet valve control circuit on HF PCB PZ-34-A0 or on control panel PK-10-A1 is damaged.
e. The welding torch is damaged. f. The tungsten is of bad quality or the
argon is impure.
a. Clear. b. Replace. c. Check. d. Check with a multi-meter if
MOSFET VT2, zener diode Z1 on HF PCB, audion Q3 or resistor R31/R33 on control PCB PK-10-A1 is damaged or if the magnet valve control cable matching the socket CON1 is disconnected.
e. Remove the welding torch and the gas-electricity tie-in, and press the welding torch switch. If there is gas out, the welding torch is damaged. Replace it.
f. Replace them if necessary.
7. The welding current is unstable and out of control.
a. The connecting cable matching socket CON2 on control PCB PK-05-A4 with socket CON10 on control panel PK-10-A1 is in loose connection.
b. The capacitor C1/C2/C3/C4/C5/C6 on bottom PCB PZ-03-B0 leaks or is damaged.
c. The input cable or output cable is too slim and too long.
d. Loose connection exists inside the machine.
e. The panel remote control conversion switch is damaged.
a. Check and replace it if necessary. b. Check and replace it if necessary. c. Enlarge the cross section area of
the cable. d. Check. e. Check.
8. Turn on the machine but it strips.
a. The rectifying bridge matching the socket CON2/CON4/CON5 on bottom PCB PZ-03-B0 is damaged.
b. The power supply cable is disconnected or short-circuited.
a. Replace. b. Check.
9. When in TIG mode, adjust the value of the decay potentiometer to the maximum and release the welding torch switch, the gas valve shuts off, and no current output.
a. The audion Q5, resistor R64/R65/R68 or chip U6 on control panel PK-31-A0 is damaged.
a. Check and replace it if necessary.
REPAIR MANUAL·AC/DC SERIES
53
10. Press the welding torch switch, there is HF discharge buzz, but no welding voltage output.
a. The earth cable of welding torch is in loose connection.
b. The output terminal of the earth cable is in loose connection with gas-electricity tie-in.
a. Check and replace it if necessary. b. Check and replace it if necessary.
11. The arc starting is bad in TIG mode.
a. The space between discharge nozzles P1 and P2 on HF PCB PZ-35-A0 is too big or small, or their surface is badly oxidized.
b. The high-voltage capacitor C6/C7 on HF PCB is damaged, or the capacitance becomes smaller.
c. The tungsten is of bad quality or argon is impure.
d. The welding torch is loose or broken. e. Incorrect turn rate or turn-to-turn
electricity leakage problem exists in arc-starting coil matching CP1/CP2 on HF PCB.
a. Adjust the space between them, or clear their surface.
b. Check and replace it if necessary. c. Check and replace it if necessary. d. Check. e. Check.
12. Turn on the machine, and it appears normal, but the malfunction LED turns on once welding is carried out.
a. The connecting cable matching socket CON11 on control PCB PK-05-A4 with the output bypass is in loose connection.
b. Loose contact exists in MOSFET VT1-VT24 on top PCB PM-04-A3 or rectifying diode U1/U24 on center PCB PD-13-B0.
c. Some part on control module PK-03-A1 is damaged.
a. Check. b. Check with a multi-meter. c. Check if the chip U2 or audion Q9
on PK-03-A1 is damaged. 13. Turn on the machine, and there is HF.
a. Some parts in manual switch control circuit are damaged.
b. The connecting cable matching socket
CON3 on control panel PK-10-A1 with socket CON3 on AC drive PCB PK-09-A3 is in loose connection, or chip U1/U4 or diode D11/D12/D14/D15 on control panel PK-10-A1 is damaged.
c. Some MOSFET on inverter PCB PN-06-A0/PN-05-A2 is damaged.
a. Check with a multi-meter if chip U3, diode D18/D22 or audion Q4 on control panel PK-10-A1 is damaged. Disconnect the connecting cable matching the socket CON5/4, and check if the manual switch board PH-10-A1 is short-circuited.
b. Check. c. Check.
