Snap-On TIG 250 AC-DC Service Manual
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Snap-On TIG 250 AC-DC Service Manual

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CEBORA S.p.A.
1
TIG 250 AC-DC
POWER SOURCE art. 236.76
SERVICE MANUAL
3.302.221
15/01/07

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  • Page 1 CEBORA S.p.A. TIG 250 AC-DC POWER SOURCE art. 236.76 SERVICE MANUAL 3.302.221 15/01/07...

  • Page 2: Table Of Contents

    CEBORA S.p.A. CONTENTS - GENERAL INFORMATION.......................... 3 - Introduction..............................3 - General service policy..........................3 - Safety information............................3 - Electromagnetic compatibility........................3 - SYSTEM DESCRIPTION ..........................4 - Introduction..............................4 - Technical specifications..........................4 - Description of TIG 250 AC/DC power source..................... 4 - MAINTENANCE............................

  • Page 3: General Information

    CEBORA S.p.A. 1 - GENERAL INFORMATION 1.1 - Introduction. The purpose of this manual is to train personnel assigned to carry out maintenance on the TIG 250 AC/DC Power Source, art. 236.76. 1.2 - General service policy. It is the responsibility of the customer and/or operator to use the equipment appropriately, in accordance with the instructions in the Instructions Manual, as well as to maintain the equipment and related accessories in good working condition, in compliance with the instructions provided in the Service Manual.

  • Page 4: System Description

    CEBORA S.p.A. 2 - SYSTEM DESCRIPTION 2.1 - Introduction. The TIG 250 AC/DC is un electronic power source suitable for AC/DC TIG welding with high-frequency arc striking. It may be used together with a range of accessories for various types of applications (see list in the Sales catalogue).
  • Page 5 CEBORA S.p.A. NOTE In the shut-off board (48) there are two low-powered thyristors, inserted into two similar circuits, one of which is always connected and available, while the other is parallel connected to the first through a relay, when the welding current exceeds approximately 50 Aac. Both are controlled by the same driver signal and thus work simultaneously.
  • Page 6 CEBORA S.p.A. The snubber board (6) also includes the load resistors for SCR1 and SCR2 (47), which make it possible for SCR1 and SCR2 (47) to function correctly even with an open circuit power source, and the capacitor C1, which helps strike the arc in DC mode. The connector (13) on the rear panel of the power source is connected to the pressure switch on the cooling unit;...

  • Page 7: Maintenance

    CEBORA S.p.A. 3 - MAINTENANCE WARNINGS ANY INTERNAL INSPECTION OR REPAIRS MUST BE CARRIED OUT BY QUALIFIED PERSONNEL. UNPLUG THE POWER SOURCE FROM THE MAINS BEFORE REMOVING THE PROTECTIVE COVERS AND ACCESSING THE INTERNAL PARTS. 3.1 - Periodic inspection, cleaning. Periodically remove any dirt or dust to ensure smooth air flow, and thus keep the internal elements of the power source cool.

  • Page 8: Power Source Tig Operation

    CEBORA S.p.A. NOTE Operations preceded by this symbol refer to operator actions. ♦ Operations preceded by this symbol refer to machine responses that must occur following an operator action. 3.2.2 - Power Source TIG operation. Connect the gas supply to the fitting on the rear panel. Connect the TIG torch to the negative pole (AB) of the power source.
  • Page 9 CEBORA S.p.A. ♦ Gas begins flowing from the torch, for as long as the button is held down. ♦ Gas continues to flow from the torch for the duration of the post-gas time set, led (X) lit, even after the start button is released. Correct? NO (see 3.3.3, 3.3.4, 3.3.5).

  • Page 10: Troubleshooting

    CEBORA S.p.A. 3.3 - Troubleshooting. WARNINGS ANY INTERNAL INSPECTION OR REPAIRS MUST BE CARRIED OUT BY QUALIFIED PERSONNEL. UNPLUG THE POWER SOURCE FROM THE MAINS BEFORE REMOVING THE PROTECTIVE COVERS AND ACCESSING THE INTERNAL PARTS. NOTE The problems the machine may suffer (symptoms) are indicated in boldface. Operations preceded by this symbol refer to situations that the operator must check into (causes).
  • Page 11 CEBORA S.p.A. CONTROL BOARD (40) POWER SUPPLY TEST. Control board (40), connector : J2, terminals 1 and 2 = 16 Vac, pulse generator synchronization signal for SCR1, SCR2 and − SCR3 on control board (40). − J3, terminals 2 - 4 - 1 = 16 - 0 - 16 Vac, power supply to internal circuits of control board (40).

  • Page 12: Power Source Powered, Control Panel On, Fan (45) Stopped

    CEBORA S.p.A. 3.3.2 - Power source powered, control panel on, fan (45) stopped. FAN (45) TEST. Fan (45) terminals on terminal board (52) = 230 Vac, with switch (15) closed and mains voltage both at 208 or 230 Vac. Correct? ♦...

