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CITIG 1500 DC

Language: English Date creation: Mar 2008 Rev.: 00

Service Manual

CITIG 1500 DC
Designed by Mario Jurik

CITIG 1500 DC

1.0 REPAIR INSTRUCTIONS


1.1 GENERAL CLEANING Remove the machine shell and clean carefully with compressed air. 1.2 MACHINE: VISUAL INSPECTION 1. On the electronic circuit ref. 3 check the varistor (fig. 1), if it presents bursting marks, replace the electronic circuit
V1 R4 R3 R5

correct value of the power resistance (fig. 2)

FIG. 2

2. Electronic circuit ref. 32: check for the presence of short circuits on the mosfet of fig. 3 between points G-S, G-D, D-S; in case of fault replace the electronic circuit.

R1

FIG. 1

2. Check on the electronic circuit ref. 1: the state of the levelling capacitors CE1, CE2, CE3 and CE4. If there are swellings or breaks on the container, replace the electronic circuit check for the presence of cracks or breaks on the welds of the following components: transformer T2 impedance L1 3. Check for the presence of burned tracks or electric discharge marks on the electronic circuit in the generator. 4. Check on all the harnesses the insulation of the cables and the state at the connection points. Always grease the thermostatic probe after replacement of the corresponding harness (grease with a basis of silicone). 1.3 CHECK OF THE MAIN COMPONENTS WITH TESTER (OHMMETER) 1. Electronic circuit ref. 3: check the presence of short circuits on the rectifier bridge and the
1 3
FIG. 3

3. Electronic circuit ref. 1: check: IGBT of the primary circuit and diodes of recycle: test points G-C, G-E, C-E of components 1 and 2; points A-K of components 3 and 4 (fig. 3); if there are short circuits in any of these components the board is broken.

4 2
FIG. 4

Diodes of the secondary circuit: check points A-B of diode 1 and points C-D of diode 2 (fig. 5): if at least one shows short circuits the board is broken.

1102

Pag. 3

CITIG 1500 DC

A B C D 2 1

If the waveform or the voltages differ from the figure or no waveform or voltage are present, the IGBT are fault.

FIG. 5

FIG. 9

Prefeeding resistances R1 and R2: verify for each resistance the value 3K3 with the levelling condensers discharged; if there are other readings the resistances are broken. 1.4 CHECK OF GENERATOR WORKING IN MMA WITH OSCILLOSCOPE AND VOLTMETER 1. Set the generator in MMA, short-circuit points A and XT1-5 (fig. 6), connect a feeder on the points XT1-1 and XT1-5 and supply with approx. 15Vdc, set the oscilloscope on a time base of 5 uS and a range of 0.5 V/DIV with probe x10 and verify:
3 1

Disconnect the feeder; set the oscilloscope with a range of 1V/DIV and connect the probe X100 between points XT23(GND) and XT2-1(probe) (fig. 10), connect the machine to the power supply, switch it on:

FIG. 10

after approx. 2 seconds a wave will appear as in fig. 11


1 5 A
FIG. 6

The presence between points: XT28(GND) - XT2-7(probe) and XT2-3(GND) XT2-4(probe) (fig. 8) of the wave form shown in fig. 9:

FIG. 11

check with a voltmeter that the output voltage is approx. 55V (see test specification point 2).
8 7 4 3

If the waveform does not appear or the output voltage is not correct, verify, the presence of approx. 300Vdc between points U (GND) and T (POS) of fig. 12; with this rea-

FIG. 8

1102

Pag. 5

CITIG 1500 DCCITIG 1500 DC

ding, the electronic circuit ref. 1 is correctly fed but it does not work.
P M

if the voltages are not regular replace the electronic circuit ref. 48; if the fault is still there replace the electronic circuit fig. 20 2. Short-circuit points G - F of the remote outlet ref. 51 and check for: the presence of a high frequency hum for approx. 2 seconds; if there is no hum, there is no command from the board ref. 32 the presence of 24Vdc on the solenoid valve ref. 46; if this is not present, replace the electronic circuit ref. 20; if the fault is still there replace the electronic circuit ref. 32 3. In case of malfunction of the tig functions (slope down spot, pre-and post gas) replace the electronic circuit ref. 48 Carry out the final test after the repair.