REPAIR MANUAL·AC/DC SERIES
54
14. Incessant HF exists when welding is carried out.
a. The relay RELAY1 or MOSFET VT1 on HF PCB PZ-34-A0 is damaged, or the value of variable resistor R6 varies.
b. Some part on inverter PCB PN-05-A2 is
damaged.
a. Check and replace it if necessary; adjust the value of resistor R6 smaller to make sure that there is no HF when welding.
b. Check if rectifying diode D1/D3, zener diode Z3, MOSFET VT13 or resistor R14 is damaged.
15. There is deviation between the preset value and real value of the show value of the meter.
a. The value of the variable resistor R9 on control PCB PK-05-A4 or VR1 on preset PCB PH-10-A01 changes.
a. Adjust. Methods: 1. Turn to ARC mode, adjust the value of variable resistor R9 on control PCB PK-05-A4 to make the show value of the meter be the value of the corresponding machine type. 2. Turn to TIG mode, do not press the manual switch, adjust the value of variable resistor VR1 on preset PCB PH-10-A01 to make the show value of the meter be the value of the corresponding machine type.
16. When no-load in ARC mode, it appears normal in DC mode, but there is abnormal sound in AC mode.
a. Some MOSFET on the secondary inverter PCB PN-05-A2/PN-06-A1 is damaged.
a. Check. Method: Turn to ARC mode, then AC mode, turn off the machine after 3mins of no-load, touch the MOSFET on the secondary inverter PCB with your hand one by one. The extra hot ones are damaged.
17. No AC output in AC mode. a. The AC/DC conversion switch on the panel is damaged.
b. Some part on the control panel PK-10-A1 is damaged.
c. Some part on the secondary drive PCB
PK-09-A3 is damaged.
a. Check. b. Check if the diode D23/D24, chip
U4 or potentiometer VR2 on control panel PK-10-A1 is damaged.
c. Check with a multi-meter if chip U2/U4/U8/U9/U3, audion Q1-Q8 or zener diode Z1/Z2/Z3/Z4 on drive PCB is damaged.
18. No AC sound when welding in AC mode.
a. The value of the resistor matching socket CON1 on inverter PCB PN-05-A2 varies.
b. The MOSFET VT13, rectifying diode D1/D3, resistor R14/R13 or zener diode Z3 on inverter PCB PN-05-A2 is damaged.
a. Check and replace it if necessary. b. Check and replace it if necessary.
REPAIR MANUAL·AC/DC SERIES
55
19. Press the welding torch switch, there is gas out, the show value of the meter is invariable, there is only small current, and the pre-flow time is variable.
a. The connecting cable matching socket CON10 on control panel PK-10-A1 with socket CON2 on control PCB PK-05-A4 is in loose connection.
b. Some part on control panel PK-10-A1 is damaged.
a. Check. b. Check if chip U4, audion Q1/Q2 or
potentiometer VR5 on control panel PK-10-A1 is damaged.
20. The welding current is variable, and the maximum current is too big.
a. The audion Q1/Q2 on control panel PK-10-A1 is damaged.
a. Check and replace it if necessary.
21. Turn on the machine, the indicator of protection status is on because the voltage is too low.
a. The input voltage is too low or is unstable.
b. The thermal switch matching socket CON11 on control panel PK-10-A1 is damaged.
c. The connecting cable matching socket CON3 on control panel PK-10-A1 is in loose connection.
d. The resistor R17/R19 or chip U4 on control panel PK-10-A1 is damaged.
a. Check. b. Check. c. Check. d. Check. Method: properly reduce
the value of resistor R17. 22. The tungsten is badly burned out in AC mode.
a. The value of AC clean width on the panel is adjusted too big.
a. Adjust the clean width smaller.
23. The manual control is normal, but the pedal control goes wrong.
a. The connecting cable matching socket CON1 on control panel PK-10-A1 is in loose connection, or the panel remote control matching socket CON2 is damaged.
b. The potentiometer inside the pedal control or the toggle switch is damaged.
a. Check. b. Check.