  • Page 13: System Powered, Display And Signals Do Not Show The Correct Values

    CEBORA S.p.A. 3.3.3 - System powered, display and signals do not show the correct values. LAMP-TEST. On control panel, all leds and displays lit for one second after closing the switch (15). Correct? ♦ Carry out the CONTROL BOARD (40) POWER SUPPLY TEST of par. 3.3.1, especially the one referred to J3.
  • Page 14 CEBORA S.p.A. ♦ With the power source off, temporarily disconnect torch signal connector from connector (AE) of the Power Source, and check on connector (AE), terminals 3(+) and 4(-) voltage = +5 Vdc (current external adjustment potentiometer power supply). If incorrect, temporarily disconnect, with the power source off, connector J5 from control board (40) and make sure, restarting the Power Source, on terminals 6(+) and 8(-) of J5 on control board (40) voltage = +5 Vdc.

  • Page 15: The Start Button Produces No Effect

    CEBORA S.p.A. 3.3.4 - The start button produces no effect. START SIGNAL TEST. Control board (40), connector J5, terminals 3 and 4 = approximately 0 Vac, with start button pressed (26 Vac with button released ). Correct? ♦ Check the wiring between J5 control board (40) and TP2 and TP3 on connector board (49).

  • Page 16: In Tig Mode, No Gas Flows From The Torch

    CEBORA S.p.A. 3.3.5 - In TIG mode, no gas flows from the torch. SOLENOID VALVE (43) TEST. Terminals of solenoid valve (43) = approximately 30 Vac, in TIG mode with start button pressed (the time the solenoid remains open also depends on the post-gas set). Correct? ♦...

  • Page 17: In Tig Mode, Gas Flows From The Torch, The Arc Does Not Strike (No High Frequency)

    CEBORA S.p.A. 3.3.6 - In TIG mode, gas flows from the torch, the arc does not strike (no high frequency). HF OSCILLATOR TEST. Via the control panel, set TIG operation with HF (ex.: Leds L and G lit). HF board (42), discharger SP2 emits discharges at regular intervals, with start button pressed. Correct? ♦...
  • Page 18 CEBORA S.p.A. ♦ Check the presence of 30 Vac supply voltage, conducting the CONTROL BOARD (40) POWER SUPPLY TEST, par. 3.3.1 if necessary, particularly the one relating to J8. ♦ Replace HF (42) and/or control (40) boards. HF BOARD (42) POWER SUPPLY TEST. WARNING FOR THIS TEST RE-CONNECT CONNECTOR J3 AND DISCONNECT THE CONNECTOR J4 ON HF BOARD (42) TO KEEP THE HIGH FREQUENCY GENERATION...

  • Page 19: In Open Circuit Operation, The Output Voltage Is Not Regular

    CEBORA S.p.A. 3.3.7 - In open circuit operation, the output voltage is not regular. WARNING FOR THESE TESTS DISCONNECT THE CONNECTOR J4 ON HF BOARD (42) TO PREVENT HIGH FREQUENCY GENERATION. OPEN CIRCUIT VOLTAGE OUTPUT TEST. Output terminal – (AB)(-) and output terminal + (AC)(+) of the power source = voltages according to the table.
  • Page 20 CEBORA S.p.A. FIRING PULSES FOR SCR1 (47) AND SCR2 (47) TEST. NOTE In AC operation the output voltage becomes alternating only in presence of output current, thus SCR2 is not driven in AC operation with open-circuit power source. Shut-off board (48), connector J1, terminals 2 and 4 (gnd) = fig. 5.2.2a, pulses for SCR1, with AC/DC selector switch (30) in the “0”...
  • Page 21 CEBORA S.p.A. A1-K2(+) - K1(-) = 0.5 Vdc; A1-K2(-) - K1(+) = >Mohm; − A2(+) - A1-K2(-) = 0.5 Vdc; A2(-) - A1-K2(+) = >Mohm; − A3(+) - K3(-) = 0.5 Vdc; A3(-) - K3(+) = >Mohm. − If incorrect replace the defective diodes or the entire diode module (19). ♦...

  • Page 22: In Resistive Load Operation, The Output Voltage Is Not Regular

    CEBORA S.p.A. 3.3.8 - In resistive load operation, the output voltage is not regular. WARNING FOR THESE TESTS DISCONNECT THE CONNECTOR J4 ON HF BOARD (42) TO PREVENT HIGH FREQUENCY GENERATION. OPEN CIRCUIT OUTPUT VOLTAGE TEST. Output terminals - (AB)(-) and + (AC)(+) of power source = voltages according to the table. Process Voltage Condition...
  • Page 23 CEBORA S.p.A. SCR3 FIRING PULSES TEST. Shut-off board (48), connector J3, terminals 1 and 2 (gnd) = fig. 5.2.6, pulses for SCR3 in the AC operation and power source loaded in table conditions. Correct? ♦ Check the wiring between J3 shut-off board (48) and J7 control board (40). ♦...