FIG. 12

1.5 CHECK OF GENERATOR WORKING IN TIG 1. Set the generator to tig mode, switch it on and verify: on the electronic circuit ref. 20 check the voltage on the following points: between XF3 and X F2 a voltage of 230 Vac (fig. 13)

2.0 FINAL TEST


1. Carry out the safety test according to our operative instruction N. SLL12, before proceeding, act as follows: disconnect the fan faston, the ground cable and the clamp screw of the electronic board turret ref. 3 insert an insulating thickness to avoid discharges or short circuits between the electronic board (ref. 3) and her supporting turrets

XF2 XF3

FIG. 13

on the electronic board (ref. 1) short-circuit points U, T and a rheophore of the primary circuit of the transformer (fig. 15)
U T

on the connector x4 between points 1 (POS) and 2 (GND) (fig. 14) measure a voltage of approx. + 15Vdc

3 2 1
FIG. 15 FIG. 14 RHEOPHORE
THE PRIMARY CIRCUIT

switch on on the connector X4 between points 2 (GND) and 3 (POS.) (fig. 14) measure a voltage of approx. - 1,2Vdc short-circuit the feeder plug short-circuit the output dinse.

1102

Pag. 7

CITIG 1500 DC

After the test remove all the short circuits and restore the connections. 2. Connect the generator to the power supply (230 Vac), set it in MMA and check if the voltage of the outputs is 55 Vdc (+/- 5%): switch off the generator. 3. Connect the generator to the resistive load: the load must be regulated so that the voltage o n th e l o a d , w it h ma x i mu m c u r r e n t , is between 20V and 25V. Apply oscilloscope probe as in fig. 8 4. Set the regulation knob to the centre of the dial, switch on the generator, turn the knob to the maximum welding current and read with the amperometer the maximum current indicated on the technical table with +/- 5% tolerance. See on the oscilloscope a waveform as in fig. 16

8. Disconnect the probe, switch off the generator and with the load to the maximum current, let the machine work at the greatest capacity till the thermostatic protection intervenes (the thermostatic protection led turns on). 9. Wait until the machine starts working again (the thermostatic protection led turns off) and disconnect the machine from the resistive load. 10.Carry out MMA welding tests at the maximum current (one electrode). 11. Carry out welding tests in tig either in 2 strokes or in 4 strokes and check the following functions: SLOPE DOWN SPOT PRE-GAS POST-GAS

FIG. 16

5. If the current readings differ, adjust the trimmer T (fig. 17) till the correct current value is obtained

T
FIG. 17

6. Short-circuit the load and check that after 1,5 sec. the current descends to approx. 34A (model 90A) or to approx. 40A (model 150A). 7. Regulate the resistive load to measure the minimum current (8A - 20A), set the minimum current on the frontal panel and check that the amperometer shows a value lower than the one indicated on the technical table.Disconnect the probe, switch off the generator and with the load to the maximum current, let the

1102

Pag. 9

SPARE PARTS LIST - PICES DTACHES - LISTA DE LAS PIEZAS DE RECAMBIO - ERSATZTEILLISTE EAS SOBRESSELENTES - RESERVDELAR - WISSELSTUKKEN - LISTA PIESE COMPONENTE LISTA CZCI ZAMIENNYCH - -

38 13 56 12 57

42 13.1 11 51 52

36 48 10 15 20 25 32 14 33 01 03 46 09 08

SPARE PARTS LIST - PICES DTACHES - LISTA DE LAS PIEZAS DE RECAMBIO - ERSATZTEILLISTE EAS SOBRESSELENTES - RESERVDELAR - WISSELSTUKKEN - LISTA PIESE COMPONENTE LISTA CZCI ZAMIENNYCH - -

R.
01 03 08 09 09.1 10 11 12 13 13.1 14 15 20 32 33 36 38 46 48 51 52 56 56.1 57

CODE
W000050170 W000232541 W000236149 W000227612 W000227620 W000233525 W000070027 W000231163 W000070032 W000228005 W000050067 W000050193 W000050187 W000070040 W000070016 W000050188 W000262754 W000050181 W000050179 W000070019 W000070047 W000070049 W000228008 W000227589

DESCRIPTION
CIRCUIT BOARD HF 344/TH CIRCUIT BOARD HF 343C POWER CABLE CABLE CLAMP KNOB D.49 SECURING BLOCK SWITCH OUTLET CONNECTOR KNOB HOOD FAN UNIT BRACKET FOR DINSE CIRCUIT BOARD TV 316 CIRCUIT BOARD HF 317 COUPLER CIRCUIT BOARD CE 22660 PLASTIC TRIM SOLENOID VALVE LONG TRIMMER PIN CLAMP GAS CONNECTION KNOB HOOD SOCKET

DESCRIPTION
CIRCUIT LECTRONIQUE HF 344/TH CIRCUIT LECTRONIQUE HF 343C CBLE ALIMENTATION SERRE-FIL ECRU SERRE-CBLE D.49 BLOC DE FIXATION INTERRUPTEUR RACCORD SORTIE BOUTON CAPUCHON MOTOVENTILATEUR QUERRE CIRCUIT LECTRONIQUE TV 316 CIRCUIT LECTRONIQUE HF 317 COUPLEUR CIRCUIT LECTRO-NIQUE CE 22660 PROFIL ARTE LECTROVANNE ARBRE LONG POUR TRIMMER BORNE RACCORD GAZ BOUTON CAPUCHON PRISE