6. AC/DC160 6.1 The structure drawing of AC/DC160:
REPAIR MANUAL·AC/DC SERIES
56
No. Description No. Description No. Description
1 Cover 9 Pilot-socket (2 pins) 17 Inverter PCB 2 2 Handle 10 Pilot-socket (3 pins) 18 AC Driver PCB 3 Button 11 Rubber foot 19 Fan 4 Function switch 12 Coupling socket 20 Inductance 5 EMC PCB 13 Bottom PCB 21 Heat sink 6 Main switch 14 Center PCB 22 Input cable 7 Front panel 15 Top PCB 23 Digital meter 8 Fast-socket 16 Inverter PCB 1
6.2 The general connection diagram of AC/DC160:
ELECTRIC DIAGRAM
Top Board
DRIVE MODULE
AC/DC160
REMOTE RESISTANCE
PK-07-B0
PM-21-A0
CON
9
CON
5
Port
Port
CP3
CP4
INPUT AC220V
CON
5 C
ON
9
CON
1
DC308V
CON3 CON8
AC220V
PZ-36-A0
BOTTOM BOARD
CON
1
CO
N10
CON7
CO
N2
CENTER BOARD
PD-22-A2VH
-07(
6)
AC220V FAN *2
CON1
+
-
+-
OU
T1
OU
T2
INVERTER BOARD
PN-0
2-A
2PN
-01-
A1
CON8
PROTECT LEDCURRENT R
CON9
CON11
THERMAL SWITCH
CONTROL BOARD
PK-32-A2
CON
1V
H-0
5V
H-0
4
50W
160R
CON1 CON5
PK-09-A3
DRIVE BOARD
CO
N12
CON
3AC2
0V*4
0
AC
380V
AC
220V
T
CO
N2
O
R
C
ON
4
XH-03(2)
PH-10-A2Gun Switch Board
Gun switch
CON
5
CON7
AC/DC
CONTROL HF
CON1
CON6
CO
N7HF
CONTROL MODULE
PK-02-A1
+24V
CON
2
FEED BACK
CONTROL GAS TIME
CON4
CON4 CON10CON8
THERMAL SWITCH
CON3
CON3
METER
CON6
CON10
CO
NT
RO
L L
INE
CONTROL HF
PK-32-A0 CON4
CON2
TIG/ARC
CON
6 2T/4T
REPAIR MANUAL·AC/DC SERIES
57
6.3 The diagram of AC/DC160’s top PCB PM-21-A0, control module PK-02-A1, center PCB PD-22-A1, bottom PCB PZ-36-A0, AC drive PCB PK-09-A3, inverter PCB PN-01-A1/PN-02-A2 and control panel PK-32-A0:
+
+
++
+
R11
CON3
CON6
R14
R12
C2
U2
U3
R29
LED2
CON8C18
R23
R24
C19
CON10
R26
LED1
C15
R19R18 CON4
R16
Q1
R15
C9
Z3
Z2
C6
Z1
R7
R33R32R31
R34
R1 R4R3R2
C17 C16
C11
D5
D4
C12U4
P1
C10
T1
C23C22 CON9
VT9 VT10 VT11 VT12
VT4VT3VT2VT1
R9C7
R10C8
R28 C24R27C21
P2
D3
D2
CON2CON1
C13
VT7
VT8
VT6
VT5
R25
C20
C3
C26 C27
C5
R30
C25
P3
R21R22
R13Z4
D8D9
D7D6
R20C14
D1
R5R6R8
C1
U1
T2CON5
R17
C4
CON7
X2
PM-21-A0
2006.02.08
++
R19 R20
R25
C10
R22
R27
C15
Q2
U2
C9
C7
D4
R29
Q4
Q1
R16
R18
C3
R24
Q3
Q8
Q9
Q6U1
C13
LED1
LED2
D1 D2
R8
Z4
R28
C5
C6
C2
C8
C14
Z2
R23
C1
C11
D3
Z1
C16
R9
R17
R3
R10
R13
R2R12
R14
R11
R4R5 R6
R15
R26
R30
Q7
Q5
R7
Z3
C4
C12
R1
R21
2006.02.08PK-02-A1
REPAIR MANUAL·AC/DC SERIES
58
R1
C4
C3
RV1
D9 D10
D1D4
T1T2