  • Page 24: Ac Operation, Arc Unstable, Welding Irregular

    CEBORA S.p.A. 3.3.9 - AC operation, arc unstable, welding irregular. NOTE In AC operation the quality of the welding may be unacceptable due to the oxidation that forms when welding certain materials (aluminium and similar). To avoid this problem, in each period of the welding current, specifically each time SCR1 (47) engages, a high voltage pulse is generated (normally 150 - 250 volts, but it may vary depending on the type of material being welded) that is applied between torch and workpiece to destroy the oxidation, which impedes the...

  • Page 25: Alarm Signals

    CEBORA S.p.A. 3.4 - Alarm signals. 3.4.1 - Led (Y) off. Power source output voltage greater than 48 Vac. Alarm active only in AC operation. For safety reasons the power source is blocked if the voltage at its output exceeds 48 Vac, in AC operation.

  • Page 26: Components List

    CEBORA S.p.A. 4 - COMPONENTS LIST 4.1 - Power source art. 236.76 : see file ESP236.76.pdf enclosed at the end of the manual. 4.2 - Components table : see file ESP236.76.pdf enclosed at the end of the manual. 4.3 - Spare parts list. Essential spare parts.

  • Page 27: Electrical Diagrams

    CEBORA S.p.A. 5 - ELECTRICAL DIAGRAMS 5.1 - Power source art. 236.76 : see file SCHE236.76.pdf enclosed at the end of the manual. 5.2 - Waveforms. 5.2.1a 5.2.1b 5.2.1 - Output voltage with open-circuit power source (par. 3.3.7). 5.2.2a 5.2.2b 5.2.2 - Firing pulses for SCR1 with open-circuit power source (par.

  • Page 28: Output Current With Power Source Loaded In Table Conditions (Par. 3.3.8)

    CEBORA S.p.A. 5.2.4a 5.2.4b 5.2.4 - Output current with power source loaded in table conditions (par. 3.3.8). 5.2.5a 5.2.5b 5.2.5 - Output voltage with power source loaded in table conditions (par. 3.3.8). 5.2.6 - Firing pulses for SCR3 with power source loaded in table conditions (par. 3.3.8). 3.302.221 15/01/07...

  • Page 29: Mains Filter Board (51) Code 5.600.993/A

    CEBORA S.p.A. 5.3 - Mains filter board (51), code 5.600.993/A. 5.3.1 - Topographical drawing. 5.3.2 - Connector table. Conn. Terminals Function earth connection. mains input phase R. mains input phase S. 5.4 - Fuse board (4), code 5.602.288. 5.4.1 - Topographical drawing. 5.4.2 - Connector table.

  • Page 30: Control Board (40) Code 5.602.293/A

    CEBORA S.p.A. 5.5 - Control board (40), code 5.602.293/A. 5.5.1 - Topographical drawing. 5.5.2 - Connector table. Conn. Terminals Function 1 - 2 1 - 2 16 Vac input, synchronization signal for control board (40). 1 - 4(0v) - 2 dual 16 Vac input to control board (40) power supply (+/-15 Vdc).

  • Page 31: Shut-Off Board (48) Code 5.602.289

    CEBORA S.p.A. 5.6 - Shut-off board (48), code 5.602.289. 5.6.1 - Topographical drawing. 5.6.2 - Connector table. Conn. Terminals Function 1(K) - 3(G) gate command input for SCR1 (47). 2(K) - 4(G) gate command output for SCR1 (47). 1 - 2 2nd shut-off circuit enable relay command input, on shut-off board (48).

  • Page 32: Snubber Board (6) Code 5.602.294

    CEBORA S.p.A. 5.7 - Snubber board (6), code 5.602.294. 5.7.1 - Topographical drawing. 5.7.2 - Connector table. Conn. Terminals Function converter output voltage input (- potential). converter output voltage input (+ potential). 1 - 2 converter output voltage signal output. 5.8 - HF board (42), code 5.602.290.

  • Page 33: Hf-Filter Board (41) Code 5.602.291

    CEBORA S.p.A. 5.9 - HF-filter board (41), code 5.602.291. 5.9.1 - Topographical drawing. 5.9.2 - Connector table. Conn. Terminals Function TP1 - TP2 converter output voltage input. earth connection. 5.10 - Connector board (49), code 5.602.292. 5.10.1 – Topographical drawing. 5.10.2 - Connector table.

  • Page 34: Diode Group (19) Code 3.200.090/A

    CEBORA S.p.A. 5.11 - Diode group (19) code 3.200.090/A. 5.11.1 - Assembly drawing. 3.302.221 15/01/07...
  • Page 36 KNOB 5602293 MICRO CIRCUIT 5602291 FILTER CIRCUIT 5602290 HF CIRCUIT CKSB7105370 SOLENOID VALVE 3065118 3165051 MOTOR 5610096 TRANSFORMER 5605539 SCR. GROUP 5602289 CIRCUIT 5602292 CONNECTOR CIRCUIT 3205314 INDUCTOR ALL CONSUMABLES AND REPAIR PARTS SHOULD BE ORDERED THROUGH YOUR SNAP-ON DEALER.

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