DESCRIPCIN
CIRCUITO ELECTRNICO HF 344/TH CIRCUITO ELECTRNICO HF 343C CABLE DE ALIMENTACIN PRENSACABLE PERILLA D.49 BLOQUEO DE FIJACIN INTERRUPTOR RACOR DE SALIDA PERILLA CAPUCHN MOTOR DEL VENTILADOR ESCUADRA CIRCUITO ELECTRNICO TV 316 CIRCUITO ELECTRNICO HF 317 ACOPLADOR CIRCUITO ELECTRNICO CE 22660 PROFIL ARTE ELECTROVALVULA EJE LARGO DEL TRIMMER BORNE RACOR GAS PERILLA CAPUCHN TOMA

BESCHREIBUNG
ELEKTRONISCHE SCHALTUNG HF 344/TH ELEKTRONISCHE SCHALTUNG HF 343C SPEISEKABEL KABLEKLEMME DREHKNOPF BEFESTIGUNGSBLOCK SCHALTER AUSGANGSANSCHLUSS DREHKNOPF KAPPE MOTORVENTILATOR WINKEL ELEKTRONISCHE SCHALTUNG TV 316 ELEKTRONISCHE SCHALTUNG HF 317 KUPPLUNGSSCHLAUCH ELEKTRONISCHE SCHALTUNG CE 22660 RAHMENPROFIL MAGNETVENTIL WELLE FR TRIMMER KLEMME GASANSCHLUSS DREHKNOPF KAPPE STECKDOSE

R.
01 03 08 09 09.1 10 11 12 13 13.1 14 15 20 32 33 36 38 46 48 51 52 56 56.1 57

CODE
W000050170 W000232541 W000236149 W000227612 W000227620 W000233525 W000070027 W000231163 W000070032 W000228005 W000050067 W000050193 W000050187 W000070040 W000070016 W000050188 W000262754 W000050181 W000050179 W000070019 W000070047 W000070049 W000228008 W000227589

DESCRIO
CIRCUITO ELECTRNICO HF 344/TH CIRCUITO ELECTRNICO HF 343C CABO DE ALIMENTAO GRAMPO DO CABO PORCA EM NYLON BLOCO DE FIXAO INTERRUPTOR UNIO DE SADA BOTO TAMPA VENTILADOR ELCTRICO ESQUADRO CIRCUITO ELECTRNICO TV 316 CIRCUITO ELECTRNICO HF 317 ACOPLADOR CIRCUITO ELECTRNICO CE 22660 MOLDURA SOLENIDE EIXO DO TEMPORIZADOR TERMINAL UNIO DO GS BOTO TAMPA TOMADA

BESKRIVNING
ELEKTRONISK KRETS HF 344/TH ELEKTRONISK KRETS HF 343C NTKABEL KABELKLMMA RATT FSTBLOCK STRMBRYTARE KOPPLING RATT NIPPEL FLKT VINKELHAKE ELEKTRONISK KRETS TV 316 ELEKTRONISK KRETS HF 317 KOPPLAR ELEKTRONISK KRETS CE 22660 RAMPROFIL ELEKTROVENTIL AXEL FR TRIMMER KONTAKTDON GASKOPPLING RATT NIPPEL UTTAG

BESCHRIJVING
ELEKTRONISCH CIRCUIT HF 344/TH ELEKTRONISCH CIRCUIT HF 343C VOEDINGSKABEL KABELKLEM KNOP BEVESTIGINGSBLOKJE SCHAKELAAR AANSLUITSTUK KNOP DOPJE MOTORVENTILATOR HOEK ELEKTRONISCH CIRCUIT TV 316 ELEKTRONISCH CIRCUIT HF 317 KOPPELSTUK ELEKTRONISCH CIRCUIT CE 22660 LIJSTPROFIEL ELEKTROMAGNETISCHE KLEP AS VOOR TRIMMER CONNECTOR GASAANSLUITING KNOP DOPJE STOPCONTACT

DESCRIERE
CIRCUIT ELECTRONIC HF 344/TH CIRCUIT ELECTRONIC HF 343C CABLU DE ALIMENTARE MANON CABLURI PIULI NYLON BLOC DE FIXARE NTRERUPTOR RACORD IEIRE BUTON CAPAC VENTILATOR CADRU CUPRU CIRCUIT ELECTRONIC TV 316 CIRCUIT ELECTRONIC HF 317 CUPLAJ COMPLET CIRCUIT ELECTRONIC CE 22660 PROFIL CADRU ELECTROVALV AX PENTRU TRIMMER CONECTOR RACORD GAZ BUTON CAPAC PRIZ