D7 D8
C5
C1
D3D2
R5
R2
C6R6
L3
L2
C2R3
CON1
D5 D6
Cu
R4
Cu
L1
2005.12.20PD-22-A2
P1 P2
+ +
+
+ +
C6
D7
CON3
R8
R6
VT1
R7
R9
CON6
RV1
RELAY2
R11
C10
VT2
CON1
C4C3
RV2 RV3
RV4RT1
CP3
CP4RELAY3
VT3
U1
CON4
R10
CON9
CON5
RV5
CON8
C11C12
D11
D12
R5
R4
D10
C2
CON10
Z2Z1
Z3
CON7
C1
C7 C8
RELAY1
T1
D6
C5
C3
C4
C2
CP1
CP2
R1
R3
D5
D2
D1
C9
C1
CON2
R2
2
1
Q1
AC/DC160(D) 2005.09PZ-36-A0
1R1 L1
+
+
+
C13
C12
C5
C17
C2
C8
CON3
CON2
R5
U1
C7
D1
C6Q3
Q4
U4U5
C1
C4
R1
U3
U2Q2
Q1C3
C10 Q5
Q6
U8
U6
R10
U7
D5
C11
C9
C16
CON1
U10
U9
Q8
Q7 C14
D7
C15
U11
R13
CON5
CON4
R3
R7
R11
R15
D2
Z1
Z2
Z3
Z4
D6
D3
D4
R14
R6
R2R4
R8
R12
R16
R9
2006.02.08PK-09-A3
REPAIR MANUAL·AC/DC SERIES
59
C1
Z4
Z3
Z2
Z1 R3 R4
R12R11R10R9
R5 R6
R7 R8
R2R1
VT1 VT2 VT3 VT6
VT7 VT9 VT10 VT11
35
32
34
37
VT5
VT12
VT4
VT8
AC/DC200(D)
2005.09
PN-01-A1
R8
R7
Z5
Z4
Z2
Z1
R3 R4
R15R14R13R12
R5 R6
R10 R11
R2R1
VT1 VT2 VT3 VT6
VT8 VT9 VT10 VT12
VT5
VT13
VT4
VT11
C5
CON1
C6
Z3R9
D1
VT7
D1
C3
C1
C4
C2
AC/DC200(D)
PN-02-A2
2005.09
REPAIR MANUAL·AC/DC SERIES
60
PK-32-A0 2006.02.08
+-
-+
D33
D1
Z1
D10D9 D11 D12D8
D16
D17
D27
D25
D23
D21
D18D20
D24
D22
D19
Z3
D7D6
D5
D3
D2
D28
Z2
D34
D35
D15
D13
D26
D4
D14
R64
R59
C26U10
VR5
U1
C17
C21
R12
R10
R25
CON2
L2 L1
C4
R2
R3
R5
CON1
R31
R21
C6
R19R15R14 R16 R17 R18
C13
R50
R63
R60R61
R53R52
R62
R65
R54
Q5Q4
C22
C2
C3
Q1
C7C9
C8
R36
Q3Q2
R35
CON3
U5
R33
R38
R40
R43
R46
U9
C16
C12
U7
CON6
CON7
CON10 CON11
CON9CON8
CON12
CON4
U8
R51
R58
R37
R39
R55
R9
R66
R6
R7
R27
R30
R34
R44
R47
R57
R20
R24
R26
R28
R45R48R49
R1
R42
LED2
LED1
VR2
VR9
VR7
VR1
U4
CON5
C10
U3\U6
R11
R13
C1
R41
U2
C15
Q6
C20
C24
C23
C25R68
L4
L5
D31
D32
D29
D30
C11
C19R32
C18
R23R22
C5
R29
C14
R67
R56
L7
R8
R4
L3
L6
6.4 Troubleshooting of AC/DC160:
Trouble Analysis Solution 1. Turn on the machine, no display of the meter, the fan doesn’t work, no no-load voltage output.
a. The input voltage is abnormal. b. The input cable is not in good connection
with CP3/CP4 on bottom PCB PZ-36-A0, or the tie-in is damaged.
c. The power supply switch may be damaged or not closed.
d. The connecting cable matching socket CON6/CON7/CON8 on bottom PCB PZ-36-A0 is in loose connection.
a. Check if the input voltage is AC 220V.
b. Check. c. Check and replace the power
supply switch if it’s damaged. d. Check.
REPAIR MANUAL·AC/DC SERIES
61
2. Turn on the machine, the meter displays, press the welding torch switch in TIG mode, there is gas out, no HF, turn to ARC mode, no no-load voltage output.
a. The connecting cable matching socket CON1 on bottom PCB PZ-36-A0 is in loose connection.
b. The prime relay RELAY3 on bottom PCB PZ-36-A0 doesn’t close well; the value of resistor RT1/RT2/RT3/RT4 increases.
c. The connecting cable matching socket CON5/CON9 on bottom PCB PZ-36-A0 with rectifying bridge is in loose connection.
d. Some part on control module PK-02-A1 is damaged.
e. Some part on top PCB PM-21-A0 is
damaged.
a. Check and make sure the voltage of socket CON1 is DC308V.
b. Check and replace if necessary. c. Check. d. Check with a multi-meter if chip
U1 on PK-02-A1 is damaged. Check if the 16th pin of U1 is 5V. If it’s not, replace the chip because U1 is damaged. Check if diode D1/D2/D3, audion Q1/Q2/Q3/Q5/ Q6/Q7/Q8/Q9 or zener diode Z1/Z2/Z3/Z4 is damaged.
e. Check if MOSFET VT5-VT8, pin P3 or manostat U2 is damaged.
3. Turn on the machine, the meter displays, but the thermal resistor RT1/RT2/VT3/VT4 on bottom PCB PZ-36-A0 heats and smokes after a while.
a. The connecting cable (+24V) matching socket CON10 on bottom PCB PZ-36-A0 with socket CON1 on top PCB PM-21-A0 is in loose connection.
b. The relay RELAY3 on bottom PCB PZ-36-A0 is damaged.
c. The auxiliary power supply part on top PCB PM-21-A0 is damaged.
a. Check. b. Check. c. Check with a multi-meter if
resistor R17, diode D4/D5, chip U3 or OC U4 on top PCB PM-21-A0 is damaged.
REPAIR MANUAL·AC/DC SERIES
62
4. Turn on the machine and it appears normal, press the welding torch and there is gas out, the malfunction LED is not on, no HF, but there is no-load voltage output.
a. The connecting cable matching socket CON7 on top PCB PM-21-A0 with socket CON2 on bottom PCB PZ-36-A0 is in loose connection.
b. High voltage silicon granule D1/D2/D5/D6 or high voltage output capacitor C7/C8/C9 on bottom PCB PZ-36-A0 is damaged.
c. CP1/CP2 is disconnected with the bottom PCB.
d. The discharge nozzles P1/P2 on bottom PCB have conglutination, excessive clearance or serious oxidation problem.
e. The connecting cable matching socket CON 4 on control panel PK-32-A0 with socket CON3 on bottom PCB PZ-36-A0 is in loose connection, or HF relay RELAY1, MOSFET VT1, audion Q1, diode D7, resistor R6-R9, rectifying bridge D1 or resistor R1/R3 on bottom PCB is damaged.
a. Check. b. Check. c. Check. d. Adjust or replace it if necessary. e. Check.