II

SPARE PARTS LIST - PICES DTACHES - LISTA DE LAS PIEZAS DE RECAMBIO - ERSATZTEILLISTE EAS SOBRESSELENTES - RESERVDELAR - WISSELSTUKKEN - LISTA PIESE COMPONENTE LISTA CZCI ZAMIENNYCH - -
R.
01 03 08 09 09.1 10 11 12 13 13.1 14 15 20 32 33 36 38 46 48 51 52 56 56.1 57

CODE
W000050170 W000232541 W000236149 W000227612 W000227620 W000233525 W000070027 W000231163 W000070032 W000228005 W000050067 W000050193 W000050187 W000070040 W000070016 W000050188 W000262754 W000050181 W000050179 W000070019 W000070047 W000070049 W000228008 W000227589

OPIS
OBWD ELEKTRONICZNY HF 344/TH OBWD ELEKTRONICZNY HF 343C KABEL ZASILAJCY OPASKA KABLOWA NAKRTKA Z NYLONU PYTKA MOCUJCA WYCZNIK ZCZKA WYJCIOWA POKRTO NASADKA WIRNIK JARZMO MIEDZIANE OBWD ELEKTRONICZNY HF TV 316 OBWD ELEKTRONICZNY HF HF 317 KOMPLETNY UKAD CZCY OBWD ELEKTRONICZNY CE 22660 PROFIL RAMKI ELEKTROZAWR TRZPIE TRYMERA CZNIK ZCZE GAZOWE POKRTO NASADKA PRZYCISKU

HF 344/TH HF 343C

OA CA HF 344/TH OA CA HF 343C AA OA O A CO OO AA OA OA OO COA OA CA TV 316 OA CA HF 317 A OA CA CE 22660 O A OAA A A A OOOC CO AO AA OA OA ae


DINSE

TV 316 HF 317 CE 22660 o TRIMMER


III

DUTY CYCLE - FACTEUR DE MARCHE - CICLO DE TRABALHO - BEDRIJFSCYCLUS - CICLO DE TRABAJO INTERMITTENSFAKTOR - BEDRIJFSCYCLUS - CICLUCL DE LUCRU - SE
WELDING CURRENT - COURANT DE SOUDAGE - CORRIENTE DE SOLDADURA SCHWEISSSTROMBEREICH - CORRENTE DE SOLDADURA - SVETSSTRM - SNIJSTROOM CORENT DE TAIERE - PRD SPAWANIA - -

DUTY CYCLE - FACTEUR DE MARCHE - CICLO DE TRABAJO - EINSCHALTDAUER - CICLO DE TRABALHO - INTERMITTENSFAKTOR BEDRIJFSCYCLUS - CICLUCL DE LUCRU - -

VOLT/AMPERE CURVES - COURBES VOLT /AMPERE - CURVA VOLTIOS/AMPERIOS - KURVEN VOLT/AMPERE CURVAS VOLTAMPRICA - VOLT/AMPERE CURVES - KURVOR VOLT/AMPERE - CURBE VOLT-AMPERE KRZYWE VOLT-AMPER - VOLT/AMPERE -

V OUT

I OUT

IV

WIRING DIAGRAM - SCHMA LECTRIQUE - ESQUEMA ELCTRICO - STROMLAUFPLAN ESQUEMAS ELCTRICOS - ELSCHEMOR - ELEKTRISCHE SCHEMA'S - SCHEMA ELECTRICA SCHEMAT ELEKTRYCZNY - -

CIRCUIT BOARD HF 344/TH CE 22519 (W000050170)

ELECTRONIC CIRCUIT BOARD HF 344/TH CE 22519 (W000050170) page 1of2

ELECTRONIC CIRCUIT BOARD HF 344/TH CE 22519 (W000050170) page 2of2

CIRCUIT BOARD HF 344/TH CE 22538 (W000232541)

ELECTRONIC CIRCUIT BOARD HF 344/TH CE 22538 (W000232541)

CIRCUIT BOARD TV 316 CE 22438 (W000050187)

ELECTRONIC CIRCUIT BOARD TV 316 CE 22438 (W000050187)

CIRCUIT BOARD HF 317 CE 22437 (W000070040)

ELECTRONIC CIRCUIT BOARD HF 317 CE 22437 (W000070040)

CIRCUIT BOARD CE 22692

ELECTRONIC CIRCUIT BOARD CE 22692