5. Turn on the machine, and it appears normal, press the welding torch switch and there is gas out, the malfunction LED is on.
a. Over-current protection occurs when welding is carried out.
b. Over-heating protection occurs when welding is carried out.
c. Some parts on top PCB, center PCB, or
bottom PCB are damaged.
a. Turn off the machine for 5mins and restart.
b. Stop the welding operation for 5mins, or the secondary inverter thermal switch is damaged.
c. Check. Turn off the machine, pull out the connecting cable matching the socket CON7 on top PCB PM-21-A0 with the socket CON2 on bottom PCB PZ-36-A0, turn on the machine. If the malfunction LED is off, the transformer T1 on bottom PCB is short-circuited or damaged. If it’s on, turn off the machine, pull out the connecting cable matching socket CON5 on top PCB PM-21-A0, turn on the machine. If the malfunction LED is on, MOSFET VT1-4/VT9-12 on top PCB or some part on drive module PK-07-B0 is damaged; if it’s off, transformer T1/T2 or rectifying diode D1-4/D7-10 on center PCB PD-22-A1 is damaged.
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6. Turn on the machine and it appears normal, it can start arc, but the welding point appears black.
a. The magnet valve or the gas tube is blocked.
b. The magnet valve is damaged. c. The connecting cable matching socket
CON10 on bottom PCB PZ-36-A0 with socket CON3 on control panel PK-32-A0 is in loose connection.
d. Some part in the magnet valve control circuit on bottom PCB PZ-36-A0 or on control panel PK-32-A1 is damaged.
e. The welding torch is damaged. f. The tungsten is of bad quality or the
argon is impure.
a. Clear. b. Replace. c. Check. d. Check with a multi-meter if
MOSFET VT2, diode D10/D11, zener diode Z1, relay RELAY2 on bottom PCB or audion Q1 on control PCB PK-32-A0 is damaged or if the magnet valve control cable matching the socket CON4 is disconnected.
e. Remove the welding torch and the gas-electricity tie-in, and press the welding torch switch. If there is gas out, the welding torch is damaged. Replace it.
f. Replace them if necessary.
7. The welding current is unstable and out of control.
a. The connecting cable matching socket CON8 on control panel PK-32-A0 with socket CON4 on top PCB PM-21-A0 is in loose connection.
b. The capacitor C1/C2/C3/C4/ on bottom PCB PZ-36-A0 leaks or is damaged.
c. The input cable or output cable is too slim and too long.
d. Loose connection exists inside the machine.
a. Check and replace it if necessary. b. Check and replace it if necessary. c. Enlarge the cross section area of
the cable. d. Check.
8. Turn on the machine but it strips.
a. The rectifying bridge matching the socket CON5/CON9 on bottom PCB PZ-36-A0 is damaged.
b. The power supply cable is disconnected or short-circuited.
a. Replace. b. Check.
9. Adjust the value of the decay potentiometer to the maximum and release the welding torch switch, the gas valve shuts off, and no current output.
a. The audion Q4, resistor R54/R59 or diode D27 on control panel PK-32-A0 is damaged.
a. Check and replace it if necessary.
10. Press the welding torch switch, there is HF discharge buzz, but no welding voltage output.
a. The earth cable of welding torch is in loose connection.
b. The output terminal of the earth cable is in loose connection with gas-electricity tie-in.
c. Check and replace it if necessary. d. Check and replace it if necessary.
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11. The arc starting is bad. a. The space between discharge nozzles P1 and P2 on bottom PCB PZ-36-A0 is too big or small, or their surface is badly oxidized.
b. The high-voltage capacitor C7/C8/C9 on bottom PCB is damaged, or the capacitance becomes smaller.
c. The tungsten is of bad quality or argon is impure.
d. The welding torch is loose or broken. e. Incorrect turn rate or turn-to-turn
electricity leakage problem exists in arc-starting coil matching CP1/CP2 on bottom PCB.
a. Adjust the space between them, or clear their surface.
b. Check and replace it if necessary. c. Check and replace it if necessary. d. Check. e. Check.
12. Turn on the machine, and it appears normal, but the malfunction LED turns on once welding is carried out.
a. The connecting cable matching socket CON2 on top PCB PM-21-A0 with socket CON1 on center PCB PD-22-A2 is in loose connection.
b. Loose contact exists in MOSFET VT1-4/VT9-12 on top PCB PM-21-A0 or rectifying diode U1-4/U7-10 on center PCB PD-22-A2.
c. Some part on control module PK-02-A1 is damaged.
a. Check. b. Check with a multi-meter. c. Check if the chip U2 or audion Q9
on PK-02-A1 is damaged. 13. Turn on the machine, and there is HF.
a. Some parts in manual switch control circuit are damaged.
b. The connecting cable matching socket
CON12 on control panel PK-32-A0 with socket CON3 on AC drive PCB PK-09-A3 is in loose connection, or chip U5 or diode D16/D17/D20/D24/D26 on control panel PK-32-A0 is damaged.
c. Some MOSFET on inverter PCB PN-01-A1/PN-02-A2 is damaged.
a. Check with a multi-meter if chip U1, diode D1/D2 on control panel PK-10-A1 is damaged. Disconnect the connecting cable matching the socket CON5, short-circuit CON5, and check if the manual switch board PH-10-A1 is short-circuited.
b. Check. c. Check with a multi-meter one by
one. 14. Incessant HF exists when welding is carried out.
a. The relay RELAY1, audion Q1 or MOSFET VT1 on bottom PCB PZ-36-A0 is damaged.
b. Some part on inverter PCB PN-02-A2 is damaged.
a. Check and replace it if necessary. b. Check if rectifying diode D1, zener
diode Z3, MOSFET VT7 or resistor matching socket CON1 is damaged.
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15. Press the manual switch, when no load, it appears normal in DC mode, but there is abnormal sound in AC mode.
a. Some MOSFET on the secondary inverter PCB PN-02-A2/PN-01-A1 is damaged.
a. Check. Method: Turn to ARC mode, then AC mode, turn off the machine after 3mins of no-load, touch the MOSFET on the secondary inverter PCB with your hand one by one. The extra hot ones are damaged.
16. No AC output in AC mode. a. The AC/DC conversion switch on the panel is damaged.
b. Some part on the control panel PK-32-A0 is damaged.
c. Some part on the secondary drive PCB
PK-09-A3 is damaged.
a. Check. b. Check if the diode D19, chip U9,
potentiometer VR5 or audion Q6 on control panel PK-32-A0 is damaged.
c. Check with a multi-meter if chip U2/U4/U8/U9/U3, audion Q1-Q8 or zener diode Z1/Z2/Z3/Z4 on drive PCB is damaged.
17. No AC sound when welding in AC mode.
a. The value of the resistor matching socket CON1 on inverter PCB PN-02-A2 varies.
b. The MOSFET VT7, rectifying diode D1, or zener diode Z3 on inverter PCB PN-02-A2 is damaged.
a. Check and replace it if necessary. b. Check and replace it if necessary.
18. Press the welding torch switch, there is gas out, there is only small current, and the pre-flow time is variable.
a. The connecting cable matching socket CON8 on control panel PK-32-A0 with socket CON4 on top PCB PM-21-A0 is in loose connection.
b. Some part on control panel PK-32-A0 is damaged.
a. Check. b. Check if chip U8, audion Q3/Q2 or
potentiometer VR9 on control panel PK-32-A0 is damaged.
19. Turn on the machine, the indicator of protection status is on because the voltage is too low.
a. The input voltage is too low or is unstable.
b. The thermal switch matching socket CON11 on control panel PK-32-A0 is damaged.
c. The connecting cable matching socket CON12 on control panel PK-32-A0 is in loose connection.
d. The resistor R46/R43 or chip U9 on control panel PK-32-A0 is damaged.
a. Check. b. Check. c. Check. d. Check. Method: properly reduce
the value of resistor R46. 20. The tungsten is badly burned out in AC mode.
a. The value of clean width potentiometer VR5 on control panel PK-32-A0 is adjusted too big.
a. Adjust the clean width smaller, or parallel connect a resistor of 200K with resistor R18 on control panel PK-32-A1.
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21. The manual control is normal, but the pedal control goes wrong.
a. The conversion switch on the panel is damaged.
b. The toggle switch inside the pedal control is damaged.
c. The potentiometer inside the pedal control is damaged.
d. The connecting cable matching socket CON1 on control panel PK-32-A0 is in loose connection.
a. Check. b. Check. c. Check. d. Check.
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